EP3921241A1

EP3921241A1 - Injection moulded food grade container with recycled plastic

Info

Publication number: EP3921241A1
Application number: EP20705032.9A
Authority: EP
Inventors: Benny Nielsen
Original assignee: RPC Superfos AS
Current assignee: RPC Superfos AS
Priority date: 2019-02-08
Filing date: 2020-02-10
Publication date: 2021-12-15
Also published as: WO2020161361A1

Abstract

A container suitable for containing food products for human consumption, said container comprising a bottom portion and a sidewall portion extending upwardly from the bottom portion, said sidewall portion having an upper edge forming an opening which is closable by mounting a lid onto the upper edge. The sidewall portion and the bottom portion comprise a first layer and a second layer, said second layer being arranged outside the first layer, said second layer being injection moulded from a plastics material comprising at least 20% recycled plastics material and said first layer comprising a functional barrier material such that a food product arranged inside the container would be separated from the second layer by the functional barrier material of the first layer.

Description

Injection moulded food grade container with recycled plastic

The current invention relates to a container suitable for containing food products for human consumption, said container comprising a bottom portion and a sidewall portion extending upwardly from the bottom portion, said sidewall portion having an upper edge forming an opening which is closable by mounting a lid onto the upper edge. In this type of container, the food product is held inside the container and the food product is in contact with the side walls of the container. As such the material of the container itself needs to be made from a material which is food grade certified.

Recently, due to increased environmental concerns, many people wish to reduce the amount of plastic material consumed globally. One way to reduce the amount of plastic consumed, is to increase the amount of recycling of plastics. It is expected that in the future specific rules will be imposed forcing manufacturers to use more recycled plastics. This can already be seen in for example the UK where the authorities require that injection moulded plastic containers comprise at least 30% by weight recycled plastic. This is typically fine for normal containers, since large quantities of recycled plastics are already available for use. However for food grade containers where a food product is in direct contact with the plastic material, the plastic material needs to be plastic which is food grade certified. Recycled plastic which is food grade certified is not so common and is quite expensive.

For typical food containers, it is desired to use Poly Propylene (PP). There is a lot of recycled PP material on the market, but it is used for all sorts of other products and it is expensive to treat to make it food grade certified. It is therefore difficult and expensive to get a hold of food grade certified recycled PP Summary of the invention

A first aspect of the current invention is therefore to provide a food grade injection moulded container with a high percentage of recycled plastics material.

A second aspect of the current invention is to provide a food grade injection moulded container with a reduced cost.

These aspects are provided at least in part by a container as mentioned in the opening paragraph and where the sidewall portion and the bottom portion comprise a first layer and a second layer, said second layer being arranged outside the first layer, said second layer being injection moulded from a plastics material comprising at least 20% recycled plastics material and said first layer comprising a functional barrier material such that a food product arranged inside the container would be separated from the second layer by the functional barrier material of the first layer. In this way, a container is provided where the food product is separated from the recycled plastic material by the functional barrier material. In one embodiment, the plastics material comprises at least 30%, at least 35%, at least 40% or at least 50% recycled plastics material.

The term functional barrier material should, in the context of the current invention, be understood as a material which prevents undesired chemicals trapped in the recycled plastics material of the second layer from wandering out of the recycled plastics material and through the layer with the functional barrier material in a quantity which is undesireable. Depending on the degree of contamination or risk of contamination of the recycled plastics material, the functional barrier material could be different types. In a case where a light contamination is present, a rather simple functional barrier material could be provided. In a case where a more significant contamination is present, a stronger functional barrier material would be needed. One typical functional barrier material would be ethylene vinyl alcohol (EVOH). Another material could be PolyEster or Polyethylene terephthalate (PET). However, in certain cases, it might be enough to provide a clean layer of PP on one side of the contaminated plastics material layer. The person skilled in the art will be able to test a material if it is suitable for use as a functional barrier material when considering the food product and the material of the second layer.

In one embodiment, the first layer is a thermoformed layer. In this case, the thermoforming could be made via a pressure applied on the inside of the thermoformed layer, or it could be made with a vacuum applied on the outside of the thermoformed layer. In one embodiment, the thermoformed layer is preformed with a mechanical press prior to the pressure or vacuum forming.

