WO2008060688A1 - Procédé de fabrication de conteneur avec réservoir interne - Google Patents

Procédé de fabrication de conteneur avec réservoir interne Download PDF

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Publication number
WO2008060688A1
WO2008060688A1 PCT/US2007/068869 US2007068869W WO2008060688A1 WO 2008060688 A1 WO2008060688 A1 WO 2008060688A1 US 2007068869 W US2007068869 W US 2007068869W WO 2008060688 A1 WO2008060688 A1 WO 2008060688A1
Authority
WO
WIPO (PCT)
Prior art keywords
tray
forming
define
drain aperture
reservoir
Prior art date
Application number
PCT/US2007/068869
Other languages
English (en)
Other versions
WO2008060688A8 (fr
Inventor
Jon Michael Larue
Craig Edward Cappel
Frank Andrew Petlak
Marshall Vandomelen
Original Assignee
Pactiv 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
Priority claimed from PCT/US2006/044289 external-priority patent/WO2007059187A1/fr
Application filed by Pactiv Corporation filed Critical Pactiv Corporation
Priority to MX2009005157A priority Critical patent/MX2009005157A/es
Priority to CA002669319A priority patent/CA2669319A1/fr
Priority to US12/514,564 priority patent/US8083887B2/en
Publication of WO2008060688A1 publication Critical patent/WO2008060688A1/fr
Publication of WO2008060688A8 publication Critical patent/WO2008060688A8/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/006—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor for making articles having hollow walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/06905—Using combined techniques for making the preform
    • B29C49/0691—Using combined techniques for making the preform using sheet like material, e.g. sheet blow-moulding from joined sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/266—Auxiliary operations after the thermoforming operation
    • B29C51/267—Two sheets being thermoformed in separate mould parts and joined together while still in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/022—Particular heating or welding methods not otherwise provided for
    • B29C65/028—Particular heating or welding methods not otherwise provided for making use of inherent heat, i.e. the heat for the joining comes from the moulding process of one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7437—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc the tool being a perforating tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/545—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles one hollow-preform being placed inside the other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91421—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91441—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time
    • B29C66/91443—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile
    • B29C66/91445—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile by steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/005—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore cutting-off or cutting-out a part of a strip-like or sheet-like material, transferring that part and fixing it to an article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/24—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants
    • B65D81/26—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants with provision for draining away, or absorbing, or removing by ventilation, fluids, e.g. exuded by contents; Applications of corrosion inhibitors or desiccators
    • B65D81/261—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants with provision for draining away, or absorbing, or removing by ventilation, fluids, e.g. exuded by contents; Applications of corrosion inhibitors or desiccators for draining or collecting liquids without absorbing them
    • B65D81/262—Rigid containers having false bottoms provided with passages for draining and receiving liquids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/007—Using fluid under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0009—Cutting out
    • B29C2793/0018—Cutting out for making a hole
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4895—Solvent bonding, i.e. the surfaces of the parts to be joined being treated with solvents, swelling or softening agents, without adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/58—Snap connection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/824—Actuating mechanisms
    • B29C66/8242—Pneumatic or hydraulic drives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/824—Actuating mechanisms
    • B29C66/8246—Servomechanisms, e.g. servomotors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
    • B29C66/949—Measuring or controlling the joining process by measuring or controlling the time characterised by specific time values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages

Definitions

  • the present invention relates to a container for packaging. Particularly, the present invention is directed to a method of forming a container for packaging products or other items susceptible to exuding liquids, wherein the container has an internal reservoir for the collection of liquids exuded therefrom.
  • Conventional containers for packaging and display of meat, produce and other products for consumers are made of plastic foam or paperboard, and generally are simple concave trays having a separate transparent film cover or overwrap. Consumers prefer to purchase items such as meat, poultry, seafood and products that release liquid, in dry packages. However, the amount of liquid residing in a food container typically increases over time, as the product ages and exudes liquid. Accordingly, retailers frequently rewrap the package, reduce the sale price of the product, or remove the product from the shelf because of consumer perception that the product might be spoiled. Moreover, such liquid can leak from a package if the package is not well sealed.
  • a common practice to reduce the problems caused by exuded liquids inside such containers includes the use of an absorbent pad, which is placed in or glued to the bottom of the container, typically between the container and the contents of the package.
  • this practice requires a separate supply line in the manufacturing process for delivering the absorbent pad to the container, an additional step in the manufacturing process for application of the adhesive, and a dwell period to allow the adhesive to firmly bond the absorbent pad to the container.
  • the particular composition of absorbent pad and adhesive must comply with Federal Drug Administration guidelines and regulations regarding materials in direct contact with edible products.
  • liquid held by an absorbent pad can be squeezed out if the pad is pressed, which may occur as a result of handling or due to the force exerted by the film overwrap.
  • Such pads also tend to leak fluid when products are merchandised on their side.
  • the manufacturing process is labor intensive and requires a separate processing line to make and insert the pads into the containers, fabricating an assortment of pad sizes for use in varying tray sizes, and additional quality inspection is required to ensure proper placement of the pads.
  • a self-absorbing tray using an open cell foam structure is another conventional solution to absorb excess fluids.
  • the material becomes absorbent when holes are pierced through the surface of the tray.
  • an open cell tray structure is weaker overall, thereby increasing the chance for folded, cracked or broken trays during wrapping and transport of the product.
  • open cell trays can wick moisture through the tray and transfer liquid to the consumer's hands.
  • Some open cell foam trays change color when saturated with fluid and are therefore unsightly to consumers.
  • open cell trays offer a limited amount of absorbency. Trays loaded with large amounts of meat can easily overwhelm the absorbent capacity of the tray, resulting in unabsorbed liquid pooling at the bottom of the package.
  • Moisture is introduced to the absorbent core through holes in the inner tray.
  • the liquid within the pad may have a propensity to be wicked up to and leaked from top edges of these types of trays. Further, the process used to manufacture these trays results in a rough edge that tends to pierce film wraps, which also results in leakage of liquid from the container.
  • Packaging containing an absorbent pad either glued inside or sandwiched between inner and outer trays, creates a packaging container comprised of many different materials. The added labor and expense required to remove the absorbent materials from the package prohibit recycling of such packaging.
  • An object of the invention is to provide a packaging tray for products that tend to release liquids that avoid the drawbacks of existing trays set forth above.
  • the invention includes a method of manufacturing a packaging container including first and second trays.
  • the method includes providing a first web of material and a second web of material, and heating each of the first and second webs to facilitate the forming of the webs into a particular container shape, as desired.
  • the first web is formed into a first tray having a shape which includes a first bottom wall, and a surrounding first sidewall extending generally upwardly from the first bottom wall to define a space therein.
  • the second web is formed into a second tray having a shape which preferably includes a second bottom wall and a surrounding second sidewall extending generally upwardly from the second bottom wall to define a space therein.
  • the second tray is sized such that it can be positioned within the space defined by the first tray such that the second bottom of the second tray is spaced from the first bottom of the first tray to define a reservoir therebetween. Further, the first and second trays are joined to one another about at least a portion of the perimeter, the joined first and second tray defining a product receiving unit for receiving a food product.
  • the method of forming the container includes a dwell period to cool the first and second trays to a desired temperature, wherein at least one drain aperture is formed in the second tray, the at least one drain aperture in fluid communication with the reservoir.
  • the central drain region is proximate to the center, or a centerline of first bottom the second tray, depending on the specific embodiment.
  • the second bottom of the second tray can be formed with a downward slope towards the drain aperture(s) to facilitate the draining of exuded liquid into the reservoir.
  • the first and second webs are unwound from separate rolls of stock material, which can be of either homogenous or dissimilar material compositions, and formed into the desired tray shape via vacuum or pressure thermoformer.
  • the thermoformer can be configured to form the first and second tray simultaneously, as well as form a plurality of first and second trays simultaneously, if so desired.
