EP1725474A1 - Barquette absorbante et isolante pour aliments a emporter - Google Patents

Barquette absorbante et isolante pour aliments a emporter

Info

Publication number
EP1725474A1
EP1725474A1 EP05726028A EP05726028A EP1725474A1 EP 1725474 A1 EP1725474 A1 EP 1725474A1 EP 05726028 A EP05726028 A EP 05726028A EP 05726028 A EP05726028 A EP 05726028A EP 1725474 A1 EP1725474 A1 EP 1725474A1
Authority
EP
European Patent Office
Prior art keywords
layer
tray
lid
liner
multilayer sheet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP05726028A
Other languages
German (de)
English (en)
Inventor
William Harry Grassel
Bruce Robbins
Donald Robert Smith
Robert James Speer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Publication of EP1725474A1 publication Critical patent/EP1725474A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/24—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants
    • B65D81/26—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants with provision for draining away, or absorbing, or removing by ventilation, fluids, e.g. exuded by contents; Applications of corrosion inhibitors or desiccators
    • B65D81/264—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants with provision for draining away, or absorbing, or removing by ventilation, fluids, e.g. exuded by contents; Applications of corrosion inhibitors or desiccators for absorbing liquids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514—Oriented
    • B32B2307/518—Oriented bi-axially
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2398/00—Unspecified macromolecular compounds
    • B32B2398/20—Thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B32B2439/70—Food packaging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/38—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
    • B65D81/3813—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container being in the form of a box, tray or like container
    • B65D81/3823—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container being in the form of a box, tray or like container formed of different materials, e.g. laminated or foam filling between walls
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1303—Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]

Definitions

  • the invention relates to a thermoplastic tray comprising a liner and the liner comprises a multilayer sheet.
  • Composite or multilayer sheets or wraps have long been used for packaging foods. Such sheets aim to keep freshly-made food hot from the time it is prepared until it is consumed.
  • Current commercial sheets or wraps include polyethylene-coated paper or tissue, hot-melt coated paper, foil/tissue laminations, tissue/aluminum foil/polyethylene film, dry wax, etc. These wrap materials are of high moisture resistance to maximize heat retention. Liquid water from condensation is often still left in contact with food, which can leave the food undesirably soggy. Most of the known sheets or wraps involve an absorbent layer and an impermeable layer.
  • the invention includes a rigid, thermoplastic tray comprising a bottom portion and a lid wherein the lid fits over the bottom portion to generally seal along the perimeter where the lid and bottom portion meet; the tray comprises or is produced from a liner; the liner comprises a multilayer sheet comprising or produced from at least two layers including a first layer, a second layer, and optionally a third layer; the first layer comprises or is produced from a water-wicking material; the second layer comprises or is produced from an absorbent and insulating material; and the third layer comprises or is produced from a structural material.
  • Th'elrive ⁇ tl ⁇ further includes packages such as trays, lids and boxes comprising package liners comprising the liner.
  • FIG. 1 is a cross-sectional view of a specific embodiment of the multilayer sheet illustrating a fiberfill batt as the insulating and absorbent material of the second layer, positioned between and adhesively bonded to a film, as the structural material of the outermost layer, and a water- wicking material, as the inner layer, via two separate adhesive layers.
  • FIG. 2 is a cross-sectional view of another specific embodiment of the multilayer sheet illustrating a fiberfill batt as the insulating and absorbent material of the second layer, positioned between a film, as the structural material of the outermost layer, and a water-wicking material, as the inner layer, employing an adhesive layer between the fiberfill batt and inner water-wicking material.
  • a multilayer sheet that can be used for packaging hot foods can comprise or be produced from a combination of a first inner layer comprising a water-wicking material with a second layer comprising an absorbent and highly-thermally insulating material.
  • the multilayer sheet can provide moisture control while maintaining heat retention.
  • Freshly- cooked food quality can be maintained (e.g., "crispness” especially in fried or baked foods) for time periods of at least about 10, or 20, or 30 minutes under ambient conditions, and the food quality is judged to be "excellent".
  • the multilayer sheet may be used in various packaging embodiments and can be used for the "take-out" food packaging market.
