WO2014175891A1

WO2014175891A1 - Peelable resealable package with integrated cutting and serving platform

Info

Publication number: WO2014175891A1
Application number: PCT/US2013/038331
Authority: WO
Inventors: Jordan R. TRACY; Seamus A. WEDGE
Original assignee: Curwood, Inc.
Priority date: 2013-04-26
Filing date: 2013-04-26
Publication date: 2014-10-30
Also published as: EP2989022A1; EP2989022A4; BR112015026762A2

Abstract

The present invention relates to improved peelable resealable package for an unportioned or uncut food item having an integrated food cutting and serving platform formed from a substantially rigid planar laminate. The substantially planar rigid laminate comprises a rigid layer and a first thermoplastic film. The packages of the present also include a second thermoplastic member having a thermoformed cavity which encloses the food item and has a shape which generally conforms to the shape of the food item. The packages further comprise a planar marginal flange extending around the thermoformed cavity, and a continuous peelable resealable hermetic seal circumscribing the food item formed by heat sealing the first thermoplastic film to the second thermoplastic film.

Description

PEELABLE RESEALABLE PACKAGE WITH

INTEGRATED CUTTING AND SERVING PLATFORM!

BACKGROUND OF THE INVENTION

The present invention relates to peelable reseaiabSe packages for unportioned or uncut food products such as a chunk of cheese and more particularly, peelable reseaiabSe packages for use for unportioned or uncut food products having an integrated cutting and serving platform.

A common method of packaging foods, such as meats and cheese, is by use of horizontal form, fill, and seal (HFFS) procedures. These procedures involve shaping a portion of film ("form"), placing the food article inside or upon the formed film portion ("fill"}, completing the closure of the film portion around the food article and "sealing" open edges to complete the packaging process, Unportioned or uncut food products such as chunk cheese, butter, sausages, fruits and vegetables can be packaged by HFFS packaging methods. With conventional HFFS packaging methods, unportioned or uncut food products are frequently packaged in flexible pouches. As with all such unportioned or uncut food products, the product being stored within the container will require cutting (e.g., slicing, dicing, comminuting and the like) into smaller portions prior to being consumed. Preferably such cutting is performed on a suitable food cutting surface (e.g., a counter or tabietop) to avoid damage to the container. However, suitable food cutting surfaces are not always available particularly during outdoor activities such as when camping, hiking and picnicking. It would be desirable to provide packaging for unportioned food products which have sufficient durability and rigidity to enable the unportioned food product to be cut sliced or diced within the package without the need to remove the product from the package.

The freshness of these food products contained within these HFFS pouches depends upon the extent to which the package is packed and subsequently hermetically sealed. Often the consumer does not use or consume the entire product at once, but rather uses them over an extended period of time. Once the pouch has been opened, it cannot be effectively reseated to in a manner to presea¾ the freshness of the product. In such instances, the food product is removed from its original pouch and repacked in a different suitabiy rectosable container, Reseaiable packages are convenient in that they can be closed and reseated after the initial opening to preserve the enclosed contents. The need to locate a storage container for the unused portion of the products in the package is thus avoided. As such, providing products in reseaiable packages appreciably enhances the marketability of those products. Brand owners prefer to have their products remain packaged in its original container.

There is a need in the art for improved packages that address at least some of the above concerns, and other concerns related to manufacture and use of the package.

SUMMARY OF THE INVENTION

The present invention is concerned with peeiabie reseaiable food packages fo packaging an unportioned, uncut or whole food item having an integrally formed food cutting and serving platform. The integrally formed food cutting and serving platform comprises a substantially planar rigid laminate having a cut resistant surface. The substantially pianar rigid laminate comprises a rigid layer having a stiffness value of at least about 1.70 kilogram-force and a first thermoplastic film. The packages of the present also include a second thermoplastic member having a thermoformed cavity which encloses the food item and has a shape which generally conforms to the shape of the food item. The packages further comprise a planar marginal flange extending around the thermoformed cavity, and a continuous peeiabie reseaiable hermetic seal circumscribing the food item formed by heat sealing the first thermoplastic fi!m to the second thermoplastic film.

BRIEF DESCRIPTION OF THE DRAWINGS [07] FIG, 1 depicts an isometric view of one embodiment of the present invention in the dosed state.

[083 F!G. 2 depicts an isometric view of one embodiment of the present invention of the package of FIG. 1 in the partially opened state.