  • the thermoformer includes an upper tool which is configured to impart the desired geometry of the second tray into the second web, and a lower tool which is configured to impart the desired geometry of the first tray into the first web.
  • the steps of forming the first and second trays, joining the first and second trays, and forming the at least one drain aperture in the second tray can be performed in a single thermoformer.
  • the joining of the first and second trays can be achieved by a conductive coil or heating element, disposed within either the upper or lower tool of the thermoformer, which forms a heat seal that extends around at least a portion of the perimeter of the first and second trays.
  • the heating element is employed at sufficient temperature and duration that a portion of sidewalls of the first and second tray are joined together.
  • the first bottom of the first tray may be formed to include at least one raised surface feature, to which the second bottom of the second tray can be joined.
  • the temporal order of the heating, forming, joining, forming of the drain aperture, and trimming can be performed in any sequence, as desired.
  • a container is formed by providing pre-formed first and second trays, wherein the first tray has a bottom wall and a surrounding sidewall extending generally upwardly from the bottom wall to define a space therein.
  • the second tray is configured to be received within the space of the first tray, such that the second tray is spaced from the bottom of the first tray to define a reservoir therebetween.
  • the first and second trays are joined to each other along at least a portion of the perimeter of the second tray.
  • the drain aperture(s) is formed by perforating at least one section of the second tray to define at least one drain aperture in fluid communication with the reservoir, with at least a portion of the perforated section being joined to the first tray.
  • the perforation of the drain aperture(s) is performed via a punch device.
  • the punch device can include a conduit for introducing air through the drain aperture(s) to displace the second tray relative to the bottom of the first tray.
  • the perforated section(s) is welded to the bottom of the first tray.
  • Figure 1-A is a cross-sectional view of a first embodiment of a container having an internal reservoir, in accordance with the invention.
  • Figure 1-B is a bottom-perspective view of a first embodiment of a container having an internal reservoir, in accordance with the invention.
  • Figure 1-C is a cross-sectional view of a first embodiment of a container having an internal reservoir, in accordance with the invention.
  • Figure 1 -D is a cross-sectional view of a first embodiment of a container having an internal reservoir, in accordance with the invention.
  • Figure 1-E is a top-perspective view of a first embodiment of a container having an internal reservoir, in accordance with the invention.
  • Figure 2- A is a top view of a second embodiment of a container having an internal reservoir, in accordance with the invention.
  • Figure 2-B is a cross-sectional view of a second embodiment of a container having an internal reservoir, in accordance with the invention.
  • Figure 2-C is a cross-sectional view of a second embodiment of a container having an internal reservoir, in accordance with the invention.
  • Figure 2-D is a perspective view of a second embodiment of a container having an internal reservoir, in accordance with the invention.
  • Figure 3 is a schematic representation of the method of manufacturing a container having an internal reservoir in accordance with the invention.
  • Figure 4 is a cross-sectional side view illustrating the forming of the drain aperture(s).
  • Figure 5A-D is an enlarged view of various drain aperture configurations for the container of Figures IA-E.
  • first and second tray are disclosed in detail in copending United States Nonprovisional Patent Application Serial Number 11/559,653 filed November 14, 2006, and United States Provisional Application Number 60/737,023 filed November 14, 2005, which are herein incorporated by reference in its entirety.
  • Figures IA- IE illustrate an example of the product produced by the inventive method described in detail below.
  • Figures IA- IE illustrate a container 100 which generally includes a first tray 220 and a second tray 110.
  • the first or "bottom" tray 220 is preferably larger than the second tray 110, having a sidewall 221 and a bottom wall 225 defining a recessed space.
  • the space is preferably large enough to accommodate at least a portion of the second tray 110, if not essentially the entire second tray 110.
  • the second or “top” tray 110 includes a bottom wall 115 which rests on or nests within the first tray 220 as shown in Figure IA.
  • a sidewall 1 11 preferably extends from the bottom wall 1 15.
  • An outer edge 112 of the second tray 110 rests on and, preferably, is attached to an outer edge 212 of the first tray 220.
  • Sidewall 1 11 of the second tray 110 connects the edge region 112 to the bottom wall 113 of the second tray 110.
  • a flange is provided at the edge of at least one of the edge regions 112, 212. Attachment of the two trays is preferably effected by any suitable method, and preferably, a watertight connection is formed, such as by heat welding or adhesive, cohesive, ultrasonic welding or chemical bonding techniques as discussed below.
  • Fig. 3 For purpose of explanation and illustration, and not limitation, an exemplary embodiment of the method in accordance with the invention is shown in Fig. 3 and is designated generally by reference character 500.
  • the system 50 generally includes providing a first web of material (20) and a second web of material (10) from separate stock, or alternatively providing a single supply of stock material which is then converted into first and second webs.
  • first and second webs are delivered from separate stock rolls by simultaneously unwinding the rolls at equal rate of speed.
  • the first and second webs each or both can be of homogenous or dissimilar material compositions, and include indicia such as differing colors for various aesthetic configurations or marketing purposes, among other things.
