DE102020130120A1 - Absorbent pad for a food carrier, absorbent pad web for manufacturing an absorbent pad, food carrier and method for producing an absorbent pad web and/or an absorbent pad - Google Patents

Abstract

The invention relates to an absorbent pad for a food carrier for absorbing a liquid escaping from a foodstuff, the absorbent pad having an upper side for contact with the food and an underside for lying on the food carrier, and an interior space being formed between the upper side and the underside, the interior space being a absorption material for absorbing the liquid, and the upper side has a liquid-tight film layer and the lower side has a liquid-permeable fleece layer, which are connected to one another at one edge or more edges by means of thermal joining, in particular ultrasonic welding and/or sealing, so that there is an absorbent pad that is closed on all sides . Furthermore, the invention relates to an absorbent pad web for manufacturing an absorbent pad, a food carrier for a foodstuff and a method for producing an absorbent pad web and/or an absorbent pad.

Description

The invention relates to an absorbent pad for a food carrier for absorbing liquid escaping from a foodstuff, the absorbent pad having an upper side for contact with the food and an underside for lying on the food carrier, and an interior space being formed between the upper side and the underside, the interior space being a Having absorption material for absorbing the liquid. Furthermore, the invention relates to an absorbent pad web for manufacturing an absorbent pad for a food carrier, a food carrier for a foodstuff and a method for producing an absorbent pad web and/or an absorbent pad.

In the food trade, absorbent pads are used to absorb and bind liquids from foods such as meat, poultry, fruit, vegetables or fish. In addition to an attractive presentation for sale, absorbent pads are used for hygienic storage and a longer shelf life of the respective food. Absorbent pads are used both in the service area in the food trade and, for example, placed under the food to be presented on a presentation tray or directly on the counter floor, as well as for packaging in the self-service area. For the self-service area, meat and poultry products in particular are often arranged in a food carrier comprising a bowl or a trough, with a base with an absorbent material for absorbing liquid (tissue water, blood, and the like) is arranged.

Nowadays, predominantly open absorbent pads are used in which all four cut edges or at least two opposite cut edges are open. Because of the open cut edges of conventional absorbent pads, there is a risk that the liquid-absorbing material and/or the absorbed liquid will escape from the absorbent pad and come into contact with the foodstuff arranged on the absorbent pad. This is undesirable for reasons of hygiene and food law.

In addition, in the case of known absorbent pads, a perforated film is often used on the upper side, which allows disadvantageous active suction of the food product lying thereon. Thus, there is a risk that more blood and/or tissue juice will be withdrawn from the food product by this type of absorbent pad than would naturally escape freely.

The production of conventional absorbent pads requires the use of cost-intensive airlaid processes with a very high investment volume in the range of 8 to 10 million euros, in which very short fibers and/or powder, especially made of cellulose, are transported by air as a dry fleece process and formed into a fleece be formed. Since different types of meat, such as pork and poultry, have different bleeding rates, different suction powers are usually used depending on the packaged food product with the same dimensions of the absorbent pads. In the case of absorbent pads produced using the airlaid process, this inevitably means that the quantity of fibers and powder must be increased in proportion to the required suction power, so that the absorbent pad has a relatively high weight.

In addition, when processing and handling the open absorbent pads, especially when cutting them to the desired length using a conventional knife, a considerable amount of dust is generated, which must be minimized by complex extraction systems during processing and handling. Furthermore, there is a risk that the dusty absorbent material of conventional absorbent pads will wash onto the food and come into contact with it. This danger exists in particular if the liquid is not completely absorbed from the food and if the food packaging is moved externally. Improper handling of the absorbent pad with open cut edges by the consumer can also result in contamination of the food.

An absorbent pad that is closed on all sides, in which there is no risk of contamination of the food by escaping absorber particles and a secure binding of the absorbed liquid inside the absorbent pad is ensured EP 2 364 927 B1 famous. In this absorbent pad, the absorbent body is surrounded by an absorber material in a liquid-permeable tubular bag made from a one-piece film, the film of the tubular bag being fused to the absorbent body in one or more punctiform attachment areas. The disadvantage of this absorbent pad that is closed on all sides is that these absorbent pads are prefabricated with the respective desired size and/or dimensions and have to be stored by the users, for example in butchers' shops, which significantly increases the inventory.

Furthermore, a complete recyclability of the food packaging has not yet been achieved Shell, absorbent pad and top film are not given and the soaked absorbent pad must be assigned to the residual waste by hand, while the shell with the top film can be fed into the yellow bin/yellow sack as packaging waste to be recycled. Due to the tightening of the legal requirements in Germany, the recyclability of the entire food packaging including absorbent pads is now required.

The object of the invention is to improve the prior art.

The object is achieved by an absorbent pad for a food carrier for absorbing a liquid escaping from a food item, the absorbent pad having an upper side for contact with the food and an underside for lying on the food carrier, and an interior space being formed between the upper side and the lower side, the Interior has an absorption material for absorbing the liquid, and the upper side has a liquid-tight film layer and the lower side has a liquid-permeable fleece layer, which are connected to one another at one edge or at several edges by means of thermal joining, in particular ultrasonic welding and/or sealing, so that an all-round closed absorbent pad is present.

Because the absorbent pad is closed on all sides, dust and/or absorbent material cannot get out of the absorbent pad and onto the food lying on it. Consequently, contamination of the food through the absorbent pad is prevented.

This provides an optimal absorbent pad that is closed on all sides, which enables increased hygiene, a longer shelf life for the food to be packaged and an appealing presentation of the food.

Due to the fact that the upper side has a liquid-tight film layer, the liquid that has already been absorbed via the liquid-permeable fleece layer on the underside cannot re-enter and/or enter the food from the absorbent pad and recontaminate it. In addition, in particular the liquid-tight and thus in particular hydrophobic film layer does not stick to the food.

