US20030182903A1 - Continuous packaging in enclosed conduits - Google Patents

Abstract

Packaging methods and apparatus for bonding a lidding web to a tray web, characterized in that the lidding web is placed under tension in both the longitudinal and lateral directions before being bonded to a tray web. A tray web having recesses and channels that form a conduit when the tray web is overwrapped with a lidding web is provided. A lidding web has microperforations to control the transfer of gases.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application is a divisional of PCT/US03/00167, filed Jan. 2, 2003, which in turn is a continuation-in-part of application Ser. No. 10/320,863, filed Dec. 16, 2002; Ser. No. 10/027,929, filed Dec. 20, 2001; Ser. No. 10/037,440, filed Jan. 2, 2002; PCT/US01/45146, filed Nov. 28, 2001, Ser. No. 09/724,287, filed Nov. 28, 2000, which in turn is a continuation-in-part of Application No. PCT/US00/29038, filed Oct. 19, 2000, now abandoned, which in turn is a continuation of U.S. application Ser. No. 09/550,399, filed Apr. 14, 2000, now abandoned, which in turn is a continuation-in-part of U.S. application Ser. No. 09/392,074, filed Sep. 8, 1999, now abandoned, which in turn is a continuation of U.S. application Ser. No. 09/039,150, filed Mar. 13, 1998, now abandoned, which in turn claims the benefit of U.S. Provisional Application No. 60/040,556, filed Mar. 13, 1997, and claims the benefit of U.S. Provisional Application No. 60/129,595, filed Apr. 15, 1999; No. 60/141,569, filed Jun. 29, 1999; No. 60/144,400, filed Jul. 16, 1999; No. 60/148,227, filed Jul. 27, 1999; No. 60/149,938, filed Aug. 19, 1999; No. 60/152,677, filed Sep. 7, 1999; No. 60/154,068, filed Sep. 14, 1999; No. 60/160,445, filed Oct. 19, 1999; No. 60/175,372, filed Jan. 10, 2000; No. 60/255,684, filed Dec. 13, 2000; No. 60/286,688, filed Apr. 26, 2001; No. 60/291,872, filed May 17, 2001; No. 60/299,240, filed Jun. 18, 2001; No. 60/312,176, filed Aug. 13, 2001; No. 60/314,109, filed Aug. 21, 2001; No. 60/323,629, filed Sep. 19, 2001; No. 60/335,760, filed Oct. 19, 2001; No. 60/373,222, filed Apr. 15, 2002; No. 60/373,232, filed Apr. 16, 2002; No. 60/385,710, filed Jun. 3, 2002; No. 60/388,067, filed Jun. 10, 2002; No. 60/391,702, filed Jun. 24, 2002; No. 60/411,138, filed Sep. 16, 2002; No. 60/422,949, filed Oct. 30, 2002; No. 60/424,388, filed Nov. 5, 2002; No. 60/427,516, filed Nov. 19, 2002; No. 60/429,644, filed Nov. 25, 2002; No. 60/433,526, filed Dec. 13, 2002. All the above applications are herein expressly incorporated by reference in their entirety for all purposes.[0001]
FIELD OF THE INVENTION
• The present invention relates to the packaging of perishable goods in a selected gas and most particularly packaging in low oxygen environments.[0002]
BACKGROUND OF THE INVENTION
• Methods of boning, grinding, and subsequent packaging of beef in a substantially oxygen-free environment have been disclosed in PCT/US01/45146. In one aspect, these steps occurred in an essentially continuous and enclosed conduit. The method results in a food item, such as beef, having high amounts of deoxymyoglobin. The beef, high in deoxymyoglobin, is then packaged in oxygen free individual trays and depending on the ultimate destination, may be packaged in master containers. Master containers are used to transport the individual beef packages in a substantially oxygen-free state up to the point of sale. In either event, however, it is desirable that oxygen is exchanged with the controlled atmosphere within the individual packages prior to sale to allow the beef to produce a bright red color, known as “bloom” (or oxymyoglobin), that is visually pleasing to consumers. The previous application disclosed trays with means, such as apertures in the tray and in the overwrapping lidding webs at strategic locations to provide for the rapid exchange of the controlled gas within the packaged trays for the oxygen in air outside of the packaged trays while restricting leaking of liquid therefrom. Other ways of exchanging the controlled atmosphere for air and oxygen included an oxygen permeable package that comprises a polypropylene thermoformed tray with a plasticized polyvinyl chloride web hermetically sealed to the flanges of the tray. In this manner, gas exchange occurs by permeation through the permeable packaging materials.[0003]
• When a retail package with controlled atmosphere therein is removed from an oxygen-free atmosphere and placed in the normal ambient air atmosphere, the controlled gas in the free spaces on the inside of the package is displaced by atmospheric gases over time by the normal process of diffusion. It has been observed that a deleterious phenomena can occur to the beef if the oxygen content in the packages is not elevated from 0.05% to at least 3% oxygen within about 15 minutes, and sometimes this effect even occurs if the oxygen content of the package is not elevated from 0.05% to at least oxygen within about 10 minutes. Without this rapid elevation in oxygen content, it has been observed that the physical and chemical mechanisms taking place on the surface of the beef favor the production of increased amounts of undesirable metmyoglobin relative to the desirable brightly colored red oxymyoglobin. Therefore, it is advantageous to produce methods and materials to exchange gases within the allotted time to reduce the production of metmyoglobin and the unsightly appearance caused by it.[0004]
• Microperforated wrapping materials have been known and used in the food industry; however, one drawback that has been observed is “weeping” or the purge of liquids associated with the meat contents through the microperforations. This weeping effects the quality of the packaged meat in two ways. First, condensation from the weeping liquids can accumulate on the internal surfaces of the retail package. These water droplets can hinder the diffusion of gases to the extent that the gas exchange can be slowed to several hours. Second, previous attempts to use microperforated materials as an overwrapping web material resulted in direct contact of the microperforated web with the food item of the package. It was later found that weeping of liquids through the package as a result of this contact, occurred to such an extent that made it unacceptable to consumers.[0005]
• Therefore, there is a need to refine the methods and materials useful in the packaging of perishable food items within enclosed conduits, including the use of microperforated lidding webs to provide a desired gas diffusion rate without allowing the escape of liquids from the package. Also lacking in the prior art are methods and apparatus that can apply longitudinal and lateral tension on a web of lidding material. The present invention fulfills these needs and provides further related advantages.[0006]
SUMMARY OF THE INVENTION
• One aspect of the invention is a package having a first web defining a cavity and a second web bonded to the first web, wherein the second web includes microperforations at a location that is specific to minimize the escape of liquids from the cavity to the exterior of the package. In one particular embodiment, the first web defines a four-sided cavity with walls, a flange, and corresponding flaps attached to the flange that can be folded and bonded to the cavity walls. The second web is an overwrapping lidding web, wherein microperforations are provided on the lidding web at a predetermined location. For example, the microperforations are aligned with a flap recess, which in turn is in communication with the interior of the tray cavity. In this manner, suitably rapid gas exchange can occur with minimal to no escape of liquids from the tray cavity.[0007]
• Microperforations of the type that can be produced by lasers can be introduced into the tray or to the overwrapping lidding web materials to increase the gas exchange rate to within acceptable limits to, in addition to rapid production of oxymyoglobin (bloom), surpass the zone of rapid metmyoglobin formation.[0008]
• Another aspect of the invention is a method of exchanging the gas of a controlled atmosphere package with the ambient atmospheric air by including microperforations in a web. In one particular embodiment, a tray web with flaps is overwrapped with a lidding web, wherein the lidding web is provided with the microperforations at a predetermined location, more specifically, adjacent to a flap recess. In this manner the amount of weep is reduced to acceptable quantities or may be eliminated altogether.[0009]
• Another aspect of the invention is a method of reducing or substantially eliminating the amount of liquid weep from a package by allowing accumulation of the liquid in a recess. In one particular embodiment, a tray web with flaps is overwrapped with a lidding web. The flap includes an enclosed recess that is in communication with the tray cavity. The recess is overwrapped with a lidding web. The lidding web holds the accumulated liquids within the recess of the flap even though the lidding web may be perforated. This is because a nonperforated section of the lidding web, which may be in contact with the liquid, is located adjacent to the recess to hold the accumulated liquids therein.[0010]
• Another aspect of the invention is a method of bonding a stretched overwrapping lidding web to a tray web with flaps, wherein the lidding web is bonded to the flaps in a substantially horizontal position, and then the flaps are folded and bonded to the tray walls.[0011]
• Another aspect of the invention is a method of bonding a stretched overwrapping lidding web to a tray web having at least a first and a second flap, wherein the first flap is bonded to the tray wall before the lidding web is bonded to the second flap, wherein the second flap is in a substantially horizontal position. The second flap is then bonded to the tray wall.[0012]
• Another aspect of the invention is a method of trimming a lidding web from a tray web wherein the tray includes a recess that creates a gap when placed adjacent to a second tray web, and allowing better clearance for a trim device to trim the lidding web from the adjacent tray webs.[0013]
• Another aspect of the invention is a tray web forming a cavity with vertical walls, wherein a recessed area is formed on a portion of a flange surrounding the cavity. In this manner, a gap is formed from two or more adjacent trays, such that the trim device can properly cut the lidding web bonded to the trays.[0014]
• Another aspect of the invention is a method of preventing a contaminant from blocking or otherwise interfering with a bonding surface of a tray web by covering the bonding surface with a guard. Contaminants can include debris, particles, dirt, liquids, bits of food, or any other items. In one particular instance, the guard covers the bonding surfaces of the tray flange and the tray sides, such as flaps, during the loading of food items, which were the food item to contaminate the bonding surfaces, may block or otherwise interfere with the integrity of the hermetic seal between the tray web and an overwrapping lidding web bonded to the sides, such as the flaps. In one instance, the flaps are folded within the guard while loading the food item, and may be bonded to the tray web. However, in other instances, after loading the food item in the tray web cavity, the guard is removed and the flaps are debonded, and moved to a horizontal disposition. Thereafter, an adhesive is applied to the flange and flaps and a lidding web is bonded thereto. The flaps may then be folded and bonded to the tray web again. Suitable adhesives include cold seal adhesives, such as latex compounds, but other adhesives may be used, such as pressure sensitive adhesives, and the like.[0015]
• In another aspect of the invention, a guard for covering the bonding surface of a tray web includes walls to contain the tray web. The guard also includes a portion to cover the tray flange with a portion that extends into the tray cavity, but the guard includes an opening giving access for loading the tray cavity.[0016]
• Another aspect of the invention is a method of bonding a stretched overwrapping lidding web to a tray web with flaps, wherein the lidding web is bonded to the flanges at two opposing ends of the tray and to two opposing flaps and wherein the flaps are formed with a series of recesses and channels interconnecting such recesses that allow direct communication between the tray cavity and ambient atmosphere via the recesses formed in the flaps.[0017]
• Another embodiment of the invention is a method for bonding a lidding web to a tray web or any other container, characterized in that the lidding web is tensioned in the longitudinal and lateral direction before the lidding web is bonded to the tray web, or before the lidding web is applied to any bonding agent on the tray web. The lidding web can be stretched longitudinally and laterally. The lidding web can be horizontal at the first instance of contact with the tray web upper surface. The lidding web can be applied to the tray web without additional tensioning or relaxation of the lidding web so as not to cause additional stretching or contraction of the lidding web during application of the lidding web to the bonding agent, so as to prevent smearing of the bonding agent or the formation of creases in the lidding web. In one embodiment, the lidding web can be shaped into an inverted channel before applying the lidding web to the bonding agent on the tray web.[0018]
• Another embodiment of the invention is an apparatus for bonding a lidding web to a tray web, wherein the apparatus has a plurality of web stretching subassemblies, each web stretching subassembly has a horizontally translatable web gripping subassembly with a pivoting web gripping jaw. The web stretching subassembly can be attached to a timing belt. The web gripping subassembly is attached to a pair of independently actuatable shafts, wherein one shaft operates the web gripping jaw, and the other shaft operates the horizontal motion of the web gripping subassembly. The shafts can have cam followers attached to the distal ends of the shafts, wherein the cam followers ride on the cam tracks and the cam followers follow the cam tracks.[0019]
• Another embodiment of the invention is a method for tensioning a lidding web in the longitudinal and lateral direction prior to bonding to a tray web, characterized in that the longitudinal tension is applied by gripping the edges of the lidding web with a plurality of web gripping subassemblies, and longitudinally pulling on the lidding web while the lidding web supply is under tension. The lateral tension can be applied to the lidding web by moving the web gripping subassemblies, which grip the edges of the lidding web, apart in relationship to one another. The lateral tension alternatively can be applied to the lidding web by passing the lidding web over a pair of longitudinal members and under a pair of longitudinal members wherein the spacing between pairs diverges along the length of the members, and one pair will terminate ahead of the other, so as to drop the lidding web to a tray web.[0020]
• Another embodiment of the invention is a method for controlling the transfer of gases from packages and reducing the amount of liquid weep from packages, characterized by overwrapping a tray web containing goods with a lidding web, wherein the lidding web has an area of microperforations adjacent to a web tray recess that is in communication with a web tray cavity.[0021]
• Another embodiment of the invention is a tray having a web with sides and a base to provide a cavity and defining a series of recesses with connecting channels on one side of the web, wherein the channels and recesses provide a conduit for gases from the web cavity to the exterior thereby allowing transfer of the gases and minimization of liquid loss when a second web is bonded at least over the cavity and sides.[0022]