  • the first and second webs are heated, such as in an oven (30) or equivalent device which preferably provides heat from both above and below at least one of the webs, to facilitate the shaping of the webs into the desired container geometry as well as assisting the joining of the webs, as will be discussed in detail below.
  • the first and second webs are delivered to a tray forming station (40), which in a particular embodiment is a vacuum or positive pressure thermoformer, though various molds and other devices suitable for imparting the desired tray geometries to the webs are contemplated to be within the scope of this invention.
  • the first and second webs preferably are formed into first and second trays, respectively.
  • the former can be configured to form the first (220) and second (110) tray simultaneously, and can further be configured to form a plurality of first and second trays concurrently, if so desired.
  • the thermoformer includes an upper tool (42) configured to impart the desired geometry of the upper surface of the second tray (110) into the second web (10), and a lower tool (44) which is configured to impart the desired geometry of the lower surface of the first tray (220) into the first web (20).
  • the inverse arrangement can be performed in which the upper tool imparts the geometry of the first tray into the first web while the lower tool imparts the geometry of the second tray into the second web.
  • the first and second webs are vertically aligned and indexed into the thermoformer (40) such that the first and second webs are disposed between the upper (42) tool and lower tool (44).
  • a vacuum force is applied through channels in the upper and lower tool to bring the webs (10, 20) into contact with the upper and lower tools, respectively.
  • the upper and lower tools also bring portions of the first and second webs, which can be formed into flanges or ledges of one or both trays, into contact with each other.
  • the vacuum force applied via the upper and lower tool bring each web into conformance with the respective tool geometry.
  • a positive pressure can be introduced into the space between the first and second webs, to further urge the webs against the respective tools and enhance formation of the first and second trays, respectively.
  • the upper and lower tools can be moved toward each other and converge to apply a compressive force which facilitates the formation of the flanges, as well as creation of the seal between the two trays as discussed in further detail below.
  • the first web is formed into a first tray having a shape which includes a first bottom wall, and a surrounding first sidewall extending generally upwardly from the first bottom wall to define a space therein.
  • the second web is formed into a second tray having a shape which includes a second bottom wall.
  • the second tray also includes a surrounding second sidewall extending generally upwardly from the second bottom wall to define a space therein.
  • the second tray is sized and shaped such that at least a portion of the second tray can be positioned within the space defined by the first tray such that the second bottom of the second tray is spaced from the first bottom of the first tray to define a reservoir (300) therebetween.
  • the reservoir (300) is sized to contain approximately 100 grams of exuded liquid.
  • one or more raised surface features such as ribs or protrusions can be formed on the bottoms of one or both trays.
  • the first tray can be provided with raised surface features to contact with the second bottom of the second tray.
  • Such raised surface features are advantageous for enhancing the structural integrity of the overall container, and if joined to the second bottom of the second tray as illustrated, can ensure the size of the reservoir, i.e. the space (300) between the first bottom of the first tray and the second bottom of the second tray, generally remains constant.
  • the raised surface features can be formed in a variety of desired quantity or pattern.
  • the surface features are configured to aide the flow of exuded liquid to the aperture, and into the reservoir.
  • the surface features furthermore, support the product to be packaged above the upper surface of the bottom wall of the second tray to minimize contact with the exuded liquid and prevent the contents from occluding the drain aperture.
  • first and second trays are joined to one another about at least a portion of the perimeter, the joined first and second tray defining a product receiving container for receiving a food product.
  • suitable techniques may be employed for joining the trays depending upon the material selected for each tray, such as adhesive, cohesive, lip rolling, mechanical crimping, ultrasonic welding, vibration welding, chemical bonding, mechanical snap fitting and induction welding, or combinations thereof can also be used to join the first and second trays.
  • Other known types of bonding techniques can be used, as can mechanical interlocking or interference fit techniques for joining the two trays.
  • a thermally conductive ring is provided in at least one of, and preferably both of, the upper and lower tools of the thermoformer. Each ring generates sufficient heat to form a heat seal about the perimeter of the first and second trays disposed within the flange portion of the trays. More preferably, the position of the rings in the upper and lower tools can be adjustable in a vertical direction to allow for the modification to the clamp force provided by the upper and lower tools.
  • the heating elements preferably are continuously activated, however the intermittent operation of the rings is also possible, if desired.
  • the heating element may be activated to a predetermined temperature, for example for use with webs having a thickness in the range of approximately 40 ⁇ 90 mm, to a temperature of approximately 22O 0 F or higher, and for a sufficient duration, for example approximately 3.75 seconds, to form a heat seal which can extend beyond the flange portion of the trays and downwardly a desired distance of approximately 1 inch along adjacent sidewalls of the trays as shown in Fig. 1-D.