Furthermore, it is particularly advantageous that the liquid-tight film layer, which is in direct contact with the food, is not actively sucking on the food on the upper side of the absorbent pad, since the film layer is closed and not perforated. Thus, only the blood and tissue juice freely escaping from the food, which collects at the bottom of a bowl, is continuously absorbed by the liquid-permeable fleece layer on the underside of the absorbent pad.

Because the edge or edges of the liquid-tight film layer and the liquid-permeable fleece layer are connected to one another by means of thermal joining and are closed on all sides, an additional auxiliary material, such as an adhesive, is not required to form the connection and consequently there is also no risk of contamination by a additional excipient.

A cost-effective absorbent pad that is easy for the end customer to handle and is completely food-compatible is thus provided. In addition, due to the liquid-tight film layer and the liquid-permeable fleece layer and the absorption material arranged in the interior space between them, the absorbent pad can be produced without a cost-intensive airlaid system. Consequently, different required suction powers, for example for different types of meat, are set in a simple and cost-effective manner exclusively via the amount of absorption material introduced per square meter.

An essential idea of the invention is based on the fact that an absorbent pad has a liquid-tight film layer on the outside on its upper side and a liquid-permeable fleece layer on its underside, which, after the liquid-tight film layer and/or the liquid-permeable fleece layer has been cut to size, can be directly thermally bonded at its outer edges and/or cut edges were joined without an additional connecting means, so that the absorbent pad is closed on all sides and the liquid escaping from the food only enters through the lower liquid-permeable fleece layer into the interior between the upper liquid-tight film layer and the lower liquid-permeable fleece layer and is bound in the interior by an absorption material, however, the absorption material does not escape through the upper liquid-tight film layer and also not through the lower liquid-permeable fleece layer insert can escape.

