US20180086531A1

US20180086531A1 - Food packaging with multi-layer structure

Info

Publication number: US20180086531A1
Application number: US15/275,016
Authority: US
Inventors: Dave Lefkow; Marcus McDuffie
Original assignee: Amazon Technologies Inc
Current assignee: Amazon Technologies Inc
Priority date: 2016-09-23
Filing date: 2016-09-23
Publication date: 2018-03-29
Also published as: WO2018057538A1

Abstract

Packaging for a food item can comprise a container configured to contain a food item, at least a portion of the container comprising a multi-layer structure configured to protect the food item against damage during transit from a fulfillment center to a delivery location. The multi-layer structure can comprise a first layer of fluid resistant material, a second layer comprising pliable pockets filled with a fluid medium, and a third layer of polymer material, wherein the first layer, the second layer, and the third layer are laminated together to form the multi-layer structure. An inner layer that is proximate the food item when the food item is disposed within the container can comprise a food grade material that is safe to bring into contact with food.

Description

BACKGROUND

Food items are commonly sold to consumers through grocery stores and restaurants. It is only recently that consumers have started purchasing food items online for delivery to their home or business address. When food items are delivered to the consumer's home via the electronic commerce (e-commerce) supply chain, the food items are handled differently than their counterpart food items that are placed on grocery store shelves. For example, food items purchased online are often handled more frequently by couriers as they are delivered to the consumer's home. As a consequence, fragile food items are often damaged during transit. A bag of chips, for example, will often arrive at a consumer's doorstep as a bag full of crumbs.
A food item that is delivered via the e-commerce supply chain can also sit on a doorstep for a long period of time before the consumer brings the food item into his/her home, thereby exposing the food item to the outdoor environment for longer periods of time than its counterpart food item on the grocery store shelf. Exposure to extreme temperatures can also damage food items. For instance, a chocolate bar can melt if left in the hot sun for too long, or a jar of mayonnaise can separate into a layer of oil and a layer eggs upon freezing.
Existing food packaging is insufficient for protecting food items from damage that can occur during transit through the e-commerce supply chain. Furthermore, existing packaging for non-food related items cannot be used as a solution because such packaging is not made of food grade materials that are safe to bring into contact with the food items. Furthermore, existing ad hoc solutions, such as over-bagging (or double bagging), are prohibitively expensive from a manufacturing standpoint.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical components or features.

FIG. 1 illustrates a perspective view of an example container in the form of a bag, a portion of the bag having a multi-layer structure for protecting a food item disposed within the container.

FIG. 2 illustrates a partial cross-sectional view of the example container of FIG. 1 along section A-A according to one embodiment.

FIG. 3 illustrates a partial cross-sectional view of the example container of FIG. 1 along section A-A according to another embodiment.

FIG. 4 illustrates a partial cross-sectional view of the example container of FIG. 1 along section B-B according to another embodiment.

FIG. 5A illustrates a perspective view of an example container in the form of a bag, a portion of the bag having a multi-layer structure for protecting a food item disposed within the container, the bag further comprising a gusset and a two-part attachment mechanism for resealing the bag after opening.

FIG. 5B illustrates a bottom plan view of the example container of FIG. 5A, showing the gusset in more detail.

FIG. 6 illustrates a perspective view of an example container in the form of tray and a lid, the lid having a multi-layer structure for protecting a food item disposed within the container.

