KR20050107602A - System and method for forming an integrated tray for use in vacuum packaging - Google Patents

Abstract

A bag for use in vacuum packaging can comprise a first panel (320) and a second panel (322) overlapping each other. One or more trays (230) for retaining a perishable or other product is formed on one or more of the panels. Each tray can optionally have ridges (234) for suspending a product above the tray so that liquid can collect in the tray. In one embodiment, a method for forming such a bag between a cooling roll (104) and laminating roll (102) includes feeding a gas-impermeable material (108) to a nip formed between the rolls. Resin is extruded to the nip such that the resin fills a plurality of cavities of the cooling roll, forming an inner layer that adheres to the gas-impermeable material. A resultant sheet is then folded to form the first and second panel and sealed such that an envelope is formed.

Description

System and Method For Forming An Integrated Tray For Use In Vacuum Packaging}

The present invention relates to a bag for vacuum packaging and to a method and apparatus for manufacturing a bag for vacuum packaging.

Methods and devices for preserving perishable foods and perishable foods, such as fish and meat, processed foods, cooked foods and leftovers, are widely known and varied. Food is susceptible to damage due to the growth of organics such as bacteria, fungi and fungi over time after food containers are opened to the atmosphere and food is exposed to the atmosphere. Most methods and devices protect food from organic-filled air to preserve food. Common methods and devices place food in a gas-impermeable plastic bag, suck it with a vacuum pump or other suction source to degas from the bag to tightly seal the bag. It includes.

Bags for vacuum packaging may consist of a first panel and a second panel, each panel consisting of a single layer of heat-sealable, plastic-based film (eg polyethylene). The panels are sealed together along a substantial portion of the periphery of the panel by heat-sealing technology to form an envelope. Perishable products or other products, such as perishable foods, are packaged into bags through unsealed portions and subsequently degassed through unsealed portions. After the perishable product is packaged in a bag and the air is degassed inside the bag, the unsealed portions are heated and pressurized so that the panels adhere to each other to seal the bag.

US Pat. No. 2,778,173, incorporated herein by reference, discloses an improved method of degassing from the bag by forming channels in at least one of the panels with the aid of an embossing technique. Air exits the bag along the channel during degassing. The embossing forms a pattern of protuberances in at least one of the panels. The protrusions may be separate (discrete) pyramids, hemisphericals, etc. and are formed by pressing the panel using heated female dies and male dies. The first panel is superimposed on the second panel so that the protrusions of one panel face the panel. The contact peripheral edges of the panel are sealed to each other to form an envelope having an inlet in the peripheral unsealed portion. Perishable products or other products are packaged into bags through inlets and the inlets are sealed. The opening is then drilled in a portion of the panel material through the channel, air is removed from the interior of the bag through the channel and openings and the opening is sealed. Bags of this kind require two additional steps of sealing after packaging perishable or other product into an envelope. Another additional problem is that embossing creates impressions in the plastic such that indentations are formed on the opposite side of the panel.

In order to prevent additional sealing steps, the vacuum bag is formed with first and second panels composed of laminated films. Each panel includes a heat-sealable inner layer, a gas-impermeable outer layer and any one or more intermediate layers. Such bags are described in US Pat. No. 34,929, which is incorporated herein by reference. At least one film of the at least one panel is embossed using an embossing mold to form a channel defined by the protrusion and the spacing between the protrusions, so that the air is easily degassed in the vacuum bag.

US Pat. No. 5,554,423, incorporated herein by reference, discloses another bag that can be used for vacuum packaging. The bag consists of first and second panels, each panel comprising a gas-impermeable outer layer and a heat-sealable inner layer. Multiple heat-seal strand elements are thermally bonded at regular intervals with respect to the inner layer of the first panel or the second panel. The space between the strand elements acts as a degassing channel. The strand element is extruded from an extrusion head and thermally bonded to the heat-sealable layer using a pressure roll. A separate device is needed to form the strand element, and the procedure of thermally coupling multiple strand elements to the heat-sealable inner layer at regular intervals is complicated. In addition, various types of patterns are difficult to form by the above method.

