Packaging container

Abstract

Packaging container for accommodating an item therein, and comprises a lined tray and a lid film (25) that is heat-sealed to said lined tray, the lined tray comprising a rigid cellulose tray (2) and a liner film (22), wherein the rigid cellulose tray (2) comprises a bottom portion, a wall connected to the bottom portion, a brim connected to and extending in the radial direction from the upper end of the wall, and a holding tab connected to and extending in the radial direction outwards from the brim, wherein the liner film (22) is adhered to at least an upper surface (20) of the brim and an upper surface (21) of the holding tab.

Description

Technical field of the Invention

[0001] The present invention relates in general to the field of packaging containers for accommodating an item / content therein, such as groceries, food, cosmetics, industrial goods, consumer goods, etc. The packaging container comprises a lined tray and a lid film that is heat-sealed to said lined tray, wherein the lined tray comprises a rigid cellulose tray made of cellulose fibres. Thus, the rigid cellulose tray is intended to be used as a single use disposable article / product in order to replace corresponding plastic tray. In addition to the cellulose tray, the lined tray also comprises a liner film adhered to the rigid cellulose tray in order to act as a barrier in order to enhance the physical properties of the cellulose tray, such as a barrier for gas, grease, flavour, moisture, etc. The present invention also relates to a lined tray to be used together with a lid film configured to be heat-sealed to the lined tray in order to generate a packaging container for accommodating an item therein.

[0002] The rigid cellulose tray comprises a bottom portion for receiving the item, a wall connected to and extending in the axial direction upwards from the bottom portion, a brim connected to and extending in the radial direction outwards from the upper end of the wall, and a holding tab connected to and extending in the radial direction outwards from the brim. The liner film is adhered to at least an upper surface of the brim, and an upper surface of the holding tab.Background of the Invention

[0003] There are many situations where it is desirable to provide three-dimensional (3D) shaped objects made of sustainable materials, such as biomaterials, instead of plastic / polymer materials. When storing items that for instance have a certain content of moisture / grease, known trays made of plastic / polymer materials have the advantage that the tray itself constitute the barrier to prevent penetration and disintegration of the tray.

[0004] A biomaterial commonly used for packaging is wet moulded pulp based on cellulose fibres. Such wet moulded pulp has the advantage of being considered as a sustainable packaging material, since it is produced from biomaterials and can be recycled after use. Wet moulded pulp comprises more or less only water and separated cellulose fibers, and consequently, wet moulded pulp has been popular to use for packaging applications and as single / multiple use disposable articles. Such trays make use of a liner film acting as a barrier in order to enhance the physical properties of the cellulose tray.

[0005] However, a common disadvantage with all wet-forming techniques is the need for large amounts of water during the preparations of the cellulose pulp and the need for drying during the manufacturing / moulding of the product, which is time as well as energy consuming step leading to low production speed and substantial high investment cost in machines and tooling. Meaning that the wet-forming techniques are not feasible to replace fossil-based alternatives neither in small nor large scale production of rigid cellulose products. Thereto, the aesthetical and mechanical properties of a wet-moulded cellulose product are hard to control with desirable precision, due to un-uniform cellulose pulp and due to the wet moulding manufacturing technique per se.

[0006] Therefore many actors / companies, starting a few decades ago, have changed their focus and investments towards dry-forming techniques wherein rigid cellulose products are manufactured from separated cellulose fibres that are introduced into a product forming unit in the shape of a dry cellulose blank / web, wherein the cellulose blank is formed into the shape of the intended cellulose product and wherein the cellulose fibres are bonded to each other using heat and pressure in the product forming unit. The dry-forming techniques comprises different steps of generating an air-laid cellulose blank, that is fed into the product forming unit. Alternative dry-forming techniques makes use of a paperboard / cardboard cellulose blank, that is fed into the product forming unit.

[0007] However, in order to have a fully recyclable lined tray that comprises a rigid cellulose tray made of cellulose fibres and a liner film, the liner film has to be easily separable from the cellulose tray after use of the container. Manual separation at home after use of the lined tray / container has to be easy and efficient, i.e. too much of the recyclable cellulose tray and / or the recyclable liner film must not remain adhered to the other component after separation. Thus, an increasing difficulty of separating the cellulose tray from the liner film entails a decreasing likelihood of recycling the pieces.

[0008] When the item is filled into the container, the lid film is heat sealed to the liner film in a conventional manner. Thus, the liner film and the lid film together delimit the actual compartment holding / storing the item by constituting a sealed enclosure, and the cellulose tray provides stability to the packaging container. Thus, the sealing property of the heat seal is important in order to keep the desired atmosphere in the compartment, and thereby the strength of the heat seal is increased to secure improved / required sealing property. At the same time as the strength of the heat seal is increased, the openability / separability of the lid film from the lined tray is decreased. Decreased openability result in the necessity to use more or less sophisticated home-made solutions including sharp objects / tools.

[0009] If incorrect relationship between the different bonding is achieved, the user trying to open the packaging container may end up with a bag in one hand, liner film and lid film still interconnected, and the cellulose tray in the other hand. Thereto, this might be hazardous to the user especially if the item / food in the packaging container has been heated in a microwave.

[0010] There are known ways trying to solve the above requirements and problems, for instance US 4905838 and WO 2021 / 257099. Reference is also made to a document from the remote technical field of plastic trays, i.e. WO 2021 / 180961. But none of them solve all problems and requirements. Thus, there is a need in the art for a reliable packaging container, that provide proper sealing of the compartment holding the item, easy access to the item and easy separation of the liner film from the cellulose tray for recycling.Object of the Invention

[0011] The present invention aims at obviating the aforementioned and other disadvantages and failings of previously known packaging containers and lined trays, and at providing an improved packaging container and an improved lined tray.

[0012] A primary object of the present invention is to provide an improved packaging container and lined tray, wherein the packaging container provides proper sealing of the compartment holding the item and easy access to the item. It is also an object of the present invention to provide an improved packaging container providing easy separation of the liner film from the cellulose tray for suitable recycling thereof. It is also an object of the present invention to provide an improved packaging container providing easy separation of the lid film and the liner film from each other for suitable recycling thereof.Summary of the Invention

[0013] According to the invention at least the primary object is attained by means of the initially defined packaging container and the lined tray having the features defined in the independent claims. Preferred embodiments of the present invention are further defined in the dependent claims.

[0014] According to the present invention, there is provided a packaging container and a lined tray, wherein the lined upper surface of at least a distal portion of the holding tab in relation to the lined upper surface of the adjacent brim, is in the axial direction located offset towards the bottom portion a distance equal to or more than 1 mm and equal to or less than 5 mm, wherein the lid film is heat-sealed to the lined upper surface of the brim, and wherein the lid film comprises a gripping tab located in overlapping configuration with the holding tab of the lined tray, and located axially separated from said distal portion of the holding tab.

[0015] Thus, the present invention is based on the insight that the weakest bonding of the packaging container is the internal bindings between the individual cellulose fibres in the cellulose tray. Thereby the cellulose fibres at the surface of the cellulose tray will adhere to and follow the liner film during separation. In order to minimize the amount of cellulose fibres following the liner film, the adhesion between the liner film and the cellulose tray is made as weak as possible. The new and inventive lined tray is provided a design that secures that the gripping tab of the lid film is not adhered to the lined holding tab of the lined tray during heat-sealing, and thereto the user has easy access to firmly grip the holding tab and the gripping tab, respectively, in order to open the packaging container by separating the lid film from the lined tray. The rigid holding tab of the lined tray also protects the gripping tab of the lid film from being damaged during transportation and storing of the container.

