Note: Descriptions are shown in the official language in which they were submitted.
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RECLOSABLE CONTAINER FOR SLICED FOOD PRODUCTS
Field
[0002] The present disclosure reiates generally to food packaging, and more
specifically to reclosable food packages for containing pre-sliced food
products having a
shingled appearance.
Background
[0003] Many food products are presliced and packaged for sale to consumers.
These food products can be packaged in reclosable packaging, such that the
food
product can be stored therein and its freshness maintained.. 'For example,
thinly sliced
food products, such as deli-sliced cheeses, are often presliced and packaged
in an
ordered stack wherein only the first or top slice is viewed from the package
exterior, or
altematively, a shingled arrangement where the first slice and portions of the
underlying
slices are viewed. In another instance, deli-sficed cheese stacks are packaged
in a
flexible bag or pouch and accessed from a side edge only.
[0004] In one known example, a presliced stack is sealed within a flexible
package
or pouch that is either printed or labeled. The flexible package can contain
reclosable
features, such as a press-and-seal or.slider zipper feature, at one side of
the package to
gain acdess to the food product therein. One problem with such flexible
packages is that
the food product can only be accessed from one side, which is the side
containing the
zipper or seal closure at an opening of the package. As a result, the consumer
is not able
to access the entire sliced product upon opening the package, but rather only
can access
a single side edge of the sliced food product, the edge that is adjacent the
opening. This
can require the consumerto handle multiple sliced food products (i.e., by
removing therri
from the package) in order to access and remove a single sliced food product.
For
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example, where the food product comprises cheese slices, the cheese slices are
often
arranged in a shingled arrangement within a flexible package, i.e., such that
one slice is
overlayed over the top of another slice beneath it but slightly offset. Where
the cheese
slices are packaged in a shingled arrangement and the consumer would like to
remove a
single cheese slice, due to the limited opening in the top of the package the
consumer
may not be able. to insert their hand or other tool used for removal far
enough into the
package in order to remove the top most cheese slice. As a result, this can
often require
the consumer to remove a portion or substantially all of the cheese slices
from the
package just to remove a single slice from the top of the shingled arrangement
of cheese
slices.
[0005] Furthermore, if upon reinsertion of the cheese slices into the flexible
package the slices are not positioned properly in the package such that one or
a portion
of the cheese slices are placed in the path of the reclose feature, the
reclose feature may
.slide over the cheese upon closure of the package and become contaminated
with
cheese, thus making it more difficult to reclose the package properly and to
maintain
freshness. Additionally, the press-and-seal zipper feature requires more
attention by the
consumer to match up the male and female sides of the reclose feature and to
press the
two together from one edge to another. Therefore, the flexible package for
cheese slices
can require increased handling of the entire shingled product, can have
limited access
from a single side of the cheese package, and can be difficult to reclose the
zipper
feature. Additionally, externally applied forces to the exterior surfaces of
the flexible
package due to handling and storage can compress portions of the sliced food
product
therein. Such forces can cause the sliced food product to become compressed in
places
where the force was exerted, which can alter the appearance of the sliced food
product
and give it the perception that the product is not fresh, or make it difficult
to separate
slices.
[0006] In another known example, the sliced food product can be packaged in a
sealed flexible package with the sealed flexible package further placed inside
a generally
rigid plastic tub with a lid. The tub is typically shaped in a rectangular or
square
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arrangement such that the sliced food product is stacked on top of one
another. As a
result, the sliced food product being stacked upon itself in this fashion can
often prove to
be difficult to separate the top slice from the slices underneath it, which
may again result
in removing at least a portion of the stack of sliced food product from the
package in order
to separate and remove the desired slice, thus increasing unnecessary handling
of the
food product. Furthermore, when the package is initially opened, the consumer
must
open two packages, the tub with its lid and the sealed flexible package, in
orderto access
the food product. This requires the consumer to open multiple packaging
elements in
order to gain initial access to the food product.
[0007] It is also known that rigid food packages may contain one or more lugs
to
aid in snapping a lid onto a tray and provide a better fit, however, these
trays are usually
tailored to specific food products, such as deli-shaved meat, and may have a
rectangular
shaped package with a relatively flat bottom, such that the food product would
again lay
flat and stacked upon one another or in a randomly fluffed arrangement, and
not in a
shingled arrangement. The lugs are spaced at various distances and designed
about the
tray, rather than substantially continuously about the tray. As a result, this
type of closure
does not provide the consumer with tactile feedback that the package is indeed
closed
and sealed, i.e., the consumer may not feel as though the lid is completely
snapped onto
the perimeter of the base tray for a sturdy and reliable closure.
[0008] Yet in anotlier known example, the package may comprise an in-line
thermoformed semi-rigid tray with a flexible film lidding material as a
closure. The semi-
rigid tray may also be shaped in a rectangular or circular configuration with
the lidding film
shaped to compliment it. The lidding film material can have a pressure
sensitive adhesive
(PSA) resealable label or a buried layer of cohesive sealant that is exposed
upon the
initial opening peel by the consumer. In the first instance, the flexible film
has an opening
spaced inwards from the flanges that is covered by a label that peels back to
reveal the
opening and reseals to the film to recover and in the second the flexible film
is peeled
away from and reseals onto the outer flanges of the, tray perimeter.
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[0009] However, many of the resealable flexible lidding materials do not have
adequate reclose quality such that after a few uses the film layer may not
stick to the tray
and can become wrinkled or creased, thus not properly preserving the freshness
of the
sliced food product therein. Additionally, food product can stick to the
sealant and further
adversely affect the reclose quality. Upon opening of the.lidding material
there can be a
resistance upon opening which makes it difficult to pull back the lid film.
Furthermore, in
regards to the first instance, the opening in the lid film may not be large
enough to
remove the sliced food product easily and upon reclosing the fiim upon itself
the
consumer must push down upon the film which is flexible and could cause the
film to
further sink inside the tray and not properly reseal. With the flexible
lidding option, the
sliced food product is usually stacked upon itself in the semi-rigid tray and
may require
removal of the entire product or a portion thereof simply to remove a single
slice, again
increasing unnecessary handling of the product.
