Packaging, Packaged Products, and Methods of Use

Abstract

A packaging article includes a lid having a peel-initiate region, a remaining portion, and a lid-flange portion. The packaging article further includes a tray. The tray includes a rigid component and a cushioning component, the cushioning component including a cushion-flange portion. The packaging article further includes an adhesive region, the adhesive region including a seal between the peel-initiate region and the cushioning component. The lid-flange portion includes a peel-initiate region and a remaining portion. The adhesive region includes the cushion-flange portion and the lid-flange portion of the peel-initiate region. Furthermore, the adhesive region includes 90% or less of the peel-initiate region.

Description

Technical Field

[0001] The present invention relates generally to packaging and, in particular, to packaging that facilitates separation of packaging portions for more environmentally friendly disposal. The present invention also relates to packaging products including such packaging and methods of using such packaging. Background Art

[0002] Conventional packaging includes recyclable components (such as base trays) and non-recyclable components (such as polymer liners). Base trays with polymer liners have been used in various applications. These applications include packaging for various items, including industrial or consumer products and food. Base trays have the advantages of low cost, light weight, recyclability, thermal insulation, a tangible feel, and high rigidity. Polymer liners are added to enhance the physical properties of the base tray, including sealing properties, moisture resistance, gas barrier properties, resistance to grease and fragrances, and durability. Currently, polymer liners are insufficient in recyclability, so that the polymer liners must be separated from the base tray to facilitate recycling of the base tray.

[0003] Often manual separation can be difficult or result in excessive amounts of the recyclable component (i.e., base tray) and / or non-recyclable component (i.e., polymer liner) remaining adhered to each other after separation. Thus, as the difficulty of separating the two components increases, the likelihood that the recyclable component will be recycled decreases. Summary of the Invention

[0004] A packaging has been developed that includes a tray having a rigid component and a cushioning component. The packaging facilitates separation of non-recyclable and recyclable packaging components, or recyclable and differentially recyclable packaging components, from one another after use. The packaging further includes a lid that includes a peel initiator portion and an adhesive region that includes a seal between the peel initiator portion and the cushioning component, such that the peel initiator portion allows separation of the cushioning component from the rigid component.

[0005] One embodiment of the present disclosure is a package comprising a lid, a tray, and an adhesive region. The lid comprises a peeling initiation zone portion, a remaining portion, and a lid-flange portion. The tray comprises a rigid component and a liner component, the liner component comprising a liner-flange portion. The adhesive region comprises a seal between the peeling initiation zone portion and the liner component. The lid-flange portion comprises a peeling initiation zone portion and a remaining portion. The adhesive region comprises the liner-flange portion, and the lid-flange portion of the peeling initiation zone portion. Further, the adhesive region comprises 90% or less of the peeling initiation zone portion.

[0006] In some embodiments, the liner-flange portion includes an edge including a non-linear edge portion, and the adhesion area includes the non-linear edge portion.

[0007] In some embodiments, the packaging includes a cushion bond strength between the rigid component and the cushion component, and a bond strength of the adhesive region, wherein the bond strength of the adhesive region is greater than the cushion bond strength.

[0008] In some embodiments, the peel initiation portion further includes an unadhered area adjacent to the adhered area.

[0009] In some embodiments, the peel initiation portion and the remaining portion are contiguous along a line of weakness.

[0010] In some embodiments, the rigid component comprises at least one of a semi-rigid polymer material, a rigid polymer material, a fiber-based component, and a formable paper.

[0011] In some embodiments, the rigid component comprises amorphous polyethylene terephthalate (APET).

[0012] In some embodiments, the pad component includes at least one barrier layer.

[0013] In some embodiments, the material of the rigid component and the material of the cushion component have different recycling profiles.

[0014] One embodiment of the present disclosure is a method of using the aforementioned method, comprising: providing the package; and grasping the peel initiation area of the cover to peelably separate the liner component from the rigid component.

[0015] One embodiment of the present disclosure is a package comprising a lid, a tray, and an adhesive region. The lid comprises a peel-start region portion, a remaining portion, and a lid edge. The tray comprises a rigid component and a liner component, the liner component comprising a liner edge. The liner edge comprises a nonlinear edge portion. The adhesive region comprises a seal between the peel-start region portion and the liner component. The lid edge comprises a peel-start region portion and a remaining portion. The adhesive region comprises the lid edge of the peel-start region portion and the nonlinear edge portion of the liner edge. Further, the adhesive region comprises 90% or less of the peel-start region portion.

[0016] In some embodiments, the packaging further comprises a cushion bonding strength between the rigid component and the cushion component, and a bonding strength of the adhesive region, wherein the bonding strength of the adhesive region is greater than the cushion bonding strength.

[0017] In some embodiments, the peel initiation region includes an unadhered area adjacent to an adhered area.

[0018] In some embodiments, the peel initiation portion and the remaining portion are contiguous along a line of weakness.

[0019] One embodiment of the present disclosure is a packaged product comprising a lid, a tray, an adhesive region, and a product. The lid comprises a peeling initiation zone portion, a remaining portion, and a lid-flange portion. The tray comprises a rigid component and a cushioning component, the cushioning component comprising an edge of the cushion-flange portion. The adhesive region comprises a seal between the peeling initiation zone portion and the cushioning component. The product is disposed within the tray. The lid-flange portion comprises a peeling initiation zone portion and a remaining portion. The adhesive region comprises the cushion-flange portion, and the lid-flange portion of the peeling initiation zone portion. Further, the adhesive region comprises 90% or less of the peeling initiation zone portion.

