BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to composite containers for food products, and more
particularly, to multiple-ply tubular containers including a paperboard ply, an inner
liner ply and an outer polymeric sleeve.
Description of Related Art.
[0002] In the packaging of perishable food products, a container is required that is rigid
enough to retain its shape when subjected to internal pressure produced in the container
while tightly sealing the food product to protect against deterioration, leakage and
contamination. Thus, perishable food products are often packaged in composite tubular
containers that are sealed at both ends. The tubular body portion of these containers
conventionally includes three separate plies or sets of plies.
[0003] At least one structural body ply made of paperboard material is included which is
formed into a tubular structure by wrapping a continuous strip of body ply paperboard
material around a shaping mandrel. The body ply strip may be spirally wound around
the mandrel or passed through a series of forming elements so as to be wrapped in
a convolute shape around the mandrel to form the tubular structure. As it is formed,
the tubular structure is advanced to a cutting station. At the cutting station, the
tube is cut into predetermined lengths at the downstream end of the mandrel and fitted
with one end closure to prepare the container for shipping to the customer. The can
is then filled and the other end closure is applied.
[0004] The completed container includes a heat-sealable liquid impermeable ply ("the liner
ply") adhered to the inner surface of the paperboard ply. The liner ply seals the
food product, such as potato crisps, chips, refrigerated dough or juice, within the
container, and also prevents liquids, which may possibly contaminate the food product,
from entering the container. Some liner plies are also gas and vapor impermeable,
so as to not only prevent food product odors from escaping the can, but also prevent
atmospheric air and water vapor from entering the container and spoiling the food
product. Thus, while the purpose of the body ply is to provide necessary structural
properties to the container, the liner ply provides barrier properties necessary to
protect and maintain the perishable food product. The liner ply is typically integrated
into the can during the mandrel winding process.
[0005] A label ply, which is typically a paper-based ply, is included and adhered to the
outer surface of the paperboard body ply. The label ply serves two primary functions.
First, a composite can label is a source of information. The label carries the graphical
matter that conveys product information, instructions, and regulatory compliance information.
The label is also preferably decorative and aesthetically pleasing to the consumer,
which enhances shelf appeal and increases consumer interest in the food product. In
particular, the gloss of a label is important for consumer appeal, with high and even
gloss being preferable. The label is commonly integrated into the can during the mandrel
winding process, although convolute labels may be applied at a later time.
[0006] The graphics included on conventional paper labels are either rotogravure or flexographically
printed and may require thermosetting-type overlacquers over the inks to protect the
inks used in the label printing process. However, the overlacquers may not absorb
evenly into the paper resulting in inconsistent gloss characteristics. In addition,
paper labels have a relatively high surface roughness which reduces the smoothness
of the label even after application of the overlacquer.
[0007] In addition to being a source of information, the composite can label imparts physical
characteristics to the can. For example, the wet strength of the label ply can be
an important factor in composite container design. If the container is exposed to
moisture and the paperboard ply gets wet, the strength of the can may be compromised.
Such moisture is sometimes encountered during shipping. At other times, condensation
may form on the surface of the can if the can is refrigerated, or otherwise exposed
to cold temperatures, and then moved to a warmer, humid environment. If the wet strength
of the label ply is low, then the label will provide little additional strength to
the body ply to prevent the premature rupturing of the container.
[0008] The wet strength of conventional paper label plies is especially important when the
plies are used in conjunction with composite cans for dough. Composite dough cans
are designed differently from other composite containers such that most of them can
be opened by forcefully striking container against a sharp surface, such as the edge
of a kitchen counter. Others are designed to self-open immediately once the label
has been peeled off. The edges of the body ply strip are typically abutted and held
together with an unadhered, or weakly adhered, joint or seam. Accordingly, when the
label ply is removed the internal pressure of the dough, and in the case of non self-opening
cans the force of the impact against a sharp edge, causes the body ply seam to separate.
Separation of the body ply seam causes failure of the liner ply and allows removal
of the dough product from the can. The label ply is thus designed to provide a substantial
component of the total strength of the can necessary to prevent the can from prematurely
opening. Exposure of the paperboard ply, which has a low wet strength, makes the strength
of the label ply even more critical.
[0009] U.S. Patent No. 6,290,119 to Reese et al. ("Reese"), commonly assigned and incorporated
herein by reference, discloses a composite container
10 having a polymer film label ply. As shown in Figure 1 of Reese, the composite container
includes a tubular body ply
12, a liner ply
13 adhered to the inner surface of the tubular body ply, and a film label ply
14 adhered to the outer surface of the tubular body ply. A pair of end closures
16,
18 are secured to opposite ends of the composite container.