[07] 3 depicts an isometric view of another embodiment of the present invention in the opened state,

[083 FIG. 4 depicts a cross-sectional embodiment of a rigid member of the present invention,

DETAILED DESCRIPTION OF THE INVENTION

[09] The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as iimited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

[10] Referring now more particularly to FIGS. 1-3 of the drawings, a preferred embodiment of package 10 embodying the present invention is shown. Package 10 for packaging an unportioned or uncut food item 20 is depicted having an integrally formed food cutting and serving platform 30 comprising a substantially rigid planar laminate 50. Rigid planar laminate 50 is formed from a rigid layer 100 and a first thermoplastic film 101 (see FIG. 4). Preferably, rigid layer 100 has a cut resistant surface and a stiffness va!ue of at least about 1.70 ki!ogram-force. Package 10 comprises a second thermoplastic film 102 having a thermoformed cavity 40 which encioses food item 20 and has a shape which generally conforms to the shape of the food item 20. Package 10 also includes a planar marginal flange 90 extending around the thermoformed cavity 40 to the distal edges of the rigid planar laminate 50 Package 10 further comprises a continuous peelable resealabie hermetic seai 75 (shown in FIG. 1 ) which circumscribes food item 20 formed by heat sealing the first thermoplastic film 101 (shown in FIG. 4} to the second thermoplastic film 102. FIG. 1 illustrates a preferred embodiment of package 10 having a flexible second thermoplastic film 102 in the unopened or closed state. The unopened continuous peelable resealabie hermetic seal 7Sa is depicted with cross-hatched lines. FIG. 2 illustrates a preferred embodiment of package 10 having a flexible first thermoplastic film 101 in the partially opened state with an opened continuous peelable resealabie hermetic seal 7Sb depicted with diagonal lines. FIG. 3 shows a preferred embodiment of package 10 having a rigid or semi-rigid first thermoplastic film 01 in the partially opened state with an opened continuous peelable resealabie hermetic sea! 7Sb depicted with diagonal lines.

[11j As shown in FIGS. 1-3_t food item 20 is packaged so that it rests on and is supported by platform 30. Package 1 is readily opened by a consumer by peeling second thermoplastic film 102 away from planar flange 90. After opening, a desired serving portion food item 20 may be cut or sliced with a knife or other cutting utensil directly on platform 30 without removing the entire food item from the package. Since platform 30 is designed to be dimensionai!y stable, the desired serving portion may then be served conveniently and directly from the package. Second thermoplastic film 102 can be re-sealed to planar flange 90 to preserve the remaining portion of food item 20, Thus, platform 30 functions as a cutting surface and food handling/serving surface.

[ 23 5° accordance with an important aspect of the present invention, the interface between first thermoplastic film 101 (shown in FIG. 4) and second thermoplastic film 102 of package 10 is peelable and resealabie as shown in FIGS. 1 -3. When first thermoplastic film 101 is separated from second thermoplastic film 102, an interface of pressure sensitive adhesive is created because of cohesive failure of the pressure sensitive adhesive layer of first thermoplastic film 101. Because the pressure sensitive adhesive layer of first thermoplastic film 101 is designed to cohesively fail relative to other film layers, package 10 provides a relatively low initial (or first) peel strength of no greater than 2.50 kilogram/inch (0.98 kilogram/centimeter). Moreover, since there is a residual amount of pressure sensitive adhesive on the surface of each fiim after separation, package 10 is afforded consistent reseal (or second peel) strengths of at least 0.700 kilogram/inch (0.28 kilogram/centimeter) even after five consecutive separations and reseaiing operations.

Substantially Planar Rigid Laminate

As used throughout this application, the term "rigid" refers to a material having a stiffness value of at least about 1 .70 kilogram-force (3.75 pound-force), in one embodiment, rigid layer 100 has a stiffness value of at least about 1 .70 kilogram-force (3.75 pound-force), at least about 2.00 kilogram-force (4.41 pound-force), at ieasf about 3.00 kilogram-force (6.61 pound-force), at least about 4.00 kilogram-force (8.82 pound-force), at least about 5.00 kilogram- force ( 1 ,02 pound-force), at least about 6,00 kilogram-force (13.23 pound- force), at least about 7.00 kilogram-force (15.43 pound-force), at least about 8.00 kilogram-force (17.64 pound-force), or at least about 9.00 kilogram-force (19.84 pound-force).

As used throughout this application, the term "cut resistance" refers to a material having a slow rate penetration resistance of at least 85.77 kilogram- force (145 pounds-force). In one embodiment, rigid layer 100 has a slow rate penetration resistance of at least about 85.77 kilogram-force (145 pounds- force), at least about 70.31 kilogram-force (155 pounds-force), at least about 74,84 kilogram-force (165 pounds-force), at least about 183,91 kilogram-force (85 pounds-force) or at least about 90.72 kilogram-force (200 pounds-force).

In a preferred embodiment, the substantially planar rigid laminate 50 comprises a rigid layer 100 of aromatic polyesters, aliphatic polyesters, styrenic polymers, poly propylenes, high density polyethylenes, polypropylene, poSyamide, polycarbonate, paperboard, and combinations thereof, and a first thermoplastic film 101 as shown in FIG. 4, In one preferred embodiment, first thermoplastic film 101 is a peeiable and reseaiabie film. In another preferred embodiment, first thermoplastic film 101 is a peeiable and resealabie coexiruded blown film comprising moisture and oxygen barrier properties. Rigid planar laminate SO may be readily formed in a manner well-known in the industry such as extrusion coating rigid layer 100 onto first thermoplastic film 101 by use of an appropriate laminating adhesive.