• Eine „Saugeinlage“ (auch „Pad“ genannt) ist insbesondere ein saugfähiger Körper, welcher eine aus einem Lebensmittel austretende Flüssigkeit aufnehmen und/oder binden kann. Eine Saugeinlage weist im Vergleich zu ihrer Länge und/oder Breite und/oder ihrem Durchmesser nur eine geringe Höhe auf. Eine Saugeinlage kann prinzipiell jegliche Form, wie rund, dreieckig, quadratisch und/oder rechteckig, aufweisen. Die Saugeinlage weist beispielsweise eine Breite in einem Bereich von 30 mm bis 300 mm, insbesondere von 50 mm bis 200 mm, bevorzugt von 80 mm bis 120 mm, auf. Die Saugeinlage weist beispielsweise eine Länge in einem Bereich von 50 mm bis 300 mm, insbesondere 100 mm bis 200 mm, bevorzugt 130 mm bis 150 mm, auf. Die Höhe der Saugeinlage liegt beispielsweise in einem Bereich von 1 mm bis 10 mm, insbesondere von 1,5 mm bis 5 mm, bevorzugt von 2 mm bis 4 mm. Die Saugeinlage weist an ihrer oberen Außenseite insbesondere eine flüssigkeitsdichte Folienschicht zum Kontakt mit einem Lebensmittel und an ihrer Unterseite eine flüssigkeitsdurchlässige Vliesschicht zum Aufliegen auf einem Lebensmittelträger auf. Die flüssigkeitsdichte Folienschicht und die flüssigkeitsdurchlässige Vliesschicht bilden einen Innenraum aus, welcher ein Absorptionsmaterial und/oder eine weitere Vliesschicht oder mehrere weitere Vliesschichten aufweist. An dem Rand oder den Rändern, an denen die obere flüssigkeitsdichte Folienschicht und die untere flüssigkeitsdurchlässige Vliesschicht aneinander anliegen, sind diese mittels thermischen Fügens, insbesondere Ultraschallschweißen und/oder -versiegeln miteinander fest verbunden, sodass die Saugeinlage an ihren Außenrändern komplett geschlossen ist.
• Ein „Lebensmittelträger“ ist insbesondere ein Behälter für den Transport, die Lagerung, den Verkauf und/oder die Präsentation eines Lebensmittels. Bei einem Lebensmittelträger kann es sich beispielsweise um eine Schale oder einen Trog handeln, welche oder welcher mit einer Oberfolie luftdicht geschlossen ist. Die Saugeinlage ist insbesondere auf und/oder in dem Lebensmittelträger angeordnet und/oder in ihrer Lage fixiert. Bei einem Lebensmittelträger kann es sich auch um eine Platte, ein Brett und/oder einen Boden eines Präsentationstresens handeln.
• Eine „austretende Flüssigkeit“ ist insbesondere Gewebewasser, dem Lebensmittel zugeführtes und/oder im Lebensmittel vorhandenes Wasser, Blut und/oder Frucht- und/oder Gemüsesaft. Die austretende Flüssigkeit kann insbesondere weitere gelöste oder feste Stoffe, wie Salze, Proteine, Lipide, Kohlenhydrate, Bakterien und/oder Viren, enthalten.
• Unter einer „Oberseite“ wird insbesondere die Seite in Richtung entgegen einer Gewichtskraft verstanden. Auf die Oberseite der Saugeinlage wird insbesondere das Lebensmittel draufgelegt.
• Unter einer „Unterseite“ wird insbesondere die Seite der Saugeinlage verstanden, welche sich in Wirkrichtung der Gewichtskraft befindet.
• Unter „Innenraum“ wird insbesondere ein Raum verstanden, welcher durch die Unterseite der oberen flüssigkeitsdichten Folienschicht und die Oberseite der unteren flüssigkeitsdurchlässigen Vliesschicht begrenzt ist. Der Innenraum ist insbesondere vollständig von der flüssigkeitsdichten Folienschicht und der flüssigkeitsdurchlässigen Vliesschicht umgeben und vollständig umschlossen. Insbesondere im Falle einer Saugeinlagebahn muss der Innenraum jedoch nicht auf allen Seiten und/oder an allen Rändern vollständig geschlossen sein, sondern eine Seite und/oder ein Rand oder mehrere Seiten und/oder mehrere Ränder können auch offen sein.
• Ein „Absorptionsmaterial“ ist insbesondere ein Material, welches Flüssigkeiten aufsaugt und/oder bindet. Bei einem Absorptionsmaterial handelt es sich insbesondere um einen Superabsorber (Super Absorbent Polymers, SAP), bei dem es sich insbesondere um Kunststoffe handelt, welche ein Vielfaches ihres Eigengewichts an Flüssigkeit aufsaugen und/oder binden können. Bei der Aufnahme der austretenden Flüssigkeit quillt der Superabsorber auf und bildet ein Hydrogel. Das Absorptionsmaterial und/oder der Superabsorber weist insbesondere eine Partikelgröße in einem Bereich von 100 µm bis 1.000 µm auf. Das Absorptionsmaterial und/oder der Superabsorber weist insbesondere Polyacrylamid, Polyvinylpyrrolidon, Amylopektin, Gelatine und/oder Zellulose auf. Bevorzugt weist das Absorptionsmaterial und/oder der Superabsorber ein Copolymer aus Acrylsäuren und einem Acrylamid auf. Die Saugeinlage weist in ihrem Innenraum insbesondere eine derartige Menge an Absorptionsmaterial und/oder Superabsorber auf, dass die aus dem Lebensmittel austretende Flüssigkeit vollständig aufgenommen und gebunden wird.
• Eine „Folienschicht“ ist insbesondere ein sehr dünnes Blatt aus Kunststoff. Die Folienschicht weist eine Wandstärke in einem Bereich von 2 µm bis 500 µm, insbesondere 10 µm bis 100 µm, bevorzugt 20 µm bis 50 µm, auf. Die Folienschicht ist insbesondere flüssigkeitsdicht und/oder hydrophob. Die Folienschicht wird insbesondere als flüssigkeitsdichte Folienschicht-Bahn und somit als Endlosbahn gefertigt, aufgerollt und zur Fertigung der Saugeinlage in passende Stücke zugeschnitten. Die Folienschicht weist insbesondere ein Polyolefin auf.
• Eine „Vliesschicht“ ist insbesondere ein flächiges Gebilde aus einem Vliesstoff. Eine Vliesschicht weist insbesondere Fasern einer begrenzten Länge, Endlosfasern und/oder zugeschnittene Abschnitte jeglicher Art und jeglichen Ursprungs auf, welche zu einer Faserschicht zusammengefügt und auf irgendeine Weise miteinander frei von Verkreuzen und/oder Verschlingen von Garn miteinander verbunden sind. Eine Vliesschicht ist insbesondere flüssigkeitsdurchlässig und/oder hydrophil. Die Flüssigkeitsdurchlässigkeit der Vliesschicht wird insbesondere dadurch erreicht, dass die Vliesschicht eine Dichte und/oder Porengröße gezielt aufweist, welche einen Durchtritt von Flüssigkeit und/oder Wasser erlaubt. Die flüssigkeitsdurchlässige Vliesschicht kann ebenfalls in Form einer flüssigkeitsdurchlässigen Vliesschichtbahn und somit als Endlosbahn gefertigt, aufgerollt und später in passende Stücke für die Saugeinlage zugeschnitten werden.
• Ein „Rand“ ist insbesondere die äußere Begrenzung der Fläche der flüssigkeitsdichten Folienschicht und/oder flüssigkeitsdurchlässigen Vliesschicht. Ein Rand ist insbesondere auch eine Seitenlänge der flüssigkeitsdichten Folienschicht und/oder der flüssigkeitsdurchlässigen Vliesschicht. Je nach Form der flüssigkeitsdichten Folienschicht und der flüssigkeitsdurchlässigen Vliesschicht weist die Saugeinlage einen Rand, beispielsweise bei einer runden Form, oder mehrere Ränder, beispielsweise bei einer rechteckigen Form, auf, wobei die aneinander liegenden Ränder der flüssigkeitsdichten Folienschicht und der flüssigkeitsdurchlässigen Vliesschicht durch thermisches Fügen direkt miteinander verbunden und somit geschlossen sind.
• Unter „thermischem Fügen“ wird insbesondere ein Fügen unter Einfluss von Wärme und/oder durch Druck verstanden. Beim thermischen Fügen werden die Fügestellen und somit der Rand oder die Ränder der flüssigkeitsdichten Folienschicht und der flüssigkeitsdurchlässigen Vliesschicht, welche aneinander liegen, aufgeschmolzen und dadurch fest verbunden. Das thermische Fügen findet insbesondere ohne weitere Hilfs- und Verbindungsmittel statt. Das thermische Fügen erfolgt insbesondere durch Laserdurchstrahlschweißen oder durch Ultraschallschweißen und/oder -versiegeln.
• Beim „Ultraschallschweißen“ wird insbesondere eine mechanische Schwingung über eine Sonotrode als Schweißwerkzeug in die zu fügenden flüssigkeitsdichte Folienschicht und flüssigkeitsdurchlässige Vliesschicht an deren entsprechenden Rändern eingeleitet, wodurch es aufgrund von inneren Molekular- und äußeren Grenzflächenreibungen zu einem Erwärmen und Plastifizieren des Materials und somit zu einem Verschmelzen der flüssigkeitsdichten Folienschicht und der flüssigkeitsdurchlässigen Vliesschicht an deren Rändern kommt. Nach Schalleinleitung kann durch eine Abkühlphase unter Druck eine homogene Schweißverbindung zwischen den Rändern der flüssigkeitsdichten Folienschicht und der flüssigkeitsdurchlässigen Vliesschicht erzielt werden. Gleichzeitig und/oder zusätzlich mit dem Ultraschallschweißen kann auch ein Ultraschallversiegeln durchgeführt werden, bei dem die Ultraschallschweißnähte luft- und wasserdicht homogen versiegelt werden.

