WO2005009658A1 - Structures ondulees et procede pour thermoformer des emballages - Google Patents

Structures ondulees et procede pour thermoformer des emballages Download PDF

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Publication number
WO2005009658A1
WO2005009658A1 PCT/US2004/023285 US2004023285W WO2005009658A1 WO 2005009658 A1 WO2005009658 A1 WO 2005009658A1 US 2004023285 W US2004023285 W US 2004023285W WO 2005009658 A1 WO2005009658 A1 WO 2005009658A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
corrugated
secured
flat
coating layer
Prior art date
Application number
PCT/US2004/023285
Other languages
English (en)
Inventor
Mark Olin Mason
Barry Gene Calvert
Original Assignee
Meadwestvaco Corporation
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 Meadwestvaco Corporation filed Critical Meadwestvaco Corporation
Priority to EP04757147A priority Critical patent/EP1646469A1/fr
Publication of WO2005009658A1 publication Critical patent/WO2005009658A1/fr

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
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • 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
    • 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
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/06—Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
    • 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
    • B32B2307/70—Other properties
    • B32B2307/738—Thermoformability
    • 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
    • B32B2323/00—Polyalkenes
    • 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
    • B32B2439/00—Containers; Receptacles
    • B32B2439/70—Food packaging
    • 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
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y10T428/24669—Aligned or parallel nonplanarities
    • Y10T428/24694—Parallel corrugations

