TRAY-SHAPED PACKAGING

Abstract

The invention relates to a tray-shaped packaging for food comprising a bottom and a circumferential margin. The bottom comprises at least one collecting section and at least one supporting section, wherein the support section comprises a plurality of elevations for carrying a product, and wherein the collecting section at least in a certain area has a greater depth relative to the margin of packaging than the support section.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application claims priority to European Application Number 12004227.0 filed Jun. 1, 2012, to Patricia A. Chee and Ronald W. Nelson entitled “Tray-Shaped Packaging,” currently pending, the entire disclosure of which is incorporated herein by reference.

FIELD OF THE INVENTION

The invention relates to a tray-shaped packaging, in particular for food products, the packaging having a bottom and a circumferential margin.

BACKGROUND OF THE INVENTION

Such a packaging as well as a packaging machine and method for manufacturing same are known, for example, from DE 102010034021 A1 or the related document US 2012/0036815 A1.

EP 0 535 451 A1 discloses a comparatively simple packaging in particular for food with a high grease content, such as bacon strips. This packaging is produced by simply placing two transparent foils on top of each other. In order to allow the bacon to become crispy during a microwave treatment, the packaging comprises a pad underneath the food product, this pad having hydrophobic and grease-absorbing properties. This pad can be produced in a rather complicated manner, for example, from blown microfibers (BMF).

Another bacon packaging is known from EP 1 939 098 A1.

SUMMARY OF THE INVENTION

It is the object of the present invention to provide a packaging that is easy to manufacture, and which offers superior properties regarding a treatment of food products, in particular greasy food products.

Due to having a tray-shaped configuration with a bottom and a circumferential margin, the packaging according to the present invention has a three-dimensional shape and is very stable. The bottom of the packaging can comprise at least one collecting section and at least one support section. The support section may comprise a plurality of elevations for jointly supporting or carrying a product, in particular a food product. Supporting the product on a plurality of elevations instead of supporting same with a planar surface offers the advantage of establishing a drainage effect, which allows grease dripping from the product during a heating of the product to be guided away from the product. This allows the product (which might, for example, be bacon, ham or sausages) to become crispier during the heating process.

Further, the packaging bottom can comprise a collecting section. This collecting section could synonymously be termed “reservoir section” and has the function of collecting excess grease or other fluids, which drip from the product during a heat treatment. In order to ensure that the grease or fluid is guided away from the product, the collecting section, in total or at least in a certain area (i.e., at least in a sub-range of its total area), may have a greater depth relative to the margin of the packaging than the support section. Typically, it may be advantageous to manufacture the collecting section without any elevations in order to maximize the storage volume of the collecting section.

The support section can be arranged between at least two collecting sections. This allows excess grease to be guided away from the heated product even more efficiently.

In another embodiment, a support section may even be circumscribed entirely (i.e., on all sides) from a collecting section.

The elevations may be pin-shaped, pyramid-shaped, rib-shaped, dome-shaped or other suitable shapes. It is also conceivable to have elevations of different size and/or different shape on a single packaging.

In principle, the elevations may be arranged in any configuration on the packaging, which enables them to carry or support a product. In one embodiment, the elevations are arranged in the form of a matrix having n lines and m columns, with n and m being integers and ≧1, respectively. Preferably, n and m are each >3, such that there are at least 4 lines and at least 4 columns of elevations. This will ensure a generally homogeneous distribution of the weight of the product, thereby preventing an undesirable deformation of the product.

In one embodiment, each of the elevations comprises a peak, and the peaks of all elevations of a common support section are arranged in a common plane. Depending on the product and on the optimum way to present the product within the packaging, the common plane may be planar or curved.

Drainage channels leading towards a single collecting section or towards one (or several) of the plurality of collecting sections may be arranged between the elevations. This will ensure an even faster and more efficient guiding of the excess grease away from the product.

This efficiency may be increased even further by providing the drainage channels with a downward slope directed towards the collecting section.

Alternatively, or additionally, it is conceivable that the support section of the bottom is convex on its side facing the interior of the packaging. The convex shape refers to the (virtual) surface combining the valleys between the elevations. The convex shape of the surface will again lead to an efficient drainage of the excess grease towards the collecting section.

