WO2022191834A1

WO2022191834A1 - Multi-compartment tray and package

Info

Publication number: WO2022191834A1
Application number: PCT/US2021/021710
Authority: WO
Inventors: Christoph Dietrich; Rik Engelhart; Albert Bijsterbosch
Original assignee: Amcor Flexibles North America, Inc.
Priority date: 2021-03-10
Filing date: 2021-03-10
Publication date: 2022-09-15
Also published as: EP4304946A1

Abstract

A multi-compartment tray and a package are disclosed. The multi-compartment tray includes a first unit, a second unit, and a polymer bead. The first unit includes a first compartment and a first metal layer. The second unit includes a second compartment and a second metal layer. The polymer bead is connected to both the first unit and the second unit. Further, the package includes the multi-compartment tray and a lid. The lid is connected to the first unit at a first seal and the lid is connected to the second unit at a second seal. Each of the first and second units is independently hermetically sealed.

Description

MULTI-COMPARTMENT TRAY AND PACKAGE

TECHNICAL FIELD

The present application relates generally to a multi-compartment tray, and in particular to a recyclable multi-compartment tray, and a package including the multi- compartment tray.

BACKGROUND

Packages including a multi-compartment tray may be used to package one or more items in different compartments of the multi-compartment tray. Conventional multi- compartment trays are generally made of plastics or multilayer coextruded polymer sheets. Therefore, the conventional multi-compartment trays may be non-recyclable.

SUMMARY

A recyclable multi-compartment tray has been developed. In an aspect, a package may include the multi-compartment tray. The multi-compartment tray may be used to store a single product, multiple variants of the single product, or multiple different products. The products may include a variety of edible and non-edible products. The products may be intended to be used together or in small portions/servings. Therefore, the multi-compartment tray may provide a convenient, multi-serve, and portable package for users.

Conventional multi-compartment trays may be made of plastics that may be easy to thermoform. The conventional multi-compartment trays may be manufactured by thermoforming a multilayer coextruded sheet including an ethylene vinyl alcohol (EVOH) layer sandwiched between two polypropylene (PP) layers. Therefore, the conventional multi-compartment trays may be thermoformed into a multi-serving design or any other design. However, such conventional multi-compartment trays are generally non- recyclable.

Further, thermoforming multi-compartment trays may not be feasible with certain materials, such as metals. Multi-compartment trays including metal layers and two or more compartments cannot be typically manufactured with existing deep drawing technologies. In some designs, the multi-compartment trays including metal layers may include two or more containers connected to each other by conventional connections, such as paper sleeve, adhesive tape, hot melt, etc. Such multi-compartment trays may not be suitable to undergo a retort process. Specifically, the conventional connections in such multi-compartment trays may not be durable enough to withstand high temperatures and water immersion. The conventional connections in such multi-compartment trays may therefore fail during the retort process.

One embodiment of the present disclosure is a multi-compartment tray including a first unit, a second unit, and a polymer bead. The first unit includes a first compartment and a first metal layer. The second unit includes a second compartment and a second metal layer. The polymer bead is connected to both the first unit and the second unit.

The first and second units including the first and second metal layers, respectively, may be recyclable. Therefore, the multi-compartment tray may be recyclable. Further, the first and second units may be individually manufactured using the existing deep drawing technologies. In addition, manufacturing and packaging the multi-compartment tray of the present disclosure may not require major modifications in the existing manufacturing and packaging lines or processes. Therefore, manufacturing and filling of the multi-compartment tray may be inexpensive and simple to implement. The polymer bead connected to both the first unit and the second unit may also be recyclable. The polymer bead may be deposited by a micro-extrusion process. The first and second units may be detachably connected to each other via the polymer bead, such that they may be detached when desired by a user.

Moreover, the multi-compartment tray may be capable of undergoing a retort process. In other words, the multi-compartment tray may withstand high temperatures and water immersion. The multi-compartment tray may undergo the retort process without damaging the connection between the first and second units. More specifically, the polymer bead connected to both the first and the second unit may not get damaged when the multi-compartment tray undergoes the retort process.

In some embodiments, the first unit further includes a first inner polymer layer and the second unit further includes a second inner polymer layer. In some embodiments, the first inner polymer layer includes at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer, and the second inner polymer layer includes at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer.

In some embodiments, the first metal layer and the second metal layer include aluminum.

In some embodiments, the first metal layer and the second metal layer include steel.

In some embodiments, the first unit further includes a first peripheral rim including a first curled portion and the second unit further includes a second peripheral rim including a second curled portion.

In some embodiments, the polymer bead is connected to the first unit at the first peripheral rim and the polymer bead is connected to the second unit at the second peripheral rim.

In some embodiments, the polymer bead includes at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer.

Another embodiment of the present disclosure is a multi-compartment tray including a first unit, a second unit, and a polymer bead. The first unit includes a first peripheral rim including a first curled portion. The second unit includes a second peripheral rim including a second curled portion. The polymer bead is connected to both the first peripheral rim and the second peripheral rim.

In some embodiments, the polymer bead includes a longitudinal direction, a longitudinal length, a mid-point of the longitudinal length, and a maximum cross-section. The longitudinal direction is approximately parallel to the first peripheral rim. The longitudinal length is measured along the longitudinal direction. The maximum cross- section thickness is at the mid-point and perpendicular to the longitudinal direction of the polymer bead. The maximum cross-section thickness is greater than 10 microns and less than 1 ,000 microns.

In some embodiments, the maximum cross-section thickness is greater than 10 microns and less than 100 microns.

Another embodiment of the present disclosure is a package including the multi- compartment tray of any of the previous embodiments and a lid. The lid is connected to the first unit at a first seal and the lid is connected to the second unit at a second seal. Each of the first and second units is independently hermetically sealed.