A more detailed implementation of the invention is described according to the accompanying drawings:

1A is a perspective view showing a vacuum bag manufacturing method according to one embodiment of the present invention;

1B is a side view of the method shown in FIG. 1A showing the embossing method used in the implementation of the present invention;

1C is an enlarged partial view of the portion of FIG. 1B;

2A is a plan view on a panel according to an embodiment of the present invention made by the method shown in FIGS. 1A-1C;

2B is a cross sectional view on a panel according to an embodiment of the present invention made by the method shown in FIGS. 1A-1C;

3 is a perspective view of a vacuum bag according to one embodiment of the present invention.

1A-1C show one embodiment of a vacuum bag manufacturing method according to the present invention. The vacuum bag comprises a first panel and a second panel, each panel comprising a gas-impermeable base layer 108 and a heat-sealable inner layer 106, wherein at least one panel is contained within the vacuum bag. Or has raised walls to prevent movement of other products. The laminating roll 102 and the cooling roll 104 are arranged such that as the melt-extruded resin is cooled, the heat-sealable inner layer 106 may be laminated to the gas-impermeable base layer 108. As shown in FIG. 1C, the gap between the laminating roll 102 and the cooling roll 104 can be adjusted according to the specifications (eg, thickness) of the panel used for vacuum packaging. The temperature of the cooling roll 104 is maintained in a range in which the melt-extruded heat-sealing resin is sufficiently cooled to form a desired pattern. For example, a temperature range of about −15 to −10 ° C. is sufficient to adequately form the desired pattern. The temperature range of the cooling roll 104 may vary depending on the resin composition, the composition of the gas-impermeable base layer 108, environmental conditions, and the like, and may require cablibration. In addition, the chill roll 104 can be sized to have a larger diameter than the laminating roll 102, thus allowing the melt-extruded resin to contact a larger cooled surface area. For example, the diameter of the cooling roll 104 may be about 1.5-3 times greater than the diameter of the laminating roll 102.

The heat-sealable inner layer 106 is typically made of thermoplastic resin. For example, the resin may be made of polyethylene (PE), which is suitable for preserving (storing) food and is harmless to the human body. A vacuum bag can be made by stacking two panels so that heat-sealing inner layer 106 of the two panels is in contact and heat can be applied to a portion of the edge of the panel to form an envelope. The thermoplastic resin can be chosen such that the two panels are strongly bonded to each other when sufficient heat is applied.

The gas-impermeable base layer 108 is supplied to the gap between the cooling roll 104 and the laminating roll 102 by a supply means (not shown). The gas-impermeable base layer may comprise polyester, polyamide, ethylene vinyl alcohol (EVOH), nylon or other materials with similar properties, may be used in the manufacturing process, and may also be heated. The gas-impermeable base layer 108 may consist of one layer or two or more layers. When using a multi-structure base layer, their total thickness is also adjusted within the allowable range for the total gas-impermeable base layer 108.

The extruder 110 is positioned such that the melt-extruded resin forms a layer on the gas-impermeable base layer 108 by feeding the melt-extruded resin into the nip between the cold roll 104 and the gas-impermeable layer 108. The resin is fed through nozzle 112 of the extruder 110. The temperature of the melt-extruded resin depends on the type of resin used and may typically range from about 200 to 250 ° C. The amount of resin extruded into the laminating unit 100 depends on the desired thickness of the heat-sealing inner layer 106.

According to one embodiment of the present invention, the pattern formed on the outer circumferential surface of the cooling roll 104 may include cavities that form raised walls that define one or more separate (discontinuous, discrete) trays. The pattern is a groove (and / or groove) that forms ridges or protuberances within the range of the raised wall so that perishable or other product is suspended at the top of the tray's base and thus liquid is collected in the tray. Protrusions) may optionally also be included. The resin extruded from the nozzle 112 is pressed between the chill roll 104 and the gas-impermeable base layer 108 and flows into the grooves of the chill roll 104. The melt-extruded resin is attached to the gas-impermeable base layer 108 and quickly cooled and solidified in the desired pattern to form the heat sealable inner layer 106 of panel 220. Unlike the conventional method of employing a post-embossing process in which the heat sealable inner layer is drawn by a die or embossed between male and female components, the heat sealable inner layer Layer 106 may be formed by heating the resin sufficiently to allow the resin to flow, thus molding the resin.