The following terms are explained:

• An “absorbent insert” (also called “pad”) is in particular an absorbent body which can absorb and/or bind a liquid escaping from a food. An absorbent pad has only a small height in comparison to its length and/or width and/or its diameter. In principle, an absorbent pad can have any shape, such as round, triangular, quad ratic and/or rectangular. The absorbent insert has a width in a range from 30 mm to 300 mm, in particular from 50 mm to 200 mm, preferably from 80 mm to 120 mm. The absorbent insert has a length in a range from 50 mm to 300 mm, in particular 100 mm to 200 mm, preferably 130 mm to 150 mm. The height of the absorbent pad is, for example, in a range from 1 mm to 10 mm, in particular from 1.5 mm to 5 mm, preferably from 2 mm to 4 mm. On its upper outer side, the absorbent pad has in particular a liquid-tight film layer for contact with a foodstuff and on its underside a liquid-permeable fleece layer for lying on a food carrier. The liquid-tight film layer and the liquid-permeable fleece layer form an interior which has an absorption material and/or a further fleece layer or several further fleece layers. At the edge or edges where the upper liquid-tight film layer and the lower liquid-permeable non-woven layer rest against one another, these are firmly connected to one another by means of thermal joining, in particular ultrasonic welding and/or sealing, so that the absorbent pad is completely closed at its outer edges.
• A “food carrier” is in particular a container for transporting, storing, selling and/or presenting a foodstuff. A food carrier can be, for example, a bowl or a trough which is closed airtight with a top film. The absorbent insert is in particular arranged on and/or in the food carrier and/or fixed in its position. A food carrier can also be a plate, a board and/or a base of a presentation counter.
• A “leaking liquid” is in particular tissue water, water added to and/or present in the food, blood and/or fruit and/or vegetable juice. The exiting liquid can in particular contain other dissolved or solid substances such as salts, proteins, lipids, carbohydrates, bacteria and/or viruses.
• An “upper side” is understood to mean in particular the side in the direction counter to a weight force. In particular, the food is placed on the upper side of the absorbent pad.
• A "bottom" is understood in particular to mean the side of the absorbent pad that is in the effective direction of the weight force.
• “Interior space” is understood to mean, in particular, a space which is delimited by the underside of the upper liquid-tight film layer and the upper side of the lower liquid-permeable fleece layer. The interior is in particular completely surrounded and completely enclosed by the liquid-tight film layer and the liquid-permeable fleece layer. However, particularly in the case of an absorbent pad web, the interior space does not have to be completely closed on all sides and/or all edges, but one side and/or one edge or several sides and/or several edges can also be open.
• An "absorption material" is in particular a material that absorbs and/or binds liquids. An absorption material is in particular a super absorber (Super Absorbent Polymers, SAP), which is in particular plastics which can absorb and/or bind a multiple of their own weight in liquid. When absorbing the escaping liquid, the super absorber swells and forms a hydrogel. The absorption material and/or the super absorber has, in particular, a particle size in a range from 100 μm to 1000 μm. The absorption material and/or the super absorber contains, in particular, polyacrylamide, polyvinylpyrrolidone, amylopectin, gelatin and/or cellulose. The absorption material and/or the super absorber preferably has a copolymer of acrylic acids and an acrylamide. In its interior, the absorbent pad has, in particular, such an amount of absorption material and/or super absorber that the liquid escaping from the food is completely absorbed and bound.
• Specifically, a "foil layer" is a very thin sheet of plastic. The film layer has a wall thickness in a range from 2 μm to 500 μm, in particular from 10 μm to 100 μm, preferably from 20 μm to 50 μm. The film layer is in particular liquid-tight and/or hydrophobic. The foil layer is produced in particular as a liquid-tight foil layer web and thus as a continuous web, rolled up and cut into suitable pieces for the production of the absorbent insert. The film layer has, in particular, a polyolefin.
• A "fleece layer" is in particular a flat structure made of a nonwoven material. A fleece layer has in particular fibers of a of limited length, continuous filaments and/or cut sections of any kind and origin, assembled into a fibrous layer and connected in any way to one another free of yarn crossing and/or entanglement. A fleece layer is in particular liquid-permeable and/or hydrophilic. The liquid permeability of the fleece layer is achieved in particular in that the fleece layer specifically has a density and/or pore size that allows liquid and/or water to pass through. The liquid-permeable fleece layer can also be produced in the form of a liquid-permeable fleece layer web and thus as an endless web, rolled up and later cut into suitable pieces for the absorbent insert.
• An "edge" is in particular the outer boundary of the surface of the liquid-tight film layer and/or liquid-permeable fleece layer. An edge is in particular also a side length of the liquid-tight film layer and/or the liquid-permeable fleece layer. Depending on the shape of the liquid-tight film layer and the liquid-permeable non-woven layer, the absorbent pad has one edge, for example in the case of a round shape, or several edges, for example in the case of a rectangular shape, with the edges of the liquid-tight film layer and the liquid-permeable non-woven layer lying on one another directly by thermal joining connected and thus closed.
• “Thermal joining” is understood to mean, in particular, joining under the influence of heat and/or pressure. During thermal joining, the joining points and thus the edge or edges of the liquid-tight film layer and the liquid-permeable nonwoven layer, which lie against one another, are melted and thereby firmly connected. The thermal joining takes place in particular without further auxiliary and connecting means. The thermal joining takes place in particular by laser transmission welding or by ultrasonic welding and/or sealing.
• In "ultrasonic welding", a mechanical vibration is introduced via a sonotrode as a welding tool into the liquid-tight film layer and liquid-permeable fleece layer to be joined at their corresponding edges, which causes the material to heat up and plasticize due to inner molecular and outer boundary surface friction and thus to a Fusion of the liquid-tight film layer and the liquid-permeable fleece layer comes at the edges. After sound has been introduced, a homogeneous welded connection between the edges of the liquid-tight film layer and the liquid-permeable fleece layer can be achieved by a cooling phase under pressure. At the same time and/or in addition to the ultrasonic welding, ultrasonic sealing can also be carried out, in which the ultrasonic weld seams are homogeneously sealed in an airtight and watertight manner.

