System and method for forming an integrated tray for use in vacuum packaging

Abstract

A bag for use in vacuum packaging can comprise a first panel and a second panel overlapping each other. One or more trays for retaining a perishable or other product is formed on one or more of the panels. Each tray can optionally have ridges for suspending a product above the tray so that liquid can collect in the tray. In one embodiment, a method for forming such a bag between a cooling roll and laminating roll includes feeding a gas-impermeable material to a nip formed between the rolls. Resin is extruded to the nip such that the resin fills a plurality of cavities of the cooling roll, forming an inner layer that adheres to the gas-impermeable material. A resultant sheet is then folded to form the first and second panel and sealed such that an envelope is formed. This description is not intended to be a complete description of, or limit the scope of, the invention. Other features, aspects, and objects of the invention can be obtained from a review of the specification, the figures, and the claims.

1 . A bag adapted to receive an article, comprising: 
 a first panel defining a tray adapted to receive the article and a plurality of protuberances within the tray, which protuberances are adapted to support the article over a base of the tray;    a second panel; and    the first panel and the second panel secured together to form the bag.    
     
     
         2 . The bag of  claim 1  wherein said first panel is formed of a heat sealable material and said second panel is formed of a gas impermeable material.  
     
     
         3 . A bag adapted to receive an article, comprising: 
 a first panel having: 
 a first outer layer; and  
 a first inner layer connected with the first outer layer, the first inner layer including at least one tray integrally formed with the first inner layer;  
   a second panel connected with the first panel such that the first panel and the second panel form an envelope having an inlet, the second panel having: 
 a second outer layer; and  
 a second inner layer connected with the second outer layer.  
   
     
     
         4 . The bag of  claim 3 , further comprising a plurality of protuberances within the at least one trays.  
     
     
         5 . The bag of  claim 3 , wherein the first outer layer and the second outer layer comprise a gas-impermeable material.  
     
     
         6 . The bag of  claim 5 , wherein the gas-impermeable material is one of polyester, polyamide, ethylene vinyl alcohol, and nylon.  
     
     
         7 . The bag of  claim 3 , wherein the first inner layer and the second inner layer comprise a thermoplastic resin.  
     
     
         8 . The bag of  claim 7 , wherein the thermoplastic resin is polyethylene.  
     
     
         9 . The bag of  claim 5 , wherein when the article is positioned within the tray, the article is supported by the plurality of protuberances.  
     
     
         10 . The bag of  claim 4 , wherein when the article is positioned within the tray, the article is supported above a base of the at least one tray.  
     
     
         11 . The bag of  claim 4 , wherein the plurality of protuberances define a plurality of pockets formed such that liquid can collect in the plurality of pockets; and 
 wherein when the article is positioned within the tray, the article is positioned above liquid collected in the plurality of pockets.    
     
     
         12 . A bag adapted to receive an article, comprising: 
 a first panel including: 
 a first gas-impermeable layer; and  
 a first Inner layer laminated to the first gas-impermeable layer, the first inner layer including at least one tray integrally formed with the first inner layer;  
   a second panel including: 
 a second gas-impermeable layer; and  
 a second inner layer laminated to the second gas-impermeable layer; and  
 wherein the first panel is connected with the second panel to form an envelope such that the first inner layer opposes the second inner layer, the envelope including a heat-sealable opening for evacuating gas.  
   
     
     
         13 . The bag of  claim 12 , further comprising a plurality of protuberances within the at least one trays.  
     
     
         14 . The bag of  claim 12 , wherein the first gas-impermeable layer and the second gas-impermeable layer comprise one of polyester, polyamide, ethylene vinyl alcohol, and nylon.  
     
     
         15 . The bag of  claim 12 , wherein the first inner layer and the second inner layer comprise a thermoplastic resin.  
     
     
         16 . The bag of  claim 15 , wherein the thermoplastic resin is polyethylene.  
     
     
         17 . The bag of  claim 13 , wherein when the article is positioned within the tray, the article is supported by the plurality of protuberances.  
     
     
         18 . The bag of  claim 13 , wherein when the article is positioned within the tray, the article is supported above a base of the at least one tray.  
     
     
         19 . The bag of  claim 13 , wherein the plurality of protuberances define a plurality of pockets formed such that liquid can collect In the plurality of pockets; and 
 wherein when the article is positioned within the tray, the article is positioned above liquid collected in the plurality of pockets.    
     