FIG. 2A is a plan view of a panel formed by a cooling roll 104 used as a vacuum bag, where the heat-sealable inner layer 106 is bound to the tray 230 such that the raised wall 232 limits perishability or other product movement. Is formed. Within the range of the raised wall 232 of the tray, the ridges 234 suspend or decay other products on top of the base of the tray. As shown, the ridge 234 is cross-hatched and forms a reservoir 236 for collecting liquid. In other implementations, the ridges may be formed in a number of different patterns to form reservoirs 236 having a number of different shapes and sizes. In another implementation, the tray 230 can include protrusions, where the protrusions can be separate (discontinuous, pyramid), hemispherical, etc., thus allowing liquid to be evenly collected in the base of the tray 230. In another implementation, panel 220 may include a plurality of discrete (discrete) trays 230, each of which may be sized to be suitable for the application, optionally having ridges 234 or protrusions. One skilled in the art can understand several different ways of arranging panel 220 to limit the movement of perishable products in a vacuum bag.

The thickness of the ridge wall 232 and the ridge 234 formed on the heat-sealing inner layer 106 of the panel 220 may be determined according to the depth of the groove of the cooling roll 104, and the width of the ridge wall 232 and the ridge 234 may be It can be determined according to the width of. Thus, the shape, width and thickness of the ridge wall 232 and the ridge 234 can be adjusted by changing the specifications of the grooves of the cooling roll 104. 2B is a cross sectional view of the panel 220 described above. In the heat-sealable inner layer 106, the ridge wall 232 may be, for example, in a range of about 35-75 mils in height or more, and the gas-impermeable base layer 108 is, for example, in a thickness of about 0.5-8.0 mils. And heat-sealable inner layer 106 may be, for example, in a thickness range (without ridge 232) of about 0.5-6.0 mils. Optionally, ridges 234 or protrusions may be included. The ridges 234 or protrusions may be lower than the ridge wall 232, so that perishable or other products may be suspended while retaining the perishables in the tray 230. For example, the height of ridge wall 232 may be 75 mils, and the height of ridge 234 or protrusion may be about 30 mils. The dimensions of the ridge wall 232, the ridge 234, the base layer 108, and the inner layer 106 are for illustration, and are not intended to limit the dimensions.

Figure 3 shows a bag used for vacuum packaging according to an embodiment of the present invention. The vacuum bag 350 includes a first panel 320 and a second panel 322 superimposed on each other. According to the above implementation, at least one tray 230 is formed in the first panel 320. Second panel 322 (or first panel 320) optionally includes channels (not shown) for venting air and other gases from the bag along a portion of the panel. The channel can be formed, for example, as described in "Liquid-Trap Bags for Vacuum Packaging", incorporated herein by reference. The heat-sealable resin layer 106 and the gas-impermeable base layer 108 of the first and second panels 320 and 322 are typically made of the same material, respectively, but are also heat-sealable and gas-impermeable, respectively. It can be made of other materials that represent. As described above, the heat-sealable resin layer 106 is used as the inner layer, and the gas-impermeable base layer 108 is used as the outer layer. The bottom, left and right edges of the first and second panels 320, 322 are thermally coupled to each other to form an envelope containing the perishable or other product to be vacuum packed. Once the perishable or other product is placed in the vacuum bag 350, air and / or other gases may be degassed in the bag 350, for example with the vacuum sealer described in US Pat. No. 4,941,310, incorporated herein by reference. . Once the air and / or other gases are degassed to the satisfaction of the user, heat-sealing inner layers 106 are activated and bonded to each other by applying heat to seal the inlet.