DETAILED DESCRIPTION

Disclosed herein is packaging for a food item that is configured to protect the food item against damage during transit from a fulfillment center to a delivery location. The packaging can comprise a container configured to contain a food item, at least a portion of the container comprising a multi-layer structure. The multi-layer structure can comprise a first layer of fluid resistant material, a second layer comprising pliable pockets filled with a fluid medium, and a third layer of polymer material, wherein the first layer, the second layer, and the third layer are laminated together to form the multi-layer structure. An inner layer that is proximate the food item when the food item is disposed within the container can comprise a food grade material that is safe to bring into contact with food.
The food packaging described herein protects food items that are susceptible to damage during transit from a fulfillment center to a delivery location by virtue of the multi-layer structure included as part of the food packaging. In this manner, fragile food items, such as chips or crackers, will be less prone to breaking and crumbling as the food items are transported from a fulfillment center to a delivery location. This is at least partly due to the layer of pliable pockets filled with a fluid medium that cushions the food item upon impact with an external object (e.g., the ground, a human hand, etc.). Meanwhile, the packaging is made to be “food safe” by use of a food grade material (i.e., a material that is deemed safe, as determined by a compliance agency, such as the Food and Drug Administration (FDA) (e.g., compliance with ISO 9000 from the International Organization for Standardization) to bring into contact with food) for the inner layer that can come into contact with the food item.
In some configurations, the layer of fluid resistant material comprises a metallized film, such as an aluminum film. Such a metallized layer can slow the rate of heat transfer to or from the food item in the container, which allows packaged food item to be exposed to extreme temperatures for longer periods of time without damaging the food item inside the packaging.
The techniques, systems, and devices described herein may be implemented in a number of ways. Example implementations are provided below with reference to the following figures.
FIG. 1 illustrates a perspective view of an example container 100 in the form of a bag, a portion of the bag having a multi-layer structure for protecting a food item disposed within the container 100. In general, the container 100 can be used for packaging one or more food items that can be ordered by a consumer online (e.g., by completing a transaction via an electronic marketplace) and delivered, within the container 100, to a delivery location associated with the consumer. For example, an electronic marketplace can offer food items that are available to consumers for purchase. The electronic marketplace can be made accessible to consumers through any suitable technology and/or computing device, such as a website that is accessible to a client computing device of the consumer, or a client application (e.g., a mobile application) executing on the client computing device that allows a user to search and browse food items available from a food item catalog maintained by a provider of the electronic marketplace. In some configurations, a consumer can access the electronic marketplace using a digital assistant executing on a client computing device, the digital assistant being configured to receive voice input from the user, find food items available from the electronic marketplace based on the received voice input, and purchase selected food items for the user.
Food items that are purchased by consumers can be packaged and delivered to consumers in the food packaging described herein, such as the container 100 shown in FIG. 1. Different food packaging can be utilized for different food items depending on the fragility of the food items to be delivered. In general, the term “food item,” as used herein, may include any type of tangible food or drink product that is consumable by a human or animal as food. It is to be appreciated that the food packaging described herein, which comprises the disclosed multi-layer structure, can be used to package any type of food item for delivery via the e-commerce supply chain to a delivery location. Although the disclosed food packaging can be used for any type of food item regardless of how susceptible it is to damage during transit, the multi-layer structure described herein affords added protection to food items that are particularly susceptible to damage during transit from the fulfillment center to the delivery location, such as breakable chips, crackers, or cookies, or fresh fruit that is easily bruised upon impact with other objects.
Examples of food items that are prone to breakage (or “crumblage”) during transit can include, without limitation, fragile food items such as chips (tortilla, potato, etc.), crackers, pretzels, dried fruit, cookies, pasta shells, popcorn, cereal, chocolate bars, and the like. Other fragile food items include, without limitation, fresh fruit, which can be easily bruised if handled too often and/or too roughly during transit. Some types of food items are additionally, or alternatively, prone to melting in hot temperatures, such as chocolate food items, and other types of sugar-based candies, etc. Some types of food items, such as mayonnaise, salad dressing, and the like, are susceptible to damage when exposed to cold temperatures. For example, if mayonnaise, which consists of an emulsion of oil and eggs, reaches a temperature that is below a threshold temperature (e.g., below 0 degrees Celsius (° C.)), the emulsion in the mayonnaise can break, leaving a consumer with a jar containing a layer of oil and a layer of eggs that can be inedible, in some instances.
The food packaging described herein, such as the container 100 shown in FIG. 1, comprises a multi-layer structure that is configured to protect these types of “fragile” food items during transit. This is at least partly due to the layer of pliable pockets filled with a fluid medium, which is configured to protect against breakage (or bruising) by cushioning the food item(s) within the packaging. Additionally, a metallized film used for the fluid resistant material in the multi-layer structure can decrease the rate of heat transfer to or from the food item during transit within the container 100 so as to prevent damage to the food item caused by exposure to extreme temperatures. Meanwhile, a food grade material used for the inner layer of the multi-layer structure that can come into contact with the food item provides a food-safe package for the food item.