[0010] During assembly, the liner and tubular body plies are wound around a mandrel
26, as shown in Figure 6 of Reese. The film label ply includes reverse-printed indicia
and a heat-sealing adhesive coating on its inner surface. The film label ply is passed
through a heater
44 which activates the adhesive coating. Once heated, the film label ply is applied
to the outside of the body ply so as to form a continuous tube. The continuous tube
is cut into discrete lengths in register to label graphics at a cutting station
48, one end closure is applied to each of the discrete lengths for shipping to, and
later filling and application of the second end closure at, the customer.
[0011] Advantageously, the film layer increases the gloss of the label ply and protects
the indicia applied to its inner surface. In addition, the film label ply is relatively
strong and isolates the body ply from moisture to prevent premature opening of the
can. Despite these advantages, additional improvements in the strength, durability
and protective ability of composite cans are highly desirable.
[0012] Therefore, it would be advantageous to have a composite can that protectively contains
perishable food items and isolates the food items from the environment. It would be
further advantageous if the can had a glossy outer surface bearing indicia so as to
be easily handled and attractive to consumers. It would be further advantageous if
the composite can had an outer ply that provides additional strength to the can and
inhibits premature opening of the can.
BRIEF SUMMARY OF THE INVENTION
[0013] The present invention addresses the above needs and achieves other advantages by
providing a container for protectively encapsulating a product, such as a perishable
food product, during shipment and display. The container includes a tubular body constructed
of a composite sheet material and defining a receptacle for receiving the food product.
An outer surface of the body defines an edge surrounding an entrance of the receptacle.
An end closure abuts the edge of the tubular body so as to extend over the entrance.
Extending over the end closure and the outer surface of the body is a polymeric film
sleeve. The polymeric sleeve has a glossy outer surface, and durable, appealing graphics
through reverse printing on its interior surface. An adhesive can be used to seal
the film sleeve to the end closure, or to seal the film sleeve to both the end closure
and the body, so as to hermetically seal a juncture between the end closure and the
body. Opening of the container may be facilitated by laser scoring a spiral liner
score line onto the film sleeve that extends only partially through the film sleeve
to preserve its barrier properties. Alternatively, a tear strip or notch may be incorporated
on the edge of film which may have a spiral or linear tear preference.
[0014] In one embodiment, the present invention includes a container for protectively encapsulating
a product during shipment. The container includes a body, at least one end closure,
a film sleeve and an adhesive. A receptacle is defined within the body and the body
includes an outer surface. The outer surface of the body defines an edge surrounding
an entrance of the receptacle. The receptacle and the entrance are sized and shaped
to receive the product. Abutting the edge of the body is the end closure which extends
over the entrance of the receptacle. The end closure includes an outer end closure
surface wherein adjacent portions of the outer end closure surface and outer body
surface form a juncture. The film sleeve covers the body and extends over the juncture
between the body and outer end closure surfaces. The adhesive adheres the film sleeve
to the outer surface of at least the end closure so as to seal the juncture between
the end closure and the body.
[0015] In another embodiment, the present invention includes a container for protectively
encapsulating a perishable food product during shipment and display. The container
includes a tubular body constructed of a composite sheet material including a body
ply and an inner liner ply. Also, the tubular body has an outer surface and defines
a cylindrical receptacle having a pair of opposing end entrances. Defined by the outer
surface of the body is an edge that surrounds each entrance to the cylindrical receptacle.
The cylindrical receptacle and at least one of the entrances are sized and shaped
to receive the perishable food product. An end closure is shaped to abut the edge
of the tubular body and extend over one of the entrances of the cylindrical receptacle.
The end closure includes an outer end closure surface wherein adjacent portions of
the outer end closure surface and outer body surface form a juncture. A film sleeve
covers the body and extends over the juncture between the body and the outer end closure
surfaces.
[0016] In another aspect, the end closure has a circular shape and is sized to abut the
circular shaped edge defining the entrance to the receptacle. The other end of the
tubular body also has a circular shape and the container includes a second end closure
having a circular shape. The second end closure is sized to abut the circular shaped
edge of the other end of the tubular body. Similar to the first end closure, the second
end closure has an outer end closure surface with a portion adjacent to a portion
of the outer body surface so as to form a second juncture. The film sleeve extends
over the second juncture and the adhesive adheres the sleeve to at least the outer
surface of the second end closure. Additionally, the film sleeve may be adhered to
the outer body surface.
[0017] In yet another aspect, the outer ply is a paperboard ply and the inner liner ply
is at least partially impermeable to fluids, gasses and vapors. The inner liner ply
may include a metal foil, or a metalized film layer.