• The present invention provides numerous advantages. In one instance, the amount of metmyoglobin formed on the surfaces of beef food items is reduced. Other aspects of the present invention increase the throughput of trays in the packaging conduit. For example, by providing a gap between adjacent tray webs, more trays per unit area of conveyor are allowed in the packaging conduit, because the gap allows for the clearance needed by a trimming device, thus averting the spacing of tray webs farther apart on the conveyor. By folding the leading and trailing flaps of trays before entering the packaging conveyor, more trays per unit area of conveyor are allowed in the packaging conduit. By using an enclosed packaging conduit, the need to use a vacuum chamber to provide a controlled atmosphere on a tray by tray basis is eliminated.[0023]
BRIEF DESCRIPTION OF THE DRAWINGS
• The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:[0024]
• FIG. 1 shows a cross section illustration of a packaging conduit according to the present invention;[0025]
• FIG. 2 shows a top plan illustration of a packaging conduit according to the present invention;[0026]
• FIG. 3 shows a side illustration of two adjacent tray webs according to the present invention;[0027]
• FIG. 4 shows a top plan illustration of a packaging conduit according to the present invention;[0028]
• FIG. 5 shows a perspective illustration of a sealed package according to the present invention;[0029]
• FIG. 6 shows a top plan illustration of a tray web portion according to the present invention;[0030]
• FIG. 7 shows a cross section illustration of tray and lidding webs according to the present invention;[0031]
• FIG. 8 shows a detailed illustration of a tray web communication portion with serrations between a tray web cavity and a flap recess according to the present invention;[0032]
• FIG. 9 shows a perspective illustration of a flange guard according to the present invention;[0033]
• FIG. 10 shows a cross section illustration of a flange guard and tray web according to the present invention;[0034]
• FIG. 11 shows a perspective illustration of a tray web with channels formed into the tray web side walls according to the present invention;[0035]
• FIG. 12 shows a side view illustration of a tray web with channels formed into the side walls according to the present invention;[0036]
• FIG. 13 shows an end view illustration of a tray web according to the present invention;[0037]
• FIG. 14A shows a diagrammatic plan view illustration of an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray web according to the present invention;[0038]
• FIG. 14B shows a cross sectional illustration of the apparatus of FIG. 14A;[0039]
• FIG. 14C shows a cross sectional illustration of the apparatus of FIG. 14A;[0040]
• FIG. 14D shows a cross sectional illustration of the apparatus of FIG. 14A;[0041]
• FIG. 15 shows a perspective illustration of an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray web according to the present invention;[0042]
• FIG. 16 shows a cross section illustration of the web stretching arrangement in an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray with channels formed therein according to the present invention;[0043]
• FIG. 17 shows a cross section illustration of the web stretching arrangement in an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray web according to the present invention;[0044]
• FIG. 18 shows a plan view illustration of the web stretching arrangement in an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray with channels formed therein according to the present invention;[0045]
• FIG. 19 shows a perspective illustration of the web stretching arrangement in an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray according to the present invention;[0046]
• FIG. 20 shows a side elevation illustration of a biaxial stretch packaging apparatus according to the present invention;[0047]
• FIG. 21 shows a plan view illustration of a biaxial web stretching apparatus according to the present invention;[0048]
• FIG. 22 shows an isometric illustration of a web stretching subassembly with web gripping subassembly and cam track portions according to the present invention;[0049]
• FIG. 23 shows a cross sectional view illustration, A-A, across web stretching subassembly shown in FIG. 21;[0050]
• FIG. 24 shows a cross sectional view illustration, B-B, across web stretching subassembly shown in FIG. 21;[0051]
• FIG. 25 shows a cross sectional view illustration, C-C, across web stretching subassembly shown in FIG. 21;[0052]
• FIG. 26 shows a cross sectional view illustration, D-D, across web stretching subassembly shown in FIG. 21;[0053]
• FIG. 27 shows a cross sectional view illustration, E-E, across web stretching subassembly shown in FIG. 21;[0054]
• FIG. 28 shows a cross sectional view illustration, F-F, across web stretching subassembly shown in FIG. 21;[0055]
• FIG. 29 shows a cross section illustration of a guard and tray web according to the present invention;[0056]
• FIG. 30A shows a diagrammatic plan view illustration of an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray web according to the present invention;[0057]
• FIG. 30B shows a cross sectional illustration of the apparatus of FIG. 30A;[0058]
• FIG. 30C shows a cross sectional illustration of the apparatus of FIG. 30A;[0059]
• FIG. 30D shows a cross sectional illustration of the apparatus of FIG. 30A;[0060]
• FIG. 31 shows a cross section illustration of the web stretching arrangement in an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray with channels formed therein according to the present invention;[0061]
• FIG. 32 shows a cross section illustration of the web stretching arrangement in an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray web according to the present invention;[0062]
• FIG. 33 shows a plan view illustration of the web stretching arrangement in an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray with channels formed therein according to the present invention; and[0063]
• FIG. 33 shows a plan view illustration of the web stretching arrangement in an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray with channels formed therein according to the present invention; and[0064]
• FIG. 34 shows a plan view illustration of the web stretching arrangement in an apparatus for applying a biaxially stretched web of material to the upper surface and side walls of a tray with channels formed therein according to the present invention.[0065]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
• The aforementioned application PCT/US01/45146, entitled CONTINUOUS PRODUCTION AND PACKAGING OF PERISHABLE GOODS IN LOW OXYGEN ENVIRONMENTS, filed Nov. 28, 2001, is herein expressly incorporated by reference in its entirety for all purposes.[0066]
• Referring to FIG. 1, one embodiment of a packaging conduit includes a[0067]frame114 for carrying theconduit100.Conduit100 is substantially enclosed to contain any suitable gas or combination of gases, including carbon dioxide, carbon monoxide, or nitrogen or any liquid thereof. However, in other embodiments, oxygen in any proportions greater or less than that found in air can be used. Thepackaging conduit100 includes aconveyor102 for carryingtrays104 containing perishable food items.Conveyor102 may include a continuous conveyor section running the length of the entire conduit or may be divided into a plurality of more than one conveyor section. The advantage of having more that one conveyor section is to provide different conveyor speeds. This is useful as will become apparent from the disclosure below to “bunch” adjacent trays together at a desirable location, thus increasing the throughput of the packaging conduit and minimizing the amount of lidding web material used by eliminating scrap lidding sections that would otherwise occur.Conveyor102 may include a continuous flat belt on whichtrays104 rest orconveyor102 may include cleats or brackets to holdtrays104 in position. Flat, smooth belts may allow the sliding of packages in the manner described to bunch trays in close proximity or adjacent to one another. Alternatively, the tray carrying the conveyor may comprise of a pair of parallel belts, such as2316 in FIG. 23, each having a cross sectional profile that enhances contact friction and resultant adhesion with the underside of each tray, wherein the pair of belts are spaced apart so as to enable improved tray stability.
• [0068]Packaging conduit100 includes first andsecond gripper chains110 disposed adjacently on either side ofconveyor102, for at least a portion of the conveyor length.Gripper chains110 extend along a portion of theconveyor102 wherein bonding of an overwrapping lidding web takes place. The path traveled of thegripper chains110 is adjusted by any number ofsprockets116 to direct motion of gripper chains substantially parallel toconveyor102 or perpendicular or at any desirable angle. Thepackaging conduit100 includes a supply oflidding web material106. Lidding web material is provided in aroll106 and can be outside of thepackaging conduit100, andopenings112 are provided to allow the passage of lidding web108 andgripper chain110 into and out of thepackaging conduit100.Openings112 can be desirably configured to minimize the escape of any suitable gas within thepackaging conduit100. In one particular instance,gripper chains110 can take hold of lidding web108 at either edge thereof atsprocket118.Gripper chains110 can apply tension to the lidding web108 thereto in a transverse direction to thepackaging conduit100. Longitudinal tension may be applied to the lidding web108 by applying a braking action to the roll oflidding web material106, whilegripper chains110 pull the lidding web108 forward. Lidding web108 is carried into thepackaging conduit100 wherein the lidding web108 is bonded to surfaces of thetray web104, including any flange and flaps.
• One aspect of the invention is a method of bonding a stretched lidding web[0069]108 to atray104 with flaps, wherein the lidding web108 is bonded to the flaps, while the flaps are in a substantially horizontal position. Once the lidding web108 is bonded to the flaps, the flaps are next folded and bonded to the tray wall. This operation results in an advantage over other methods that first bond the flaps to the tray and thereafter bond the lidding web to the folded and bonded tray flaps. According to the invention, the lidding web can be tensioned after being bonded to flaps when the flaps are folded into the side locations of the tray.
• Another aspect of the invention is a method of bonding a stretched lidding web[0070]108 to atray104 having at least a first and second flap, wherein the first flap is bonded to the tray wall before the lidding web108 is bonded to the second flap, wherein the second flap is in a substantially horizontal position to the tray. In this instance, bonding the lidding web to the first tray flap is optional, since the bond of the lidding web to a tray flange is adequate to provide for hermetic sealing of the package.
• Another aspect of the invention is a method of trimming a lidding web[0071]108 from atray104, wherein the tray includes a recessed region around the outer periphery of the tray flange. Thus when two or more trays are in adjacent disposition, a gap is formed allowing the proper clearance access to a lidding web trimming device between the adjacent trays. This results in numerous advantages. For example, trays can be spaced closer to one another resulting in less waste of the lidding material and increased throughput on the packaging conduit conveyor so long as there is sufficient clearance for a trimming device to transversely and longitudinally cut the lidding web108. In one particular instance, theadjacent trays104 can be positioned so as to be touching or nearly touching any adjacent trays. In this instance, suitable clearance is provided by the gap between trays to allow the trimming device access to trim the lidding web108 betweenadjacent trays104 resulting in very little waste of lidding web material and increased throughput.
• A further aspect of the invention is a package assembled from a tray web with flaps with a cavity wherein the lidding web is bonded to the tray and the lidding web includes microperforations at specific locations to minimize the escape of liquids produced by the perishable food item.[0072]
• A further aspect of the invention is a method of preventing a contaminant from blocking or otherwise interfering with a bonding surface of a tray web by covering the bonding surface with a guard. Contaminants can include debris, particles, dirt, liquids, bits of food, or any other items common to or used in a packaging operation. In one particular instance, the guard covers the tray flange of a tray web during loading of food items, which may block or otherwise interfere with the integrity of the hermetic seal between the tray flange and an overwrapping lidding web bonded to the flange if the food item were to contaminate the bonding surfaces of the flange. In another embodiment, the guard covers the tray sides, such as flaps, of a tray web during the loading of food items that may block or otherwise interfere with the integrity of the hermetic seal between the tray sides, such as flaps, and an overwrapping lidding web bonded to the sides, such as the tray web flaps. In one instance, the flaps are folded within the guard while loading the food item, and may be bonded to the tray web. However, in other instances, after loading the food item in the tray web cavity, the guard is removed and the flaps are debonded, and moved to a horizontal disposition. Thereafter, an adhesive is applied to the flange and flaps and a lidding web is bonded thereto. The flaps may then be folded and bonded to the tray web again.[0073]
• Referring now to FIG. 2, one suitable embodiment of a[0074]lidding web202 and a top side view of apackaging conduit200 is illustrated. It is to be appreciated that while one row of trays for a packaging conduit is illustrated, any number of tray rows can be provided in a packaging conduit, the single tray row being merely one example. In one embodiment,lidding web202 can include twoareas204 and206, respectively, placed at opposite edges of thelidding web202.Areas204 and206 can be areas containing microperforations or alternatively and/or additionally can include printed material. However, it is to be readily appreciated that the combination ofareas204 and206 as shown is merely one example of where microperforations can be placed on the lidding web based on one configuration of a tray with flaps. It is to be readily appreciated that other areas not shown in the figure can also include microperforations, the combination ofareas204 and206 being an example of one embodiment.