In some embodiments, the lid includes a line of weakness or is fully separated in a location between the first seal and the second seal.

In some embodiments, upon application of manual force, the first unit can be separated from the second unit and the separation includes at least partial cohesive failure within the polymer bead.

In some embodiments, upon application of manual force, the first unit can be separated from the second unit and the separation includes at least partial adhesive failure between the polymer bead and either the first or second unit.

There are several other aspects of the present subject matter which may be embodied separately or together. These aspects may be employed alone or in combination with other aspects of the subject matter described herein, and the description of these aspects together is not intended to preclude the use of these aspects separately or the claiming of such aspects separately or in different combinations.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings, in which:

FIG. 1 illustrates a schematic perspective view of a multi-compartment tray in accordance with an embodiment of the present disclosure;

FIG. 2A illustrates a schematic cross-sectional view of a first unit of the multi- compartment tray in accordance with an embodiment of the present disclosure; FIG. 2B illustrates a schematic cross-sectional view of a second unit of the multi- compartment tray in accordance with an embodiment of the present disclosure;

FIG. 3A illustrates a schematic top view of the multi-compartment tray of FIG. 1 ;

FIG. 3B illustrates a schematic cross-sectional view of the multi-compartment tray of FIG. 3A;

FIG. 4 illustrates a schematic cross-sectional view of another multi-compartment tray in accordance with an embodiment of the present disclosure;

FIG. 5 illustrates a schematic cross-sectional view of another multi-compartment tray in accordance with an embodiment of the present disclosure;

FIG. 6 illustrates a schematic cross-sectional view of another multi-compartment tray in accordance with an embodiment of the present disclosure;

FIG. 7 illustrates a schematic cross-sectional view of another multi-compartment tray in accordance with an embodiment of the present disclosure;

FIG. 8A illustrates a schematic cross-sectional view of a standard curled portion in accordance with an embodiment of the present disclosure;

FIG. 8B illustrates a schematic cross-sectional view of a reverse curled portion in accordance with an embodiment of the present disclosure;

FIG. 8C illustrates a schematic cross-sectional view of a standard curled portion in accordance with another embodiment of the present disclosure;

FIG. 9 illustrates a schematic cross-sectional view of a package in accordance with another embodiment of the present disclosure;

FIG. 10 illustrates a schematic top view of a lid in accordance with an embodiment of the present disclosure; and

FIG. 11 illustrates a schematic cross-sectional view of the package of FIG. 9 during application of a manual force in accordance with an embodiment of the present disclosure.

The figures are not necessarily to scale. Like numbers used in the figures refer to like components. It will be understood, however, that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number. The drawings show some but not all embodiments. The elements depicted in the drawings are illustrative and not necessarily to scale, and the same (or similar) reference numbers denote the same (or similar) features throughout the drawings.

DETAILED DESCRIPTION

The present disclosure relates to a recyclable multi-compartment tray including a first unit, a second unit, and a polymer bead. The polymer bead is connected to both the first unit and the second unit.

Conventional multi-compartment trays may be made of plastics that may be easy to thermoform. The conventional multi-compartment trays may be manufactured by thermoforming a multilayer coextruded sheet including an ethylene vinyl alcohol (EVOH) layer sandwiched between two polypropylene (PP) layers. Therefore, the conventional multi-compartment trays may be thermoformed into a multi-serving design or other designs. However, such conventional multi-compartment trays are generally non- recyclable.

Further, thermoforming multi-compartment trays may not be feasible with materials, such as metals. Specifically, multi-compartment trays including metal layers and two or more compartments cannot be typically manufactured with existing deep drawing technologies. In some designs, the multi-compartment trays including metal layers may include two or more containers connected to each other by conventional connections, such as paper sleeve, adhesive tape, hot melt, etc. Such multi-compartment trays may not be suitable to undergo a retort process. Specifically, the conventional connections in such multi-compartment trays may not be durable enough to withstand high temperatures and water immersion. The conventional connections in such multi- compartment trays may therefore fail during the retort process.

The multi-compartment tray of the present disclosure includes a first unit, a second unit, and a polymer bead. The first unit includes a first compartment and a first metal layer. The second unit includes a second compartment and a second metal layer. The polymer bead is connected to both the first unit and the second unit.

The first and second units including the first and second metal layers, respectively, may be recyclable. Therefore, the multi-compartment tray may be recyclable. Further, the first and second units may be individually manufactured using existing deep drawing technologies. In addition, the multi-compartment tray of the present disclosure may not require major modifications in the existing manufacturing and packaging lines or processes. Therefore, manufacturing and filling of the multi-compartment tray may be inexpensive and simple to implement. The polymer bead connected to both the first unit and the second unit may also be recyclable. The polymer bead may be deposited by a micro-extrusion process. The first and second units may be detachably connected to each other via the polymer bead, such that they may be detached when desired by a user. Moreover, the multi-compartment tray may be capable of undergoing a retort process. In other words, the multi-compartment tray may withstand high temperatures and water immersion. The multi-compartment tray may undergo the retort process without damaging the connection between the first and second units. More specifically, the polymer bead connected to both the first and the second unit may not get damaged when the multi-compartment tray undergoes the retort process.

As used in the present disclosure, the term “layer” refers to a thickness of material within a film that has a relatively consistent formula. Layers may be of any type of material including polymeric, cellulosic, and metallic or a blend thereof. A given polymeric layer may consist of a single polymer-type or a blend of polymers and may be accompanied by additives. A given layer may be combined or connected to other layers to form films. A layer may be either partially or fully continuous as compared to adjacent layers or the film. A given layer may be partially or fully coextensive with adjacent layers. A layer may contain sub-layers.