When a food item(s) is packaged for shipment within the container 100, the food item(s) can be inserted through an opening 102 defined in the container 100 in order to fill the container 100 with the food item. For example, a plurality of potato chips can be provided through the opening 102 of the container 100 and disposed within the container 100. After filling the container 100, at least partially, with one or more food items, the container 100 can be closed, such as by sealing the opening 102 of the container 100, in order to enclose the food item(s) within the container 100. Closure of the container 100 by sealing the opening 102 can create an air-tight food package so that the food item(s) is preserved within the container 100. The container 100 is the mechanism by which the food item(s) can be transported to a customer in a protected manner.
The container 100 can comprise a plurality of walls that define a cavity in which the food item can be disposed. FIG. 1 shows a front wall 104 of the container 100 that can be attached to a rear (or back) wall 106 to form a cavity in which one or more food items can be placed. The front wall 104 and the rear wall 106 make up multiple lateral walls of the container 100 shown in FIG. 1. It is to be appreciated that the container can comprise a single, continuous lateral wall, as opposed to the multiple lateral walls 104 and 106 shown in FIG. 1, without changing the basic characteristics of the food packaging described herein. Furthermore, the container 100 can comprise any number of lateral walls (e.g., more than two lateral walls, such as a front wall, a rear wall, and two side walls).
The front wall 104 of the container 100 can be attached to the rear wall 106 of the container 100 by attaching a first lateral edge 108(1) of the front wall 104 to a corresponding lateral edge 108(3) (See FIG. 2) of the rear wall 106, and by attaching a second lateral edge 108(2) of the front wall 104 to a corresponding lateral edge of the rear wall 106. Any suitable attachment mechanism can be utilized for this purpose, such as an adhesive on one or more inside surfaces of the lateral edges 108, heat sealing the lateral edges 108(1)/(2) of the front wall 104 to corresponding lateral edges (See 108(3) of FIG. 2) of the rear wall 106, or any other suitable attachment mechanism. In order to create an air-tight enclosure when the opening 102 of the container 100 is sealed, an attachment mechanism at the lateral edges 108(1)/(2) of the front wall and corresponding lateral edges (See 108(3) of FIG. 2) of the rear wall, such as heat sealing or adhesives, can be used to provide such an air-tight enclosure.
In the example of FIG. 1, a continuous piece of material is shown as being folded at a bottom end 110 of the container 100 to create the front wall 104 and the rear wall 106, which can then be sealed at the lateral edges thereof. However, it is to be appreciated that two separate pieces of material can be used for the front wall 104 and the rear wall 106, respectively, and the separate front wall 104 can be attached to the separate rear wall 106 at both lateral edges, as well as a bottom edge at the bottom end 110 of the container. In other words, separate pieces of material that make up the front wall 104 and the rear wall 106 of the container 100, respectively, can be attached together at three adjacent or contiguous edges thereof. In such a configuration, the front wall 104 can include a bottom edge that is attached to a corresponding bottom edge of the rear wall 106 in a similar manner to that described herein for attachment of the lateral edges 108(1)/(2) of the front wall 104 to corresponding lateral edges (See 108(3) of FIG. 2) of the rear wall 106, as shown in FIG. 1. Alternatively, the container 100 can include a bottom wall at the bottom end 110 of the container 100, as will be described in more detail below with reference to the following figures.
The front wall 104 can comprise multiple portions, such as a first portion 112(A) and a second portion 114(A). The rear wall 106 can similarly comprise multiple portions, such as a first portion 112(B) and a second portion 114(B). The first portions 112(A) of the front wall 104 can be partially surrounded by the first lateral edge 108(1), the bottom end 110, and the second lateral edge 108(2) of the front wall 104. Similarly, the first portion 112(B) of the rear wall 104 can be partially surrounded by corresponding lateral edges (See 108(3) of FIG. 2) and the bottom end 110 of the rear wall 106. Furthermore, the first portions 112(A)/(B) can make up a substantial percentage of the front wall 104 and rear wall 106, respectively (e.g., the first portion 112(A) of the front wall 104 can comprise about 90% of the front wall 104). The second portions 114(A)/(B) can make up a relatively smaller portion of the front wall 104 and the rear wall 106, respectively (e.g., the second portion 114(A) of the front wall 104 can comprise about 10% of the front wall 104). The second portions 114(A) and 114(B) of the front wall 104 and the rear wall 106, respectively, can be configured to be sealed together in order to enclose the food item within the container 100. For example, the second portion 114(A) of the front wall 104 can be heat sealed together with the second portion 114(B) of the rear wall 106. However, any suitable attachment mechanism, such as adhesive, can be used to seal the second portion 114(A)/(B) together after one or more food items have been placed within the container 100.
FIG. 1 also shows a cutaway view 116 on the inside surface of the first portion 112(B) of the rear wall 106 of the container 100, which exposes the construction of part of the multi-layer structure that makes up a first portion 112(B) of the rear wall 106. A similar construction would be exposed if a cutaway view of the first portion 112(A) of the front wall 104 were shown in FIG. 1. The cutaway view 116 illustrates part of a multi-layer structure that can be included in at least a portion of the container 100. In FIG. 1, the portion of the container that includes the multi-layer structure includes the first portion 112(A) of the front wall 104, and the first portion 112(B) of the rear wall 106 of the container 100. The multi-layer structure will be described in more detail below with reference to the following figures. In general, the multi-layer structure used in at least a portion of the container 100 (e.g., in one or more walls of the container 100) can include a first layer of fluid resistant material, a second layer comprising pliable