[0020] In some embodiments, the liner-flange portion includes an edge including a non-linear edge portion, and the adhesion area includes the non-linear edge portion.

[0021] In some embodiments, the packaged product includes a cushion bond strength between the rigid component and the cushion component, and a bond strength of the adhesive region, wherein the bond strength of the adhesive region is greater than the cushion bond strength.

[0022] In some embodiments, the peel initiation portion includes an unadhered area adjacent to an adhered area.

[0023] In some embodiments, the peel initiation portion and the remaining portion are contiguous along a line of weakness.

[0024] In some embodiments, the material of the rigid component and the material of the cushion component have different recycling properties.

[0025] There are several aspects of the subject matter that can be embodied individually or together. These aspects can be employed individually or in combination with other aspects of the subject matter described herein, and the description of these aspects together is not intended to exclude the use of these aspects individually or to claim such aspects individually or in different combinations. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The present disclosure may be more fully understood by considering the following detailed description of various embodiments of the present disclosure in conjunction with the accompanying drawings, in which:

[0027] Figure 1 A schematic perspective view of an embodiment of a packaging article is shown;

[0028] Figure 2 Shown Figure 1 A schematic top view of one embodiment of the package depicted in ;

[0029] Figure 3A cross-sectional view showing one embodiment of a packaged product;

[0030] Figure 4A A schematic top view illustrating one embodiment of a peel initiation area portion of a lid of a package;

[0031] Figure 4B a schematic top view illustrating one embodiment of a portion of a cushion edge of a cushion component of a wrapper;

[0032] Figures 5A to 5H Schematic top views showing various embodiments of peel initiation region portions having different adhesion areas;

[0033] Figures 6A to 6C Demonstrates exemplary methods of using the wrapper;

[0034] 7A to 7B schematic diagrams showing a tray and a liner member coupled to a lid after the tray and the liner member are separated;

[0035] Figures 8A to 8C Steps illustrating another exemplary method of using the package; and

[0036] Figures 9A to 9C An exemplary method of making a package is presented.

[0037] The accompanying drawings are not necessarily drawn to scale. Like reference numerals used in the accompanying drawings refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component labeled with the same number in another figure. DETAILED DESCRIPTION

[0038] This application describes a package comprising a lid, a tray, and an adhesive region. The lid comprises a peel-start region portion, a remainder portion, and a lid-flange portion. The tray comprises a rigid component and a cushioning component, the cushioning component comprising a cushion-flange portion. The adhesive region comprises a seal between the peel-start region portion and the cushioning component. The lid-flange portion comprises a peel-start region portion and a remainder portion. The adhesive region comprises the cushioning-flange portion and the lid-flange portion of the peel-start region portion. Further, the adhesive region comprises 90% or less of the peel-start region portion. The peel-start region portion of the lid can facilitate separation of the cushioning component from the rigid component after use of the package. Specifically, the peel-start region portion can allow a user to peelably separate the cushioning component from the rigid component after use, so that the cushioning component and the rigid component can be placed into appropriate waste and recycling streams. The peel-start region portion can allow the cushioning component of the package to be separated from the rigid component without any additional materials, equipment, or tools. Thus, the present disclosure may provide ease in recycling either the rigid or non-rigid components of a package if they are suitable for recycling.

[0039] Figure 1 An embodiment of a package 100 is shown in FIG. Figure 2 1 is a top view of the package 100 . Figure 3 2 is a cross-sectional view of a packaged product 200 , which includes a package 100 and a product 130 .

[0040] refer to Figures 1 to 3 The package 100 includes a package body 102 having a top portion 104, a bottom portion 106, and a side portion 108 connecting the bottom portion 106 to the top portion 104. The bottom portion 106 and the side portion 108 define a recessed cavity 110 (at Figure 3 ). The top portion 104 includes an opening 112 (in Figure 3 ), which provides access to the recessed cavity 110 .

[0041] The bottom portion 106 and the side portions 108 of the package body 102 comprise a tray 116 (hereinafter referred to as "tray 116") that is thermoformed. Specifically, the bottom portion 106 and the side portions 108 of the combination are in the form of a tray 116. The tray 116 can be any desired shape, such as, for example, a rectangle, square, circle or polygon, depending on both functional and aesthetic requirements. The tray 116 can be thermoformed to any depth as required, depending on the type and amount of the product 130 to be packaged. In the embodiment shown, the tray 116 comprises a recessed cavity 110. It should also be understood that the tray 116 can be configured to include two or more recessed areas (not shown), which again depends on both functional and aesthetic requirements of specific packaging applications.

[0042] The tray 116 includes a rigid component 117 and a cushioning component 119. The cushioning component 119 is arranged on the rigid component 117 so that the product 130 is arranged on the cushioning component 119. The rigid component 117 and the cushioning component 119 form the top portion 104, the bottom portion 106 and the side portion 108 of the package body 102. The rigid component 117 further includes a flange 123 in the top portion 104. The flange 123 is defined by the rigid component 117 and surrounds the opening 112 of the top portion 104. The cushioning component 119 includes a cushion-flange portion 121 and a cushioning edge 124. The cushion-flange portion 121 is a portion of the cushioning component 119 that includes (i.e., covers) the flange 123. In some embodiments, the material of the rigid component 117 and the material of the cushioning component 119 have different recycling properties, i.e., are made of different recyclable materials. In some cases, both the liner component 119 and the rigid component 117 may be recyclable in separate recycling streams. In some other cases, the liner component 119 may not be recyclable and may be disposed of in a waste stream. In other cases, the liner component 119 may be recyclable and the rigid component 117 may not be recyclable and may be disposed of in a waste stream.