The foregoing preferred embodiments of the present invention are for illustration and description, and are not intended to limit the present invention. Modifications and variations of the present invention will be apparent to those skilled in the art. The foregoing implementations are chosen and described in order to best explain the principles and practical applications of the present invention to those skilled in the art to understand various modifications of the present invention and to provide variations suitable for the particular use.

The present invention discloses U.S. Provisional Patent Application 60 / 452,172, entitled Docket No. TILA, entitled Henry Wu et al., Filed March 5, 2003, entitled "Sealable Bag with Integrated (Integrated) Tray for Vacuum Packaging."-01178SU0); US Provisional Patent Application 60 / 452,171, entitled Docket No. TILA-01178SU1, entitled "Method for Making Sealable Bags with Integrated Trays Used for Vacuum Packaging," filed on March 5, 2003. ); US Patent Application No. 10 / entitled "Sealable Bag with Integrated (Integrated) Tray Used for Vacuum Packaging" filed dated Mar. 2004. (Agent Docket No. TILA-01178SU2); And U.S. Patent Application No. 10 / , entitled Docket No. TILA-01178SU3, entitled "Method for Manufacturing Sealable Bags with Integrated Trays Used for Vacuum Packaging," filed dated April 4, 2004, and Hongyu Wu et al. to be.

Literature related to this patent application

This application includes all of the following pending applications by reference:

US Provisional Patent Application No. 60 / 452,168 (Agent Docket No. TILA-01177US0), entitled “Liquid-Traping Bags Used in Vacuum Packaging,” filed on March 3, 2003;

 US Provisional Patent Application No. 60 / 452,171 (Agent Docket No. TILA-01177US1) entitled Henry Wu et al., Filed dated Mar. 2003, entitled "Method for Making Liquid-Trap Bags for Vacuum Packaging";

US Provisional Patent Application No. 60 / 451,954, entitled Docket No. TILA-01179US0, entitled " Sealable bag with label for use in vacuum packaging "

US Provisional Patent Application No. 60 / 451,948 (Agent Docket No. TILA-01179US1) entitled Henry Wu et al., Filed dated Mar. 2003, entitled "Method for Making Sealable Bags with Labels Used in Vacuum Packaging";

US Provisional Patent Application No. 60 / 452,142 (Attorney Docket No. TILA-01180US0) entitled Henry Wu et al., Filed dated Mar. 2003, entitled "Sealable Bag with Integrated Zipper for Use in Vacuum Packaging";

United States Provisional Patent Application No. 60 / 452,021 (Agent Docket No. TILA-01180US1), entitled "Method for Producing Sealed Bags with Integrated Zippers Used for Vacuum Packaging," filed on March 3, 2003;

US Provisional Patent Application No. 60 / 451,955 (Agent Docket No. TILA-01181US0), entitled “Sealable Bag with Integrated Valve Structure for Vacuum Packaging,” filed on 2003.3.5;

US Provisional Patent Application No. 60 / 451,956 (representative Docket No. TILA-01181US1) entitled Henry Wu et al., Filed dated Mar. 2003, entitled "Method for Producing Sealed Bag with Integrated Valve Structure for Vacuum Packaging";

US Provisional Patent Application No. 60 / 452,157 (agent Docket No. TILA-01182US0), entitled "Sealable Bag with Integrated Timer / Sensor for Vacuum Packaging," filed on 2003.3.5;

US Provisional Patent Application No. 60 / 452,139 (representative Docket No. TILA-01182US1) entitled Henry Wu et al., Filed dated Mar. 2003, entitled "Method for Making Sealed Bags with Integrated Timers / Sensors for Vacuum Packaging";

US patent application Ser. No. 10 / 169,485, entitled "Method for Making Air Channel-Mounted Films Used for Vacuum Packaging," filed February 200, 26;

US Patent Application No. 10 / , (Dokcket No. TILA-01177US2), entitled " Liquid-Trap Bag for Vacuum Packaging "

