Food packaging container

Abstract

A package for holding food includes a tray and a lid. The tray includes a substrate defining a base inside surface and a base outside surface, the base inside surface supporting each of a base barrier coating and a first base heat seal coating. The base barrier coating covers a base food contact portion of the base inside surface and the first base heat seal coating covers a flange portion of the base inside surface. The lid includes a substrate defining a lid inside surface and a lid outside surface, the lid inside surface including a lid barrier coating and a lid heat seal coating. The lid barrier coating covers a lid food contact portion of the lid inside surface and the lid heat seal coating covers a sealing portion of the lid inside surface, the sealing portion configured to at least partially mate with the flange portion.

Description

FOOD PACKAGING CONTAINERCROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Patent Application No. 63 / 673,484, filed July 19, 2024, the disclosure of which is incorporated herein in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates to packaging containers. More specifically, the present disclosure relates to coatings for food packaging.BACKGROUND

[0003] In some situations, it can be beneficial to store food in disposable containers. Such containers can be exposed to extreme temperatures, such as freezing, as well as contact with liquids, such as the food itself or condensation during thawing. Therefore, fiber-based trays with polymer lids have been used for food containers, although many traditional polymers used are not recyclable or compostable and / or are not made from sustainable or biorenewable precursors.SUMMARY

[0004] In Example 1 , a package for holding food, the package comprising a tray including a substrate defining a base inside surface and a base outside surface, the base inside surface supporting each of a base barrier coating and a first base heat seal coating wherein the base barrier coating covers at least a base food contact portion of the base inside surface and the first base heat seal coating covers a sealing portion of the base inside surface, a lid including a substrate defining a lid inside surface and a lid outside surface, the lid inside surface including a lid barrier coating and a lid heat seal coating, wherein the lid barrier coating covers at least a lid food contact portion of the lid inside surface and the lid heat seal coating covers a sealing portion of the lid inside surface, the sealing portion of the lid inside surface configured to at least partially mate with the sealing portion of the base inside surface.

[0005] In Example 2, the package of Example 1 wherein the first base heat seal coating further covers at least one corner portion of the base, the corner portion including a corner fold.

[0006] In Example 3, the package of Example 1 , further comprising a second base heat seal coating covering at least one corner portion of the base, the corner portion including a corner fold.

[0007] In Example 4, the package of any of Examples 1 -3, further comprising a primer disposed between the base inside surface and at least one of the barrier coating and the first base heat seal coating.

[0008] In Example 5, the package of any of Examples 1-4, wherein the base barrier coating the lid barrier coating comprises an electron-beam curable acrylate.

[0009] In Example 6, the package of any of Examples 1-5, wherein the base barrier coating comprises a curable acrylate.

[0010] In Example 7, the package of any of Examples 1 -6, wherein the first and second base heat seal coatings comprise an acrylic emulsion polymer mixture.

[0011] In Example 8, the packaging tray of any of Examples 1 -7, wherein the first base heat seal coating has a different formulation than the second base heat seal coating.

[0012] In Example 9, the packaging tray of any of Examples 1 -7 wherein the first base heat seal coating has a same formulation as the lid heat seal coating.

[0013] In Example 10, a method of making a packaging container for holding a food product, the method comprising providing a paperboard tray substrate, the tray substrate having a tray inside surface and a tray outside surface, printing a barrier coating onto a first portion of the tray inside surface intended to contact the food product, electron-beam curing the barrier coating on the tray inside surface, printing a heat seal coating onto a second portion of the tray inside surface associated with an outside flange of the tray inside surface, printing the heat seal coating onto a corner portion of the tray outside surface, the comer portion adapted for folding to form a wall portion of the tray, cutting a tray preform out of the tray substrate, the tray preform being configured to be folded into the tray, heating selected portions of the heat seal coating, and folding the tray preform to form the tray.

[0014] In Example 11 , the method of Example 10, further comprising providing a paperboard lid substrate, the lid having an inside lid surface and an outside lid surface, printing the barrier coating onto a third portion of the lid inside surface intended to contact the food product, electron-beam curing the barrier coating on the lid inside surface, printing the heat seal coating onto a perimeter portion of the lid inside surface intended to mate with the outside flange, heating selected portions of the heat seal coating of the second portion of the tray and the perimeter portion of the lid, aligning the lid with the tray; and sealing the lid and the tray to form the packaging container.