[0043] In some embodiments, the rigid component 117 comprises at least one of a semi-rigid polymer material, a rigid polymer material, a fiber-based component, and a moldable paper. In a non-limiting example, the rigid component 117 comprises amorphous polyethylene terephthalate (APET). PET is a recyclable polymer resin. Semi-rigid and rigid are terms that refer to different levels of rigidity of the rigid component 117.

[0044] In some embodiments, the cushioning component 119 comprises a thermoformable cushioning component material designed to be applied to the rigid component 117 so that the cushioning component 119 can be removed from the rigid component 117, for example, to facilitate recycling of the rigid component 117. The cushioning component 119 can include at least one barrier layer to provide advantageous barrier properties, such as a low oxygen transmission rate (OTR) and / or a low moisture vapor transmission rate (MVTR). Other advantageous properties of the cushioning component 119 are that the material used to make the cushioning component 119 (or at least the portion that contacts the product) can be selected to minimize release of the cushioning component 119 into the package 100 or any unintentional contamination.

[0045] In some embodiments, the liner component 119 can be relatively thin (e.g., about 4 mils to about 8 mils, equivalent to a thickness of about 101.6 microns to about 203.2 microns) so that relatively little polymer resin is required to produce the liner component and the process of discarding the liner component results in relatively little waste. In the case of being composed of a mixture of polymer resins, the liner component 119 may actually be non-recyclable. However, the ability to peel the liner component 119 from the rigid component 117 means that the larger rigid or semi-rigid components 117 of the pallet 116 can be recycled, while only the relatively small (lower volume) liner component 119 may need to be discarded (or incinerated) as waste. In this way, removing the liner component 119 from the rigid components 117 of the pallet 116 can significantly reduce the amount and volume of waste that must be landfilled, incinerated, or otherwise disposed of.

[0046] The packaging material 100 further comprises a lid 122. The lid 122 is arranged on the top portion 104 of the liner-flange portion 121 and covers the opening 112. Specifically, the lid 122 is arranged on the liner component 119 of the tray 116. The lid 122 can be made of a polypropylene film coated with a pressure-sensitive adhesive on one side. In certain embodiments, the thickness of the lid 122 can change from about 20 microns to about 65 microns. In some cases, the lid 122 can be a multilayer film, that is, a film comprising more than one layer, and one of these layers can include a barrier material, such as ethylene vinyl alcohol copolymer (EVOH) or any other suitable barrier material. The lid 122 can have any suitable shape, for example, rectangular, square, polygonal, circular or oval, depending on both the functional and aesthetic requirements of the tray 116 that is applicable to correspondence.

[0047] In some embodiments, the material used in the cover 122 can be such that the cover 122 can be attached to the backing component 119 and can exhibit one or more properties required for the desired application (e.g., tensile strength, barrier properties, ability to bear printed or adhesive labels, and surface appearance). The material of the cover 122 and the material of the backing component 119 can be the same or different.

[0048] The cover 122 includes a peeling initiation area portion 125, a remaining portion 118, a cover-flange portion 114, and a cover edge 115. The cover-flange portion 114 includes the peeling initiation area portion 125 and the remaining portion 118. The cover-flange portion 114 corresponds to the portion of the cover 122 disposed above the liner-flange portion 121 in the flange 123 of the rigid component 117. Figures 1 to 3In the illustrated embodiment, the package 100 includes a single peel initiation area portion 125 disposed on the lid 122. However, in other embodiments, multiple peel initiation area portions 125 may be provided on the lid 122. The package 100 further includes an adhesive region 126. The adhesive region 126 includes the liner-flange portion 121 and the lid-flange portion 114 of the peel initiation area portion 125. Specifically, the adhesive region 126 includes a portion of the lid-flange portion 114 of the peel initiation area portion 125 and a portion of the liner-flange portion 121 disposed below the lid-flange portion 114. More specifically, the adhesive region 126 includes a portion of the lid edge 115 of the lid-flange portion 114 including the peel initiation area portion 125 and a portion of the liner-flange portion 121 including the liner edge 124. The adhesive region 126 includes a seal 127 between the peel initiation area portion 125 and the liner-flange portion 121. In other words, the peel initiation zone portion 125 and the liner-flange portion 121 are sealed to each other by a seal 127. The peel initiation zone portion 125 is disposed within the flange 123 of the rigid component 117. Therefore, the seal 127 is also provided within the flange 123 of the rigid component 117. The seal 127 can be formed using impulse, ultrasonic, pressure, or other seal-forming methods. In some embodiments, the seal 127 can be a heat seal formed by heating and compressing the adhesive region 126 of the lid 122 and a corresponding region of the liner-flange portion 121. In other embodiments, the seal 127 can be formed by an adhesive disposed between the adhesive region 126 and the liner-flange portion 121. In some cases, the adhesive region 126 can include the lid edge 115 and the liner edge 124. In other cases, the adhesive region 126 may not include the lid edge 115 or the liner edge 124. The peel initiation zone portion 125 can facilitate separation or peeling of the liner component 119 from the rigid component 117.