• Referring now to the top side view of the[0075]packaging conduit200, a section of the apparatus wherein the two horizontally disposedgripper chains208 and210 carry a firmly stretched lidding web therebetween, such aslidding web202, is illustrated.Lidding web202 is carried substantially horizontally and directly above aconveyor carrying trays216 containing food items. In one instance, eachtray216 can have four flaps for side walls; however, by this view, the flaps disposed on the leading and trailing ends of thetrays216 have been bonded to the tray cavity walls and thus they are not shown. Alternatively, thetrays216 can eliminate the leading and trailing flaps and have only the two opposite side flaps212 and214. In this instance, atray flange218 disposed around the perimeter of the tray cavity will provide sufficient surface area to adequately bond to thelidding web material202, thus providing a hermetic seal. In either event, flaps212 and214 are positioned in a substantially horizontal disposition, which is substantially aligned with the tray flange. Adhesive is applied to the tray flange and flap areas by any suitable application device.Lidding web202 is then bonded thereto. Following bonding of thelidding web202 to thetray flange218 and flaps212 and214, adhesive is applied to the underside offlaps212 and214, which are then folded and bonded to the vertically disposed side walls of thetray cavity216.Lidding web202 can be perforated and/or printed atsections204 and206 as required, either before bonding to the tray or in some instances can be perforated or printed after bonding to the tray thereto. The printed material can be arranged and configured to come to reside adjacent to the tray sides, after bonding the lidding web to the tray web. To this end, the roll of lidding web can be incrementally indexed forward according to the sections of printed material. In one embodiment, the underside of the tray web is exposed and is not covered by the lidding web after bonding. In this manner, a suitable marking on the tray web, such as a bar code or RFID tag or any other identifying mark can be provided on the tray web, and a scanner can read the marking on the underside of the tray web. Trimming devices will suitably cut the web both longitudinally and transversely. Any remainingscrap lidding web208 can be discarded or recycled and reused as desired. One particular benefit of bonding the two leading and trailing flaps that come before and after adjacent trays or alternatively eliminating them is that trays may be stacked closer to one another. In this manner, the throughput of trays through thepackaging conduit200 is increased. Another benefit is that the amount oflidding web202 used per package is reduced because the amount of spacing between trays is also reduced, leading to fewer quantities of scrap lidding web. However, in other alternatives of the present invention, the leading and trailing flaps of the trays may be bonded to a lidding web. Suitable materials for tray webs and lidding webs and methods for making them have been described in the aforementioned PCT application.
• It should be appreciated that once the lidding web is applied to any suitable package, the assembled package can further be packaged within a master container, which may contain a plurality of like packages. In one embodiment, the master container keeps the individual packages in a substantially oxygen deficient environment until the individual packages are ready to be shelved for display to consumers, whereas in another embodiment, the environment may comprise an oxygen enriched gas blend. While the individual packages remain in the master container there may be exchange of gases from within the individual packages with the interior of the master container. When the individual packages are removed from the master container to the normal ambient atmosphere containing higher quantities of oxygen, the controlled atmosphere within the packages is displaced by air including oxygen. Under some circumstances, the individual packages may not be stored in a master container, in which case, a form of peelable tab can be applied to the area of microperforations to prevent the premature displacement of controlled atmosphere gas. In this case, the tab may be hermetically sealed to the lidding web by suitable adhesives. The tab is pulled just prior to the packages being shelved for consumer display, exposing the microperforations, and initiating the exchange of gas therethrough.[0076]
• Referring now to FIG. 3, one particular aspect of trays to increase the capacity of a packaging conduit is shown.[0077]Tray webs300 and301 withflaps304 and305 are shown in nearly touching or actual touching disposition, wherein flaps304 and305 are folded and bonded totrays300 and301, respectively, on a wall thereof.Trays300 and301 are travelling on theconveyor302 and can be bunched by providing conveyor runs at varying speeds. For example, a conveyor at a relatively higher speed is followed by a conveyor at a relatively low speed.Flaps304 and305 are shown with agap clearance310 created by recessing a portion of the outer periphery edge of the tray web atlocations314 and316, respectively, inflaps304 and305.Recesses314 and316 may be any suitable shape which when abutted against one another will create thegap310.Recesses314 and316 may be any suitable dimensions to allow a desired trimming device, such asslitter device312, access to cut thelidding web308.Gap clearance310 can be provided at any location where two adjacent trays are in close or touching proximity to one another. In this instance,trays300 and301 can be spaced in relatively close proximity to one another while allowing thetrimming device312 ample clearance to operate properly. Benefits provided by the present invention is that trays may be closely spaced to each other on theconveyor302, thus increasing the throughput of packages through the packaging conduit and reducing the amounts of wasted lidding material.
• One suitable method for creating the[0078]recesses314 and316 intray webs300 and301 is thermoforming. In thermoforming, suitable molds can be provided which can be arranged as the negative of the eventual tray web. In one instance, raised projections can be provided at a location adjacent to or in close proximity to what will become the outer edge periphery of the tray web or at a portion connecting the tray flange with the respective flaps, such as a hinge. Thus, when ejected from the mold, the projections show up as recesses in the tray web, wherein the recesses appear on what will become the outer edge periphery when the package is assembled. In one particular instance, flaps304 and305 have been molded to include a recess running lengthwise and front and back of thetrays300 and301, such that therecesses314 and316 are transversely positioned when the tray is arranged in thepackaging conduit100 of FIG. 1, for example. However, recesses314 and316 can be provided around the entire periphery or on three sides for other packaging conduit configurations. For example, in the illustration provided in FIG. 4, two lanes of trays are provided. Therefore, any tray is adjacent to three other trays, and thus in this instance, a suitable tray, such astray104 surrounded bytrays118,120 and122 can have three or more sides having recesses to allow gap clearances for suitable lidding web cutting devices. In this instance,tray104 can have a gap clearance along the longitudinal direction as well as gaps provided in the transverse direction. In this manner, trays can be provided closely spaced to each other on the conveyor in two or more lanes while providing ample clearance for cuttingdevice124 to operate properly. Cuttingdevice124 can have a plurality of longitudinally oriented blades to cut the lidding web in the longitudinal direction on either side of trays, as well as have a transverse blade to cut the lidding web in a transverse direction before and after adjacent trays.
• It is to be appreciated that a twin lane stretch sealing machine as depicted is merely one example of the present invention. It is to be appreciated that one, two or more lanes of trays can be provided on the conveyor, the specific configurations shown in FIGS. 3 and 4, being merely examples of the present invention.[0079]
• Referring now to FIG. 5, a three-dimensional view of a corner of a tray with flaps constructed according to the present invention is shown. The[0080]tray web500 has been assembled as a completed package with afood item545, such as ground beef, for example, placed therein. Thetray500 includes a tray cavity, which contains thefood item545. Thetray500 includes aflange544 constructed around the periphery of the tray cavity. The flange upper surface is generally substantially horizontal. Thetray500 includes afirst flap543 and asecond flap546, attached to thetray flange544 at atray hinge549. While only first and second adjacent flaps are shown, it is to be appreciated that oppositely placed third andfourth flaps543 and546 can be similarly configured. Thetray500 includes acommunication structure540, which allows the exchange of gases from the tray cavity to a recessed portion of the outward facing side of thesecond flap546. The flap recess is bordered by a raised surface atlocation550, which borders therecess547, but for the area of thecommunication548 to allow for free gas passage therethrough. In this instance, thecommunication540 includes serrations formed on thetray flange544, which may extend downward and include thetray hinge549.
• A lidding web is bonded to the[0081]tray500 in the following manner. A bead of adhesive is provided to unite the cavity and the flap recesses as a continuous space closed to the outside with a lidding web. A bead of adhesive541 is provided at thetray flange544, such that the adhesive is applied to the upper surfaces of theflange544. The bead of adhesive541 continues downward from the communication atlocation560. The bead of adhesive541 is applied to the flap surfaces that border theflap recess550 atlocations562. While only a portion of the tray with flaps is shown, it is to be appreciated that an adhesive bead is provided in a similar manner on the opposite side of theflap546 so that when the lidding web is bonded thereto, the tray cavity forms a continuous united space with the outward facing recess on at least one of the tray flaps.
• A[0082]lidding web544 is stretched and applied to the adhesive to form a seal between the tray web and the lidding web and the flap and the lidding web. In this manner, a continuous space is created from the tray cavity and the flap recess that is connected via thecommunication540. The lidding web is microperforated at thearea547 that is placed adjacent to the flap recess. In this manner, gas exchange can take place at the location of microperforations547. Gas exchange is further enabled by theserrations540, which provide for passages from the tray cavity and the flap recess, thus, enabling gas exchange of the tray cavity with the exterior atmosphere, such as is desired before placing the package for retail sale. The area ofmicroperforations547 may be smaller than the area of the flap recess. Microperforations can begin at a distance above the lowermost edge of the recess, thus leaving a portion of nonperforated lidding web between the lowermost recess edge and the area ofmicroperforations547. In this manner, any liquids that pass from the tray cavity into the flap recess via the communication accumulate at the bottom of the flap recess and are kept out of contact from the microperforations; therefore the liquid does not weep from the microperforations. The lidding web is bonded to the tray corner with a bead of adhesive556 that is provided to bond anyloose edges551 and554 of lidding web to the tray corners.
• Referring now to FIG. 6, a top plan view of a section of a tray web with flaps is shown. While only two flaps are shown, one[0083]end flap601 and oneside flap605, it should be readily appreciated that oppositely arranged third and fourth flaps are to be of substantially similar configuration to the flaps shown. A centrally locatedcavity603 is enclosed by the four vertically disposed walls of the tray web, only two of which are shown. The cavity is bordered by aflange607, substantially continuous and flat at all upper surfaces but for thecommunication structure604. In thecommunication structure604, theflange607 is provided withserrations604, which readily allow gases to pass therethrough into aflap recess606 via anopening passage609. Theflange607, which extends around the periphery of thecavity603, is formed from the tray web. Each tray flap is attached to theflange607 at arespective hinge608 which allows the flap to be folded in a downward arcing motion in preparation for bonding to the tray walls.Flaps601 and605 are shown to be substantially horizontally disposed in relation to the tray andtray flange607.Flaps601 and605 include a centrally disposedrecess portion606 bordered by raised areas. The outermost limit of the recess is shown by the line with thereference numeral622. The raised border areas are then bounded byline622 and the line withreference numeral624; thusline622 marks the boundary of therecess area606. The border area is open to therecess area606 atlocation609; thus allowingrecess606 to communicate with thetray cavity603 therethrough. The raised border area surrounding therecess606 is substantially horizontal with the flange upper surface while theflap605 is positioned as shown, and thus theflange607 and the border areas can be provided with any suitable adhesive. A continuous bead of adhesive is applied along apath602 including theflange607 and theflap605, and the raised borderareas surrounding recess606. Theadhesive bead602 is applied in a manner to unite thecavity603 and theflap recess606 into a substantially single space when enclosed by the tray and lidding webs. The spaces created by thecavity603 and theflap recess606 are joined bycommunication609 andopening604. Theadhesive bead602 is applied around thecommunication604 and609 and continues to the raised borders of theflap recess606. The adhesive bead continuous on an opposite side of thecommunication604 onflange607 so as to form a continuous bead of adhesive enclosing the spaces defined by thecavity603, theflap recess606, and thecommunication604 and609 between these two spaces. When a web of overwrapping lidding web is applied on the tray and flaps to the adhesive bead, thetray cavity603 is joined to theflap recess606 as a continuous enclosed space joined by thecommunication604 and609.Communication structure604 includes serrations formed on theflange607, which may extend to thehinge608 and portion of theflap605.Flaps601 and605 may be bonded to the tray with discontinuousadhesive beads620 applied at flap corner edges. Likewise, lidding web may be bonded to the flap corners with adhesive beads atlocations620 with discontinuous adhesive beads.
• While the particular communication between the cavity and recessed flap area has been shown to include serrations, it is to be appreciated that other methods of establishing communication between the tray web cavity containing the goods and the flap may be used in the practice of the present invention, serrations being one example. It is also to be appreciated that other methods may include apertures from the tray cavity to the flap.[0084]
• The overwrapping lidding web applied to the tray includes an area shown bounded by the dashed line with[0085]reference numeral619. In one instance, the area bounded byline619 is microperforated by suitable laser means, for example, such that liquids and any pathogens are restricted from passing therethrough, but gases such as atmospheric oxygen and air can pass directly through the microperforated section into the recess, through the communication at609 and604, and into thetray cavity603. Likewise, any controlled atmosphere packaging gases contained within thecavity603 can pass through thecommunication604 with serrations andopening609 into theflap recess606 and out through the microperforated area bounded by theline619. As can be seen, the area bounded by theline619 is smaller than the area bounded by622, the later marking the boundary of therecess area606. Thus it is advantageous to provide an area between themicroperforated area619 and the boundary of therecess622 that does not include perforations. In this manner, any liquids which pass into therecess606 will accumulate at the bottom of the cupped recess (i.e., the nonperforated area betweenlines622 and619). While an area of microperforations has been shown to nearly extend to the boundaries of the recess, it is to be appreciated that the eventual area of the microperforations will be determined experimentally. For instance, the size, number, and the spacing of the microperforations may influence the eventual size of the microperforated area. The area shown here is merely one example of a suitable microperforated area. Furthermore, one or more flaps may include areas with microperforations. In addition, tray cavity walls and flaps may alternatively or additionally be microperforated in any location thereof in accordance with the invention to provide gas exchange without release of liquids.