As used in the present disclosure, the term “package” refers to any article or combination of articles used to surround an item wholly or partially. A package may take many, various forms. For example, the term “package” may include bags that wholly surround an item (or items) to be packaged; the term “package” may also include films that partially surround an item (or items) to be packaged and, when used in conjunction with another material (such as a tray), wholly surround an item (or items). As used in the present disclosure, “polyolefin” refers to polyethylene homopolymers, polyethylene copolymers, polypropylene homopolymers or polypropylene copolymers.

As used in the present disclosure, the term “polyethylene” refers to polymers that include an ethylene linkage. Polyethylenes may be a homopolymer, copolymer or interpolymer. Polyethylene copolymers or interpolymers may include other types of polymers (i.e., non-polyethylene polymers). Polyethylenes may have functional groups incorporated by grafting or other means. Polyethylenes include, but are not limited to, low-density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium- density polyethylene (MDPE), ultra-low density polyethylene (ULDPE), high-density polyethylene (HOPE), cyclic-olefin copolymers (COC), ethylene vinyl acetate copolymers (EVA), ethylene acrylic acid copolymers (EAA), ethylene methacrylic acid copolymers (EMAA), neutralized ethylene copolymers such as ionomer, and maleic anhydride grafted polyethylene (MAHgPE).

As used in the present disclosure, the term “polypropylene” refers to polymers that are derived from monomers of propylene. Polypropylenes may be a homopolymer, copolymer or interpolymer. Polypropylene copolymers or interpolymers may include other types of polymers (i.e., non-polypropylene polymers). Polypropylenes may have functional groups incorporated by grafting or other means. Polypropylenes include, but are not limited to, propylene-ethylene copolymers, ethylene-propylene copolymers, and maleic anhydride grafted polypropylenes (MAHgPP).

As used in the present disclosure, the term “retort process” refers to a process of heating of food products prone to microbial spoilage in hermetically sealed containers to extend their shelf life. Retort process may be used to obtain commercial sterilization by application of heat.

As used in the present disclosure, the term “micro-extrusion” refers to a micro- forming extrusion process performed at submillimeter range. Specifically, pellets of material may be melted into a viscoelastic melt and pushed through a nozzle. Further, the melt may be applied in a thin layer. A cross sectional area of the melt coming out of the nozzle may be about 1 millimeter square. As used in the present disclosure, the term “heat seal” refers to the formation of a fusion bond between two polymer surfaces by conventional heating means.

As used in the present disclosure, the term “heat-sealing process” refers to a process of sealing two or more polymer surfaces using heat and pressure. A direct contact method of heat-sealing utilizes a constantly heated die or sealing jaws to apply heat to a specific contact area or path to seal or weld the two or more polymer surfaces together. Heat-sealing is used for many applications, including heat seal connectors, thermally activated adhesives, film media, plastic ports, and foil sealing. The direct contact method of heat-sealing may utilize one or more heated bars, irons, dies, and jaws which contact the material to heat an interface and form a bond. The bars, irons, dies and jaws may have various configurations, and may be covered with a release layer or utilize various slick interposer materials (e.g., Teflon films) to prevent sticking to the two or more polymer surfaces during the heat-sealing process.

As used in the present disclosure, the term “line of weakness” refers to a continuous or non-continuous series of holes, vents, slits, slots, perforations, notches, punctures, orifices, openings, inlets, channels, etc., in the surface of or through film layer. Line of weakness may also be referred to as “score line”. A line of weakness may have varying depths. Its depth may extend from the first surface of a layer to the second surface of the layer (i.e., throughout the entire thickness of the layer). Alternatively, its depth may extend from about 50% to about 95% of the thickness of a layer. The line of weakness may provide a weakened tear point(s). The line of weakness may be formed by mechanical means (e.g., using a cutting blade), by chemical means (e.g., using solvents), by thermal means (e.g., by optical ablation), or by other means known in the art.

FIG. 1 shows a schematic perspective view of a multi-compartment tray 100 in accordance with an embodiment of the present disclosure. Multi-compartment tray 100 includes a first unit 110 and a second unit 130. In the illustrated embodiment of FIG. 1 , each of first unit 110 and second unit 130 includes a substantially rectangular portion having semi-circular portions at two opposite ends. However, in some other embodiments, each of first unit 110 and second unit 130 may have any suitable shape, such as a circle, an oval, a triangle, a square, a rectangle, or any suitable polygonal shape. Further, in some embodiments, dimensions of first unit 110 may be substantially similar to dimensions of second unit 130. However, in some other embodiments, the dimensions of first unit 110 may be different from the dimensions of second unit 130. It may be noted that the dimensions of first unit 110 and second unit 130 may vary depending on desired application attributes.

Each of first unit 110 and second unit 130 may be configured to store a single product, multiple variants of the single product, or multiple different products. First unit 110 and second unit 130 may be suitable for packaging a variety of edible and non-edible products. Further, first unit 110 and second unit 130 may be used to store liquids, particles, powders, solids, and combinations thereof. In other words, first unit 110 and second unit 130 may be used to store one or more ingredients, mixes, solids, foodstuffs, etc. In some cases, first unit 110 and second unit 130 may be used to store a personal care product, a pet food, a medical product, a pharmaceutical product, a first aid product, and a nutritional aid product. However, first unit 110 and second unit 130 may be used to store any product, and are not limited thereto. The products may be intended to be used together or in small portions. First and second units 110, 130 may be used to provide a convenient, multi-serve, and portable package for users.