  • the first layer of the multilayer sheet of the invention comprises a water-wicking material.
  • This layer can be the innermost layer of the sheet, and is the layer in direct contact with the hot food or interior of the package containing the hot food.
  • the water-wicking capability is one key to preventing the build-up of moisture in the package as the hot food cools, thereby avoiding undesirably soggy food.
  • the first layer facilitates the passage of water and moisture vapor (i.e., wicks) from the interior of the package to the second layer of the rfi ⁇ ltilciysrshfefet.”
  • T ⁇ " dtrso”
  • the water-wicking material can have a non- condensable surface and can have a moisture-vapor transmission rate of at least about 20,000 g/m 2 /day, or at least about 150,000 g/m 2 /day, or at least about 170,000 g/m 2 /day, as tested by ASTM D-6701.
  • the water-wicking material can have a hydrostatic head pressure of less than about 5 cm H 2 0, or less than about 2 cm H 2 0, as tested under AATCC Method 127-1989.
  • the first layer can comprise a nonwoven fabric, preferably a "spunlaced” or "hydroentangled” fabric.
  • spunlaced fabric or “hydroentangled fabric” refers to a nonwoven fabric that is produced by entangling fibers in the web to provide a strong fabric that is free of binders.
  • spunlaced fabrics can be prepared by supporting a nonwoven web of fibers on a porous support such as a mesh screen and passing the supported web underneath water jets, such as in a hydraulic needling process.
  • the fibers can be entangled in a repeating pattern.
  • the nonwoven fabric can be made out of fibers such as polyester, nylon 6,6, or, preferably, a combination of wood pulp and staple poly(ethylene terephthalate) fibers. Such fabrics are available from E. I. du Pont de Nemours and Company, Wilmington, Delaware (DuPont) under the trade name Sontara ® and the thickness can be varied, though generally in the range of about 10-50 mils (0.01 to 0.05 inches).
  • the starting nonwoven layer comprises a thin, supple web of staple fibers, continuous filaments, plexifilamentary strands or the like.
  • the term "fibers" collectively includes each of these fibrous materials.
  • the fibers may be natural fibers, e.g., cellulosic, or may be formed from synthetic organic polymers.
  • the fibers may not bond to each other.
  • Suitable starting nonwoven fibrous layer can be substantially not bonded, and composed of fibers that inherently can absorb or wick liquid, e.g. , polyester and wood pulp, or rayon and wood pulp.
  • the first layer may also comprise paper, preferably with sufficient porosity to function as a water-wicking material.
  • the multilayer sheet includes a second layer comprising an absorbent and insulating material. This layer can be highly thermally ihsufaW ⁇ g-ano! ' somewhat absorbent. The high thermal insulating capability effectively retains heat, slows condensation and thereby reduces liquid moisture formation within a given package.
  • any condensate that is produced is wicked through the first layer and absorbed by the second layer.
  • These combined characteristics of high thermal insulating capability and some absorbency may prevent the build-up of condensate in the package and avoid undesirably soggy food.
  • the multilayer sheet may work successfully because the absorbent and insulating material in the second layer aims to keep the temperature within a given package above the dew point, preventing condensation from forming within the package. If the temperature falls just below the dew point, the water-wicking material of the first layer wicks the liquid from the package interior to the second layer. Hence, the interior of the package is warm but free of liquid moisture that can cause crisp food to turn soggy.
  • the second layer can have a thermal resistance, as measured in units of insulation, or CLO, of at least about 0.05, or at least about 0.1 , or about 0.1 to about 2.5, or 0.1 to 0.5.
  • the CLO unit is defined as a unit of thermal resistance of a garment.
  • the SI unit of thermal resistance is the square-meter kelvin per watt (m 2» K/W) (See “Textile Terms and Definitions", Tenth Edition, The Textile Institute, (1995), pp. 66, 350).
  • the range of thermal resistance in SI units of the absorbent and insulating material of the present invention is at least about 0.0077, preferably at least about 0.0154 m 2, K ⁇ /V.
  • CLO is defined in terms of a garment, but it can be used to describe the thermal resistance of any textile system, and is used herein to describe the thermal resistance of the absorbent and insulating material of CLO values depend on the material used for the layer and its thickness.