[0018] The adhesive may include several types of material. Preferably, the adhesive is an
ethylene acrylic acid dispersion. Optionally the adhesive may be any one of a number
of materials such as a latex acrylic, an ionomer dispersion, a heat-activated urethane,
a heat-activated acrylic or a heat activated PVDC (polyvinylidene dicholoride). The
film sleeve may also be constructed of different types of materials such as oriented
polyethylene terephthalate, oriented polypropylene, oriented polyvinyl chloride or
oriented polystyrene or oriented polyethylene terphthalate glycol. A perforation or
score line may also be defined by the sleeve to facilitate opening of the container,
wherein the sleeve extends between the ends of the body. The score line may be accompanied
by a tear strip to further facilitate opening of the container, or a blank container
may have an eyespot line along the body ply seam that is used to register the scored
film line to the body ply seam. Preferably, the film sleeve is shrink-fit onto the
end closures and the body so as to create a hermetic seal between the film and the
end closures.
[0019] In still another aspect, coupons or game pieces may be incorporated under or inside
the film sleeve, especially between the film sleeve and one of the end closures.
[0020] Among the advantages of the present invention is the benefit of a container hermetically
sealed by a shrink wrapped, polymeric sleeve, and adhesive applied thereto, against
the passage of gasses, vapors and fluids that might contaminate the products, such
as perishable foods, enclosed therein. This is especially useful in refrigerated environments
that are moist and can discolor, or cause mildew to grow on, the paperboard or other
materials of the tubular body. In addition, the polymeric sleeve has an increased
ability to contain internal pressures and guard against premature opening as compared
to conventional labels. Generally, the container can be manufactured at a lower cost
than conventional composite containers having fluid permeable outer labels. For instance,
the increased strength of the sleeve, and its ability to block the passage of fluids
that weaken the tubular body plies allows the use of generally weaker (and less expensive)
paperboard and liner materials. Further, the polymeric sleeve is generally cheaper
to manufacture than conventional containers having multiple foil layers, such as an
outer label constructed of a foil material. The advantage of shifting application
of the polymeric sleeve to the filler is that there is no need to stock multiple types
of printed cans at the filler. Each can is labeled as it is filled, allowing quick
changes for short-run promotions.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0021] Having thus described the invention in general terms, reference will now be made
to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
Figure 1A is a perspective view of a composite container of one embodiment of the
present invention;
Figure 1B is a sectional view of the composite container shown in Figure 1A demonstrating
a film label sleeve sealed over a crimped end closure and body of the composite container
using an adhesive;
Figure 2 shows an enlarged sectional view of the film label sleeve shown in Figures
1A and 1B;
Figure 3 is a fragmentary and enlarged view of the film label sleeve shown in Figures
1A and 1B demonstrating graphical matter on at least a portion of its inner surface;
Figure 4 is a reverse fragmentary and enlarged view of a film label sleeve of another
embodiment of the present invention demonstrating graphical matter and the adhesive
in a dot pattern on an inner surface of the film label sleeve;
Figure 4A is an enlarged view of the adhesive in a dot pattern on the inner surface
of the film label sleeve shown in Figure 4;
Figure 4B is an enlarged view of an adhesive on the inner surface of the film label
sleeve in a strip pattern of another embodiment of the present invention;
Figure 5 is a greatly enlarged sectional view of the adhesive in a dot pattern taken
along line 5-5 of Figure 4A;
Figure 6 is a plan view illustrating a method for making a tubular body of the composite
container shown in Figure 1A;
Figure 7 is a front elevation view of a sleeving machine for applying the film label
sleeve around the filled and capped tubular body to form the composite container shown
in Figure 1A; and
Figure 8 is a side elevation view of the sleeving machine of Figure 7 including a
film sleeve supplier.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present inventions now will be described more fully hereinafter with reference
to the accompanying drawings, in which some, but not all embodiments of the invention
are shown. Indeed, these inventions may be embodied in many different forms and should
not be construed as limited to the embodiments set forth herein; rather, these embodiments
are provided so that this disclosure will satisfy applicable legal requirements. Like
numbers refer to like elements throughout.
[0023] The present invention includes a sealed, composite container
10 for protectively encapsulating a consumer product during shipment and display, as
shown in Figure 1A. The container includes a tubular body
11 constructed of a composite sheet material, which in the illustrated embodiment includes
a body ply
12, and an inner liner ply
13 adhered to the inner surface of the body ply. The tubular body
11 has a pair of open ends
14, the open ends being covered by a pair of end closures
15,
16. A film ply or sleeve
17 extends over the outer surface of the body ply
12 and further over a juncture
18, or seam, between the body
11 and the end closures
15, 16.