  • the heating element on the lower tool extends toward the upper tool, whereas the corresponding surface of the upper tool is flush, such that upper surface of the second tray is not embossed or otherwise altered.
  • the presence of such an elongated seal can reinforce the sidewalls and enhance the crush strength of the assembled container, while further preventing the tendency for bowing as a result of the application of a shrink wrap around the container.
  • the upper tool (42) of the thermoformer is equipped with a device for forming at least one drain aperture (117) in the second tray.
  • a plurality of apertures can be provided in a central region of the second bottom as shown in Figures 5A-D. Additionally or alternatively, apertures can be provided along the edge of the second bottom of the second tray (110).
  • the first and second webs are formed into the first and second trays while the webs are at an elevated temperature as discussed above. A cooling, or dwell period allows for the temperature of the formed trays to decrease to a desired temperature, which is above ambient temperature.
  • the drain aperture(s) preferably are formed at this above-ambient temperature.
  • the upper tool includes a punch mechanism (46) which perforates the second bottom of the second tray (110) to cut out at least one section, or slug (48), which defines the drain aperture(s).
  • the cut-out (48) section is preferably is urged toward and adheres to the first bottom of the first tray (220) by the latent heat remaining after the heating of the trays discussed above. This process is advantageous in that it avoids the need to discard or otherwise secure a cut-out that is entirely severed from the second tray.
  • the punch mechanism includes a pneumatic port for introducing positive pressure between the first and second webs during the forming process to further urge the webs against the lower and upper tools, respectively.
  • the upper tool of the thermoformer can be equipped with a plurality of punch mechanisms, i.e. one punch mechanism for forming at least one drain aperture in the upper tray for each corresponding container.
  • the punch mechanisms can be operated independently of each other, or alternatively the plurality of punch mechanisms can be driven simultaneously by a common operator.
  • the operator for driving the punch mechanism(s) is preferably an air cylinder, however a servo motor or other electromechanical device can actuate the punch mechanism(s).
  • the drain aperture(s) (117) can be formed by melting or other high temperature process for forming a hole in the second tray. For example, this can be accomplished by heating a probe in the upper tool of the thermoformer, either continuously or intermittently, to a temperature of approximately 650 0 F and advancing the probe into the second tray.
  • This high temperature technique has the advantage of not forming any scrap or slug portions, and therefore eliminates the need for any associated scrap removal steps and/or equipment.
  • a finishing punch can be used to form the final desired shape and dimensions for the aperture(s) after the first and second trays have been formed, joined and cooled.
  • the size of the apertures will depend upon the intended tray size and food product. It is preferable, however, to use an appropriate size that is sufficiently large to allow drainage of liquid into the reservoir and venting of gases out of the reservoir without the need for a separate vent hole, but sufficiently small to prevent spillage of the liquid from the reservoir.
  • the preferred aperture size therefore will depend upon the number of apertures provided, whether venting is required or provided by an alternative vent opening, the characteristics of the fluid (e.g., viscosity, surface tension), and the expected flow rate, among other factors. For example, a single round hole with a diameter of about 0.375 inches is suitable for both drainage of liquid and venting of air for a conventional meat product container.
  • a smaller aperture size can be used to accommodate the same flow rate as a single aperture of larger size.
  • the total amount of aperture area can be calculated by summing the entire area of each individual aperture. In this manner, providing a plurality of smaller apertures over a large area can reduce the risk of spillage as well as reduce any compromise to the integrity of the bottom wall of the second or "upper" tray.
  • the aperture(s) can be formed such that at least a portion of the material which is punched to form the aperture(s) remains attached to the second tray.
  • the entire boundary of the cut-out (48) is not separated from the second tray.
  • the punch is configured to sever a cut-out along an edge defining the aperture(s) that extends a distance less than the entire perimeter of the aperture(s). Accordingly, a portion of the cut-out remains connected to the remainder of the second tray. The cutout can be depressed downwards and adhered to the first tray to allow liquid to flow into the internal reservoir.
  • the punch device can be configured with an internal conduit for channeling air into the reservoir.
  • a blast of heated air can be delivered via the conduit through the aperture(s) to facilitate the separation of the bottoms of the first and second trays and further assist the shaping of the trays in the thermoformer, as discussed above.
  • the upper (42) and lower (44) tools of the thermoformer (40) diverge to release the assembled container and allow for the first and second webs to be indexed to the trimming station (50).
  • the trim station (50) is a separate station.
  • a trim-in-place device can be employed in which the trimming operation is performed in the same station as used for forming of the trays, joining of the trays, and formation of the drain aperture(s).
  • a trim press can operate along the flange portion to sever each assembled container from the webs and thereby define a product container unit.
  • the trim press can operate to sever one assembled container at a time, or alternatively a plurality of assembled containers simultaneously, if so desired.
  • a plurality of severed containers can be stacked to reduce storage space and advanced to further product handling and shipping processes. Suitable equipment for such forming, joining and trimming processes are available from Irwin Research and Development, Inc. and can be modified accordingly as desired.