Multi-compartment tray 100 further includes a polymer bead 150 (shown by hatching in FIG. 1) connected to both first unit 110 and second unit 130. Polymer bead 150 may be deposited on multi-compartment tray 100 by any suitable process. In some embodiments, polymer bead 150 may be deposited between first unit 110 and second unit 130 by a micro-extrusion process. Polymer bead 150 may include any suitable polymer. In some embodiments, polymer bead 150 includes at least one polyolefin. In some embodiments, polymer bead 150 includes at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer. In some embodiments, polymer bead 150 may include any suitable extrudable resin.

First and second units 110, 130 may be detachably connected to each other by polymer bead 150 such that they may be detached when desired by the users. In some embodiments, multi-compartment tray 100 may include multiple units similar to first and second units 110, 130. Further, the multiple units may be connected to each other by a plurality of polymer beads similar to polymer bead 150.

Manufacturing or connecting of multi-compartment tray 100 may not require major modifications in existing manufacturing lines or processes. Further, filling or packaging of multi-compartment tray 100 may not require major modifications in the existing packaging lines or processes. Moreover, multi-compartment tray 100 may undergo a retort process without damaging polymer bead 150 connected to both first and second units 110, 130. In other words, multi-compartment tray 100 may be durable enough to undergo the retort process and may withstand high temperatures and water immersion.

FIG. 2A shows a schematic cross-sectional view of first unit 110 in accordance with an embodiment of the present disclosure.

Referring to FIGS. 1 and 2A, first unit 110 includes a first compartment 112 and a first metal layer 114. First metal layer 114 may at least partially form an outer surface of first unit 110. In the illustrated embodiment of FIGS. 1 and 2A, first unit 110 further includes a first inner polymer layer 116. In some embodiments, first inner polymer layer 116 may encompass an inner surface of first metal layer 114. In some cases, first inner polymer layer 116 may be attached to first metal layer 114. First inner polymer layer 116 may be attached to first metal layer 114 by any suitable means. For example, first inner polymer layer 116 may be laminated on first metal layer 114 by an adhesive.

First inner polymer layer 116 may include any suitable polymer. In some embodiments, first inner polymer layer 116 includes at least one polyolefin. Specifically, in some embodiments, first inner polymer layer 116 includes at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer.

In some embodiments, first unit 110 further includes a first peripheral rim 118 including a first curled portion 120. As shown in FIG. 2A, in some embodiments, first inner polymer layer 116 and first metal layer 114 may be curled together to form first curled portion 120. First curled portion 120 may avoid exposure of sharp edges of first metal layer 114 to the user. Advantageously, first curled portion 120 may further secure first inner polymer layer 116 and first metal layer 114 together. FIG. 2B shows a schematic cross-sectional view of second unit 130 in accordance with an embodiment of the present disclosure.

Referring to FIGS. 1 and 2B, second unit 130 includes a second compartment 132 and a second metal layer 134. Second metal layer 134 may at least partially form an outer surface of second unit 130. In the illustrated embodiment of FIGS. 1 and 2B, second unit 130 further includes a second inner polymer layer 136. In some embodiments, second inner polymer layer 136 may encompass an inner surface of second metal layer 134. In some cases, second inner polymer layer 136 may be attached to second metal layer 134. Second inner polymer layer 136 may be attached to second metal layer 134 by any suitable means. For example, second inner polymer layer 136 may be laminated on second metal layer 134 by an adhesive.

Second inner polymer layer 136 may include any suitable polymer. In some embodiments, second inner polymer layer 136 includes at least one polyolefin. Specifically, in some embodiments, second inner polymer layer 136 includes at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer.

In some embodiments, second unit 130 further includes a second peripheral rim 138 including a second curled portion 140. As shown in FIG. 2B, in some embodiments, second inner polymer layer 136 and second metal layer 134 may be curled together to form second curled portion 140. Second curled portion 140 may avoid exposure of sharp edges of second metal layer 134 to the user. Advantageously, second curled portion 140 may further secure second inner polymer layer 136 and second metal layer 134 together.

Referring to FIGS. 2A and 2B, in some embodiments, each of first curled portion 120 and second curled portion 140 may be a standard curled portion. Examples of the standard curled portion are shown in FIGS. 8A and 8C. Specifically, first inner polymer layer 116 and first metal layer 114 may be curled downwards from first peripheral rim 118 to form first curled portion 120. Further, second inner polymer layer 136 and second metal layer 134 may be curled downwards from second peripheral rim 138 to form second curled portion 140. However, in some other embodiments, each of first curled portion 120 and second curled portion 140 may be a reverse curled portion. An example of the reverse curled portion is shown in FIG. 8B. Specifically, first inner polymer layer 116 and first metal layer 114 may be curled upwards from first peripheral rim 118 to form first curled portion 120. Further, second inner polymer layer 136 and second metal layer 134 may be curled upwards from second peripheral rim 138 to form second curled portion 140. In some embodiments, first curled portion 120 may be the standard curled portion and second curled portion 140 may be the reverse curled portion. In some embodiments, first curled portion 120 may be the reverse curled portion and second curled portion 140 may be the standard curled portion. In some embodiments, first curled portion 120 and second curled portion 140 may have a maximum width between about 1 millimeter (mm) and about 3 mm. In some embodiments, first curled portion 120 and second curled portion 140 may have the maximum width between about 1.1 mm and about 2.2 mm.

First metal layer 114 and second metal layer 134 may include any suitable metal or metal alloys. In some embodiments, first metal layer 114 and second metal layer 134 include aluminum. In some other embodiments, first metal layer 114 and second metal layer 134 include steel. Therefore, first metal layer 114 of first unit 110 and second metal layer 134 of second unit 130 may be recyclable. First and second units 110, 130 including first and second compartments 112, 132, respectively, may be individually manufactured using any suitable manufacturing process (e.g., deep drawing process).