pockets filled with a fluid medium, and a third layer of polymer material, wherein the first layer, the second layer, and the third layer are laminated together to form the multi-layer structure. The cutaway view 116 of FIG. 1 shows that some of the inner layer of fluid resistant material has been cut away to expose a middle layer of pliable pockets filled with fluid medium. In some embodiments, the pliable pockets filled with fluid medium can comprise an air cellular material, such as Bubble Wrap®, sold by Sealed Air Corporation®. Accordingly, the first portions 112(A)/(B) of the front wall 104 and the rear wall 106, respectively, can include the multi-layer structure described herein, while the second portions 114(A)/(B) of the front wall 104 and the rear wall 106, respectively, do not include the multi-layer structure, so as to enable the opening 102 of the container 106 to be sealed after one or more food items have been placed within the container 100. For example, the second portions 114(A)/(B) of the first wall 104 and the second wall 106, respectively, can comprise a layer of fluid resistant material, and a layer of polymer material, without the layer of pliable pockets filled with a fluid medium that is otherwise included in the multi-layer structure of the first portions 112(A)/(B).
FIG. 2 illustrates a partial cross-sectional view of the example container 100 of FIG. 1 along section A-A according to one embodiment. Notably, section A-A of FIG. 1 “cuts through” the first portions 112(A)/(B) of the front wall 104 and the rear wall 106, respectively, of the container 100 to expose the construction of the multi-layer structure included in the first portions 112(A)/(B). For instance, FIG. 2 shows a multi-layer structure 200(A) included in the front wall 104 of the container 100, and a multi-layer structure 200(B) included in the rear wall of the container 106. FIG. 2 also depicts a cavity 202 where one or more food items can be contained within the container 100. The first lateral edge 108(1) of the front wall 104 is shown as being attached to a corresponding first lateral edge 108(3) of the rear wall 106, which enables attaching the front wall 104 to the rear wall 106 to define the cavity 202 of the container 100.
The multi-layer structure 200(A) included in the front wall 104 can comprise a first (inner) layer 204(A) of fluid resistant material (sometimes referred to herein as a “barrier layer”) that is proximate the food item when the food item is disposed within the container 100 (i.e., within the cavity 202), a second (middle) layer 206(A) disposed on the first layer 204(A) and comprising a plurality of pliable pockets filled with a fluid medium, and a third (outer) layer 208(A) of polymer material that is disposed on the second layer 206(A), and is farther from the food item than the first layer 204(A) when the food item is disposed within the cavity 202 of the container 100. Said another way, the first (inner) layer 204(A) of fluid resistant material can be a first distance from the food item at a time at which the food item is disposed within the container 100, the second (middle) layer 206(A) comprising a plurality of pliable pockets filled with a fluid medium can be a second distance from the food item that is greater than the first distance at the time at which the food item is disposed within the container 100, and the third (outer) layer 208(A) of polymer material can be a third distance from the food item that is greater than the second distance at the time at which the food item is disposed within the container 100.
The individual pairs of adjacent layers within the multi-layer structure 200(A) can be attached via an adhesive layer (sometimes called a “tie layer”). As such, the multi-layer structure 200(A) is shown as including a first adhesive layer 207(A) and a second adhesive layer 209(A). The first adhesive layer 207(A) can be interposed between the first (inner) layer 204(A) and the second (middle) layer 206(A) in order to bond (or otherwise attach) the first layer 204(A) to the second layer 206(A). The second adhesive layer 209(A) can be interposed between the second (middle) layer 206(A) and the third (outer) layer 208(A) in order to bond (or otherwise attach) the second layer 206(A) to the third layer 208(A). It is to be appreciated that the multi-layer structure 200(A) can include any suitable number of layers, including adhesive layers. Accordingly, the multi-layer structure 200(A) is not limited to the five layers comprising the first layer 204(A), the first adhesive layer 207(A), the second layer 206(A), the second adhesive layer 209(A), and the third layer 208(A), and fewer or greater layers (e.g., additional adhesive layers, additional layers of films, etc.) can be included within the multi-layer structure 200(A).
The fluid resistant material of the first (inner) layer 204(A) can comprise any suitable fluid resistant material that is configured to restrain or resist the ingress of fluid to and/or egress of fluid from the container 100. Such fluids that are restrained from crossing the first (inner) layer 204(A) can include, without limitation, water (e.g., in the form of moisture), oxygen, or any similar liquid or gaseous fluid. For example, when oxygen penetrates food packaging, it can spoil the food items within the packaging. Thus, the fluid resistant characteristics of the first (inner) layer 204(A) can act as a barrier (e.g., by having a relatively low fluid transmission rate) to such fluids in order to extend the shelf life and prevent rapid spoilage of the food item contained in the container 100. For example, the fluid resistant material of the first (inner) layer 204(A) can have an oxygen transmission rate of no greater than about 1 cubic centimeters (cc or cm³) per 100 square inches (in²) per day, no greater than about 0.8 cc/100 in²/day, no greater than about 0.6 cc/100 in²/day, no greater than about 0.4 cc/100 in²/day, no greater than about 0.2 cc/100 in²/day, or no greater than about 0.1 cc/100 in²/day. Similarly, the fluid resistant characteristics of the first (inner) layer 204(A) can act as a barrier for locking moisture, flavor, aroma, and so on, in the container 100 so as to preserve the food item(s) and keep the food item(s) fresh for longer periods of time. The fluid resistant material of the first (inner layer) 204(A) can also be resistant to organic solvents, such as hydrocarbons, oils, and similar organic solvents often found in food items.
