The disclosures of U.S. Provisional Patent Application No. 61/795,501, which was filed Oct. 17, 2012, and U.S. Provisional Patent Application No. 61/795,852, which was filed Oct. 29, 2012, are hereby incorporated by reference as if presented herein in their entirety.
The present disclosure relates to blanks, containers, trays, constructs, and various features to facilitate forming a container from a blank.
In one aspect, the disclosure is generally directed to a container for holding an article. The container comprises a lamination layer at least partially secured to a base layer, a bottom wall, and a side wall. The bottom wall and the side wall cooperate to at least partially define a cavity of the container with the lamination layer at least partially comprising an interior surface of the container adjacent the cavity. A plurality of score lines extend in the container for at least partially reducing buckling of the lamination layer into the cavity of the container.
In another aspect, the disclosure is generally directed to a blank for forming a container for holding an article. The blank comprises a lamination layer at least partially secured to a base layer, a bottom portion, and a marginal portion. The bottom portion and the marginal portion are for cooperating to at least partially define a cavity of the container formed from the blank. The lamination layer is for at least partially forming an interior surface of the container formed from the blank. A plurality of score lines extend in the blank for at least partially reducing buckling of the lamination layer into the cavity of the container formed from the blank.
In another aspect, the disclosure is generally directed to a method of forming a container. The method comprises obtaining a blank comprising a lamination layer at least partially secured to a base layer and a plurality of score lines. The method further comprises forming the container comprising a bottom wall and a side wall from the blank. The forming the container comprises forming a cavity at least partially defined by the bottom wall and the side wall. The lamination layer comprises an interior surface of the container adjacent the cavity. During the forming the container, the plurality of score lines at least partially reduces buckling of the lamination layer into the cavity of the container.
Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.
According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.
Corresponding parts are designated by corresponding reference numbers throughout the drawings.
The present disclosure relates generally to various aspects of containers, constructs, trays, materials, packages, elements, and articles, and methods of making such containers, constructs, trays, materials, packages, elements, and articles. Although several different aspects, implementations, and embodiments are disclosed, numerous interrelationships between, combinations thereof, and modifications of the various aspects, implementations, and embodiments are contemplated hereby. In one illustrated embodiment, the present disclosure relates to forming a container or tray for holding food items or various other articles. However, in other embodiments, the container or tray can be used to form other non-food containing articles or may be used for heating or cooking.
The blank 3 can be formed from a laminate that includes more than one layer, but alternatively the laminate can be replaced with a single ply of material, such as, but not limited to, paperboard, cardboard, paper, or a polymeric sheet. In accordance with the exemplary embodiments of the present disclosure, the laminate can include a lamination layer 8, which can be a microwave interactive layer such as is common in MicroRite® containers available from Graphic Packaging International of Marietta, Ga. The lamination layer can be commonly referred to as, or can have as one of its components, a foil, a microwave shield, or any other term or component that refers to a layer of material suitable for shielding microwave energy and/or causing heating in a microwave oven. Alternatively, the lamination layer 8 can be any suitable material that is laminated onto a substrate. The lamination layer 8 comprises the inner/interior surface 12 of the blank 3 (
As shown in
In one embodiment, the marginal portion 15 of the blank 3 includes a plurality of score lines 19. The score lines 19 are all positioned in the marginal portion 15 in the end regions 25 such that the score lines extend generally radially from the outer edge 13 of the blank. In one embodiment, adjacent score lines 19 in respective curved regions 27 (e.g., where the outer edge 13 is generally curved) can be spaced apart by an angle A1 of at least approximately 5 degrees. Alternatively, the angle A1 could be any suitable angle. In respective straight portions 29 (e.g., where the outer edge 13 is generally straight), the score lines 19 are generally parallel. In one embodiment, the score lines 19 extend to the outer edge 13 of the blank 3, but the score lines could have a radially outer end point that is spaced in from the outer edge of the blank without departing from the disclosure. Also, in one embodiment, the score lines 19 are formed on the interior surface 12 such the score lines 19 comprise slight indentations in the interior surface 12 of the blank on the surface of the lamination layer 8 and slight protrusions on the exterior surface 16 of the blank on the outer surface of the base layer 14. The score lines 19 could be omitted or could be otherwise shaped, arranged, and/or configured without departing from the disclosure.