In one embodiment, the second layer is provided with at least one opening in the bottom portion of the second layer of the container to allow air trapped in the space between the first and second layers to escape the space. This could be formed via the injection moulding process where holes are formed via the injection mould itself. In another embodiment, holes are made after the injection moulding process is completed.

In one embodiment, the at least one opening in the bottom portion of the second layer comprises a plurality of spaced apart small holes arranged at the intersection between the bottom portion and the sidewall portion.

In one embodiment, the container further comprises a label or a foil layer arranged on the outside of the second layer. In one embodiment, said label or foil layer comprises a functional barrier material. In one embodiment, the label is arranged on the outside of the second layer via an In Mould Label (IML) process during the injection moulding of the second layer. In one embodiment, the container comprises an upper stacking element and a lower stacking element, where the upper and lower stacking elements are arranged such that when a first container is stacked on top of a second container, then the upper stacking element of the second container is in contact with the lower stacking element of the first container and where the upper and/or the lower stacking elements are provided with a functional barrier element which separates the inner surface of the container from the recycled material of the second layer.

In one embodiment, the upper stacking element is a rib on a lower portion of the inside surface of the container and that the lower stacking element is a bottom edge of the container and in that the upper stacking element is covered by the thermoformed inner layer and in that the lower stacking element is provided with a film comprising a functional barrier material on the outside of the lower stacking element.

In another embodiment, the upper edge of the container comprises an outwardly extending portion having an upper surface and a lower surface, said upper stacking element being an upwards facing surface of the outwardly extending portion and said lower stacking element being a downwards facing surface of the outwardly extending portion, said container being arranged such that when a first container is stacked on top of a second container, the outer surface of the first container is not in contact with the inner surface of the second container.

In one embodiment, the thermoformed first layer has a wall thickness of less than 200 pm. In one embodiment, the first layer has a thickness of less than 100 pm or less than 50 pm.

In one embodiment, an upper and outer edge of the second layer has an outer diameter D and the first layer has a tab portion arranged at the upper edge of the container, said tab portion extending outwardly past the upper and outer edge of the second layer. In this way, it is easy for a user to grip the tab and separate the first and second layers. In one embodiment, the tab portion extends at least 5mm, at least 7mm or at least 10mm past the upper and outer edge of the second layer.

In one embodiment, an upper and outer edge of the second layer has an outer diameter D and the second layer has a weakened area in the upper and outer edge which extends inwardly from the upper and outer edge. In one embodiment, the first layer covers the weakened area of the upper and outer edge of the second layer. In one embodiment, the weakened area extends down from the upper and outer edge into the sidewall portion of the second layer. In one embodiment, the weakened area is encircled by a line of perforations or a groove in the material of the second layer. By providing a weakened area in the second layer, the weakened area can be separated from the remainder of the second layer to allow easier removal of the first layer from the second layer.

In one embodiment, instead of a weakened area, the second layer has a recess in the upper and outer edge which extends inwardly from the upper and outer edge. In one embodiment, the recess extends down from the upper and outer edge into the sidewall portion of the second layer. In one embodiment, the recess in the second layer is covered by the foil of the first layer.

In one embodiment, the weakened area and/or the recess has an area of at least 1 cm², at least 1 .25cm² or at least 1 .5cm². In one embodiment, the width of the weakened area and/or the recess is at least 1 cm, at least 1 25cm or at least 1 5cm. In one embodiment, the weakened area or the recess is clearly identified on the outside of the container by visual indications.

The invention also relates to a method of manufacturing a container, said method comprising the steps of: a) providing a first batch of plastic material having at least 20% by weight of recycled plastic material, b) injection moulding an outer container from the first batch of plastic material, c) providing a film comprising a layer with a functional barrier material, and d) thermoforming the film onto the inside of the outer container.

In one embodiment, prior to thermoforming the film onto the inside of the outer container, the outer container is heated and/or the inner surface is coated with an adhesive.