In a further embodiment of the absorbent pad, another liquid-permeable fleece layer, two further liquid-permeable fleece layers or several further liquid-permeable fleece layers are or are arranged in the inner space, with the absorption material being arranged in the further liquid-permeable fleece layer and/or between the further liquid-permeable fleece layers.

An absorbent body consisting of at least one further liquid-permeable fleece layer and the absorption material can thus be provided, which can optimally absorb as much liquid escaping from the food as is required during transport and/or storage of a food. It is particularly advantageous that the absorbent insert with an absorbent body made of at least one further liquid-permeable fleece layer and the absorption material does not release dust and the further liquid-permeable fleece layer or the further liquid-permeable fleece layers can be manufactured free of cellulose. Consequently, a cost-intensive airlaid process for manufacturing the fleece layers can be dispensed with.

The absorbent insert preferably has in its interior and thus the absorbent body at least two further liquid-permeable fleece layers between which the absorption material is arranged. Thus, the absorption material in the interior of the absorbent insert can be optimally flown from above and below through the further liquid-permeable fleece layers and/or laterally between the further liquid-permeable fleece layers and swell up optimally.

The design of the absorbent pad with an absorbent body made of two further liquid-permeable fleece layers with absorption material in the interior, and the liquid-tight film layer on the upper side and the liquid-permeable fleece layer on the underside allows an absorbent pad with a low weight of a few grams, in particular in the range of 1 g up to 10 g per absorbent pad. For example, the total basis weight is Absorbent insert with a further two-layer, liquid-permeable fleece layer in the interior in a range from 100 g/m ² to 300 g/m ² , preferably between 150 g/m ² and 250 g/m ² .

The further liquid-permeable fleece layer and the further liquid-permeable fleece layers correspond in their design to the liquid-permeable fleece layer defined above.

In order to prevent and/or reduce the escape of absorption material even in the event of improper use or destruction of the all-round closed cover made of a liquid-tight film layer and a liquid-permeable fleece layer, a pocket or several pockets are arranged between two further liquid-permeable fleece layers, with the pocket or in the plurality of pockets the absorbent material is arranged.

At the same time, this embodiment achieves a homogeneous distribution of the absorbent over the surface of the further liquid-permeable fleece layers and thus of the absorbent body.

The term "pocket" means in particular a complete or largely closed interior which is formed between two further liquid-permeable fleece layers and in which the absorption material is contained. To form the pocket, the underside of the first, upper, further, liquid-permeable fleece layer and the top of the second, lower, further, liquid-permeable fleece layer form the walls of a cavity, with the two fleece layers being connected to one another at the edges of the cavity. The two other liquid-permeable fleece layers are connected around the cavity, in particular by needling.

In a further embodiment of the absorbent pad, the liquid-tight film layer, the liquid-permeable fleece layer, the further liquid-permeable fleece layer and/or the further liquid-permeable fleece layers have a thermoplastic material, in particular polypropylene, polyethylene and/or polyethylene terephthalate.

This achieves both optimal thermal bonding and thus a tight connection between the upper liquid-tight film layer and the lower liquid-permeable fleece layer at their edges, and also enables high recyclability.

It is particularly advantageous that the layers of the absorbent insert are free of cellulose and therefore no complex and cost-intensive airlaid process has to be used to manufacture them. In addition, both the thermoplastic material and the recyclate from it can be used. Consequently, a high recycling rate of the entire absorbent pad can be achieved.

In order to provide a single-variety material pairing of the components of the absorbent pad, the liquid-tight film layer, the liquid-permeable nonwoven layer, the further liquid-permeable nonwoven layer and/or the further liquid-permeable nonwoven layers have the same thermoplastic material, so that the absorbent pad can be recycled according to type.

Because the layers of the absorbent insert have the same pure, thermoplastic material and are free of cellulose, a high recycling rate of 97% to 98% can be achieved. In addition, this results in optimal fusion during thermal joining and a permanent and resilient connection.

A “thermoplastic plastic material” is in particular a plastic which can be thermoplastically deformed in a specific temperature range. This thermoplastic deformation is in particular reversible and the thermoplastic material can be welded.

In a further aspect of the invention, the object is achieved by an absorbent pad web for manufacturing an absorbent pad for a food carrier, the absorbent pad web having a larger dimension of its longitudinal sides in a longitudinal direction than its transverse sides and a lower web and an upper web, with between the upper web and the lower web is formed with an inner space and the inner space has an absorption material for absorbing a liquid from a foodstuff and/or at least one further liquid-permeable nonwoven layer, and the upper web is a liquid-tight film layer web and the lower web is a liquid-permeable nonwoven layer web, which are connected to one another on their long sides by means of thermal joining, in particular ultrasonic welding and/or sealing, so that a section of the absorbent pad web can be cut to a predetermined length for the manufacture of the absorbent pad and when cutting to size on the transverse sides sformed cut edges of the liquid-tight film layer web and the liquid-permeable nonwoven layer web can be connected by thermal joining, in particular ultrasonic welding and/or sealing, so that the previously described absorbent insert closed on all sides is present.