     
         20 . A heat-sealable bag adapted to receive an article, comprising: 
 a first panel including: 
 a first gas-impermeable layer;  
 at least one first intermediate layer connected with the first gas-impermeable layer; and  
 a first inner layer laminated to the at least one first intermediate layer, the first inner layer including at least one tray integrally formed with the first inner layer; and  
   a second panel including: 
 a second gas-impermeable layer;  
 at least one second intermediate layer connected with the second gas-impermeable layer; and  
 a second inner layer laminated to the at least one second intermediate layer;  
   wherein the first panel is connected with the second panel to form an envelope such that the first inner layer opposes the second Inner layer, the envelope including a heat-sealable opening for evacuating gas.    
     
     
         21 . The bag of  claim 20 , further comprising a plurality of protuberances within the at least one trays.  
     
     
         22 . The bag of  claim 20 , wherein the first gas-impermeable layer and the second gas-impermeable layer comprise one of polyester, polyamide, ethylene vinyl alcohol, and nylon.  
     
     
         23 . The bag of  claim 20 , wherein the first inner layer and the second inner layer comprise a thermoplastic resin.  
     
     
         24 . The bag of  claim 23 , wherein the thermoplastic resin is polyethylene.  
     
     
         25 . The bag of  claim 21 , wherein when the article is positioned within the tray, the article is supported by the plurality of protuberances.  
     
     
         26 . The bag of  claim 21 , wherein when the article is positioned within the tray, the article is supported above a base of the at least one tray.  
     
     
         27 . The bag of  claim 21 , wherein the plurality of protuberances define a plurality of pockets formed such that liquid can collect In the plurality of pockets; and 
 wherein when the article is positioned within the tray, the article is positioned above liquid collected in the plurality of pockets.    
     
     
         28 . A method for forming a panel for use in a sealable bag, comprising: 
 flowing a material onto a backing film, such that the flowing material is molded to form a structure;    wherein the structure includes a tray;    cooling the flowing material such that the flowing material solidifies to form an inner layer having the structure; and    wherein the inner layer adheres to the backing film.    
     
     
         29 . A method for forming a bag adapted to receive an article, the bag being partially formed between a laminating roll and a cooling roll having a plurality of cavities for forming a structure, comprising: 
 feeding a gas-impermeable film to a nip formed by the cooling roll and the laminating roll;    extruding resin such that the resin fills the nip and the plurality of cavities exposed to the nip;    pressing the resin between the cooling roll and the laminating roll;    cooling the resin such that the resin forms the structure and adheres to the gas-impermeable film, forming a panel;    folding the panel such that a first portion of the panel overlaps a second portion of the panel;    applying heat to a first, second, and third side of the first and second portions such that an envelope is formed; and    wherein the structure includes one or more trays having a plurality of protuberances.    
     
     
         30 . A method for manufacturing a bag adapted to receive an article, comprising: 
 feeding a first gas-impermeable film to a first nip formed by a first cooling roll and a first laminating roll, the first cooling roll having a plurality of cavities for forming a structure;    wherein the structure is one or more trays having a plurality of protuberances;    extruding resin such that the resin fills the first nip and the plurality of cavities exposed to the first nip;    pressing the resin between the first cooling roll and the first laminating roll;    cooling the resin such that the resin forms the structure and adheres to the first gas-impermeable film, forming a first panel;    feeding a second gas-impermeable film to a second nip formed by a second cooling roll and a second laminating roll;    extruding resin such that the resin fills the second nip;    pressing the resin between the second cooling roll and the second laminating roll;    cooling the resin such that the resin adheres to the second gas-impermeable film, forming a second panel;    overlapping the first panel with the second panel;    applying heat to a first, second, and third side of the first and second panels such that an envelope is formed; and    wherein the structure includes one or more trays having a plurality of protuberances.    
     