Summarv
[0010] A reclosable food package for containing a sliced food product therein
is
provided that allows for shingled arrangement of the sliced food, product and
a reclosable
feature. The food package contains a generally rigid base member and a
generally rigid
lid member. The base member is comprised of a bottom wall and a pair of
generally
upstanding sidewalls. The bottom wall has a generally flat central portion
disposed
between two inclined portions. A peripheral rim surrounds an opening opposite
the
bottom wall. Each of the inclined portions of the bottom wall may further have
at least
one channel therein, where the bottom surface of the channels define feet for
providing
support to the package and provide stability upon standing the package flat
upon its
bottom wall for consumer usage purposes. The inner compartment of the base
member
is configured to allow for the sliced food product to rest upon the bottom
wall of the base
member such that it can be easily removed from the package and can further be
removed
by placing a finger or other tool for removal into a recessed portion of the
channels and
lifting the desired slice upwards and out of the inner compartment of the
package, if
necessary. The inner compartment is also slightly angled inside such that when
food
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slices are placed therein they can be placed in a shingled arrangement, rather
than a
stack of slices one on top of the other.
[0011] The rigid lid rnemberof the package provides an audible snap closure
upon
being placed over the opening of the base member to indicate a proper closure.
The
generally rigid lid member provides for an easy closure once it is placed upon
the opening
of the base member. Furthermore, the lid has a central portion and a
peripheral edge
about the central portion, with the central portion slightly inset reiative to
the peripheral
edge. The perimeter of the lid me.mber may contain a continuous undercut
annular bead
area or ridge along the inner perimeter of the peripheral edge that mates with
the base
member upon closure. The tactile feedback that the snap closure provides can
give
consumers an impression or feeling that the lid is properly and securely
closed. The
annular bead around the inner lid perimeter may further be reinforced in the
corner areas
such that there is slightly more resistance in the corner as a result upon
closing. This
further can provide a more secure and tactile feel that the lid is properly
closed. The inset
central portion provides for a convenient way to stack one package on top of
another for
shipping and storage purposes, because the feet, or tapered channels, of one
package
can be placed on top of the lid of another package beneath it to form a
relatively stable
stack of packages.
[0012] Furthermore, the package can contain a flexible film that is placed
over the
base member opening such that the film seals the base member in a plane that
is
relatively even with the outer flanges and is located between the base member
and the
lid. As a result of the combination of the package design, including an inner
compartment
that is slightly angled, and the flexible film, the headspace in the inner
compartment is
minimized to reduce Calcium Lactate Crystal (CLC) formation on cheese slices.
[0013] The disclosed food package advantageously can contain a sliced food
product in a shingled arrangement that allows easy removal of the sliced food
product.
The sliced food product can be accessed through the opening, such,that the
entire top
slice of the food product is exposed and can be easily removed. This allows
the
consumer to easily remove only the desired number of sliced food products,
rather than
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having to remove all or substantially all of the sliced food products from the
package in
order to separate the desired number of slices. Therefore, the reniaining,
untouched
sliced food products can remain inside of the package without incurring
unnecessary
handling.
[0014] In addition, the package has a generally rigid-rigid construction and
can
include a pegging feature for vertical display purposes. The shingled
arrangement of the
cheese together with the inclined portions of the bottom wall helps to
minimize food
movement when displayed in the vertical position. Furthermore, the generally
rigid
construction of the package protects the food product inside from becoming
impacted or
crushed by normal externally applied forces on the surfaces of the package, as
can
happen with a flexible pouch package.
[0015] Additionally, in another feature, the generally rigid lid is snapped
against the
rigid base member at peripheral flanges extending about the opening of the
base
member, and the flexible film is sealed to the flanges of the base member
underneath the
.Iid. Prior to being initially opened, the flexible film seal may be
substantially hermetic.
Advantageously, due to this hermetic seal, the food product is not required to
be sealed
within an additional flexible bag or pouch within the base and lid, and a
simple peelable
film across the opening of the base will suffice. This feature also reduces
packaging
costs, saves packaging material and eliminates steps in the assembly process.
Additionally, according to one embodiment, once the rigid lid is removed and
the flexible
film is unsealed by the consumer, the rigid lid may be reclosed over the
compartment to
provide easy storage of the food package in the consumer's refrigerator. Thus,
the
consumer is not required to provide another container or bag within which to
store the
food product.
Brief Description of the DrawinAs
[0016] FIG. 1 is a perspective view of a reclosable food package in a closed
state;
[0017] FIG. 2 is an exploded perspective view of the food package of FIG. 1;
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[0018] FIG. 3 is a cross-sectional view of the assembled reclosable food
package
of FIG. I taken along the line 3-3;
[0019] FIG. 4 is a top plan view of the assembled lid and base of FIG. 1;
[0020] FIG. 5 is a side elevation view of the assembled reclosable food
package of
FIG. 1;
[0021] FIG. 6 is an end elevation view of the assembled reclosable food
package
of FIG. 1;
[0022] FIG. 7 is a bottom plan view of the base of the reclosable food package
of
FIG. 1;
[0023] FIG. 8 is a perspective view of the base of the reclosable food package
of
FIG. 1;
[0024] FIG. 9 is a partial bottom plan view of the lid of the food package of
FIG. 1
viewed from its food-side surface; and
[0025] FIG. 10 is a flow chart of a method for filling and sealing the
reclosable
cheese package of FIG. 1.
[0026) Corresponding reference characters indicate corresponding components
throughout the several views of the drawings.
Detailed Description of the Drawincgs
[0027] A reclosable food package for packaging and displaying sliced food
products, the package having.a generally rigid base member, a generally rigid
lid member
and a flexible film, is disclosed herein and illustrated in FIGS 1-10. In
particular, the rigid
base member further has a bottom wall, having a generally flat central portion
disposed
between two inclined portions, and a pair of generally upstanding sidewalls.
The bottom
wall further contains channels that facilitate removal of the food product and
have bottom
surfaces that cooperate to provide stability.