[0016] According to various example embodiments of the present invention the liner film is also adhered to an upper surface of the bottom portion and / or to an inner surface of the wall of the rigid cellulose tray. Thereby the adhesion force between the liner film and the cellulose tray may be decreased since the adhesion interface between the liner film and the cellulose tray is increased.

[0017] According to various example embodiments of the present invention the liner film is a multilayer film comprising polymer and / or metal. Thereby different liner films may be chosen depending on the barrier properties and / or appearance required.

[0018] According to various example embodiments of the present invention the lid film is a multilayer film comprising polymer, metal, and / or paper. Thereby different lid films may be chosen depending on the barrier properties and / or appearance required.

[0019] According to various example embodiments of the present invention the width of the upper surface of the brim is equal to or more than 2 mm and equal to or less than 10 mm. A narrower upper surface of the brim would require that the strength per area of the heat-seal is increased too much, such that the lid film and liner film becomes inseparable without breaking. A wider upper surface of the brim entails that the total strength of the heat-seal is increased too much, such that the lid film and liner film becomes inseparable without breaking.

[0020] Further advantages with and features of the invention will be apparent from the following detailed description of preferred embodiments.Brief description of the drawings

[0021] A more complete understanding of the abovementioned and other features and advantages of the present invention will be apparent from the following detailed description of preferred embodiments in conjunction with the appended drawings, wherein: Fig. 1is a schematic illustration of a production line or apparatus for dry manufacturing rigid cellulose products, Fig. 2is a schematic illustration of a moulding tool, wherein a cellulose blank is loaded therein, Fig. 3is a schematic illustration of the moulding tool according to figure 2, wherein the cellulose blank is pressed into final rigid non-flat general shape, Fig. 4is a schematic illustration of the moulding tool according to figures 2 and 3, wherein the rigid cellulose product is released, Fig. 5is a schematic view from above of a cellulose tray of the inventive packaging container, Fig. 6is a schematic exploded side view of an inventive packaging container, Fig. 7is a schematic illustration of the packaging container according to figure 6 accommodating an item therein, and Fig. 8is a schematic enlarged side view of the holding tab and gripping tab of the inventive packaging container according to figure 7. Detailed description of preferred embodiments of the invention

[0022] As used herein, the term "air / dry moulding / forming or air / dry laying / laid" means a well-known method according to which separated cellulose fibres, i.e. cellulose fluff, are formed into a cellulose blank / sheet.

[0023] In air-laying technique, small / short fibres having a normal length in the range of 0,5 to 70 mm, for instance 1 to 50 mm, are separated and captured by an air stream / flow, and then laid on / applied to a forming mesh / surface, usually using a low pressure at the other side of the mesh / surface. The terms "air / dry laying" and "air / dry moulding" are used interchangeably herein. The cellulose fibre carrying air flow may be generated by suitable device located upstream and / or downstream the forming mesh / surface.

[0024] Reference is initially made to figures 1-4. Figure 1 disclosing a schematic illustration of a generic production line / apparatus for dry manufacturing rigid cellulose products, generally designated 1. The production line 1 is configured for manufacturing rigid cellulose products, generally designated 2, having essentially non-flat general shape from separated cellulose fibres. Such a production line 1 may be arranged and set-up according to different well-known ways.

[0025] Cellulose raw material 3 is provided to the production line, and is fed to a separating / disintegrating unit 4 in order to obtain individualized / separated cellulose fibres. The separated cellulose fibres are thereafter transported by an air stream / flow to a dispenser of a cellulose blank / sheet forming unit 5. The cellulose fibres are laid by the dispenser on a moving or stationary perforated surface of the cellulose blank forming unit 5. The cellulose fibre carrying air flow may be generated by suitable device located upstream and / or downstream the perforated surface. Thereafter the generated cellulose blank 6 is transported to a product forming unit 7, whereby rigid cellulose products 2 are formed and discharged from the product forming unit 7. The rigid cellulose product 2 is in this embodiment made of a heat-pressed sheet of air-laid cellulose fluff comprising cellulose fibers.

[0026] The cellulose blank forming unit 5 may be configured to generate a continuous cellulose blank and / or discontinuous / discrete cellulose blanks. Preferably discontinuous / discrete cellulose blanks 6 are fed into the product forming unit 7.

[0027] The cellulose raw material 3 may be in the form of reeled pulp or paper, bale of cellulose pulp, paper, etc. and / or sheets of paper, cellulose pulp, etc. In case said cellulose raw material 3 is in the form of sheets and / or reeled pulp or paper, it can be fed directly into the separating unit 4. However, in case said cellulose raw material 3 is in the form of a bale or compact stacks of sheets, etc. one or more shredders and / or one or more additional separating / disintegrating units 4 may be necessary to be used for separating and dosing said cellulose raw material 3 from said bale or sheets in smaller quantities. The shredder(s) prepare cellulose raw material 3 to be accepted by said separating unit 4. The separating unit 4 disintegrates the cellulose raw material 3 into separated cellulose fibres. Said one or plurality of shredder(s) are arranged before said one or a plurality of separating unit(s) 4, so that an output of one of said shredder is connected to an input of one of said separating units 4. The shredders may be arranged in parallel to each other or in series with each other, and the disintegrating units 4 may be arranged in parallel to each other or in series with each other. The shredders and the disintegrating units 4 together constitute a cellulose fibre separating unit, arranged upstream the cellulose blank forming unit 5.

[0028] Said cellulose raw material 3 may be constituted by virgin cellulose fibres and / or recycled cellulose fibres and may originate from wood pulps such as kraft pulp, sulphite pulp, mechanical pulp, thermomechanical pulp (TMP), chemical treated mechanical pulp, chemi-thermomechanical pulp (CTMP), and / or from non-wood pulps such as bagasse, bamboo, abaca, hemp, flax, cotton.

[0029] The separating unit 4 may according to various embodiments be constituted by a hammer mill. In said separating unit 4 the cellulose raw material is separated into fibres having a normal length in the range of 0,5-70 mm. The length of said fibres may be customized by adjusting the internal properties of the separating unit 4 and / or by choosing a different separating unit 4 and / or choosing different cellulose raw material. The fibre length for wood pulp is according to various embodiments in the range 0,5-4 mm, preferably in the range 1,7-3,6 mm. According to various embodiments the fibre length for non-wood pulp is in the range 0,5-70 mm.

[0030] The production line 1 may comprise a pre-compression and / or imprinting unit 8, located downstream the cellulose blank forming unit 5 and upstream the product forming unit 7. In the pre-compression and / or imprinting unit 8, an air-laid fluffy cellulose blank having a first thickness may be compressed into a cellulose blank having a second thickness, wherein said second thickness is thinner than said first thickness, and / or may be provided with an imprinted pattern. During the pre-compression / imprinting the cellulose blank is made more coherent and easier to handle, since the pre-compression / imprinting generates internal bindings between individual cellulose fibres preventing mutual separation of the cellulose fibres.