     
         31 . A method for manufacturing a bag adapted to receive an article, comprising: 
 rotating a first cooling roll at a first rate, the first cooling roll including a plurality of cavities for forming a structure;    wherein the structure includes one or more trays having a plurality of protuberances;    rotating a first laminating roll at a second rate;    introducing a first film to a first nip between the first cooling roll and the first laminating roll;    extruding molten material to the first nip;    pressing the molten material between the first cooling roll and the first film such that the molten material fills the plurality of cavities exposed to the first nip;    cooling the molten material such that a first inner layer is formed;    wherein the first inner layer includes the structure;    wherein the first Inner layer adheres to the first film, thereby forming a first panel;    rotating a second cooling roll at a third rate;    rotating a second laminating roll at a fourth rate;    introducing a second film to a second nip between the second cooling roll and the second laminating roll;    extruding molten material to the second nip;    pressing the molten material between the second cooling roll and the second film;    cooling the molten material such that a second inner layer is formed;    wherein the second inner layer adheres to the second film, thereby forming a second panel;    overlapping the first panel with the second panel; and    applying heat to a portion of a periphery of the first and second panels such that the first panel and the second panel form an envelope.    
     
     
         32 . The method of  claim 31 , wherein the second rate Is an integer multiple of the first rate and the fourth rate is an integer multiple of the third rate.  
     
     
         33 . The method of  claim 31 , wherein the first film and the second film comprise at least one layer.  
     
     
         34 . The method of  claim 33 , wherein the at least one layer comprises a gas-impermeable material.  
     
     
         35 . The method of  claim 34 , wherein the gas-impermeable material is one of polyester, polyamide, ethylene vinyl alcohol, and nylon.  
     
     
         36 . The method of  claim 31 , wherein the molten material is polyethylene.  
     
     
         37 . The method of  claim 31 , wherein a thickness of the first inner layer Is determined by the size of the first nip and the thickness of the second inner layer Is determined by the size of the second nip.  
     
     
         38 . The method of  claim 31 , wherein the structure Is formed such that when the article is positioned within the tray, the article is supported by the plurality of protuberances.  
     
     
         39 . The method of  claim 31 , wherein the structure is formed such that when the article is positioned within the tray, the article is supported above a base of the at least one tray.  
     
     
         40 . A method of manufacturing a bag adapted to receive an article, comprising: 
 rotating a first roller having a plurality of recesses that can define one or more trays including a plurality of protuberances;    rotating a second roller adjacent to the first roller, said second roller can feed a first film adjacent to the first roller;    applying a molten material between the first roller and the film;    said molten material filling the recesses of the first roller, and said molten material and film moving between the first roller and the second roller forming a first panel with a plurality of receptacles;    forming a second panel; and    mating the first panel to the second panel in order to form a bag.    
     
     
         41 . The method of  claim 40 , further comprising: 
 using a gas Impermeable material for the film; and    using a heat sealable material for the molten material.    
     
     
         42 . The method of  claim 41 , wherein the first panel is formed such that when the article is positioned within the tray, the article is supported by the plurality of protuberances.  
     
     
         43 . The method of  claim 41 , wherein the first panel is formed such that when the article is positioned within the tray, the article is supported above a base of the at least one tray.  
     
     
         44 . The method of  claim 40 , wherein said second panel is formed with the first roller and the second roller.  
     
     
         45 . The method of  claim 40 , wherein said second panel Is formed with the first roller and the second roller, and the mating step includes folding the first panel over the second panel.  
     
     
         46 . The method of  claim 40 , wherein said first roller includes a peripheral surface having a first portion including the plurality of recesses for defining the one or more trays including the plurality of protuberances.  
     
     
         47 . A method for manufacturing a bag adapted to receive an article, comprising: 
 feeding a first gas-impermeable film to a first nip formed by a first cooling roll and a first laminating roll, the first cooling roll having a plurality of cavities for forming at least one tray;    extruding resin such that the resin fills the first nip and the plurality of cavities exposed to the first nip;    pressing the resin between the first cooling roll and the first laminating roll;    cooling the resin such that a first inner layer having the first structure and the second structure is formed;    wherein the first inner layer adheres to the first gas-impermeable film, thereby forming a first panel;    feeding a second gas-impermeable film to a second nip formed by a second cooling roll and a second laminating roll, the second cooling roll having a plurality of cavities and protuberances for forming a third structure;    wherein the third structure is the other of the receiving feature and the insertion feature;    extruding resin such that the resin fills the second nip and the plurality of cavities exposed to the second nip;    pressing the resin between the second cooling roll and the second laminating roll;    cooling the resin such that a second inner layer having the third structure is formed;    wherein the second inner layer adheres to the first gas-impermeable film, thereby forming a second panel;    overlapping the first panel with the second panel; and    applying heat to a first, second, and third side of the first and second panels.