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[0028] Turning to FIGS. 1 and 2, a reclosable food package or container 10 is
shown having a generally rigid base member 12, a generally rigid lid member
14, and a
flexible film 16. Both the base member 12 and the lid member 14 are
constructed of a
generally rigid sheet material or resin and can be formed by suitable
thermoforming or
injection molding techniques. The term "rigid" is used herein to indicate that
the
structures made of these sheets or resins have the ability to retain their
respective shapes
during normal handling, and preferably, rigid sheet construction materials can
include a
rigid plastic material. The food package 10 can be used to package sliced food
products,
such as meats or cheeses, and preferably to package sliced food products in a
shingled
arrangement. The base member 12 and the lid member 14 may provide a protective
display package 10 for a stack of cheese slices 72 or other food prodUct
arranged in the
shingled configuration. Although cheese slices 72 are discussed, it will be
appreciated
that other types of food products can be packaged in the food package 10.
[0029] The base member 12,.as shown in FIGS. 1, 5 and 7, has a bottom wall 26
comprised of a generally rectangularflat central portion 30 disposed between
two inclined
portions 28a and 28b. The central portion 30 has a pair of opposing
longitudinal edges
200 and 201 and a pair of opposing transverse edges 202 and 203. Likewise, the
inclined portions 28a and 28b also each have a pair of transverse edges 302,
303, 402
and 403, and a pair of longitudinal edges 300, 301, 400 and 401. The inciined
portions
28a and 28b further each have a transverse edge 303 and 402 adjacent an
associated
one of the transverse edges 202 and 203 of the central portion 30', and an
opposite
transverse edge 302 and 403 of the inclined portions 28a and 28b is positioned
closer to
the peripheral flange 38 than the bottom wall 26.
[0030] The bottom wall 26 is angled at inclined portions 28a and 28b, which
aids. to
display the food product therein. The angled bottom wall 26 can further aid in
decreasing
or minimizing. headspace between the shingled food product and the flexible
film 16, as
described herein. The inclined portions 28a and 28b can have a respective
inclination
angle a (alpha) in the range from about 10 to about 70 degrees, relative to a
plane X that
is co-planar with the central portion 30 of the bottom wall 26, as shown in
FIG. 5, and
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preferably from about 10 to about 50 degrees, and still preferably from about
10 to about
40 degrees. It is also preferable for the angle to be on the lower end of the
range, such
as about 20 degrees, so that the angle provides more of a gradual incline
along the
bottom wall 26 of the package 10. This gradual incline helps to minimize food
movement
relative to the spacing between each slice of the shingled food product when
the package
is displayed in a vertical position, such as when it is hung vertically from a
pegged
member 60. The inclined portions 28a and 28b generally have widths identified
by
sections 100 and 102, respectively, that are between about 1 inch and about 3
inches.
The widths 100 and 102 can generally be equal to the width 101 of the central
portion 30
of the bottom wall 26 (see FIG. 7).
[0031] The bottom wall 26 further contains channels, and preferably at least
four
channels 32a-d. The channels 32a-d preferably are positioned in the inclined
portions
28a and 28b of the bottom wall 26 to facilitate removal of the food product
from an inner
compartment 27 of the base member 12. The channels 32a-d facilitate removal of
food
products by providing recesses 50a-d, as shown in FIG. 4, in the inclined
portions 28a
and 28b of the bottom wall 26 such that a consumer can easily insert a finger
or other
object into the gap of the recesses 50a-d to aid in lifting of the food
product contained
therein off of the bottom wall 26. Preferably, the channels 32a-d and their
associated
recesses 50a-d are spaced from the sidewalls by a segment of the inclined
portions 28a
and 28b of the bottom wall 26, or by a segment equal to a side inclined
portion 54. This
provides easier access to the channels 32a-d where a finger or other object
has more
space to be inserted therein without having to fit into a tight space next to
a sidewall.
Furthermore, the side inclined portion 54 can also help prevent the corners of
the
shingled food product from sagging down into the channels 32a-d by providing a
support
for the corners of the shingled food product to rest upon.
[0032] For example, the inclined portions 28a and 28b are angled up towards a
peripheral flange 38 of the base member 12 such that a ramp is created from
the central
portion 30 of the bottom wall 26 up towards the periphery of the base 12. This
ramp can
have three parts, a, center inclined portion 52, and two side inclined
portions 54. The
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center inclined portion 52 can be wider than the side inclined portions 54 and
can
terminate at a groove 53 at an upper end of the center inclined portion 52.
The groove 53
is positioned between adjacent recesses 50a-b and 50c-d of the base 12, such
that it
connects the adjacent recesses 50a-b and 50c-d at the upper end of.the
inclined portion
52. One of the purposes of this groove 53 is to provide further stability to
the base 12
after thermoforming so that the base 12 does not shrink inwards from the
perimeter to a
significant degree. This added stability further ensures that the four corners
of the base
12 do not also droop downwards. If the corners droop downwards, the base 12
can
become slightly deformed, thus preventing the lid from engaging and snapping
over the
corners of the base 12 properly for an adequate closure. The two side inclined
interior
portions 54 can terminate or merge with a horizontal rim 58, which then merges
into the
endwall 22, if one is present. Where a horizontal rim 58 is present, it can
function as a
"stack shoulder," which is used when stacking empty tray base members, one
nested
inside the other, prior to filling. The horizontal rim 58 prevents the stacked
base members
from becoming lodged too deeply inside one another and allows for easier
separation of
the base members just prior to filling. Alternatively, the side inclined
portions 54 and
center inclined portion 52 can terminate at the base member peripheral flange
38.
[0033] The channels 32a-d further have a bottom surface or panel 66, a
vertical
end surface or panel 70 that is positioned at an end portion 20a or 20b of the
base
member 12, and two opposing side portions or panels 68, as showri'in FIGS. 6
and 8.
The two opposing side portions 68 can have varying heights adjacent the
inclined
portions 28a and 28b and can be generally parallel to each other and can
further be
generally triangular shaped. Typically, the bottom surface 66 of the channels
32a-d can
be in the same plane as the central portion 30 of the bottom wall 26, and act
as support
portions or feet,. thus providing a flat and even surface to stand the package
10 upon to
provide stability when displaying in an upright or horizontal position.
Alternatively, the
bottom surface 66 of the channels 32a-d may not be in the same plane as the
central
portion 30, such that either the package 10 stands upon the central portion 30
of the
bottom wall 26 alone, or the package 10 stands upon the bottom surface 66 of
the
channels 32a-d alone.