[0024] Although illustrated as having a circular cross-section, the tubular body
11 may have any cross-sectional shape which can be formed by wrapping the composite
sheet material around an appropriately shaped mandrel. One example is a generally
rectangular shaped tubular body having rounded comers. The container
10 of the present invention is particularly advantageous when used to encapsulate perishable
goods that should be isolated from the environment to ensure freshness, such as dough
or potato crisps. The container
10 of the present invention may also be used to encapsulate other consumer products
that are sensitive to the environment, such as tennis balls or grass seed.
[0025] The body ply
12 of the composite container
10 of one embodiment of the present invention is preferably formed of a paperboard material.
The film sleeve
17 is adhered to the outer surface of either, or both, of the end closures
15, 16. Optionally, the film sleeve
17 is adhered to the outer surface of the body ply
12 and extends over the end closures
15,16. Adherence of the film sleeve
17 to the paperboard material of the body ply
12 seals the tubular body
11 against the passage of liquids, gasses and vapors. Adhering the film sleeve
17 to both of the end closures
15,16 seals each juncture
18 against entrance or exit of fluids, vapors and gasses. Preferably, extension of the
film sleeve
17 over the body ply
12 and each juncture
18 is combined with fluid, gas and vapor impermeable end closure
15, 16 materials. For instance, the end closure materials may include a metal, such as a
tin-free chrome plated steel, or a barrier plastic sufficiently strong to withstand
external and internal pressures on the container
10. In this manner, the entire container
10 can be hermetically sealed against the environment to provide improved protection
for the perishable food product enclosed therein.
[0026] The film sleeve
17 is preferably constructed of a polymeric material that can either be transparent
or opaque, and includes an inner surface
17A and an outer surface
17B, as shown in Figure 3. One type of film sleeve
17 that can be used is oriented polyvinylchloride (PVC) that has an attractive gloss
and predictable tear characteristics, such as 200 gauge, SR-AE PVC film from Bonset
America Corporation of Browns Summit, NC. During formation, oriented polypropylene
is stretched a number of cycles in a machine direction and different number of cycles
in a cross-machine direction under selected heating conditions. Such differential
stretching gives the material a preferred orientation that promotes predictable tearing
patterns facilitating its use as an outer ply in dough containers that must be split
open. Other materials that may be used for film sleeve 17 include oriented polyethylene
terephthalate, oriented polyethylene terephthalate glycol, oriented polypropylene,
oriented polystyrene and laminates thereof.
[0027] In one embodiment, the inner surface
17A of the film sleeve
17 is printed with graphical matter
20, such as product information, package opening instructions, and regulatory compliance
information. The graphical matter is preferably printed on the inner surface
17A of the film sleeve
17, instead of on the outer surface
17B of the film sleeve, by a reverse printing process. Reverse printing the graphical
matter
20 on the inner surface
17A of the film sleeve, which is adhered to the outer surface of the body ply
12, advantageously protects the graphical matter from exposure to outside elements.
The graphical matter
20 can be rotogravure or flexographically printed, with an overlacquer (not shown) included
over the graphical matter to further protect its ink. Generally, the overlacquer is
not necessary on reverse printed film sleeves and labels.
[0028] As shown in Figure 4, the inner surface
17A of the film sleeve
17 also preferably includes an adhesive
22 for adhering the film sleeve to the outer surface of the body ply
12 and the end closures
15,16. The adhesive
22 is preferably an ethylene acrylic acid dispersion which is a water-based adhesive
that bonds well to both metal, paperboard and films. Additional adhesives that may
be used include temperature-activated urethane and acrylic heat seal coatings, and
cold seal coatings which are activated by pressure. Still other adhesive compositions
that can be used include a latex acrylic which bonds well to plastic as a cohesive
material, or an ionomer which is an acid polymer revitalized with a metal salt.
[0029] The adhesive
22 can be applied to the entire inner surface
17A of the film sleeve
17 and over the printed graphical matter
20 as shown in Figure 2. Alternatively, the adhesive
22 can be applied to a portion of the inner surface
17A of the film sleeve
17 in a pattern of dots
23, as shown in Figure 4A, or in a pattern of strips
24, as shown in Figure 4B. The adhesive strips may also be printed in an angular pattern
as is prompted by the helical construction of the tubular body
11 so as to influence or enhance the tear properties of the film sleeve
17. Further, the adhesive may be applied in a continuous strip at the edges of the film
for adhesion to the metal end closures
15,16. As shown in Figures 2 and 5, the adhesive
22 is disposed on the inner surface
17A of the film sleeve
17, but over the reverse-printed graphical matter
20. An adhesive could also be separately applied to the body ply
12 and the film sleeve
17 during manufacture such as with rollers and the like. For example, adhesion can be
promoted by applying the ethylene acrylic acid to both the body ply
12 and the film sleeve
17.