In this way, an absorbent pad web is provided as a piece of goods and/or rolled up endless web, which is already closed on its two opposite long sides by thermal joining and at the customer, for example a tray manufacturer, only has to be cut to the desired length and closed by thermal joining of the cut edges . A continuous web is in particular a roll with a web of adjustable length.

In an additional aspect of the invention, the object is achieved by a food carrier for a foodstuff, the food carrier having an absorbent pad as described above or a section of an absorbent pad web as described above that has been cut to size and thermally joined on all sides.

Consequently, a food carrier is provided which has an absorbent pad with optimal liquid absorption without contamination of the food to be stored and/or packaged.

As a result, the absorbent pad can be inserted directly by the manufacturer of the food carrier and immediately fixed in the shells in the inline process, so that the manufacturer of the food carrier can deliver the food carrier with the fixed absorbent pad to slaughterhouses and cutting plants. Thus, for example, a bowl can be formed as a food carrier in the thermoformer and the absorbent insert can be inserted and thermally fixed at the same time. As a result, the slaughterhouses and cutting plants as end customers can work with a high level of automation without the meat being contaminated by the absorbent pad. By using an ultrasonic cutting, welding and/or sealing system, the absorbent pad can easily be cut to size on site from a web of absorbent pads and closed directly on the open transverse sides and/or cut edges.

• - Auf- und/oder Einbringen von Absorptionsmaterial auf und/oder in eine einschichtige flüssigkeitsdurchlässige Vliesschicht-Bahn und/oder zwischen einer zweischichtigen flüssigkeitsdurchlässigen Vliesschicht-Bahn,
• - Zusammenführen einer unteren flüssigkeitsdurchlässigen Vliesschicht-Bahn, der darauf angeordneten einschichtigen flüssigkeitsdurchlässigen Vliesschicht-Bahn und/oder zweischichtigen flüssigkeitsdurchlässigen Vliesschicht-Bahn mit dem Absorptionsmaterial und einer oberen flüssigkeitsdichten Folienschicht-Bahn in einer Längsrichtung,

• - Thermisches Fügen, insbesondere Ultraschallschweißen und/oder -versiegeln, der unteren flüssigkeitsdurchlässigen Vliesschicht-Bahn und der oberen flüssigkeitsdichten Folienschicht-Bahn an ihren Längsseiten, sodass eine Saugeinlagebahn vorliegt, und/oder
• - Zuschneiden der Saugeinlagebahn auf eine vorgegebene Länge unter Ausbildung von Schnittkanten an gegenüberliegenden Querseiten und thermisches Fügen, insbesondere Ultraschallschweißen und/oder -versiegeln, der zugeschnittenen unteren flüssigkeitsdurchlässigen Vliesschicht-Bahn und der oberen flüssigkeitsdichten Folienschicht-Bahn an den Schnittkanten, sodass eine allseitig geschlossene Saugeinlage vorliegt.

In an additional aspect of the invention, the object is achieved by a method for producing an absorbent pad web and/or an absorbent pad with the following steps:

• - application and/or introduction of absorption material onto and/or into a single-layer, liquid-permeable, non-woven layer web and/or between a two-layer, liquid-permeable, non-woven layer web,
• - bringing together a lower liquid-pervious nonwoven layer web, the single-layer liquid-pervious nonwoven layer web and/or two-layer liquid-pervious nonwoven layer web arranged thereon with the absorption material and an upper liquid-tight film layer web in a longitudinal direction,

• - Thermal joining, in particular ultrasonic welding and/or sealing, of the lower liquid-permeable fleece layer web and the upper liquid-tight film layer web on their longitudinal sides, so that an absorbent pad web is present, and/or
• - Cutting the absorbent pad web to a specified length, forming cut edges on opposite transverse sides and thermal joining, in particular ultrasonic welding and/or sealing, of the cut lower liquid-permeable fleece layer web and the upper liquid-tight film layer web at the cut edges, so that an absorbent pad closed on all sides present.

As a result, a completely new and simplified method for producing an absorbent pad sheet and/or an absorbent pad is provided, in which the various sheet-like components are only fed in and made up continuously. Since the process is limited to bringing together the various materials and/or components, no cost-intensive large-scale systems are required. In this case, absorption material is introduced in a predetermined amount, in particular by dusting and/or blowing into and/or onto an inner, single-layer, liquid-permeable nonwoven web and/or between the two lying layers of a two-layer, liquid-permeable nonwoven web. The individual web-like materials are arranged according to the arrangement in the absorbent pad described and continuously brought together as a common web before the longitudinal sides of the lower liquid-permeable nonwoven layer web and the upper liquid-tight film layer web are thermally joined to form an absorbent pad web. It is particularly advantageous that the method for producing a sheet of absorbent pads and/or an absorbent pad is carried out in a continuous process and the bringing together takes place, for example, by means of rollers.

The cutting and thermal joining of the absorbent pad web to form an absorbent pad that is closed on all sides can optionally follow directly after the thermal joining of the long sides or, as described above, this is only carried out by the customer or end customer.

In a further embodiment of the method, the cutting and thermal joining is carried out in one work step using ultrasound cutting and ultrasonic welding and/or sealing.

As a result, an absorbent pad that is closed on all sides can be produced from an absorbent pad web in a simple manner, since only a single work step is necessary for this, for example using a so-called ultrasonic cut-and-seal system. It is particularly advantageous that the cutting and thermal joining are carried out simultaneously without using additional glue and/or other connecting means.