• Referring now to FIG. 7, a cross section through a[0086]tray web700 with alidding web731 sealed thereto is shown. Thetray700 includes atray cavity732 with cavity walls extending upward and substantially vertically or at a small incline from thecavity base767. It should be readily appreciated that other walls and flaps form the remainder of the tray with flaps, the portion shown in the figure, being merely an example of one suitable flap with recess bonded to a lidding web with microperforations. Aflap733 is bonded to the tray cavity wall by a bead of adhesive applied atlocation736. An outward facing side of theflap733 defines arecess738. Therecess738 is bounded by raisedborders739. Alidding web731 is bonded to the tray flange at the upper surface thereof with an adhesive735. Thelidding web731 is also bonded to theborders739 surrounding therecess738 withadhesives735. Adhesive is therefore placed atlocations735 on an upper surface of the tray flange and at vertical surfaces of the flap adjacent to theflap recess738 at upper andlower borders739 thereof. A passage or communication is provided between thetray cavity732 and theflap recess738 at thecommunication604 andopening609 as shown in FIG. 6. An area oflidding web731 denoted byreference numeral730 includes microperforations. In one instance, thearea730 is spaced a distance from the lower boundary of theflap recess738 atlocation734. In this manner, any liquids that may flow from thetray cavity732 into therecess738 are prevented from exiting and the liquids accumulate in theflap recess738. The liquids are retained within theflap recess738 by thelidding web731 that is nonperforated and is located between the lower most boundary of themicroperforated area730 and the lower boundary of theflap recess734 belowlocation734. In this manner, liquids are substantially kept away from microperforated areas and prevented from exiting to the exterior of the package. Thus, one advantage of the present invention is the elimination of liquid weep.
• Referring now to FIG. 8, one example of a gas exchange communication structure between a tray cavity and a flap recess is shown. The[0087]communication800 is formed in atray flange823. Thetray flange823 is shown to be recessed, wherein the recessed portion can accommodateserrations821 therein. The serrations can be the full width of theflange823 or the serrations can be less than the full width of theflange823 to leave a flat area. The serrations can be located at either the inner edge or the outer edge of theflange823. The serrations can also continue downward or throughout the thickness of thetray flange823. The serrations maintain thelidding web822 from collapse around thecommunication800, yet allow the passage of gases therethrough. While one example of gas exchange communication has been shown and described, it is to be appreciated that other communication structures between tray cavities and flap recesses are within the scope of the present invention. For example, numerous communication passages and apertures and other examples of communicating between a tray cavity and a flap recess can be provided.
• Referring now to FIG. 9, a[0088]guard900 for covering a tray web is illustrated. The guard is used in preventing a contaminant, such as a food item, from blocking or otherwise interfering with a bonding or sealing surface of a tray web by covering the bonding surface during packaging, including during the loading of the food item within the tray cavity. Theguard900 includeswalls902, vertically disposed and connected to adjacent walls at a corner section, thus forming a box like structure having no bottom. While only a first and a second wall are shown, it is apparent that the opposite third and fourth walls are configured similar to the two that are shown. The height and length ofguard walls902 can be adjusted to coincide with any suitable tray web height and length, including a tray web with flaps. It is also appreciated that theguard900 can be configured and adjusted in any manner to contain the tray web with the flaps in a folded disposition, meaning the flaps of the tray web have been placed adjacent to the tray cavity prior to placing the guard on the tray web. Theguard900 can also be configured to be used while the flaps are in an open disposition, meaning the flaps are not adjacent to the tray web. Upper portions of thewalls902 extend inwardly and horizontally forming ahorizontal shelf903 to coincide with the flange of any suitable tray web. The horizontally extendingshelf903 terminates substantially coextensively with the tray cavity to provide an opening for accessibility to the tray cavity during loading. However, theshelf903 may extend further in toward the tray cavity, and in some instances includes a lip that extends into the tray cavity. It is to be appreciated that some amount of misalignment when placing the guard over a tray web can be tolerated, and thus the walls and shelf need not be exactly dimensioned to the tray web.
• Referring now to FIG. 10, a cross section of a[0089]guard1000 andtray web1002 defining acavity1004,flange1008, andflap1005, is illustrated.Tray web flap1005 is in close and sometimes firm contact with the internal sides ofguard walls1000.Guard1000 includes ahorizontal shelf1006 at an upper portion of theguard walls1000.Shelf1006 is directed inward from walls and terminates to form anopening1002 to provide accessibility to thetray cavity1004 for loading of the food item.Wall1000 coversflap1005 at an exterior side thereof during packaging, including loading a food item.Shelf1006 coversflange1008 at an upper surface thereof during packaging, including loading a food item.Shelf1006 includes alip1003.Lip1003 is formed vertically to partly enter thetray cavity1004. Any amount of protrusion oflip1003 into the tray cavity is advantageous, as thelip1003 prevents contaminants from contact with theflange1008.
• If the food item were to spill in the area of the flap or flange bonding surfaces, the spilled food item would block or otherwise interfere with a hermetic seal from being formed thereon. The guard thus prevents spillage of a food item upon the flap or flange bonding surfaces.[0090]
• Referring now to FIG. 29, a cross-sectional view of a guard[0091]2900 andtray web2902, defining acavity2904 loaded withgoods2906, such as food items, for example, is illustrated.Tray web2902 rides onconveyor2908 and the guard2900 is positioned adjacent to thetray web2902. The guard2900 has ahorizontal shelf2912 extending above thetray web flap2916. The tray web flap's profile follows an arcuate path so that spaces are created between thetray web flap2916 and theinner surfaces2918 of the guard walls and horizontal shelf. Thehorizontal shelf2912 terminates in a downwardly projectinglip2910. Thelip2910 extends into the tray cavity and is adjacent to the inner upper portion of the tray web flap. In this manner, anadhesive bead2914 can be located on the exterior of thetray web flap2916 and the guard2900 prevents any contaminants from interfering with the bonding agent located on thetray web2902.
• The guard can be made using conventional plastic or metal materials. In one instance, the guard can be made from plastic by injection molding. However, the guard can also be made by thermoforming. The guard is reusable after each use by sanitizing in an appropriate manner. The guard can be manually placed on the individual tray webs during packaging, and before loading of any food items. However, in other instances, the guard can be automatically placed by machine over the tray webs. The guards can be attached to a continuous conveyor, wherein the trays are located within the guard at a first location on the conveyor and the trays are removed at a second location, such as where the trays can enter a stretch sealing apparatus, for example. In one instance, if the tray web includes flaps, the flaps may be folded, and additionally or alternatively bonded to the tray web side walls before placement of the tray web within the guard. In another instance, the flaps can be lightly bonded to the tray web with a spot of pressure sensitive adhesive. In this manner, the tray web size is minimized, rendering the tray web easier to handle. Once the food item is loaded, the guard is removed and the flaps can be opened to a substantially horizontal disposition and an adhesive can be applied thereto and to the flange in the manner described above. A stretched lidding web can then be bonded to the adhesive to create a hermetic seal between the tray web and the lidding web. The lidding web can be microperforated and additionally can include printed material on a portion thereof. Following bonding of the lidding web to the tray web, the flaps may be more rigidly bonded to the tray web.[0092]
• Microperforation of lidding webs may be performed by lasers. Microperforation of lidding webs can take place before or after bonding to the tray web. Furthermore, printing in the areas of mircoperforations may also take place with mircoperforation without hindering the ability of the microperforations to perform as desired. Suitable laser techniques and methods for use in the present invention can be provided by the Rofin Company. Information concerning laser techniques can be located at the Web site http.//www.rofin-sinar.com/home-e.htm. Microperforations as small as 0.1 mm (0.004 inch) diameter can be provided by these techniques. Other entities capable of performing suitable microperforations by laser include Laser Machining Inc. of Somerset, Wis. Information about Laser Machining Inc. is available at the Web site http.//www.lasermachining.com/company/company.htm. By use of a carbon dioxide laser, microperforations in the range of 40-400 μm and perforation speeds as high as 500,000 holes per second can be achieved. While proportions and methods of providing microperforations have been provided with reference to two makers, it is to be appreciated that other methods exist which can be used in the present invention, such methods can include mechanical methods, such as puncturing the lidding web with pins of suitable diameter. Other methods can utilize high voltage corona discharge. The methods of making herein described being merely examples. Other dimensions of microperforations less than or greater than the dimensions herein described can be used to practice the present invention, the dimensions described herein being examples.[0093]
• Suitable adhesives for use in the present invention are known as pressure sensitive adhesives (PSAs). Suitable adhesives are provided by the National Starch and Chemical Company of Bridgewater, N.J. For instance, one example of a suitable adhesive for use in the present invention, known by the trademark DURO-TAK34-449A. DURO-TAK34-449A, is a family of hot melt pressure sensitive adhesives designed and qualified for direct food contact. Further information can be obtained from the National Starch and Chemical Company. However, it should be readily appreciated that the adhesive disclosed herein is merely one example of a suitable adhesive for use in the present invention. Other suitable adhesives are well known to those in the art.[0094]
• There are several advantages to using pressure sensitive adhesive as opposed to a heat sealable lidding web. First, PSAs do not require a heating bank. Pressure sensitive adhesives are thus quicker to apply because they do not require a heating or setting time as is required of heat sealable materials. Second, by using a packaging conduit for controlled atmosphere packaging, the use of vacuum chambers for individually evacuating each tray of oxygen and substituting a suitable gas is eliminated. Third, the use of pressure sensitive adhesives eliminate the need to have a heat sealable layer as part of the lidding web composite. This reduces the amount of scrap material. In some instances, heat sealable material is not reusable or recyclable, making the use of pressure sensitive adhesives much more economical and advantageous. If desired however, a heat sealable lidding web can be used in the present invention.[0095]
• In one aspect of the invention, a tray is loaded with a food item. The tray is then carried on a conveyor and the flaps are substantially horizontally disposed so as to extend outwardly from the tray walls. The tray web of FIG. 6 described above shows one instance of a tray with horizontally disposed flaps before bonding of the flaps to the tray walls. A suitable adhesive, such as a pressure sensitive adhesive, is then applied to the flange and to the flaps at locations where desired bonding of the tray web with the lidding web is to take place. Flaps can be supported by supports on the conveyor to substantially stay in a horizontal disposition until desired to be folded and bonded to the tray walls. The stretched lidding web is brought into contact with the pressure sensitive adhesive applied to the flaps and to the tray flange. The lidding web is then severed in a longitudinal and transverse manner, thus allowing the flaps with bonded lidding web thereto to fold in a downward motion. A suitable adhesive is applied, in one instance, on the outside tray cavity walls and the flaps are folded and bonded thereto. In one particular embodiment, the lidding web can be perforated at desired locations such as described hereinabove or additionally or alternatively, the lidding web can be provided with printed material on sides of the tray.[0096]
• In another embodiment of the present invention, two of the four flaps of a tray, either two ends or two sides, can be selectively bonded to the tray cavity walls without a lidding web bonded to the flaps, while the remaining two flaps left in a horizontal disposition can be bonded to the lidding web followed by severing the lidding web and bonding of the flaps with lidding web to the tray cavity walls. The two flaps that are folded in advance of this step may or may not be provided with a lidding web bonded thereto. In any event, when adhesive is provided to the tray flange, adequate hermetic sealing of the lidding web to the tray occurs even though the lidding web may not extend to the folded flaps. In one particular embodiment, a food tray having four flaps is loaded with a food item. A suitable adhesive, such as a pressure sensitive adhesive can be applied to the tray flange and the two horizontally disposed flaps. A lidding web having microperforations and printing thereon at specific locations can be stretched and bonded to the tray flange and the flaps. Suitable cutting devices can trim the lidding web both longitudinally and across the tray. The two horizontally disposed flaps are folded in a downward arcing motion and are bonded to the vertical cavity walls. In this manner, by first bonding leading and trailing flaps (FIG. 2), trays are in close and sometimes touching proximity to one another, thus increasing the capacity of the packaging conduit. Since two of the four flaps have been provided with a lidding web, it is convenient to have communication between the tray cavity and the flap recess on one or both of these longitudinal sides.[0097]