Turning now to FIG. 4, t ere is illustrated one particular embodiment of a substantially planar rigid laminate SO having a rigid layer 100 and a first thermoplastic film 101. It will be appreciated that thermoplastic film 101 may include any number of film layers and film layer compositions depending upon bot functional and aesthetic requirements of the package. As shown in FIG. 4, this particular example of thermoplastic film 101 includes seven film layers. The composition of the layers is described in more detail herein below.

Rigid layer 100 may include a material selected from the group consisting of aromatic polyesters, aliphatic polyesters, styrenic polymers, polypropylenes, high density poSyethySenes, polyamides, polycarbonates, paperboard and blends of such. As used throughout this application, the term "planar" refers to the overall dimensions of the rigid planar member having a generally flat surface.

Preferably, rigid layer 100 has a thickness typically at least about 5.0 mil (about 127 micron), more typically at least about 6.5 mil (about 185.1 micron) and most typically at ieast about TO mil (about 254 micron).

Polyesters suitable fo use as a rigid layer 00 may include a homopolymer or copolymer of a!kyi-aromatic esters including but not limited to polyethylene terephthalate (PET), amorphous polyethylene terephihalate (APET), crystalline polyethylene terephthalate (CPET), glycol-modified polyethylene terephthalate {PETG} and po!ybutylene terephthalate; a copolymer of terephthalate and isophthaiaie including but not limited to polyethylene terephthalate/isophthaSate copolymer. Aliphatic polyester may also be used which include, but are not limited to poiyiactic acid (PLA); poiyh droxyaikonates including but not limited to polyhydroxypropionate, poly(3~hydroxybutyrate) (PH3B), poiy{3~hydroxyvaleraie) (PH3V), poly(4- hydroxybutyrate) (PH4B), poiy(4-hydroxyvaieraie) (PH4V), poly(5- hydroxyvalerate) (PH5V), poiy(6-hydroxydodecanoate) (PH6D); and blends of any of these materials. Examples of aromatic polyesters include but are not limited to polyethylene terephthalate (PET), oriented polyethylene terephthalate (OPET), amorphous polyethylene terephthalate (APET) and glycol-modified polyethylene terephthalate (PETG). A non-limiting exampie of APET is Eastman™ PET 9921 , which is available from Eastman Chemical Company (Kingsport, Tennessee). A non-limiting exampie of PETG is Eastar™ Copolyester 6762, which Is also available from Eastman Chemical Company (Kingsport Tennessee), An example of an aliphatic polyester includes but is not limited to poiyiactic acid (PLA).

Examples of suitable styrenie materials which may be used for a rigid layer 100 include, but are not limited to_t high impact polystyrene (HIPS), general purpose polystyrene (GPPS), styrene block copolymer (SBC) (including but not limited to styrene butadiene copolymer (SB). Examples of HIPS include but are not limited to Impact Polystyrene 825E and impact Polystyrene 945E, bot of which are available from Totai Petrochemicals USA, Snc; EB602S Rubber Modified High Impact Polystyrene, which is available from Chevron Phillips Company (The Woodlands, Texas); and 6210 High Impact Polystyrene, which is available from !neos Nova LLC (Channahon, iiiinois), GPPS is often called crystal polystyrene, as a reference to the ciarity of the resin. Examples of GPPS include but are not limited to Crystal Polystyrene 524B and Crystal Polystyrene 5258, both of which are available from Total Petrochemicals USA, Inc. Styrene block copolymers (SBC) include styrene butadiene copolymers (SB). The styrene-butadiene copolymers that are suitable for packaging applications are those resinous block copolymers that typically contain a greater proportion of styrene than butadiene and that are predominantly polymodai with respect to molecular weight distribution. (See HartSGCk, "Styrene-Butadiene Copolymers," The Wiley Encyclopedia of Packaging Technology, Second Edition, 1997, pp. 863-884 (John Wiley & Sons, Inc., New York, New York), which is incorporated in its entirety in this application by this reference.) A non-limiting example of SB is DK13 K- Resin® Styrene-Butadiene Copolymer, which is available from Chevron Phillips Chemical Company (The Woodlands, Texas).

Examples of suitable poiypropyienes for use as a rigid layer 100 may include but are not limited to those polypropylene homopolymers traditionally used to cast sheets. Non-limiting examples of such poiypropyienes include Polypropylene 3287WZ, which is available from Total Petrochemicals USA, Inc. (Houston, Texas); and H02C-00 Polypropylene Homopoiymer, which is availabie from Ineos Olefins & Polymers USA (League City, Texas).