[0049] The remaining portion 118 is the portion of the lid 122 excluding the peel initiation area 125. In some embodiments, the remaining portion 118 is adhered or sealed to the gasket-flange portion 121 of the gasket component 119 or elsewhere using any suitable sealing method. A peelable seal can be formed between the remaining portion 118 of the lid 122 and the gasket-flange portion 121 in the flange 123 of the rigid component 117. The remaining portion 118 can be at least partially peeled from the gasket-flange portion 121 to provide access to the recessed cavity 110. In some embodiments, the remaining portion 118 is sealed to the gasket-flange portion 121 by a resealable seal. In some other embodiments, the remaining portion 118 is sealed to the gasket-flange portion 121 by a non-resealable seal. In some embodiments, the remaining portion 118 of the lid 122 can be attached to the gasket-flange portion 121 by a non-peelable seal (e.g., a fusion seal).

[0050] Peel-initiation area portion 125 and remaining portion 118 are adjacent along a line of weakness 120. In some embodiments, line of weakness 120 can be at least one of a score, a cut, and a perforation that can be positioned between peel-initiation area portion 125 and remaining portion 118. In some cases, line of weakness 120 can be formed by mechanical scoring or cutting. In some other cases, line of weakness 120 can be formed by laser scoring or cutting.

[0051] When opening the package 100, the lid 122 is initially removed (e.g., pulled, peeled) from the area of the tray 116 other than the peel initiation area portion 125, and the remaining portion 118 is separated from the peel initiation area portion 125 at the weakening line 120. In some cases, the remaining portion 118 of the lid 122 can be resealed based on application requirements. The weakening line 120 can thus allow the peel initiation area portion 125 to be attached to the liner-flange portion 121 at the adhesive area 126 without interfering with the normal use or opening of the package 100.

[0052] Can be used in various packaging applications for food and non-food items such as Figure 1 and Figure 3100 shown in the packaging material 200. Specifically, the product 130 in the packaged product 200 can be a food item or a non-food item. For example, the packaging material 100 can be used as a creamer cup, a pudding cup, a meat tray, etc. The packaging material 100 can promote the recycling of relatively small packaging materials, such as single-portion packaging materials of beverage ingredients (for example, coffee powder or tea) or condiments (for example, dipping sauce, milk, cream or non-dairy creamer). Due to the small volume of these packaging materials and the relative difficulty of manually peeling off the bound liner components from these packaging materials, users may choose to give up recycling these packaging materials. The packaging material 100 can make it easy to peel off the liner components 119 from small packaging materials, and thus encourage the recycling of the recyclable parts of such packaging materials. The packaging material 100 can also be used together with medium and large packaging materials for accommodating various items, and various items are, for example, cheese, sliced cheese, sliced meat, cut meat, poultry, medical supplies or components, industrial components, etc.

[0053] Figure 4A The peel initiation area portion 125 of the cover 122 is shown. Figures 1 to 4A, a peel initiation region portion 125 of the lid 122 and the remaining portion 118 are adjacent along a line of weakness 120. The peel initiation region portion 125 includes an adhesive area 126 that includes a seal 127. In some embodiments, the adhesive area 126 comprises approximately 90% or less of the peel initiation region portion 125. In some other embodiments, the adhesive area 126 includes a seal 127 that includes the lid edge 115 and the liner edge 124. The peel initiation region portion 125 further includes an unadhered region 129 adjacent to the adhesive area 126. The unadhered region 129 of the lid 122 can be detached from the liner component 119 (e.g., devoid of adhesive, not adhered to adhesive, not bonded by adhesive). It should be understood that the unadhered region 129 of the lid 122 can include a low level of adhesion to the liner component 119, e.g., 100 g / 25.4 mm or less. In these cases, the manufacturing operation may impose static forces or pressures between the material of the unadhered region 129 and the material of the cushion component 119, resulting in low or substantially no adhesion. The unadhered region 129 can function as a grippable portion (e.g., a handle, a handle, a grip) and can be grasped by a user to separate the cushion component 119 from the rigid component 117. For example, the unadhered region 129 can facilitate peeling the cushion component 119 from the rigid component 117 in the peel initiation portion 125. The unadhered region 129 can provide a sufficient amount of material for the user to grip onto, thereby allowing the cushion component 119 to be pulled (e.g., peeled) from the rigid component 117 without ergonomic issues. The unadhered region 129 can eliminate the need for a tab (e.g., a material that extends beyond the lid edge 115 and / or the cushion edge 124 and can serve as a grippable feature). For example, the tab can be a separate material attached to the cushion component, placed between the cushion component and the rigid component, or an extension of the cushion component.

[0054] like Figure 4B As shown in FIG, the pad edge 124 includes a nonlinear edge portion 141 and a linear edge portion 142. Figures 1 to 4BThe shape of the liner-flange portion 121 conforms to the shape of the flange 123 of the rigid component 117. In the illustrated embodiment, the nonlinear edge portion 141 corresponds to the rounded (e.g., arcuate) portion of the liner-flange portion 121, while the linear edge portion 142 corresponds to the straight portion adjacent to the nonlinear edge portion 141. The adhesion region 126 includes the liner-flange portion 121 and the lid-flange portion 114 in the peel initiation zone 125. In other words, the adhesion region 126 also includes the corresponding area of the liner-flange portion 121. That is, the lid edge 115 and the liner edge 124 (which may include the nonlinear edge portion 141 and the linear edge portion 142) may correspond to each other in the peel initiation zone 125. The adhesion region 126 includes the nonlinear edge portion 141 of the lid-flange portion 114. Therefore, the adhesion region 126 may be located in the nonlinear edge portion 141 of the lid-flange portion 114.