In order to be able to cook or grill the products while remaining within the packaging, it is advantageous if the packaging is heat resistant up to a temperature of 150° C., preferably up to a temperature of at least 200° C. When contemplating a use of the packaging in a microwave oven, it is further advantageous if the packaging is essentially transparent to microwave radiation.

An example of a material that may be used for the bottom and the margin of the packaging is a polyethylene (PET) web or foil. This packaging material may both offer the desired heat resistance, and an advantageous transparency.

Preferred examples include the use of a bi-axially oriented polyethylene (PET) foil (boPET foil) for at least the bottom and the margin of the packaging. Such a boPET foil, which is obtainable (e.g., under the trade name Mylar) is very heat resistant and is also stable at temperatures below the freezing point, such that the goods packaged with this material can also be frozen. Further, this material is transparent and has a high resistance against punching and stretching.

The invention is also directed to a deep drawing station for producing a tray-shaped packaging of the above-described type from a web-like material, such as boPET, this deep drawing station preferably comprising a heating device, for example an electrical heating device, as well as a forming or deep drawing tool.

Further, the invention also relates to a deep drawing packaging machine that is configured for manufacturing a tray-shaped packaging of the above-described type.

Other and further objects of the invention, together with the features of novelty appurtenant thereto, will appear in the course of the following description.

DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawing, which forms a part of the specification and is to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views:

FIG. 1 is a schematic side view of a thermoforming packaging machine;

FIG. 2 is a perspective view of a first embodiment of a packaging according to the present invention;

FIG. 3 is a top view of the packaging of FIG. 2;

FIG. 4 is a lateral view of the packaging of FIG. 2;

FIG. 5 is a perspective view of a second embodiment of a packaging according to the present invention;

FIG. 6 is a top view of the packaging of FIG. 5;

FIG. 7 is a lateral view of the packaging of FIG. 5;

FIG. 8 is a sectional view of a third embodiment of a packaging according to the present invention; and

FIGS. 9a to 9d are different embodiments of the elevations used in the packaging according to the present invention.

Identical components are designated by identical reference numerals throughout the figures.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures.

The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The present invention is defined by the appended claims and the description is, therefore, not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled.

FIG. 1 shows, in a schematic side view, a thermoform packaging machine 1 comprising a forming station 2, a sealing station 3, a cross cutting station 4 and a longitudinal cutting station 5, which are arranged on a machine frame 6 in a working direction R in this sequence. On the input side, a supply roll 7 is provided on the machine frame 6, from which a first web-shaped material 8, e.g. a boPET foil, is unwound. In the area of the sealing station 3, a material storage unit 9 is provided, from which a second web material 10 (e.g., a cover film such as a PET foil) is unwound. On the output side, a discharge device 13 in the form of a transport conveyor may be provided at the thermoform packaging machine 1, with which finished, singulated packages 21 are transported away. Furthermore, the packaging machine 1 can comprise a feeding device, which is not shown, said feeding device gripping the first web-shaped material 8 and transporting it cyclically in a main work cycle in the working direction R. The feeding device can, for example, be realized by laterally arranged transport chains

In the embodiment shown, the forming station 2 (or deep-drawing station) is realized as a thermoforming station in which package lower parts or tray-shaped packagings 14 are formed in the first web-shaped material 8 by thermoforming (or deep-drawing). The forming station 2 comprises a heating element 2a and a forming tool 2b and can be configured such that in the direction perpendicular to the working direction R several tray-shaped packagings 14 are formed side by side. In the working direction R behind the forming station 2, an infeed line 15 is provided, in which the package lower parts 14 formed in the first web-shaped material 8 are filled with the product 16.

The sealing station 3 may be provided with a closable chamber 17 in which the atmosphere in the tray-shaped packagings 14 can be substituted, prior to sealing, by an exchange gas or by an exchange gas mixture (e.g., by gas flushing).

The cross cutting unit 4 can be configured as a punch separating the first web-shaped material 8 and the second web material 10 in a direction transversely to the working direction R between neighbouring package lower parts 14. In so doing, the cross cutting unit 4 works such that the first web-shaped material 8 may not be cut across the whole width of the web, but instead may remain uncut in at least an edge area thereof. This allows controlled further transport by the feeding device.

