Plastic packaging, and method and apparatus for producing same

Abstract

A plastic package uses a substrate and an overlay, where both the substrate and the overlay are of materials which can be recycled together, for example polyethylene terephthalate (PET). The plastic used for the overlay may be different from the plastic used for the substrate, provided that the plastics are of the same thermoplastic family, or are of types which are compatible for recycling together. A method of making the package includes the steps of: positioning the product on a vacuum-forming fixture; heating a first layer of thermoplastic, positioning it over the product, and applying a vacuum to the fixture to pull the first layer of thermoplastic onto the product; and thermally bonding the first layer and a second layer of recycling-compatible thermoplastic to each other with the product between them, so as to capture the product. Apparatus having lease two stations is provided to carry out the method and thereby produce the package.

1 . A plastic package for a product, comprising a thermoplastic substrate and a thermoplastic overlay bonded to each other so as to capture the product between them, wherein the substrate and the overlay are of thermoplastics suitable for recycling together. 
     
     
         2 . A plastic package as recited in  claim 1 , wherein the substrate and the overlay are made of the same thermoplastic, though not necessarily the same thickness. 
     
     
         3 . A plastic package as recited in  claim 1 , further comprising a thermoplastic front, the front including a pocket, the pocket being provided with projections for engaging the product to keep the product from moving once inside the package. 
     
     
         4 . A plastic package as recited in  claim 1 , further comprising a security tag, which is captured on the substrate by a thermoplastic cover. 
     
     
         5 . A method of packaging a product, comprising the steps of:
 positioning the product on a vacuum-forming fixture;   heating a first layer of thermoplastic, positioning it over the product, and applying a vacuum to the fixture to pull the first layer of thermoplastic onto the product; and   thermally bonding the first layer and a second layer of recycling-compatible thermoplastic to each other with the product between them, so as to capture the product.   
     
     
         6 . A method of  claim 5 , further comprising the step of bonding a security tag and a label to the substrate. 
     
     
         7 . Apparatus for packaging a product, comprising:
 a first station adapted for positioning the product on a vacuum-forming fixture, heating a first layer of thermoplastic and positioning it over the product, and applying a vacuum to the fixture to pull the first layer of thermoplastic onto the product; and   a second station adapted for thermally bonding the first layer and a second layer of recycling-compatible thermoplastic to each other with the product between them, so as to capture the product.