PACKAGING DEVICE AND METHOD FOR ABSORBING MOISTURE

DISPOSITIF D'EMBALLAGE ET PROCEDE D'ABSORPTION D'HUMIDITE

English Abstract

A packaging device and method for absorbing and reducing moisture as well as a
manufacturing process for such device. The packaging device is a container
made from paperboard such as containerboards or linerboards with a corrugated
medium. The paperboard is insulated with moisture absorbing additives
comprising charcoal, activated charcoal, activated carbon, or substances
mostly comprised of carbon. Perforations may be added in the boards to further
permit moisture to reach the corrugated medium, permitting further absorption
by the additives embedded within the corrugated medium in between the boards.
This packaging device and method is favorable for storing or transporting
objects which are sensitive to or would benefit from low moisture/humidity
conditions.

French Abstract

La présente invention concerne un dispositif d'emballage et procédé d'absorption et de réduction d'humidité ainsi qu'un processus de fabrication de ce dispositif . ce dispositif d'emballage est un récipient fabriqué en carton tel qu'un contenant en carton ou qu'un doublage de carton avec un support ondulé. Ce carton est isolé avec des additifs absorbant l'humidité comprenant du barbon, du charbon actif du carbone actif ou des substances constituée principalement de carbone. On peut ajouter des perforations dans les cartons pour permettre encore davantage à l'humidité d'atteindre le support ondulé, ce qui permet une meilleure absorption par les additifs intégrés dans le support ondulé entre les plaques de carton. Ce dispositif d'emballage et ce procédé favorisent le stockage et le transport d'objets qui sont sensibles à des conditions humides ou qui peuvent tirer profit de conditions à faible humidité.

Claims

WHAT IS CLAIMED IS:
1. A method for absorbing moisture from food within a container
comprising:
forming the container with a plurality of sheets of paper; and
embedding carbon additives within one of the plurality of sheets of
paper.
2. The method of claim 1, wherein the carbon additives include charcoal.
3. The method of claim 1, wherein the carbon additives include one of
activated charcoal and activated carbon.
4. The method of claim 1, wherein the paper is one of a linerboard, a
containerboard, and a corrugated boxboard.
5. The method of claim 1, wherein the at least one of the plurality of
sheets of paper is made from a mixture of pulp, water, and the carbon
additives.
6. The method of claim 1, wherein at least one of the plurality of sheets is
corrugated.
7. The method of claim 1, wherein two of the plurality of sheets are
embedded with the carbon additives.
9

8. The method of claim 1, wherein three of the plurality of sheets are
embedded with the carbon additives.
9. The method of claim 1, wherein the plurality of sheets include an inner
sheet and a corrugated sheet, the inner sheet having perforations and the
corrugated
sheet having the embedded carbon additives.
10. The method of claim 1, wherein the step of embedding carbon
additives includes blade coating.
11. The method of claim 10, wherein the blade coating includes use of a
flexible blade.
12. The method of claim 10, wherein the blade coating includes use of one
of a paper making machine and an off-machine coater.
13. The method of claim 1, wherein the step of embedding carbon
additives includes bath coating.
14. The method of claim 1, where the step of embedding carbon additives
includes surface siezing coating.
15. A process for manufacturing a container for housing food comprising:
forming a sheet of paper with embedded carbon additives by mixing
pulp, water, and the carbon additives; and
10

forming a boxboard with a plurality of sheets of paper to house the
food.
16. The process of claim 15, wherein the step of forming a box includes
using a plurality of sheets of paper forming linerboards, including at least
an inner
linerboard and an outer linerboard.
17. The process of claim 15, further including adding perforations to the
inner linerboard.
18. The process of claim 15, further including corrugating one of the
plurality of sheets of paper.
19. The process of claim 15 wherein the step of forming a sheet of paper
includes blade coating.
20. The process of claim 19, wherein the step of forming a sheet of paper
includes use of one of a paper making machine and an off-machine coater.
21. The process of claim 15, wherein the step of forming a sheet of paper
includes bath coating.
22. The process of claim 15, wherein the step of forming a sheet of paper
includes surface siezing coating.
11

Description

CA 02523772 2005-10-26
WO 2004/071871 ~ ~ PCT/US2004/003745
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Attorney Docket: 8082-4 PCT
PACKAGING DEVICE AND METHOD FOR ABSORBING MOISTURE
s This application claims priority benefits to provisional application serial
number 60/445,673 filed on February 7, 2003. This application is a
continuation-in-
part of copending application serial No. 10/140,755 filed on May 7, 2002, the
disclosure of which in its entirety is incorporated by reference herein.
io BACKGROUND OF THE INVENTION
Field of the Invention
The invention is directed to a packaging device and method for absorbing
moisture, steam, or condensation through the use of embedded carbon-containing
substances.
is
Discussion of Related Art
A problem with packaging of goods arises when the packaging creates an
environment which negatively affects the packaged content. One example is the
packaging of fine art or other materials which decay or go bad when moisture
or a
zo humid condition is trapped. Another example is the negative effect on
packaged food
due to steam vapor in a container such as a paper box or bag. The steam that
emanates from a hot food such as pizza, french fries, etc. forms condensation
that
settles within the box or bag, making the pizza or french fries soggy or
spongelike.
In the case of packaging used for temporarily storing and transporting a hot
pizza pie,
zs the packaging is typically a box constructed of either corrugated boxboard,
or
containerboard. Corrugated boxboard is made by gluing an accordion-like sheet
of
paper (corrugated medium) in between two sheets of linerboard. Containerboard,
or
1