As used throughout this application, the term "high density polyethylene" or ΉΟΡΕ" refers high molecular weight polyethylenes which may be homopolymers or copolymers of ethylene which have densities of at least 0.980 gram/centimeter³, at least 0.970 gram/centimeter³, at least 0.980 gram/centimeter, or at least 0.990 gram/centimeter³.

As used throughout this application, the term "polyamide" or "PA" or "nylon" refers to a homopoiymer or copolymer having an amide linkage between monomer units which may be formed by any method known to those skilled in the art. The amide linkage can be represented by the general formula: [C(O)- R-CiOJ-NH-R'-NHjr, where R and R' are the same or different alky) (or aryi) group. Examples of suitable nyion polymers for use as a rigid member may include but are not limited to nylon 6 (polycapro!aetam), nylon 11 (po!yundecanolactam), nylon 12 (po!yauryi!actam), nylon 4,2 (polytetramethy!ene ethyfenediamide), nylon 4,6 (poiytetramethy!ene adipamide), nylon 6,6 (po!yhexamethylene adipamide), nylon 6,9 (poiyhexamethyiene azeiamide), nyion 6,10 (polyhexamethylene sebacamide), nylon 6,12 {polyhexamethylene dodecanediamide), nylon 7,7 (polyheptamethyiene pimeiamide), nylon 8,8 (poiyoctamethylene suberamide), nylon 9,9 (po!ynonamethyiene azeiaiaroide), nylon 10,9 (po!ydecamethyiene azeiamide), and nylon 12,12 (poiydodecamethyiene dodecanediamide). Examples of nylon copolymers inciude but are not limited to nylon 6,6/6 copolymer (poiyhexamethyiene adipamide/caproiaciam copolymer), nylon 6,6/9 copolymer (poiyhexamethyiene adipamide/azelaiamide copolymer), nylon 6/6,6 copolymer {poSycaprolactam/hexamethylene adipamide copolymer), nylon 6,2/6,2 copolymer (poiyhexamethyiene ethyienediamide/hexamethyiene ethylenediamide copolymer), and nylon 6,6/6,9/6 copolymer (poiyhexamethyiene adipamide/hexamethy!ene azelaiamide caprolaciam copolymer). Examples of aromatic nyion polymers inciude but are not limited to nylon 4,1, nylon 6,1, nylon 6,6/61 copolymer, nylon 6,6/61 copolymer, nylon MXD6 (poSy-m-xyiyiene adipamide), poly-p-xyiylene adipamide, ny!on 6I/6T copolymer, nylon 61/61 copolymer, nylon XDI, nyion 6/MXDT/l copolymer, nylon 6T (poiyhexamethyiene terephthaiamide), nyion 12T (poiydodecamethyiene terephthaiamide), nyion 66T, and nyion 6-3-T (poiy(trimethyi hexamethylene terephthaiamide}).

[24] As used throughout this application, the term "paperboard" refers to heavy papers Sike board stock, paperboard and corrugated paperboard materials. Board stock is a subgroup of paperboard used to make paper cups and plates, hot and coid food containers, ice cream containers, paperback book covers and the like. Paperboard may include both coated and uncoated paperboard. Boxboard, a second subgroup of paperboard, is used to make folding cartons such as cereai boxes, beverage carriers, and tissue boxes.

[25] In accordance with an important aspect of the present invention, rigid laye

100 should exhibit sufficient stiffness. Different materials and thicknesses were evaluated as possible backing layer candidates with respect to their stiffness as a function of ioop stiffness measurement. For the loop stiffness measurement, an instron tensile tester from Instron Corporation, Norwood, Massachusetts was used having a 100-pound (approximately 45.36 kilogram) load ceil Specimen samples were prepared by cutting a 4 inch b 4 inch sample of each materia! and folding opposing ends of the sample towards themselves to form a loop. The folded sample was placed into a specimen holding fixture so that the opposing sides of the sample were separated by a distance of 1 .0 inch (2,54 centimeter). A 0.25 inch (0.635 centimeter) thick by 5 inch (12,7 centimeter) Song stainless steel test probe was fitted to an Instron^® mechanical testing instrument. The instrument was set to the "stiffness" internal protocol. The amount of force required to bend o deflect the sample approximately 0.5 inch (1 ,2? centimeter) at the vertex of the loop was measured. The results of these measurements are shown in TABLE 1 below:

OPET/APET-cornbination of a 48 gauge (12 micron) oriented polyethylene terephthaiate copolymer with 3.5 mil (88,9 micron) APET,

APET=a food grade amorphous polyethylene terephthaiate copolymer having a density of 0.90 gram/centimeter³ and intrinsic viscosity of 0.80 deciliter/gram which is commercially available and sold under the trademark PERFORMANCE™ PET 1 08 by StarPet inc., Asheboro, North Carolina.