In a further embodiment of the method, when the absorption material is introduced into the two-layer, liquid-permeable nonwoven web, the two layers of the liquid-permeable nonwoven web are partially connected to one another by means of needling, in particular by means of ultrasonic needling, so that the absorption material introduced in the pocket or in the pockets.

Advantageously, the pocket or several pockets between the two layers of the liquid-permeable nonwoven web are formed simultaneously with the introduction of the absorption material, whereby the absorption material introduced is prevented from escaping even if the outer cover of the absorbent pad or the absorbent pad web is damaged. In addition, the formation of several pockets prevents the absorption material from slipping between the two layers of the liquid-permeable nonwoven web when the absorbent pad is used, and the absorption material is thus distributed homogeneously between the two layers and in the absorbent pad.

It is particularly advantageous that the needling of the two layers of the liquid-permeable fleece layer web can be carried out not only conventionally with needles, but also by needling using ultrasound. Thus, no new and/or no additional system technology is required to carry out the method, but the system for ultrasonic welding and/or sealing can also be used for needling.

In a further aspect of the invention, the object is achieved by an absorbent pad sheet and/or an absorbent pad manufactured using a method described above.

• 1 eine stark schematische dreidimensionale Darstellung einer Saugeinlagebahn im Querschnitt,
• 2 eine stark schematische Darstellung einer Draufsicht auf einen Saugkörper mit Taschen, und
• 3 eine stark schematische dreidimensionale Darstellung einer Lebensmittelschale mit Saugeinlage.

The invention is explained in more detail below using exemplary embodiments. Show it

• 1 a highly schematic three-dimensional representation of an absorbent pad web in cross section,
• 2 a highly schematic representation of a plan view of an absorbent body with pockets, and
• 3 a highly schematic three-dimensional representation of a food tray with an absorbent pad.

An absorbent pad web 101 is rolled up by the meter on a (continuous) roll, not shown, where 1 Figure 12 shows a cross-section along a lateral side 131 of the absorbent pad web 101 and this illustration is not to scale. The absorbent pad web 101 has on its top 107 a PP film 103 (PP = polypropylene) with a wall thickness of 25 microns and on its underside 109 a PP spunbonded layer 105. On opposite longitudinal sides 129 are the PP film 103 and the PP spunbonded layer 105 connected to each other in a liquid-tight manner as a welded edge 121 in each case. The upper PP film 103 is liquid-impermeable, while the lower PP spunbonded layer 105 is liquid-permeable. An inner space 111 is arranged between the PP film 103 and the PP spunbonded layer 105 . In the interior 111 there is an absorbent body 113 which is guided in a longitudinal direction 127 on the inside along the longitudinal sides 129 of the absorbent pad web 101 . The absorbent body 113 has an upper PP spunbonded absorbent layer 115 and a lower PP spunbonded absorbent layer 117, with superabsorber granules 119 being arranged between the two PP spunbonded absorbent layers 115, 117.

The following work steps are carried out to produce the absorbent pad web 101:

The materials present on rolls are brought together by placing the PP spunbonded nonwoven layer 105 as the web at the bottom, the lower PP spunbonded nonwoven absorbent layer 117 as the web on top, the upper PP spunbonded nonwoven absorbent layer 115 as the web and the PP film on top 103 are merged as a web. Between the lower PP spunbonded absorbent layer 117 and the upper PP spunbonded absorbent layer 115, the super absorber granules 119 are introduced by dusting. The two longitudinal sides 129 of the absorbent pad web 101 are connected by ultrasonic welding of the upper PP film 103 and the lower PP spunbonded layer 105, so that the common welded edge 121 is present.

The web of absorbent pads 101 produced and rolled up in this way, with closed longitudinal sides 129 and open transverse sides 131, is delivered to a manufacturer of food trays. The food tray manufacturer thermoforms a food tray 151 from polypropylene. The absorbent pad web 101 is using an ultrasonic cutting and welding system in one Step cut to a desired length of 130 mm with an existing width of 90 mm and the resulting cut edges on the transverse sides 131 immediately sealed by ultrasonic welding, so that an absorbent pad 141 closed on all sides is present. The absorbent pad 141, which has pure polypropylene, is fixed in the food tray 151 by heat during the thermoforming of the food tray 151, with the PP spunbonded layer 105 being arranged at the bottom and the PP film 103 at the top.

In a slaughterhouse, a piece of meat is placed in the prepared food tray 151 on the PP film 103 of the absorbent pad 141 and sealed gas-tight by means of a PP top film (not shown). During transport to a supermarket and until it is consumed by a consumer, the tissue fluid escaping from the piece of meat, which collects at the bottom of the food tray 151 and enters the interior 111 through the liquid-permeable PP spunbonded layer 105 of the absorbent pad 141, is absorbed by the superabsorbent -Granulate 119 is absorbed and bound so that the piece of meat is stored safely and hygienically.

The absorbent insert 141 with dimensions of 130 mm in length and 90 mm in width as well as a height of 2 mm has a very low weight of 2 g without the absorbed liquid and therefore uses very little material.

Since the absorbent pad 141 with its various layers is made of polypropylene and both the food tray 151 and its top film (not shown) are made of polypropylene, the food tray 151 including the absorbent pad 141 and the top film (not shown) can be easily disposed of by the consumer for recycling and has a high recycling rate of up to 98%.

In an alternative of the suction body 113, which in 2 is shown in cross-section as a top view, diamond-shaped pockets 125 are formed between the upper PP spunbonded absorbent layer 115 and the lower PP spunbonded absorbent layer 117, the edges of which are connected to one another by means of a needle stitching 123. During the introduction of the needling seams 123, the super absorber granulate 119 was introduced into the rhombic pockets 125 by dusting and the respective pocket 125 was closed after introduction by means of the next subsequent needling seam 123. In this case, the needling seams 123 have been introduced by means of ultrasonic needling. through the in 2 In the embodiment of the absorbent body 113 shown, the superabsorbent granules 119 are enclosed in the respective pockets 125 and even if the PP film 103 and/or the PP spunbonded layer 105 of the absorbent pad 141 is damaged, the superabsorbent granules 119 in the absorbent body 13 cannot escape from the pockets 125 and consequently also do not lead to contamination of the food stored on the absorbent pad 141.

