FORMED ARTICLE AND METHOD OF USE

TECHNICAL FIELD

The present application relates generally to formed articles, and in particular to formed articles which aid in separation between packaging parts for more environmentally friendly disposal. The present application also relates to methods of using such packages.

BACKGROUND

Formed articles are generally used in various applications, such as packaging. Conventional formed articles include recyclable components, such as base trays, and non-recyclable components, such as polymeric liners. Base trays with polymeric liners have been used in various applications. These applications include packaging for various items, including industrial or consumer goods products and food products. The base tray has advantages of low cost, low weight, recyclability, thermal insulation, tangible haptics, and high stiffness. The polymeric liner is added to enhance the physical properties of the base tray, including sealing properties, moisture resistance, gas barrier, grease and flavor resistance, and durability. Since, there are currently no recyclable options in polymeric liners, the base tray must be separated from the polymeric liner in order to facilitate recycling of the base tray.

Often manual separation can be difficult or results in too much of the recyclable component (i.e., the base tray) and/or the non-recyclable component (i.e., the polymeric liner) remaining adhered to each other after separation. Thus, as the difficulty of separating the two components increases, the likelihood that the recyclable component will be recycled decreases.

SUMMARY

A formed article has been developed which includes a rigid film with a line of weakness. The formed article further includes a liner film. The rigid film and the liner film are joined to each other, such that the rigid film can be peelably separated from the liner film along the line of weakness.

One embodiment of the present disclosure is a formed article including a rigid film, a liner film, and a cavity. The rigid film includes a thickness and a line of weakness. The rigid film and the liner film are joined to each other. Further, the line of weakness is positioned in the cavity.

In some embodiments, the formed article further includes a flange. The line of weakness includes a length from a point on the flange to an opposing point on the flange.

In some embodiments, the line of weakness includes a depth. The depth of the line of weakness is less than or equal to the thickness of the rigid film.

In some embodiments, the line of weakness includes at least one of a cut, a perforation and a score.

In some embodiments, the line of weakness is provided in the rigid film before forming of the cavity.

In some embodiments, the formed article further includes an additional film. The additional film is joined to the liner film opposite to the rigid film.

In some embodiments, the additional film includes a thickness equal to or less than the thickness of the rigid film.

In some embodiments, the additional film includes one or more of amorphous polyester (APET), crystalline polyester (CPET), olefin-based materials, polystyrene, and polylactic acid (PLA).

In some embodiments, the rigid film includes one or more of amorphous polyester (APET), crystalline polyester (CPET), olefin-based materials, polystyrene, and polylactic acid (PLA).

In some embodiments, the liner film includes at least one of ethylene vinyl alcohol (EVOH) and high-density polyethylene (HOPE).

In some embodiments, the liner film further includes a compatibilizer.

In some embodiments, the liner film includes a barrier material.

In some embodiments, a bond strength between the rigid film and the liner film is greater than or equal to 50 grams (g)/25.4 millimeters (mm).

In some embodiments, the formed article further includes a lidding component.

In some embodiments, the line of weakness is centrally positioned along a length of the rigid film.

In some embodiments, a material of the rigid film and a material of the liner film have different recycling profiles.

One embodiment of the present disclosure is a method for removing the rigid film from the liner film of the formed article, as previously described. The method includes: supplying the formed article; subjecting the formed article to a fracturing energy that separates the rigid film into a first segment and a second segment at the line of weakness; and grasping the first segment and the second segment of the rigid film to peelably remove the first segment and the second segment from the liner film.

One embodiment of the present disclosure is a formed article including a rigid film, a liner film, and a cavity. The rigid film includes a thickness, a length, and a line of weakness. The line of weakness includes a depth less than or equal to the thickness of the rigid film. The line of weakness extends perpendicular to the length of the rigid film. The rigid film and the liner film are joined to each other. The line of weakness is positioned in the cavity.

In some embodiments, the formed article further includes a flange. The line of weakness includes a length from a point on the flange to an opposing point on the flange.

In some embodiments, the formed article further includes an additional film. The additional film is joined to the liner film opposite to the rigid film.