In some embodiments, polymer bead 150 is connected to first unit 110 at first peripheral rim 118 and polymer bead 150 is connected to second unit 130 at second peripheral rim 138. Specifically, in some embodiments, polymer bead 150 is connected to both first peripheral rim 118 and second peripheral rim 138.

Multi-compartment tray 100 may be recyclable and suitable for packaging. In some embodiments, a package may include multi-compartment tray 100 with a lid.

FIG. 3A shows a schematic top view of multi-compartment tray 100. In the illustrated embodiment of FIG. 3A, polymer bead 150 includes a longitudinal direction 152 that is approximately parallel to first peripheral rim 118. In some embodiments, longitudinal direction 152 may also be approximately parallel to second peripheral rim 138. Polymer bead 150 further includes a longitudinal length 154 measured along longitudinal direction 152. Further, multi-compartment tray 100 defines a tray length 100A. Tray length 100A of multi-compartment tray 100 may be a maximum length of multi-compartment tray 100 measured along longitudinal direction 152 of polymer bead 150.

In the illustrated embodiment of FIG. 3A, longitudinal length 154 of polymer bead 150 is about 70% of tray length 100A of multi-compartment tray 100. However, in some other embodiments, longitudinal length 154 of polymer bead 150 may be greater than 10%, greater than 20%, greater than 30%, greater than 40%, greater than 45%, greater than 50%, greater than 55%, greater than 60%, or greater than 65% of tray length 100A of multi-compartment tray 100. In some examples, longitudinal length 154 of polymer bead 150 may be greater than 80%, greater than 85%, greater than 90%, greater than 95%, or greater than 99% of tray length 100A of multi-compartment tray 100, for example, when multi-compartment tray 100 is substantially rectangular in shape. In the illustrated embodiment of FIG. 3A, polymer bead 150 further includes a mid-point 156 of longitudinal length 154. In other words, mid-point 156 of longitudinal length 154 may divide longitudinal length 154 into two substantially equal lengths. In other words, mid-point 156 may be equidistant from opposite ends of longitudinal length 154.

FIG. 3B shows a schematic cross-sectional view of multi-compartment tray 100 in accordance with an embodiment of the present disclosure. In the illustrated embodiment of FIG. 3B, polymer bead 150 is deposited on top of both first and second peripheral rims 118, 138. Polymer bead 150 further includes a maximum cross-section thickness 158 that is at mid-point 156 (shown in FIG. 3A) and perpendicular to longitudinal direction 152 (shown in FIG. 3A) of polymer bead 150.

As shown in FIG. 3B, first curled portion 120 and second curled portion 140 are separated by a distance 125. Distance 125 may be defined as a maximum distance between first and second curled portions of 120, 140. In some embodiments, maximum cross-section thickness 158 of polymer bead 150 is greater than distance 125 between first and second curled portions of 120, 140 of first and second peripheral rims 118, 138, respectively. In some other embodiments, maximum cross-section thickness 158 may be substantially equal to distance 125. In some embodiments, maximum cross-section thickness 158 of polymer bead 150 is greater than 10 microns and less than 1 ,000 microns. In some embodiments, maximum cross-section thickness 158 is greater than 10 microns and less than 100 microns. Multi-compartment tray 100 may include various different configurations of polymer bead 150, as shown in FIGS. 4-7 and described below.

FIG. 4 shows a schematic cross-sectional view of a multi-compartment tray 200 in accordance with an embodiment of the present disclosure. Multi-compartment tray 200 is substantially similar to multi-compartment tray 100 shown in FIGS. 1 and 3A-3B. However, multi-compartment tray 200 has a different configuration from multi- compartment tray 100 with respect to relative positioning and coupling of first and second units 110, 130. Multi-compartment tray 200 includes a polymer bead 250. Polymer bead 250 is substantially similar to polymer bead 150 of multi-compartment tray 100 with respect to material properties, deposition method, and function.

In the illustrated embodiment of FIG. 4, first and second peripheral rims 118, 138 contact each other. Specifically, first curled portion 120 and second curled portion 140 contact each other. Further, polymer bead 250 is connected to first curled portion 120 of first peripheral rim 118 and second curled portion 140 of second peripheral rim 138. Polymer bead 250 is deposited on top of first curled portion 120 and second curled portion 140. Polymer bead 250 further includes a maximum cross-section thickness 258. In some embodiments, maximum cross-section thickness 258 may range from about 10 microns to about 100 microns.

FIG. 5 shows a schematic cross-sectional view of a multi-compartment tray 300 in accordance with an embodiment of the present disclosure. Multi-compartment tray 300 is substantially similar to multi-compartment tray 100 shown in FIGS. 1 and 3A-3B. However, multi-compartment tray 300 has a different configuration from multi- compartment tray 100 with respect to relative positioning and coupling of first and second units 110, 130. Multi-compartment tray 300 includes a polymer bead 350. Polymer bead 350 is substantially similar to polymer bead 150 of multi-compartment tray 100 with respect to material properties, deposition method, and function.

In the illustrated embodiment of FIG. 5, first and second peripheral rims 118, 138 contact each other. Specifically, first curled portion 120 and second curled portion 140 contact each other. Further, polymer bead 350 is connected to first curled portion 120 of first peripheral rim 118 and second curled portion 140 of second peripheral rim 138. Polymer bead 350 is deposited under first curled portion 120 and second curled portion 140. Polymer bead 350 further includes a maximum cross-section thickness 358. In some embodiments, maximum cross-section thickness 358 may range from about 10 microns to about 100 microns.