[0030] Figures 6-8 illustrate a method of making a multiple ply composite tubular body for
use in the present invention. A continuous strip of body ply
12 (preferably a paperboard ply) is advanced toward a shaping mandrel
26. As the body ply
12 is advanced toward the shaping mandrel
26, the body ply is advanced through a wet-bond adhesive applicator
28 which applies an adhesive
30 to the inner surface of the body ply, as shown in Figure 6. The liner ply
13 is also continuously advanced toward the shaping mandrel
26 as a lubricant from a roller
38 is applied to its inner face. The optional lubricant allows the liner ply
13 to slide smoothly along the mandrel
26. The liner ply
13, which is preferably constructed of a heat sealable material, is heated by an air-knife
heater (not shown) causing it to become sealed to itself as it is wound around the
mandrel
26. The mandrel may be chilled to promote the self sealing of the liner ply
13.
[0031] It will be understood to those skilled in the art that various liner constructions
with various barrier materials or properties could be employed depending upon the
item being packed in the composite container
10. The liner ply
13 may be wider than the body ply
12 depending upon the amount of liner overlap that is desired.
[0032] The body ply
12/liner ply
13 laminate is then wrapped around the shaping mandrel
26. The laminate is first wrapped under the mandrel
26 and then back over the top in a helical fashion with the liner ply
13 wound against the surface of the mandrel
26. As the body ply
12/liner ply
13 laminate advances back under the mandrel
26 after one complete revolution, its trailing edge is brought into contact with the
leading edge of the ensuing portion of the body ply/liner ply laminate, which is first
coming into contact with the mandrel. The edges become abutted together to form a
continuous, spirally wound tube that advances along the mandrel
26.
[0033] The tube is then advanced down the mandrel
26 by a winding belt
40 that extends around a pair of opposed pulleys
42. The winding belt
40 not only rotates and advances the tube, but applies pressure to the overlapping edges
of the body ply
12 and the liner ply
13 to ensure a secure bond between the respective ply edges. Instead of the "same side
winding" process described above, however, the body ply
12 and liner ply
13 could be brought together at the mandrel
26 from opposite sides of the mandrel in a process known as "opposite side winding."
The pressure of the winding belt
40 causes the body ply
12 and liner ply
13 to be adhered together. After the body ply and liner ply are adhered together on
the mandrel
26, the continuous tube is cut into discrete lengths at a cutting station
48 and then removed from the mandrel. Each discrete length, i.e., each tubular body
11 has one end
15 attached and then may be filled with dough, or other consumer products. The filled
body then has its second end
16 attached by crimping one or both end closures
15,16, as illustrated in Figure 1B, or in a manner well-known in the art, such as by conventional
double-seam end application.
[0034] Once the tubular body
11 has been filled with product, and the end closures
15,16 have been applied (typically, one of the ends has been applied before filling), the
tubular body is ensleeved by a continuous feed sleeving machine
50, as shown in Figure 7. The sleeving machine is fed by an input conveyor
74 or other conventional feeding apparatus. The filled tubular bodies may be transported
in a single-file fashion or via a flood feed. The tubular body
11 is picked up by a timing screw
70 at one of its furrows, so that only one tubular body is transported to a pedestal
system
64 at any one time. The timing screw
70 is constructed so as to engage the tubular body
11 at its center of mass so that there are few torques upon the tubular body. The tubular
body may be trapped between the timing screw
70 and a rail or guard on the opposite side. The tubular body
11 is then moved onto a pedestal
66 of the pedestal system
64.
[0035] As the filled tubular body 11 makes its transition onto the pedestal
66, a sleeved iris carrier
54 moves synchronously with the tubular body. As the tubular body
11 travels on the pedestal system
64, the iris carrier
54 with its film sleeve
17 (not shown in Figure 7 for clarity) descends about the tubular body. As the iris
carrier
54 approaches the middle portion of the tubular body
11, the film sleeve 17 is disposed about the tubular body
11, end closure
15 and end closure
16. Fingers present on the iris carrier
54 contract, causing the top of the sleeve
17 to engage the exterior of the filled tubular body
11. The film sleeve
17 begins to adhere to the sides of the tubular body
11 by friction fit and by the cold, minimally tacky adhesive
20 applied thereon.
[0036] The fingers of the iris carrier
54 are generally smooth to provide a low-friction surface engaging the interior surface
of the film sleeve
17. As the sleeve slightly adheres to the side of the tubular body
11, the iris carrier
54 and its sleeve-carrying fingers begin to disengage the sleeve
17, leaving it behind on the tubular body. As the iris carrier
54 continues to descend towards the bottom of the tubular body
11, having either the end closure
15 or end closure
16 attached thereto, the fingers increasingly disengage the sleeve, leaving it to circumscribe
the exterior of the tubular body and the end closures.