There are several 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 top perspective view of one embodiment of a formed article;

FIG. 2 illustrates a schematic bottom perspective view of the formed article of FIG. 1;

FIG. 3 illustrates a schematic top view of the formed article of FIG. 1;

FIG. 4 illustrates a schematic bottom view of the formed article of FIG. 1;

FIG. 5 illustrates a cross-sectional view of the formed article of FIG. 1;

FIG. 6 illustrates a detailed cross-sectional view of a portion of the formed article of FIG. 1;

FIGS. 7A and 7B illustrate schematic perspective views depicting an exemplary method of removing a rigid film from a liner film of the formed article of FIG. 1;

FIG. 8 illustrates a detailed cross-sectional view of an embodiment of a formed article;

FIG. 9 illustrates a detailed cross-sectional view of another embodiment of a formed article;

FIGS. 10A-10D illustrate schematic views depicting forming and use of an embodiment of a formed article;

FIGS. 11A-11D illustrate schematic cross-sectional views depicting forming and use of another embodiment of a formed article;

FIGS. 12A-12G illustrate schematic views of various embodiments of a line of weakness of a formed article; and

FIGS. 13A and 13B illustrate schematic perspective views depicting an exemplary method of using an embodiment of a formed article.

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.

DETAILED DESCRIPTION

The present application describes a formed article including a rigid film, a liner film, and a cavity. The rigid film incudes a thickness and a line of weakness. The rigid film and the liner film are joined to each other. Further, the line of weakness is positioned in the cavity. The rigid film may be peelably separated from the liner film along the line of weakness after use so that the rigid film and the liner film can be put into appropriate recycling and waste streams. The line of weakness of the rigid film may facilitate separation of the rigid film from the liner film without any additional apparatus or tools. The present disclosure may therefore provide ease in recycling of the rigid film of the formed article.

One embodiment of a formed article 100 is illustrated in FIG. 1. FIG. 2 illustrates a bottom perspective of formed article 100. FIG. 3 is a top view of formed article 100. FIG. 4 is a bottom view of formed article 100. FIG. 5 illustrates a cross sectional view of formed article 100. FIG. 6 illustrates a detailed cross-sectional view of a portion of formed article 100. Referring to FIGS. 1 to 6, formed article 100 includes a package body 114 including a top portion 116, a bottom portion 118 and a side portion 120 connecting bottom portion 118 to top portion 116. The detailed cross-sectional view of FIG. 6 may correspond to a cross-section of bottom portion 118.

Formed article 100 further includes a rigid film 102, a liner film 106, an additional film 112 and a cavity 108 (shown in FIG. 5). Package body 114 may be formed by rigid film 102, liner film 106 and additional film 112. Specifically, bottom portion 118, side portion 120 and top portion 116 of package body 114 is formed by rigid film 102, liner film 106 and additional film 112. Bottom portion 118 and side portion 120 of package body 114 define cavity 108. In some embodiments, package body 114 is a thermoformed tray. Specifically, bottom portion 118 and side portion 120 are in the form of a tray defining cavity 108. Cavity 108 may receive a product (not shown) to be packaged. The product may be a food or a non-food product. The tray may be thermoformed to any depth as desired depending upon type and amount of the product to be packaged inside cavity 108. In some embodiments, bottom portion 118 of package body 114 may be of any desired shape, such as, for example, rectangular, square, circular, or polygonal depending on both functional and aesthetic requirements. Though in the illustrated embodiment package body 114 includes one cavity 108, it should be noted that package body 114 may be configured to include two or more recessed areas (not shown) depending again on both functional and aesthetic requirements of a particular packaging application. In other words, cavity 108 may include two or more recessed areas separated by one or more partitions or walls.

Top portion 116 of package body 114 further defines an opening 119 (shown in FIG. 5) for proving access to cavity 108. Package body 114 further includes a flange 123 in top portion 116. Flange 123 extends around a periphery of cavity 108. Flange 123 may have a substantially uniform width along its length. In some other cases, flange 123 may have a non-uninform width along its length. Flange 123 is formed by rigid film 102, liner film 106 and additional film 112.

Formed article 100 further includes a lidding component 122. Lidding component 122 is disposed on top portion 116 of package body 114 and covers cavity 108. Lidding component 122 may be adhesively sealed to top portion 116 of package body 114. Specifically, lidding component 122 may be adhesively sealed to flange 123 of package body 114. In some cases, lidding component 122 may be resealable based on application requirements. In some other cases, lidding component 122 may be non-resealable. Lidding component 122 further includes a tab 130 to facilitate removal of lidding component 122 from package body 114. Tab 130 may be grasped by a user to enable peeling of lidding component 122 from flange 123.