[0031] The product forming unit 7 comprises a press unit 9, and may optionally comprise a preheating unit 10 arranged upstream the press unit 9. According to various example embodiments said cellulose blank 6 may be heated to an elevated temperature before being fed into the press unit 9 of the product forming unit 7. In such embodiment(s) where the cellulose blank is preheated before being fed into the press unit 9, said press unit 9 may or may not comprise heating. According to various example embodiment said press unit 9 may be a heated press unit 9 for heating said cellulose blank 6 during pressing. In the case of a heated press unit 9, preheating of said cellulose blank using a pre-heating unit 10 is optional. According to various example embodiments preheating of the cellulose blank in said pre-heating unit 10 may be combined with a heated press unit 9. Having a preheating unit 10 in combination with a heated press unit 9 will speed up the manufacturing process in the product forming unit 7, and improve the quality / rigidity of the final rigid cellulose product 2. In the product forming unit 7 the cellulose blank 6 is heated to a temperature in the range 120 - 200 °C in order to obtain adequate rigidity and strength in the final cellulose product 2. Thus, in this embodiment the rigid cellulose product 2 is made of a heat-pressed sheet of air-laid cellulose fluff comprising cellulose fibers.

[0032] Reference is now especially made to figures 2-4. The press unit 9 comprises a moulding tool having a first mould part 11 and a second mould part 12, wherein at least one of the first mould part 11 and the second mould part 12 is / are displaceable back and forth in relation to each other, in order to exert pressure to the cellulose blank 6 loaded therebetween. In the figures the mutual displacement is disclosed as being vertical, however the mutual displacement may be horizontal or any other suitable angle. The cellulose blank 6 loaded into the moulding tool, is constituted by an air-laid cellulose blank 6. The air-laid cellulose blank 6 may be generated upstream the product forming unit 7 in the same production line and provided to the product forming unit 7, or may be generated at a separate location and provided to the product forming unit 7 via intermediate handling and storage.

[0033] According to various embodiments the first mould part 11 of the moulding tool is a female mould part, i.e. having a recess for receiving the cellulose blank 6, and the second mould part 12 of the moulding tool is a male mould part, i.e. having a protrusion for cooperation with said recess of the first mould part 11, such that the cellulose blank 6 is pressed into a final rigid non-flat shape. The male mould part will form the inner surface of the rigid cellulose product 2 and the female mould part will form the outer surface of the rigid cellulose product 2. It shall be pointed out that both the first mould part 11 and the second mould part 12 may comprise further local / minor projections and recesses. During the pressing, disclosed in figure 3, a predetermined pressure P1 is applied by the moulding tool between the recess and the protrusion. Thus, the rigid cellulose product 2 obtains its final rigid non-flat shape, which may have any conceivable non-flat design / shape. In the disclosed embodiment the edges of the rigid cellulose product 2 are trimmed concurrently with the pressing / forming of the rigid cellulose product 2. The edges of the rigid cellulose product 2 may be trimmed in a subsequent process step separated from the pressing of the rigid cellulose product 2.

[0034] In figure 4 the cellulose product 2 is released by opening the moulding tool. The predetermined pressure P1 is in the range 40-10000N / cm 2< , preferably in the range 100-4000N / cm 2< . According to various embodiments said predetermined pressures are above 400 N / cm 2< , and according to various embodiments said predetermined pressures are below 2000 N / cm 2< . According to various embodiments the cellulose blank 6 loaded into the press unit 9 is constituted by a paperboard / cardboard cellulose blank, instead of the air-laid cellulose blank described above.

[0035] The rigid cellulose product is hereinbelow constituted by a cellulose tray 2 made of cellulose fibers. The above disclosure concerning a rigid cellulose product is fully applicable to the tray 2.

[0036] Reference is now also made to figure 5 disclosing an exemplary illustration of a rigid cellulose tray 2 from above. The rigid cellulose tray 2 may have any suitable general shape seen from above, such as square, hexagonal, polygonal, triangular, round, oval, etc. The tray 2 comprises a bottom portion 13 for receiving an item 14, a wall 15 connected to and extending in the axial direction upwards from the bottom portion 13, a brim 16 connected to and extending in the radial direction outwards from the upper end of the wall 15, and a holding tab 17 connected to and extending in the radial direction outwards from the brim 16.

[0037] According to various embodiments, including the disclosed embodiment, the wall 15 is a circumferential wall and the tray 2 comprises one compartment for receiving the item 14. According to various undisclosed embodiments, the tray 2 comprises two or more compartments separated by partition(s), wherein the wall 15 of the tray 2 may be fully or partly interrupted by the partition(s). Thus, said partition(s) may protrude to the same height as the wall 15, wherein the upper end of the partition(s) connects to the brim 16.

[0038] The bottom portion 13 comprises a bottom 18 for receiving the item 14, and a transitional edge region 19 located between the bottom 18 and the wall 15. The transitional edge region 19 may for instance be constituted by a chamfer and / or radius. The bottom 18 may be flat as in the disclosed embodiments, or may have non-flat general shape.

[0039] The wall 15 extends in the axial direction and is preferably slightly tilted outwards in the upwards direction such that multiple empty trays 2 may be stacked one in the other. According to various embodiments, the wall 15 may comprise a curvature along at least a part of the distance between the bottom portion 13 and the brim 16, i.e. bulge radially inwards and / or radially outwards. According to the disclosed embodiments the wall 15 is straight between the bottom portion 13 and the brim 16.

[0040] According to various embodiments the brim 16 is circumferential, and is preferably located in one geometrical plane. The brim 18 comprises an upper surface 20 that preferably is flat. Different parts of the brim 16 may be located at different axial distance in relation to the bottom 18. According to various embodiments, the width of the upper surface 20 of the brim 18 is equal to or more than 2 mm and equal to or less than 10 mm, preferably equal to or more than 4 mm and equal to or less than 8 mm. The width of the upper surface 20 is taken / measured in the radial direction, i.e. perpendicular to the circumferential direction of the brim 18. According to various embodiments the brim 16 comprises a chamfering / rounding at the outer periphery thereof.

[0041] The holding tab 17 comprises an upper surface 21 and according to various embodiments the upper surface 21 is parallel to the upper surface 20 of the adjacent brim 16, and according to various alternative embodiments the upper surface 21 of the holding tab 17 is tilting downwards from the upper surface 20 of the adjacent part of the brim 16, or a combination thereof. There might be a material bridge between the holding tab 17 and the brim 16. The interface / connection between the brim 16 and the holding tab 17 is preferably equal to or more than 1 cm and equal to or less than 5 cm, in the circumferential direction of the brim 17.

[0042] Reference is now also made to figures 6-8. According to the invention, the packaging container comprises a lined tray, wherein the lined tray comprises said rigid cellulose tray 2 and a liner film 22. The liner film 22 is adhered to at least the upper surface 20 of the brim 16 and to the upper surface 21 of the holding tab 17. According to various embodiments, the liner film 22 is also adhered to the inner surface of the bottom portion 13 and / or to the inner surface of the wall 15. The liner film 22 may be adhered to parts of the inner surface of the bottom portion 13 and / or to parts of the inner surface of the wall 15. The liner film 22 is typically a flat sheet before it is added to the tray 2, however it is possible to have the liner film 22 pre-shaped before it is added / adhered to the tray 2.