HSPS~a rubber modified high impact polystyrene having a specific gravity of 1.03 gram/centimeier³ and melt flow rate of 3.2 gram/ 0 min which is commercially available and sold as EB6755 by Chevron Phillips Chemical Company, LP, The Woodlands, Texas. Preferably, rigid layer 100 is cut resistant Different materials and thicknesses were evaluated as possible backing layer candidates with respect to their cut resistance as a function of slow rate penetration resistance measurement. "Slow Rate Penetration Resistance" herein refers to the test which permits flexible thermoplastic webs to be characterized by slow rate penetration resistance to a driven probe. The test is performed at room temperature, by applying a biaxial stress at a single test velocity on the material until perforation occurs. The force to perforation is determined and reported in units of kilograms-force. A person having ordinary skill in the art would recognize that slow rate penetration resistance may be determined using ASTSvl test method F1306-90.

Samples were prepared by cutting a 1 inch (2.54 centimeter) wide by 5 inch (12/7 centimeter) long specimen of each material. AST test method F13GS- 90 was modified by replacing the specimen clamping fixture with a flat surface of soft pliable material such as 0,25 to 0,50 inch (0.635 to 1.27 centimeter) silicone pad atop a fiat steel plate. The probe was also modified to one having a relatively sharp knife edge. The cut resistance as a function of slow rate penetration resistance (or "SRPR") was measured as the force required to cut through each specimen. The average of fen measurements for each materials and thickness are shown in TABLE 2 below:

First and Second Thermoplastic Films In a preferred embodiment, the first thermoplastic film 101 and the second thermoplastic film 102 can be a coextruded blown film. Preferably, first thermopiastic film 101 is adapted to be peeiabie and resealabie. As used throughout this application, the term "peeiabie" may refer to a single film layer which is adapted to cohesively separate by application of pulling or peeling force exerted away from the film. The term "peeiabie" may also refer to two film layers which are adapted to adhesively separate by application of pulling or peeling force exerted away from the film. The force required to separate or fracture a single fiim Iayer or to separate two film layers may be dependent upon the chemicai composition of each film layer and any adjacent film layers. This force may be further dependent upon both the chemicai composition of each film layer and any adjacent film layers and the relative thicknesses of each film Iayer, Separation of a single layer is commonly referred to in the art as cohesive failure or cohesive deiamination. Sn contrast, separation of two adjoining film layers is commonly referred to in the art as adhesive failure or adhesive delamination. The first thermoplastic films according to the present invention may be considered "resealabie" when the interface formed upon separation inciudes a pressure sensitive adhesive which is adapted to reseal or re-adhere to itself. Generally, the force required to "reseal" the interface is proportional to the manual pressure exerted on the film. The peeiabie resealabie interface is adapted to remain secure and unbroken during package fabrication, distribution and storage, and yet may be easily and repeatedly separated and rejoined or re-tacked together. Accordingly, the peeiabie resealabie interface of the first thermoplastic film according to the present invention may include an initial peel strength which relates to initial force required to first separate the fiim from itself, and a re-tack peel strength which relates to force require to separate the film from itself after it has been separated and re-sealed, Peeiabie resealabie films are known in the art and may include those described in U.S. Patent os. 7,422,782; 7,927,679; 8,283,010; 8,283,011 ; and 8,329,276, all of which are incorporated herein by reference. The following example in TABLE 3 illustrates a certain particular embodiment of a first coextruded thermoplastic film 101 for use in the present invention formed by blown film coextrusion methods. In this embodiment, first thermoplastic film 101 is a peeiabie and reseaiabie film having cohesive failure properties as well as oxygen and moisture barrier properties. The film structure and layer composition are presented below. A!l amounts presented in TABLE 3 are approximate weight percentages based on the total weight of the particular layer.

LLDPE=Linear low density polyethylene; A commercially available example of LLDPE is Nova SCLAIR^® FP619-A supplied by Nova Chemicals Corporation, Calgary, Alberta, Canada. od-PEi -Anhydride modified linear low density polyethylene; A commercially available example of mod-PE, is Westiake Tymax™ supplied by VVest!ake Chemical Corporation, Houston, Texas.

PSA^Pressure sensitive adhesive; A commercially available example of PSA is Bostik MX615 supplied by Bostik, In Wauwatosa, Wisconsin, PB^PoSybutene; A commerciaiiy available example of PB is Basel! Polybutene-1 PB 8640 supplied by Basel! Service Company B.V., Rotterdam, Netherlands.

: od-PE₂= Anhydride modified low density polyethylene; A commerciaiiy available example of mod-PE₂ is DuPont™ Bynef 41 E687 supplied by E, !. du Pont de Nemours and Company, Wilmington, Delaware.

EVOH=Ethy1ene vinyl alcohol copolymer; A commerciaiiy available example of EVOH is SOARNOL^® ET3803 supplied b Nippon Synthetic Chemical Industry Company, Ltd. (Nippon Gohsei), Osaka, Japan.