Lidding component 122 can exhibit one or more properties (e.g., tensile strength, barrier properties, ability to carry printing or adhesive labels, and surface appearance) required for the desired application. In some embodiments, lidding component 122 may be a monolayer film. In embodiments where lidding component 122 is a monolayer film, lidding component 122 may include oriented polypropylene (OPP) or polyester (e.g., PET), as non-limiting examples. In some other embodiments, lidding component 122 may be a multilayer film, that is, a film including more than one layer, and one of the layers may include a barrier material, such as ethylene vinyl alcohol copolymer (EVOH), or any other suitable barrier material. Lidding component 122 may have any suitable shape, for example, rectangular, square, polygonal, circular, or elliptical depending on both functional and aesthetic requirements.

With reference to FIGS. 5 and 6, formed article 100 further includes rigid film 102. Rigid film 102 includes a thickness T and a line of weakness 104. In the illustrated embodiment, line of weakness 104 extends perpendicular to a length L_Rof rigid film 102. However, in some other embodiments, line of weakness 104 may be inclined obliquely to length L_Rof rigid film 102. Length L_Ris disposed along a longitudinal axis of rigid film 102. With reference to FIGS. 1 and 3, line of weakness 104 is partially shown as dashed lines as line of weakness 104 may not be generally visible through liner film 106 and additional film 112. In some embodiments, line of weakness 104 may be indicated or highlighted with a different color, profile, style, and the like to facilitate identification by a user. In some cases, indicia (e.g., arrows, instructions, etc.) may be provided on an outer surface of formed article 100 to aid in the identification of line of weakness 104. In the illustrated embodiment, line of weakness 104 has a substantially linear and uniform configuration along its length. Specifically, line of weakness 104 may extend linearly along length L_Rof rigid film 102. Such a configuration may be preferable from manufacturing and application considerations. However, line of weakness 104 may have a curved, non-linear, non-uniform, or combinations of configuration based on application requirements. In the illustrated embodiment, line of weakness 104 is continuous. However, in some other embodiments, line of weakness 104 may be discontinuous with two or more portions separated from each other.

Formed article 100 further includes liner film 106. Rigid film 102 and liner film 106 are joined to each other and line of weakness 104 is positioned in cavity 108. Line of weakness 194 extends at least partially along side portion 120 and bottom portion 118 within cavity 108. Formed article 100 further includes additional film 112. Additional film 112 is joined to liner film 106 opposite to rigid film 102. Lidding component 122 may be adhesively sealed to additional film 112. Additional film 112 may be an optional component. In some embodiments, additional film 112 may be omitted and lidding component 122 may be joined to liner film 106.

With reference to FIGS. 2 and 4, in some embodiments, line of weakness 104 includes a length L from a point P1 on flange 123 to an opposing point P2 on flange 123. Points P1, P2 may be disposed at opposing ends of line of weakness 104. Length L is measured along rigid film 102 and follows a shape of formed article 100. Rigid film 102 includes an edge 132 that form a part of flange 123. Points P1, P2 are disposed on opposing sides of edge 132 of rigid film 102. Line of weakness 104 is centrally positioned along length L_Rof rigid film 102. Specifically, line of weakness 104 may be located at a distance of about L_R/2 from edge 132 that is distal to line of weakness 104. Line of weakness 104 may be centrally positioned for symmetric peeling of rigid film 102 from liner film 106. However, a relative position of line of weakness 104 in rigid film 102 may be varied as per application requirements. In some embodiments, ends of line of weakness 104 around points P1, P2 may be provided with tabs, protrusions, or any other engagement members to facilitate grasping by a user.

In an embodiment, line of weakness 104 may include a length equal to or preferably greater than a length of bottom portion 118 of package body 114. In the illustrated embodiment, line of weakness 104 extends from one end of flange 123 to an opposite end of flange 123. In some embodiments, length L of line of weakness 104 includes widths of flange 123 at opposite sides, lengths of side portion 120 at opposite sides and the length of bottom portion 118. Therefore, line of weakness 104 includes two portions disposed on flange 123 at the opposite sides, two portions disposed on side portion 120 at the opposite sides, and a portion disposed on bottom portion 118. However, in some embodiments, line of weakness 104 may extend only partially along flange 123 at the opposite sides. In other words, points P1 and P2 may be spaced apart from edge 132 of rigid film 102. In some other embodiments, line of weakness 104 may extend only partially along side portion 120 and may not extend up to flange 123.

In some embodiments, line of weakness 104 includes at least one of a cut, a perforation and a score. A type of line of weakness 104 may be chosen based on ease of separation and peeling of rigid film 102 from liner film 106. Further, line of weakness 104 may be provided in rigid film 102 before or after forming of cavity 108. In some cases, line of weakness 104 can be formed by mechanical scoring or cutting. In some other cases, line of weakness 104 can be formed by laser scoring or cutting.