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:,~se~ ifwlE,l~~~ 'y
what is also called 'clay kraft back' is a paperboard that does not have any
corrugated
layer. Containerboard is commonly used for forming boxes such as a shoe box.
The condensation that settles on the inside bottom surface of the pizza box is
absorbed by the pizza dough by the time the pizza is transported to a place
where it
can be consumed. Similarly, the Kraft Paper commonly used as grocery bags for
temporarily housing other hot food such as french fries, fried chicken, etc.
also cannot
absorb the vapor from the hot food. The trapped vapor renders the french fries
soggy.
Accordingly, it is desirous to have a packaging device and method capable of
absorbing moisture, steam, or condensation.
io
SUMMARY OF THE INVENTION
According to an embodiment of the present invention, a container for
housing food is provided, comprising paper having carbon additives for
absorbing
is moisture emanating from the food, wherein the carbon additives include one
of
charcoal, activated charcoal and activated carbon, wherein the paper is one of
a
containerboard, a linerboard, and a corrugated medium.
According to an aspect of the present invention, the container, preferably a
corrugated boxboard, includes a plurality of sheets or linerboards, and the
carbon
zo additives are embedded in at least one of the plurality of sheets or
linerboards,
wherein the sheets of paper are made from a mixture of pulp, water, and the
carbon
additives.
Preferably, one, two, or three of the plurality of sheets is/are selectively
embedded with the carbon additives. In one embodiment, one of the plurality of
zs sheets is corrugated and another sheet is perforated.

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A method is also provided for absorbing moisture from food within a
container comprising; embedding carbon additives within paper, and forming the
container using the paper. Preferably, the carbon additives include charcoal,
activated
charcoal and activated carbon. The paper is one of a linerboard, a
containerboard, and
a corrugated medium. The paper includes a plurality of sheets, each sheet
formed
from a plurality of layers, and the carbon additives are embedded in at least
one of the
plurality of sheets. The sheets of paper are made from a mixture of pulp,
water, and
the carbon additives, wherein one, two or three of the plurality of sheets are
embedded
with the carbon additives.
io According to another embodiment of the invention, the plurality of sheets
include an inner sheet and a corrugated sheet, the inner sheet having
perforations and
the corrugated sheet having the embedded carbon additives.
A process for manufacturing a container for storing food is also provided,
comprising; forming layers of paper with embedded carbon additives by mixing
pulp,
is water, and the carbon additives; and forming a boxboard with a plurality of
sheets of
linerboards of the paper to house the food, wherein the step of forming a box
includes
using a plurality of layers of paper forming sheets or linerboards, including
at least an
inner linerboard and an outer linerboard. The process further including adding
perforations to the inner linerboard and corrugating one of the plurality of
sheets of
zo paper.

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. BRIEF DESCRIPTION OF THE DRAWINGS
Other uses and features of the present invention will become apparent from the
following detailed description considered in connection with the accompanying
drawings which disclose several embodiments of the present invention. It
should be
s understood, however, that the drawings are designed for the purpose of
illustration
only and not as an exhaustive list of its possible uses.
In the drawings wherein similar reference characters denote similar elements
throughout the different embodiments:
Figure 1 shows a paper box in an opened configuration according to the
io present invention;
Figure 2 shows a sideview of the paper box; and
Figure 3 shows a cross-sectional view of a corrugated medium in a boxboard.
DETAILED DESCRIPTION OF THE PREFFERED EMBODIMENTS
is The invention is directed to packaging product for housing goods. The
packaging product is preferably made of paperboard, linerboard, or
containerboard
having charcoal, activated charcoal, or activated carbon as an additive for
absorbing
moisture, vapor, or condensation (hereinafter referred to as "Coalboard").
Charcoal,
activated charcoal, carbon, or substances mostly comprised of carbon are used
as
zo additives because of their superior absorbent characteristics, partly due
to their
extremely vast surface area. The charcoal, activated charcoal, activated
carbon, or
substances mostly comprised of carbon is mixed with the wood fiber (more
commonly known as pulp) in the blend chest. The refined pulp and water with
the
charcoal, activated charcoal, activated carbon, or substances mostly comprised
of
zs carbon added would then be sent on to the papermaking machine. In one
4