In another method of manufacturing a container, the method comprises the steps of: a) providing a first batch of plastic material having at least 20% by weight of recycled plastic material, b) injection moulding an outer container from the first batch of plastic material, c) providing a film comprising a layer with a functional barrier material, and d) forming an inner container from the film, said inner container having an outer surface which corresponds to the inner surface of the outer container, and e) inserting the inner container into the outer container.

In one embodiment, an adhesive is applied to the outer surface of the inner container and/or the inner surface of the outer container prior to inserting the inner container into the outer container. In one embodiment, the inner container is compression injection moulded or thermoformed.

In one embodiment of the method, in between steps a) and b) a label or foil comprising a layer with a functional barrier material is inserted into the mould of the outer container, such that after moulding the outer container, the label or foil forms at least a portion of the outer surface of the outer container.

In another embodiment of a method of manufacturing a container, the method comprises the steps of: a) providing a first batch of plastic material having at least 20% by weight of recycled plastic material, b) injection moulding an outer container from the first batch of plastic material, c) providing a second batch of plastic material, said second batch comprising a food grade plastics material and a barrier material, d) compression injection moulding an inner container from the second batch of plastic material, and e) inserting the inner container into the outer container.

The invention also relates to a container as described above but where the container further comprises a lid mounted on the container to seal the opening and a food product suitable for human consumption arranged inside the container.

It should be emphasized that the term "comprises/comprising/comprised of when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

Brief description of the drawings

In the following, the invention will be described in greater detail with reference to embodiments shown by the enclosed figures. It should be emphasized that the embodiments shown are used for example purposes only and should not be used to limit the scope of the invention. Figure 1 shows a schematic perspective view of one potential embodiment of a container according to the current invention.

Figure 2 shows a schematic perspective exploded view of one potential embodiment of a container according to the current invention.

Figure 3 shows a schematic side cross section view showing a container according to a first embodiment of the current invention.

Figure 4 shows a schematic side cross section view showing an upper stacking element and a lower stacking element according to a second embodiment of a container according to the current invention.

Figure 5 shows a schematic side cross section view showing two containers stacked on top of each other according to the second embodiment of a container according to the current invention.

Figure 6 shows a schematic side cross section view showing an upper stacking element and a lower stacking element according to a third embodiment of a container of the current invention.

Figure 7 shows a schematic side cross section view showing two containers stacked on top of each other according to the third embodiment of a container of the current invention.

Figure 8 shows a flowchart illustrating a method for manufacturing a container according to a potential embodiment of a container of the current invention. Figure 9 shows a flowchart illustrating a method for manufacturing a container according to an alternative potential embodiment of a container of the current invention.

Figure 10 shows a schematic exploded perspective view of an alternative potential embodiment of a container according to the the current invention.

Figure 11 shows a schematic perspective view of an alternative potential embodiment of the second layer of a container according to the current invention.

Detailed description of the embodiments

Figure 1 shows a perspective view of a container 100 according to a first embodiment of the current invention, and Figure 2 shows an exploded view of the first embodiment of the container 100 according to the current invention. The container 100 includes a bottom portion 102 and a sidewall portion 104 extending upwardly from the bottom portion 102. In the current embodiment, the sidewall portion 104 extends from the bottom portion 102 in a cylindrical shape or an inverted frustoconical shape. Flowever, in other embodiments, other cross sectional shapes, for example square or rectangular, could also be imagined. The sidewall portion 104 defines an upper edge 106 of the container 100. The upper edge 106 is disposed away from the bottom portion 102 and defines an access opening 110 of the container 100. The access opening 110 facilitates an entry of a food article inside the container 100 and an exit of the food article from the container 100. Further, a bottom edge 112 of the container 100 may be defined at an interface between the bottom portion 102 and the sidewall portion 104.

Referring to FIG. 1 , FIG. 2, and FIG. 3, the bottom portion 102 and the sidewall portion 104, are each formed by a first layer 120 and a second layer 122 disposed outside of the first layer 120. The second layer 122 is formed as an injection moulded container, made from a plastic material having at least 20% by weight of a recycled plastic material. In the current embodiment, the second layer 122 of the container 100 is made from a Poly Propylene (PP) plastics material with at least 20% by weight of a PP material. In one embodiment, the first layer 120 has a wall thickness of less than 200 pm. In one embodiment, the first layer 120 has a thickness of less than 100 pm or less than 50 pm.