In some embodiments, line of weakness 104 may be plug-assist thermoformed. This may ensure that line of weakness 104 may not be inadvertently damaged, for example, prematurely opened or ruptured. Further, various parameters of line of weakness 104, such as type, shape, depth, length, and aspect ratio, may be varied in accordance with a configuration of rigid film 102 (e.g., thickness T), or any other factor or component related to formed article 100. Additionally, or alternatively, a configuration of line of weakness 104 may be decided based upon volume of material (e.g., PET) which may remain after scoring or creation of line of weakness 104. Line of weakness 104 may be formed by removing material (e.g., PET) from a portion of rigid film 102. In a non-limiting example, about 10% to about 96% of the material in the portion of rigid film 102 may be present or left after line of weakness 104 is formed on rigid film 104.

In the illustrated embodiment, formed article 100 includes package body 114 defining cavity 108 between bottom portion 118 and side portion 120. Cavity 108 may be of any desired shape, such as, for example, rectangular, square, circular, or polygonal depending on both functional and aesthetic requirements. Formed article 100 includes package body 114 made of multiple films, namely, rigid film 102, liner film 106 and additional film 112. The multiple films may provide rigidity as well as enhanced oxygen and moisture barrier properties. This may be suitable in applications having certain barrier requirements for a desired shelf life. These applications may include packaging of meat and dairy products (e.g., cheese). In the illustrated embodiment, rigid film 102 is joined to liner film 106. Rigid film 102 and additional film 112 are joined to opposing surfaces of liner film 106. With bottom portion 118 as reference, liner film 106 is joined to a top surface of rigid film 102, while additional film 112 is joined to a top surface of liner film 106. Therefore, additional film 112 may form a surface of cavity 108. In cases where additional film 112 is omitted, liner film 106 may form the surface of cavity 108. In a non-limiting example, additional film 112 may provide additional support and strength to liner film 106 particularly during peeling of rigid film 102 from liner film 106. In some embodiments, the multiple films of formed article 100 may be joined to each other using adhesive, extrusion lamination, thermal lamination, or any other suitable joining method. Rigid film 102 and liner film 106 may be joined to each other such that rigid film 102 can be peeled from liner film 106. In an example, rigid film 102 and liner film 106 may be joined using adhesives.

Line of weakness 104 includes a depth D (shown in FIG. 6). Depth D of line of weakness 104 is less than or equal to thickness T of rigid film 102. As illustrated, line of weakness 104 may partially extend through thickness T of rigid film 102. Further, line of weakness 104 extends from a bottom surface 134 (shown in FIG. 6) of rigid film 102 toward liner film 106. Bottom surface 134 of rigid film 102 may form an outer surface of package body 114 (shown in FIG. 1). In some other embodiments, line of weakness 104 may be spaced apart from bottom surface 134. In the illustrated embodiment, line of weakness 104 extends substantially perpendicular to bottom surface 134. However, in some other embodiments, line of weakness 104 may be inclined obliquely relative to bottom surface 134. In other words, line of weakness 104 may be inclined relative to thickness T of rigid film 102.

In some embodiments, depth D of line of weakness 104 is greater than 0% and less than or equal to 100% of thickness T of rigid film 102. In some embodiments, depth D of line of weakness 104 is at least about 2%, 5%, 10%, 30%, 50%, 70%, 80%, or 90% of thickness T of rigid film 102. Further, additional film 112 includes a thickness T_A(shown in FIG. 6). In some embodiments, additional film 112 includes thickness T_Aequal to or less than thickness T of rigid film 102. In some embodiments, liner film 106 includes thickness T_L(shown in FIG. 6). In an embodiment, thickness T_Lof liner film 106 may be less than or equal to thickness T_Aof additional film 112. In some other embodiments, thickness T_Lof liner film 106 may be greater than thickness T_Aof additional film 112. In a further embodiment, thickness T_Lof liner film 106 may be less than or equal to thickness T of rigid film 102. In the illustrated embodiment, thickness T_Lof liner film 106 is less than thickness T of rigid film 102 and thickness T_Aof additional film 112 is less than thickness T_Lof liner film 106, i.e., T >T_L>T_A. Further, depth D of line of weakness 104 is less than thickness T of rigid film 102. In some embodiments, thickness T of rigid film 102 may be in a range from about 5 mils (127 microns) to about 55 mils (1,397 microns). Further, depth D of line of weakness 104 may be in a range from about 0.45 mils (11.43 microns) to about 49.5 mils (1,257.3 microns).