  • - O- container includes: i) heating of the first and second webs; ii) forming first and second trays from the first and second webs, respectively; iii) joining the first and second trays; iv) punching a drain aperture(s); and v) trimming the assembled container from the web.
  • forming, joining and punching are performed simultaneously.
  • the method for manufacturing the container can be performed in the following sequence: i) heating the first and second webs; ii) forming first and second trays from the first and second webs, respectively; iii) joining the first and second trays; iv) trimming the assembled container from the web; and v) punching a drain aperture(s).
  • At least forming and joining are performed simultaneously, and trimming and punching are formed simultaneously.
  • the punching of the drain aperture(s) can be performed in a station or apparatus which is separate and independent from the thermoformer, and/or trim press station.
  • at least forming of the first and second trays and joining of the first and second trays can be performed as a single integral step.
  • a representative example of a method of forming a tray is set forth below for purpose of illustration and not limitation.
  • a first web of polymeric material and approximately 40 mm thickness is provided and heated to approximately 220 degrees Fahrenheit.
  • a second web of polymeric material and approximately 90 mm thickness is provided and heated to 220 degrees Fahrenheit.
  • the first and second webs are directed into a modified Irwin Magnum model thermoforming system with an upper tool and a lower tool.
  • a negative approximate-vacuum pressure is applied to draw each web against the corresponding tool for a dwell time of approximately 1 second, and a positive pressure of approximately 5 lbs. can be applied between the first and second webs to further enhance the thermoforming process.
  • the upper and lower tools converge to apply a compressive force along heating elements heated to a temperature of about 220 degrees Fahrenheit for a period of approximately 3.75 seconds.
  • the joined webs are then cooled to a desired temperature and trimmed of excess material form the perimeter.
  • the method of forming the container (200) includes forming a tray having (220) a bottom wall (225) and a surrounding sidewall (221) extending generally upwardly from the bottom wall to define a space therein.
  • a separate insert member (150) can be formed and/or provided from an independent manufacturing line.
  • the insert member (150) can be a thermoformed sheet having an alternative contoured configuration, or can be a film or panel having a substantially flat or planar shape.
  • at least one drain aperture (117) is formed in the insert member as previously described.
  • the insert member is inserted into the space of the first tray, so as to be spaced from the bottom of the first tray to define a reservoir (300) with the drain aperture(s) (117) in fluid communication with the reservoir. At least a portion of the perimeter of the insert member is joined to the first tray by adhesive, cohesive, heat welding, ultrasonic welding or chemical bonding techniques or other suitable techniques.
  • the first tray and insert member can be formed from similar or dissimilar material compositions, and further have differing aesthetic designs, e.g. color.
  • a raised surface feature can be formed on the bottom of the first tray, and/or on the second tray or insert member, in any of the shapes or configurations as described above. Additionally, a ledge (222) which protrudes inwardly towards the space of the first tray can be formed in the surrounding side wall of the first tray. The second tray or insert member can be disposed within the space of the first tray on top of the raised surface feature(s) and/or protruding shelf (222).
  • the second tray or insert member is provided with a downward slope towards the drain aperture(s) to facilitate the draining of exuded liquid into the underlying reservoir.
  • This sloped geometry can be provided by employing a relatively rigid member of shape memory material in which the desired geometry is imparted directly into the second tray or insert member during the manufacture of the insert member.
  • a flexible insert member can be utilized in which the weight of the food product deflects the second tray or insert member downward to provide the desired slope.
  • raised surface features can be provided on the bottom of the first tray such that the height of the surface features decreases towards the center of the first tray. The second tray or insert member can be adhered to these raised surface features of the underlying tray so as to create the desired slope.
  • the containers described herein can be manufactured from any suitable material, for example, expanded polystyrene foam, metal foil, such as aluminum foil, oriented polystyrene (OPS), polypropylene, mineral filled polypropylene, amorphous polyethylene terephthalate (APET), thermoplastics. It is to be understood that the foregoing list is not exhaustive, and that the containers can be made from other materials. The use of foams in forming of the trays and/or insert member requires less material and thus provides a cost benefit over sheet materials.
  • OPS oriented polystyrene
  • APET amorphous polyethylene terephthalate
  • the containers described herein can be of any shape desired, such as, for example, circular, rectangular, oblong, oval, or square.
  • the containers can be used for packaging uncooked foods, but can also be used for cooking and/or holding of cooked food, such as a cooked chicken.
  • the subject containers are capable of retaining the liquid exuded during and after cooking of a roast chicken, for example. If used for cooking, the materials used for the container must be capable of satisfactorily withstanding oven temperatures.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Food Science & Technology (AREA)
  • Containers Having Bodies Formed In One Piece (AREA)
  • Packages (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Abstract