A tab 103 is provided on the first layer to allow a user to grip the foil material of the first layer and more easily separate it from the material of the second layer to make recycling easier.

While the second layer 122 is made of the recycled plastic material, in this embodiment, the first layer 120 is a thermoformed layer and includes a functional barrier material to prevent migration of impurities from the second layer 122 to an inner surface 146 of the container 100. In certain implementations, the first layer 120 may be made entirely from the functional barrier material. In an embodiment, ethylene vinyl alcohol (EVOH) may be used as a functional barrier material. Another material that may act as functional barrier material may be Polyester or Polyethylene terephthalate (PET).

However, in certain cases, it might be enough to provide a first layer as a clean layer of poly propylene on the inside of the second layer which contains the potentially contaminated recycled plastics material. Using a combination of a clean material layer and a potentially contaminated layer where the base material of the clean and contaminated layer are the same, makes recycling the final product easier. It may be appreciated that the depending on the degree of contamination or risk of contamination of the recycled plastics material, the functional barrier material could be different types. In a case where a light contamination is present, a rather simple functional barrier material could be provided. In a case where there is a higher risk of a more significant contamination being present, a stronger functional barrier material would be needed. The person skilled in the art will be able to test a material if it is suitable for use as a functional barrier material based on the food product and the amount of impurities present in the second layer. In an embodiment, the person skilled in the art may perform a permeability test to ascertain a suitability of material as a functional barrier material.

In certain implementations, the first layer 120 may include two layers made of different materials. For example, the first layer 120 may be comprised of an inner layer 130 (hereinafter referred as a third layer 130) made of food grade plastic material, and an outer layer 132 (hereinafter referred as a fourth layer 132) sandwiched between the third layer 130 and the second layer 122. In such a case, the fourth layer 132 may contact the second layer 122, and includes functional barrier material to prevent a migration of impurities from the second layer 122 to the third layer 130. In certain embodiments, the first layer 120 is a thermoformed layer made from a film comprising the third layer 130 of polypropylene and the fourth layer 132 of ethylene vinyl alcohol (EVOH). In such a case EVOH may act as functional barrier material.

In an embodiment, the bottom portion 102 may include one or more openings 140 (shown in FIG. 3, FIG. 4, and FIG. 7) extending from an outer surface 142 of the container 100 and through an entire thickness of the second layer 122. One or more openings 140 facilitate escaping of gases trapped between the first layer 120 and the second layer 122 during an assembly of the first layer 120 and the second layer 122. In the figures, the openings are shown schematically. In one actual embodiment, the openings are placed in the bottom portion and adjacent to the sidewall portion, i.e. in the bottom corner at the intersection between the bottom portion and the sidewall portion.

For food containers, it is very typical that the containers are manufactured in one location, then they are stacked one inside the other and then transported to a second location where they are filled with a food product and closed. In the case where they are stacked inside each other, the outer surface of an upper container will most likely be in contact with the inner surface of another stacked container. In the case where the outer layer comprises a plastic material with a “non-clean” recycled material, there is a risk that the impurities of the recycled material wander over onto the inner surface of the clean inner layer i.e. the first layer 120, when the containers are stacked.

Therefore, for facilitating a stacking of the containers and preventing the risk of migration of contaminants in the recycled material wandering to the inner surface 146 of the first layer 120, the container 100, additionally, or optionally, may include a barrier film 170 (shown in FIG. 3) disposed outside the second layer 122 and abutting the second layer 122. In such a case, the second layer 122 is sandwiched between the first layer 120 and the barrier film 170. The barrier film 170 may extend along an entire sidewall portion 104 and the bottom portion 102 of the container 100. The barrier film 170 may include functional barrier material to prevent the impurities of the recycled material from wandering over onto the inner surface 146 (i.e. the first layer 120) of the container 100” in stacking of the containers 100.