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[0034] When the base member 12 is viewed from a bottom surface of the package
10, as in FIG. 7, the channels 32a-d appear as protrusions, or feet, that
stick outwards
from the bottom wall 26 to provide support for standing the package 10 in a
horizontal
position or for stacking packages one on top of another. The feet or channels
32a-d act
to further stabilize the package 10 for the consumerparticularly when the lid
14 is being
placed onto the base 12. Where there are four channels 32a-d, the channels 32a-
d and
the central portion 30 are configured to form an H-shape along the bottom
surface of the
bottom wall 26. The width of the channels 32a-d may vary from about 1/4 inch
to about 1
inch and further having a depth of about 1/4 inch to 1 inch, with the length
of the channels
32a-d generally equal to the width of the inclined portion (indicated by 100
and 102) or
about 1 inch to about 3 inches. In other words, the channels 32a-d may have a
maximum
depth adjacent its end panels 70 of between 25 to 75% of the distance from the
peripheral flange 38 to the central portion 30 of the bottom wall 26.
[0035] It is preferred that the feet or channels 32a-d of the package 10
provide
stability along with the central portion 30 of the bottom wall 26. This
combination of
support provides increased stability to the package 10 when placed in a
horizontal
orientation, such that the package 10 is reasonably supported on its bottom
wall 26, as in
FIG. 1. This arrangement of the feet 32a-d and the central portion 30 having a
coplanar
relationship with each other helps to keep the package 10 balanced and to
avoid tipping
over, espeCially when the number of food slices are being depleted as they are
being
used up, which can cause the food slices themselves to be positioned off-
center and
become unbalanced and further cause instability to a package 10 if it were not
already
stable. Addifionally, having a stable and balanced package 10 helps during
closure of the
package 10 while the lid 14 is being placed over the base member 12 and
snapped
thereto, it is easier to place the lid 14 on the base 12 and easier to clbse
when the base
member 12 is balanced and does not tip or rock during closure.
[0036] Other variations of the channels 32a-d may be provided such as where
the
channels 32a-d are located irt a portion of the bottom wall 26 that is not
included in the
inclined portions 28a and 28b. For example, the bottom wall 26 may comprise a
central
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portion 30 disposed between two inclined portions 28a and 28b and adjacent to
the
inclined portions 28a and 28b can be substantially flat horizontal extensions
of the bottom
wall 26 positioned next to the endwalls 22a and 22b. It is at these
substantially flat
extensions of the bottom wall 26 that the channels 32a-d may be positioned.
[0037] Another alternative embodiment may consist of the channels 32a-d
extending across the bottom wall 26, from-one side edge or portion 18a to the
other side
edge 18b, such that the channel forms one long trough-like protrusion. This
would further
provide a recess in the inner compartment 27 along the inclined portions 28a
and 28b
that extends across the inclined portion 28a and 28b from approximately one
side edge
portion 18a to approximately the opposite side edge portion 18b.
Alternatively, the
trough-like channels can be positioned at a flat extension of the bottom wall
26 rather
than in the inclined portions 28a and 28b. Preferably, however, the channels
32a-d will
be provided as illustrated in FIGS. 1-8, where four channels are provided, two
in each
inclined portion. 28a and 28b, and each of the four channels 32a-d further has
its
respective bottom surface 66 in a co-planar relationship with one another and
with the
central portion 30 of the bottom wall 26 to provide for a stable bottom wall
26 surface.
This is preferred due to the fact that this orientation of the channeis 32a-d
provides
additional support to the base 12 of the package 10. As can be appreciated,
there are
any number of variations that are possible to position the channels 32a-d
thereat.
[0038] An inner compartment 27 of the base member 12 can be defined by the
central portion 30 of the bottom wall 26, the two inclined portions 28a and
28b of the
bottom wall 26, a pair of opposing, generally upstanding sidewalls 24a and
24b, and a
pair of opposing, generally upstanding endwalls 22a and 22b to receive the
sliced food
product therein.. Alternatively, the base member 12 may not contain endwalls
22a and
22b. Where both a pair of sidewalls 24a and 24b and a pair of endwalls 22a and
22b are
included, a peripheral flange 3.8 can be located at an upper section of each,
such that it is
positioned at a periphery of the package 10 and defines an opening 25 of the
base 12,
where the opening 25 is opposite the bottom wall 26.
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[0039] Furthermore, the pair of opposing sidewalls 24a and 24b each can extend
between the peripheral flange 38 and the longitudinal edges 300, 301, 400,
401, 200, and
201 of the inclined portions 28a and 28b and the central portion 30.
Basically, the pair of
opposing sidewalls 24a and 24b extends between the bottom wall 26-and the
peripheral
flange 38, where each sidewall 24a and 24b extends along a side of the central
portion
30 and a side of each of the inclined portions 28a and 28b of the bottom wall
26. The
peripheral flange 38 can.comprise a lip or horizontal rim about the opening 25
of the
package 10. On one side of the peripheral flange 38 and extending downwards is
the
endwall 22 or sidewall 24, and on the other side extending downwards is a
vertical flange
portion 39 with a small generally horizontal edge 37 at the base of the
vertical flange
portion 39. The peripheral flange 38 can have any shape that is commonly used
for food
packaging, and preferably will be rectangular in shape and having rounded
corners. The
body of the base 12 may contain a different shape or configuration than the
periphery of
the base 12, or it may be the same. Preferably, the body of the base 12 will
have a
generally V-shape. A rectangular shaped base with a generally V-shape bottom
is
preferable for arranging sliced food products in a shingled arrangement.
Additionally,
gently rounded corners of the base member peripheral flange 38 provide for
better
closure between the lid 14 and base member 12.
[0040] The shape of the base member 12 is generally a V-shape along its bottom
surface, or bottom wall 26, the V-shape being formed as a result of the
positions of the
two inclined portions 28a and 28b and central portion 30 of the bottom wall
26. The V-
shape of the base member 12 provides for packaging of the sliced food product
in a
shingled arrangement, such that at least a portion of each of the cheese
slices rests upon
the bottom wall of the base, rather than being stacked one on top of the
other. Where the
food product comprises cheese slices, the V-shape further aids in minimizing
moisture
loss and Calcium Lactate Crystal (CLC) formation on the cheese before
initially opening
the package.
