Composite package structure for containing articles and method for producing thereof

Abstract: This invention relates to paperboard and plastic composite package structures that combine an intricate thermoformed shell with a paperboard base or cover. Such structures of this type, generally, provide a lightweight package with a good printing surface on the outside of the package.

Description: Field of the Invention This invention relates to paperboard and plastic composite package structures that combine an intricate thermoformed shell with a paperboard base or cover. Such structures of this type, generally, provide a lightweight package with a good printing surface on the outside of the package. Description of the Related Art It is known, in composite package structures, to make use of a book-like container paperboard cover and a plastic inner tray. Exemplary of such structures is U.S. Patent No. 4,724,957 ('957), to 0. Burgschweiger, entitled "Container." While the '957 patent teaches a paperboard cover and a plastic inner tray, the cover is not connected to the inner tray along the spine. Also, foil is located on the exterior side of the cover. It is apparent, that if the inner tray were bonded to the paperboard cover along the length of the spine, greater package rigidity would result. Also, if the foil cover were eliminated, a wide range of printed graphics could be used. Consequently, more advantageous container, then, would be presented if the rigidity and range of printed graphics were increased. It is also known, in composite packages, to make use of an inner molded tray and an outer cover. Exemplary of such prior art is U.S. Patent No. 4,635,797 ('797) to J. D Bankier, entitled "Pilfer Resistant Software Package" While the '797 patent teaches the use of a composite paperboard and plastic package, the plastic inner tray is welded to the paperboard cover by conventional RF techniques along the peripheral flange. The use of the high temperature RF techniques may cause temperature deformation of the thermoformable inner tray Consequently, a still further advantageous composite package, then, would be presented if a low temperature heat sealable coating were used. It is apparent from the above that there exists a need in the art for a composite package which is rigid and which is capable of employing a wide range of printed graphics but which at the same time avoids the use of high temperatures. It is a purpose of this invention to fulfill this and other needs in the art in a manner more apparent to the skilled artisan once given the following disclosure. SUMMARY OF THE INVENTION Generally speaking, this invention fulfills these needs by providing a composite package for containing articles as defined is the claims. According to a second aspect, the invention also relates to a method for producing such a composite package. The above and other features of the present invention which will become more apparent as the description, proceeds, are best understood by considering the following detailed description in conjunction with the accompanying drawings, wherein like characters represent like part throughout the several views and in which: BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a schematic illustration of a method for producing a composite package, according to the present invention; FIGURE 2 is a side, exploded view of the composite, package, according to the present invention; FIGURE 3 is a side view of another embodiment of the composite package, according to the present invention; FIGURE 4 is a side view of still another embodiment of the composite package, according to the present invention and FIGURE 5 is a side view of the constructed composite package of FIGURE 2 and folded, according to the present invention. DETAILED DESCRIPTION OF THE DRAWINGS With reference first to Figure 1, there is illustrated system 2 for manufacturing a composite package 22. In particular, system 2 includes in part, thermoformable polymer roll 4, thermoformable polymer sheet 6, conventional thermoformer 8, thermoformed polymer trays 10, conventional magazine 12, paperboard covers 14, conventional heat sealer 16, intermediate composite packages 18, conventional trimmer 20 and composite packages 22. Thermoformable polymer roll 4 and sheet 6, preferable are constructed of polystyrene or any suitable plastic material which can be thermoformed to create an inner tray shaped to match the product of interest. Paperboard covers 14, preferably, include a coating 30 (Figure 2) of particulate minerals on one side and a coating 24 (Figure 2) of a low temperature, heat sealable polymer) material on the other side. The particulate minerals, preferably are clay. The low temperature, heat sealable polymeric material, preferably, is a coating a polyethylene (PE) and an ethylene-methyl acrylate copolymer (EMA) having an initiation temperature of below 60°C (140°F) and a Vicat softening point of below 54°C (130°F). It is to be understood that coating 24 can be applied to the cover 14 by conventional techniques such as, coextrusion. During the construction of composite packages 22, roll 4 is unrolled such that sheet 6 is formed. Sheet 6 is transferred through thermoformer 8 such that a web of tray 10 is produced. After the web of trays 10 is produced, paperboard cover 14 is placed upon one side of trays 10 such that coating 24 (Figure 2) is adjacent to tray 10. After the paperboard cover 14 is placed upon tray 10, tray 10 and cover 14 are heat sealed in heat sealer 16 such that an intermediate package 18 is produced. Intermediate package 18 is then transferred to trimmer 20 such that composite package 22 is formed. Figure 2 illustrates, in more detail, the final construction of composite package 22. In particular, composite package 22 includes, in part, thermoformed polymer tray 10, paperboard cover 14, low temperature, heat sealable coating 24, flange 26, score lines 28 and particulate coating 30. Coating 24, preferably, is the same low temperature, heat sealable coating 24, as described above. Also, coating 30 is the same coating 30, as described above. Finally, score lines 28 are placed on paperboard cover 14 in order to provide a desired flexibility It is to be understood, however, that score lines 28 may be omitted in certain instances. In order to secure articles within package 22, package 22 is oriented such that the articles are placed in one section of tray 10. The other section of tray 10 is then folded over in a book-like manner, along score lines 28 and coupled with the section of tray 10 holding the articles In this manner, the articles are retained within tray 10 and package 22. Also, the end user is free to place printed graphics on cover 14. Figure 3 illustrates another embodiment of a composite package 50. In particular, composite package 50 includes in part, paperboard cover 52, low temperature, heat sealable coating 54, thermoformed polymer tray 56, flange 57, paperboard lid 58, low temperature, heat seal coating 60 and particulate coating 62. It is to be understood that coatings 54 and 60 preferably, are constructed of the same materials a coating 24 (Figure 2). Also, coating 62, preferably, is constructed of the same materials as coating 30 (Figure 2). Composite package 50 is constructed in substantially the same -manner as composite package 22. In particular tray 56 is thermoformed in thermoformer 8 (Figure 1). Paperboard cover 52 is then placed over tray 56 and heat sealed to tray 56 by heat sealer 16 (Figure 1). After tray 56 is heat sealed to base or cover 52, the intermediate packages are then trimmed in trimmer 2 (Figure 1). After the trimming is done, an article (not shown) is placed within tray 56 such as, food, and lid 58 is then heat sealed to flanges 57 such that composite package 50 is formed. Figure 4 shows still another embodiment of a composite package 100. Composite package 100 includes in part paperboard cover 102, low temperature, heat sealable coating 104, thermoformed polymer tray 106 paperboard cover 108, low temperature, heat sealable coating 110, and flanges 112, and particulate coating 114. Coating 104, preferably, is the same as coating 24 in Figure 2. Coating 110, preferably, is any suitable heat sealable coating which will adequately bond to paperboard flanges 112. Finally, coating 114, preferably, is constructed of the same materials as coating 30 (Figure 2) The construction of composite package 100 is substantially similar to the construction of composite package 50. In particular, tray 106 is thermoformed. Cover 102 is then heat sealed to tray 106. Articles are placed within tray 106. Finally, lid 108 is then heat sealed to flanges 112. Finally, Figure 5 shows composite package 22 in folded form. In particular, package 22 is folded along score lines 28 such that mating sections of polymer tray 10 mate with each other in order to retain articles (not shown) within package 22 after package 22 is folded over.