In the illustrated embodiment, a plurality of score lines 30 can be included in the bottom corner area 9 of the blank 3 for helping to reduce delamination of the lamination layer 8 from the base layer 14. The plurality of score lines 30 can include first side score lines 33 extending adjacent the first side region 21, second side score lines 35 extending adjacent the second side region 23, and end score lines 37 extending adjacent each of the end regions 25. In one embodiment, as schematically shown in
In one example, the paperboard base layer 14 of the blank 3 can comprise 18 point paperboard having a thickness of approximately 0.018 inch (0.46 mm), and the lamination layer 8 can have a thickness of approximately 0.001 inch (0.025 mm) so that the blank 3 has a total thickness Tb of approximately 0.019 inch (0.48 mm). The thickness of a foil within the lamination layer 8 can be approximately 0.000275 inch (0.007 mm), for example. In one embodiment, the thickness of the paperboard base layer 14 can be in the range of approximately 0.013 inch (0.33 mm) to approximately 0.030 inch (0.72 mm), the thickness of the lamination layer 8 can be in the range of approximately 0.0005 inch (0.013 mm) to approximately 0.0015 inch (0.038 mm), and the total thickness Tb can be in the range of approximately 0.0135 inch (0.34 mm) to approximately 0.0315 inch (0.80 mm). Any of the above noted thicknesses or other dimensions noted above could be larger or smaller than noted or could be inside or outside the listed ranges without departing form the scope of the disclosure. All of the dimensional information presented herein is intended to be illustrative of certain aspects of the disclosure and is not intended to limit the scope of the disclosure, as various other embodiments of the disclosure could include dimensions that are greater than or less than the dimensions included herein.
As shown in
As shown in
In the illustrated embodiment, when the blank 3 is formed into the container 5, the score lines 19 form overlapped portions or pleats 31. In the illustrated embodiment, the overlapped portions 31 are in the flange 7 of the container and the side wall 137, and extend down the side wall to a location adjacent the bottom wall 133. The overlapped portions 31 could be otherwise shaped, arranged, and/or configured without departing from the disclosure.
As shown in
In one embodiment, the lamination layer 8 can be generally more resistant to compression—especially compared to the paperboard base layer 14. Since the lamination layer 8 is interior to the base layer 14, the material of the lamination layer 8 can bunch up or buckle at the bottom corner 135 and separate from the base layer 14. For example, micro-layer interactions between the lamination layer and the base layer can cause an adhesive securing the layers together to fail where the adhesive is weaker and/or absent (e.g., due to uneven application). If the scores 30 are omitted, the material of the lamination layer 8 could separate from the base layer 14 and extend into the interior 145 of the container 5. The separated portions of the lamination layer could be damaged by an eating utensil, for example, and could be torn away from the interior surface 12 and mix with a food item contained in the container 5. While the materials used in the lamination layer 8 typically are generally inert, the damage to the interior surface of the container 5 can reduce the visual appeal of the container and food items (or other items) contained therein. Additionally, the loose pieces of lamination can cause concern and/or affect the enjoyment of a food item (or other item) in the container by a consumer.
The scores 30 can help to prevent the lamination layer 8 from buckling into the interior 145. As shown schematically in
In one embodiment, the blank 3 is formed into the container by conveying a blank and placing the blank in the forming tool T (schematically shown in
Any of the features of the various embodiments of the disclosure can be combined with, replaced by, or otherwise configured with other features of other embodiments of the disclosure without departing from the scope of this disclosure.
Optionally, one or more portions of the blank or other constructs described herein or contemplated hereby may be coated with varnish, clay, or other materials, either alone or in combination. The coating may then be printed over with product advertising or other information or images. The blanks or other constructs also may be selectively coated and/or printed so that less than the entire surface area of the blank or substantially the entire surface area of the blank may be coated and/or printed.
Further, the containers 5, 405 may cooperate with a lid (not shown) for holding, heating, and/or cooking a food product or other item that is held in the container without departing from the disclosure.
Any of the blanks, containers, or other constructs of this disclosure may optionally include one or more features that alter the effect of microwave energy during the heating or cooking of a food item that is associated with the tray or other construct. For example, the blank, tray, container, or other construct may be formed at least partially from one or more microwave energy interactive elements (hereinafter sometimes referred to as “microwave interactive elements”) that promote heating, browning and/or crisping of a particular area of the food item, shield a particular area of the food item from microwave energy to prevent overcooking thereof, or transmit microwave energy towards or away from a particular area of the food item. Each microwave interactive element comprises one or more microwave energy interactive materials or segments arranged in a particular configuration to absorb microwave energy, transmit microwave energy, reflect microwave energy, or direct microwave energy, as needed or desired for a particular construct and food item.
In the case of a susceptor or shield, the microwave energy interactive material may comprise an electroconductive or semiconductive material, for example, a vacuum deposited metal or metal alloy, or a metallic ink, an organic ink, an inorganic ink, a metallic paste, an organic paste, an inorganic paste, or any combination thereof. Examples of metals and metal alloys that may be suitable include, but are not limited to, aluminum, chromium, copper, inconel alloys (nickel-chromium-molybdenum alloy with niobium), iron, magnesium, nickel, stainless steel, tin, titanium, tungsten, and any combination or alloy thereof.
Alternatively, the microwave energy interactive material may comprise a metal oxide, for example, oxides of aluminum, iron, and tin, optionally used in conjunction with an electrically conductive material. Another metal oxide that may be suitable is indium tin oxide (ITO). ITO has a more uniform crystal structure and, therefore, is clear at most coating thicknesses.
Alternatively still, the microwave energy interactive material may comprise a suitable electroconductive, semiconductive, or non-conductive artificial dielectric or ferroelectric. Artificial dielectrics comprise conductive, subdivided material in a polymeric or other suitable matrix or binder, and may include flakes of an electroconductive metal, for example, aluminum.