Referring to FIG. 4, a container 100’ is shown according to an alternative embodiment of the disclosure. A structure and construction of the container 100’ is similar to a structure and construction of the container 100 apart from that the container 100’ includes an upper stacking element 148’ and a lower stacking element 150’ for facilitating stacking of the containers 100’. Also, the container 100’ includes the barrier film 170’ that covers the lower stacking element and/or the upper stacking element instead of a barrier film of the container that covers the entire second layer of the container. Further, the elements of the container 100’ having similar constructional and structural aspects as that of the elements of the container 100 will have same reference numerals.

As shown in FIG. 4, the upper stacking element 148’ and the lower stacking element 150’ may be, respectively, defined by an upward facing surface 152 and a downward facing surface 154 of an outwardly extending portion 156 of the upper edge 106 of the container 100. Therefore, the upper stacking element 148’ may form a part of an inner surface 146 of the container 100’. In an embodiment, the upper stacking element 148’ may be defined as a step 158 disposed on an inner side 160 of the container 100’, and is covered by the first layer 120. Further, the lower stacking element 150’ may form a part of the outer surface 142 of the container 100’. In an embodiment, the lower stacking element 150’ may be defined as a step 162 disposed on an outer side 164 of the container 100’, and is covered by the second layer 122. Further, the lower stacking element 150’ includes the barrier film 170’ covering the second layer 122 and containing a functional barrier material to prevent the impurities of the recycled material from wandering over onto an inner surface 146 of an adjacent stacked container.

Alternatively, the upper stacking element 148’ may be a protrusion extending radially inwardly from the inner surface 146 of the container 100’ and covered by the first layer 120. In some implementations, the upper stacking element 148’ may extend continuously in a circumferential direction along the inner surface 146 the container 100’. Alternatively, the upper stacking element 148’ may be disposed along a part of the circumference of the container 100’, thereby the upper stacking element 148’ has a length corresponding to a circumference of a sector or an arc of a circle. In certain other implementations, the container 100’ may include a plurality of upper stacking elements circularly arrayed circumferentially on the inner surface 146 of the container 100’. In such a case, a gap may exist between two consecutive upper stacking elements 148’. Similar to the upper stacking element 148’, in certain other scenarios, the lower stacking element 150’ may be a protrusion extending radially outwardly from the outer surface 142 of the container 100’, and may extend along an entire outer circumference of the container 100’ in a shape of a ring. Alternatively, the lower stacking element 150’ may be disposed along a part of the circumference of the container 100’ thereby the lower stacking element 150’ has a length corresponding to a circumference of a sector or an arc of a circle. In certain other implementations, the container 100’ may include a plurality of lower stacking elements circularly arrayed circumferentially on the outer surface 142 of the container 100’. In such a case, a gap may exist between two consecutive lower stacking elements 150’.

Referring to FIG. 5, a stacking of two containers 100’, for example a first container 100’a and a second container 100’b are shown. As shown, in a stacked configuration of the containers 100’a, 100’b, the lower stacking element 150’ of the second container 100’b abuts and rests on the upper stacking element 148’ of the first container 100’a. The abutment of the upper stacking element 148’ of the first container 100’a with the lower stacking element 150’ of the second container 100’b facilitates in maintaining a gap ‘G’ between inner surface 146 (i.e. first layer 120) of the first container 100’a and the outer surface 142 (i.e. second layer 122) of the second container 100’b. Therefore, the lower stacking element 150’ and the upper stacking element 148’ together are configured to prevent an abutment of a first layer 120 of the container 100’ with a second layer 122 of a consecutive container that is stacked on top of the container 100’ and is disposed, at least partly, inside the container 100’ in a stacking of the containers 100’. In so doing, a transfer or migration of impurities of recycled plastic material of the second layer 122 of the second container 100’b to the first layer 120 of the first container 100a is prevented in the stacking of the containers 100’a, 100’b.

Referring to FIG. 6, a container 100” is shown according to an alternative embodiment of the disclosure. A structure and construction of the container 100” is similar from a structure and construction of the container 100’ apart from a structure, construction, and positioning of the upper stacking element and the lower stacking element. Further, the elements of the container 100” having similar constructional and structural aspects as that of the elements of the container 100’ will have same reference numerals.