[0041] CLC formation is a natural phenomena of natural cheese which can be
esthetically unpleasant because it forms white crystals on the surface of the
cheese.
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Without wishing to be bound by theory, it is believed that the lactic acid,
which is present
in natural cheese, converts to CLC and is deposited as crystals on the cheese
surface as
moisture is lost. Furthermore, the more headspace that there is in a package
10 the
more capacity to draw moisture from the cheese product. The "headspace" in a
package
can be described as the empty space around the food product that is between
the base
member 12 and the film 16 prior to initially opening the package 10. It is
this space that
can contribute to moisture loss in cheese and other food products, which it is
desired to
minimize. The V-shape of the base member 12 and the close proximity fit of the
film 16 to
the shingled food product all act together to reduce the amount of headspace
that there is
in the package 10 prior to initial opening, thus reducing the amount of
moisture that is lost
from the cheese. As a result of the package 10 design, the CLC formation is
minimized.
[0042] Where the base member 12 has a generally rectangular periphery with
rounded corners, it may also contain two opposing side portions 18a and 18b
and two
opposing end portions 20a and 20b of the package 10. The sidewalls 24a and 24b
can
be positioned at the opposing side portions 18a and 18b and the endwalls 22a
and 22b
can be positioned at the opposing end portions 20a and 20b. An upper section
of the
inclined portions 28a and 28b of the bottom wall 26 can intersect the end
portions 20a
and 20b of the package 10 at either the periphery flange 38 of the package 10
or at
endwalls 22a and 22b. The inclined portions 28a and 28b can merge with the
upstanding
endwalls 22a and 22b, such that an upper section of the endwalls 22a and 22b
would
then form the periphery about the opening 25 of the base 12. Although not
required, a
plurality of vertically-oriented ribs 64 may also be integrally molded into
the base member
12 along its sidewalls 24a and 24b for additional structural reinforcement.
Alternatively,
the plurality of vertically-oriented ribs 64 may be located along endwalls 22a
and 22b of
the package 10.
[0043] The flexible film 16 can be heat-sealed to the base member peripheral
flange 38 that is located about the periphery of the opening 25 of the base
member 12.
The flexible film 16 can generally have a shape that resembles the shape of
the opening
25 however may be slightly larger in area so that it can overlap the opening
25 and be
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CA 02645705 2008-12-03
sealed to the base member peripheral flange 38. For example, if the base
member
peripheral flange 38 is shaped in a rectangular configuration, then the
flexible film 16 can
also be shaped in a rectangular configuration just slightly larger than the
opening 25 to
allow the edges of the film 16 to be sealed to the flange 38. Alternatively,
the flexible film
16 may further contain a tab 17 or an extension of flexible film material,
typically in a
corner of the film, that allows for grasping and easy removal of the flexible
film 16
material. The flexible film 16 material may be clear and it may be made out of
a
lamination film material.
[0044] Preferably, though not necessarily, the flexible film 16 is pre-trimmed
inboard of the outer base 12 dimensions just prior to heat-sealing, instead of
applying a
larger piece of film and trimming the film 16 after it has been sealed to the
base 12. This
method allows for the film 16 to be sealed to the flange 38 of the base 12
without
requiring any additional trimming of the film 16 after it has been sealed to
the base 12. In
this aspect, the pre-trimmed film 16 does not extend to or beyond the outside
edge of the
flange 38, as with a larger film that is cut after being sealed. Film that
does extend
beyond the flange edge often can interfere with the closure of the lid 14 and
the base 12
by creating a thickness of film between the two that the lid 14 must be forced
onto upon
closing. Providing a film 16 that is pre-trimmed allows for better closure of
the lid 14 upon
the base 12 due to the fact that the lid 14 is substantially in contact with
the flange 38
directly, rather than having the intermediate film 16 which can increase the
tightness of
the fit when present, as well as result in an undesirably looser fit when not
present.
[0045] The lid member 14 can comprise a central lid panel 34 surrounded by a
peripheral rim or edge portion 36, such that the central lid panel 34
is.iraset slightly relative
to the peripheral rim 36 of the lid 14 when viewed from its upper surface,
i.e., its non-food
side, as depicted in FIGS. I and 2. The lid 14, as shown in FIG. 9, further
contains a
relatively continuous undercut bead closure 46, or an inwardly extending
annular bead or
nub, about the lid peripheral rim 36 on the underside 35, or food side, of the
rim 36 such
that the annular bead 46 engages the peripheral flange 38 of the base member
12 to
secure the lid 14. The undercut annular bead 46 is configured to slide past
the base
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CA 02645705 2008-12-03
member peripheral flange 38, vertical flange portion 39, and generally
horizontal flange
portion 37 as the lid 14 is being placed on the base 12 to secure the lid 14
in place, as
can be seen in FIG. 3. The undercut bead 46 is an annular precision rib that
protrudes
towards the inside of the lid 14. In one aspect, the outer lid peripheral edge
portion 36
can also contain an extension at an upper edge thereof, such as a peggable
attachment
60, for hanging vertically in a display case. In yet another aspect, the outer
lid peripheral
edge portion 36 can also contain an extension of the lid 14, such as a tab
member 62,
used as a grasping point for opening the lid 14. The tab member 62 is
preferably located
at one of the typically four corners of the lid 14.
[0046] The lid member 14 allows for the package 10 to be reclosed after
opening,
thus helping to keep the food product inside in a fresh state during storage,
and the lid 14
can further provide an audible snap closure upon being placed over the opening
25 of the
base 12 to indicate adequate closure. The generally rigid lid member 14 can be
configured to cover the opening 25 of the base member 12 such that it confines
the food
product within the compartment 27 and can be securable to the base member 12
to
provide a reliable closure. This audible snap closure provides the consumer
with an
indication that the lid 14 has been properly placed upon the base 12 and gives
the
consumer the "feel" that the package 10 has been securely closed. This tactile
feedback
upon closure of the lid 14 on the base 12 is primarily due to the annular bead
or nub 46
positioned substantially around the entire inner perimeter of the lid 14.