[0015] In Example 12, the method of Example 10, further comprising drying the heat seal coating prior to cutting the tray preform.

[0016] In Example 13, a tray preform configured to be folded into a tray for food storage, the tray preform comprising a base region, a plurality of side regions extending from the base region, a plurality of flange regions, wherein each of the flange regions extends from one of the side regions, a plurality of corner regions, wherein each of the corner regions extends between two adjacent side regions, a first barrier coating on insides of the base region and the side regions, a first seal coating on the flange regions, the first seal coating being configured to connect to a lid, and a second seal coating on the corner regions, the second seal coating being different from the first seal coating, and the second seal coating being configured to adhere the corner regions to the side regions.

[0017] In Example 14, a package for storing food, the package comprising a tray formed by folding and adhering the tray preform of claim 13, the tray including a flange comprised of the flange regions, and a lid comprising a sealing region around a perimeter of a flat paperboard, a cover region in the center of the flat paperboard, a second barrier coating on an inside of the lid, and a third seal coating on the sealing region, wherein the sealing region of the lid is adhered to the flange region of the tray.

[0018] In Example 15, the package of Example 14, wherein the first seal coating and the third seal coating are the same.

[0019] In Example 16, the package of Example 14, wherein the first barrier coating and the second barrier coating are the same.

[0020] In Example 17, the package of any of Examples 13-16, wherein the first seal coating is a first heat seal coating and the second seal coating is a second heat seal coating.

[0021] In Example 18, the package of Example 17, wherein the first heat seal coating comprises an acrylic emulsion polymer mixture.

[0022] In Example 19, the package of any of Examples 13-18, wherein the first barrier coating comprises an electron-beam curable acrylate.

[0023] In Example 20, the package of any of Examples 13-19 wherein the first barrier coating comprises a curable acrylate.

[0024] While multiple embodiments are disclosed, still other embodiments of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 is a perspective view of a tray, consistent with various aspects of the present disclosure.

[0026] Figure 2 is a cross-sectional view of the tray, consistent with various aspects of the present disclosure.

[0027] Figure 3 is a top view of an inside surface of a tray flat, consistent with various aspects of the present disclosure.

[0028] Figure 4 is a bottom view of an outside surface of the tray flat, consistent with various aspects of the present disclosure.

[0029] Figure 5 is a bottom view of an inside surface of a lid flat, consistent with various aspects of the present disclosure.

[0030] Figure 6 is a flowchart of a method of making a package, consistent with various aspects of the present disclosure.

[0031] While the disclosure is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the disclosure to theparticular embodiments described. On the contrary, the disclosure is intended to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure as defined by the appended claims.DETAILED DESCRIPTION

[0032] For purposes of promoting an understanding of the principles of the present disclosure, reference is now made to the examples illustrated in the drawings, which are described below. The illustrated examples disclosed herein are not intended to be exhaustive or to limit the disclosure to the precise form disclosed in the following detailed description. Rather, these exemplary embodiments were chosen and described so that others skilled in the art may use their teachings. It is not beyond the scope of this disclosure to have a number (e.g., all) the features in a given example used across all examples. Thus, no one figure should be interpreted as having any dependency or requirement related to any single component or combination of components illustrated therein. Additionally, various components depicted in a given figure may be, in examples, integrated with various ones of the other components depicted therein (and / or components not illustrated), all of which are considered to be within the ambit of the present disclosure.

[0033] Figure 1 shows a tray 100. In the illustrated embodiment, the tray 100 forms the bottom portion of a food package (not shown). The tray 100 is formed from a flat substrate (e.g., paperboard) that has been folded to create a base 102, long sides 104A-104B (collectively “long sides 104”) that extend upwards from the base 102 and oppose each other, short sides 106A-106B (collectively “short sides 106”) that extend upwards from the base 102 and oppose each other, and a flange 108 around the top of the tray 100 that extends from the long sides 104 and the short sides 106 and is parallel to the base 102.