In the embodiment shown, the longitudinal cutting unit 5 is configured as a blade arrangement by means of which the first web-shaped material 8 and the second web material 10 are cut between neighbouring tray-shaped packagings 14 and at the lateral edge of the first web-shaped material 8, so that, downstream of the longitudinal cutting unit 5, singulated packages 21 are obtained.

The packaging machine 1 can additionally be provided with a controller 18. This controller 18 is used for controlling and monitoring the processes taking place in the packaging machine 1. A display device 19 with operating controls 20 serves to make the sequences of process steps in the packaging machine 1 visible to an operator and to influence them by the operator.

FIG. 2 shows a perspective view of a tray-shaped packaging 14 of the present invention. As shown, the packaging 14 comprises a generally horizontal bottom 21, a circumferential and again substantially horizontal margin 22, as well as side walls 23, circumscribing the bottom 22 and interconnecting the bottom 21 with the margin 22. The bottom 21, margin 22 and side walls 23 of the packaging 14 can be deep drawn from a web material, such as PET, boPET or a multilayer web material. For example, any material disclosed in U.S. Pat. No. 7,705,078 B2 can be used, this document being hereby incorporated by reference with respect to the material.

The bottom 21 of the packaging 14 can comprise a central support section 24, as well as two lateral collecting or reservoir sections 25, i.e., one to either side of the support section 24. A step 26 may be present between the support section and each of the collecting sections 25, such that each of the collecting sections 25 has a greater depth relative to the margin 22 than the support section 24.

Further, a plurality of pin-shaped elevations 27 may be arranged on the support section 24. In one embodiment, the elevations are arranged in a matrix of n=11 lines and m=12 columns The elevations 27 have a height of, for example, 1-3 mm above the remainder of the support section 24. They serve to support the underside of a product, in particular, a food product, such as bacon, ham or sausages placed on the support section 24.

FIG. 3 shows a top view of the tray-shaped packaging 14 of FIG. 2. FIG. 4 shows a lateral view of the packaging 14. From FIG. 4, it might be appreciated that the step 26 provides a smooth transition from the support section 24 towards the collecting sections 25, respectively. It might further be appreciated that the elevations 27 have a height that is low enough in order to allow sufficient space for the product between the peak of the elevations and a cover foil 28 sealed to the margin 22 with a circumferential seal, the cover foil 28 extending in the same plane as the margin 22.

FIG. 5 shows a second embodiment of a packaging 14 of the present invention. This second embodiment of a tray-shaped packaging 14 is consistent with the first embodiment in comprising a central support section 24 and two lateral collection sections 25, as well as a margin 22 and side walls 23 circumscribing the bottom 21.

In contrast to the first embodiment, however, the elevations 27 are now pyramid-shaped. The pyramidal elevations 27 are arranged in a matrix pattern. Again, a step 26 is present between the central support section 24 and each of the collecting sections 25, such that each collecting section 25 entirely has a larger depth relative to the margin 22 than the support section 24.

FIG. 6 shows a top view of the tray-shaped packaging 14 of FIG. 5. FIG. 7 shows a lateral view of the packaging 14 of FIG. 5. FIG. 7 allows appreciating in particular the pyramid shape of the elevations 27.

In each of the embodiments of the packaging 14 according to FIG. 2 or 5, drainage channels 29 are provided between the elevations 27 (cf. FIGS. 3 and 6). These drainage channels 29 are configured to lead excess grease or liquid dripping from the product towards one of the collecting sections 25.

Further, FIGS. 4 and 7 show that the tray-shaped packaging 14 may rest stably on the two collecting sections 25 when it is placed on a horizontal surface, such as an oven tray. Due to the step 26, the central support section 24 is then elevated with respect to the surface on which the packaging 14 is placed, such that hot air can flow around the complete packaging 14, in particular below the support section 24. This accelerates the heating of the product within the packaging 14.