[0047] This annular bead 46 can further be reinforced adjacent the four
corners of
the lid 14, such that it provides a segment of the annular bead 46' having a
greater
thickness than the remaining portions of the annular bead 46 (i.e., the
remaining portions
along the side or longitudinal edges of the lid 14) to provide more resistance
upon closing
and a greater "snap" sound giving a "feel" to the consumer that the package 10
closes
better. The reinforced annular bead 46 can comprise extended undercut beads
added
adjacent the corners where the corner radii intersect the generally straight
portions of the
sides or longitudinal edges of the lid 14, thus providing for a slightly
thtcker portion in that
area. For example, each comer will have two such reinforced annular bead 46'
sections,
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CA 02645705 2008-12-03
one at each comer radii intersection. These reinforced segments can be about 1-
2cm in
length and gradually increase in thickness such that the middle section of the
reinforced
bead 46' is the thickest with its ends the thinnest. This intersection with
the corner radii is
typically the area where the lid 14 gets "stretched" upon engaging it with the
base 12.
When a force is applied to the lid 14 to close it upon the base 12, this force
is applied
primarily to the area around the four corners of the lid 14; therefore, the
added
reinforcement around the comers helps provide the tactile confirmation that
the package
is securely closed. Additionally, in order to improve alignment of the lid 14
with the
base 12 upon closure, the corner radii can be slightly greater than typical
packages, such
as 1.1 inches or greater versus 0.5 inches. For instance, a corner radius of
about 1.20
inches can be used that results in a good, "tight" fit between the lid 14 and
the base 12
such that at the corners there can be a gap between the lid 14 and base 12 of
about 0.03
inches. This slightly larger corner radius allows the lid 14 to align with the
base 12 by
"sliding" into place, thus decreasing the effort required to both remove the
lid 14 from the
base 12 and to close the lid 14 on the base 12.
[0048] For example, upon closing, the base member peripheral flange 38 slides
past the annular bead 46 of the lid 14 such that one or both of the lid and
flanges are
deformed to allow the base member peripheral flange 38 to slide past the
annular bead
46, and once it is past, snap back to shape thus securing it in place against
the lid 14 and
not allowing separation. The annular bead 46 allows substantially the entire
portion of the
base member peripheral flange 38 to pass during closure, as well as the
vertical flange
portion 39 and its horizontal edge 37 at its lower end. All of these elements
of the base
periphery slide past the annular bead 46 and become locked in -place once
closed,
positioned between an upper part 40 of the lid peripheral rim 36 and the
annular bead 46.
Thus, the annular bead closure 46 provides for a reliable fit and closure when
the lid 14
is placed over the base member 12, thus allowing essentially for the
peripheral rim 36 to
mate with the peripheral flange 38. Furthermore, it is the annular bead 46
arrangement
that provides an audible sound, or snap, upon package closure as the lid 14 is
placed
over the base member 12, thus additionally providing audible indication to the
consumer
that the package 10 has been adequately closed.
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CA 02645705 2008-12-03
[0049] When the lid member 14 is placed over the opening 25 and onto the base
member 12, the central portion 34 of the lid 14 rests relatively in the same
plane as the
peripheral flange 38 of the base 12 or just slightly above it. The central
portion 34 of the
lid 14 does not need to nest inside of the base member 12. Where a flexible
film 16 is
used, the central portion 34 of the lid 14 rests just above or adjacent to the
flexible film
16.. Furthermore, the flexible film 16 can be placed between the base member
12 and the
lid member 14 such that the flexible film 16 covers the opening 25 in the base
12.
[0050] Furthermore, multiple packages can be stacked on topof one another for
display purposes such that the feet 32a-d of one package 10 can be placed on a
top
surface (i.e., non-food side) or the central portion 34 of the lid 14 of
another package 10
beneath it. The slightly raised peripheral rim 36 of the lid 14 acts as a
barrier to the
stacked package 10 to keep it from sliding off of the central portion 34 of
the lid 14.
Therefore, providing a simplified way of stacking multiple packages in a
stable fashion.
[0051] An interior section of the peripheral rim 36 of the lid 14 can contain
a small
groove 44 or channel about the periphery of the interior or underside 35 of
the lid 14.
This groove or, channel 44 further contains ribs 48 that span the groove 44.
The ribs 48
can be provided for added support along the rim 36 and to provide additional
stiffness to
the lid 14. The upper surface of the ribs 48, as in FIG. 9, are substantially
in the same
plane as the central portion 34 of the lid 14 such that a relatively even
surface between
them is provided. When the lid 14 is placed over the top of the base 12, the
ribs 48 can
contact the peripheral flange 38 of the base 12 and further prevent the base
member
peripheral flange 38 from entering into the groove 44 of the lid 14. The ribs
48 help with
the alignment of the lid 14, and in particular with keeping the central
portion 34 of the lid
14 slightly above the opening in 25 the base 12 such that the lid 14 does not
become
nested in the inner cavity or compartment 27 of the base member 12. Due to the
small
thickness of the flexible film 16, the film 16 does not substantially
interfere with the initial
mechanical interfit made between the lid 14 and the base 12 at their
respective peripheral
edge portions 36 and 38.
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CA 02645705 2008-12-03
[0052] In another embodiment, a structural feature can be included as an
integral
part of the periphery of at least one of the base 12 or lid 14 to facilitate
the initiation of
manual separation of the component parts from each other. For example, the lid
14 may
contain at least one outward extending, easy-open tab 62 along the peripheral
rim 36 of
the lid 14. The tab 62 can be located at one of the corners of the lid 14, or
any other
convenient location, to allow the consumer to grasp the tab 62 and apply a
generally
upward force to remove the lid 14. A{ternatively, such a tab 62 can be
positioned at
multiple comers or still alternatively, can be positioned along the base 12.