Definitions

  • the present invention relates to coated corrugated structures that may be thermoformed into packages or containers.
  • Conventional methods and corrugated structures have been used to form a variety of corrugated packages.
  • Conventional corrugated structures include a base material, an intermediate flute and a liner material.
  • the intermediate flute secures the liner to the base material.
  • a corrugated structure requires less material to form a rigid structure that is as strong as a much thicker single ply structure.
  • U.S. Patent No. 6,491,214 to Plummer et al. illustrates a conventional corrugated food container.
  • Conventional containers formed from conventional corrugated structures include paper plates, bowls, clamshells, trays and other disposable products.
  • the containers are formed from a corrugated structure blank.
  • the container described in Plummer et al. has three layers or plies.
  • the first layer contacts the food or product placed on the container.
  • the middle layer is a corrugated flute and secures the first layer to the third layer.
  • the third layer forms the support base for the container.
  • the blank is formed or shaped into the container using a conventional technique, such as thermoforming.
  • thermoforming technique involves applying heat and mechanical force concurrently to the container blank in a container-forming die.
  • Exemplary container forming equipment is manufactured by Gralex Corporation of Lewis Center, Ohio.
  • thermoformable corrugated structures that allow for flexible manufacturing techniques and practices, and for improved coatings for these structures which exhibit substantial improvement in barrier properties compared to those which have previously been available.
  • the present invention describes a coated three layer corrugated structure that provides flexibility in the manufacturing process.
  • One embodiment of the present invention is a structure having a first flat layer, a first corrugated layer secured to the first flat layer, a second flat layer having a first side and a second side, wherein the first side is secured to the first corrugated layer on a side opposite of the first flat layer, a polymeric coating layer secured to the second side of the second flat layer, wherein the polymeric coating layer has a melting temperature of at least about 450 degrees Fahrenheit and chloroform-soluble extractives of at most about 0.5 milligrams per square inch.
  • a second embodiment of the present invention is a similar structure, wherein the said first flat layer comprises a side opposite of the said first corrugated layer which has been coated with a composition to improve its printability (commonly referred to as clay coated). Printing on this improved surface may occur prior to or after the corrugated structure is formed.
  • Fig. 1 is a front elevational view, shown in cross-section, of a corrugated structure of the present invention
  • Fig. 2 is a front elevational view, shown in cross-section, of the corrugated structure of Fig. 1 without abase layer;
  • Fig. 3 is a front elevational view, shown in cross-section, of an alternative embodiment of the corrugated structure of the present invention.
  • the present invention covers a wide range of corrugated packages, containers, vessels and the like formed from the basic corrugated structure 100 illustrated in Fig. 1.
  • a first layer 10 is illustrated as forming the base or outer side 11 of the structure 100.
  • the first layer 10 is essentially flat and can be formed from conventional paper or paperboard materials that provide sufficient strength for the intended structure 100.
  • Exemplary materials for the first layer include solid bleached sulphate (SBS) paperboard material either clay coated or uncoated.
  • SBS solid bleached sulphate
  • the paperboard has a coating of a liquid suspension of minerals such as coating clay, calcium carbonate, and/or titanium dioxide with starch or an adhesive.
  • This mineral coating is applied to the paperboard surface to smooth the surface. Densification and mechanical polishing (calendering) finish the mineral coated surface to a high degree of smoothness and provide a superior print surface.
  • the first layer 10 could also be bleached or unbleached as desired. A bleached paper or paperboard is desirable when the structure 100 will be used in a cooking application.
  • Typical basis weights for the first layer 10 are in the range of about 50 pounds per 3,000 square feet to about 140 pounds per 3,000 square feet.
  • the paperboard substrate used for the first layer 10 has a thickness range of about 0.004 inches to about 0.035 inches.
  • the invention covers the full range of paper or paperboard substrates, as applied to the packaging field and other suitable applications.
  • the fluted or second layer 20 is any suitable material such as the coated or uncoated paperboard described above for the first layer 10.
  • the second layer is folded or scored to produce a flute, also referred to as corrugation, with ridges 21, 22.
  • the height of the flute is denoted by the letter "H".
  • Typical flute height sizes includes size "E,” defined as approximately 90 flutes per foot with a chordal height of about 0.043 to about 0.046 inches, although any flute height H providing sufficient strength and adhesion between the various layers 10, 20, 30 is acceptable.
  • Exemplary basis weights for this second layer 20 are in the range of about 50 pounds per 3,000 square feet to about 140 pounds per 3,000 square feet.
  • the paperboard substrate used for the second layer 10 has a thickness range of about 0.004 inches to about 0.035 inches.
  • the second layer 20 secures the first layer 10 and third layer 30 to each other at the ridge points 21, 22.
  • the first and third layers 10, 30 can be secured using conventional adhesives and techniques.
  • the adhesive can be applied to the flute 20 along the ridge points 21, 22 or along the inner surfaces 12, 31 of the two layers 10, 30.
  • the third layer 30 is essentially flat and can be formed of conventional paper or paperboard materials that provide sufficient strength for the intended structure 100.
  • Exemplary materials for the third layer 30 includes SBS paperboard material either coated or uncoated. Typical coatings may include clay or other mineral compounds that are typically used to improve the surface of materials.
  • the third layer 30 could also be bleached or unbleached as desired.
  • Typical basis weights for the third layer 30 are in the range of about 50 pounds per 3,000 square feet to about 140 pounds per 3,000 square feet. If needed, other suitable coatings could be placed on the outer side 32 of the third layer 30.
  • the fourth layer 40 has a surface 42 that is in contact with an article (not shown) placed inside a container (not shown) fo ⁇ ned from the structure 100.
  • the fourth layer 40 is any suitable coating such as a polymer coating.
  • a specific coating is a coating suitable for food contact.
  • Exemplary food contact coatings 40 include polyethylene terephthalate (PET) and polymethylpentene (PMP).
  • Suitable coating weight ranges for PET include a coat weight range of about 8 pounds per 3,000 square feet to about 30 pounds per 3,000 square feet with an exemplary range of about 15 pounds per 3,000 square feet or greater.
  • Suitable coating ranges for PMP include a coat weight range of about 5 pounds per 3,000 square feet to about 15 pounds per 3,000 square feet with an exemplary range of about 8 pounds per 3,000 square feet or greater.
  • the fourth layer 40 is extrusion coated using conventional extrusion methods onto the top surface 32 of the third layer 30.
  • An ideal coating material is mass stable or has a melting point of about 450 degrees Fahrenheit or higher and has chloroform-soluble extractives not exceeding 0.5 milligrams per square inch of the food contact surface.
  • Fig. 2 illustrates an alternative embodiment of the present invention, generally designated 200 (commonly called a single-face corrugated structure).
  • the structure 200 is formed in a similar manner as described above with respect to the structure depicted in Fig. 1.
  • the first layer 10 is absent in structure 200.
  • the structure 200 may be secured to a variety of first layers and provides a great deal of flexibility in manufacturing operations. For example, if printed material is placed on the outer side 11 of the first layer 10 described in Fig. 1, the printing could be done offline prior to securing the first layer 10 to the structure 200 illustrated in Fig. 2.
  • a container manufacturer could use the structure 200 with a wide variety of first (or base) layers 10 (see Fig. 1) thereby giving rise to many advantages (e.g., reduced inventory).
  • the printed material on the first layer 10, as well as the thickness and material type for the first layer 10 could be varied while structure 200 remains consistent for a wide range of applications.
  • Fig. 3 illustrates a further alternative embodiment of the present invention, generally designated 300 (commonly called a double-wall corrugated structure).
  • the structure 300 is fo ⁇ ned in a similar manner as described above with respect to Fig. 1.
  • a second fluted (i.e., corrugated) layer 320 and third flat layer 310 have been secured to the first flat layer 10 of Fig. 1.
  • This second fluted layer provides a structure 300 with additional strength relative to the structure 100 depicted in Fig. 1.
  • the first corrugated layer made up of 10, 20, and 30, and the second corrugated layer made up of 310 and 320 could be formed in two separate processes or in one continuous operation.
  • An advantage of the methods and structures according to the present invention is the manufacturing flexibility for container manufacturers.
  • a manufacturer can purchase different quantities of the first layer 10, second layer 20, third layer 30 previously coated with layer 40, second corrugation layer 320, and third flat layer 310
  • the first flat layer 10 or third flat layer 310 can be printed off-line and in varying quantities to provide maximum flexibility with minimum inventory.
  • the container manufacturer can then form the structures 100, 200, 300 described above for subsequent converting into container blanks (not shown).
  • the blanks can then be formed into containers.
  • the container manufacturer can buy the various layers 10, 20, 30 with various coatings 40, 310, 320 and form a wide range of structures and containers as needed.
  • a conventional forming technique involves thermoforming the container blank into the container shape. This technique involves applying heat and mechanical force concu ⁇ ently to the container blank in a container-forming die.
  • exemplary container thermoforming equipment is commercially available from Gralex Corporation of Lewis Center, Ohio.