[0043] According to various embodiments the adhesion of the liner film 22 to the rigid cellulose tray 2 is heat activated, i.e. the part of the liner film 22 facing the tray 2 is partly melted / activated by the heat such that the liner film 22 sticks to at least the surface fibres of the tray 2. According to one embodiment, the liner film 22 is applied to the tray 2 by generating an under-pressure through the cellulose tray 2, i.e. the liner film 22 is sucked towards / against the tray 2, and / or by generating an over-pressure at the upper side of the liner film 22. The adhesion of the liner film 22 may be constituted by or complemented by applying a liquid adhesive onto the liner film 22 and / or onto the tray 2. The heat may be constituted by hot air, irradiation, remaining heat in the tray 2 from the pressing / forming thereof, etc.

[0044] According to various embodiments the liner film 22 is a multilayer film comprising polymer and / or metal, depending on the barrier characteristics / properties needed. The liner film 22 may comprise fossil-based or biobased polymer. The purpose of the lower layer of the liner film 22 is primarily to act as a heat activated adhesive. The purpose of the other layer(s) of the liner film 22 is primarily to act as a barrier for moisture, gas, grease, flavour, etc., but may also relate to the appearance of the lined tray 2 regarding pattern, colour, figures, text, etc. The liner film 22 may be cold and / or heat resistance in order to be used in a freezer, fridge, microwave-oven, oven, etc.

[0045] According to the invention, the lined upper surface 23 of at least a distal portion of the holding tab 17 in relation to the lined upper surface 24 of the adjacent brim 16, is in the axial direction located offset towards the bottom portion 13 a distance A equal to or more than 1 mm and equal to or less than 5 mm, preferably equal to or more than 2 mm and equal to or less than 4 mm.

[0046] According to various embodiments, the distal portion of the holding tab 17 has an area that is equal to or more than 1 cm 2< and equal to or less than 3 cm 2< .

[0047] According to the invention, the packaging container comprises a lid film 25 that is heat-sealed to the lined tray 2, more precisely heat-sealed to the lined upper surface 24 of the brim 16. The lid film 25 is typically a flat sheet before it is added to the tray 2.

[0048] According to various embodiments the lid film 25 is a multilayer film comprising polymer, metal and / or paper, depending on the barrier characteristics / properties needed. The lid film 25 may comprise fossil-based or biobased polymer. The purpose of the lower layer of the lid film 25 is primarily to act as a heat activated adhesive. The purpose of the other layer(s) of the lid film 25 is primarily to act as a barrier for moisture, gas, grease, flavour, etc., but may also relate to the appearance of the lined tray 2 regarding pattern, colour, figures, text, etc. The lid film 25 may be cold and / or heat resistance in order to be used in a freezer, fridge, microwave-oven, oven, etc.

[0049] The liner film 22 and the lid film 25 may be constituted by the same multilayer film, or they may be constituted by different multilayer films since usually the item 14 is abutting the liner film 22 and the lid film 25 is only in contact with the enclosed atmosphere / gas of the packaging container. For instance the liner film 22 might need to constitute a barrier for moisture and grease in order to protect the cellulose tray 2 and the lid film 25 has to let moisture through in order to prevent vapor or frost in the packaging container.

[0050] According to the invention, the lid film 25 comprises a gripping tab 26 located in overlapping configuration with the holding tab 17 of the lined tray 2, and located axially separated from said distal portion of the holding tab 17. Thereby, the gripping tab 26 and the holding tab 17 are easily accessible and the lid film 25 can be securely removed from the lined tray 2 since the user when holding the holding tab 17 also holds the liner film 22 adhered to the holding tab 17. The axial distance A between the lined upper surface 23 of the distal portion of the holding tab 17 and the lined upper surface 24 of the adjacent brim 16 secures that the lid film 25 is not heat-sealed to the holding tab 17 when the lid film 25 is heat-sealed to the lined upper surface 24 of the brim 16. The gripping tab 26 is at the same time protected by the holding tab 17 and thereby prevented from being damaged. The holding tab 17 and the gripping tab 26 preferably has the same general shape seen in the axial direction.

[0051] The present invention also relates to the lined tray 2 as such, wherein the lined tray 2 is configured to be used together with the lid film 25 configured to be heat-sealed to the lined tray 2 in order to generate a packaging container for accommodating an item 14 therein.Feasible modifications of the Invention

[0052] The invention is not limited only to the embodiments described above and shown in the drawings, which primarily have an illustrative and exemplifying purpose. This patent application is intended to cover all adjustments and variants of the preferred embodiments described herein, thus the present invention is defined by the wording of the appended claims and the equivalents thereof. Thus, the equipment may be modified in all kinds of ways within the scope of the appended claims.

[0053] Throughout this specification and the claims which follows, unless the context requires otherwise, the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or steps or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0054] It shall be pointed out that the final rigid cellulose product may be constituted by three or more segments, wherein each pair of neighbouring segments are joined / connected to each other according to the present invention.

Examples

Embodiment Construction

[0022]As used herein, the term "air / dry moulding / forming or air / dry laying / laid" means a well-known method according to which separated cellulose fibres, i.e. cellulose fluff, are formed into a cellulose blank / sheet.

[0023]In air-laying technique, small / short fibres having a normal length in the range of 0,5 to 70 mm, for instance 1 to 50 mm, are separated and captured by an air stream / flow, and then laid on / applied to a forming mesh / surface, usually using a low pressure at the other side of the mesh / surface. The terms "air / dry laying" and "air / dry moulding" are used interchangeably herein. The cellulose fibre carrying air flow may be generated by suitable device located upstream and / or downstream the forming mesh / surface.

[0024]Reference is initially made to figures 1-4. Figure 1 disclosing a schematic illustration of a generic production line / apparatus for dry manufacturing rigid cellulose products, generally designated 1. The production line 1 is configured for manufacturing rigid ...

Technical field of the Invention

[0001] The present invention relates in general to the field of packaging containers for accommodating an item / content therein, such as groceries, food, cosmetics, industrial goods, consumer goods, etc. The packaging container comprises a lined tray and a lid film that is heat-sealed to said lined tray, wherein the lined tray comprises a rigid cellulose tray made of cellulose fibres. Thus, the rigid cellulose tray is intended to be used as a single use disposable article / product in order to replace corresponding plastic tray. In addition to the cellulose tray, the lined tray also comprises a liner film adhered to the rigid cellulose tray in order to act as a barrier in order to enhance the physical properties of the cellulose tray, such as a barrier for gas, grease, flavour, moisture, etc. The present invention also relates to a lined tray to be used together with a lid film configured to be heat-sealed to the lined tray in order to generate a packaging container for accommodating an item therein.

[0002] The rigid cellulose tray comprises a bottom portion for receiving the item, a wall connected to and extending in the axial direction upwards from the bottom portion, a brim connected to and extending in the radial direction outwards from the upper end of the wall, and a holding tab connected to and extending in the radial direction outwards from the brim. The liner film is adhered to at least an upper surface of the brim, and an upper surface of the holding tab.Background of the Invention

[0003] There are many situations where it is desirable to provide three-dimensional (3D) shaped objects made of sustainable materials, such as biomaterials, instead of plastic / polymer materials. When storing items that for instance have a certain content of moisture / grease, known trays made of plastic / polymer materials have the advantage that the tray itself constitute the barrier to prevent penetration and disintegration of the tray.