[0055] In the illustrated embodiment, the peel initiation region portion 125 is substantially triangular in shape with rounded (e.g., arcuate) corners. However, any other shape of the peel initiation region portion 125 is possible within the scope of the present disclosure. Exemplary shapes include circular, elliptical, rectangular, square, oval, trapezoidal, polygonal, and the like. Further, the peel initiation region portion 125 is located in a rounded corner of the flange 123 of the rigid component 117. However, any other location of the peel initiation region portion 125 on the flange 123 is possible within the scope of the present disclosure (e.g., linear, non-linear, or arcuate edge portion).

[0056] In some embodiments, the material in the peel initiation area portion 125 can be made thicker than the remaining portion 118 to provide a better grip for the user. This can be achieved by adding one or more additional film layers to the peel initiation area portion 125.

[0057] In some embodiments, the peel initiation area portion 125 can be provided with one or more protrusions (e.g., embossing, texture) to improve the user's grip on the peel initiation area portion 125 in various situations (such as, for example, in applications involving slippery or greasy products). The peel initiation area portion 125 can have any suitable shape and size on the flange 123 of the rigid member 117. The peel initiation area portion 125 can be colored, textured, embossed, or provided with any other properties to distinguish it from the remaining portion 118.

[0058] Further, in the illustrated embodiment, the adhesive region 126 has a substantially rectangular shape. However, the adhesive region 126 may have any alternative shape, such as circular, elliptical, oval, triangular, polygonal, irregular, etc.

[0059] The packaging 100 further includes a liner bond strength between the rigid component 117 and the cushion component 119, as well as a bond strength of the adhesive region 126. In some embodiments, the bond strength of the adhesive region 126 is greater than the liner bond strength. This allows the cushion component 119 to be peeled off from the rigid component 117 by grasping or pulling the peel initiation region 125 without the adhesive region 126 failing or rupturing. In some embodiments, multiple adhesive regions 126 may be included in the peel initiation region 125 to increase the bond strength between the peel initiation region 125 and the liner-flange portion 121.

[0060] Figures 5A to 5H The peel initiation area portion 125 is shown with different shapes, areas, and locations of the adhesive area 126. The adhesive area 126 can be provided with different areas, locations, and shapes based on the application requirements (e.g., form-fill seal or preformed tray application). The parameters of the adhesive area 126 can be selected to allow the liner component 119 to be easily peeled off from the rigid component 117 using the peel initiation area portion 125. Furthermore, the unadhered area 129 can provide sufficient material area for the user to grasp the peel initiation area portion 125. In addition, the bonding strength of the adhesive area 126 can be high enough to avoid any undesirable peeling of the peel initiation area portion 125 from the liner-flange portion 121.

[0061] The following will be combined Figures 1 to 4B Let's discuss in detail Figures 5A to 5H . Figure 5A An adhesion area 202 is shown that is approximately 80% of the area of the peel initiation portion 125. Further, the adhesion area 202 includes the rounded corners (arcuate edges) and the linear edges of the peel initiation portion 125, including the lid edge 115 and the liner edge 124.

[0062] Figure 5B An adhesion area 204 is shown that is about 20% or less of the area of the peel initiation portion 125. The adhesion area 204 includes the rounded corners of the peel initiation portion 125, which includes the lid edge 115 and the liner edge 124.

[0063] Figure 5C An adhesion area 206 is shown that is about 10% or less of the area of the peel initiation portion 125. Further, the adhesion area 206 does not include either the lid edge 115 or the liner edge 124 of the peel initiation portion 125.

[0064] Figure 5DAn adhesion area 208 is shown that is about 15% or less of the area of the peel initiation portion 125. Further, the adhesion area 208 includes one of the linear edges of the lid edge 115 and the liner edge 124 of the peel initiation portion 125.

[0065] Figure 5E An adhesion area 210 is shown that is about 30% or less of the area of the peel initiation portion 125. The adhesion area 208 further includes the lid edge 115 and the liner edge 124 of the peel initiation portion 125.

[0066] Figure 5F An adhesive area 212 is shown that is about 15% or less of the area of the peel initiation portion 125. The adhesive area 212 includes the lid edge 115 and the liner edge 124 of the peel initiation portion 125. Figure 5F The geometry of the adhesion area 212 shown in FIG is different from Figure 5B However, the locations of the adhesive regions 204, 212 relative to the peel initiation portion 125 can be substantially similar.

[0067] Figure 5G An adhesion area 214 is shown that is about 15% or less of the area of the peel initiation portion 125. The adhesion area 214 also includes the lid edge 115 and the liner edge 124 of the peel initiation portion 125. Figure 5G The geometry of the adhesion area 214 shown in FIG is similar to that of Figure 5F The geometry of the adhesion area 212 is shown in FIG. However, the locations of the adhesion areas 212, 214 are different.

[0068] Figure 5H An adhesion area 216 is shown that is about 50% or less of the area of the peel initiation portion 125. The adhesion area 216 does not include the lid edge 115 or the liner edge 124 of the peel initiation portion 125.