FIG. 6 shows a schematic cross-sectional view of a multi-compartment tray 400 in accordance with an embodiment of the present disclosure. Multi-compartment tray 400 is substantially similar to multi-compartment tray 100 shown in FIGS. 1 and 3A-3B. However, multi-compartment tray 400 has a different configuration from multi- compartment tray 100 with respect to relative positioning and coupling of first and second units 110, 130. Multi-compartment tray 400 includes a polymer bead 450. Polymer bead 450 is substantially similar to polymer bead 150 of multi-compartment tray 100 with respect to material properties, deposition method, and function.

In the illustrated embodiment of FIG. 6, first and second peripheral rims 118, 138 do not contact each other. Specifically, first curled portion 120 and second curled portion 140 are separated by a distance 425. Polymer bead 450 is connected to first curled portion 120 of first peripheral rim 118 and second curled portion 140 of second peripheral rim 138. Polymer bead 450 further includes a maximum cross-section thickness 458. In some embodiments, maximum cross-section thickness 458 may range from about 10 microns to about 1000 microns. In the illustrated embodiment of FIG. 6, maximum cross- section thickness 458 may be substantially equal to distance 425 between first curled portion 120 and second curled portion 140.

FIG. 7 shows a schematic cross-sectional view of a multi-compartment tray 500 in accordance with an embodiment of the present disclosure. Multi-compartment tray 500 is substantially similar to multi-compartment tray 100 shown in FIGS. 1 and 3A-3B. However, multi-compartment tray 500 has a different configuration from multi- compartment tray 100 with respect to coupling of first and second units 110, 130. Multi- compartment tray 500 includes a polymer bead 550. Polymer bead 550 is substantially similar to polymer bead 150 of multi-compartment tray 100 with respect to material properties, deposition method, and function.

In the illustrated embodiment of FIG. 7, first and second peripheral rims 118, 138 do not contact each other. Specifically, first curled portion 120 and second curled portion 140 are separated by a distance 525. Polymer bead 550 is connected to first curled portion 120 of first peripheral rim 118 and second curled portion 140 of second peripheral rim 138. Polymer bead 550 is deposited under first curled portion 120 and second curled portion 140. Polymer bead 450 further includes a maximum cross-section thickness 558. In some embodiments, maximum cross-section thickness 558 may range from about 10 microns to about 1000 microns. In the illustrated embodiment of FIG. 7, maximum cross- section thickness 558 is greater than distance 525 between first curled portion 120 and second curled portion 140.

FIG. 8A shows a standard curled portion 501A in accordance with an embodiment of the present disclosure. Standard curled portion 501 A includes one or more layers curled downwards. In the illustrated embodiment of FIG. 8A, the one or more layers include a metal layer 502A and an inner polymer layer 503A. In some embodiments, a maximum width 504A of standard curled portion 501 A may range from about 1.1 mm to about 2.2 mm. In some embodiments, maximum width 504A of standard curled portion 501A may range from about 1 mm to about 3 mm. In some embodiments, maximum width 504A may depend upon thickness of the one or more layers of standard curled portion 501A. In some embodiments, maximum width 504A may depend upon thickness of metal layer 502A and inner polymer layer 503A. In some embodiments, each of first curled portion 120 (shown in FIG. 2A) and second curled portion 140 (shown in FIG. 2B) is equivalent to standard curled portion 501 A. In some embodiments, a peripheral rim 505A includes standard curled portion 501 A.

FIG. 8B shows a reverse curled portion 501 B in accordance with an embodiment of the present disclosure. Reverse curled portion 501 B includes one or more layers curled upwards. In the illustrated embodiment of FIG. 8B, the one or more layers include a metal layer 502B and an inner polymer layer 503B. In some embodiments, a maximum width 504B of reverse curled portion 501 B may range from about 1.1 mm to about 2.2 mm. In some embodiments, maximum width 504B of reverse curled portion 501 B may range from about 1 mm to about 3 mm. In some embodiments, maximum width 504B may depend upon thickness of the one or more layers of reverse curled portion 501 B. In some embodiments, maximum width 504B may depend upon thickness of metal layer 502B and inner polymer layer 503B. In some embodiments, each of first curled portion 120 (shown in FIG. 2A) and second curled portion 140 (shown in FIG. 2B) may be equivalent to reverse curled portion 501B. In some embodiments, a peripheral rim 505B includes reverse curled portion 501 B.

FIG. 8C shows a standard curled portion 501 C in accordance with another embodiment of the present disclosure. Standard curled portion 501C includes one or more layers curled downwards. In the illustrated embodiment of FIG. 8C, the one or more layers include a metal layer 502C and an inner polymer layer 503C. In some embodiments, a maximum width 504C of standard curled portion 501 A may range from about 1.1 mm to about 2.2 mm. In some embodiments, a maximum width 504C of standard curled portion 501 A may range from about 1 mm to about 3 mm. In some embodiments, maximum width 504C may depend upon thickness of the one or more layers of standard curled portion 501 C. In some embodiments, maximum width 504C may depend upon thickness of metal layer 502C and inner polymer layer 503C. In some embodiments, each of first curled portion 120 (shown in FIG. 2A) and second curled portion 140 (shown in FIG. 2B) may be equivalent to standard curled portion 501 C. In some embodiments, a peripheral rim 505C includes standard curled portion 501 C. Further, in the illustrated embodiment of FIG. 8C, standard curled portion 501 C rises above a plane of peripheral rim 505C.

FIG. 9 shows a schematic cross-sectional view of a package 601 in accordance with an embodiment of the present disclosure. Package 601 may be configured to store a single product, multiple variants of the single product, or multiple different products. Package 601 may be suitable for food packaging and may provide a convenient, multi- serve, and portable package for the users. In some embodiments, package 601 may be used to store liquids, particles, powders, solids, and combinations thereof. Specifically, package 601 may be used to store one or more ingredients, mixes, solids, foodstuffs, etc. Package 601 may also be used for packaging of ready-to-eat food items.