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embodiment, the linerboard with the embedded charcoal is disposed within a
packaging container which is perforated on the interior side to enable steam
vapor or
humidity to enter into the corrugated medium. In another embodiment, a
boxboard is
made of containerboard with embedded charcoal, activated charcoal or
substances
s mostly comprised of carbon. With this packaging and method according to the
present invention, the contents of the package can be protected against
humidity,
moisture, and steam.
Figure 1 shows a pizza box made of Coalboard according to the present
invention. The steam vapor that is emitted from the pizza would be drawn
through
io the perforations and be absorbed by the charcoal. It is readily apparent
that pizza is
only one example of packaged food that would benefit from the vapor absorbing
qualities of CoalBoard. Although this is one embodiment of the present
invention, it
is not the exclusive embodiment.
Referring to Figures 1 to 3 and according to a first embodiment of the present
is invention, all three sheets of the boxboard 1, which comprises exterior
linerboard 3,
interior linerboard 5, and corrugated medium 4 are embedded with charcoal,
activated
charcoal, activated carbon, or substances mostly comprised of carbon. The
interior
linerboard 5 that faces the food product includes perforations 2 to enable the
steam
vapor generated from the hot food to enter into the corrugated medium 4.
ao According to a second embodiment of the invention, two sheets of the
boxboard l, preferably interior linerboard 5, and corrugated medium 4 are
embedded
with charcoal, activated charcoal, activated carbon, or substances mostly
comprised of
carbon as an additive. The interior linerboard 5 facing the food product is
preferably
perforated 2 to enable the steam vapor generated from the hot food to enter
into the
Zs corrugation 4.

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According to a third embodiment of the invention, the exterior linerboard 3,
and corrugated medium 4 are embedded with charcoal, activated charcoal,
activated
carbon, or substances mostly comprised of carbon as an embedded additive. The
interior linerboard 5 facing the food product would be perforated 2 to enable
the
steam vapor generated from the hot food to enter into the corrugation 4.
According to a fourth embodiment of the invention, one sheet of the boxboard
1, preferably the interior linerboard 5 is embedded with charcoal, activated
charcoal,
carbon, or substances mostly comprised of carbon as an embedded additive. The
interior linerboard 5 facing the food product would be perforated 2 to enable
the
io steam vapor generated from the hot food to enter into the corrugation 4.
According to a fifth embodiment of the invention, the exterior linerboard 3 is
the only sheet having charcoal, activated charcoal, carbon, or substances
mostly
comprised of carbon as an embedded additive. The interior linerboard 5 facing
the
food product would be perforated 2 to enable the steam vapor to enter into the
is corrugation 4.
According to a sixth embodiment of the invention, the corrugated medium 4 is
the sheet having charcoal, activated charcoal, carbon, or substances mostly
comprised
of carbon as an embedded additive. The interior linerboard 5 facing the food
product
would be perforated 2 to enable the steam vapor generated from the hot food to
enter
zo into the corrugation 4.
According to a seventh embodiment of the invention, the boxboard is made
from containerboard having charcoal, activated charcoal, carbon, or substances
mostly
comprised of carbon as an embedded additive. In this embodiment, the boxboard
does not include a corrugated medium.

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As an alternative to mixing the additive in the pulp formulation process,
there
are a number of processes that can be used to introduce charcoal, activated
charcoal,
activated carbon, or substances mostly comprised of carbon into paper. One
exemplary process is by blade coating, which is a method of coating paper and
s paperboard using a flexible blade to control the amount of coating applied
to the
paper. Blade-coating can take place either on a papermaking machine or on an
off
machine coater. The paper may be coated on one side (C1S) or both sides (C2S),
or
between layers of paper as described in the above embodiments. Off machine
coating
refers to coating paper after it comes off the papermaking machine rather than
while it
io is still on the machine. Preferably, an off machine coater is used to add
one or more
layer of coating of the carbon material to the paper. Other known processes
such as
bath coating or surface siezing coating may also be used to mix or coat the
carbon
material onto the paper.
We did four side-by-side tests with identical pizza pies under the identical
is conditions. We lined the perimeter of one of the boxes with pulverized
charcoal, and
left the other box as it would normally be used. After nine minutes cooking at
500
degrees (industry standard), we placed both pies in their respective boxes and
let them
settle for 5, 7, 10, and 15 minutes. The ftrst three tests were conducted as
stated
above, the third test we perforated an additional box top and stapled it to
the actual
zo top with charcoal sandwiched in between. In each case, the pizza that was
in the box
with the charcoal was noticeably more crispy. The longer the period of time
that we
let the pies settle, the more pronounced the effect.
Having thus described the invention with the details and particularity
required
by the patent laws, it is noted that modifications and variation can be made
by persons
zs skilled in the art in light of the above teachings. It is therefore to be
understood that
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changes may be made in the particular embodiments of the invention disclosed
which
are within the scope and spirit of the invention as defined by the appended
claims.

Representative Drawing