[0069] In some embodiments, the adhesion areas 126, 202, 204, 206, 208, 210, 212, 214, 216 can be from greater than 0% to 90% of the area of the peel initiation portion 125. For example, the adhesion areas 126, 202, 204, 206, 208, 210, 212, 214, 216 can be 90%, 85%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, 10%, 5%, or any percentage therebetween that is greater than 0% of the area of the peel initiation portion 125.

[0070] In some embodiments, a method may be provided, the method comprising: providing a package 100 . Further, the method may include: grasping a peel initiation portion 125 of a cover 122 to peelably separate the liner component 119 from the rigid component 117 .

[0071] Figures 6A to 6C A first method of using the packaging 100 is shown. In some embodiments, the first method includes providing the packaging 100. The first method further includes grasping the peel initiation area portion 125 to peelably separate the liner component 119 from the rigid component 117 (and more specifically, grasping the unadhered area 129). The user can perform the first method before disposing of the packaging 100. The user can separate the remaining portion 118 from the peel initiation area portion 125 along the weakened line 120, as shown in FIG. Figure 6A and Figure 6B In the example, when the user opens the cover 122, the remaining portion 118 can be separated from the peel initiation area portion 125 along the weakening line 120 (when the user opens the cover 122). Figure 6A When compared, see Figure 6B The lid 122 is opened to access the contents of the package 100. In the illustrated method, the remaining portion 118 may be resealable or reclosable. This may allow the lid 122 of the package 100 to be opened to access the contents, followed by resealing the remaining portion 118 to obtain a configuration of the package 100 such as Figure 6B In some cases, the user can reseal the remaining portion 118 to the cushioning member 119 before disposing of the package 100. The user can then grasp the peel initiation area portion 125 (or more specifically, the unadhered area 129) and begin to remove the cushioning member 119 (attached to the peel initiation area portion 125 via the adhesive area 126) from the rigid member 117 of the tray 116, as shown in FIG. Figure 6C As shown in FIG. , the bonding strength between the peeling initiation area portion 125 and the liner edge 121 is greater than the bonding strength between the liner edge 121 and the rigid component 117. This difference in bonding strength can facilitate the peeling of the liner-flange portion 121 and / or the liner edge 125 from the rigid component 117, as shown in FIG. Figure 6C Reference 7A to 7B , this difference in bonding strength can allow the liner component 119 and the cover 122 (the cover including the peel initiation area portion 125 and the remaining portion 118) (in Figure 7B ) and rigid member 117 (shown in Figure 7A ) for the desired recycling.

[0072] In some cases, the liner component 119 and the cover 122 may be recyclable in a recycling stream that is different from the recycling stream of the rigid component 117. Therefore, separation of the liner component 119 and the cover 122 from the rigid component 117 may be required prior to recycling.

[0073] 7A to 7B The rigid component 117 is shown separated from the liner component 119 and the lid 122. In some embodiments, the rigid component 117 comprises recyclable APET (amorphous polyethylene terephthalate). Thus, after separation from the liner component 119, the rigid component 117 can be recycled, while the liner component 119 and the lid 122 can be recycled or disposed of accordingly. With a resealable attachment between the remaining portion 118 of the lid 122 and the liner edge 121 of the liner component 119, simultaneous removal of both the liner component 119 and the lid 122 may be possible.

[0074] In some embodiments, the bond strength of the adhesive region 126 is greater than the bond strength of the liner between the rigid component 117 and the cushion component 119. More particularly, the bond strength between the cushion-flange portion 121 of the cushion component 119 and the peel-initiation portion 125 of the lid 122 is greater than the bond strength of the liner between the cushion component 119 and the rigid component 117 of the tray 116. Thus, during removal of the cushion component 119, the rigid component 117 remains in its original state (it has not been cut, bent, folded, scored, altered, etc.), while the cushion component 119 remains adhered to the peel-initiation portion 125 and can subsequently be peeled from the rigid component 117.

[0075] Figures 8A to 8C A second method of using the package 100 is shown. In this second method, the remaining portion 118 of the cover 122 is removed before disposing of the package 100, such as Figure 8B However, the liner component 119 and the peel initiation area portion 125 of the lid 122 are still adhered to each other by the seal 127. When opening the package 100, the user separates the remaining portion 118 of the lid 122 from the peel initiation area portion 125 at the weakened line 120. This allows the remaining portion 118 to be removed while retaining the peel initiation area portion 125. Figure 8C As shown in FIG, the liner component 119 is peeled off from the rigid component 117 by grasping and pulling the unadhered area 129 of the peel initiation zone portion 125. The rigid component 117 can then be recycled, while the liner component 119 can be recycled or disposed of.

[0076] As used herein, "peel strength" is a measure of the average force used to separate two bonded materials (such as tapes, labels, fabrics, or plastic films). The strength is calculated during a peel test (ASTM F88) conducted at a constant rate by dividing the average force required during the test by the unit width of the bonded sample. As will be apparent to one skilled in the art, the closure to the backing component 119 (i.e., the lid 122) can be varied to produce a range of peel strengths. The ranges of peel strengths listed in this disclosure should be wide enough to cover both the peak peel strength and the average peel strength; however, this disclosure is not limited in any way to these peel strengths.