In some embodiments, a material of rigid film 102 and a material of liner film 106 have different recycling profiles. In some cases, both rigid film 102 and liner film 106 may be recyclable in separate recycling streams. In some other cases, only rigid film 102 is recyclable while liner film 106 is not recyclable. In some embodiments, a material of additional film 112 may be similar to the material of rigid film 102. In some other embodiments, the material of additional film 112 may be different from the material of rigid film 102.

In some embodiments, rigid film 102 includes at least one of a semi-rigid polymeric material, a rigid polymeric material, a fiber-based component, and a formable paper. In an embodiment, rigid film 102 includes one or more of amorphous polyester (APET), crystalline polyester (CPET), olefin-based materials, polystyrene, and polylactic acid (PLA). In some embodiments, additional film 112 includes one or more of amorphous polyester (APET), crystalline polyester (CPET), olefin-based materials, polystyrene, and polylactic acid (PLA). In a non-limiting example, the olefin-based materials may be polypropylene (PP) and polyethylene (PE).

In some embodiments, liner film 106 includes at least one of ethylene vinyl alcohol (EVOH) and high-density polyethylene (HDPE). In some embodiments, liner film 106 further includes a compatibilizer. In some embodiments, liner film 106 includes a barrier material.

In some embodiments, a bond strength, as measured according to ASTM F904-98 between rigid film 102 and liner film 106 is greater than or equal to 50 grams (g)/25.4 millimeters (mm). In some other embodiments, the bond strength between rigid film 102 and liner film 106 may lie within a range from about 40 g/25.4 mm to about 260 g/25.4 mm. The bond strength between rigid film 102 and liner film 106 may be such that rigid film 102 can be easily peeled from liner film 106 without any rupture of liner film 106. In some embodiments, the bond strength between rigid film 102 and liner film 106 is less than a bond strength between liner film 106 and additional film 112. This may enable peeling of rigid film 102 from liner film 106 without removing liner film 106 from additional film 112.

Formed article 100 is shown in a “closed state” in FIGS. 1-5. In the closed state, formed article 100 includes lidding component 122 attached to flange 123 of package body 114. In an “open state” of formed article 200, as shown in FIGS. 7A and 7B, lidding component 122 is removed from flange 123. FIG. 7A illustrates formed article 100 in the open state during peeling of rigid film 102 from liner film 106. FIG. 7B illustrates formed article 100 after rigid film 102 has been removed from liner film 106.

Referring to FIGS. 1-6 and 7A-7B, during use of formed article 100, lidding component 122 may be removed from package body 114 in order to access the product contained within cavity 108. Lidding component 122 may be removed from package body 114 by use of tab 130 provided on lidding component 122. FIGS. 7A and 7B show separation of rigid film 102 from liner film 106 after lidding component 122 is removed from package body 114. However, in some cases, rigid film 102 may be separated from liner film 106 while lidding component 122 is attached to package body 114.

FIGS. 7A and 7B further illustrate a method for removing rigid film 102 from liner film 106 of formed article 100. The method includes steps of supplying formed article 100 and subjecting formed article 100 with a fracturing energy for separating formed article 100 into a first segment 126 and a second segment 128 at line of weakness 104. First segment 126 and second segment 128 are illustrated as partially peeled in FIG. 7A. In some embodiments, the fracturing energy may depend upon various factors, such as the material, dimensions, type, and shape of line of weakness 104. In some embodiments, the fracturing energy may lie in a range from about 8 Newtons (1.8 pound-force) to about 36 Newtons (8.0 pound-force). First segment 126 and second segment 128 may therefore be formed as a result of separation of rigid film 102 along line of weakness 104.

The method further includes a step of grasping first segment 126 and second segment 128 of rigid film 102 to peelably remove first segment 126 and second segment 128 from liner film 106. Separation of rigid film 102 from liner film 106 may enable recycling of rigid film 102 and liner film 106 in different recycling streams. First segment 126 and second segment 128 of rigid film 102 may be partially or fully recyclable.

After removal of rigid film 102, liner film 106 and additional film 112 remain as part of formed article 100. In some cases, additional film 112 may be peeled from liner film 106, such that additional film 112 and liner film 106 can be recycled in different recycling streams. In some other cases, additional film 112 and liner film 106 may be partially or fully recycled together. In some other cases, additional film 112 and liner film 106 may be discarded as waste material.