In the illustrated embodiment of FIG. 9, package 601 includes multi-compartment tray 100 and a lid 602. However, in some other embodiments, package 601 may include any one of multi-compartment trays 200, 300, 400, 500 shown in FIGS. 4-7.

As shown in FIG. 9, first unit 110 includes a first product 611 in first compartment 112. Furthermore, second unit 130 includes a second product 631 in second compartment 132. In some embodiments, first product 611 and second product 631 may be liquids and/or solids. In some embodiments, first product 611 and second product 631 may be a food product, a personal care product, a pet food, a medical product, a pharmaceutical product, a first aid product, and a nutritional aid product. In some embodiments, first product 611 and second product 631 may be different. In some other embodiments, first product 611 and second product 631 may be similar.

Referring to FIGS. 9 and 10, lid 602 covers both first and second units 110, 130 securing first product 611 and second product 631 separately in first and second compartments 112, 132, respectively. In some embodiments, lid 602 may include a thermoplastic sealing layer. In the illustrated embodiment of FIG. 9, lid 602 is connected to first unit 110 at a first seal 622. Further, lid 602 is connected to second unit 130 at a second seal 642. In some embodiments, first seal 622 and second seal 642 may be one of heat seals, cold seals, and pressure sensitive seals. In some embodiments, first seal 622 and second seal 642 may be heat seals formed by a heat-sealing process. In some embodiments, first and second seals 622, 642 may extend along first and second peripheral rims 118, 138, respectively.

In some embodiments, each of first and second units 110, 130 is independently hermetically sealed. In other words, each of first and second units 110, 130 may be independently sealed in an air-tight manner.

In some embodiments, lid 602 further includes a line of weakness 604 or is fully separated in a location 606 between first seal 622 and second seal 642.

In some embodiments, a manual force may be applied on package 601 to separate first and second units 110, 130. The manual force may have sufficient magnitude to separate first and second units 110, 130. Referring to FIG. 11 , in some cases, first and second units 110, 130 may be separated by rotating first unit 110 in a first direction 660 about longitudinal length 154 (shown in FIG. 3A) of polymer bead 150 and rotating second unit 130 in a second direction 662 opposite to first direction 660 about longitudinal length 154 of polymer bead 150. In some other cases, first and second units 110, 130 may be separated by pulling first unit 110 apart from second unit 130 in a direction normal to longitudinal length 154 of polymer bead 150.

In some embodiments, upon application of the manual force, first unit 110 may be separated from second unit 130 and the separation includes at least partial cohesive failure within polymer bead 150. Cohesive failure within polymer bead 150 may refer to a rupture of polymer bead 150 such that first unit 110 separates from second unit 130.

In some other embodiments, upon application of the manual force, first unit 110 may be separated from second unit 130 and the separation includes at least partial adhesive failure between polymer bead 150 and either first unit 110 or second unit 130. Adhesive failure between polymer bead 150 and either first unit 110 or second unit 130 may refer to a debonding of polymer bead 150 from either first unit 110 or second unit 130.

Therefore, first and second units 110, 130 may be detachably connected to each other via polymer bead 150, such that first and second units 110, 130 may be detached when desired by the user.

Further, upon application of the manual force, lid 602 may be separated along line of weakness 604. In some cases, lid 602 may split into two parts, and the parts may independently seal each of first unit 110 and second unit 130.

Each and every document cited in this present application, including any cross referenced, is incorporated in this present application in its entirety by this reference, unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any embodiment disclosed in this present application or that it alone, or in any combination with any other reference or references, teaches, suggests, or discloses any such embodiment. Further, to the extent that any meaning or definition of a term in this present application conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this present application governs.

Unless otherwise indicated, all numbers expressing sizes, amounts, ranges, limits, and physical and other properties used in the present application are to be understood as being preceded in all instances ay the term “about”. Accordingly, unless expressly indicated to the contrary, the numerical parameters set forth in the present application are approximations that can vary depending on the desired properties sought to be obtained by a person of ordinary skill in the art without undue experimentation using the teachings disclosed in the present application. As used in the present application, the singular forms “a”, “an”, and “the” encompass embodiments having plural referents, unless the context clearly dictates otherwise. As used in the present application, the term “or” is generally employed in its sense including “and/or”, “unless” the context clearly dictates otherwise.

Spatially related terms, including but not limited to, “lower”, “upper”, “beneath”, “below”, “above”, “bottom” and “top”, if used in the present application, are used for ease of description to describe spatial relationships of an element(s) to another. Such spatially related terms encompass different orientations of the device in use or operation, in addition to the particular orientations depicted in the figures and described in the present application. For example, if an object depicted in the drawings is turned over or flipped over, elements previously described as below, or beneath other elements would then be above those other elements.

The drawings show some but not all embodiments. The elements depicted in the drawings are illustrative and not necessarily to scale, and the same or similar) reference numbers denote the same (or similar) features throughout the drawings.

The description, examples, embodiments, and drawings disclosed are illustrative only and should not be interpreted as limiting. The present invention includes the description, examples, embodiments, and drawings disclosed; but it is not limited to such description, examples, embodiments, or drawings. As briefly described above, the reader should assume that features of one disclosed embodiment can also be applied to all other disclosed embodiments, unless expressly indicated to the contrary. Modifications and other embodiments will be apparent to a person of ordinary skill in the packaging arts, and all such modifications and other embodiments are intended and deemed to be within the scope of the present invention.