[0077] In some embodiments, the packaging 100 of the present disclosure may have different peel strength values between different components, layers, etc. The peel strength between the cushioning component 119 and the rigid component 117 may be based on various parameters, such as the peeling position, the peeling action, the type of peeling action performed by the user, the position, the style, etc. In the case of a flat sheet or strip taken from the bottom portion 106 of the tray 116, the peel strength of the cushioning component 119 to the rigid component 117 may be in the range of from about 300 grams per inch (g / in equals g / 25.4 mm) to about 1,500 g / in. If the peel strength is greater than about 100 g / in from the flange 123 (at Figure 3 1 . If peeled from around the center of the flange 123 of the rigid component 117, the peel strength of the liner component 119 from the rigid component 117 can be in the range of from about 2,000 g / in to about 6,500 g / in. Further, the bond strength between the rigid component 117 and the liner component 119 can vary with the thickness of the tray 116. The peel strength between the lid 122 and the liner component 119 can be in the range of from about 400 g / in to about 4,000 g / in (in some embodiments, the fused seal or non-peelable lid can have a value greater than 5,000 g / in). In some embodiments, the bond strength of the adhesive area 126 including the seal 127 can be greater than 3,000 g / in. In some other embodiments, the bond strength of the adhesive region 126 including the seal 127 may be greater than 5,000 g / in.

[0078] Figures 9A to 9CA method of manufacturing a packaged product 200 is shown. The method involves selecting a rigid component 117 of any suitable polymeric thermoformable material known in the art. In the present disclosure, APET (amorphous polyethylene terephthalate) may be the material of choice, which is a polymer resin and has many advantageous properties as already discussed above. After the material for the rigid component 117 is selected, the material for the cushioning component 119 may be selected. Again, the cushioning component 119 may be made of any suitable thermoformable material known in the art. The different possibilities for materials for the cushioning component 119 have been discussed in more detail above. After the materials for the rigid component 117 and the cushioning component 119 are selected, the rigid component 117 and the cushioning component 119 are adhered or sealed together using any suitable sealing method, such as Figure 9A As shown in Figure 9A In the embodiment, the rigid component 117 and the cushion component 119 are in the form of sheets.

[0079] In some embodiments, the bond strength can be altered by the composition of the cushion component 119 and the amount or thickness of the rigid component 117. Further, the bond strength can be altered based on the draw depth due to the additional stress imposed on the bonded pieces as they are formed into a package.

[0080] After being adhered together, the cushion component 119 and the rigid component 117 form a multi-layer component that is thermoformed to form a component in the shape of the tray 116, as shown. Figure 9B In the most common method of high-volume, continuous thermoforming of multi-layer parts, the multi-layer part is fed from a roll or extruder into a set of indexing chains that incorporate pins or spikes for piercing the multi-layer part and transporting it through an oven for heating to a forming temperature of approximately 280 degrees Fahrenheit (138 degrees Celsius). The heated multi-layer part is then indexed into a forming station where a mating mold and pressure box close the multi-layer part, and a vacuum is applied to remove trapped air and the material is pulled into or onto the mold along with pressurized air to form the multi-layer part into the detailed shape of the mold.

[0081] After the tray 116 is formed, the product 130 to be packaged can be placed in the recessed cavity 110 of the tray 116. The lid 122 is then applied to the tray 116. A seal 127 can be formed to seal or adhere the peel initiation area portion 125 of the lid 122 to the liner edge 121. Different sealing methods can be used to attach the liner edge 121 to the remaining portion 118 of the lid 122. Typically, the bonding strength of the seal 127 is greater than the bonding strength between the remaining portion 118 of the lid 122 and the liner edge 121. Further, the bonding strength of the adhesive area 126 is greater than the bonding strength between the rigid component 117 and the liner component 119. The lid 122 is then divided into two parts, namely, the peel initiation area portion 125 and the remaining portion 118, by forming a weakening line 120, as shown in FIG. Figure 9C As discussed above, the line of weakness 120 can be formed mechanically or by laser. In some embodiments, the line of weakness 120 is first formed in the cover 122, and then the cover 122 is attached to the gasket edge 121.

[0082] Example

[0083] Packaging Example:

[0084] A. A packaging material, comprising:

[0085] a lid comprising a peel-initiation region portion, a remainder portion, and a lid-flange portion;

[0086] a pallet comprising a rigid member and a cushion member including a cushion-flange portion; and

[0087] an adhesive region comprising a seal between the peel initiation region portion and the liner component;

[0088] wherein the lid-flange portion includes a peel initiation area portion and a remaining portion, wherein the adhesion area includes the liner-flange portion and the lid-flange portion of the peel initiation area portion, and wherein the adhesion area includes 90% or less of the peel initiation area portion.

[0089] B. The package of embodiment A, wherein the liner-flange portion includes an edge including a non-linear edge portion, and wherein the adhesive region includes the non-linear edge portion.

[0090] C. The package of any other embodiment, further comprising a cushion bonding strength between the rigid component and the cushion component, and a bonding strength of the adhesive region, and wherein the bonding strength of the adhesive region is greater than the cushion bonding strength.

[0091] D. The package of any other embodiment, wherein the peel initiation portion further comprises an unadhered area adjacent to the adhered area.

[0092] E. The package of any other embodiment, wherein the peel initiation region portion and the remaining portion are contiguous along a line of weakness.

[0093] F. The package of any other embodiment, wherein the rigid component comprises at least one of a semi-rigid polymer material, a rigid polymer material, a fiber-based component, and a moldable paper.

[0094] G. The package of any other embodiment, wherein the rigid component comprises amorphous polyethylene terephthalate (APET).

[0095] H. The package of any other embodiment, wherein the cushion component comprises at least one barrier layer.