Claims: A method for producing a composite package (22) to be filled with articles, comprising: a) forming a sheet of polymeric material (6) into a web of a plurality of polymeric trays (10, 56, 106), each of said polymeric trays having an opening and a base; b) coating a first side of a paperboard cover means (14, 52, 102) with a low temperature, heat sealable coating (24); c) placing said coated cover means substantially over one of said plurality of polymeric trays with said coating (24) located adjacent to at least one of said trays; d) securing one of said trays to said coated cover means to form an intermediate composite package; and e) trimming said intermediate composite package to form a final composite package (22). The method of claim 1, wherein said forming step a) comprises thermoforming said sheet of polymeric material (6). The method of claim 1 or 2, wherein said polymeric material (6) comprises polystyrene. The method of any one of the preceding claims, wherein said step b) of coating of said low temperature, heat sealable coating (24) comprises the coextrusion of polyethylene and an ethylene-methyl acrylate copolymer. The method of any one of the preceding claims further comprising: f) coating a second side of said cover means (14) with a layer of particulate minerals (30); The method of claim 5, wherein said layer of particulate minerals (30) comprises clay. The method of any one of the preceding claims, wherein said securing step d) comprises heat sealing said coated cover means (14) to one of said polymeric trays (10). The method of any one of the preceding claims, further comprising: g) folding over said final composite package (22), after placing the articles in one section of the tray, in a book-like manner. The method of any one of the preceding claims, wherein said coated cover means (52, 102) is secured to the base of said one of plurality of polymeric trays (56, 106). The method of claims 1 to 8, wherein said cover means (14) is secured across the opening of said one of plurality of polymeric trays (10). The method according to any one of the preceding claims, wherein said low temperature, heat sealable coating (24) of said cover means (14) is located exterior to said first side of said paperboard cover means (14) and substantially facing one of said plurality of trays (10). The method of any one of claims 5 to 11, wherein said coating of particulate minerals (30) is located exterior to said second side of said cover means (14). A composite package (22) for containing articles comprising: a web of a plurality of thermoformable polymeric trays (10) each having an opening and a base, and a cover means (14) having a first side and a second side, wherein said cover means (14) is placed adjacent to at least one of said plurality of polymeric trays, said first side of said cover means (14) is coated with a layer of a low temperature, heat sealable polymeric coating (24), said polymeric coating (24) comprising a co-extrusion product of polyethylene and an ethylene-methyl acrylate copolymer, said second side of said cover means (14) is coated with a layer of particular minerals (30) and, said at least one of said polymeric trays (10) being rigidly attached to said low temperature, heat sealable polymeric coating (24).

Inventors: PETERSON RALPH SCOTT, PETERSON, RALPH SCOTT
Applicants: WESTVACO CORP, WESTVACO CORPORATION
Application year: 1997
Main classification: B65B9
IPC codes: B65B9, B31B7, B65D75