As shown in Fig. 6, the container 100” may include a rib 200 on a lower portion of the inner surface 146 of the container 100”. In an embodiment, the rib 200 may extend from the bottom portion 102 towards the upper edge 106, and may define a second step 202. The second step 202 and therefore the rib 200 defines an upper stacking element 148” of the container 100”. The upper stacking element 148” is covered by the first layer 120. In an embodiment, the second step 202 may include a seat 204 defined along an edge 206 of the step 202 to facilitate a seating of a container inside the container 100” in a stacking of the containers. In an embodiment, the seat 202 may include an L-shape. Further, as shown, the upper stacking element 148” may be disposed proximate to the bottom edge 112 relative to the upper edge 106.

Further, the container 100” may include a lower stacking element 150” defined by the bottom edge 112 of the container 100”. The lower stacking element 150” is provided with a barrier film 170’ having a functional barrier material on the outside of the lower stacking element 150” and covering the second layer 122. In an embodiment, the lower stacking element 150” may be defined at least partly by the bottom portion 102 disposed along the bottom edge 112 and at least partly by the sidewall portion 104 disposed along the bottom edge 112. In such a case, the lower stacking element 150” may include a shape and dimension which is complementary to the seat 202. Therefore, in some embodiments, the lower stacking element 150” may include an L shaped cross-section. Further, the lower stacking element 150” includes a barrier film 170” covering the second layer 122 and containing a functional barrier material to prevent the impurities of the recycled material wander over onto an inner surface 146 of a consecutively stacked container.

Referring to FIG. 7, a stacking of two containers 100”, for example a first container 100”a and a second container 100”b are shown. As shown, in a stacked configuration of the containers 100”a, 100”b, the lower stacking element 150” of the second container 100”b abuts and rests on the upper stacking element 148” of the first container 100”a. The abutment of the upper stacking element 148” of the first container 100”a with the lower stacking element 150” of the second container 100”b facilitates in maintaining a gap ‘GT between the inner surface 146 (i.e. first layer 120) of the first container 100”a and the outer surface 142 (i.e. second layer 122) of the second container 100”b. Therefore, the lower stacking element 150” and the upper stacking element 148” together are configured to prevent an abutment of a first layer 120 of the container 100’ with a second layer 122 of a consecutive container that is stacked on top of the container 100” and is disposed, at least partly, inside the container 100” in a stacking of the containers 100”. In so doing, a transfer or migration of impurities of recycled plastic material of the second layer 122 of the second container 100”b to the first layer 120 of the first container 100”a is prevented in the stacking of the containers 100”a, 100”b.

Referring to Fig. 8, a method 800 for forming the container 100 according to an exemplary embodiment, is described. Although, the method 800 is described for manufacturing the container 100, it may be appreciated that method 800 and its various steps may also be applied for manufacturing the container 100’, 100”. The method 800 includes a step 802 in which a first batch of plastic material is provided into an injection moulding machine for forming a second layer 122 of the container 100. The plastic material includes at least 20% by weight of a recycled plastic material. In an embodiment, the plastic material used for forming the second layer 122 may include poly propylene. Although poly propylene is considered as a suitable plastic material for forming the second layer 122 of the container 100, it may be appreciated that any other such plastic material, such as, but not limited to, PET, Polyvinyl chloride, or any other suitable material for forming the second layer 122 of the container 100 may also be utilized.

After providing the first batch of plastic material in to the machine, the machine is operated to melt the first batch of plastic material, and the melted plastic material is injected into a mould for injection moulding the first batch of plastic material into an outer container (i.e. the second layer 122) at a step 804 of the method 800.

Additionally, or optionally, in certain embodiments, before injecting the melt of first batch of plastic material into the mould, a foil comprising a layer with a functional barrier material is inserted into the mould, such that after moulding the outer container (i.e. the second layer 122), the label forms at least a portion of the outer surface 142 of the outer container (i.e. the second layer 122). For example, for manufacturing the container 100, the foil may be attached to the entire outer surface of the second layer 122— thereby forming the foil layer or label 170 of the container 100. In some other embodiments, the foil layer may be attached to an outer surface corresponding to the lower stacking element 150’, 150” of the container 100’, 100”, and thereby correspondingly form the foil layer or the label or the barrier film 170’, 170”.