La présente invention concerne un procédé de fabrication d'un conteneur (100) comprenant les étapes consistant à chauffer deux toiles de matériau et à indexer les toiles dans une unité de thermoformage sous vide (40) qui forme des premier (220) et second (110) plateaux simultanément, le second plateau étant disposé dans un espace du premier plateau de manière à définir un réservoir (300) entre ceux-ci. Une portion du premier plateau est amenée en contact avec une portion de bride du second plateau, et jointe à l'unité de thermoformage sous vide à l'aide d'un joint thermique. Un dispositif de perforation dans l'unité de thermoformage sous vide perfore une ouverture d'évacuation (117) dans une région centrale de la base du second plateau, de telle sorte que l'ouverture d'évacuation est en communication fluidique avec le réservoir. La section découpée est collée à la base du premier plateau de manière à éliminer la présence de tout déchet de matériau. Les premier et second plateaux joints sont indexés hors de l'unité de thermoformage sous vide et rognés pour séparer un conteneur assemblé de l'alimentation en toile.
PCT/US2007/068869 2005-02-09 2007-05-14 Procédé de fabrication de conteneur avec réservoir interne WO2008060688A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
MX2009005157A MX2009005157A (es) 2006-11-14 2007-05-14 Metodo de formacion de recipiente que tiene deposito interno.
CA002669319A CA2669319A1 (fr) 2006-11-14 2007-05-14 Procede de fabrication de conteneur avec reservoir interne
US12/514,564 US8083887B2 (en) 2005-02-09 2007-05-14 Method of forming a container having an internal reservoir