Formed article 100 including package body 114 may be used in various packaging applications for food and non-food items. For example, formed article 100 may be used as creamer cups, pudding cups, meat trays, etc. Formed article 100 may facilitate recycling of relatively small packages, such as single-portion sized packages of beverage components (e.g., ground coffee or tea) or condiments (e.g., dipping sauces, milk, cream, or beverage whiteners). Due to the small bulk of these packages and the relative difficulty of manually peeling bound liner components from them, users may choose to forego the hassle of recycling these packages. Formed article 100 may ease separation of liner film 106 and rigid film 102 in small packages and thereby encourage recycling of the recyclable portions of such packages. Formed article 100 may also be used as medium and large sized packages for containing various items, for example, cheeses, cuts of meat and poultry, etc., as well as industrial, health care related or non-food items.

FIG. 8 illustrates a detailed sectional view of a formed article 170 according to an embodiment of the present disclosure. As shown in FIG. 8, liner film 106 is disposed or sandwiched between rigid film 102 and additional film 112. Thickness T_Aof additional film 112 is equal to thickness T of rigid film 102. Further, thickness T_Aof additional film 112 is greater than thickness T_Lof liner film 106. Depth D of lines of weakness 104 is less than thickness T of liner film 106.

FIG. 9 illustrates a detailed sectional view of a formed article 180 according to another embodiment of the present disclosure. Formed article 180 does not include additional film 112 (shown in FIG. 1). As shown in FIG. 9, rigid film 102 and liner film 106 are joined to each other. Thickness T_Lof liner film 106 is less than thickness T of rigid film 102. Further, depth D of lines of weakness 104 is less than thickness T of liner film 106.

FIGS. 10A-10D illustrate various steps of forming and using formed article 100. As shown in FIG. 10A, rigid film 102, liner film 106 and additional film 112 are laminated or joined to each other such that liner film 106 is disposed between rigid film 102 and additional film 112. As shown in FIG. 10B, line of weakness 104 is formed in rigid film 102. FIGS. 10C-10D depict a method of removing rigid film 102 from liner film 106 of formed article 100. The method includes a step of supplying formed article 100. Referring to FIGS. 10B and 10C, the method includes a step of subjecting formed article 100 to a fracturing energy that separates rigid film 102 into first segment 126 and second segment 128 at line of weakness 104. In some embodiments, the fracturing energy may lie in a range from about 8 Newtons (1.8 pound-force) to about 36 Newtons (8.0 pound-force). A user may apply a force (e.g., with their hands) at line of weakness 104 to provide the fracturing energy that separates rigid film 102 into first and second segments 126, 128. First and second segments 126, 128 are partially separated in FIG. 10C. Referring to FIG. 10D, the method further includes a step of grasping first segment 126 and second segment 128 of rigid film 102 to peelably remove first segment 126 and second segment 128 from liner film 106. First and second segments 126, 128 are completely separated in FIG. 10D. The user may manually grasp first and second segments 126, 128 and pull them apart to peelably separate first and second segments 126, 128 from liner film 106. First and second segments 126, 128 may be recycled. Additional film 112 attached to liner film 106 may optionally be removed before disposal or recycling.

FIGS. 11A-11D illustrate various steps of forming and using formed article 180. As shown in FIG. 11A, rigid film 102 and liner film 106 are joined to each other such that liner film 106. As shown in FIG. 11B, line of weakness 104 is formed in rigid film 102. FIGS. 11C-11D depict a method of removing rigid film 102 from liner film 106 of formed article 180. The method is substantially similar to the method described above with reference to FIGS. 10A to 10D. After separating first and second segments 126, 128 of rigid film 102 from liner film 106, liner film 106 may be recycled or disposed as waste material.

FIGS. 12A-12G illustrate various embodiments of rigid film 102 with different shapes, aspect ratios, positions, and dimensions of the line of weakness. Various parameters of the line of weakness 104 may be varied based on application requirements.

FIGS. 12A and 12B illustrate lines of weakness 104A and 104B, respectively, which are substantially rectangular. However, lines of weakness 104A, 104B have different aspect ratios. Specifically, the aspect ratio of line of weakness 104A is less than the aspect ratio of line of weakness 104B. Further, both lines of weakness 104A, 104B extend only partially along thickness T of rigid film 102. FIG. 12C also illustrates a line of weakness 104C which is substantially rectangular. However, line of weakness 104C extend fully along thickness T of rigid film 102. In other words, a depth D1 of line of weakness 104C is substantially equal to thickness T of rigid film 102.