  • the necessary level of thermal resistance can be high enough to maintain the temperature within the package above the dew point for at least about 10 or 20 or 30 minutes when the package is exposed to ambient conditions.
  • the water-wicking material of the first layer may also contribute some thermal resistance.
  • the " second Tayef'can have some absorbency due to the high efficiency of the insulating capability, and the resulting minimization of condensation formation. In most cases, the absorbency, in terms of water pressure resistance, may be less than about 50 cm H 2 0.
  • the second layer may comprise an organic thermoplastic fiber- based material comprising, e.g., polyester, polyethylene or polypropylene.
  • the thermal insulating layer can be a fiberfill batt comprising polyester.
  • a fiberfill batt sold as Thermolite ® Active Original by DuPont can be used.
  • the fiberfill batt useful can have an areal weight in the range of 10 gm/m 2 to 200 gm/m 2 , and a bulk density of less than about 0.3 gm/cm 3 .
  • the thermal insulating layer may comprise melt-blown fibers, such as melt- blown polyolefins, sold as THINSULATE ® , by 3M.
  • the absorbent and insulating material may possibly comprise an inorganic thermoplastic fiber-based material comprising glass wool, borosilicate glass or rockwool.
  • the absorbent and insulating material may comprise a knit fabric made, for example, from a tetrachannel or scalloped oval fiber, sold under the trademark Coolmax ® by DuPont.
  • the absorbent and insulating material may be a woven or fleece material.
  • the absorbent and insulating material could also comprise some sort of nonwoven, such as felt, or a highloft nonwoven or needled nonwoven fabric.
  • the thickness of the second layer may vary or depend on the desired level of insulating capability, i.e., thermal resistance. As more thermal resistance is required, the thickness of the layer may increase. Generally, the thickness can fall in the range of about 10 mils to about 500 mils, or about 10 to about 200 mils, or about 10 to about 50 mils. For a second layer comprising polyester fiberfill batt, and within the preferred range for the thermal resistance, the thickness for the layer can range from about 10 to about 500 mils.
  • the multilayer sheet may comprise an optional third, outermost layer comprising a structural material. Use of the third layer may be helpf tl I " f dr ⁇ c ⁇ rtairi 1 considerations in designing a practical package (e.g., impermeability, strength, flexibility).
  • the structural material may comprise film, foil, paper and/or fabric.
  • a film may be made of a thermoplastic material comprising, e.g., polyester, polyethylene or polypropylene.
  • films of oriented polypropylene or oriented polyester can be used. Films of oriented polyester are available from DuPont Teijin Films of Wilmington, Delaware (DuPont Teijin) under the trade names Mylar ® and Melinex ® .
  • the choice of material for the third layer may depend on how the multilayer sheet is used in the packaging, e.g., what type of package is used and what type of food product is packaged. For example, if the desired packaging is a bag or pouch, then paper, foil or a film may be useful.
  • the multilayer sheet may have the structural material contain an adhesive layer to adhere the multilayer sheet to the inside of the package.
  • a peelable backing can also be useful in such a case.
  • a film that is suitable for use as a structural material is Melinex ® 854, commercially available from DuPont Teijin.
  • Melinex ® 854 is a multilayered film, one layer being heat-sealable. This can allow for heat-sealing between the second and third layers.
  • Melinex ® 854 is a 120 gauge (0.0012 inch, or 0.0030 cm.) thick co- extruded biaxially oriented polyester film.
  • the first layer of the film is made from a standard polyester homopolymer, intrinsic viscosity of about 0.590, containing 2500 ppm of inorganic slip additive particles. This layer comprises approximately 65% of the total film thickness.
  • a co-polyester resin comprised of 18 weight % isophthalic acid, intrinsic viscosity of about 0.635, containing 2300 ppm inorganic slip additive particles, is co-extruded to form the heat-sealable layer and comprises 35% (or 15-40%) of the total film thickness.
  • the surface of the first layer opposite the heat sealable layer can be coated in-line by a gravure coater (during the film manufacturing process) with a print primer coating based on an aqueous polyester dispersion at a dry coat-weight of 0.03 g/m 2 .