Thereafter, the method 800 moves to a step 806 in which a film having a layer with a functional barrier material is provided. Thereafter, at step 808 of the method 800, the film is thermoformed on an inside of the outer container. For so doing, according to an embodiment, the finished injection moulded container i.e. the outer container is transferred into a thermoforming mould, where the film is joined to an upper edge of the outer container (i.e. second layer 122). In an embodiment, the film may be adhesively joined to the upper edge of the inner surface of the outer container. Alternatively, the film may be welded to the upper edge. Other forms of joining the film to the upper edge of the inner surface of the outer container may also be contemplated.

Thereafter, the film is heated and thermoformed into the outer container, resulting into a formation of the first layer 120 of the container 100. In one embodiment, a mandrel is pressed into the foil material to pre-stretch it, after which pressure is applied to the foil to push it out into contact with the inner surface of the outer container. Since the foil is heated, it will attach to the inner surface of the second layer 122 (i.e. the outer container).

In one embodiment, instead of applying pressure on the inside surface of the foil to press it outwards, in one embodiment, a vacuum may be applied on the outside of the foil to pull it outwardly.

In both cases of applying pressure and applying vacuum, it is necessary to evacuate the air between the foil and the second layer 122 (i.e. outer container). In one embodiment, the second layer 122 is formed with at least one opening 140 in the second layer 122 through which air can escape. In one embodiment, the plurality of openings 140 is placed in the bottom portion of the second layer 122 during the injection moulding process. In another embodiment, the openings 140 are made by perforating the bottom portion of the second layer 122 after injection moulding the second layer 122.

Referring to Fig. 9, a method 900 for forming the container 100, according to an alternative exemplary embodiment, is described. The method 900 includes a step 902 which is similar to the step 802 of the method 800 in which an operator or a conveyor provides a first batch of plastic material containing at least 20% by weight of recycled material to a machine. Thereafter, the method 900 proceeds to a step 904 which is similar to the step 804 of the method 800. At the step 904, the first batch of plastic material is formed into an outer container by injection moulding. Thereafter, the method moves to a step 906 which is similar to the step 806 of the method 800. At the step 906, a film is provided for thermoforming an inner container (i.e. the first layer 120)

At a step 908 of the method 900, the inner container is formed by using a thermoforming method such that an outer surface of the inner container is complementary to a shape of an inner surface of the outer container (i.e. the second layer 122) formed at the step 904. In this case, the thermoforming of the inner container could be made via a pressure applied on the inside of the film, or it could be made with a vacuum applied on the outside of the film. In one embodiment, the film is preformed with a mechanical press prior to the pressure or vacuum forming. In another method, instead of thermoforming the film, a first layer is made from a compression injection moulding process. In this way, a very thin first layer 120 can be manufactured. In an embodiment, PET or polyester material may be used for forming the inner container (i.e. the first layer 120). PET material has good barrier properties as well as good stretching properties, making it both suitable for a compression injection moulded first layer and a thermoformed first layer.

Thereafter, the method 900 moves to a step 910. At the step 910, the inner container is inserted inside the outer container and assembled with the outer container. The inner container (i.e. the first layer 120) may be assembled with the outer container (i.e. the second layer 122) such that the fourth layer 132 of the first layer 120 contacts the inner surface of the outer container. In an embodiment, prior to inserting the inner container inside the outer container, the inner surface of the outer container may be heated and an adhesive may be applied to adhesively attach the outer container with the inner container. In another embodiment, a welding may be performed to attach the inner container to the outer container. Further, it may be appreciated that the other known processes may also be utilized for assembling the inner container inside the outer container to form the container 100.

Figure 10 schematically shows an embodiment 300 of a container, which is very similar to the embodiment 100 shown in figures 1 and 2. As such, similar reference numerals will be used for similar portions and the details which are similar to the embodiment in figures 1 and 2 will not be described in detail again here.

The main difference in this embodiment is that there is no“tab” portion on the upper edge of the first layer. Instead, a weakened area 302 is provided on the upper edge and on the sidewall portion of the second layer. In this embodiment, the weakened area is delimited by a perforation line 304 shown by a dotted line. In another embodiment, the weakened area could also be delimited by a groove or a thinner portion of the second layer. The weakened area could be provided after the injection moulding step has been completed, for example, by pressing a series of perforations or a groove into the material after the moulding operation. In another embodiment, the injection moulding operation itself provides the weakened area, for example via a retractable core, or by providing a thinner area in the injection mould.