In other embodiments, the microwave energy interactive material may be carbon-based, for example, as disclosed in U.S. Pat. Nos. 4,943,456, 5,002,826, 5,118,747, and 5,410,135.
In still other embodiments, the microwave energy interactive material may interact with the magnetic portion of the electromagnetic energy in the microwave oven. Correctly chosen materials of this type can self-limit based on the loss of interaction when the Curie temperature of the material is reached. An example of such an interactive coating is described in U.S. Pat. No. 4,283,427.
The use of other microwave energy interactive elements is also contemplated. In one example, the microwave energy interactive element may comprise a foil or high optical density evaporated material having a thickness sufficient to reflect a substantial portion of impinging microwave energy. Such elements typically are formed from a conductive, reflective metal or metal alloy, for example, aluminum, copper, or stainless steel, in the form of a solid “patch” generally having a thickness of from about 0.000285 inches to about 0.005 inches, for example, from about 0.0003 inches to about 0.003 inches. Other such elements may have a thickness of from about 0.00035 inches to about 0.002 inches, for example, 0.0016 inches.
In some cases, microwave energy reflecting (or reflective) elements may be used as shielding elements where the food item is prone to scorching or drying out during heating. In other cases, smaller microwave energy reflecting elements may be used to diffuse or lessen the intensity of microwave energy. One example of a material utilizing such microwave energy reflecting elements is commercially available from Graphic Packaging International, Inc. (Marietta, Ga.) under the trade name MicroRite® packaging material. In other examples, a plurality of microwave energy reflecting elements may be arranged to form a microwave energy distributing element to direct microwave energy to specific areas of the food item. If desired, the loops may be of a length that causes microwave energy to resonate, thereby enhancing the distribution effect. Microwave energy distributing elements are described in U.S. Pat. Nos. 6,204,492, 6,433,322, 6,552,315, and 6,677,563, each of which is incorporated by reference in its entirety.
If desired, any of the numerous microwave energy interactive elements described herein or contemplated hereby may be substantially continuous, that is, without substantial breaks or interruptions, or may be discontinuous, for example, by including one or more breaks or apertures that transmit microwave energy. The breaks or apertures may extend through the entire structure, or only through one or more layers. The number, shape, size, and positioning of such breaks or apertures may vary for a particular application depending on the type of construct being formed, the food item to be heated therein or thereon, the desired degree of heating, browning, and/or crisping, whether direct exposure to microwave energy is needed or desired to attain uniform heating of the food item, the need for regulating the change in temperature of the food item through direct heating, and whether and to what extent there is a need for venting.
By way of illustration, a microwave energy interactive element may include one or more transparent areas to effect dielectric heating of the food item. However, where the microwave energy interactive element comprises a susceptor, such apertures decrease the total microwave energy interactive area, and therefore, decrease the amount of microwave energy interactive material available for heating, browning, and/or crisping the surface of the food item. Thus, the relative amounts of microwave energy interactive areas and microwave energy transparent areas may be balanced to attain the desired overall heating characteristics for the particular food item.
As another example, one or more portions of a susceptor may be designed to be microwave energy inactive to ensure that the microwave energy is focused efficiently on the areas to be heated, browned, and/or crisped, rather than being lost to portions of the food item not intended to be browned and/or crisped or to the heating environment. Additionally or alternatively, it may be beneficial to create one or more discontinuities or inactive regions to prevent overheating or charring of the food item and/or the construct including the susceptor.
As still another example, a susceptor may incorporate one or more “fuse” elements that limit the propagation of cracks in the susceptor, and thereby control overheating, in areas of the susceptor where heat transfer to the food is low and the susceptor might tend to become too hot. The size and shape of the fuses may be varied as needed. Examples of susceptors including such fuses are provided, for example, in U.S. Pat. No. 5,412,187, U.S. Pat. No. 5,530,231, U.S. Patent Application Publication No. US 2008/0035634A1, published Feb. 14, 2008, and PCT Application Publication No. WO 2007/127371, published Nov. 8, 2007, each of which is incorporated by reference herein in its entirety.
All dimensional information presented herein is intended to be illustrative of certain aspects, features, etc., of various embodiments of the disclosure, and is not intended to limit the scope of the disclosure. The dimensions of the blanks, containers, forming tools, features, or any other dimension, can be more or less than what is shown and described in this disclosure without departing from the scope of this disclosure and can be within the listed ranges of dimensions for each feature or outside the listed ranges of dimensions for each feature without departing from the scope of this disclosure.
The blanks according to the present invention can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks.
In accordance with the exemplary embodiments, the blanks may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the carton package to function at least generally as described above.
The foregoing description illustrates and describes various embodiments of the present disclosure. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, and alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are contemplated and are within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments without departing from the scope of the disclosure.
This application claims the benefit of U.S. Provisional Patent Application No. 61/795,501, filed Oct. 17, 2012, and U.S. Provisional Patent Application No. 61/795,852, filed Oct. 29, 2012.
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