  • THe' s m ⁇ lti yir sheet ' or liner can further comprise an additive.
  • the additive can be a desiccant such as silica, thermal and ultraviolet (UV) stabilizers, UV absorbers, antistatic agents, processing aids, fluorescent whitening agents, pigments, lubricants, etc. These additives may be present in the compositions used in this invention in quantities that are generally from 0.01 to 20, or 0.1 to 15, weight.
  • the structural material may be modified on the surface facing away from the second layer to facilitate printing thereon by a corona discharge treatment.
  • surface modification i.e., coating or corona discharge treatment
  • an adhesive primer layer may be applied to the untreated surface of the structural material or to the corona discharge treated surface. This adhesive primer layer is pressure sensitive to enable application of the multilayer sheet to a container to function as a package liner.
  • the layers of the multilayer sheet of the invention may be joined by various methods known in the art, one such method being lamination, i.e., uniting layers of material by an adhesive or other means.
  • the adhesive can be applied in various ways, e.g., pattern-application or spray application, or through the use of an adhesive layer, e.g., a thermoplastic adhesive scrim, which is a web-like layer of adhesive.
  • an adhesive layer e.g., a thermoplastic adhesive scrim, which is a web-like layer of adhesive.
  • pattern-application adhesive or an adhesive scrim achieves a similar effect within the multilayer sheet, i.e., there is no complete barrier to moisture transport due to the abundance of free space or holes within the adhesive layer which allows moisture to flow through. This is desirable when laminating the first and second layers.
  • Other means of joining the layers may include pinpoint embossing, needling and quilting, among others known to those of skill in the art. These methods may allow for the free transport of moisture between layers.
  • the adhesive may be a heat-sealable coating on one of the layers to be joined, e.g., on the structural material.
  • the multilayer sheet may be sealed, such as with a hot knife, at its edges so that fluid cannot penetrate the edges.
  • f He" nidltMyilr ⁇ hedl may be used in various ways to package hot foods.
  • One embodiment is simply to use the multilayer sheet in sheet form as a packaging wrap to directly wrap hot foods.
  • the multilayer sheet may be formed into a pouch or bag for wrapping hot foods, e.g., hot sandwiches.
  • the pouches or bags may be manufactured according to any well-known method.
  • a "pouch” means an enclosure sealed on at least two of four sides, though generally sealed on three of four sides with the fourth side being an opening.
  • a pouch is made from a flat web of film by forming a tubular film therefrom with a longitudinal seal and subsequently flattening the tubular film at a first position and transversely heat-sealing said tubular film at the flattened position.
  • a “bag” may be a pouch, but is also meant to include a "stand-up pouch", similar to the commonly-known paper lunch bag, comprising four sides and a rectangular bottom opposite an opening. After inserting the hot food into a pouch or bag of the invention herein, the pouch or bag can be sealed or closed in various ways known to those of skill in the art. The closing may be done mechanically, such as flaps or tabs that can be folded over and/or tucked in; and/or adhesive, such as pressure sensitive adhesive, among others.
  • the multilayer sheet may be used in sheet form as a liner in a package.
  • the package may be a rigid, thermoplastic tray, a box, or even a pouch or bag as discussed above, among others.
  • the box may be a conventional-type box made from paperboard, or possibly could be made from other materials including polymers or foams. Rigid, thermoplastic trays are used often for storing hot food in the
  • Such trays generally comprise a bottom reservoir portion and a lid.
  • the bottom reservoir portion typically comprises a reservoir for holding the food, and the lid is similar in size and shape to the bottom portion.
  • the lid is constructed to fit over the bottom portion to generally seal along the perimeter where the bottom portion and lid meet.
  • the lid and bottom portion may lock together by a variety of mechanisms known in the art, e.g., through the use of small protruding notches on the perimeter of the lid which fit into matching cavities in the bottom portion, or vide Versa.
  • the material " used for the tray and/or lid may be any suitable thermoplastic such as polyester or oriented polystyrene.
  • the tray and/or lid material may also be foam comprising polystyrene, polypropylene or polyester, preferably polystyrene.