[0053] The flexible film 16 preferably is transparent and at least one of the
lid
member 14 and the base member 12 is also preferably transparent, such that
portions of
the food product inside the package 10 can be readily viewed and inspected by
a
consumer prior to purchase. Preferably, all of the base member 12,-lid member
14, and
flexible film 16 are transparent. In other embodiments, one or all portions
may be partially
or entirely opaque. The material of construction of the base member 12 and lid
14 can
comprise materials such as polyester, polypropylene, high-impact polystyrene
and high
density polyethylene. Preferably, a clarified polypropylene material is used
for both the
base 12 and the lid 14. The material of construction.-of the-flexible film 1-6
-material may
be a lamination film, such as a polyester film laminated to a sealant, which
may be a
multilayer polyolefin or ethylene vinyl acetate (EVA) material. The sealant
material may
have a barrier layer that keeps out oxygen, has an antifog feature, and
provides for easy
open of the flexible film 16 from the base member peripheral flange 38. The
flexible film
16 may also be a clear or relatively transparent film to allow for viewing of
the interior of
the inner compartment 27. Additionally, it is preferable that the lid 14 is
formed by
injection-mold techniques from a resin material and that the base 12 is formed
by
thermoforming methods from a sheet material, however, the base could also be
injection-
molded.
[0054] Typical overall dimensions of the package 10 can comprise a base member
12 having a height of about 1 inch to about 2 inches, a length of about 6
inches to about 8
inches, and a width of about 4 inches to about 6 inches. The lid 14 can have
an overall
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CA 02645705 2008-12-03
length of about 6 inches to about 8 inches, and a width of about 4 inches to
about 6
inches. The recessed central portion 34 of the lid 14 can be recessed about
1/4 inches
from the uppermost portion of the lid peripheral rim 36, and the groove 44 on
the
underside 35 of the lid 14, i.e., the food side, can have a width of about 1/4
inches.
[0055] The dimensions of the package 10 are provided such that various sizes
can
be accommodated. For instance, it may be desirable to size the package 10 such
that it
can hold approximately 6 ounces (oz.) of food product slices or up to about 16
ounces.
Where the larger amount of food slices are to be packaged, such as about 16
ounces, a
slightly deeper base member 12 is required, while the same configuration lid
14 can be
used as for the smaller 6 oz. package. For example, the base member 12 for a
larger
package 10, i.e.,12 oz., will typically have a deeper base member 12 such that
the height
of the base 12 is greater than a smaller 8 oz. package; thus, only the height
of the base
12 is increased to accommodate a larger package 10. The length and width of
the
deeper package 10 remain esseritially the same as for the smaller package 10.
However,
the height of the channels 32a-d increase and the angle of inclination of the
inclined
portions 28a and 28b also increase compared to the 8 oz. package. In one
aspect, the 8
oz. package may have an angle of about 20 degrees at the intersection of the
inclined
portion with the central portion, whereas the 12 oz. package can have an angle
of about
40 degrees at the same intersection.
[0056] Additionaily, one or more labels may be included on the package 10. The
labels may comprise clear or opaque film, or paper including legible print
thereon. For
example, paper labels may be used with one side containing print and the other
side
containing an adhesive. Three such paper labels can be provided, one on the
bottom
surface, or horizontal central portion 30, of the bottom wall 26 and two on
the top surface
of the lid such that the lid labels create a central portion or window on the
lid without any
labels, for viewing the contents of the package therethrough. Alternatively,
one or more
such labels may be film-based and largely transparent. The printed labels may
also be
affixed to the package 10 by adhesive or in-mold labeling. In one embodiment,
pressure
sensitive labels can be used, which may be affixed to an exterior side of the
lid member
-20-
CA 02645705 2008-12-03
14, base member 12, or both. Alternatively, the labels may be affixed to an
interior
surface (i.e., a food side surface adjacent the food product, where a non-food
side is the
exterior or outer surface) of a transparent package component. Still, in
another
embodiment, a print can be directty applied to a package component, such as
either a
fiim, a sheet, or a finished rigid member.
[0057] Referring to FIG. 10, the base member 12 and lid member 14 can be
filled
and sealed shown on an in-iine packaging process 500. In one embodiment, the
base
member 12 may be separately manufactured from thermoformable sheets, and the
lid
member 14 (or base member 12) may be manufactured by injection molding the
member.
For example, the base member 12 rimay be separately manufactured from a
suitable
plastic sheet that is shaped by thermoforming, or other suitabie plastic
shaping
techniques known in the art. Separate plastic sheets may be converiiently
processed on
continuous and intermittent motion vacuum thermoforming 'machines, or
comparable in-
line forming equipment, to form the base member 12. Suitable.thermoforming
methods,
for example, include a vacuum forming or a plug-assist vacuum forming method.
[0058] in a vacuum forming method, a plastic sheet is heated to a forming
temperature, stretched onto or into a mold and is held against the mold by
applying a
vacuum between the mold surface and the sheet, causing the sheet to be drawn
or
pushed by atmospheric pressure on the opposite side of the sheet from the
vacuum and
down into the preformed mold. In a plug-assist vacuum forming method, afterthe
forming
sheet has been heated and placed across a mold cavity, a plug shape similar to
the mold
shape impinges on the opposite side of the forming sheet and, upon the
application of
vacuum, the forming sheet transfers to the mold surface. A sheet thermoformed
into the
base member 12 may be deep drawn in this manner to form a receptacle having
the base
surface contour described herein for receiving shingled cheese. The base
member 12
may comprise thermoplastic or thermosetting materials that can be shaped into
the
desired base configuration.
[0059] In the method 500 for filling the reclosable packages shown in FIG. 10,
a
preformed base member 12 is supplied to. the process (step 501) by manual or
-21-
<
CA 02645705 2008-12-03
automated loading, such as by a tray denester as in step 502. The base members
12
can be preformed utilizing one of the methods described above, and preferably
are
preformed using a thermoforming process. Next, the cheese or other desired
food
product is supplied (step 503) and sliced and then shingled (step 504), which
is then
dropped into the base member 12 (step 505). .