US patent application Ser. No. 10 / , filed under Hongyu Wu et al. Filed on Mar. 4, 2004, entitled " Method for Manufacturing Liquid-Trap Bag for Vacuum Packaging & quot ; (Agent Docket No. TILA-01177US3);

US Patent Application No. 10 / , (Dokcket No. TILA-01179US2) entitled " Sealable bag with label for use in vacuum packaging "

Designation, such as a Hongyu Wu, filed on 04.03.2004 on "the seal with a cover that is used for vacuum packaging property bag method" U.S. Patent Application No. 10 /, (Attorney Docket No. TILA-01179US3);

US patent application Ser. No. 10 / , (Dongcket Docket No. TILA-01180US2), entitled Hongyu Wu et al. Filed 2004.3.4, entitled “Sealable Bag with Integrated Zipper for Use in Vacuum Packaging”;

US patent application Ser. No. 10 / , (representative Docket No. TILA-01180US3), entitled "Method for Making Integrated Zipper Sealable Bags Used for Vacuum Packaging," filed on May 3, 2004;

Designation, such as a Hongyu Wu, filed on 04/03/2004 date of U.S. Patent Application "sealable bag having a valve structure used in the integrated vacuum package" 10 /, (Attorney Docket No. TILA-01181US2);

US patent application Ser. No. 10 / , filed under Hongyu Wu et al. Filed on Mar. 4, 2004, entitled " Method for Producing Sealed Bag with Integrated Valve Structure for Vacuum Packaging "

US Patent Application No. 10 / , Representative Docket No. TILA-01182US2, entitled " Sealable bag with integrated timer / sensor used for vacuum packaging " And

US patent application No. 10 / , entitled Docket No. TILA-01182US3, entitled "Method for Making Sealed Bags with Integrated Timers / Sensors Used in Vacuum Packaging," filed on May 3, 2004, filed by Hongyu Wu.

Claims (47)