[0096] I. The package of any other embodiment, wherein the material of the rigid component and the material of the cushion component have different recycling properties.

[0097] J. A method of using a package according to any other embodiment, the method comprising the steps of:

[0098] provide the packaging; and

[0099] The peel initiation area portion of the cover is grasped to peelably separate the liner component from the rigid component.

[0100] K. A packaging material comprising:

[0101] a lid comprising a peeling initiation region portion, a remaining portion, and a lid edge;

[0102] a pallet comprising a rigid component and a cushion component, the cushion component comprising a cushion edge, the cushion edge comprising a non-linear edge portion; and

[0103] an adhesive region comprising a seal between the peel initiation region portion and the liner component;

[0104] wherein the cover edge includes a peel initiation portion and a remainder, wherein the adhesion region includes the nonlinear edge portion of the cover edge and the liner edge of the peel initiation portion, and wherein the adhesion region includes 90% or less of the peel initiation portion.

[0105] L. The package of any embodiment, wherein the material of the rigid component and the material of the cushion component have different recycling properties.

[0106] Packaging product example:

[0107] M. A packaged product comprising:

[0108] a lid comprising a peel-initiation region portion, a remainder portion, and a lid-flange portion;

[0109] a pallet comprising a rigid member and a cushion member, the cushion member comprising a cushion-flange portion;

[0110] an adhesive region comprising a seal between the peel initiation region portion and the liner component; and

[0111] a product, the product being disposed in a tray;

[0112] wherein the lid-flange portion includes a peel initiation area portion and a remaining portion, wherein the adhesion area includes the liner-flange portion and the lid-flange portion of the peel initiation area portion, and wherein the adhesion area includes 90% or less of the peel initiation area portion.

[0113] N. The packaged product of any other embodiment, wherein the liner-flange portion includes an edge, the edge includes a non-linear edge portion, and the adhesive region includes the non-linear edge portion.

[0114] O. The packaged product of any other embodiment, further comprising a cushion bonding strength between the rigid component and the cushion component, and a bonding strength of the adhesive region, and wherein the bonding strength of the adhesive region is greater than the cushion bonding strength.

[0115] P. The packaged product of any other embodiment, wherein the peel initiation portion further comprises an unadhered area adjacent to the adhered area.

[0116] Q. The packaged product of any other embodiment, wherein the peel initiation region portion and the remaining portion abut along a line of weakness.

[0117] R. The packaged product of any other embodiment, wherein the material of the rigid component and the material of the cushion component have different recycling properties.

[0118] S. The package of any other embodiment, wherein the rigid component comprises at least one of a semi-rigid polymer material, a rigid polymer material, a fiber-based component, and a formable paper.

[0119] Unless expressly excluded or otherwise limited, each document cited in this application (including any cross-references) is incorporated herein by reference in its entirety. The citation of any document is not an admission that it is prior art with respect to any embodiment disclosed in this application, or that it teaches, suggests, or discloses any such embodiment, either alone or in any combination with any other reference or references. Further, to the extent that any meaning or definition of a term in this application conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to the term in this application shall prevail.

[0120] The disclosed descriptions, examples, embodiments, and figures are illustrative only and should not be construed as limiting. Unless expressly indicated to the contrary, the numerical parameters set forth in this application are approximate and may vary depending on the desired properties sought to be obtained by one of ordinary skill in the art using the teachings disclosed in this application without undue experimentation. Modifications and other embodiments will be apparent to one of ordinary skill in the packaging arts, and all such modifications and other embodiments are intended and considered to be within the scope of the present invention.

Claims

1. A recyclable package comprising a lid, a tray, and an adhesive area: The cover includes a peel initiation region portion and a contiguous remainder portion along a line of weakness; The pallet includes a rigid component and a cushion component, the cushion component including a cushion-flange portion; wherein the packaging includes a liner bonding strength between the rigid component and the liner component, wherein the lid is disposed on a top portion of the liner-flange portion, wherein the peel initiation portion includes an unadhered area adjacent to the adhered area, wherein the adhered area includes a seal between the peel initiation portion and the liner component and the adhered area has a bonding strength; wherein the unadhered area is deattached from the cushion component; wherein the adhesive region comprises 90% or less of the peel initiation portion, wherein the adhesive region's bond strength is greater than the liner bond strength such that the liner component can be peeled from the rigid component by grasping or pulling the peel initiation portion without failure or rupture of the adhesive region.

2. The package according to claim 1, wherein The gasket-flange portion includes a gasket edge, the gasket edge includes a non-linear edge portion, and the adhesion area includes the non-linear edge portion.

3. The package according to claim 1 or 2, wherein: The rigid component includes at least one of a semi-rigid polymer material, a rigid polymer material, a fiber-based component, and a formable paper.

4. The package according to claim 1 or 2, wherein: The rigid component includes amorphous polyethylene terephthalate (APET).

5. The package according to claim 1 or 2, wherein: The pad component includes at least one barrier layer.

6. The package according to claim 1 or 2, wherein: The material of the rigid component and the material of the cushion component have different recycling properties.

7. A method of using the packaging material according to any one of claims 1 to 6, the method comprising the following steps: providing the packaging; as well as The peel initiation area portion of the cover is grasped to peelably separate the liner component from the rigid component.

8. The method of claim 7, wherein the cover and the liner member are removed simultaneously when the peel-initiation zone portion is grasped to peelably separate the liner member from the rigid member.

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