[0060] After a food product is loaded into an open base member 12, the loaded
base 12 is advanced through a packaging machine to apply a gas flush (step
506) prior to
sealing the film, or relatively simultaneously therewith. A vacuum is drawn
and a carbon
dioxide/nitrogen (CO2/N2) gas flush (step 507) is applied to the interior of
the base 12 and
a flexible film 16 is placed over the opening of the base member 12`and heat
sealed to
the base with standard packaging techniques and equipment. The gas flush
replaces the
standard atmosphere in the interior of the base with a modified atmosphere
before the
film is sealed over the opening. The flexible sealing film is cut and sealed
to the base
member 12 (step 508) and can be separately provided in prefabricated roll
form. The
flexible film 16 is preferably pre-trimmed, such that it is trimmed tq the
shape of the
opening in the base member prior to affixing it to the base member flanges and
sealing.
In one example, the flexible film is made from a laminated polyester film and
the gas flush
comprises a mixture of CO2 and N2 which is applied simultaneously with or
after a
vacuum is drawn.
[0061] When packaging cheese, the air in the headspace of the package (i.e.,
the space between the inside surfaces of the package and the food product) can
be
replaced with gas, most commonly C02, N2, or a combination of the two. This
can
serve several purposes. For example, the oxygen in the air is removed to deter
spoilage and CO2 is believed to have anti-microbial effects. The situation is
more
compiex with products that create or consume gas. Swiss cheese can generate or
absorb C02, which causes a change in headspace volume. A flexible package can
accommodate a substantial change in volume, while the same change in a rigid
package may bloat or contract enough to make the package unacceptable.
Optimizing the package material and gas mixture can control the magnitude of
volume
-22-
CA 02645705 2008-12-03
change and allow products like Swiss cheese to be successfully packaged in a
rigid
container. It is preferable that the package intemal pressure be equal to or
less than
atmosphere throughout shelf life. One way to accomplish this- is to use
moderately
breathable materials and an optimum level of C02 with the balance being N2.
The
C02 level and the gas transmission rate of the breathable materials can be
determined based on the particular type of cheese packaged and the size of the
package. The moderately breathable materials can have an oxygen transmission
rate
of 3-12 cc/100in2/24h @ 23 C based upon the package dimensions or sizes as
disclosed herein. A typical optimum range of CO2 can be from 40 to 100%, or
more
particularly from 40-60%. Preferably, about 55% CO2 with approxiniately the
balance
as N2 can be used for a Swiss cheese product.
[0062] Lids 14 from a supply of preformed lids (step 509) are separated such
as by
a lid denester (step 510) and are attached to the filled base 12 at flange
portions thereof
(step 511) to form the packages 10. A lid 14 is mechanically joined, such as
by a snap-fit,
to the base 12 supporting the food product that has already been packed, gas-
flushed,
and sealed within the flexible film 16 (step 508). The lid member 14 may be
injection
molded by injecting molten plastic at high pressure into a moid, to preform
the lid member
14 into the appropriate shape. The stiffness of the lid member 14 may
optionally be
enhanced by the mold design, such as the peripheral edge portion 36 and
structural
supports 48. The base member 12, as filled with cheese slices, receives the
lid member
14, which has been separately formed, at the respective mating peripheral
flange 38 of
the base member 12 and lid peripheral edge portion 36 of the lid member 14
(step 511).
For example, the lid peripheral edge portion 36 is seated upon the base member
peripheral flange 38 in a contiguous manner.
[0063] The lid member 14 and base member 12 do not need to be heat sealed at
their respective aligned and contacting peripheral flanges 36 and 38, since
the flexible
film 16 seals the opening 25 in the base member 12 in a hermetic sealing
manner.
Therefore, the base-member 12 and lid member 14 can be configured for
reclosable
mechanical interconnection without the need for heat sealing them. Although
not
required, heat'sealing or other one-time reieasable attachment maybe provided.
In this
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CA 02645705 2008-12-03
manner, the flexible film 16, iid member 14, and base member 12 form a
substantially
gas- and debris-impermeable enclosure for the shingled cheese slices. The
mechanical
attachment of the lid member 14 and base member 12 can be sufficiently strong
to
withstand the expected handling and use conditions of the package 10.
[0064] The lid member 14 (or base member 12) may be made of materials suitable
for injection molding, such as polypropylene, polystyrene, polyvinyl chloride,
and the like.
The base member 12 independently can be made from a variety of materials
including
homogenous plastics, multi-layered laminates, and/or co-extruded plastics or
resins, and
the like. In one embodiment, packaging material useful for the base member 12
and lid
member 14 is polypropylene, and particularly, a polypropylene sheet or resin
suitable for
packaging of refrigerated cheese products. Preferably, both the base member 12
and lid
member 14 have a construction that has sufficient structural characteristics
so that the
laminate is sufficiently rigid for shape retention during handling and is
substantially
impervious to oxygen. In one example, the base member 12 is made from a
polypropylene sheet and may additionally have a sealant layer thermally
laminated to it,
such as a coextruded film comprising any one or more of polypropylene, ethyl
vinyl
alcohol and. low-density polyethylene. The lid member 14 can also be made from
a
polypropylene resin.
[0065] The loaded and covered packages 10 may be optionally labeled (step
513);
such as using conventional pressure sensitive adhesive (PSA) food package
labeling
(step 512). In this embodiment, the individual sealed packages 10 may be
packaged into
corrugated shipping cartons (step 514), shipped, and or shelved in any
convenient
manner.
(0066] The use of the term preformed in this example includes components
formed
offsite, as well as components formed onsite but at different times or using
different steps
than those discussed in the example of FIG. 10.
[0067] In addition to the above and subject to any requirements indicated
herein,
one or more of the flexible film 16, lid 14 and/or base 12 plastic materials
may also
include one or more additives useful for packaging functions, such as,
antiblocking
-24-
CA 02645705 2008-12-03
agents, slip agents, flavorants, antimicrobial agents, cheese preservatives,
antioxidants,
fillers, light barriers, oxygen scavengers, and antistatic agents, and so
forth. Such
additives, and their effective amounts, are generally known in the art.
[0068] -From the foregoing, it will be appreciated a reclosable food package
is
provided such that numerous modifications and variations could be made thereto
by
those skilled in the art without departing from the scope of the package set
forth in the
claims, and thus the sliced food product package design may be utilized with
other
container designs than those described herein. Therefore, the disclosure is
not limited to
the aspects and embodiments described hereinabove, or to any particular
embodiments.
Various modifications to the reclosable food package can result in
substantially the same
container and methods of manufacture.
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