[0037] The iris carrier
54 descends until the sleeve-carrying fingers completely disengage the sleeve
17. At this point, the fingers then dilate, moving outward to expand the central aperture
of the iris carrier
54 and the iris carrier begins its upward ascent about the tubular body
11 from its base to its top. In so traveling, the iris carrier
54 may help the tubular body
11 make the transition from the pedestal system
64 to the exit conveyor
76. Once the iris carrier
54 has fully disengaged the tubular body
11 by ascending past its top, the iris carrier is ready to receive another sleeve from
a sleeve feeder
52.
[0038] It should be noted that the embodiment of the sleeving machine
50 described above is considered to be exemplary. Other apparatuses known to those of
skill in the art may also be employed and still achieve the objective of positioning
the sleeve
17 about the filled tubular body
11 and the end closures
15, 16.
[0039] The sleeving machine
50 is continuously supplied with tubular film sleeves each having an opening therethrough
sized to receive the tubular body
11 and a length greater than the tubular body. Preferably, the length of the "un-shrunk"
film sleeve
17 is sufficient to also extend past the end closures
15, 16 attached to the ends of the tubular body
11. The tubular film sleeves may be supplied in a number of ways known to those of skill
in the art. For example, the sleeve feeder
52 includes a stepper motor
104 that controls a nip roller
106 that receives a ribbon
108 of pre-printed, adhesived sleeve material, as shown in Figure 8. The ribbon
108 is held on one, or more, spools
112 each mounted on a shaft
116 which is supported by a stand
114. The nip roller
106 controls the travel of the unspooled ribbon
108 into the sleeving machine
50. The stepper motor
104 controls the length and rate of travel of the ribbon
108. The stepper motor
104 causes the ribbon to pause briefly so that it may be cut by a guillotine-type cutter.
As a discrete sleeve
17 is being cut, it is engaged and opened by a pair of sleeve feeding arms
120 which release it onto the iris carrier
54.
[0040] The ribbon
108 is constructed of a continuous sheet of polymeric material. The graphical matter
20 is pre-printed on the sheet's inner surface. The adhesive
22 is also applied to the inner surface of the polymeric sheet material, but over the
graphical matter. The adhesive
22 is gravure-applied continuously, or in a pattern, depending upon the portions of
the tubular body
11, closure
15 and end closure
16 to which the sleeve
17 is meant to adhere. Other methods of applying the adhesive
22 and graphical matter
20, and the machines for such application, are known to those of skill in the art and
are therefore not described herein in further detail. The sheet of polymeric material
is then shaped into a tube, flattened and wound into spools
112 as is also known to those of skill in the art.
[0041] Once the sleeve
17 has been disposed over the tubular body
11, the filled tubular body and its sleeve is advanced into a heat tunnel. The heat
tunnel generates heat, such as through the use of resistive heating elements and laminar
airflow, or the generation of steam, that causes the sleeve
17 to shrink about the tubular body
11 and end closures
15,16. In addition to causing the polymeric material of the sleeve
17 to shrink, the heat causes the temperature of the adhesive
22 to rise and become tacky. Once tacky, the adhesive causes the sleeve
17 to adhere to a portion of the outer surfaces of the end closures
15,16. Closely adhering the fluid and gas impermeable sleeve
17 to the end closures
15,16, which are also preferably constructed of fluid, vapor and gas impermeable materials,
hermetically seals the composite container
10. Optionally, the adhesive
22 can be applied over the juncture between the end closures
15,16 and the body ply
12, for additional barrier protection. Further optionally, the adhesive can be applied
to the entire inner surface
17A of the film sleeve
17, for even more barrier protection and/or body ply strength enhancement.
[0042] As yet another option, the polymeric sleeve
17 may be scored, such as during or after application of the sleeve, to facilitate opening
of the container
10, as shown in Figure 1A. For instance, a double-line peel tab
122 may be positioned at one end of the container
10. Extending from the peel tab
122 is a parallel set of score lines
124 that generally follow the directional tearing tendency of the polymeric material,
especially if it is oriented material such as OPP, extending in the direction of the
other end of the container
10. The score lines
124 may be formed by a conventional cutting apparatus, or are preferably formed using
a laser that can cut the polymeric sleeve
17 material to a half depth, thereby preserving its barrier properties.