[0034] In the illustrated embodiment, the tray 100 includes web corners 110A- 110B (collectively “web corners 110”) and tabs 112A-112D (collectively “tabs 112”). The tray 100 includes four web corners 110, although only two web corners 110 are visible in Figure 1. The web corners 110 are formed from folding the corner (i.e., the material positioned between and connected to the long sides 104 and the short sides 106,respectively) outwards along the corner fold lines (shown in Figure 4). The web corners 110 have been adhered together on their inside surfaces, and then the web corners 110 have been folded over and adhered to the outside surfaces of the short sides 106, respectively. Thus, the corner edges of the tray 100 will not leak since there are no joints made from separate pieces located thereat.

[0035] In the illustrated embodiment, the tray 100 includes tabs 112. Tabs 112 are formed from adhering material connected to the outsides of the long sides 104 to material connected to the inside surfaces of the short sides 106, respectively. This allows the flange 108 to be continuous around the top of the tray 100 so that the flange 108 can be the sealing portion of the tray 100. Thus, a lid (indicated in Figure 5) can be attached to the top of the tray 100 to form a sealed food package.

[0036] Figure 2 is a cross-sectional view of the tray 100. In the illustrated embodiment, the tray 100 is comprised of a plurality of layers with the main structural layer being a paperboard 120. The paperboard 120 can be a three-ply solid bleached sulphate (SBS) substrate that includes an inner layer 122 surrounded by two outer layers 124A-124B, although in other embodiments, the paperboard 120 has a fewer or greater number of plies. To form the inside surface of the tray 100 (shown in Figure 1 ), the top side of the paperboard 120 includes a printed coating 126, and to form the outside surface of the tray 100, the bottom side of the paperboard 120 includes a printed heat seal coating 128. Optional primer layers 130, 132 can be included, for example, to assist in adhering the printed coatings 126, 128 to the paperboard 120, to further seal the paperboard 120 from moisture and / or oil, and / or to assist in art printed on the inside and outside surfaces of the tray 100. In other embodiments, there are multiple layers of printed coatings and / or primer layers. In some embodiments, one or both of the primer layers 130, 132 are clay layers that aid the printed coatings 126, 128 to hold out, respectively.

[0037] The application of the coatings 126, 128 and the layers 130, 132 can be performed, in some embodiments, according to US Patent Pub. No. 2024 / 0092547 (“Packaging Film and Package” by Chaplain et al.), which is hereby incorporated by reference. Alternatively or additionally, equipment and methods (not shown) that are traditionally used to make single or multi-layer bags or other types of food packages canbe used to apply coatings 126, 128 and layers 130, 132. In addition, in some embodiments, coatings and / or layers are only useful on one side of the paperboard 120. In such embodiments, for example, the heat seal coating 128 and the layer 132 are not added to the paperboard 120. In the aforementioned embodiments where one or both of the primer layers 130, 132 are clay, the clay primer layers 130, 132 are pre-applied to the paperboard 120 by a machine that is separate from the printing press.

[0038] Figure 3 is a top view of an inside surface of a tray flat 140. In the illustrated embodiment, the flat 140 includes a base region 142, side regions 144A- 144D (collectively “side regions 144”) that extend outwards from each side of the base region 142, flange regions 146A-146D (collectively “flange regions 146”) that extend outwards from each of the side regions 144, and corner regions 148A-148D (collectively “corner regions 148”) that extend between the base region 142 and the side regions 144, respectively. In some embodiments, the flat 140 can be a portion of a continuous roll of material or the flat 140 can be a blank of material that is oversized compared to the tray preform that is configured to be folded into the tray 100 (shown in Figure 1 ). The region or blank is defined by the edge 150 whereas the tray preform is defined by the border 152. The tray preform can be cut out along the border 152, for example, using a die or a rotary cutter, after the coatings 126 and / or 128 have been applied.