• In further aspects of the present invention, in addition to the lidding web being microperforated, the tray can also be perforated at strategic locations to increase the exchange of controlled atmosphere gas with air including oxygen. For instance, microperforations on the tray web in addition or alternatively to the lidding web, can be located on the tray cavity walls and the flap walls to provide some communication between gases from the tray cavity to the flap recess.[0098]
• Many variables can be tested to identify a suitable configuration and achieve the desired gas exchange rate. For example, the area, number, and size and placement of microperforations can be increased or decreased to meet the desired gas exchange rates, or any combination of these variables. For instance, these variables independently or in combination can be manipulated so that the level of oxygen within the tray cavity can be elevated from less than or about 0.05% (500 ppm) oxygen to greater than or about 10% (100,000 ppm) oxygen within less than or about 10 minutes. However, under other circumstances, the level of oxygen within the tray cavity can be elevated from less than or about 0.05% (500 ppm) oxygen to greater than or about 3% (30,000) oxygen within less than or about 15 minutes. The diffusion and gas exchange rates can vary based on a number of variables. For instance, the diameter of microperforations can be adjusted to an optimum, taking into consideration the desired gas exchange rate and the need to reduce the amount of liquid weep. Other variables that may be considered is the amount of free space volume within the tray cavity, the volume of the communication, and the volume of the flap recess. Greater volumes can add to the time for sufficient gas exchange to take place. Other variables, not mentioned here are also considered to affect the gas exchange rate and can be taken into consideration by varying the area of microperforations, the amount of microperforations, the spacing between perforations and the diameter and location of the microperforations, to name but a few examples. These variables can again be determined experimentally to meet the desired application. Other variables, which may or may not be under the control of the designer, may effect the gas exchange, such as temperature, pressure, humidity, air composition, etc., and can be accommodated in the manner described.[0099]
• Referring now to FIG. 11 another embodiment of a tray web according to the invention is shown wherein a[0100]tray1100 withcavity1102 is assembled with anend flap1104 andside flap1106 that are hinged athinges1108 and1110, respectively, with corresponding third and fourth flaps on the opposite sides oftray1100, which cannot be seen in this figure. It is apparent that opposing flaps can be of similar construction to the ones shown. Theside flap1106 is formed with a series of recesses and channels that connect the recesses together in a sequence that will inhibit the escape of liquids, but will allow direct communication of gases there through when a web material has been stretched and sealed to the flap, and in the manner as will be described herein below.Side flap1106 is formed with a sidelower recess1112 that continues along its full length close to the lower edge of theflap1106, as seen in FIG. 11. Sidelower recess1112 is formed with a base and sides so that a bead of adhesive1114 can be extruded and deposited along its full length, or intermittently, or as otherwise may be determined appropriate. The depth ofrecess1112 is such thatadhesive bead1114 does not extend beyond its depth.Adhesive bead1116 is extruded onto theflange1118 andbead1120 is extruded ontoflange1122.Additional beads1124 and1126 are extruded and applied toflap1106, and corresponding beads of adhesive are applied to the opposite end offlap1106, but cannot be seen in the illustration of the tray shown in FIG. 11. Beads of adhesive are also applied to the corresponding locations of the opposing flap on the other side oftray1100, but this cannot be seen in FIG. 11. A bead of adhesive1128 can also be applied to the outer ends offlap1104, and also to the opposite end offlap1104 as well as to the opposing flap at the corresponding locations. Beads of adhesive in all cases are applied at locations that cannot be contacted by guards or guides that may be used to retain a multiplicity of such trays with adhesive as they are transferred down a conveyor. Such guards and guides would be situated parallel to a conveyor used to transfer the trays, and would therefore not come into contact with the adhesive beads that have been deposited in recessed channels, or at the corners and on the radius of the flanges as shown on the perpendicular side and end planes. A pre-stretched web of lidding material can therefore be applied with apparatus herein described such that it contacts substantially all of the adhesive beads that will then hold the web securely, which can then be cut appropriately such that the section covering the opening tocavity1102, the side flap11064, and the opposing side flap not shown in FIG. 11. The adhesive used may be a pressure sensitive adhesive or other suitable bonding agent as specified herein above, and will hold the stretched web material in position, retaining its tension, the web will conform to theflanges1118,1122,1130 and also the flange of the fourth side opposite toflange1130, which cannot be seen. The tension will cause the lidding web to conform to not only the flanges, but also to the surfaces offlap1106 in contact with lidding web.
• Referring now to FIG. 13, which shall be detailed additionally below, the surface of[0101]flap1106 atsurface1132 and opposingflap1134 atsurface1136 have an arcuate shape that continues in a substantially continuous line from the base of one flap, upwardly around thesurfaces1138,1140, and1142, and across the entire package toradius1136. This configuration provides for conformity of the stretched web to those exposed surfaces around the recesses and channels, formed into flap, such asflap1106, and the correspondingopposite flap1134.
• Referring again to FIG. 11,[0102]channels1144,1146,1148,1150,1154, and1168 connectrecesses1156,1158,1160,1162,1164, and1166 together. The series of channels and recesses ends inchannel1144 that is open to the outside. It can therefore be seen, after application of a web of material that has been bonded to an adhesive, gas or ambient air can freely follow the channels and the recesses, and connect tochannels1170,1171,1172, and1174 directly into thecavity1102 oftray1100.Channels1172 and1174 are formed into the peaks on the inner facing side wall of tray web. It can also be seen thatchannels1148 and1150, for example, are arranged at different locations, i.e., at different heights. Differing channel height is provided to inhibit the escape of any liquids that may be present incavity1102 after packaging. For example, if a finished package comprising tray, ground beef contents, and a stretched web lidding material fully assembled, is turned onto a side, any liquids that may be present will firstly fillrecesses1176, formed into the inner facing side of the tray side walls. Assuming that there is sufficient liquid present so as to fillrecesses1176 to such a level that liquid may enterchannels1172 and1174, the liquid would then flow intorecess1156 viachannels1170 and1171, and most likely be retained inrecess1156 or in any of the recesses extending outward fromrecess1156. The end ofchannels1144 and1178 are exposed to atmosphere, but the opening is located at a different plane to the outer surface offlap1106, and therefore for any liquid to escape from the package throughchannels1144 and1178, all recesses would need to fill with such liquid up to the level of the opening ofchannels1144 and1178. However, the package will have to experience all sorts of twisting and turning such that liquid will escape from a plane different from the flap plane. However, gases will be capable of communicating from the outside of the package to the inside ofcavity1102 freely. It should also be noted that during the normal handling of a finished package that is constructed in the manner herein described, will result in a partial squeezing of the tray vertical side walls and stretch web material, toward each other. Such an action will cause elevation of internal gas pressure, therefore expelling some gas along thechannels1144 and1178. After gas has been expelled in this manner and the package is released, the tray sides will relax to their normal position and cause a lowering of gas pressure withincavity1102. This will then cause gas such as ambient atmosphere, to be drawn alongchannels1144 and1178 and towardcavity1102. This “bellows” action will enhance the transfer of gases from withincavity1102 to ambient atmosphere, and vice versa. Gas will also diffuse more rapidly along the referenced channels and allow more rapid exchange of atmospheric oxygen with gases incavity1102, and therefore facilitate the more rapid generation of oxymyoglobin at the surface of any meat contained therein.
• Referring now to FIG. 12, a side elevation of the tray as described in association with FIG. 11, is shown.[0103]Adhesive strips1116,1124,1126,1114,1128,1120,1180,1182, and1184 are shown conveniently located so as to provide secure bonding of a stretch web material that is applied thereto. It should be apparent also that material not capable of stretching but nevertheless can be put under tension both longitudinally and laterally, can be used in practicing the invention. A clear detail ofchannels1144,1146,1148,1150,1154,1168,1170,1171,1172, and1174 are shown connectingrecesses1156,1158,1160,1162,1164, and1166 together to provide a passageway that will allow gases to pass frompoint1186 via all channels and recesses, and to enter at thetray cavity1102 atchannels1172 and1174.Channels1178,1188,1190,1192,1194, and1196 are shown connectingrecesses1156,1198,1101,1103,1105, and1107 together to provide a passageway that will allow gases to pass frompoint1178 via all channels and recesses and to enter at thecavity1102 atchannels1172 and1174. It can be seen that a stretched web of material that has been applied to the adhesive will enclosecavity1102 and the channels and recesses, leaving onlyopenings1178 and1186 to communicate directly with ambient atmosphere fromtray cavity1102.
• Referring now to FIG. 13, an end view of the tray is shown with adhesive strips shown at[0104]1116,1124,1126,1128,1111,1113, and1115.Openings1178 and1117 are therefore provided when a stretched web of material is applied and bonded to the adhesive strips.
• Referring now to FIG. 14A, a plan view illustration and cross section illustrations of a lidding web stretching and packaging apparatus is shown. The views shown give detail of a web stretching apparatus that is arranged to apply a stretched web of material to trays similar to those described in association with FIGS. 11, 12, and[0105]13, thereby bonding the stretched web of lidding material to an adhesive or bonding agent applied to the tray, generally as described in association with FIGS. 11, 12, and13. FIG. 14B, FIG. 14C, and FIG. 14D show detail of cross sections through the web stretching apparatus at various locations along its length.
• Referring to FIG. 14A, a web of[0106]lidding material1202 is gripped at each side edge by a pair ofgripping chains1204 and1206, and continuously carried forward by the chains. Thelidding web1202 is unwound from aroll1208 of source material. Theroll1208 is mounted on a device having a braking mechanism to apply longitudinal tension on the web as the web is pulled forward. As the web is carried forward the web engages with two outer cords and two inner cords. Theweb1202 is laterally stretched between the series of outer andinner cords1210,1212,1214, and1216. Longitudinal stretch inweb1202 is induced by applying a controlled brake to theroll1208 of material from whichweb1202 is unwound so that the speed ofroll1208 is slower than the speed of thechains1204,1206.Web gripping chains1204 and1206 apply tension thereby inducing a longitudinal stretch to a controlled extent of, for example, 10%, but not exceeding 20%, by carrying the web forward. Lateral stretch is induced by increasing the distance between thegripping chains1204,1206, and thecords1214,1216.Gripping chains1204 and1206, as well ascords1210,1212,1214, and1216, are constructed as endless devices to accommodate continuous processing.Cords1210,1212,1214, and1216 andchains1204 and1206 are also driven by variable speed driving motors, which are not shown. The web oflidding material1202 and the stretching assembly are located directly above asuitable conveyor1202 carrying loaded trays, such as1218 and1220, which can be similar to those trays described in association with FIGS. 11, 12, and13. Thecords1210,1212,1214, and1216 are driven at a relatively equal and constant speed as is the conveyor carrying the trays. The cords are retained in a vertical disposition as shown in FIG. 14D. FIG. 14D showsendless cord1210, for example, held captive by retainingbar1222 and apivot1224. Cord assembly, comprising cord, bar, wheels, and pivots, has a lower and upper run ofcord1210 trained on two wheels located on either end of thebar1222 to which the cords are trained in an endless loop. A wheel is driven by a suitable variable speed driving motor so as to drivecord1210 in the required direction, and at any velocity that is selected.
• Referring to FIG. 14B, it can be seen that[0107]gripping chains1204 and1206grip web1202 at its lateral edges.Cords1214 and1216 are below theweb1202 andcords1210 and1212 are above theweb1202. The web is being laterally stretched over and below the cords as the cords are spaced relatively further apart from each other and fromchains1204 and1206, while theweb1202 is held at its edges by grippingchains1204 and1206. As theweb1202 is carried forward by grippingmeans1204 and1206, thecords1210,1212,1214, and1216 are in contact with and will stretchweb1202. It is to be appreciated that rigid or semi-rigid web materials may undergo little or no stretching. Moreover, even these materials can be put under longitudinal and lateral tension with the apparatus of the present invention. As can be seen in FIG. 14A, webedge gripping means1204 and1206 andcords1210,1212,1214, and1216 converge inwardly toward the longitudinal center of the apparatus. As grippingmechanisms1204 and1206 converge,cord assemblies1210,1212,1214, and1216 follow a parallel path inwardly toward the center. As the cords and gripper means converge,cords1210 and1212 are angled downwardly andcords1214 and1216 are angled downwardly to bring the lidding web closer to the trays. The downward angle ofcords1214 and1216 and the downward angle ofcords1210 and1212 are arranged to provide a lateral stretch inweb1202, and simultaneously alter the profile of an initiallyflat web1202 to that of an inverted channel as shown in FIG. 14C.Cords1214 and1216 terminate atlocations1226 and1228 along the conduit, respectively; thereby allowing stretchedweb1202 to come in contact with the upper surface of the trays.
• Referring to FIG. 14C, a[0108]base1230 andcover1232 comprise a section of a conduit to enclose a section of the web stretching apparatus wherein the stretchedweb1202 has been applied by allowingcords1214 and1216 to terminate. Thus,web1202 is allowed to fall to the upper surfaces oftray1234.Web1202 is now in contact with the upper flanges oftray1234. However,cords1210 and1212 are still in contact with theweb1202 on opposing sides thereof and are at a spaced distance to hold theweb1202 away from contact with the tray sides. Theweb1202 continues to be gripped at each edge by grippingmeans1204 and1206.Rollers1236 and1238 located on opposing sides of the conveyor are provided to apply pressure in the direction shown by arrows adjacent thereto, and causeweb1202 to contact the sides oftray1234.Rollers1236 and1238 can be arranged so as to depressweb1202 into therecess1112, shown in FIG. 11, and to cause contact and therefore bonding ofweb1202 to adhesive1114 located in the recess. After bondingweb1202 totray1234, the trays are separated from the web.