ULDPE=Ultra low density polyethylene; A commercially available example of ULDPE is Dow ATTANE® NG 4701 G supplied by Dow Chemical Company, Midland, Michigan.

LLDPE₂=Unear low density polyethylene; A commercially available example of LLDPEs is Nova Chemical Novapo PF-01 18-F supplied by Nova Chemicals Corporation, Calgary, Alberta, Canada.

The following examples in TABLE 4 and TABLE 5 illustrate a certain particular embodiments of a flexible coextruded second thermoplastic film 102 for use in the present invention each having a totai thickness of about 6.0 mil (about 152,4 micron) and formed by blown film coextrusion methods. In TABLE 6 there is illustrated a particular example of a rigid or semi-rigid flexible second thermoplastic film 102 for use in the present invention. The film of TABLE 6 was prepared by first forming a 13.75 mii {349.3 micron) coextruded blown film of layers 1 through 7 and then, extrusion coating onto to this structure a 12.0 mil (305 micron) layer of amorphous polyethylene terephthaiate. These examples exhibited both oxygen and moisture barrier properties. The film structure and layer composition are presented below. All amounts presented in TABLE 4 , TABLE 5 and TABLE 6 are approximate weight percentages based on the total weight of the particular layer. TABLE 4

1^st Ingredient- 2"° ingredient- 3^ro !ngredient- wt.% wi.% wt.%

Layer 1 ULDPE-87.2 LLDPE 10.0 Additives-2.,8 (1^st outer iayer)

Layer 2 ULDPE-87.2 LLDPErtO.O Additives-2.8

Layer 3 ULDPE-100

Layer 4 ULDPE-90.0 od-PE₂-10.0

Layer 5 PA 85.0 PAa-15.0

Layer 6 EVOH-100

Layer 7 PA 85.0 PAa-15.0

Layer 8 ULDPE-90.0 LLDPE₂-10.0

Layer 9

PA,-83.9 PA2-15.0 Additives- 1 , 1 (2^nd outer layer)

PA(~nyion 8; A commercially availabie example of PAi is Uliramid polyamide supplied by BASF Chemical Company, Freeport, Texas.

ΡΑ2=¾η amorphous nylon 8I/8T copo!ymer; A commercially availabie example of PA2 is DuPont Selar® PA 3426 supplied by E. L du Pont de Nemours and Company, Wilmington, Delaware.

1 ^si Ingredient- 2"^d fngrectient- 3^R Sngredient- wt.% vvt.% wt.%

Layer 1 EVA-95.0 Additives-5.0

(1^st outer layer)

Layer 2 EVA- 100

Layer 3 Mod~PE₂~100

Layer 4 EVOHP OQ

Layer 5 od-PE 100

Layer 6 ULDPE-64.1 LLDPE2-35.0 Additives-0.9

Layer 7 ULDPE-64.1 LLDPE2-35.0 Additives-0.9

Layer 8 PVDC Adhesive-100

Layer 9

APET-100

(2^nd outer layer)

EVA-eihylene vinyl acetate copolymer; A commercialiy available exampte of EVA is Petrothene^® NA442-051 supplied by Lyondeil Chemical Company, Houston, Texas.

PVDC Adhesive^ polyvinyl idene dichforide emulsion adhesive; A commercially available example of PVDC Adhesive is SERFENE™ 2010 supplied by the Dow Chemical Company, Midland, Michigan.

The first and second thermoplastic films according to the present invention may each provide an oxygen transmission rate of less than about 1.0 centimeter³/! 00 tnch²/24 hours at 73° F, 0% Relative Humidity and 1 atmosphere {or about 15.5 centimeterVmeter²/24 hour at 23° C, 0% Relative Humidity and 1 atmosphere), preferably, less than about 0.5 centmeter³/100 inch²/24 hour at 73° F, 0% Relative Humidity and 1 atmosphere {or about 7,75 centimeterVmeter²^ hour at 23° C, 0% Relative Humidity and 1 atmosphere), and most preferably, about 0,2 cenfimeterVlOO inch /24 hour at

18 73° F, 0% Relative Humidity and 1 atmosphere (or about 3.1 centimete /rneter²^ hour at 23^s C, 0% Relative Humidity and 1 atmosphere).

In one embodiment, second thermoplastic film 102 is flexible. Exemplary structures for use as a flexible second thermoplastic film 102 as shown above in TABLES 4 and 5. In another embodiment, second thermoplastic film 102 is rigid or semi-rigid. An exemplary structure for use as a rigid or semi-rigid flexible second thermoplastic film 102 is shown in TABLE 6 above.