A first panel having a tray for receiving the article and a plurality of protrusions formed in the tray to support the article at the top of the base of the tray; And Second panel; Including; And the first panel and the second panel are secured together to form a bag. The bag of claim 1 wherein said first panel is formed of a heat sealable material and said second panel is formed of a gas impermeable material. A first outer layer; And a first panel having a first inner layer connected with the first outer layer, the first inner layer including at least one tray integrally formed with the first inner layer; And A second outer layer; And a second panel having a second inner layer coupled to the second outer layer, the second panel coupled to the first panel so that the first panel and the second panel form an envelope having an inlet. 4. The bag of claim 3, further comprising a plurality of protrusions within the at least one tray range. 4. The bag of claim 3, wherein the first outer layer and the second outer layer comprise a gas-impermeable material. 6. The bag of claim 5, wherein the gas-impermeable material is one of polyester, polyamide, ethylene vinyl alcohol and nylon. 4. The bag of claim 3, wherein the first inner layer and the second inner layer are made of thermoplastic resin. 8. The bag of claim 7, wherein said thermoplastic resin is polyethylene. 6. The bag of claim 5 wherein said article is located in a tray and said article is supported by a plurality of protrusions. 5. A bag according to claim 4, wherein the article is located in a tray and the article is carried on top of the base of at least one tray. 5. The apparatus of claim 4, wherein the plurality of protrusions form a plurality of pockets configured to collect liquid in the plurality of pockets; A bag, characterized in that when the article is placed in a tray, the article is carried on top of the liquid collected in the plurality of pockets. A first gas-impermeable layer; And a first inner layer laminated to the first gas-impermeable layer, wherein the first inner layer comprises at least one tray integrally formed with the first inner layer; And A second gas-impermeable layer; And a second panel comprising a second inner layer laminated to the second gas-impermeable layer, Wherein the first panel is coupled to the second panel such that the first inner layer faces the second inner layer to form an envelope, the bag having a heat-sealable degassing opening. 13. The bag of claim 12, further comprising a plurality of protrusions in the at least one tray. 13. The bag of claim 12, wherein the first gas-impermeable layer and the second gas-impermeable layer consist of one of polyester, polyamide, ethylene vinyl alcohol and nylon. 13. The bag of claim 12, wherein the first inner layer and the second inner layer are made of thermoplastic resin. The bag of claim 15 wherein said thermoplastic resin is polyethylene. 14. The bag of claim 13, wherein the article is located in a tray and the article is supported by a plurality of protrusions. 14. The bag of claim 13, wherein the article is located in a tray and the article is carried on top of the base of at least one tray. 14. The apparatus of claim 13, wherein the plurality of protrusions form a plurality of pockets configured to collect liquid in the plurality of pockets; A bag, characterized in that when the article is placed in a tray, the article is carried on top of the liquid collected in the plurality of pockets. A first gas-impermeable layer; And at least one first intermediate layer coupled to the first gas-impermeable layer, wherein the first inner layer is laminated to the at least one first intermediate layer and the first inner layer is integrally formed with the first inner layer. A first panel including at least one tray formed; And A second gas-impermeable layer; And at least one second intermediate layer connected to the second gas-impermeable layer, the second inner layer comprising: a second panel laminated to the at least one second intermediate layer;  Wherein the first panel is coupled to the second panel such that the first inner layer faces the second inner layer to form an envelope, the bag adapted to receive an article including a heat-sealable degassing opening. 21. The bag of claim 20, further comprising a plurality of protrusions in the at least one tray. 21. The bag of claim 20, wherein the first gas-impermeable layer and the second gas-impermeable layer consist of one of polyester, polyamide, ethylene vinyl alcohol and nylon. 21. The bag according to claim 20, wherein the first inner layer and the second inner layer are made of thermoplastic resin. The bag of claim 23 wherein said thermoplastic resin is polyethylene. 22. The bag of claim 21, wherein the article is located in a tray and the article is supported by a plurality of protrusions. 22. The bag of claim 21, wherein the article is located in a tray and the article is carried on top of the base of at least one tray. 22. The apparatus of claim 21, wherein the plurality of protrusions form a plurality of pockets configured to collect liquid in the plurality of pockets; A bag, characterized in that when the article is placed in a tray, the article is carried on top of the liquid collected in the plurality of pockets. Flowing the material onto the backing film to form a flowable material to form a structure including the tray; And  Cooling the flow material such that the flow material solidifies to form an inner layer having the structure, In the cooling step, the inner layer is attached to the backing film, the panel forming method used for the sealing bag. Supplying a gas-impermeable film to the nip formed by the cooling roll and the laminating roll; Extruding the resin such that the resin fills the nip and a plurality of cavities exposed to the nip; Pressing the resin between a cooling roll and a laminating roll; Cooling the resin so that the resin forms a structure and adheres to the gas-impermeable film to form a panel; Folding the panel such that the first portion of the panel overlaps the second portion of the panel; And Applying heat to the first, second and third sides of the first and second portions to form an envelope; The structure includes one or more trays having a plurality of protrusions, and is formed in part between a laminating roll and a cooling roll having a plurality of grooves forming the structure. Feeding the first gas-impermeable film to the first nip formed