[0043] The score lines
124 may also be registered with the seam between the abutting edges of the spirally wound
plies
12, 13 of the tubular body
11. During the sleeving operation, registration of the score lines
124 with the seam of the body
11 can be facilitated by marking spots on the body ply
12. These "eye spots" are positioned along one of the edges of the body ply
12 material and allow the use of a sensor to track the ply edges and register them with
the score lines
124. Other score line configurations may also be used, such as a single, linear score
line between the ends of the container
10, or multiple score lines without the use of a peel tab. The peel tab
122 could also be combined with a thickened strip of polymeric material extending between
parallel score lines
124 to further facilitate opening of the container
10. As yet another option, the peel tab
122 could be employed without the score lines
124 and be initiated with starter notches.
[0044] Among the advantages of the present invention is the benefit of a container
10 hermetically sealed by a shrink wrapped, polymeric sleeve
17, and adhesive
22 applied thereto, against the passage of gasses, vapors and fluids that might contaminate
the products, such as perishable foods, enclosed therein. This is especially useful
in refrigerated environments that are moist and can discolor, or cause mildew to grow
on, the paperboard or other materials of the tubular body
11. In addition, the polymeric sleeve
17 has an increased ability to contain internal pressures and guards against premature
opening. The container
10 can be manufactured at a lower cost than conventional composite containers. For instance,
the increased strength of the sleeve
17, and its ability to block the passage of fluids that weaken the tubular body plies
12,13 allows the use of generally weaker (and less expensive) paperboard and liner materials.
The container with the polymeric sleeve
17 is also cheaper to manufacture than conventional containers having foil layers, such
as an outer label constructed of a foil material. The polymeric sleeve
17 has a glossy outer surface, and durable, appealing graphics through reverse printing
on its interior surface. The polymeric sleeve
17 allows flexibility with selected opening methods, such as the peel tab
122 and dual score lines
124.
[0045] Many modifications and other embodiments of the inventions set forth herein will
come to mind to one skilled in the art to which these inventions pertain having the
benefit of the teachings presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the inventions are not to be limited
to the specific embodiments disclosed and that modifications and other embodiments
are intended to be included within the scope of the appended claims. For instance,
the polymeric film could be adhered over the tubular body
11, the closure
15 and the end closure
16 by being spirally wound similar to the construction of the plies of the tubular body,
and then heat shrunk. However, sleeved application of the polymeric material generally
has improved barrier properties for blocking the passage of fluids and gasses into,
and out of, the container
10. Although specific terms are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
1. A container for protectively encapsulating a product during shipment, said container
comprising:
a tubular body constructed of a composite sheet material and including an outer body
surface, said body defining therein a receptacle, said outer surface of the body defining
an edge surrounding an entrance of the receptacle, said receptacle and entrance sized
and shaped to receive the product;
a end closure shaped to abut the edge of the body and extend over the entrance of
the receptacle, said end closure including an outer end closure surface wherein adjacent
portions of the outer end closure surface and outer body surface form a juncture;
a film sleeve covering the body and extending over the juncture between the body and
outer end closure surfaces; and
an adhesive adhering the film sleeve to the outer surface of at least the end closure
so as to seal the juncture between the end closure and the film.
2. A container of Claim 1, wherein the body has a tubular shape including a pair of opposed
ends, at least one of the ends having a circular shaped edge defining the entrance
to the receptacle.
3. A container of Claim 2, wherein the end closure has a circular shape and wherein the
end closure abuts the circular shaped edge.
4. A container of Claim 3, further comprising a second end closure having a circular
shape, wherein the second end closure abuts a circular shaped edge of the other end.
5. A container of Claim 4, wherein the second end closure has an outer end closure surface
with a portion adjacent to a portion of the outer body surface so as to form a second
juncture.
6. A container of Claim 5, wherein the film sleeve extends over the second juncture and
wherein the adhesive adheres the film sleeve to the outer surface of the second end
closure.
7. A container of Claim 1, wherein the composite material includes multiple plies.
8. A container of Claim 7, wherein the multiple plies include an inner liner ply and
an outer paperboard ply.
9. A container of Claim 8, wherein the inner ply is at least partially impermeable to
fluids.
10. A container of Claim 8, wherein the inner ply is at least partially constructed of
a metal foil.
11. A container of Claim 7, wherein the inner ply is a metalized film.
12. A container of Claim 1, wherein the adhesive is an ethylene acrylic acid dispersion.
13. A container of Claim 1, wherein the adhesive is any one of a latex acrylic, an ionomer,
a heat-activated urethane, a heat-activated PVDC and a heat-activated acrylic material.
14. A container of Claim 1, wherein the film sleeve includes at least one ply of a polyethylene
terephthalate, oriented polypropylene, oriented PVC, oriented polystyrene and oriented
polyethylene terephthalate glycol materials.