[0039] In the illustrated embodiment, the flat 140 includes multiple coatings 126A- 126B (collectively “coatings 126”) on selected portions of the inside surface and a single heat seal coating 128 on selected portions of the outside surface. The barrier coating 126A is configured to be a barrier coating between the paperboard 120 (shown in Figure 2) and the food (not shown). Thus, the barrier coating 126A has been applied to completely cover the regions 142, 144, and the barrier coating 126A extends into the regions 146, 148 to increase the allowable registration tolerance of the flat 140. In some embodiments, the barrier coating 126A is a curable acrylate that is biodegradable, sustainable, and biorenewable. In some embodiments, the barrier coating 126A is a curable material that is recyclable or compostable. In some embodiments, the barrier coating 126A is eGreen220 from Cork Industries Inc. that can be electron-beam cured. In some embodiments, the barrier coating 126A can comprise a water-based acrylic dispersion, a coating that is heat cured, and / or a coating that is ultraviolet (UV) lightcured. In some embodiments, the barrier coating 126A can comprise a solvent-based acrylic coating that is a dispersion or solution. In some embodiments, the barrier coating 126A is a thermoplastic or a thermo-setting material, such as, for example, ethylene vinyl acetate (EVA), aminos (including hydrolyzed proteins), fluroplastics (including polytetrafluoroethylene), epoxy, polyamides (including nylon), phenolics, vinyl, nonextruded polyesters (including polycarbonates and alkalyds), polyethylene terephthalate, polybutylene terephthalate, unsaturated polyesters, epoxy-esters, urethanes, styrene acrylics, polyolefins (including polypropylenes, polybutylenes, ionomers and polyethylenes of differing densities), natural polymers, cellulosics (including cellophane and viscose), nitrocellulose, polyimides, styrenics (including polystyrene), silicones, polysulfones, or polymethylpentene. While some of these materials may not be compostable or recyclable per se, the amount employed in the barrier coating 126A is sufficiently small as to not affect the compostability or recyclability of the tray 100 (shown in Figure 1 ) as a whole.

[0040] In the illustrated embodiment, the heat seal coating 126B is configured to be a heat seal coating for forming the web corners 110 (shown in Figure 1 ) and for connecting the lid (indicated in Figure 5) to the tray 100 (shown in Figure 1 ). Thus, the heat seal coating 126B has been applied to completely cover the flange regions 146 and cover most of the corner regions 148. In addition, the heat seal coating 126B extends into side regions 144 and out to the edge 150 to increase the allowable registration tolerance of the flat 140. In some embodiments, the heat seal coating 126B is an acrylic emulsion polymer mixture that is biodegradable, sustainable, and biorenewable. In certain embodiments, the heat seal coating 126B is renewable or compostable. Such a heat seal coating 126B can be, for example, CK-5609 from Cork Industries Inc. The heat seal coating 126B (e.g., on the flange 108, shown in Figure 1 ) can be heated and then pressed against another component (e.g., the lid, indicated in Figure 5) to adhere the two components together. In some embodiments, the heat seal coating 126B includes materials that are not be compostable or recyclable per se, but the amount employed in the heat seal coating 126B is sufficiently small as to not affect the compostability or recyclability of the tray 100 as a whole.

[0041] The heat seal coating 126B can have different properties than that of the barrier coating 126A. For example, the adherent strength of the heat seal coating 126B can be chosen to provide the proper balance between protection of the food and removability by the end user. Similarly, the barrier coating 126A can be cured on the paperboard 120 without needing the capability of reactivation for adhering to another component at a later time. While there are transition areas that will include both coatings 126, the coatings 126 will not adversely affect one another. Furthermore, which coating 126A, 126B is applied first can be selected based on various factors.

[0042] Figure 3 also generally indicates where the heat seal coating 128 is applied on the outside surface of the flat 140. Therefore, Figure 4 has been included to show more precisely where the heat seal coating 128 is applied. In the illustrated embodiment, the heat seal coating 128 is configured to be a heat seal coating for holding the web corners 110 (shown in Figure 1 ) against the short sides 106 (shown in Figure 1 ) and for holding the tabs 112 to form the flange 108 (shown in Figure 1 ) either from the top or the bottom. Thus, the heat seal coating 128 has been applied to the portions of the corner regions 148 that are between the centrally-located corner fold lines 149A-149D and the side regions 144A and 144C, for example, to avoid applying too much heat seal coating 128, as may be the case if the entirety of the corner regions 148 were coated.