  • the multilayer sheet can be used as a liner to improve heat retention and moisture control within the tray. As demonstrated in the Examples, improvement in food temperature and food quality can be attained by affixing the liner to the inside lid of such a package. It is possible that extending the duration of desired temperature and moisture levels within the package could also be attained by affixing the liner to other areas within a package, such as the inside, bottom, of the package.
  • the invention also includes a lid for covering a package, wherein a liner comprising the multilayer sheet is affixed thereto. The lid can be made to cover a variety of package types.
  • Such packages can come in a variety of sizes, shapes and materials and the lid comprising the multilayer sheet disclosed herein.
  • the lid and the package it covers can certainly be made of different materials.
  • Polyester or oriented polystyrene can be useful as materials for lids.
  • a flexible, impermeable layer may be used to prevent leakage of moisture from the food to the consumer.
  • the multilayer sheet can be used in sheet form to act as liner within a package (e.g., take-out tray, box, bag, etc.), or even on the exterior of a package (e.g., covering perforations in a take-out tray lid).
  • the method for making a multilayer sheet can involve laminating a first inner layer to a second inner layer under suitable pressure and heat depending on the type of adhesive method used.
  • Adhesives may be activated by chemical reaction, or be activated by heat, i.e. heat-sealable.
  • other methods known in the art for laminating the layers may also be used, e.g., pinpoint embossing, as discussed above.
  • Pressure may be useful when laminating two layers to facilitate even bonding across the layers, to ensure contact between the two layers to be joined, e.g., for adhesives that are activated by chemical reaction.
  • the first inner layer may be coated with a suitable pattern-applied adhesive on one side, which is the side placed in contact with the second layer prior to lamination.
  • a thermoplastic adhesive scrim can be interposed between the first inner layer and second layer prior to lamination. These methods may be used to join the second layer to an optional third layer. Many other lamination methods known in the art could be used.
  • the multilayer sheet can also be produced by co-extrusion known to one skilled in the art. The following examples are intended to illustrate, not to limit, the scope of the invention. The test method used to determine thermal resistance is also disclosed.
  • Thermolabo II which is an instrument with a refrigerated bath, commercially available from Kato Tekko Co. L.T.D., of Kato Japan, and the bath is available from Allied Fisher Scientific of Pittsburgh, Pennsylvania. Lab conditions were 21 °C and 65% relative humidity. Each sample was a one-piece sample measuring 10.5 cm x 10.5 cm. The thickness of the sample (in inches) at 6 gm/cm 2 was determined using a Frazier Compressometer, commercially available from Frazier Precision Instrument Company, Inc., of Gaithersburg, Maryland.
  • the BT box measured 3.3 inch x 3.3 inch (8.4 cm x 8.4 cm).
  • a heat plate measuring 2" x 2" was in the center of the box, and was Efufrddi ⁇ de ' d By ' Styr ⁇ f diti.
  • 11 Room temperature water was circulated through a metal water box to maintain a constant temperature. A sample was placed on the water box, and the BT box was placed on the sample. The amount of energy (in watts) required for the BT box to maintain its temperature for one minute was recorded.
  • the value 0.00164 was a combined factor including the correction of 2.54 (correcting thickness from inches to cm) times the correction factor of 0.0006461 to convert thermal resistance in cm 2 x °C/Watts. To convert heat conductivity to resistance, conductivity was put in the denominator of the equation.
  • EXAMPLE 1 Preparation of Multilayer Sheet
  • the first layer, 1 is a water-wicking material
  • second layer, 2 is an absorbent and insulating material
  • a third layer, 3, is a structural layer.
  • interposed between these layers are porous, thermoplastic adhesive scrims, 4.
  • These adhesive scrims, 4 are constructed of polyester materials that are spunlaced. They provide a web-like layer, with an abundance of holes, through which water vapor or condensed water can easily pass through.
  • These layers were bonded together by thermal lamination means on a tunnel laminator with a calendar roll, such as the one provided by Inta-Roto Machine Company of Richmond, Va.
  • the structural layer, 1 was a film of the type sold by DuPont Teijin under the trade name Mylar ® .
  • the film was 1.2 mils (0.0012 inch or 0.0030 cm) thick.