Abstract

L'invention concerne une structure ondulée (100) présentant une première couche plate (10), une première couche ondulée (20) fixée à la première couche plate (10), une deuxième couche plate (30) présentant un premier côté (31) et un deuxième côté (32), le premier côté (31) étant fixé à la première couche ondulée (20) sur un côté opposé à la première couche plate, une couche de revêtement (40) fixée au deuxième côté (32) de la deuxième couche plate (30), cette couche de revêtement (40) présentant une température de fusion d'au moins environ 450 degrés Fahrenheit et contenant des matières extractibles, solubles dans le chloroforme, représentant au maximum 0,5 milligramme environ par pouce carré.
PCT/US2004/023285 2003-07-23 2004-07-21 Structures ondulees et procede pour thermoformer des emballages WO2005009658A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP04757147A EP1646469A1 (fr) 2003-07-23 2004-07-21 Structures ondulees et procede pour thermoformer des emballages

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US48943303P 2003-07-23 2003-07-23
US60/489,433 2003-07-23

Publications (1)

Publication Number Publication Date
WO2005009658A1 true WO2005009658A1 (fr) 2005-02-03

Family

ID=34102873

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2004/023285 WO2005009658A1 (fr) 2003-07-23 2004-07-21 Structures ondulees et procede pour thermoformer des emballages

Country Status (3)

Country Link
US (1) US20050031834A1 (fr)
EP (1) EP1646469A1 (fr)
WO (1) WO2005009658A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113226728A (zh) * 2018-11-19 2021-08-06 3M创新有限公司 抗压包装材料和构造

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8883237B2 (en) 2002-04-11 2014-11-11 The Ovenable Paper Pan Company LLc Ovenable corrugated paper container
US8304003B1 (en) * 2002-04-11 2012-11-06 The Ovenable Paper Pan Company, Llc Ovenable corrugated paper container
US8304004B2 (en) 2002-04-11 2012-11-06 The Ovenable Paper Pan Company, Llc Ovenable corrugated paper container
GB2477772A (en) * 2010-02-12 2011-08-17 Smurfit Kappa Uk Ltd Corrugated board construction

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3308006A (en) * 1961-10-19 1967-03-07 Continental Oil Co Laminated corrugated paper board
WO1993022138A2 (fr) * 1992-04-27 1993-11-11 The University Of British Columbia Systemes d'emballage en carton ondule couche et revetu pour l'emballage sous atmosphere modifiee de fruits et de legumes frais
US5855973A (en) * 1995-08-28 1999-01-05 Westvaco Corporation Heat sealed, ovenable food cartons and lids

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USRE32270E (en) * 1978-03-28 1986-10-28 James River-Norwalk, Inc. Polyester coated paperboard for forming food containers and process for producing the same
US5153061A (en) * 1991-01-29 1992-10-06 Westvaco Corporation Barrier coating to reduce migration of contaminants from paperboard
CA2107456C (fr) * 1993-09-30 1997-06-24 Chiu Hui Wu Systemes d'emballage en carton ondule recouvert de membranes plastiques permeables au gaz pour conditionnement sous atmosphere modifiee de fruits et legumes frais et de fleurs coupees
US6184510B1 (en) * 1997-11-05 2001-02-06 Rupaco Paper Corporation Cakeboard and methods of manufacturing and use
US6491214B2 (en) * 1998-04-17 2002-12-10 The Procter & Gamble Company Multi-ply food container

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3308006A (en) * 1961-10-19 1967-03-07 Continental Oil Co Laminated corrugated paper board
WO1993022138A2 (fr) * 1992-04-27 1993-11-11 The University Of British Columbia Systemes d'emballage en carton ondule couche et revetu pour l'emballage sous atmosphere modifiee de fruits et de legumes frais
US5855973A (en) * 1995-08-28 1999-01-05 Westvaco Corporation Heat sealed, ovenable food cartons and lids

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113226728A (zh) * 2018-11-19 2021-08-06 3M创新有限公司 抗压包装材料和构造

Also Published As

Publication number Publication date
EP1646469A1 (fr) 2006-04-19
US20050031834A1 (en) 2005-02-10

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