• Referring now to FIG. 15, an illustration of an[0109]apparatus1300 for biaxially stretching a web of material and applying the web to trays, as described in association with FIGS. 11, 12, and13, is illustrated. The apparatus includes aframe1302 supported byadjustable legs1304,1306, and1308. An assembly of rollers is located at an upper location on theframe1302. A roll ofweb material1310, such materials being described in PCT/US01/45146, for example, is located at an upper location on theframe1302. A suitable lidding web material is plasticized polyvinyl chloride “pPVC”, which is capable of stretching and has memory, i.e., can expand under tension and then contract once the tension is removed. However, semi rigid materials, including biaxially oriented polyester can be used in the invention. One feature of the apparatus is that it does not substantially allow further tensioning or relaxation of the initial tension applied to the lidding webs until only after bonding the lidding webs to the trays. By not allowing additional tensioning or relaxation of tension, the lidding webs are not allowed to undergo further stretching, which could result in smearing of the bonding agent that may lead to failures of the hermetic seal, or if tension is relaxed, lidding webs may undergo contraction that may lead to creases in the web, an unattractive appearance to consumers. Adrive roller1312 is located adjacent to the roll ofweb material1310. Thedrive roller1312 unwinds theweb material1314 as it travels overidler rollers1316 and1318. Additionally, or alternatively, a secondlidding web material1320 can be laminated to the first material ofroll1310. Thelidding material1314, whether single or multi-ply material, travels underneathidler roller1318. Fromidler roller1318, thelidding material1314 is captured at its edges by gripping means, such asgripping chains1350 and1352.Gripping chains1350 and1352 are positioned on opposite sides of thelidding material1314. The gripping chain can be trained on a longitudinally extending structure assembly wherein the chains glide over upper and lower surfaces thereof. Gripper chains can be trained on sprocket wheels located on either end of the longitudinal structure. One sprocket wheel may be a drive sprocket where the opposite sprocket is an idler sprocket. A stream of trays, such as1322 and1324, are carried on aconveyor belt1326 at any suitable speed.Conveyor belt1326 has abase platform1327 supporting theconveyor belt1326.Conveyor belt1326 can be connected a variable driver (not shown). The speed ofconveyor belt1326 can be adjusted via the driver.
• Outer[0110]right cord assembly1330, outerleft cord assembly1332, innerleft cord assembly1328, and innerright cord assembly1340 that cannot be seen are arranged such thatweb1314 engages with the cords, and is stretched as it is carried forward.
• In one embodiment, a[0111]vacuum chamber1334 is attached toconduits1336 that are located so as to carry any scrap lidding material that has been cut and separated from thecontinuous lidding material1314 by a suitable cutting means1333.
• Referring now to FIGS. 16 and 17, cross-sectional illustrations of the apparatus of FIG. 15 are illustrated. FIG. 16 shows a cross section of the packaging conduit after the inner cord assemblies have terminated and only the[0112]outer cord assemblies1330,1332 remain, while FIG. 17 shows both inner1340,1328 and outer1330,1332 cord assemblies. Cord assemblies are seen more clearly comprising an elongated bed, wheels, and cords supported by the bed, and trained on the wheels at either end of the elongated beds. Referring to FIG. 17, theconveyor platform1327 andbelt1326 are shown carrying trays.Outer cord assemblies1330 and1332 are located alongside theconveyor1326 on either side of a tray.Inner cord assemblies1328 and1340 are angled downwardly as the cord assemblies are arranged alongside theconveyor1327.Cord assemblies1328 and1340 are fitted withendless cords1329 and1341.Cords1329 and1341 endlessly revolve oncord assemblies1328 and1340, respectively.Cords1329 and1341 are driven by any suitable driver.Outer cord assemblies1330 and1332 carry a second set ofcords1331 and1333, respectively.Outer cord assemblies1330 and1332 are angled downwardly ascord assemblies1330 and1332 travel alongside theconveyor1327.Cords1331 and1333 endlessly revolve oncord assemblies1330 and1332, respectively.Cords1331 and1333 can be driven at any suitable speed by drivers (not shown).Lidding material1314 is moved forwardly bygripper chain assemblies1350 and1352 gripping the respective opposite edges oflidding material1314.Gripping chain assemblies1350 and1352 havesuitable gripper chains1354 and1356 that hold the edges oflidding material1314.Gripping chains1354 and1356 can be trained in an endless fashion about grippingstructure assemblies1350 and1352, respectively.Gripping chains1354 and1356 endlessly revolve on grippingassemblies1350 and1352, respectively.Gripping chains1354 and1356 can be driven at any suitable speed. From the grippingchains1354 and1356,lidding material1314 is in contact with the lower runs ofcords1331 and1333 of theouter cord assemblies1330 and1332, respectively.Lidding material1314 is then in contact with the upper runs ofcords1341 and1329 on theinner cord assemblies1340 and1328, respectively. In this fashion,lidding material1314 is suitably formed into an inverted channel. The channel created by the stretchedweb1314 has an upper middle portion extending downward along either side of conveyor so that the inverted channel surrounds the trays from the top and two sides.
• Referring now to FIG. 16, a cross-sectional illustration of the stretching apparatus of FIG. 15 is illustrated. FIG. 16 shows the cross-section of the[0113]apparatus1300 of FIG. 15 where the only set of cord assemblies that are shown arecord assemblies1330 and1332, whereas FIG. 17 shows a cross-section illustration of thestretching apparatus1300 of FIG. 15 where the two sets of inner and outer cord assemblies are shown disposed adjacent on opposite sides of the conveyor. In FIG. 17,outer cord assemblies1330 and1332 angle downwardly as they continue from the entrance to the apparatus to the exit, andinner cord assemblies1340 and1328 also angle downwardly as they travel from the entrance to the exit of the apparatus.Inner cord assemblies1340 and1328 terminate ahead ofouter cord assemblies1330 and1332.
• FIG. 16 shows a cross-sectional illustration of the apparatus of FIG. 15 after termination of the[0114]inner cord assemblies1340 and1328.Outer cord assemblies1330 and1332 are shown in conjunction withgripping chain assemblies1350 and1352.Gripping chain assemblies1350 and1352 have agripping chain1354, and1356, respectively trained in an endless fashion about grippingchain assemblies1350 and1352. The edges of thelidding material1314 at theedges1358 and1360 are held captive to thegripping chain assemblies1350 and1352 by the lower run of thegripping chains1354 and1356, respectively.Lidding material1314 is therefore positioned against the lower runs ofcords1331 and1333. From the lower runs ofcords1339 and1332,lidding material1314 is directed upwards and is in contact with thetray1362 at the upper surface in a stretched manner.Outer cord assemblies1330 and1332 includecords1331 and1333 trained in an endless fashion about thecord assemblies1330 and1332, respectively. Any outer or inner cord assembly can include drive wheels, such as1364 and1366, to drive cords in an endless manner about the cord assemblies. Depending on whether cord assemblies are the inner or outer assemblies, the lidding material can be positioned on the lower or upper run of cord.
• Referring now to FIG. 18, a top plan view of a section of the stretching apparatus of FIG. 15 is illustrated. Gripping[0115]assemblies1350 and1352 are located exterior to the conveyor and to the inner1348,1340 and outer1330,1332 cord assemblies. Theweb1314 is carried forward in the direction of thearrow1376.Inner cord assemblies1340 and1328 terminate ahead ofouter cord assemblies1330 and1332. Theweb1314 is stretched overinner cord assemblies1340 and1328, and beneathouter cord assemblies1330 and1332.Rollers1370 and1372 are positioned adjacent to conveyor and in close proximity to passingtray1374.Rollers1370 and1372 are located in the apparatus only afterinner cord assemblies1340 and1328 have terminated.Rollers1370 and1372 are allowed to roll about an axis that is substantially perpendicular to a horizontal plane.Rollers1370 and1372 are arranged so as to press theweb1314 against the side flaps of thetray1374.
• [0116]Rollers1370 and1372 can have an annular raised section or bump located about the periphery of the roller body. The bump corresponds to therecess1112 of the tray illustrated in FIG. 11. In this manner, theweb1314 can be pushed against theadhesive bead1114 located in therecess1112 of the tray of FIG. 11. Slitting means1378 and1380 cut the excess material from the edges of theweb1314. The excess material is then removed through evacuation throughconduits1382 and1383 after release by the grippingassemblies1350 and1352. Traverse slitting means (not shown) can be used to cut theweb1314 in a traverse direction between trays.
• Referring now to FIG. 19, a three-dimensional view of the web stretching apparatus is illustrated. A section of the[0117]web1314 has been deleted so as to show a clear view of the apparatus.Tray1325 is transported on theconveyer belt1326 in the direction shown by thearrow1323. Grippingassemblies1350 and1352 release theweb1314 after slitters1378 and1380 have removed the excess web material. The excess material is removed through evacuation throughconduits1382 and1383.
• Referring now to FIGS.[0118]30A-34 collectively, another embodiment of a packaging apparatus for biaxially stretching a lidding web material prior to bonding to a tray web, is illustrated. This embodiment of the packaging apparatus of FIGS.30-34 is similar to the apparatus described in association with FIGS.14-19. However, more detail is provided with regard to one embodiment of gripping means. As shown in FIG. 31, the grippingmeans3100 comprises upper andlower jaws3102 and3104, respectively. Theupper jaw3102 includes a portion extending horizontally at an upper surface. The portion extends vertically downward to make contact with anelastomeric rubber rod3106. On the opposite side, a vertical arm connects the upper jaw to apivoting mechanism3108. Thelower jaw3104 holds therubber rod3106. A suitable spring (not shown) biases the upper and lower jaws into contact. Theupper jaw3102 can be actuated to open, to allow insertion of a lateral edge of a lidding web and to close, thus gripping the lidding web between the end of the upper jaw and therubber rod3106. It is to be appreciated that the operation of all other gripping means is similar. Also shown in the alternate embodiment is the web being gripped by the upper portions of the gripping chains rather than the lower portions, as earlier described. The separate embodiments illustrate how different arrangements of the inner and outer cords and the web gripping chains can be configured for the purpose of achieving a biaxially stretched lidding web prior to bonding to a tray.
• Referring now to FIG. 20, a front elevation illustration of an alternate embodiment of a stretch packaging apparatus that has been constructed for the purpose of sealing a biaxially stretched web of material to a continuously moving stream of packaging trays, with goods loaded therein, is shown. One embodiment of the packaging apparatus includes multiple[0119]horizontal conveyors2033,2026,2023, and2019.Horizontal conveyors2033,2026,2023, and2019 are arranged to carry loadedpackaging trays2000,2034,2017,2018, and2030 in the machine direction shown from left to right in FIG. 20. Theconveyors2019,2023,2026, and2033 are enclosed from the exterior in anenclosure2001. The enclosure is supported bylegs2031,2025, and2021. Theenclosure2001 contains a selected gas provided in theinterior space2035 within theenclosure2001. The gas pressure inside theenclosure2001 can be greater than the ambient atmospheric pressure. The gas may include blends of gases having a majority of the gas being carbon dioxide, carbon monoxide, or nitrogen, for example. However, other embodiments use oxygen atmospheres having oxygen amounts that may be greater than the amounts of oxygen found in the air. Each conveyor section can have one idler roller and a drive roller disposed on either end of the conveyor.Conveyor2033 is driven bydrive roller2032.Conveyor2026 is driven bydrive roller2037.Conveyor2023 is driven bydrive roller2022.Conveyor2019 is driven by a roller not shown, and wherein the drive roller is mounted at the opposite end ofidler roller2020.Conveyors2033,2023 and2019 travel at a rate faster than the centrally locatedconveyor2026. The variation in conveyor speed facilitates the transfer of trays such as2000 and2034 ontoconveyor2026, so as to maintain a space between said trays when onconveyor2033, however when transferred toconveyor2026, thetrays2030 and2036 will contact each other and the trays adjacent thereto.
• The[0120]enclosure2001 is connected to abacking plate2013, fixed to an upper portion of theenclosure2001. A web unwinding mechanism is mounted to thebacking plate2013. The source of aweb material2006 is one of two rolls ofweb material2039 and2012 that are mounted to thebacking plate2013, enablinglidding web material2006 to be unwound therefrom. Theweb2006 is wound overidler rollers2010,2005,2004 and2029. Tensioning ofweb2006 is facilitated bysurface drive mechanism2011. Surface drive mechanism includes a drive roller connected to anarm2009 which pivots aboutpivot2040, enabling an alternative drive position wherein drive roller atposition2008 engages with the surface ofweb roll2039. However, as shown in FIG. 20,web2006 is unwound fromroll2012.Web2006 is carried overidler rollers2010,2005,2004, and2029. The lateral edges ofweb2006 are gripped by gripping mechanisms that will be described below. Gripping mechanisms pull theweb2006 in the same direction as the conveyor direction. As theweb2006 is pulled in the conveyor direction, tensioning bysurface drive mechanism2011 can induce longitudinal stretching of stretchable materials. Surface drive mechanism can drive the speed of theweb roll2012 at a slower speed than the speed of the conveyor so as to induce a controlled rate of stretch to the web. Alternatively, rigid or semi-rigid materials can be used instead of stretchable materials and would be placed under tension but may have little or no stretch and speeds at surface drive mechanism and conveyor can be substantially the same.Web2006 entersenclosure2001 throughnarrow opening2002. The pressure inenclosure2001 prevents atmospheric air from entering theenclosure2001. Web stretching subassemblies, described below, are mounted to a pair of horizontally disposed timing belts on opposite sides of the conveyor, and are driven so as to carryweb2006 along a path that is denoted byline2027. The web is eventually brought to the level of the trays. Pressure sensitive adhesive is applied to all trays, including2000 and2034.Web2006 will be stretched longitudinally and laterally before bonding to trays. After bonding, acutting mechanism2015 is located above the continuous stream of loaded trays such thatblade holder2014 reciprocates in a hunting motion parallel with the conveyor direction along a retaining linear bearing to sever thelidding web2006 while the trays move forward, without stopping to sever the web. Blades held inblade holder2014, enable lateral cutting ofweb2006, after bonding to trays wherein the severing occurs between each tray. Blades held byblade holder2014 can be controlled with a suitable vision system that recognizes the location between each tray, and automatically positions the blades to enable lateral cutting of the web between each tray.