by the first cooling roll and the first laminating roll having a plurality of cavities forming a structure that is one or more trays having a plurality of protrusions ; Extruding the resin to fill the first nip and the plurality of grooves exposed to the first nip; Pressing the resin between the first cooling roll and the first laminating roll; Cooling the resin such that the resin forms a structure and adheres to the first gas-impermeable film to form a first panel; Supplying a second gas-impermeable film to a second nip formed by the second cooling roll and the second laminating roll; Extruding the resin such that the resin fills the second nip; Pressing the resin between a second cooling roll and a second laminating roll; Cooling the resin to adhere the second gas-impermeable film to form a second panel; Overlapping the first panel with the second panel; And Applying heat to first, second, and third sides of the first and second panels to form an envelope; Wherein the structure comprises one or more trays having a plurality of protrusions. Rotating at a first speed a first cooling roll comprising a plurality of grooves forming a structure comprising one or more trays having a plurality of protrusions; Rotating the first laminating roll at a second speed; Supplying a first film to a first nip between the first chill roll and the first laminating roll; Extruding molten material into the first nip; Pressing the molten material between the first cooling roll and the first film such that the molten material fills the plurality of grooves exposed to the first nip; Cooling said molten material to form a first inner layer comprising said structure and attached to a first film to form a first panel; Rotating the second cooling roll at a third speed; Rotating the second laminating roll at a fourth speed; Introducing a second film into a second nip between the second cooling roll and the second laminating roll; Extruding molten material into the second nip; Pressing the molten material between the second cooling roll and the second film; Cooling the molten material to form a second inner layer attached to a second film to form a second panel; Overlapping the first panel with a second panel; And Applying heat to a portion of the edges of the first and second panels such that the first and second panels form an envelope; Method for manufacturing a bag containing the article. 32. The method of claim 31, wherein the second speed is an integer multiple of the first speed and the fourth speed is an integer multiple of the third speed. 32. The method of claim 31, wherein the first film and the second film comprise at least one layer. 34. The method of claim 33, wherein said at least one layer comprises a gas-impermeable material. 35. The method of claim 34, wherein the gas-impermeable material is one of polyester, polyamide, ethylene vinyl alcohol and nylon. 32. The method of claim 31 wherein the molten material is polyethylene. 32. The method of claim 31 wherein the thickness of the first inner layer is determined by the size of the first nip and the thickness of the second inner layer is determined by the size of the second nip. 32. The method of claim 31, wherein the structure is formed such that when the article is placed in a tray, the article is supported by a plurality of protrusions. 32. The method of claim 31, wherein the structure is configured such that when the article is placed in a tray, the article is supported on top of the base of the at least one tray. Rotating a first roller having a plurality of recesses that can form one or more trays comprising a plurality of protrusions; Rotating a second roller adjacent to the first roller capable of supplying a first film around the first roller; Applying a molten material between the first roller and the film; The molten material fills a recess of the first roller, and the molten material and the film move between the first roller and the second roller forming a first panel having a plurality of receptacles; Forming the second panel; And Mating the first panel and the second panel to form a bag; Method for manufacturing a bag containing the article. 41. The method of claim 40 further comprising: using a gas impermeable material in the film; And Using the heat sealable material in the molten material. 42. The method of claim 41, wherein the first panel is formed such that when the article is placed in a tray, the article is supported by a plurality of protrusions. 42. The method of claim 41, wherein the first panel is configured such that when the article is placed in a tray, the article bears on top of the base of at least one tray. 41. The method of claim 40, wherein the second panel is formed of a first roller and a second roller. 41. The method of claim 40, wherein the second panel is formed of a first roller and a second roller, and the mating step comprises folding the first panel onto the second panel. 41. The method of claim 40, wherein the first roller comprises an outer circumferential surface having a first portion comprising a plurality of recesses forming one or more trays with a plurality of protrusions. Supplying a first gas-impermeable film to a first nip formed by a first cooling roll and a first laminating roll having a plurality of cavities forming at least one tray; Extruding the resin such that the resin fills the first nip and the plurality of grooves exposed to the first nip; Pressing the resin between a first cooling roll and a first laminating roll; Cooling the resin to form a first inner layer having a first structure and a second structure, attached to the first gas-impermeable film and thus forming the first panel; The second gas-impermeable film is formed by a second cooling roll and a second laminating roll having a plurality of grooves and protrusions forming a third structure, which is another receiving feature and an insertion feature. Feeding a second nip; Extruding the resin such that the resin fills the second nip and the plurality of grooves exposed to the second nip; Pressing the resin between a second cooling roll and a second laminating roll; Cooling the resin to form a second inner layer having the third structure; The second inner layer is attached to the first gas-permeable film to form a second panel; Overlapping the first panel and the second panel; And Applying heat to first, second and third sides of the first and second panels; Method for manufacturing a bag containing the article.