  • the absorbent and insulating material, 2 was a fiberfill batt of the type sold by DuPont under the trademark Thermolite ® Active Original.
  • the fiberfill batt, 2 had an areal weight of 80 gm/m 2 at a specified thickness of 0.25 inch (0.63 cm) or a bulk density of 0.013 gm/cm 3 .
  • the water-wicking material, 3, was a nonwoven fabric available from DuPont under the trademark Sontara ® .
  • Sontara ® used in this example comprised hydroentangled, white fibers (45% polyester/55% wood pulp), having an areal weight of 68 g/m 2 and thickness of 13 mils (0.013 in or 0.033 cm).
  • the adhesive webs were of the type sold by Bostik Findley, Inc., and were about 8-10 mils (0.008 to 0.01 inches) thick.
  • EXAMPLE 2 Preparation of Multilayer Shee Bicomponent third layer A multilayer sheet for hot food packaging was made according to the process described above and as illustrated in Figure 2 wherein the first layer, 1 , was a water-wicking material, second layer, 2, was an absorbent and insulating material, and a third layer, 3, was a structural layer.
  • the structural layer, 3, was a bicomponent film of polyester and a heat-sealable layer.
  • the heat-sealable layer acts as the adhesive required to laminate the structural layer to the absorbing and insulating layer.
  • An adhesive scrim, 4, as described in Example 1 (above) was used to adhere the absorbent and insulation layer, 2, to the water-wicking nonwoven layer, 1. These layers were bonded together by thermal lamination means on a tunnel laminator with a calendar roll, such as the one provided by Inta-Roto Machine Company of Richmond, Va. The adhesive layers were activated at temperatures between 240 and 350°F (116-177 C).
  • the structural film layer, 3, was of the type sold by DuPont Teijin under the trade name Mylar ® OL.
  • Mylar ® OL is a biaxially dVierit ⁇ d !! PETfilrfl"hS , i/i i H i g i! a :!
  • the film was 1.5 mils (0.0015 inch or 0.00375 cm) thick.
  • the composition of the heat-sealable layer was an isophthalic acid-base copolyester and comprised 10-50% of the thickness of the total film thickness; 15-30% was preferred.
  • the absorbing and insulating material, 2, w/as a fiberfill batt of the type sold by E. I. du Pont de Nemours and Company under the trademark Thermolite ® Active Original.
  • the fiberfill batt had an areal weight of 80 g/m 2 at a specified thickness of 0.25 inch (0.63 cm) or a bulk density of 0.013 g/cm 3 .
  • the water-wicking layer, 1 was a nonwoven fabric available from DuPont under the trademark Sontara ® .
  • the Sontara ® used in this example comprised hydroentangled, white fibers (45% polyester/55% wood pulp), having an areal weight of B8 g/m 2 and thickness of 13 mils (0.013 in or 0.033 cm).
  • the adh&sive webs were of the type sold by Bostik Findley, Inc., and were about 3-10 mils (0.008 to 0.01 inches) thick. (The thickness varied depending on how much pressure was applied to the web during measuring.)
  • EXAMPLE 3 Chicken Nuggets - Insulated v. Un-insulated trays Using a small-scale deep fryer, two portions of chicken nuggets were produced to test the effectiveness of the multilayer sheet in packaging for heat retention with moisture control. Th e deep fryer was filled with vegetable oil and set to 340°F. A batch consisting of 18 frozen "Banquet” brand chicken nuggets was placed into the hot oil for 4 minutes. After cooking, the hot nuggets were allowed to drain for 15 seconds. After draining, the nuggets were quickly placed into a "take out"-style, polyester (PET) tray, typically available in supermarkets or restaurants for packaging fresh, hot foods.
  • PET polyester
  • the PET tray typically comprises a bottom tray reservoir portion and a top tray or lid, similar in size and shape to the bottom tray.
  • the lid fits over the bottom portion to generally seal along the> perimeter (where the lid and bottom portion meet) and lock in place, typ> ically through the use of small protruding notches on the perimeter of t lid which fit into matching cavities in the bottom portion, or vice versa, thus locking and sealing the tray container.
