Disposable food tray

• US 8,741,443 B2
• Filed: 05/18/2011
• Issued: 06/03/2014
• Est. Priority Date: 05/18/2011
• Status: Active Grant

• Current Assignee: Graphic Packaging International Incorporated
• Original Assignee: Powertray, LLC
• Inventors: Hilbish, Joseph Miller
• Primary Examiner(s): KILIMAN, LESZEK B
• Application Number:
  US13/110,561
• Publication Number:
  US 20120292226A1
• Time in Patent Office: 1,112 Days
• Field of Search: 428/532, 428/537.5, 428/34.2
• US Class Current: 428/532
• CPC Class Codes: B31B 50/592 using punches or dies
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2255/12 on paper layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/10 linear, e.g. length, distance, width
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2317/12 Paper, e.g. cardboard
• CPC Class Codes: B32B 2439/02 Open containers
• CPC Class Codes: B32B 2439/62 Boxes, cartons, cases
• CPC Class Codes: B32B 2439/70 Food packaging
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 29/005 next to another layer of paper or cardboard layer
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/24 with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• 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 38/12 Deep-drawing
• CPC Class Codes: B41P 2200/12 : Flexographic printing
• CPC Class Codes: B65D 1/34 : Trays or like shallow containers B65D81/3813 takes precedence
• CPC Class Codes: B65D 1/36 : with moulded compartments or partitions
• CPC Class Codes: B65D 2565/386 : packaging containers consisting of two or more parts made of the same material
• CPC Class Codes: B65D 65/42 : Applications of coated or impregnated materials
• CPC Class Codes: Y02A 40/90 : in food processing or handling, e.g. food conservation
• CPC Class Codes: Y02W 30/80 : Packaging reuse or recycling, e.g. of multilayer packaging bio-packaging Y02W90/10
• CPC Class Codes: Y02W 90/10 : Bio-packaging, e.g. packing containers made from renewable resources or bio-plastics
• CPC Class Codes: Y10T 156/1048 : to form dished or receptacle-like product
• CPC Class Codes: Y10T 428/1303 : Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]
• CPC Class Codes: Y10T 428/31971 : Of carbohydrate
• CPC Class Codes: Y10T 428/31993 : Of paper

Abstract

A repulpable and recyclable case ready food tray is disclosed for carrying various food items, such as meat, poultry and produce that is typically used for retail display. The food tray is formed from paperboard made from natural wood fiber that is coated to provide a waterproof food cavity for preventing leakage of liquid from the food item and a moisture proof exterior support surface which allows excess liquid to be released from the food tray during the manufacturing process while providing a moisture proof surface to prevent wicking of liquid into the food tray if the tray is placed on a wet surface.

Claims

1. A laminated paperboard for use in the fabrication of a food tray, the laminated paperboard comprising:

a first layer of natural wood fiber paperboard having opposing faces;

a waterproof coating applied to one of said opposing faces of said first layer;

a second layer of natural wood fiber paperboard having opposing faces; and

a moisture resistant coating applied to one of said opposing faces of said second layer;

wherein;

the first layer of natural wood fiber paperboard consists of natural wood fibers;

said first layer and said second layer are laminated together; and

the face of the first layer having the waterproof coating and the face of the second layer having the moisture resistant coating are the outermost surfaces of the laminated paperboard.

2. The laminated paperboard as recited in claim 1, wherein the composition of wood fiber in the first layer is the same as the composition of wood fiber in the second layer.

3. The laminated paperboard as recited in claim 1, wherein the composition of wood fiber in the first layer is different from the composition of wood fiber in the second layer.

4. The laminated paperboard as recited in claim 1, wherein the composition of wood fiber in one or the other of the first layer or second layer is a hardwood fiber.

5. The laminated paperboard as recited in claim 1, wherein the composition of wood fiber in one or the other of the first layer or second layer is softwood fiber.

6. The laminated paperboard as recited in claim 1, wherein the composition of wood fiber in one or the other of the first layer or second layer is a combination of a softwood fiber and a hardwood fiber.

17. The laminated paperboard as recited in claim 1, wherein the first and second layer of natural wood fiber paperboard consist of a hardwood fiber, a softwood fiber, or a combination thereof, and

the laminated paperboard comprises 94wt % to 96wt % of the overall weight of the laminated paperboard.

18. The laminated paperboard as recited in claim 17, wherein the waterproof coating comprises polyethylene in an amount of from 2.9wt % to 3.3wt % of the overall amount of the laminated paperboard.

19. The laminated paperboard as recited in claim 18, wherein the moisture resistant coating is a water based acrylic coating.

20. The laminated paperboard of claim 19, wherein a polyvinyl acetate adhesive adheres a portion of the first layer of natural wood fiber paperboard to a portion of the second layer of natural wood fiber paperboard.

21. The laminated paperboard of claim 1, wherein the first layer and second layer remain visually distinguishable when viewed in cross-section after the first layer and second layer are laminated together to form the laminated paperboard.

7. A food tray comprising:

a waterproof food cavity; and

a moisture proof support surface, wherein said food tray is formed from a laminated paperboard, the laminated paperboard comprising;

a first layer of natural wood fiber paperboard having opposing faces;

a waterproof coating applied to one of said opposing faces of said first layer;

a second layer of natural wood fiber paperboard having opposing faces; and

a moisture resistant coating applied to one of said opposing faces of said second layer;

wherein;

the first layer of natural wood fiber paperboard consists of natural wood fibers;

said first layer and said second layer are laminated together; and

the face of the first layer having the waterproof coating and the face of the second layer having the moisture resistant coating are the outermost surfaces of the laminated paperboard.

8. The food tray as recited in claim 7, wherein said food tray is formed in a generally square shape.

9. The food tray as recited in claim 7, wherein said food tray is formed in a generally rectangular shape.

10. The food tray as recited in claim 7, wherein said food tray is formed in a generally circular shape.

11. The food tray as recited in claim 7, wherein said food tray is formed with a single compartment.

12. The food tray as recited in claim 7, wherein said food tray is formed with a multiple compartments.

13. The food tray as recited in claim 12, wherein said food tray is formed with a multiple compartments having the same size.

14. The food tray as recited in claim 12, wherein said food tray is formed with a multiple compartments having different sizes.

15. The food tray as recited in claim 12, wherein said food tray is formed with a multiple compartments having the same shape.

16. The food tray as recited in claim 12, wherein said food tray is formed with a multiple compartments having the same shape.