FIG. 8 shows a third embodiment of a tray-shaped packaging 14 according to the present invention. This embodiment is similar to the embodiment shown in FIG. 5, except for lacking a step between the central support section 24 and the two lateral collection sections 25. Rather, the bottom of the support section 24 has a convex shape on its side facing the interior of the packaging 14. The elevations 27 on the support section 24 are again pyramid-shaped. However, the size of the elevations 27 is smaller in the center and larger in the periphery of the support section 24. This ensures that the peaks 30 of all elevations 27 are arranged in a common plane (P), which is represented by a dashed line. In the present embodiment, this plane is planar, but it could alternatively be curved.

FIG. 8 shows that the packaging 14 rests on a support surface 31, such as an oven tray.

FIGS. 9a to 9d show different embodiments of the elevations 27, which can be provided on the support section 24. In FIG. 9a, the elevation 27 is pin-shaped. Its top surface constitutes the peak 30 of the elevation 27, i.e., the pin-shaped elevation 27 has a planar, two-dimensional peak 30.

FIG. 9b shows the pyramid-shaped elevation 27 used in the embodiment of FIG. 5. Here, the peak 30 corresponds to the peak of the pyramid.

FIG. 9c shows a dome-shaped elevation 27, which may have a circular or ellipsoidal cross-section.

FIG. 9d shows a rib-shaped elevation 27. In this embodiment, the elevation 27 has a linear peak 30, corresponding to the top edge of the rib.

The packaging 14 of the present invention is advantageous in particular for greasy food products, such as bacon, ham and sausages. When being placed in an oven or a microwave oven and heated, the excess grease may drip from the product and enter into the drainage channels 29 between the elevations 27. From here, the grease may flow into the collecting sections 25, thereby allowing the food product to be crispier after heating.

Starting from the described embodiments, the invention may be carried out in various alternative ways. For example, any shape, size and arrangement of the elevations 27 are conceivable. In particular, the shape of the elevations 27 is not limited to the embodiments shown in 9a to 9d. For example, elevations 27 may also have a conical shape.

From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.

The constructions and methods described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.

Claims

1. Tray-shaped packaging for a product, the tray-shaped packaging comprising:

a bottom having at least one collecting section and at least one support section, wherein the at least one support section includes a plurality of elevations for supporting the product; and

a circumferential margin;

wherein the at least one collecting section at least in certain areas has a depth relative to the margin that is greater than a depth of the support section to the margin.

2. Tray-shaped packaging according to claim 1, wherein the support section is arranged between at least two collecting sections.

3. Tray-shaped packaging according to claim 1, wherein the support section is circumscribed entirely by a collecting section.

4. Tray-shaped packaging according to claim 1, wherein the elevations are pin-shaped, pyramid-shaped, rib-shaped or dome-shaped.

5. Tray-shaped packaging according to claim 1, wherein the elevations are arranged in the form of a matrix with n lines and m columns, wherein n and m are integers and each larger than 1, preferably n and m≧4, respectively.

6. Tray-shaped packaging according to claim 1, wherein each elevation comprises a peak and wherein the peaks of all elevations of each support section are arranged in a common plane.

7. Tray-shaped packaging according to claim 1, wherein drainage channels leading towards the at least one collecting section are provided between the elevations.

8. Tray-shaped packaging according to claim 7, wherein the drainage channels have a downward slope towards the collecting section.

9. Tray-shaped packaging according to claim 1, wherein the support section of the bottom is convex on its side facing the interior of the packaging.

10. Tray-shaped packaging according to claim 1, wherein a step is arranged between the support section and the collecting section.

11. Tray-shaped packaging according to claim 1, wherein the packaging is heat resistant up to a temperature of at least 150° C.

12. Tray-shaped packaging according claim 1, wherein the bottom and the margin of the packaging are made from a PET foil.

13. Tray-shaped packaging according to claim 1, wherein the bottom and the margin of the packaging are made from a bi-axially oriented PET foil.

14. Deep drawing station for producing a tray-shaped packaging, said deep drawing station comprising a forming tool adapted for deep drawing a tray-shaped packaging with a bottom and a circumferential margin, such that the bottom comprises at least one collecting section and at least one support section, wherein the support section comprises a plurality of elevations for supporting a product and wherein the collecting section at least partially has a depth relative to the margin of the packaging that is greater than a depth of the support section relative to the margin.