• Referring now to FIG. 21, a plan view illustration of a web stretching assembly that can be mounted to a packaging apparatus is shown. The apparatus of the present invention can biaxially stretch a web, meaning tension is applied to the web both longitudinally and laterally. The tension reduces any creases or ripples that are unattractive to the consumer and also enables tensioned contact with goods in the tray cavity, at the central portions thereof. The web stretching apparatus includes web stretching subassemblies, timing belts, cam followers, and cam tracks. The web stretching assembly comprises a plurality of similarly constructed web stretching subassemblies attached to a pair of timing belts. Web stretching subassemblies are also in contact with the cam tracks, described below. The cam tracks allow for and guide the operation of the web stretching subassemblies. A continuous stream of loaded trays, including[0121]2110 and2117, are carried onhorizontal conveyors2100 in a left to right direction. A series of web stretching subassemblies, including2103 and2114, are mounted onto a pair of right and leftside timing belts2106 and2113. Thetiming belts2106 and2113 are, in turn, mounted to a common drive pulley and suitable idler pulley fixtures. Cam tracks2104 and2115 are constructed in a fixed position adjacent to the timing belts. The web stretching subassemblies, including2103 and2114, are designed with cam follows that ride on the cam tracks. Cam tracks are designed to follow a particular path that will direct cams and shafts attached thereto to reciprocate laterally and to open and close a web gripping jaw on every web stretching subassembly. The web stretching subassemblies are designed to grip lateral edges ofweb2102 and apply lateral and longitudinal tension to the web such that its width is reduced as shown atlocations2105 and2118 in FIG. 21, due to the longitudinal stretching. Web stretching subassemblies are mounted to and carried on the timing belts, and can therefore tension and also stretchweb2102 laterally and over trays carried onconveyors2100. A lateral cutting mechanism is shown whereinblade holder2108 is mounted to linear bearing2109. A reciprocating drive mechanism is described below in association with FIG. 27 wherein an assembly of lateral cutting blades enable cutting lateral cutting of the web as required. After lateral cutting of the web, finished trays, such as2111 and2112, are transferred byconveyor2119 to further processing or packaging operations, that may include packaging in a master container or any other suitable container.
• Referring now to FIG. 22, a three dimensional illustration of a web stretching subassembly, such as[0122]web stretching subassembly2103 of FIG. 21, is shown. Theweb stretching subassembly2103 is intended for use in conjunction with a plurality of similar devices wherein all such subassemblies are mounted onto a timing belt. At least twotiming belts2106 and2113 are arranged to travel in a horizontal disposition on either side of a conveyor as shown in FIG. 21.
• A section of a[0123]timing belt2207 is shown with abase plate2212 attached on an upper surface of the timing belt. Thebase plate2212 is rigidly fitted to anend plate2218 and at the opposing end of the base plate, ablock2206, is fixed rigidly to thebase plate2212. Theblock2206 has apertures to accommodate a number ofshafts2209,2208, and2296 therethrough.Shafts2208 and2296 traverse theblock2206 and extend between upper2297, middle2205, and lower2204 cam track plates.Shafts2208 and2296 can be actuated horizontally to operate the web stretching subassembly, as dictated by the direction of the cam tracks in the cam track plates. Theshaft2209 is threaded at both ends, and nuts2213 and2214 hold theshaft2209 in a rigid and horizontal position withbase plate2212 andtiming belt section2207. Aweb gripping subassembly2250 is provided betweenrigid block2206 andend plate2218. Theweb gripping subassembly2250 is a part of the largerweb stretching subassembly903. The Web gripping subassembly can slide onshaft2209. Theweb gripping subassembly2250 can move in the lateral direction between the extremes of theblock2206 and theend plate2218. Theweb gripping subassembly2250 has a machinedblock2215 centrally disposed between theplate2295 andjaw block2216 andjaw end plate2217 all arranged in a relatively fixed position to each other, and held together byshaft2208 withnut2289 tightened onto a threaded end.Shaft2208 also connects theweb gripping subassembly2250 to block2206. Uppergripping jaw2210 is mounted to pivot atlocation2211. When closed, uppergripping jaw2210, contacts acylindrical rubber member2290, manufactured from a suitable extruded or molded rubber compound.Upper jaw2210 can thusly be actuated open and closed, so that in the closed position,jaw2210 andrubber member2290 are compressed against one another.Block2215 andend plate2295 are in touching proximity toupper surface2220 ofbase plate2212 andblock2215 andplate2295 can slide or otherwise move along the upper surface of thebase plate2212.Shaft2296 is attached to uppergripping jaw2210 at thepivot pin2291 via a pair of connectingarms2292 andcoupling2221. Aspring2294 is mounted onto the shaft between theplate2295 and the uppergripping jaw2210, so as to exert suitable expanding pressure betweenplate2295 andshaft end2221.Spring2294 is arranged such that in a free condition, expanding pressure provided byspring2294 causes uppergripping jaw2210 to close suitably againstrubber section2290, and in a manner that will facilitate the gripping of an edge of a flexible web material, including thin gauge pPVC.Shaft2296 is fitted with a pair ofcam followers2298, at the end opposite of thejaw2210, and arranged to engage withcam tracks2299 and2200, machined in uppercam track plate2297 and middlecam track plate2205. Similarly, a pair ofcam track followers2203 are arranged to engage withcam tracks2201 and2202, machined in middlecam track plate2205 and lowercam track plate2204. It is apparent thatcam track plates2297,2205 and2204 only constitute a portion of the total cam track structure wherein the cam track structure can lie adjacent to the web as shown in FIG. 21. It is also apparent that cam track plates are relatively stationary to the web stretching subassembly, so that the web stretching subassembly will travel along and the operation of individual web stretching assemblies will be dictated by the cam tracks. A plurality of cam track plates may extend along on both sides of the horizontal conveyors for any length that is necessary to apply lidding web to trays.Cam followers2203 onshaft2208 will ride incam tracks2201 and2202, and will correspondingly cause web gripping subassembly jaw and blocks attached therewith, to move betweenend plate2218 andend block2206. Cam tracks2299 and2200, whereincam followers2298 ride within, can be arranged to follow a similar path tocam tracks2201 and2202, and therefore maintainjaw2210 in its gripping mode as required. However, when cam tracks2299 and2200 diverge outwardly (i.e., distally,web stretching subassembly2103 has a distal end away from thegripping jaw subassembly2250, and a proximal end, toward the jaw gripping subassembly) relative tocam tracks2201 and2202,jaw2210 will separate from the opposingrubber member2290 allowing any web thereby gripped, to be released.
• Referring now to FIG. 23, a cross sectional view A-A through the horizontal conveyor assembly, as detailed in FIG. 21, is shown. A pair of[0124]web stretching subassemblies2350 and2352, are shown on opposite sides of atray2314. While operation of only one web stretching subassembly will be described, the operation is mirrored in the directly opposite web stretching subassembly. Cam tracks2303 withcam followers2302, andcam tracks2300 withcam followers2301, are shown in relative locations that compressspring2308, thereby openingjaw2310 to allowweb2315 to be placed uponrubber member2311, and on the opposing similar rubber member on the opposite side ofcenter line2353. When cam tracks2303 move outward relative tocam tracks2301, theweb gripping jaw2310 will open. Similar cam tracks operate in a similar manner onweb stretching subassembly2350Conveyor belts2316 with thepackaging tray2314 mounted thereupon, are disposed to follow a path between opposingweb stretching subassemblies2350 and2352. The pair of opposingweb stretching subassemblies2350 and2352 are mounted onto correspondingly opposingtiming belts2305 and2306, respectively, and are shown withweb gripping jaws2310 and2319 in an open disposition.Web2315 is provided, having a flat width proportionately shorter than the width as provided in roll form. This is due to the extent that when longitudinal tension is applied, the width of theweb2315 will be decreased if stretch is induced. However, the width ofweb2315 can be increased by web stretching subassemblies applying lateral tension.
• Referring now to FIG. 24, a cross sectional view B-B through the horizontal conveyor assembly as detailed in FIG. 21 is shown. It can be seen that cam tracks[0125]2303 withcam followers2302 have moved inwardly relative tocam tracks2301, and are in vertical alignment tocam tracks2301, withcam followers2300. Similar cam tracks operate in similar manner onweb stretching subassembly2350. Thus,jaws2310 and2319 have closed therebygripping web2315 between uppergripping jaws2310 and2319 and correspondingrubber members2311, and2312. However,web2315 can be stretched laterally by simultaneously outwardly directingcam tracks2303 and2301, thereby outwardly directing the web gripping subassemblies in relation to the tray, while maintaining web gripping mode and thereby increasing the lateral tension ofweb2315, prior to contact withtray2314. It should be noted that any stretching ofweb2315, most preferably will occur prior to the web contacting any bonding agent on thepackaging tray2314. Web gripping mode ofjaws2310 and2319 is in part facilitated bysprings2308 and2354.Springs2308 and2354 have expanded such thatjaw2310 and the corresponding opposingjaw2319, are both biased in gripping contact withrubber member2311 and the opposingrubber member2312.Web2315 accordingly, is gripped at both lateral edges by grippingjaws2310 and2319.Timing belt2305 and opposingtiming belt2390, can remain in a horizontally disposed path and driven by a common variable speed drive such that all web stretching subassemblies follow the same path. Cam track plates can be stationary relative to timing belts, however, cam tracks will follow the path suited for gripping and stretching web.Packaging tray2314 travels parallel to and at the same speed astiming belts2305 and2390 so as to avoid moving web once web has made contact with a bonding agent.Blocks2391 and2324 are relatively inwardly positioned onbase plates2304 and2321, respectively, and lateral tensioning will not begin untilblocks2391 and2324 are biased outwardly withjaws2310 and2319 in the gripping mode. Alternatively, the lateral tension can be applied by fixed web gripping subassemblies, and directing the timing belts outwardly relative to the center.
• Referring now to FIG. 25, a cross-sectional view C-C through horizontal conveyor assembly as detailed in FIG. 21, is shown. Gripping[0126]jaws2310 and the opposingjaw2319 are shown in the gripping, closed position mode.Blocks2391 and2324 have been biased outward, thus putting lateral tension onweb2315 and stretchingweb2315.Web2315 is also now in contact with the uppermost surfaces oftray2314, as a consequence of the changing relative position ofconveyor belts2316, andtiming belts2305 and2390. Pressure sensitive adhesive beads have been applied to selected locations oftray2314, as described in association with FIGS. 111 through 13, and are in position to allow bonding contact withweb2315.Web stretching subassemblies2350 and2352 travel at substantially the same speed asconveyor belts2316 to avoid smearing adhesive beads.
• Referring now to FIG. 26, cross sectional view D—D through horizontal conveyor assembly of FIG. 21, is shown. It can be seen that[0127]web2315 has been wrapped around the upper surface and vertical sides oftray2314 by controlling the relative position oftiming belts2305 and2390 andconveyor2316, and also by the appropriate guidance of the web gripping subassemblies. Theweb2315 is wrapped under the lower corners oftray2314, and in such a manner thatweb2315 makes full bonding contact with adhesive beads applied as described in association with FIGS. 111 through 13. However, once initial contact is made betweenweb2315 and a bonding agent on the tray, the tension on the web is neither increased or reduced so as to cause the web neither to stretch or contract so as to avoid causing smearing of the adhesive or the formation of creases in the web. Thus, once initial contact betweenweb2315 and a bonding agent is made, the web width or length is substantially maintained constant while the web is being bonded to the tray. It should be noted that timingbelts2305 and2390 are held captive by drive and idler pulleys, mounted at opposite ends. However, cam tracks have been arranged to direct web gripping subassemblies inward, alongshafts2306 and2391. In this way, grippingjaws2310 and2319 can be positioned on the underside of thepackaging tray2314.
• Referring now to FIG. 27, cross sectional view E-E through horizontal conveyor assembly detailed in FIG. 21 is shown. As can be seen, the relative position of[0128]cam tracks2303 withcam followers2302 have moved outward relative tocam tracks2301 withcam followers2300 and are not vertically aligned but are arranged so as to fully withdraw andopen jaw2310, and the corresponding cam tracks and cam followers releasing opposingjaw2319. Openingjaws2310 and2319 allows sufficient clearance forlateral cutting mechanism2392, withvertical cutting blades2393 and2394, attached thereto, and movable in the manner as indicated by the adjacent arrow.Lateral blade2392 is mounted to a reciprocating mechanism that follows a hunting motion, and is associated with a vision system, or an alternative mechanism, that enables the alignment of cutting blades with the space between each tray. Thus,cutting mechanism2392 will reciprocate upwards and downwards as well as forwards and backwards. An alternative mechanism enables the synchronized release of the stretched web and withdrawal of the web stretching subassemblies; the withdrawal of selected subassemblies occurring only at locations in the vicinity of where the lateral cutting is to take place. The remaining web stretching subassemblies continue to grip the web upstream and downstream of the only withdrawn subassemblies. The remaining subassemblies are withdrawn after the web has bonded to the tray. This alternative mechanism is not shown, however in this instance, cam followers and cam tracks can be arranged to open the jaws and withdraw the jaw gripping subassemblies only at locations between trays where cutting is to occur. This location can be determined by a vision system utilizing a suitable form of radiation, including visible light, for example. Other alternative cutting devices can be used, utilizing high pressure fluids or heat, for example.
• Referring now to FIG. 28, cross sectional view F-F through horizontal conveyor assembly as detailed in FIG. 21 is shown. It can be seen that complete separation of the[0129]web stretching subassemblies2350 and2352 andtray2314 has occurred. The web gripping jaws are open and are in the withdrawn position. This enables the transfer of separated trays, such as2314, alongconveyor2316, and away from the web stretching and bonding section of the apparatus.
• While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.[0130]

