Systems and Methods for Forming Laminates with Patterned Microwave Energy Interactive Material

• US 20130032283A1
• Filed: 08/02/2012
• Published: 02/07/2013
• Est. Priority Date: 08/03/2011
• Status: Active Grant

• Current Assignee: Graphic Packaging International LLC (Graphic Packaging International Incorporated)
• Original Assignee: Graphic Packaging International Incorporated
• Inventors: Walsh, Joseph C., Sinclair, Mark, Sloat, Jeffrey T.
• Granted Patent: US 9,216,564 B2
• Time in Patent Office: Days
• US Class Current: 156/247
• CPC Class Codes: B32B 2038/045 Slitting
• CPC Class Codes: B32B 2439/70 Food packaging
• CPC Class Codes: B32B 37/0076 characterised in that the layers are not bonded on the totality of their surfaces
• CPC Class Codes: B32B 37/02 characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• CPC Class Codes: B32B 37/1292 selectively, e.g. in stripes, in patterns B32B37/0076 takes precedence
• CPC Class Codes: B32B 37/20 involving the assembly of continuous webs only
• CPC Class Codes: B32B 38/0004 Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B65D 2581/344 Geometry or shape factors influencing the microwave heating properties
• CPC Class Codes: B65D 2581/3472 Aluminium or compounds thereof
• CPC Class Codes: B65D 2581/3477 Iron or compounds thereof
• CPC Class Codes: B65D 2581/3478 Stainless steel
• CPC Class Codes: B65D 2581/3479 Other metallic compounds, e.g. silver, gold, copper, nickel
• CPC Class Codes: B65D 2581/3489 Microwave reflector, i.e. microwave shield B65D2581/3487 takes precedence
• CPC Class Codes: B65D 2581/3494 Microwave susceptor B65D2581/3487 takes precedence
• CPC Class Codes: B65D 81/3446 specially adapted to be heated by microwaves
• CPC Class Codes: Y10T 156/12 Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing

Abstract

Portions of microwave energy interactive material may be cut and removed during intermediate steps in a lamination processes, so that remaining microwave energy interactive material in a resultant laminate is arranged in a pattern. Regarding the removal of the portions of the microwave energy interactive material, a compound laminate may be delaminated into parts, and one of the parts may be a sacrificial laminate that includes the removed portions of the microwave energy interactive material.

Claims

1. A method of forming a laminate comprising a pattern of microwave interactive material, the method comprising:

forming a compound laminate comprising first, second and third webs, wherein the third web is positioned between the first and second webs, and the third web comprises microwave interactive material and a plurality of lines of disruption at least partially defining first and second pluralities of sections of the third web; and

separating the compound laminate into parts comprising a first laminate and a second laminate, wherein the first laminate comprises the first web and the first plurality of sections, and the second laminate comprises the second web and the second plurality of sections.

2. The method according to claim 1, wherein the forming comprises bonding both of the first and second pluralities of sections to the first web with adhesive material.

3. The method according to claim 1, wherein:

the first plurality of sections are bonded to the first web by adhesive material; and

the forming comprises bonding the second plurality of sections to the second web with adhesive material.

4. The method according to claim 1, wherein the separating comprises delaminating the first and second laminates from one another.

5. The method according to claim 1, wherein the separating comprises causing adhesive bond failure between the first plurality of sections and the second web.

6. The method according to claim 1, wherein the separating comprises causing adhesive bond failure between the second plurality of sections and the first web.

7. The method according to claim 1, wherein the first web comprises paper.

8. The method according to claim 1, wherein the second web comprises paper.

9. The method according to claim 1, further comprising laminating a fourth web to the first laminate, so that the first plurality of sections are positioned between the first and fourth webs.

10. The method according to claim 9, wherein:

the first web comprises paper, and

the fourth web comprises a polymer film.

11. The method according to claim 1, further comprising laminating a fourth web to the second laminate, so that the second plurality of sections are positioned between the second and fourth webs.

12. The method according to claim 11, wherein:

the second web comprises paper, and

the fourth web comprises a polymer film.