[0043] In the illustrated embodiment, the heat seal coating 128 has also been applied to the portions of the side regions 144A and 144C adjacent to the corner regions 148 as well as to the flange regions 146A and 146C. In addition, the heat seal coating 128 extends out to the edge 150 to increase the allowable registration tolerance of the flat 140. In some embodiments, the heat seal coating 126B is an acrylic emulsion polymer mixture that is biodegradable, sustainable, and biorenewable. Such a heat seal coating 126B can be, for example, CK-5609 from Cork Industries Inc. The heat seal coating 128 can be heated and then pressed against another component to adhere the two components together. In some embodiments, the heat seal coating 128 may include materials that are not be compostable or recyclable per se, but the amount employed in the heat seal coating 128 is sufficiently small as to not affect the compostability or recyclability of the tray 100 (shown in Figure 1 ) as a whole.

[0044] The heat seal coating 128 can be different from the heat seal coating 126B. Thus, the heat seal coating 128 can have a different formulation with different properties than that of the heat seal coating 126B despite both coatings 126B and 128 being heat seal coatings. For example, the adherent strength of the heat seal coating 128 can be chosen to provide a permanent connection between the web corners 110 and the short sides 106 as an end user is unlikely to unfold the tray 100.

[0045] Figure 5 is a bottom view of an inside surface of a lid flat 180. In the illustrated embodiment, the flat 180 is made from a flat paperboard (a la the paperboard 120 with or without primer layers 130, 132, shown in Figure 2) and includes a sealing region 182 around the periphery and a cover region 184 in the center. The sealing region 182 corresponds in size and location to the flange 108 (shown in Figure 1 ), and the cover region 184 corresponds in size and location to a top projection of the base 102 and sides 104, 106 (shown in Figure 1 ). In some embodiments, the flat 180 can be a portion of a continuous roll of material or the flat 180 can be a blank of material that is oversized. The region or blank is defined by the edge 186 whereas the lid is defined by the border 188. The lid can be cut out along the border 188, for example, using a die or a rotary cutter, after the coatings 190 have been applied.

[0046] In the illustrated embodiment, the flat 180 includes multiple coatings 190A- 190B (collectively “coatings 190”) on selected portions of the inside surface. The barrier coating 190B is configured to be a barrier between the lid and the food (not shown). Thus, the barrier coating 190B has been applied to completely cover the cover region 184 and extends into the mating region 182 to increase the allowable registration tolerance of the flat 180. In some embodiments, the barrier coating 190B is a curable acrylate that is biodegradable, sustainable, and biorenewable. The barrier coating 190B can be, for example, eGreen220 from Cork Industries Inc. that can be electron-beam cured. Alternatively, the barrier coating 190B can comprise a water-based acrylic coating, a coating that is heat cured, or a coating that is ultraviolet (UV) light cured. In some embodiments, the barrier coating 190B may include materials that are not be compostable or recyclable per se, but the amount employed in the barrier coating 190B is sufficiently small as to not affect the compostability or recyclability of the tray 100 (shown in Figure 1 ) as a whole.

[0047] In the illustrated embodiment, the heat seal coating 190B is configured to be a heat seal coating for connecting the lid to the tray 100 (shown in Figure 1 ). Thus, the heat seal coating 190B has been applied to completely cover the sealing region 182. In addition, the heat seal coating 190B extends into the cover region 184 and out to the edge 186 to increase the allowable registration tolerance of the flat 180. In some embodiments, the heat seal coating 190B is an acrylic emulsion polymer mixture that is biodegradable, sustainable, and biorenewable, and the heat seal coating 190B can have the same formulation as the heat seal coating 126B. Such a heat seal coating 126B can be, for example, CK-5609 from Cork Industries Inc. The heat seal coating 190B can be heated and then pressed against another component (e.g., the flange 108, shown in Figure 1 ) to adhere the two components together. In some embodiments, the heat seal coating 190B may include materials that are not be compostable or recyclable per se, but the amount employed in the heat seal coating 190B is sufficiently small as to not affect the compostability or recyclability of the tray 100 as a whole.

[0048] The heat seal coating 190B can have different properties than that of the heat seal coating 128 (shown in Figure 4). For example, the adherent strength of the heat seal coating 190B can be chosen to provide the proper balance between protection of the food and removability by the end user. Similarly, because the heat seal coating 190B is used for sealing the lid onto the tray 100, the barrier coating 190B can be cured on the flat 180 without needing the capability of reactivation for adhering to another component at a later time. While there are transition areas that will include both coatings 190, the coatings 190 will not adversely affect one another. Furthermore, which coating 190A, 190B is applied first can be selected based on various factors.