[0004] A biomaterial commonly used for packaging is wet moulded pulp based on cellulose fibres. Such wet moulded pulp has the advantage of being considered as a sustainable packaging material, since it is produced from biomaterials and can be recycled after use. Wet moulded pulp comprises more or less only water and separated cellulose fibers, and consequently, wet moulded pulp has been popular to use for packaging applications and as single / multiple use disposable articles. Such trays make use of a liner film acting as a barrier in order to enhance the physical properties of the cellulose tray.

[0005] However, a common disadvantage with all wet-forming techniques is the need for large amounts of water during the preparations of the cellulose pulp and the need for drying during the manufacturing / moulding of the product, which is time as well as energy consuming step leading to low production speed and substantial high investment cost in machines and tooling. Meaning that the wet-forming techniques are not feasible to replace fossil-based alternatives neither in small nor large scale production of rigid cellulose products. Thereto, the aesthetical and mechanical properties of a wet-moulded cellulose product are hard to control with desirable precision, due to un-uniform cellulose pulp and due to the wet moulding manufacturing technique per se.

[0006] Therefore many actors / companies, starting a few decades ago, have changed their focus and investments towards dry-forming techniques wherein rigid cellulose products are manufactured from separated cellulose fibres that are introduced into a product forming unit in the shape of a dry cellulose blank / web, wherein the cellulose blank is formed into the shape of the intended cellulose product and wherein the cellulose fibres are bonded to each other using heat and pressure in the product forming unit. The dry-forming techniques comprises different steps of generating an air-laid cellulose blank, that is fed into the product forming unit. Alternative dry-forming techniques makes use of a paperboard / cardboard cellulose blank, that is fed into the product forming unit.

[0007] However, in order to have a fully recyclable lined tray that comprises a rigid cellulose tray made of cellulose fibres and a liner film, the liner film has to be easily separable from the cellulose tray after use of the container. Manual separation at home after use of the lined tray / container has to be easy and efficient, i.e. too much of the recyclable cellulose tray and / or the recyclable liner film must not remain adhered to the other component after separation. Thus, an increasing difficulty of separating the cellulose tray from the liner film entails a decreasing likelihood of recycling the pieces.

[0008] When the item is filled into the container, the lid film is heat sealed to the liner film in a conventional manner. Thus, the liner film and the lid film together delimit the actual compartment holding / storing the item by constituting a sealed enclosure, and the cellulose tray provides stability to the packaging container. Thus, the sealing property of the heat seal is important in order to keep the desired atmosphere in the compartment, and thereby the strength of the heat seal is increased to secure improved / required sealing property. At the same time as the strength of the heat seal is increased, the openability / separability of the lid film from the lined tray is decreased. Decreased openability result in the necessity to use more or less sophisticated home-made solutions including sharp objects / tools.

[0009] If incorrect relationship between the different bonding is achieved, the user trying to open the packaging container may end up with a bag in one hand, liner film and lid film still interconnected, and the cellulose tray in the other hand. Thereto, this might be hazardous to the user especially if the item / food in the packaging container has been heated in a microwave.

[0010] There are known ways trying to solve the above requirements and problems, for instance US 4905838 and WO 2021 / 257099. Reference is also made to a document from the remote technical field of plastic trays, i.e. WO 2021 / 180961. But none of them solve all problems and requirements. Thus, there is a need in the art for a reliable packaging container, that provide proper sealing of the compartment holding the item, easy access to the item and easy separation of the liner film from the cellulose tray for recycling.Object of the Invention

[0011] The present invention aims at obviating the aforementioned and other disadvantages and failings of previously known packaging containers and lined trays, and at providing an improved packaging container and an improved lined tray.

[0012] A primary object of the present invention is to provide an improved packaging container and lined tray, wherein the packaging container provides proper sealing of the compartment holding the item and easy access to the item. It is also an object of the present invention to provide an improved packaging container providing easy separation of the liner film from the cellulose tray for suitable recycling thereof. It is also an object of the present invention to provide an improved packaging container providing easy separation of the lid film and the liner film from each other for suitable recycling thereof.Summary of the Invention

[0013] According to the invention at least the primary object is attained by means of the initially defined packaging container and the lined tray having the features defined in the independent claims. Preferred embodiments of the present invention are further defined in the dependent claims.

[0014] According to the present invention, there is provided a packaging container and a lined tray, wherein the lined upper surface of at least a distal portion of the holding tab in relation to the lined upper surface of the adjacent brim, is in the axial direction located offset towards the bottom portion a distance equal to or more than 1 mm and equal to or less than 5 mm, wherein the lid film is heat-sealed to the lined upper surface of the brim, and wherein the lid film comprises a gripping tab located in overlapping configuration with the holding tab of the lined tray, and located axially separated from said distal portion of the holding tab.

[0015] Thus, the present invention is based on the insight that the weakest bonding of the packaging container is the internal bindings between the individual cellulose fibres in the cellulose tray. Thereby the cellulose fibres at the surface of the cellulose tray will adhere to and follow the liner film during separation. In order to minimize the amount of cellulose fibres following the liner film, the adhesion between the liner film and the cellulose tray is made as weak as possible. The new and inventive lined tray is provided a design that secures that the gripping tab of the lid film is not adhered to the lined holding tab of the lined tray during heat-sealing, and thereto the user has easy access to firmly grip the holding tab and the gripping tab, respectively, in order to open the packaging container by separating the lid film from the lined tray. The rigid holding tab of the lined tray also protects the gripping tab of the lid film from being damaged during transportation and storing of the container.

[0016] According to various example embodiments of the present invention the liner film is also adhered to an upper surface of the bottom portion and / or to an inner surface of the wall of the rigid cellulose tray. Thereby the adhesion force between the liner film and the cellulose tray may be decreased since the adhesion interface between the liner film and the cellulose tray is increased.

[0017] According to various example embodiments of the present invention the liner film is a multilayer film comprising polymer and / or metal. Thereby different liner films may be chosen depending on the barrier properties and / or appearance required.

[0018] According to various example embodiments of the present invention the lid film is a multilayer film comprising polymer, metal, and / or paper. Thereby different lid films may be chosen depending on the barrier properties and / or appearance required.

[0019] According to various example embodiments of the present invention the width of the upper surface of the brim is equal to or more than 2 mm and equal to or less than 10 mm. A narrower upper surface of the brim would require that the strength per area of the heat-seal is increased too much, such that the lid film and liner film becomes inseparable without breaking. A wider upper surface of the brim entails that the total strength of the heat-seal is increased too much, such that the lid film and liner film becomes inseparable without breaking.

[0020] Further advantages with and features of the invention will be apparent from the following detailed description of preferred embodiments.Brief description of the drawings

[0021] A more complete understanding of the abovementioned and other features and advantages of the present invention will be apparent from the following detailed description of preferred embodiments in conjunction with the appended drawings, wherein: Fig. 1is a schematic illustration of a production line or apparatus for dry manufacturing rigid cellulose products, Fig. 2is a schematic illustration of a moulding tool, wherein a cellulose blank is loaded therein, Fig. 3is a schematic illustration of the moulding tool according to figure 2, wherein the cellulose blank is pressed into final rigid non-flat general shape, Fig. 4is a schematic illustration of the moulding tool according to figures 2 and 3, wherein the rigid cellulose product is released, Fig. 5is a schematic view from above of a cellulose tray of the inventive packaging container, Fig. 6is a schematic exploded side view of an inventive packaging container, Fig. 7is a schematic illustration of the packaging container according to figure 6 accommodating an item therein, and Fig. 8is a schematic enlarged side view of the holding tab and gripping tab of the inventive packaging container according to figure 7. Detailed description of preferred embodiments of the invention

[0022] As used herein, the term "air / dry moulding / forming or air / dry laying / laid" means a well-known method according to which separated cellulose fibres, i.e. cellulose fluff, are formed into a cellulose blank / sheet.