13. The method according to claim 1, wherein:

an initial laminate comprises the first and third webs;

the forming comprises laminating the initial laminate and the second web to one another; and

the method further comprises forming the lines of disruption in the third web prior to the laminating of the initial laminate and the second web to one another.

14. The method according to claim 13, wherein:

the third web is a foil laminate comprising foil and a substrate; and

the forming of the lines of disruption comprises forming the lines of disruption in both the foil and the substrate, so that the lines of disruption define a pattern in the foil, the lines of disruption define a pattern in the substrate, and the pattern in the foil and the pattern in the substrate are superposed with respect to one another.

15. The method according to claim 13, wherein:

the third web is a foil laminate comprising foil and a substrate; and

the laminating is carried out so that the foil is positioned between the substrate and the second web.

16. The method according to claim 1, wherein:

an initial laminate comprises the second and third webs;

the forming comprises laminating the initial laminate and the first web to one another; and

the method further comprises forming the lines of disruption in the third web prior to the laminating of the initial laminate and the first web to one another.

17. The method according to claim 16, wherein:

the third web is a foil laminate comprising foil and a substrate; and

the forming of the lines of disruption comprises forming the lines of disruption in both the foil and the substrate, so that the lines of disruption define a pattern in the foil, the lines of disruption define a pattern in the substrate, and the pattern in the foil and the pattern in the substrate are superposed with respect to one another.

18. The method according to claim 16, wherein:

the third web is a foil laminate comprising foil and a substrate; and

the laminating is carried out so that the foil is positioned between the substrate and the second web.

19. A system for forming a laminate comprising a pattern of microwave interactive material, the system comprising:

a first laminating station for forming an initial laminate, and a second laminating station positioned downstream from the first laminating station for forming a compound laminate comprising first, second and third webs, wherein the first laminating station is configured for causing the initial laminate to comprise the first and third webs, and the second laminating station is configured for causing the third web to be positioned between the first and second webs in the compound laminate;

a cutting station positioned between the first and second laminating stations for forming a plurality of lines of disruption in microwave interactive material of the third web, so that the plurality of lines of disruption at least partially define first and second pluralities of sections of the third web; and

a delaminating station positioned downstream from the second laminating station for separating the compound laminate into parts comprising a first laminate and a second laminate, so that the first laminate comprises the first web and the first plurality of sections, and the second laminate comprises the second web and the second plurality of sections.

20. The system according to claim 19, wherein the first laminating station and the cutting station are cooperatively configured so that both the first and second pluralities of sections are bonded to the first web.

21. The system according to claim 19, wherein the delaminating station comprises a winding apparatus for forming the second laminate into a roll.

22. The system according to claim 19, further comprising a third laminating station positioned downstream from the delaminating station for laminating a fourth web to the first laminate, so that the first plurality of sections are positioned between the first and fourth webs.

23. The system according to claim 22, wherein:

the first laminating station and the cutting station are cooperatively configured so that both the first and second pluralities of sections are bonded to the first web; and

the delaminating station comprises a winding apparatus for forming the second laminate into a roll.

24. A laminate for influencing an effect of microwave energy on a food product, the laminate comprising:

microwave interactive material positioned between a barrier layer and a substrate;

a plurality of holes in the microwave interactive material, the barrier layer obstructing holes of the plurality of holes in the microwave interactive material;

a plurality of holes in the substrate; and

the plurality of holes in the microwave interactive material and the plurality of holes in the substrate being superposed with respect to one another.

25. The laminate according to claim 24, wherein the microwave interactive material is a layer of microwave interactive material.

26. The laminate according to claim 24, wherein the barrier layer spans across the holes of the plurality of holes in the microwave interactive material.

27. The laminate according to claim 24, comprising a foil laminate, wherein:

the foil laminate comprises the microwave interactive material and the substrate; and

the barrier layer comprises polymer film.

28. The laminate according to claim 27, wherein the barrier layer spans across the holes of the plurality of holes in the microwave interactive material.