FIG. 12D illustrates a line of weakness 104D having a tapered shape. Specifically, line of weakness 104D has a trapezoidal shape that tapers away from bottom surface 134 of rigid film 102. FIG. 12E also illustrates a line of weakness 104E having a tapered shape. However, line of weakness 104E has a trapezoidal shape that tapers toward bottom surface 134 of rigid film 102.

FIG. 12F illustrates a line of weakness 104F that has a rectangular portion with a curved end distal to bottom surface 134 of rigid film 102. FIG. 12G illustrates a line of weakness 104G which has a tapered curved shape. Further, line of weakness 104G tapers away from bottom surface 134 of rigid film 102.

Lines of weakness 104A-104G illustrated in FIGS. 12A-12G are exemplary in nature and other embodiments of the line of weakness are possible within the scope of the present disclosure.

Further, an angle between edges of line of weakness 104 of the present disclosure may be within a range from about 2 degrees to around 90 degrees, or any other angle as per the application.

FIGS. 13A-13B illustrate a formed article 200 including a line of weakness 204 in accordance with another embodiment. FIG. 13A shows formed article 200 in an “open state” without any lidding component. In the illustrated embodiment, formed article 200 is a cup that contains a product (not shown). Formed article 200 includes a rigid film 202 and a liner film 206. Formed article 200 includes a package body 214 and a flange 223 formed by rigid film 202 and liner film 206. Package body 214 defines a cavity 208 for receiving the product. The product may include a food item or a non-food item. In some cases, the product may include a dairy product, such as cream. Rigid film 202 includes a line of weakness 204 extending between ends of flange 223 of formed article 200. This may facilitate peeling of rigid film 202 from liner film 206.

FIG. 13B illustrates a method of removing rigid film 202 from liner film 206. Referring to FIGS. 13A and 13B, rigid film 202 has been separated into a first segment 226 and a second segment 228 along line of weakness 204. First and second segments 226, 228 may separate due to application of a fracturing energy at line of weakness 204 followed by a peeling action. Liner film 206 may undergo a change of color (indicated by shading) after separation of first segment 226 and second segment 228 of rigid film 202 from liner film 206. This change of color of liner film 206 may provide a visual indicator to users regarding different recycling profiles of rigid film 202 and liner film 206.

Formed article 200 may facilitate recycling of relatively small articles, such as single-portion sized articles (or packages) of beverage components (e.g., ground coffee or tea) or condiments (e.g., dipping sauces, milk, cream, or beverage whiteners). Due to the small bulk of these articles and the relative difficulty of manually peeling bound rigid films from them, users may choose to forego the hassle of recycling these articles. Formed article 200 may ease separation of rigid film 202 from liner film 206 in small articles and thereby encourage recycling of the recyclable portions of such articles.

The present disclosure illustrates a single line of weakness 104, 204 provided in rigid films 102, 202, respectively. However, in some embodiments, multiple lines of weakness 104, 204 may be provided in rigid films 102, 202, respectively, based on application requirements.

Test Method

The “Fracturing Energy” of the rigid film 102 can be measured as the total energy (in Newtons) at maximum force to break the rigid film into two separate sections. Test specimens included sheet material (rigid film 102, liner film 106 and additional film 112). The specimen sheet material included a total thickness of 711.2 micron (28 mil) and a structure of 304.8 micron (12 mil) PET/101.6 micron (4 mil) EVOH-HDPE blown film/304.8 micron (12 mil) PET. The test specimens included dimensions of 5.08 cm (2 in) width x 13.97 cm (5.5 in) length and a score line across the width of each specimen at 5.08 cm from one of the 5.08 cm edges of the specimen. One PET side of the specimen included the score line. Specimen score lines included depths of approximately 35%, 53% and 100% of the scored PET layer thickness of the specimens. Three specimens of each score depth were tested. The reported fracturing energy values are of the sheet material before it was formed (i.e., thermoformed) but after the sheet has been machined through a thermoforming machine (for example, Bosch TFA machines available from Syntegon Packaging Technology, LLC, New Richmond, Wis., USA).