  • the trays used for this test were Ivex Model # ' 5720-9l 10 ' r vli rfa a ⁇ upreme, medium entree style trays.
  • One tray was insulated using a multilayer sheet as described in the invention herein. The multilayer sheet was placed on the interior on the inside lid (Ex. 3).
  • the multilayer sheet comprised a first layer Sontara ® , a second layer fiberfill batt, and an outer layer Mylar ® , as disclosed in Example 2.
  • the other tray was not insulated.
  • the container was placed on a countertop at ambient conditions and readings were taken from one to twenty minutes at various intervals as shown in Table 1. Table 1
  • EXAMPLE 4 Chicken Breast Strips - Tray Liner and Pouch An experiment was conducted as described in Example 3, except that the food product used was frozen chicken breast strips, rather than chicken nuggets. Four chicken strips were placed in each package. Temperature, humidity, and dew point were recorded using a digital hygrometer. Three different packaging methods were tested; two being modifications to the PET "take-out" tray.
  • the package for Example 4A had the multilayer sheet of the invention herein (similar to that described in Example 2) attached to the lid on the exterior of the PET tray covering holes that were punched in the lid to allow moisture to escape from inside the container. Each hole was Vz inch in diameter, and there were 36 holes in the lid, for a total area of 7 square inches.
  • the package used in Example 4B was a pouch formed from the multilayer sheet of the invention herein (similar to that described in Example 2).
  • the pouch was formed as described in Example 6.
  • the package used in Example 4C was a PET "take-out" tray with a liner comprising the multilayer sheet of the invention herein attached to the inside lid. The results are shown in Table 2.
  • Example 4A Example 4B
  • Example 4C Time (min) op °F Bottom °F Top °F Top °F bottom °F 117 114 106 140 151 1 121 118 108 148 151 1.5 151 150 2
  • RH % Dew point °F RH % Dew point °F RH % Dew point °F RH % Dew point °F 100 103.7 100 118 1 100 100 108.9 100 1.5 100 99 110 100 123.3 2 100 112 93 110 88 122.5 2.5 100 113.2 88 110 83.5 121.6 3 100 113.4 86.5 110.4 80 122 3.5 100 114 86 110.1 78 122 4 100 115.1 82.3 109.5 77 121.2 4.5 100 116.1 76.8 106.6 75.4 121 5
  • Example 5A Example 5B, Example 5C, Time Top °F RH (%) DP (°F) Top °F RH (%) DP (°F) Top °F RH (%) DP (°F) 1 125.2 100 123.7 135 100 110.5 120 100 119 1.5 130.1 100 127.9 128.4 100 113 123.5 98.6 121.4 2 135.7 100 129.7 125.9 100 114 124.7 92 121.2 2.5 138.6 100 129.6 123.8 100 114.3 127.7 89 121.1 3 139.5 100 131.2 122.9 100 114.8 128.4 84 121.5 3.5 140.2 100 131.5 122.2 100 115.5 128.5 83 122.1 4 141.1 100 132 121.4 99 115.5 128.5 81 122.3 4.5 141.4 100 132.4 120.7 97.7
  • Example 5A After 30 minutes the internal chicken temperature was 140°F, and the external air temperature was 117°F. Subjective testing by a food taster rated the product as "excellent”. The food quality rating was focused on the crispness of the food and the scale ran from "excellent", “very good”, “satisfactory”, to “poor”.
  • Example 5B the internal chicken temperature was 137°F after 30 minutes, and the external temperature was 129°F. The product was again rated as "excellent”. Also, by way of comparison, one freshly cooked chicken finger was left outside of the container for 30 minutes to observe how the temperature changed during cooling without any packaging to retain heat. The external temperature was 86°F while the internal temperature was 93.5°F after 30 minutes.
  • Example 5C the internal chicken temperature was 137°F and the external chicken temperature was 133°F after 30 minutes. Product was by way of comparison, a freshly cooked chicken finger was left outside the test package for 30 minutes. After 30 minutes, the internal temperature was 103°F while the external temperature was 94°F. In Example 5D, after 30 minutes the internal chicken temperature was 138°F and the external temperature was 133°F. The food product was rated as "very good”. In Example 5E, the internal chicken temperature was 126°F, and the external temperature was 122°F after 30 minutes. The food product was rated as "very good”. In Comparative Example II, the internal chicken temperature was 127°F, and the external temperature was 119°F after 30 minutes. The food product was rated as "poor to satisfactory”.