Claims (15)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A method for bonding a lidding web to a tray web, characterized in that the lidding web is tensioned in the longitudinal and lateral directions before the lidding web is bonded to the tray web.

2. The method ofclaim 1, wherein the lidding web is stretched longitudinally and laterally.

3. The method ofclaim 1, wherein the lidding web is made from plasticized polyvinyl chloride.

4. The method ofclaim 1, wherein the lidding web is horizontal at the first instance of contact with the tray web uppermost contactable surface.

5. The method ofclaim 1, wherein the lidding web is applied to the tray web without additional tensioning or relaxation of the lidding web so as not to cause additional stretching or contraction of the lidding web during application of the lidding web to the bonding agent.

6. The method ofclaim 1, wherein the lidding web is shaped into an inverted channel before applying the lidding web to the bonding agent on the tray web.

7. The method ofclaim 1, wherein the lidding web is tensioned in the longitudinal and lateral directions before the lidding web is applied to any bonding agent on the tray web.

8. The method ofclaim 1, wherein an upper blade portion and side blade portions are arranged to cut the lidding web bonded to the tray.

9. The method ofclaim 1, wherein the lidding web includes printed material.

10. The method ofclaim 1, wherein the lidding web is bonded to the tray web with a cold-seal adhesive.

11. The method ofclaim 1, further comprising leaving an exposed area on the underside of the tray web, wherein said area is not covered by the lidding web.

12. A method for tensioning a lidding web in the longitudinal and lateral directions prior to bonding to a tray web, characterized in that the longitudinal tension is applied by gripping each edge of the lidding web with corresponding pluralities of web-gripping subassemblies, and longitudinally pulling the lidding web while the lidding web supply is under tension.

13. The method ofclaim 12, wherein the lateral tension is applied to the lidding web by moving each plurality of web-gripping subassemblies, which grip the edges of the lidding web, apart in relationship to one another.

14. The method ofclaim 12, wherein the lateral tension is applied to the lidding web by passing the lidding web over a pair of longitudinal members and under a pair of longitudinal members wherein the spacing between pairs diverges along the length.

15. The method ofclaim 12, wherein said pulling is indexed according to printed matter located on said lidding web, and wherein said printed matter is positioned adjacent the sides of said tray web.

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