Each specimen was mounted to a test fixture that included two clamps separated from each other by a 2.54 cm (1 in) gap. Each specimen was mounted such that 8.73 cm (3.4375 in) of the specimen length was mounted to the test fixture with the mounted portion of the specimen being covered by the clamps except for the portion of the specimen exposed in gap between the clamps. Further, the specimen was mounted such that the unmounted portion of the specimen included the score line being aligned with the end of the test fixture and the score line being placed 0.16 cm (0.625 in) away from the end of the test fixture. The non-scored side of the specimen faces the ground (e.g., floor, horizontal surface) and the scored side of the specimen faces away from the ground.

A steel probe was attached to a universal testing machine (UTM) that tests the tensile strength and compressive strength of materials and includes an upper crosshead (available from, for example, Instron, Norwood, Mass., USA). The probe included a tip of which is used in ASTM D3420-08a, procedure B, that includes a 1.90 cm (0.75 in) diameter and a 1.27 cm (0.5 in) radius. The probe tip was attached to a straight, cylindrical shaft. The overall probe length (probe shaft and probe tip) was 26.67 cm (10.5 in). The probe length after placement into the upper crosshead of the UTM was 23.81 cm (9.375 in), (after placement length includes the distance between the bottom of the upper crosshead and the end of the probe tip). The center of the probe was lowered onto the specimen in a location approximately 1.9 cm (0.75 in) away from the score line and centered between the side edges of the specimen at a rate of 50.8 cm/minute (20 in/minute) that broke the score. The resulting fracturing energy was reported in Newtons (N).

EMBODIMENTS
Formed Article Embodiments

A. A formed article comprising:

a rigid film comprising a thickness and a line of weakness;

a liner film; and

a cavity;

- wherein the rigid film and the liner film are joined to each other; and wherein the line of weakness is positioned in the cavity.
  
  B. A formed article comprising:

a rigid film comprising a thickness, a length and a line of weakness, the line of weakness comprising a depth less than or equal to the thickness of the rigid film, wherein the line of weakness extends perpendicular to the length of the rigid film;

a liner film; and

a cavity;

- wherein the rigid film and the liner film are joined to each other, wherein the line of weakness is positioned in the cavity.
  
  C. The formed article according to any other embodiment, wherein the line of weakness comprises a length from a point on the flange to an opposing point on the flange.
  
  D. The formed article according to any one of the embodiments A or C through Q, wherein the line of weakness comprises a depth, and wherein the depth of the line of weakness is less than or equal to the thickness of the rigid film.
  
  E. The formed article according to any other embodiment, wherein the line of weakness comprises at least one of a cut, a perforation and a score.
  
  F. The formed article according to any other embodiment, wherein the line of weakness is provided in the rigid film before or after forming of the cavity.
  
  G. The formed article of any other embodiment, further comprising an additional film, wherein the additional film is joined to the liner film opposite to the rigid film.
  
  H. The formed article according to embodiment G, wherein the additional film comprises a thickness equal to or less than the thickness of the rigid film.
  
  I. The formed article according to embodiments G or H, wherein the additional film comprises one or more of amorphous polyester (APET), crystalline polyester (CPET), olefin-based materials, polystyrene, and polylactic acid (PLA).
  
  J. The formed article according to any other embodiment, wherein the rigid film comprises one or more of amorphous polyester (APET), crystalline polyester (CPET), olefin-based materials, polystyrene, and polylactic acid (PLA).
  
  K. The formed article according to any other embodiment, wherein the liner film comprises at least one of ethylene vinyl alcohol (EVOH) and high-density polyethylene (HDPE).
  
  L. The formed article according to any other embodiment, wherein the liner film further comprises a compatibilizer.
  
  M. The formed article according to any other embodiment, wherein the liner film comprises a barrier material.
  
  N. The formed article according to any other embodiment, wherein a bond strength between the rigid film and liner film is greater than or equal to 50 g/25.4 mm.
  
  O. The formed article according to any other embodiment, further comprising a lidding component.
  
  P. The formed article according to any other embodiment, wherein the line of weakness is centrally positioned along a length of the rigid film.
  
  Q. The formed article according to any other embodiment, wherein a material of the rigid film and a material of the liner film have different recycling profiles.

Method Embodiments

R. A method for removing the rigid film from the liner film of the formed article of any one of embodiments A through Q, the method comprising the steps of:

supplying the formed article;

subjecting the formed article to a fracturing energy that separates the rigid film into a first segment and a second segment at the line of weakness; and

grasping the first segment and the second segment of the rigid film to peelably remove the first segment and the second segment from the liner film.

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.

The description, examples, embodiments, and drawings disclosed are illustrative only and should not be interpreted as limiting. 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. 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. 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.

FORMED ARTICLE AND METHOD OF USE

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