The fluid resistant material of the first (inner) layer 204(A) can comprise any suitable fluid resistant material that is also food grade, meaning it is a material that is safe (unlikely to contaminate food with harmful materials or chemicals above a threshold contamination level), as determined by a compliance agency, such as the FDA to bring into contact with food. Suitable fluid resistant materials for the first (inner) layer 204(A) include, without limitation, a metallized film (e.g., aluminum film), an ethylene vinyl alcohol (EVOH) film, or films made from thermoplastic material, polyolefins, polyethylene terephthalate (PET), polyvinyl chloride, polyvinylidene chloride, polystyrene, and so on. EVOH is an example of an fluid (e.g., oxygen) resistant copolymer that can be provided as a film for lamination in the multi-layer structure 200(A), and it is a food grade material. EVOH can also be made to be transparent in order for light to pass there through. In some embodiments, the first (inner) layer 204 of fluid resistant material can have a thickness that is no greater than about 50 microns (or micrometers (μunm), no greater than about 40 microns, no greater than about 30 microns, no greater than about 20 microns, or no greater than about 10 microns. This allows the first layer 204(A) to be provided as a film that can resist cracking and is otherwise rather flexible for use in a container 100 in the form of a bag.
In configurations where the first (inner) layer 204(A) comprises a metallized film, any suitable metal that is food grade can be utilized, such as aluminum, tin, and the like. Use of a metallized film, such as an aluminum film, for the first (inner) layer 204(A) can provide an added thermal insulation benefit to the food item contained within the container. For example, although aluminum is a good conductor of heat via conduction, an aluminum film can act as a heat insulator to convection and radiation, which are other mechanisms by which heat is transferred. Thus, a metallized film used for the first (inner) layer 204 can prevent thermal shock of the food item by slowing the rate of heat dissipation to and from the food item(s) within the container 100 as it is exposed to extreme environmental temperatures (i.e., ambient temperatures that reach extreme hot or cold temperatures) during transit from a fulfillment center to a delivery location. For example, the container 100 can be made more thermally tolerant (insulated) for an extended time period (e.g., 72 hours) by virtue of a metallized first (inner) layer 204(A). This is particularly beneficial in instances where the container 100 sits for several hours or more on a front porch, where the container 100 is exposed to extreme hot or cold environmental temperatures, depending on the delivery location. For instance, food items may be rendered inedible if frozen and subsequently thawed, or if allowed to become too warm or hot, leading to spoilage.
The second (middle) layer 206(A) that is disposed on the first layer 204(A) can comprise a plurality of pliable pockets, such as the pocket 210, filled with a fluid medium 212. Commonly referred to as Bubble Wrap®, this second (middle) layer 206(A) of pliable pockets 210 filled with the fluid medium 212 can comprise a sheet having an array of plastic air-filled bubbles. Any pliable material, such as polymer (plastic), can be utilized for pockets 210 in the second layer 206(A), and the pockets 210 can be filled with any suitable fluid medium, such as air, water, or any other suitable fluid. FIG. 2 illustrates how the second layer 206(A) can comprise a first layer 214 of pockets 210 (e.g., protruding air-filled hemispheres), attached to a second, planarized layer 216 of polymer material to seal the pockets 210 after being filled with the fluid medium 212. When the pockets 210 are filled with the fluid medium 212, the second layer 206(A) acts as a cushioning mechanism for the food item(s) by absorbing the impact from objects (e.g., the ground, a hand of a human being, etc.) external to the container 100, thereby protecting the food item(s) within the container 100 from damage (e.g., breakage, bruising, etc.). The material of the second layer 206(A) can be made transparent in order for light to pass there through.
The third (outer) layer 208(A) of polymer material can be disposed on the second (middle) layer 206(A), and can comprise a plastic film that is printed on an outside surface of the second layer 206(A) during manufacturing. In some embodiments, the third (outer) layer 208(A) of polymer material can have a thickness that is no greater than about 50 microns, no greater than about 40 microns, no greater than about 30 microns, no greater than about 20 microns, or no greater than about 10 microns. Thickness of the third (outer) layer 208(A) can be varied to produce various effects and characteristics of the package. For example, a very thin third (outer) layer 208(A) (e.g., about 10 microns) can reveal the pattern of the pockets in the second (middle) layer 206(A), and/or provide a more tactile (e.g., rough) surface on the outside of the food package to enable a human to better grip the container 100. A thicker third (outer) layer 208(A) can provide a smoother outside surface for printing labels, which may be more legible on a smooth surface than on a rough surface that reveals the pattern of pockets in the second (middle) layer 206(A).
The third (outer) layer 208(A) can act as a protective layer that protects the second (middle) layer 206(A) from being damaged (e.g., torn, ripped, punctured, etc.), and can offer a medium on which to print labels, such as a brand name for the food item, and other information related thereto (e.g., nutrition information, etc.). Accordingly, the third (outer) layer 208(A) can comprise an opaque plastic film that hides the contents of the container 100 and offers a canvas for printing logos and other textual information on the package. Alternatively, the third (outer) layer 208(A) can comprise a transparent plastic film that allows light to pass there through. A fully transparent package can be desirable in some scenarios, such as fruit, which may ripen at a desirable rate if exposed to sunlight via the transparent packaging, or when it is desirable to reveal the contents of the container 100 to the consumer before the package is opened by the consumer.
The rear wall 106 can comprise a multi-layer structure 200(B) of similar construction to that of the multi-layer structure 200(A) included in the front wall 104. For brevity, the multiple layers in the multi-layer structure 200(B) included in the rear wall 106 will not be repeated herein. It is to be appreciated, however, that the layers 204(B), 207(B), 206(B), 209(B), and 208(B) may be similar to the corresponding layers 204(A), 207(A), 206(A), 209(A), and 208(A) of the front wall 104, except that they are reversed in orientation when the front wall 104 is attached to the rear wall 106.