Figure 11 shows another embodiment, where instead of a weakened area, a recess is provided in the top edge of the second layer and/or in the sidewall portion of the second layer. During the assembly with the first layer, the recess allows the user to much more easily grasp the first layer in order to remove it from the second layer. In this way, the first and second layers can be easily separated and disposed of separately. This helps with recycling. The recess can be provided by injection moulding the recess or by cutting it out after the injection moulding process is complete.

It is to be noted that the figures and the above description have shown the example embodiments in a simple and schematic manner. Many of the specific mechanical details have not been shown since the person skilled in the art should be familiar with these details and they would just unnecessarily complicate this description. For example, the specific materials used and the specific injection moulding procedure have not been described in detail since it is maintained that the person skilled in the art would be able to find suitable materials and suitable processes to manufacture the container according to the current invention.

Claims

1. A container suitable for containing food products for human consumption, said container comprising a bottom portion and a sidewall portion extending upwardly from the bottom portion, said sidewall portion having an upper edge forming an opening which is closable by mounting a lid onto the upper edge, characterized in that the sidewall portion and the bottom portion comprise a first layer and a second layer, said second layer being arranged outside the first layer, said second layer being injection moulded from a plastics material comprising at least 20% recycled plastics material and said first layer comprising a functional barrier material such that a food product arranged inside the container would be separated from the second layer by the functional barrier material of the first layer.

2. A container according to claim 1 , characterized in that the first layer is a thermoformed layer.

3. A container according to claim 1 or 2, characterized in that the second layer is provided with at least one opening in the bottom portion of the container to allow air trapped in the space between the first and second layers to escape the space.

4. A container according to claim 3, characterized in that at least one opening in the bottom portion of the second layer comprises a plurality of spaced apart small holes arranged at the intersection between the bottom portion and the sidewall portion.

5. A container according to any one of claims 1 to 4, characterized in that the container further comprises a label or foil layer arranged on the outside of the second layer.

6. A container according to claim 5, characterized in that said label or foil layer comprises a functional barrier material.

7. A container according to any one of claims 1 to 6, characterized in that the container comprises an upper stacking element and a lower stacking element, where the upper and lower stacking elements are arranged such that when a first container is stacked on top of a second container, then the upper stacking element of the second container is in contact with the lower stacking element of the first container and where the upper and/or the lower stacking elements are provided with a functional barrier element which separates the inner surface of the second container from the recycled material of the second layer.

8. A container according to any one of claims 1 to 7, characterized in that the thermoformed first layer has a wall thickness of less than 200 pm.

9. A container according to any one of claims 1 to 8, characterized in that an upper and outer edge of the second layer has an outer diameter D and in that the first layer has a tab portion arranged at the upper edge of the container which extends outwardly past the upper and outer edge of the second layer.

10. A container according to any one of claims 1 to 9, characterized in that the upper and outer edge of the second layer has an outer diameter D and in that the second layer has a weakened area or a recess which extends inwardly from the upper and outer edge.

11. A container according to claim 10, characterized in that the weakened area or recess extends past the upper and outer edge and extends downwardly into the sidewall portion.

12. A method of manufacturing a container, said method comprising the steps of:

a. providing a first batch of plastic material having at least 20% by weight of recycled plastic material,

b. injection moulding an outer container from the first batch of plastic material,

c. providing a film comprising a layer with a functional barrier material, and

d. thermoforming the film onto the inside of the outer container.

13. A method of manufacturing a container, said method comprising the steps of:

c. providing a film comprising a layer with a functional barrier material, and

d. thermoforming an inner container from the film, said inner container having an outer surface which corresponds to the inner surface of the outer container, and

e. inserting the inner container into the outer container.

14. A method according to claims 12 or 13, characterized in that between steps a) and b) a label or foil comprising a layer with a functional barrier material is inserted into the mould of the outer container, such that after moulding the outer container, the label or foil forms at least a portion of the outer surface of the outer container.