Embodiments:

Tray Embodiment A: A multi-compartment tray comprising: a first unit comprising a first compartment and a first metal layer, a second unit comprising a second compartment and a second metal layer, and a polymer bead connected to both the first unit and the second unit. Tray Embodiment B The multi-compartment tray of Tray Embodiment A, wherein the first unit further comprises a first inner polymer layer and the second unit further comprises a second inner polymer layer.

Tray Embodiment C: The multi-compartment tray of Tray Embodiment B, wherein the first inner polymer layer comprises at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer and the second inner polymer layer comprises at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer.

T ray Embodiment D: The multi-compartment tray of T ray Embodiment A, B, or C, wherein the first metal layer and the second metal layer comprise aluminum.

T ray Embodiment E: The multi-compartment of T ray Embodiment A, B, or C, wherein the first metal layer and the second metal layer comprise steel.

Tray Embodiment F: The multi-compartment tray of any previous Tray Embodiment, wherein the first unit further comprises a first peripheral rim comprising a first curled portion and the second unit further comprises a second peripheral rim comprising a second curled portion.

Tray Embodiment G: The multi-compartment tray of Tray Embodiment F, wherein the polymer bead is connected to the first unit at the first peripheral rim and the polymer bead is connected to the second unit at the second peripheral rim.

Tray Embodiment H: The multi-compartment tray of any previous Tray Embodiment, wherein the polymer bead comprises at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer. Tray Embodiment I: A multi-compartment tray comprising: a first unit comprising a first peripheral rim comprising a first curled portion, a second unit comprising a second peripheral rim comprising a second curled portion, a polymer bead connected to both the first peripheral rim and the second peripheral rim.

Tray Embodiment J: The multi-compartment tray of Tray Embodiment I, wherein the polymer bead comprises at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer.

Tray Embodiment K: The multi-compartment tray of Tray Embodiment F, G, H I or J, wherein the polymer bead comprises: a longitudinal direction that is approximately parallel to the first peripheral rim, a longitudinal length measured along the longitudinal direction, a mid-point of the longitudinal length, and a maximum cross-section thickness that is at the mid-point and perpendicular to the longitudinal direction of the polymer bead, wherein the maximum cross-section thickness is greater than 10 microns and less than 1,000 microns.

Tray Embodiment L: The multi-compartment tray of Tray Embodiment K, wherein the maximum cross-section thickness is greater than 10 microns and less than 100 microns.

Package Embodiment M: A package comprising: a multi-compartment tray of any of Tray Embodiments and a lid, wherein the lid is connected to the first unit at a first seal and the lid is connected to the second unit at a second seal, and wherein each of the first and second units is independently hermetically sealed. Package Embodiment N: The package of Package Embodiment M, wherein the lid comprises a line of weakness or is fully separated in a location between the first seal and the second seal. Package Embodiment O: The package of Package Embodiment M or N, wherein upon application of manual force, the first unit can be separated from the second unit and the separation includes at least partial cohesive failure within the polymer bead.

Package Embodiment P: The package of Package Embodiment M or N, wherein upon application of manual force, the first unit can be separated from the second unit and the separation includes at least partial adhesive failure between the polymer bead and either the first or second unit.

Claims

1. A multi-compartment tray comprising: a first unit comprising a first compartment and a first metal layer, a second unit comprising a second compartment and a second metal layer, and a polymer bead connected to both the first unit and the second unit.

2. The multi-compartment tray of claim 1, wherein the first unit further comprises a first inner polymer layer and the second unit further comprises a second inner polymer layer.

3. The multi-compartment tray of claim 2, wherein the first inner polymer layer comprises at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer and the second inner polymer layer comprises at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer.

4. The multi-compartment tray of claim 1, wherein the first metal layer and the second metal layer comprise aluminum.

5. The multi-compartment of claim 1 , wherein the first metal layer and the second metal layer comprise steel.

6. The multi-compartment tray of claim 1, wherein the first unit further comprises a first peripheral rim comprising a first curled portion and the second unit further comprises a second peripheral rim comprising a second curled portion.

7. The multi-compartment tray of claim 6, wherein the polymer bead is connected to the first unit at the first peripheral rim and the polymer bead is connected to the second unit at the second peripheral rim.

8. The multi-compartment tray of claim 1, wherein the polymer bead comprises at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer.

9. A multi-compartment tray comprising: a first unit comprising a first peripheral rim comprising a first curled portion, a second unit comprising a second peripheral rim comprising a second curled portion, a polymer bead connected to both the first peripheral rim and the second peripheral rim.

10. The multi-compartment tray of claim 9, wherein the polymer bead comprises at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer and a polypropylene copolymer.

11. The multi-compartment tray of claim 6 or 9, wherein the polymer bead comprises: a longitudinal direction that is approximately parallel to the first peripheral rim, a longitudinal length measured along the longitudinal direction, a mid-point of the longitudinal length, and a maximum cross-section thickness that is at the mid-point and perpendicular to the longitudinal direction of the polymer bead, wherein the maximum cross-section thickness is greater than 10 microns and less than 1,000 microns.

12. The multi-compartment tray of claim 11 , wherein the maximum cross-section thickness is greater than 10 microns and less than 100 microns.

13. A package comprising: a multi-compartment tray of claim 1 or 9 and a lid, wherein the lid is connected to the first unit at a first seal and the lid is connected to the second unit at a second seal, and wherein each of the first and second units is independently hermetically sealed.

14 The package of claim 13, wherein the lid comprises a line of weakness or is fully separated in a location between the first seal and the second seal.

15. The package of claim 13, wherein upon application of manual force, the first unit can be separated from the second unit and the separation includes at least partial cohesive failure within the polymer bead.

16. The package of claim 13, wherein upon application of manual force, the first unit can be separated from the second unit and the separation includes at least partial adhesive failure between the polymer bead and either the first or second unit.