In some embodiments, the second layers 206(A)/(B) can be omitted from the multi-layer structures 200(A)/(B), and a similar cushioning effect can be provided by adhering the first layer 204(A)/(B) to the third layer 208(A)/(B) at multiple different locations to create/define pockets between the points of attachment. For example, in addition to attaching the front wall 104 to the rear wall 106 at the lateral edges 108 thereof, a middle of the front wall 104 can be attached to a middle of the rear wall 106 along the length of the lateral edges 108 thereof, creating at least two spaces, pockets, or voids, that can be filled with a fluid medium, such as the fluid medium 212. Thus, the multi-layer structure 200(A)/(B) can still provide a cushioning effect for the food items contained within the container 100 without adding the material for the layers 214 and 216 that define the plurality of pliable pockets 212 of the second layer 206(A)/(B) shown in FIG. 2.
In general, the layers 204(A)/(B), 206(A)/(B), and 208(A)/(B) of the multi-layer structure 200(A)/(B) can be laminated together using adhesive layers 207(A)/(B) and 209(A)/(B) to form the multi-layer structure 200(A)/(B) using any suitable manufacturing process. For example, the first (inner) layer 204(A)/(B) can be provided as a roll of film that can be cut to size and laminated on an inner surface of the second (middle) layer 206(A)/(B) with the first adhesive layer 207(A) there between, and the third (outer) layer 208(A)/(B) can be printed as a film on an outer surface of the second (middle) layer 206(A)/(B) with the second adhesive layer 209(A) there between to form the front wall 104 and the rear wall 106. Portions around the periphery of the front wall 104 and the rear wall 106 can be made without the second (middle) layer 206(A)/(B) in order to attach the lateral edges 108 of the front wall 104 to the lateral edges 108 of the rear wall 106 by, for example, heat sealing the lateral edges, and in order to seal the opening 102 of the container 100 after one or more food items have been placed inside the container 100.
FIG. 3 illustrates a partial cross-sectional view of the example container 100 of FIG. 1 along section A-A according to another embodiment. In the example of FIG. 3, the multi-layer structure 300(A) included in the front wall 104 comprises a middle layer 304(A) of fluid resistant material disposed between an inner layer 306(A) comprising a plurality of pliable pockets filled with a fluid medium, and an outer layer 308(A) of polymer material. Thus, the inner layer 306(A) comprised of a plurality of pliable pockets is proximate the food item when the food item is disposed within the container 100 (i.e., within the cavity 302), while the outer layer 308(A) of polymer material is farther from the food item than the inner layer 306(A) comprised of the plurality of pliable pockets filled with the fluid medium. The materials of the respective layers 304(A), 306(A), and 308(A) of the multi-layer structure 300(A) can be similar to those described above with respect to FIG. 2, except that the inner layer 306(A), which is comprised of a plurality of pliable pockets filled with fluid medium, can be made of a food grade material, such as EVOH, because the inner layer may come into contact with the food item(s) contained in the container 100. The middle layer 304(A) of fluid resistant material can, like the layer 204(A) of fluid resistant material described with reference to FIG. 2, be made of a metallized film or EVOH film to lock in freshness and otherwise act as a barrier layer to extend the shelf life of the food item(s) within the container 100. Furthermore, adhesive layers 307(A) and 309(A) can be disposed between adjacent pairs of layers within the multi-layer structure 300(A) in order to attach the respective layers together in a lamination process. The alternate configuration of the multi-layer structure 300(A) of FIG. 3 can provide protection to the food item(s) within the container 100 in a similar manner to the multi-layer structure 200(A) of FIG. 2. However, the different order of the layers within the multi-layer structure 300(A) relative to the multi-layer structure 200(A) can provide for easier lamination of the layers by providing a planar outer surface of the inner layer 306(A) on which the additional layers 304(A) and 308(A) can be laminated.
The rear wall 106 can comprise a multi-layer structure 300(B) of similar construction to that of the multi-layer structure 300(A) included in the front wall 104. For brevity, the multiple layers in the multi-layer structure 300(B) included in the rear wall 106 will not be repeated herein. It is to be appreciated, however, that the layers 304(B), 307(B), 306(B), 309(B), and 308(B) may be similar to the corresponding layers 304(A), 307(A), 306(A), 309(A), and 308(A) of the front wall 104, except that they are reversed in orientation when the front wall 104 is attached to the rear wall 106.
FIG. 4 illustrates a partial cross-sectional view of the example container 100 of FIG. 1 along section B-B according to another embodiment. The partial cross-sectional view only shows the front wall 104 (and not the rear wall 106), but it is to be appreciated that the rear wall 106 can comprise a similar construction to that of the multi-layer structure 400(A) shown in FIG. 4, except that the layers can be reversed in orientation when the front wall 104 is attached to the rear wall 106 to form the container 100.
The multi-layer structure 400(A) included in the front wall 104 of FIG. 4 includes a first (inner) layer 404(A) of fluid resistant material that is proximate to the food item when the food item is disposed within the container 100, a second (middle) layer 406(A) disposed on the first layer 404(A) and comprising a plurality of pliable pockets filled with a fluid medium, and a third (outer) layer 408(A) of polymer material that is disposed on the second layer 406(A), and is farther from the food item than the first layer 404(A) when the food item is disposed within the container 100. Furthermore, adhesive layers 407(A) and 409(A) can be disposed between adjacent pairs of layers within the multi-layer structure 400(A) in order to attach the respective layers together. For example, a first adhesive layer 407(A) can be interposed between the first (inner) layer 404(A) and the second (middle) layer 406(A), and a second adhesive layer 409(A) can be interposed between the second (middle) layer 406(A) and the third (outer) layer 408(A).