[0023] In air-laying technique, small / short fibres having a normal length in the range of 0,5 to 70 mm, for instance 1 to 50 mm, are separated and captured by an air stream / flow, and then laid on / applied to a forming mesh / surface, usually using a low pressure at the other side of the mesh / surface. The terms "air / dry laying" and "air / dry moulding" are used interchangeably herein. The cellulose fibre carrying air flow may be generated by suitable device located upstream and / or downstream the forming mesh / surface.

[0024] Reference is initially made to figures 1-4. Figure 1 disclosing a schematic illustration of a generic production line / apparatus for dry manufacturing rigid cellulose products, generally designated 1. The production line 1 is configured for manufacturing rigid cellulose products, generally designated 2, having essentially non-flat general shape from separated cellulose fibres. Such a production line 1 may be arranged and set-up according to different well-known ways.

[0025] Cellulose raw material 3 is provided to the production line, and is fed to a separating / disintegrating unit 4 in order to obtain individualized / separated cellulose fibres. The separated cellulose fibres are thereafter transported by an air stream / flow to a dispenser of a cellulose blank / sheet forming unit 5. The cellulose fibres are laid by the dispenser on a moving or stationary perforated surface of the cellulose blank forming unit 5. The cellulose fibre carrying air flow may be generated by suitable device located upstream and / or downstream the perforated surface. Thereafter the generated cellulose blank 6 is transported to a product forming unit 7, whereby rigid cellulose products 2 are formed and discharged from the product forming unit 7. The rigid cellulose product 2 is in this embodiment made of a heat-pressed sheet of air-laid cellulose fluff comprising cellulose fibers.

[0026] The cellulose blank forming unit 5 may be configured to generate a continuous cellulose blank and / or discontinuous / discrete cellulose blanks. Preferably discontinuous / discrete cellulose blanks 6 are fed into the product forming unit 7.

[0027] The cellulose raw material 3 may be in the form of reeled pulp or paper, bale of cellulose pulp, paper, etc. and / or sheets of paper, cellulose pulp, etc. In case said cellulose raw material 3 is in the form of sheets and / or reeled pulp or paper, it can be fed directly into the separating unit 4. However, in case said cellulose raw material 3 is in the form of a bale or compact stacks of sheets, etc. one or more shredders and / or one or more additional separating / disintegrating units 4 may be necessary to be used for separating and dosing said cellulose raw material 3 from said bale or sheets in smaller quantities. The shredder(s) prepare cellulose raw material 3 to be accepted by said separating unit 4. The separating unit 4 disintegrates the cellulose raw material 3 into separated cellulose fibres. Said one or plurality of shredder(s) are arranged before said one or a plurality of separating unit(s) 4, so that an output of one of said shredder is connected to an input of one of said separating units 4. The shredders may be arranged in parallel to each other or in series with each other, and the disintegrating units 4 may be arranged in parallel to each other or in series with each other. The shredders and the disintegrating units 4 together constitute a cellulose fibre separating unit, arranged upstream the cellulose blank forming unit 5.

[0028] Said cellulose raw material 3 may be constituted by virgin cellulose fibres and / or recycled cellulose fibres and may originate from wood pulps such as kraft pulp, sulphite pulp, mechanical pulp, thermomechanical pulp (TMP), chemical treated mechanical pulp, chemi-thermomechanical pulp (CTMP), and / or from non-wood pulps such as bagasse, bamboo, abaca, hemp, flax, cotton.

[0029] The separating unit 4 may according to various embodiments be constituted by a hammer mill. In said separating unit 4 the cellulose raw material is separated into fibres having a normal length in the range of 0,5-70 mm. The length of said fibres may be customized by adjusting the internal properties of the separating unit 4 and / or by choosing a different separating unit 4 and / or choosing different cellulose raw material. The fibre length for wood pulp is according to various embodiments in the range 0,5-4 mm, preferably in the range 1,7-3,6 mm. According to various embodiments the fibre length for non-wood pulp is in the range 0,5-70 mm.

[0030] The production line 1 may comprise a pre-compression and / or imprinting unit 8, located downstream the cellulose blank forming unit 5 and upstream the product forming unit 7. In the pre-compression and / or imprinting unit 8, an air-laid fluffy cellulose blank having a first thickness may be compressed into a cellulose blank having a second thickness, wherein said second thickness is thinner than said first thickness, and / or may be provided with an imprinted pattern. During the pre-compression / imprinting the cellulose blank is made more coherent and easier to handle, since the pre-compression / imprinting generates internal bindings between individual cellulose fibres preventing mutual separation of the cellulose fibres.

[0031] The product forming unit 7 comprises a press unit 9, and may optionally comprise a preheating unit 10 arranged upstream the press unit 9. According to various example embodiments said cellulose blank 6 may be heated to an elevated temperature before being fed into the press unit 9 of the product forming unit 7. In such embodiment(s) where the cellulose blank is preheated before being fed into the press unit 9, said press unit 9 may or may not comprise heating. According to various example embodiment said press unit 9 may be a heated press unit 9 for heating said cellulose blank 6 during pressing. In the case of a heated press unit 9, preheating of said cellulose blank using a pre-heating unit 10 is optional. According to various example embodiments preheating of the cellulose blank in said pre-heating unit 10 may be combined with a heated press unit 9. Having a preheating unit 10 in combination with a heated press unit 9 will speed up the manufacturing process in the product forming unit 7, and improve the quality / rigidity of the final rigid cellulose product 2. In the product forming unit 7 the cellulose blank 6 is heated to a temperature in the range 120 - 200 °C in order to obtain adequate rigidity and strength in the final cellulose product 2. Thus, in this embodiment the rigid cellulose product 2 is made of a heat-pressed sheet of air-laid cellulose fluff comprising cellulose fibers.

[0032] Reference is now especially made to figures 2-4. The press unit 9 comprises a moulding tool having a first mould part 11 and a second mould part 12, wherein at least one of the first mould part 11 and the second mould part 12 is / are displaceable back and forth in relation to each other, in order to exert pressure to the cellulose blank 6 loaded therebetween. In the figures the mutual displacement is disclosed as being vertical, however the mutual displacement may be horizontal or any other suitable angle. The cellulose blank 6 loaded into the moulding tool, is constituted by an air-laid cellulose blank 6. The air-laid cellulose blank 6 may be generated upstream the product forming unit 7 in the same production line and provided to the product forming unit 7, or may be generated at a separate location and provided to the product forming unit 7 via intermediate handling and storage.