[0049] In the illustrated embodiment, the length 192 of the lid is about 183 millimeters (mm) and the length 194 of the lid is about 144 mm. These dimensions on the lid are about the same as those of the outer edge of the flange 108 (shown in Figure 1 ). In addition, the width 196 of lap of the coatings 190A and 190B is about 2 mm, and the width 198 of excess material between the edge 186 and the border 188 is about 3 mm.

[0050] While the outside surface of the lid flat 180 is not shown, the lid flat 180 can also include printed coating(s) and / or layer(s). Such coating(s) and / or layer(s) canbe similar to or the same as, for example, coatings 126A and / or 190A. In some embodiments, the outside surface coatings include art (e.g., graphics, designs, pictures, vignettes, product images) and / or labeling (e.g., information, instructions, warnings, trademarks, registration marks). In some embodiments, these coatings / layers do not stick to each other well enough, so each coating / layer should be directly applied to the paperboard. In such embodiments, the coatings / layers are pattern applied so that one coating / layer does not cover the entire outside surface. In some embodiments, these coatings / layers may include materials that are not be compostable or recyclable per se, but the amount employed in the coatings / layers is sufficiently small as to not affect the compostability or recyclability of the lid as a whole.

[0051] The embodiments of the tray flat 140 (shown in Figure 3) and the lid flat 180 both include heat seal coatings 128B, 190B, respectively, however, there are alternatives to these embodiments. For example, in some embodiments, only one of the tray flat and the lid flat includes a heat seal coating. In such embodiments, the barrier coating can extend over the entire surface of the component that does not include the heat seal coating because the heat seal coating can bond sufficiently well to the barrier coating.

[0052] Figure 6 shows a method 200 of making a package. During the description of the method 200, references will be made to some of the components and features discussed previously with respect to Figures 1 -5.

[0053] In the illustrated embodiment, the method 200 begins at the operation 202 where the coatings 126A and 190A are applied to the tray flat 140 and the lid flat 180, respectively.

[0054] At operation 204, the coatings 126A and 190A are cured using an electron beam.

[0055] At operation 206, the coatings 126B and 190B are applied to the flats 140, 180.

[0056] At operation 208, the coatings 126B and 190B are dried.

[0057] At operation 210, art and labels are printed, for example, on the outside surfaces of the flats 140, 180.

[0058] At operation 212, the tray preform and the lid are cut from the flats 140, 180, respectively.

[0059] At operation 214, the tray preform is folded and selected portions of the heat seal coating 126B are heated to activate the said portions of the heat seal coating 126B. Also at operation 214, the tray preform is selectively pressed together to form the tray 100.

[0060] At operation 216, food is added to the tray 100.

[0061] At operation 218, the lid is aligned with and placed on the tray 100, and selected portions of the coatings 126B and 190B are heated to activate said portions of the coatings 126B and 190B. Also at operation 218, the lid and the tray 100 are pressed together to seal the package.

[0062] While one example of a food package has been discussed in the present disclosure, alternative food packages can also be made using the configurations, components, and / or operations discussed heretofore. For example, the tray can include pleats (e.g., for additional strength or to form a curve), and such pleats can include a heat seal coating to hold them in place. For another example, the lid can be a polymer film instead of a coated SBS substrate. For another example, a glue, cold seal, two-part epoxy, or other adhesive can be used instead of a heat seal coating. In the embodiments using a two-part epoxy, one part can be applied as a coating 126B and the other part can be applied as a coating 190B. Thus, when the two mating surfaces are pressed together, the epoxy can cure. For another example, other types of food packages can be made, such as food service trays, hinged-lid trays, webbed corner take out containers, French fry holders, clam shell packages, ice cream pails, scrounds, individual-serving cups, drinking / beverage cups, gable top containers, tetra pak style packaging, boxes, cartons, paper pouches and bags, or any other type of container that is sealed. In some embodiments, the embodiments of the present disclosure can be used to replace traditional packaging films that are not recyclable or compostable per se and are used in sufficiently large amounts that affect the recyclability or compostability of the package as a whole. Such traditional paperboard packages are polymer coated with, for example, polyethylene, polypropylene, polyester, or a bio-resin such aspolylactic acid (PLA), and such traditional paperboard packages have some portions that are sealed together.