In the example of FIG. 4, the second (middle) layer 406(A) is comprised of multiple layers of pliable pockets filled with fluid medium. Accordingly, the second (middle) layer 406(A) can comprise a plurality of first fluid-filled (e.g., air-filled) pockets 410(A) filled with first fluid 412(A), and a plurality of second fluid-filled (e.g., air-filled) pockets 410(B) filled with a second fluid 412(B). The arrangement of the plurality of first fluid-filled pockets 410(A) can define a plurality of first spaces between each of the first fluid-filled pockets 410(A), and the arrangement of the plurality second fluid-filled pockets 410(B) can likewise define a plurality of second spaces between each of the second fluid-filled pockets 410(B). The two sub-layers of fluid-filled pockets within the second (middle) layer 406(A) can then be fit together like a puzzle during manufacturing, where the plurality of first fluid-filled pockets 410(A) are disposed in the second spaces defined by the plurality of second fluid-filled pockets 410(B), and the plurality of second fluid-filled pockets 410(B) are disposed in the first spaces defined by the plurality of first fluid-filled pockets 410(A), as illustrated in FIG. 4. This can provide for extra cushioning in the second (middle) layer 406(A), as well as planarized surfaces on the inner surface and the outer surface of the second layer 406(A) to laminate the first layer 404(A) and the third layer 408(A) onto, respectively. Flexibility of the front wall 104 may be compromised by added stiffness, but the added protection to the food items can be beneficial if stiffness of the container 100 is not a concern.
FIG. 5A illustrates a perspective view of an example container 500 in the form of a bag, a portion of the bag having a multi-layer structure for protecting a food item disposed within the container 500. For instance, a front wall 504 of the container 500 can include a multi-layer structure, such as any of the multi-layer structures 200(A), 300(A), or 400(A) described herein. Likewise, a rear wall 506 of the container 500 can include a similar multi-layer structure, as described herein. Furthermore, the front wall 504 can comprise a first portion 512(A) that includes the multi-layer structure and a second portion 514(A) that does not include the multi-layer structure, and the rear wall 506 can comprise a first portion 512(B) that includes the multi-layer structure and a second portion 514(B) that does not include the multi-layer structure. Thus, in a similar manner to the container 100 described with reference to FIG. 1, a top end of the container 500 can be sealed after one or more food items are placed within the container 500.
The example container 500 of FIGS. 5A and 5B further comprises a gusset 502 disposed around a periphery of a bottom wall 508 of the container 500. The gusset 502 can comprise any suitable piece of material that comprises a rigid, or semi-rigid, material, such as a plastic (e.g., acrylonitrile butadiene styrene (ABS) plastic), metal, or any similar material. The gusset 502 can be pre-formed into any suitable shape, such as the elongated, hexagonal shape shown in the bottom plan view shown in FIG. 5B of the container 500 of FIG. 5A. The gusset 502 can, of course, be provided in any suitable polygonal shape, such as a circular shape, a triangular shape, a rectangular shape, or any type of polygonal shape, whether symmetrical or asymmetrical. The gusset 502 provides structure to the container 500 such that the container 500 can be set atop a flat surface, such as a table, and can stand upright without falling over on its side. This might allow a consumer to eat from the container 500 without holding the container 500, or to better situate the container 500 on a pantry shelf.
The example container 500 of FIGS. 5A and 5B also comprises a two-part attachment mechanism 510 for resealing the container 500 after opening. The two-part attachment mechanism 510 can comprise a first part 510(A) attached to the second portion 514(A) of the front wall 504, and a second part 510(B) attached to the second portion 514(B) of the rear wall 506. The first part 510(A) can represent a “male” part of the two-part attachment mechanism 510, and the second part 510(B) can represent a “female” part that receives the male part to join the front wall 504 with the rear wall 506 of the container 500. In some embodiments, the two-part attachment mechanism 510 is in the form of a zipper attachment mechanism that can be pressed by the fingers of a user to reseal the container 510 after initially opening the sealed container 500. The resealable container 500 of FIGS. 5A and 5B can allow for a consumer of the food items to consume some, but not all, of the food items within the container 500, and to save any remaining food items in the container 500 for later consumption.
FIG. 6 illustrates a perspective view of an example container 600 in the form of tray 602 and a lid 604. In the example of FIG. 6, the portion of the container 600 that comprises a multi-layer structure can include the lid 604 of the container 600. For example, the lid 604 of the container 600 can comprise any of the multi-layer structures described herein, such as the multi-layer structures 200, 300, or 400. One or more food items to be delivered to a customer that purchased the food item(s) can be placed in the tray 602 of the container, and the lid 604 comprising the multi-layer structure 200, 300, or 400, can be attached to the tray 602 at a periphery of a top portion of the tray 602. The tray 602 can be made of any suitable material, such as plastic. Alternatively, the tray 602 itself can be made, at least partially, of any of the multi-layer structures described herein to provide added protection to the food item(s) within the container 600.
It is to be appreciated that unwrapped food items, such as chips, crackers, condiments, dressings, etc., can be placed in the food packaging described herein. Alternatively, individually wrapped food items, such as chocolate bars wrapped in foil and/or paper can be placed in the food packaging described herein.
It is to be appreciated that the specific dimensions, proportions, shapes and configurations of the components described herein are not specific to the embodiments described and illustrated herein. For example, the containers can be of various sizes (length and/or width), and shapes (e.g., rectangular, square, triangular, cylindrical, etc.) without changing the basic characteristics of food packaging described herein.
Although the subject matter has been described in language specific to structural features, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features described. Rather, the specific features are disclosed as illustrative forms of implementing the claims.