[0033] According to various embodiments the first mould part 11 of the moulding tool is a female mould part, i.e. having a recess for receiving the cellulose blank 6, and the second mould part 12 of the moulding tool is a male mould part, i.e. having a protrusion for cooperation with said recess of the first mould part 11, such that the cellulose blank 6 is pressed into a final rigid non-flat shape. The male mould part will form the inner surface of the rigid cellulose product 2 and the female mould part will form the outer surface of the rigid cellulose product 2. It shall be pointed out that both the first mould part 11 and the second mould part 12 may comprise further local / minor projections and recesses. During the pressing, disclosed in figure 3, a predetermined pressure P1 is applied by the moulding tool between the recess and the protrusion. Thus, the rigid cellulose product 2 obtains its final rigid non-flat shape, which may have any conceivable non-flat design / shape. In the disclosed embodiment the edges of the rigid cellulose product 2 are trimmed concurrently with the pressing / forming of the rigid cellulose product 2. The edges of the rigid cellulose product 2 may be trimmed in a subsequent process step separated from the pressing of the rigid cellulose product 2.

[0034] In figure 4 the cellulose product 2 is released by opening the moulding tool. The predetermined pressure P1 is in the range 40-10000N / cm 2< , preferably in the range 100-4000N / cm 2< . According to various embodiments said predetermined pressures are above 400 N / cm 2< , and according to various embodiments said predetermined pressures are below 2000 N / cm 2< . According to various embodiments the cellulose blank 6 loaded into the press unit 9 is constituted by a paperboard / cardboard cellulose blank, instead of the air-laid cellulose blank described above.

[0035] The rigid cellulose product is hereinbelow constituted by a cellulose tray 2 made of cellulose fibers. The above disclosure concerning a rigid cellulose product is fully applicable to the tray 2.

[0036] Reference is now also made to figure 5 disclosing an exemplary illustration of a rigid cellulose tray 2 from above. The rigid cellulose tray 2 may have any suitable general shape seen from above, such as square, hexagonal, polygonal, triangular, round, oval, etc. The tray 2 comprises a bottom portion 13 for receiving an item 14, a wall 15 connected to and extending in the axial direction upwards from the bottom portion 13, a brim 16 connected to and extending in the radial direction outwards from the upper end of the wall 15, and a holding tab 17 connected to and extending in the radial direction outwards from the brim 16.

[0037] According to various embodiments, including the disclosed embodiment, the wall 15 is a circumferential wall and the tray 2 comprises one compartment for receiving the item 14. According to various undisclosed embodiments, the tray 2 comprises two or more compartments separated by partition(s), wherein the wall 15 of the tray 2 may be fully or partly interrupted by the partition(s). Thus, said partition(s) may protrude to the same height as the wall 15, wherein the upper end of the partition(s) connects to the brim 16.

[0038] The bottom portion 13 comprises a bottom 18 for receiving the item 14, and a transitional edge region 19 located between the bottom 18 and the wall 15. The transitional edge region 19 may for instance be constituted by a chamfer and / or radius. The bottom 18 may be flat as in the disclosed embodiments, or may have non-flat general shape.

[0039] The wall 15 extends in the axial direction and is preferably slightly tilted outwards in the upwards direction such that multiple empty trays 2 may be stacked one in the other. According to various embodiments, the wall 15 may comprise a curvature along at least a part of the distance between the bottom portion 13 and the brim 16, i.e. bulge radially inwards and / or radially outwards. According to the disclosed embodiments the wall 15 is straight between the bottom portion 13 and the brim 16.

[0040] According to various embodiments the brim 16 is circumferential, and is preferably located in one geometrical plane. The brim 18 comprises an upper surface 20 that preferably is flat. Different parts of the brim 16 may be located at different axial distance in relation to the bottom 18. According to various embodiments, the width of the upper surface 20 of the brim 18 is equal to or more than 2 mm and equal to or less than 10 mm, preferably equal to or more than 4 mm and equal to or less than 8 mm. The width of the upper surface 20 is taken / measured in the radial direction, i.e. perpendicular to the circumferential direction of the brim 18. According to various embodiments the brim 16 comprises a chamfering / rounding at the outer periphery thereof.

[0041] The holding tab 17 comprises an upper surface 21 and according to various embodiments the upper surface 21 is parallel to the upper surface 20 of the adjacent brim 16, and according to various alternative embodiments the upper surface 21 of the holding tab 17 is tilting downwards from the upper surface 20 of the adjacent part of the brim 16, or a combination thereof. There might be a material bridge between the holding tab 17 and the brim 16. The interface / connection between the brim 16 and the holding tab 17 is preferably equal to or more than 1 cm and equal to or less than 5 cm, in the circumferential direction of the brim 17.

[0042] Reference is now also made to figures 6-8. According to the invention, the packaging container comprises a lined tray, wherein the lined tray comprises said rigid cellulose tray 2 and a liner film 22. The liner film 22 is adhered to at least the upper surface 20 of the brim 16 and to the upper surface 21 of the holding tab 17. According to various embodiments, the liner film 22 is also adhered to the inner surface of the bottom portion 13 and / or to the inner surface of the wall 15. The liner film 22 may be adhered to parts of the inner surface of the bottom portion 13 and / or to parts of the inner surface of the wall 15. The liner film 22 is typically a flat sheet before it is added to the tray 2, however it is possible to have the liner film 22 pre-shaped before it is added / adhered to the tray 2.

[0043] According to various embodiments the adhesion of the liner film 22 to the rigid cellulose tray 2 is heat activated, i.e. the part of the liner film 22 facing the tray 2 is partly melted / activated by the heat such that the liner film 22 sticks to at least the surface fibres of the tray 2. According to one embodiment, the liner film 22 is applied to the tray 2 by generating an under-pressure through the cellulose tray 2, i.e. the liner film 22 is sucked towards / against the tray 2, and / or by generating an over-pressure at the upper side of the liner film 22. The adhesion of the liner film 22 may be constituted by or complemented by applying a liquid adhesive onto the liner film 22 and / or onto the tray 2. The heat may be constituted by hot air, irradiation, remaining heat in the tray 2 from the pressing / forming thereof, etc.

[0044] According to various embodiments the liner film 22 is a multilayer film comprising polymer and / or metal, depending on the barrier characteristics / properties needed. The liner film 22 may comprise fossil-based or biobased polymer. The purpose of the lower layer of the liner film 22 is primarily to act as a heat activated adhesive. The purpose of the other layer(s) of the liner film 22 is primarily to act as a barrier for moisture, gas, grease, flavour, etc., but may also relate to the appearance of the lined tray 2 regarding pattern, colour, figures, text, etc. The liner film 22 may be cold and / or heat resistance in order to be used in a freezer, fridge, microwave-oven, oven, etc.

[0045] According to the invention, the lined upper surface 23 of at least a distal portion of the holding tab 17 in relation to the lined upper surface 24 of the adjacent brim 16, is in the axial direction located offset towards the bottom portion 13 a distance A equal to or more than 1 mm and equal to or less than 5 mm, preferably equal to or more than 2 mm and equal to or less than 4 mm.

[0046] According to various embodiments, the distal portion of the holding tab 17 has an area that is equal to or more than 1 cm 2< and equal to or less than 3 cm 2< .

[0047] According to the invention, the packaging container comprises a lid film 25 that is heat-sealed to the lined tray 2, more precisely heat-sealed to the lined upper surface 24 of the brim 16. The lid film 25 is typically a flat sheet before it is added to the tray 2.