The first and second thermoplastic films, 101 and 102 according to the present invention may each provide a water vapor transmission rate less than about 1.0 gram/100 inchA/24 hour at 73^s F, 90% Relative Humidit and 1 atmosphere {or about 15.5 gram/meter²/24 hour at 23^c C, 90% Relative Humidity and 1 atmosphere} and preferably, about 0,2 gram/100 inch²/24 hour at 73° F, 90% Relative Humidity and 1 atmosphere (or about 3.1 gram/meter²/24 hou at 23° C, 90% Relative Humidity and 1 atmosphere).

Unless otherwise noted, the polymer resins utilized in the present invention are generally commercially available in pellet form and, as generally recognized in the art, may be melt blended or mechanically mixed by well- known methods using commercially available equipment including tumblers, mixers or blenders. Also, if desired, well-known additives such as processing aids, slip agents, anti-blocking agents and pigments, and mixtures thereof may be incorporated into the polymer layers, by blending prior to extrusion. The resins and any additives may be introduced to an extruder where the resins are meit-plastified by heating and then transferred to an extrusion {or coextrusion) die for formation into a tube. Extruder and die temperatures will generally depend upon the particular resin or resin containing mixtures being processed and suitable temperature ranges for commercially available resins are generally known in the art, or are provided in technical bulletins made available by resin manufacturers. Processing temperatures ma vary depending upon other processing parameters chosen. The thermoplastic film structures of the present invention may be produced using simple blown film processes which are described, for example, in The Encyclopedia of Chemical Technology, Kirk-Othmer, Third Edition, John Wiley & Sons, New York, 1981 , Vo!. 16, pp. 416-417 and Vol. 18, pp. 191 -192, the disclosures of which are incorporated herein by reference. Generally, the simple blown film process may include an apparatus having a mufti-manifold circular die head through which the film layers are forced and formed into a cylindrical multilayer film bubble. The bubble may b quenched, e.g., via cooled water bath, solid surface and/or air, and then ultimately collapsed and formed into a multilayer film. It is appreciated by a person of ordinary skill in the art that cast extrusion techniques may also be used to fabricate the film structures of the present invention.

Example 1 in a preferred embodiment, a substantially planar rigid laminate SO was formed by extrusion coating a 12.0 mi! (305 micron) rigid layer 100 of amorphous polyethylene terephthaiate (APET) onto the 2^nd outer layer of a 2.5 mil (63.5 micron) coextruded film 101 as described above in TABLE 3 using a poSyvinylidene dichlohde (PVDC-Adhesive) emulsion adhesive SERFENE™ 2010 supplied by the Dow Chemical Company, Midland, Michigan. A flexible second film 102 having a structure/composition as described in TABLE 4 was provided having a thickness of about 8.0 mil (about 152.4 micron) and thermoformed under vacuum to create a food cavity and a marginal flange surrounding the food cavity. The thermoformed food cavity had a draw depth of at least 0.50 inch ( ,27 centimeter). Flexible second film 102 was thermoformed in such a manner so that the 1^st outer layer formed an inside surface of the package. A food item was placed inside the food cavity and the rigid laminate SO was then affixed to second thermoplastic film 102 under vacuum by heat sealing the 1^st outer layer of first thermoplastic film 101 to the 1^st outer layer of second thermoplastic film 102. The sealing of first thermoplastic film 101 to second thermoplastic film 102 was performed in such a manner as to provide a marginal flange having a width of af least 0.5 inch (1 ,27 centimeter) surrounding the thermoformed cavity and food item, and a continuous peelabie reseaiabie hermetic sea! having a width of at least 0,25 inch (0.635 centimeters) which is positioned at least 0.5 inch (1.27 centimeter) away from the thermoformed cavity enclosing the food stem.

Example .2

In another a substantially planar rigid laminate 50 was formed by extrusion coating a 12.0 mil (305 micron) rigid layer 100 of amorphous polyethylene terephthaiate (APET) onto the 2^nd outer layer of a 2.5 mil (63.5 micron) coextruded film 101 as described above in TABLE 3 using a po!yviny!idene dichloride (PVDC-Adhesive) emulsion adhesive SERFENE™ 2010 supplied by the Dow Chemical Company, Midland, Michigan. A rigid second film 102 having a structure/composition as described in TABLE 6 was provided having a thickness of about 13.75 mil (about 349,25 micron) and thermoformed under vacuum to create a food cavity and a marginal flange surrounding the food cavity. The thermoformed food cavity had a draw depth of at least 1 inch (2.54 centimeter). Rigid second thermoplastic film 102 was thermoformed in such a manner so that the 1^st outer layer of the film formed an inside surface of the package, A food item was placed inside the food cavity and rigid laminate S0 was then affixed to second thermoplastic film 102 by heat sealing the 1^st outer layer of first thermoplastic film 101 to the 1^st outer layer of second thermoplastic film 102. The sealing of first thermoplastic film 101 to second thermoplastic film 102 was performed in such a manner as to provide a marginal flange having a width of at least 0.5 inch (1.27 centimeter) surrounding the thermoformed cavity and food item, and a continuous peelabie reseaiabie hermetic seal having a width of at least 0.25 inch (0.635 centimeters) which is positioned at least 0,5 inch (1.27 centimeter) away from the thermoformed cavity enclosing the food item.