[0063] As used in the present disclosure, the singular forms “a”, “an”, and “the” encompass embodiments having plural referents, unless the context clearly dictates otherwise. As used in the present application, the term “or” is generally employed in its sense including “and / or”, “unless” the context clearly dictates otherwise.

[0064] Spatially related terms, including but not limited to, “lower”, “upper”, “beneath”, “below”, “above”, “bottom” and “top”, if used in the present application, are used for ease of description to describe spatial relationships of an element(s) to another. Such spatially related terms encompass different orientations of the device in use or operation, in addition to the particular orientations depicted in the figures and described in the present application. For example, if an object depicted in the drawings is turned over or flipped over, elements previously described as below, or beneath other elements would then be above those other elements.

[0065] It is well understood that methods that include one or more steps, the order listed is not a limitation of the claim unless there are explicit or implicit statements to the contrary in the specification or claim itself. It is also well settled that the illustrated methods are just some examples of many examples disclosed, and certain steps may be added or omitted without departing from the scope of this disclosure. Such steps may include incorporating devices, systems, or methods or components thereof as well as what is well understood, routine, and conventional in the art.

[0066] The connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and / or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements. The scope is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “atleast one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B or C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. The terms “couples,” “coupled,” “connected,” “attached,” and the like along with variations thereof are used to include both arrangements wherein two or more components are in direct physical contact and arrangements wherein the two or more components are not in direct contact with each other (e.g., the components are “coupled” via at least a third component), but still cooperate or interact with each other.

[0067] In the detailed description herein, references to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art with the benefit of the present disclosure to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.

[0068] Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present disclosure. For example, while the embodiments described above refer to particular features, the scope of this disclosure also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present disclosure is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.

Claims

CLAIMSWe claim:1 . A package for holding food, the package comprising: a tray including a substrate defining a base inside surface and a base outside surface, the base inside surface supporting each of a base barrier coating and a first base heat seal coating; wherein the base barrier coating covers at least a base food contact portion of the base inside surface and the first base heat seal coating covers a sealing portion of the base inside surface; a lid including a substrate defining a lid inside surface and a lid outside surface, the lid inside surface including a lid barrier coating and a lid heat seal coating; wherein the lid barrier coating covers at least a lid food contact portion of the lid inside surface and the lid heat seal coating covers a sealing portion of the lid inside surface, the sealing portion of the lid inside surface configured to at least partially mate with the sealing portion of the base inside surface.

2. The package of claim 1 wherein the first base heat seal coating further covers at least one corner portion of the base, the corner portion including a corner fold.

3. The package of claim 1 , further comprising a second base heat seal coating covering at least one corner portion of the base, the corner portion including a corner fold.

4. The packaging tray of any of claims 1 -3, wherein the first base heat seal coating has a different formulation than the second base heat seal coating.

5. The packaging tray of any of claims 1 -4, wherein the first base heat seal coating has a same formulation as the lid heat seal coating.

6. A tray preform configured to be folded into a tray for food storage, the tray preform comprising:a base region; a plurality of side regions extending from the base region; a plurality of flange regions, wherein each of the flange regions extends from one of the side regions; a plurality of corner regions, wherein each of the corner regions extends between two adjacent side regions; a first barrier coating on insides of the base region and the side regions; a first seal coating on the flange regions, the first seal coating being configured to connect to a lid; and a second seal coating on the corner regions, the second seal coating being different from the first seal coating, and the second seal coating being configured to adhere the corner regions to the side regions.

7. A package for storing food, the package comprising: a tray formed by folding and adhering the tray preform of claim 6, the tray including a flange comprised of the flange regions; and a lid comprising: a sealing region around a perimeter of a flat paperboard; a cover region in the center of the flat paperboard; a second barrier coating on an inside of the lid; and a third seal coating on the sealing region; wherein the sealing region of the lid is adhered to the flange region of the tray.

8. The package of claim 7, wherein the first seal coating and the third seal coating are the same.

9. The package of claim 7, wherein the first barrier coating and the second barrier coating are the same.

10. The package of claim 7, wherein the first seal coating is a first heat seal coating and the second seal coating is a second heat seal coating.11 . The package of any of claims 6-10, wherein the first barrier coating comprises an electron-beam curable acrylate.

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