15. A container of Claim 1, wherein the film sleeve defines a score line extending between
the ends of the body.
16. A container of Claim 15, wherein the score line penetrates only a portion of the thickness
of the film sleeve.
17. A container of Claim 16, wherein the score line is in registration with a seam in
the composite sheet material.
18. A container of Claim 1, wherein the film sleeve defines a pair of parallel score lines
and further includes a peel tab between the pair of parallel score lines.
19. A container of Claim 18, wherein the score line penetrates only a portion of the thickness
of the film sleeve.
20. A container of Claim 1, wherein the adhesive also adheres the film sleeve to the outer
body surface.
21. A container of Claim 1, wherein the film sleeve is shrink-fit onto the end closure
and body.
22. A container for protectively encapsulating a perishable food product during shipment
and display, said container comprising:
a tubular body constructed of a composite sheet material including an body ply and
an inner liner ply, said tubular body having an outer surface and defining a receptacle
having a pair of opposing end entrances, said outer surface of the body defining an
edge surrounding each entrance of the receptacle, wherein said receptacle and at least
one of the entrances are sized and shaped to receive the product;
an end closure extending over one of the entrances of the receptacle and abutting
the edge of the entrance, said end closure including an outer end closure surface
wherein adjacent portions of the outer end closure surface and outer body surface
form a juncture;
a second end closure extending over, and fixed to, the other one of the entrances
of the receptacle and abutting the edge of the entrance, said second end closure including
an outer closure surface wherein adjacent portions of the outer closure surface and
outer body surface form a second juncture;
a film sleeve extending over the outer surface of the tubular body, the junctures
and onto the outer surfaces of the end closures, said film sleeve adhered to at least
the outer surfaces of the end closures.
23. A container of Claim 22, further comprising an adhesive adhering the film sleeve to
the outer surfaces of the end closures.
24. A container of Claim 23, wherein the adhesive is an ethylene acrylic acid.
25. A container of Claim 23, wherein the adhesive is any one of a latex acrylic, an ionomer,
a heat-sealing urethane and a heat-sealing acrylic materials.
26. A container of Claim 22, wherein the inner liner ply is fluid resistant and the body
ply is constructed of a paperboard material.
27. A container of Claim 22, wherein the inner ply is at least partially constructed of
a metal foil.
28. A container of Claim 22, wherein the inner ply is a metalized film.
29. A container of Claim 22, wherein the film sleeve includes at least one ply of a polyethylene
terephthalate, oriented polypropylene, oriented PVC, oriented polystyrene and oriented
polyethylene terephthalate glycol materials.
30. A container of Claim 22, wherein the film sleeve defines a seam extending between
the ends of the body.
31. A container of Claim 22, wherein the film sleeve defines a score line extending between
the ends of the body.
32. A container of Claim 31, wherein the score line penetrates only a portion of the thickness
of the film sleeve.
33. A container of Claim 31, wherein the score line is in registration with a seam in
the composite sheet material.
34. A container of Claim 22, wherein the film sleeve defines a pair of parallel score
lines and further includes a peel tab between the pair of parallel score lines.
35. A container of Claim 34, wherein the score line penetrates only a portion of the thickness
of the film sleeve.
36. A method of manufacturing a container having a composite tubular body and an outer
polymeric sleeve, said method comprising:
applying an end closure to one end of the composite tubular body;
applying an adhesive to at least one of an inner surface of the polymeric sleeve and
an outer surface of the composite tubular body;
sleeving the polymeric sleeve about the composite tubular body and over the end closure;
and
adhering the polymeric sleeve to the end closure of the composite tubular body so
as to hermetically seal the container.
37. A method of Claim 36, further comprising applying a second end closure to another
end of the composite tubular body after applying the end closure and wherein adhering
the polymeric sleeve includes adhering the sleeve to the end closure.
38. A method of Claim 36, wherein adhering the polymeric sleeve includes heating the polymeric
sleeve and shrinking the polymeric sleeve onto the composite tubular body, end closure
and end closure and heating the adhesive until tacky.
39. A method of Claim 36, further comprising scoring the polymeric sleeve.
40. A method of Claim 39, wherein scoring includes laser scoring the polymeric sleeve
to a depth that is only a portion of the thickness of the polymeric sleeve.
41. A composite container for products, comprising:
a tubular body of wound sheet material including at least one structural paperboard
ply, the body having an open end;
an end closure affixed to the body so as to close the open end, the end closure having
an outer surface extending adjacent to an outer surface of the body; and
a sleeve of polymer film encircling the body so as to fully cover the outer surface
thereof, the sleeve also extending onto the outer surface of the end closure so as
to substantially seal a juncture between the end closure and the body against passage
of fluid.