Thus, an absorbent pad 141 is provided, which can be produced by type and in which, due to the design being closed on all sides, contamination of the food, in particular by dust, does not occur.

Reference List

101

absorbent sheet

103

PP film

105

PP spunbonded layer

107

top

109

bottom

111

inner space

113

absorbent body

115

upper PP spunbond absorbent layer

117

lower PP spunbond absorbent layer

119

Super absorber granulate

121

welded edge

123

needling seam

125

pocket

127

longitudinal direction

129

long side

131

transverse side

141

absorbent pad

151

food bowl

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• EP 2364927 B1 [0007]

Claims (10)

Absorbent insert (141) for a food carrier (151) for absorbing a liquid escaping from a foodstuff, the absorbent insert having an upper side for contact with the food and an underside (for lying on the food carrier and an interior space (111) formed between the upper side and underside is, wherein the interior has an absorption material (119) for absorbing the liquid, characterized in that the upper side has a liquid-tight film layer (103) and the lower side has a liquid-permeable fleece layer (105) which is attached to one edge or several edges by means of thermal joining, in particular Ultrasonic welding and / or sealing, are connected to each other, so that there is an absorbent pad closed on all sides. Absorbent insert (141) after claim 1 , characterized in that a further liquid-permeable fleece layer (115, 117), two further liquid-permeable fleece layers or several further liquid-permeable fleece layers is or are arranged in the interior, the absorption material (119) in the further liquid-permeable fleece layer and/or between the further liquid-permeable Fleece layers is arranged. absorbent pad after claim 2 , characterized in that a pocket (125) or several pockets are arranged between two further liquid-permeable non-woven layers (115, 117), the absorption material (119) being arranged in the pocket (125) or the several pockets. Absorbent insert (141) according to one of the preceding claims, characterized in that the liquid-tight film layer (103), the liquid-permeable fleece layer (105), the further liquid-permeable fleece layer (115, 117) and/or the further liquid-permeable fleece layers are a thermoplastic material, in particular polypropylene , polyethylene and/or polyethylene terephthalate. Absorbent insert (141) after claim 4 , characterized in that the liquid-tight film layer (103), the liquid-permeable fleece layer (105), the further liquid-permeable fleece layer (115, 117) and/or the further liquid-permeable fleece layers have the same thermoplastic material, so that the absorbent insert (141) can be recycled by type. Absorbent pad sheet (101) for manufacturing an absorbent pad (141) for a food carrier (151), wherein the absorbent pad sheet (101) has a larger dimension of its long sides in a longitudinal direction than its transverse sides and a bottom sheet and a top sheet, with between the top sheet and the lower web has an inner space (111) and the inner space has an absorption material (119) for absorbing a liquid from a foodstuff and/or at least one further liquid-permeable fleece layer (115, 117), characterized in that the upper web has a liquid-tight film layer - web (103) and the lower web is a liquid-permeable non-woven layer web (105), which are connected to one another on their long sides (129) by means of thermal joining, in particular ultrasonic welding and/or sealing, so that for the production of the absorbent insert (141) a section of the absorbent pad web (101) can be cut to a predetermined length and during cutting The cut edges of the liquid-tight film layer web (103) and the liquid-permeable fleece layer web (105) formed on the transverse sides (131) can be connected by thermal joining, in particular ultrasonic welding and/or sealing, so that an absorbent pad (141) closed on all sides one of the Claims 1 until 5 present. Food carrier (151) for a food, wherein the food carrier (151) has an absorbent pad (141) according to one of Claims 1 until 5 or a section of an absorbent pad web (101) that has been cut to size and thermally joined on all sides claim 6 having. Method for producing an absorbent pad web (101) and/or an absorbent pad (141), with the following steps: - application and/or introduction of absorption material (119) onto and/or in a single-layer, liquid-permeable fleece layer web (115, 117) and /or between a two-layer liquid-permeable nonwoven layer web, - bringing together a lower liquid-permeable nonwoven layer web (105), the single-layer liquid-permeable nonwoven layer web (115, 117) arranged thereon and/or two-layer liquid-permeable nonwoven layer web with the absorption material (119) and an upper liquid-tight film layer web (103) in a longitudinal direction (127), - thermal joining, in particular ultrasonic welding and/or sealing, of the lower liquid-permeable nonwoven layer web (105) and the upper liquid-tight film layer web (103) on their longitudinal sides (129), so that there is an absorbent pad sheet (101), and/or - add cutting the absorbent pad web (101) to a predetermined length to form the incision Edges on opposite transverse sides (131) and thermal joining, in particular ultrasonic welding and/or sealing, of the cut lower liquid-permeable fleece layer web (105) and the upper liquid-tight film layer web (103) at the cut edges, so that an absorbent pad (141 ) exists. procedure after claim 8 , characterized in that the cutting and thermal joining is carried out in one step by means of ultrasonic cutting and ultrasonic welding and/or sealing. procedure after claim 8 or 9 , characterized in that when absorbing material (119) is introduced into the two-layer, liquid-permeable non-woven layer web (115, 117), the two layers of the liquid-permeable non-woven layer web (115, 117) to form a pocket (125) or several pockets by needling, in particular by means of ultrasonic needling, are partially connected to one another, so that the absorption material (119) introduced is present in the pocket (125) or in the pockets.

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