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
PCT/US2006/044289 WO2007059187A1 (fr) 2005-11-14 2006-11-14 Recipient muni d'un reservoir interne
USPCT/US2006/004428 2006-11-14
US11/559,653 US7921992B2 (en) 2005-11-14 2006-11-14 Container having internal reservoir
US11/559,653 2006-11-14
USPCT/US06/044289 2006-11-14

Publications (2)

Publication Number Publication Date
WO2008060688A1 true WO2008060688A1 (fr) 2008-05-22
WO2008060688A8 WO2008060688A8 (fr) 2014-05-01

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PCT/US2007/068869 WO2008060688A1 (fr) 2005-02-09 2007-05-14 Procédé de fabrication de conteneur avec réservoir interne

Country Status (1)

Country Link
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011067305A1 (fr) * 2009-12-02 2011-06-09 Cryovac, Inc. Contenant perméable au gaz à auto-absorption destiné à un emballage pour aliments et emballage pour aliments obtenu à partir de ce dernier
WO2012122427A2 (fr) * 2011-03-08 2012-09-13 Converter Manufacturing, Inc. Récipient de rétention de liquide, éventuellement avec couches détachables par décollement
US20220380111A1 (en) * 2021-05-27 2022-12-01 Mac F. Clark Rotisserie strainer device

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2564807A1 (fr) * 1984-05-22 1985-11-29 Fraigneau Michel Emballage destine au conditionnement de produits exsudant du liquide, et assurant, dans toutes positions, la retention separee du liquide
WO1986007036A1 (fr) * 1985-05-30 1986-12-04 Garwood Limited Emballage
CH663943A5 (en) * 1984-09-11 1988-01-29 Betan Ag Container for foodstuff - has double floor which holds any liquid which runs off foodstuff
WO1993006026A2 (fr) * 1991-09-27 1993-04-01 Sealed Air Corporation Plateau recyclable pour produits alimentaires presentant de meilleures caracteristiques de collecte et de retenue de liquide
FR2697809A1 (fr) * 1992-11-06 1994-05-13 Monoplast Caisse isotherme.
EP0701955A1 (fr) * 1994-09-19 1996-03-20 Groupe Guillin (S.A.) Emballage de conditionnement et de conservation longue durée

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2564807A1 (fr) * 1984-05-22 1985-11-29 Fraigneau Michel Emballage destine au conditionnement de produits exsudant du liquide, et assurant, dans toutes positions, la retention separee du liquide
CH663943A5 (en) * 1984-09-11 1988-01-29 Betan Ag Container for foodstuff - has double floor which holds any liquid which runs off foodstuff
WO1986007036A1 (fr) * 1985-05-30 1986-12-04 Garwood Limited Emballage
WO1993006026A2 (fr) * 1991-09-27 1993-04-01 Sealed Air Corporation Plateau recyclable pour produits alimentaires presentant de meilleures caracteristiques de collecte et de retenue de liquide
FR2697809A1 (fr) * 1992-11-06 1994-05-13 Monoplast Caisse isotherme.
EP0701955A1 (fr) * 1994-09-19 1996-03-20 Groupe Guillin (S.A.) Emballage de conditionnement et de conservation longue durée

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011067305A1 (fr) * 2009-12-02 2011-06-09 Cryovac, Inc. Contenant perméable au gaz à auto-absorption destiné à un emballage pour aliments et emballage pour aliments obtenu à partir de ce dernier
WO2012122427A2 (fr) * 2011-03-08 2012-09-13 Converter Manufacturing, Inc. Récipient de rétention de liquide, éventuellement avec couches détachables par décollement
WO2012122427A3 (fr) * 2011-03-08 2012-12-27 Converter Manufacturing, Inc. Récipient de rétention de liquide, éventuellement avec couches détachables par décollement
US20220380111A1 (en) * 2021-05-27 2022-12-01 Mac F. Clark Rotisserie strainer device

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