[0048] According to various embodiments the lid film 25 is a multilayer film comprising polymer, metal and / or paper, depending on the barrier characteristics / properties needed. The lid film 25 may comprise fossil-based or biobased polymer. The purpose of the lower layer of the lid film 25 is primarily to act as a heat activated adhesive. The purpose of the other layer(s) of the lid film 25 is primarily to act as a barrier for moisture, gas, grease, flavour, etc., but may also relate to the appearance of the lined tray 2 regarding pattern, colour, figures, text, etc. The lid film 25 may be cold and / or heat resistance in order to be used in a freezer, fridge, microwave-oven, oven, etc.

[0049] The liner film 22 and the lid film 25 may be constituted by the same multilayer film, or they may be constituted by different multilayer films since usually the item 14 is abutting the liner film 22 and the lid film 25 is only in contact with the enclosed atmosphere / gas of the packaging container. For instance the liner film 22 might need to constitute a barrier for moisture and grease in order to protect the cellulose tray 2 and the lid film 25 has to let moisture through in order to prevent vapor or frost in the packaging container.

[0050] According to the invention, the lid film 25 comprises a gripping tab 26 located in overlapping configuration with the holding tab 17 of the lined tray 2, and located axially separated from said distal portion of the holding tab 17. Thereby, the gripping tab 26 and the holding tab 17 are easily accessible and the lid film 25 can be securely removed from the lined tray 2 since the user when holding the holding tab 17 also holds the liner film 22 adhered to the holding tab 17. The axial distance A between the lined upper surface 23 of the distal portion of the holding tab 17 and the lined upper surface 24 of the adjacent brim 16 secures that the lid film 25 is not heat-sealed to the holding tab 17 when the lid film 25 is heat-sealed to the lined upper surface 24 of the brim 16. The gripping tab 26 is at the same time protected by the holding tab 17 and thereby prevented from being damaged. The holding tab 17 and the gripping tab 26 preferably has the same general shape seen in the axial direction.

[0051] The present invention also relates to the lined tray 2 as such, wherein the lined tray 2 is configured to be used together with the lid film 25 configured to be heat-sealed to the lined tray 2 in order to generate a packaging container for accommodating an item 14 therein.Feasible modifications of the Invention

[0052] The invention is not limited only to the embodiments described above and shown in the drawings, which primarily have an illustrative and exemplifying purpose. This patent application is intended to cover all adjustments and variants of the preferred embodiments described herein, thus the present invention is defined by the wording of the appended claims and the equivalents thereof. Thus, the equipment may be modified in all kinds of ways within the scope of the appended claims.

[0053] Throughout this specification and the claims which follows, unless the context requires otherwise, the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or steps or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0054] It shall be pointed out that the final rigid cellulose product may be constituted by three or more segments, wherein each pair of neighbouring segments are joined / connected to each other according to the present invention.

Examples

Embodiment Construction

[0022]As used herein, the term "air / dry moulding / forming or air / dry laying / laid" means a well-known method according to which separated cellulose fibres, i.e. cellulose fluff, are formed into a cellulose blank / sheet.

[0023]In air-laying technique, small / short fibres having a normal length in the range of 0,5 to 70 mm, for instance 1 to 50 mm, are separated and captured by an air stream / flow, and then laid on / applied to a forming mesh / surface, usually using a low pressure at the other side of the mesh / surface. The terms "air / dry laying" and "air / dry moulding" are used interchangeably herein. The cellulose fibre carrying air flow may be generated by suitable device located upstream and / or downstream the forming mesh / surface.

[0024]Reference is initially made to figures 1-4. Figure 1 disclosing a schematic illustration of a generic production line / apparatus for dry manufacturing rigid cellulose products, generally designated 1. The production line 1 is configured for manufacturing rigid ...

Claims

1. Packaging container for accommodating an item (14) therein, wherein the packaging container comprises a lined tray and a lid film (25) that is heat-sealed to said lined tray, the lined tray comprising a rigid cellulose tray (2) made of cellulose fibers and a liner film (22), wherein the rigid cellulose tray (2) comprises: - a bottom portion (13) for receiving the item (14), - a wall (15) connected to and extending in the axial direction upwards from the bottom portion (13), - a brim (16) connected to and extending in the radial direction outwards from the upper end of the wall (15), and - a holding tab (17) connected to and extending in the radial direction outwards from the brim (16), wherein the liner film (22) is adhered to at least: - an upper surface (20) of the brim (16), and - an upper surface (21) of the holding tab (17), characterized in that the lined upper surface (23) of at least a distal portion of the holding tab (17) in relation to the lined upper surface (24) of the adjacent brim (16), is in the axial direction located offset towards the bottom portion (13) a distance (A) equal to or more than 1 mm and equal to or less than 5 mm, in that the lid film (25) is heat-sealed to the lined upper surface (24) of the brim (16), and in that the lid film (25) comprises a gripping tab (26) located in overlapping configuration with the holding tab (17) of the lined tray, and located axially separated from said distal portion of the holding tab (17).

2. The packaging container according to claim 1, wherein the liner film (22) is adhered to an inner surface of the bottom portion (13).

3. The packaging container according to claim 1 or 2, wherein the liner film (22) is adhered to an inner surface of the wall (15).

4. The packaging container according to any of claims 1-3, wherein the rigid cellulose tray (2) is made from an air-laid cellulose blank (6) made of cellulose fibres.

5. The packaging container according to any preceding claim, wherein the liner film (22) is a multilayer film comprising polymer and / or metal.

6. The packaging container according to any preceding claim, wherein the lid film (25) is a multilayer film comprising polymer, metal, and / or paper.

7. The packaging container according to any preceding claim, wherein the lined upper surface (23) of at least a distal portion of the holding tab (17) in relation to the lined upper surface (24) of the adjacent brim (16), is in the axial direction located offset towards the bottom portion (13) a distance (A) equal to or more than 2 mm and equal to or less than 4 mm.

8. The packaging container according to any preceding claim, wherein the distal portion of the holding tab (17) has an area that is equal to or more than 1 cm2 and equal to or less than 3 cm2.

9. The packaging container according to any preceding claim, wherein the adhesion of the liner film (22) to the rigid cellulose tray (2) is heat activated.

10. The packaging container according to any preceding claim, wherein the width of the upper surface (20) of the brim (16) is equal to or more than 2 mm and equal to or less than 10 mm, preferably equal to or more than 4 mm and equal to or less than 8 mm.

11. Lined tray to be used together with a lid film (25) configured to be heat-sealed to the lined tray in order to generate a packaging container for accommodating an item (14) therein, the lined tray comprising a rigid cellulose tray (2) made of cellulose fibers and a liner film (22), wherein the rigid cellulose tray (2) comprises: - a bottom portion (13) for receiving the item (14), - a wall (15) connected to and extending in the axial direction upwards from the bottom portion (13), - a brim (16) connected to and extending in the radial direction outwards from the upper end of the wall (15), and - a holding tab (17) connected to and extending in the radial direction outwards from the brim (16), wherein the liner film (22) is adhered to at least: - an upper surface (20) of the brim (16), and - an upper surface (21) of the holding tab (17), characterized in that the lined upper surface (23) of at least a distal portion of the holding tab (17) in relation to the lined upper surface (24) of the adjacent brim (16), is in the axial direction located offset towards the bottom portion (13) a distance (A) equal to or more than 1 mm and equal to or less than 5 mm, such that the lid film (25) when heat-sealed to the lined upper surface (24) of the brim (16) comprises a gripping tab (26) located in overlapping configuration with the holding tab (17) of the lined tray, and located axially separated from said distal portion of the holding tab (17).

Images