  • the hot, freshly-cooked chicken strips that were packaged in take-out trays, with a multilayer sheet of the invention herein attached to the inside lid better retained heat and food quality (i.e., were judged to taste better, generally hotter and crisper, more like freshly- cooked) as compared to chicken packaged in take-out trays with the multilayer sheet on the exterior of the tray.
  • EXAMPLE 6 Chicken Tenders and Steak Fries - Pouches An experiment was conducted as described in Example 3, except the food product used was chicken tenders (Barber brand "Italian style") and the packaging tested was a pouch made from a multilayer sheet as constructed and described in Example 1 (Example 6A). Two pieces of the multilayer sheet, each the same size (approximately 12 in.
  • Example 6B After 15 minutes, the internal temperature of the chicken tenders was 150°F and the food was rated as "satisfactory". Steak fries were tested in a similar manner (Example 6B). A sample of approximately 370 g of frozen steak-style french fries (Ore-Ida brand) were cooked at 375°F for four minutes, drained of cooking oil for 15 seconds, and added to the pouch. Temperature, relative humidity and dew point were recorded for 15 minutes. Results are shown in Table 6.
  • Tab ⁇ e ::; 7 -thicken tenders, un-insulated pouch Time (min) Temp (°F) RH DP (°F) 1 87.8 100 89.7 2 97.8 100 95 3 98.5 100 98.3 5 96.5 100 98.7 7 95.2 100 98.9 9 91.9 100 94.9 10 91.3 100 89.8 15 92.1 100 86
  • Example 6 This example was conducted in a manner similar to that in Example 6.
  • the pouches were made from a multilayer sheet similar to that described in Example 1 with the exception that the first inner layer was a polyolefin nonwoven, available under the trade name Tyvek ® from DuPont.
  • the p ⁇ uch was formed from two pieces of the multilayer sheet, each the same size, here approximately 10 in. x 10 in., sealed on three sides with masking tape.
  • Four pieces of chicken tenders (approximately 240 g) were cooked at 340°F for four minutes, drained of cooking oil for 15 seconds, and then placed in the pouch. Temperature, relative humidity and dew point were recorded for 15 minutes. The results are shown in Table 9.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Food Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Packages (AREA)
  • Laminated Bodies (AREA)
  • Wrappers (AREA)

Abstract

L'invention concerne une barquette pourvue d'une doublure. Cette doublure comporte au moins deux couches constituées d'un matériau permettant l'imbibition d'eau par capillarité, tel qu'un nontissé, qui présente un taux de perméabilité à la vapeur d'eau d'au moins environ 20 000 g/m2 par jour et une pression de refoulement hydrostatique inférieure à environ 5 cm H20, ainsi que d'un matériau absorbant et offrant une haute isolation thermique.
EP05726028A 2004-03-19 2005-03-18 Barquette absorbante et isolante pour aliments a emporter Withdrawn EP1725474A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US55456604P 2004-03-19 2004-03-19
PCT/US2005/009504 WO2005092739A1 (fr) 2004-03-19 2005-03-18 Barquette absorbante et isolante pour aliments a emporter

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EP1725474A1 true EP1725474A1 (fr) 2006-11-29

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GB0918084D0 (en) 2009-04-17 2009-12-02 Dawson Sons & Company Wool Ltd Packaging assembly and method
US20130056369A1 (en) * 2011-09-03 2013-03-07 Antoinette K. Jorgensen Hot food container moisture absorbent insert
ITUA20163247A1 (it) * 2016-05-09 2017-11-09 Coopbox Group S P A Vaschetta multistrato con effetto drenante e relativo metodo di produzione
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CN1953913A (zh) 2007-04-25
BRPI0508201A (pt) 2007-07-17
AU2005227318A1 (en) 2005-10-06
WO2005092739A1 (fr) 2005-10-06
US20050260367A1 (en) 2005-11-24
JP2007529382A (ja) 2007-10-25

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