Claims

CLAIMS:

1. A peeiable reseaiabSe package for an unportioned food item, the container comprising:: an integrated food cutting and serving platform formed from a substantially planar rigid laminate comprising a rigid layer and a first thermoplastic film; wherein the rigid iayer is cut resistant and has a stiffness value of at least about 1 ,70 kilogram-force; a second thermoplastic film having a thermoformed cavity enclosing the food item which generally conforms to the shape of the food item; a planar flange extending around the thermoformed cavity; and a continuous peeiable reseaiabSe hermetic seal circumscribing the food item formed by heat sealing the first thermoplastic film to the second thermoplastic film,

2. The package of claim 1 , wherein the rigid layer has a thickness of at least 8,5 mils {218 microns).

3. The package of claim 1, wherein the rigid layer has a stiffness value of at Seast about 3.00 kilogram-force.

4. The package of claim 1 , wherein the rigid layer has a slow rate penetration resistance of 74.84 kilogram-force (185 pound-force}.

5. The package of claim 1, wherein the rigid layer has a stiffness value of at least 5.00 kilogram-force.

6. The package of ciaim 1 wherein the rigid layer comprises high density polyethylene, polyethylene terephthalate, amorphous polyethylene terephthalate, crystalline polyethylene terephthalate, glycol modified polyethylene terephthalate, polystyrene, high-impact polystyrene, genera! purpose polystyrene, polystyrene butadiene, polypropylene, polyamide, polycarbonate, paperboard, o combinations thereof.

7. The package of claim 1, wherein the rigid layer comprises amorphous polyethylene terephthalate.

8. The package of claim 1 , wherein the flange has a width of at least 0.5 inch (1 .27 centimeter).

9. The package of claim 1 , wherein the continuous peeiabie resea!ab!e hermetic seal has a width of at least 0.25 inch (0.635 centimeter).

10. The package of claim 1 , wherein the continuous peeiabie reseaiable hermetic seal is positioned at least 0.50 inch (1 .27 centimeter) away from the thermoformed cavity enclosing the food item,

11. The package of claim 1 , wherein the thermoformed cavity has a draw depth of at least 0,50 inch (1.27 centimeter).

12. The package of claim 1 , wherein the thermoformed cavity has a draw depth of at least 1 Inch (2.5 centimeter). 13, The package of claim 1 , wherein the second thermoplastic film is flexible.

14. The package of claim 1 , wherein the second thermoplastic film is rigid or semi-rigid.

15. A peelable reseaiable package for an unportioned food item, the container comprising: an integrated food cutting and serving platform formed from a substantially planar rigid laminate comprises a rigid layer and a peelable reseaiable first thermoplastic film; wherein the rigid layer is formed from amorphous polyethylene terephthalate and has a stiffness value of at least about 1 ,70 kilogram-force and a slow rate penetration resistance of 74.84 kilogram-force (165 pound-force); a flexible coextruded second thermoplastic film; wherein the flexible thermoplastic film has a thermoformed cavity enclosing the food item and having a shape which generally conforms to the shape of the food item; a planar flange extending around the thermoformed cavity and from the thermoformed cavity to the distal edges of the substantially planar rigid member; a continuous peeiabie reseaiable hermetic seal circumscribing the food item formed by heat sealing the thermoplastic member to the substantially planar rigid member.

18. The package of claim 15, wherein the rigid layer has a thickness of at least 8,5 mils (216 microns). 17 , The package of claim 15, wherein the rigid layer has a stiffness value of at !east 3.00 kiiogram-force.

18, A peelabie reseaiable package for an unpardoned food item, the container comprising an integrated food cutting and serving platform formed from a substantially planar rigid !aminate comprises a rigid layer and a peelabie reseaiable first thermoplastic film; wherein the rigid layer is formed from amorphous polyethylene terephthaiate and has a stiffness value of at least about 1 ,70 kilogram-force and a slow rate penetration resistance of 74.84 kilogram-force (185 pound-force); a rigid or semi-rigid second thermoplastic fiirn; wherein the rigid or semi-rigid thermoplastic film has a thermoformed cavity enclosing the food item and having a shape which generally conforms to the shape of the food item; a planar flange extending around the thermoformed cavity and from the thermoformed cavity to the distal edges of the substantially planar rigid; a continuous peelabie reseaiable hermetic seai circumscribing the food item formed by heat sealing the thermoplastic member to the substantially planar rigid member.

19, The package of claim 18, wherein the rigid layer has a thickness of at least 8.5 mils (218 microns),

20. The package of claim 18, wherein the rigid layer has a stiffness value of at ieast 3.00 kilogram-force.