Claims

What is claimed is:

1. A container for containing a food item that is susceptible to damage during transit from a fulfillment center to a delivery location, the container being in the form of a bag comprising:

a front lateral wall having a multi-layer structure including an inner layer, a middle layer, and an outer layer, wherein:

the inner layer: (i) is a first distance from the food item at a time at which the food item is disposed within the container, and (ii) comprises a fluid resistant material;

the middle layer: (i) is a second distance from the food item that is greater than the first distance at the time at which the food item is disposed within the container, and (ii) comprises an array of plastic, air-filled pockets; and

the outer layer: (i) is a third distance from the food item that is greater than the second distance at the time at which the food item is disposed within the container, and (ii) comprises a plastic film; and

a rear lateral wall attached to the front lateral wall, the rear lateral wall having the multi-layer structure.

2. The container of claim 1, wherein:

the front lateral wall comprises a first portion and a second portion;

the rear lateral wall comprises a first portion and a second portion;

the multi-layer structure is included in the first portion of the front lateral wall and the first portion of the rear lateral wall; and

the second portion of the front lateral wall and the second portion of the rear lateral wall are configured to be sealed together to enclose the food item within the container.

3. The container of claim 2, further comprising:

a bottom wall;

a gusset disposed around a periphery of the bottom wall to allow the container to stand upright on a flat surface; and

a two-part attachment mechanism for resealing the container after opening, the two-part attachment mechanism comprising:

a first part attached to the second portion of the front lateral wall; and

a second part attached to the second portion of the rear lateral wall.

4. The container of claim 1, wherein the middle layer of the multi-layer structure comprises:

a plurality of first air-filled pockets facing outward toward the outer layer, the plurality of first air-filled pockets being arranged such that a plurality of first spaces are defined between the plurality of first air-filled pockets; and

a plurality of second air-filled pockets facing inward toward the inner layer, the plurality of second air-filled pockets being arranged such that a plurality of second spaces are defined between the plurality of second air-filled pockets.

5. The container of claim 1, wherein the fluid resistant material of the inner layer comprises at least one of a metallized film or an ethylene vinyl alcohol (EVOH) film.

6. An apparatus comprising:

a container configured to contain an item, a portion of the container comprising a multi-layer structure including:

a first layer of fluid resistant material;

a second layer comprising pliable pockets filled with a fluid medium; and

a third layer of polymer material,

wherein the first layer, the second layer, and the third layer are laminated together to form the multi-layer structure.

7. The apparatus of claim 6, wherein:

the first layer is a first distance from the item at a time at which the item is disposed within the container;

the second layer is disposed between the first layer and the third layer; and

the third layer is a second distance from the item at the time at which the item is disposed within the container, the second distance being greater than the first distance.

8. The apparatus of claim 6, wherein:

the second layer is a first distance from the item at a time at which the item is disposed within the container;

the first layer is disposed between the second layer and the third layer; and

9. The apparatus of claim 8, wherein the pliable pockets of the second layer comprise ethylene vinyl alcohol (EVOH).

10. The apparatus of claim 6, wherein the fluid resistant material of the first layer comprises at least one of a metallized film or an ethylene vinyl alcohol (EVOH) film.

11. The apparatus of claim 10, wherein the metallized film comprises aluminum film.

12. The apparatus of claim 6, wherein:

the container is in the form of a bag having at least one of: (i) a continuous lateral wall or (ii) multiple lateral walls attached at respective lateral edges thereof; and

the portion of the container that comprises the multi-layer structure includes the continuous lateral wall or the multiple lateral walls of the bag.

13. The apparatus of claim 12, wherein the bag comprises:

a bottom wall;

a gusset disposed around a periphery of the bottom wall to allow the bag to stand upright on a flat surface; and

a two-part attachment mechanism at a top of the lateral wall or the multiple lateral walls for resealing the bag after opening.

14. The apparatus of claim 6, wherein:

the container is in the form of a tray containing the item and a lid attached to the tray; and

the portion of the container that comprises the multi-layer structure includes the lid.

15. An apparatus comprising:

containing container configured to contain an item, at least a portion of the container comprising:

first means for resisting ingress of fluid to, or egress of the fluid from, the container after the container has been sealed with the item contained therein;

second means for cushioning the item at a time at which the item is disposed within the container, the second means for cushioning being disposed on the first means for resisting the ingress or the egress of the fluid; and

third means for protecting the second means for cushioning, the third means for protecting being disposed on the second means for cushioning.

16. The apparatus of claim 15, wherein:

the first means for resisting the ingress or the egress of the fluid is a first distance from the item at a time at which the item is disposed within the container; and

the third means for protecting is a second distance from the item at a time at which the item is disposed within the container, the second distance being greater than the first distance.

17. The apparatus of claim 15, wherein the first means for resisting the ingress or the egress of the fluid comprises at least one of a metallized film or an ethylene vinyl alcohol (EVOH) film.

18. The apparatus of claim 15, wherein the second means for cushioning comprises a plurality of means for holding a fluid medium.

19. The apparatus of claim 15, wherein the plurality of means for holding the fluid medium is a first plurality of means for holding the fluid medium, the means for cushioning further comprising:

a second plurality of means for holding the fluid medium coupled to the first plurality of means for holding the fluid medium such that the second plurality of means for holding the fluid medium occupy first spaces defined between the first plurality of means for holding the fluid medium, and the first plurality of means for holding the fluid medium occupy second spaces defined between the second plurality of means for holding the fluid medium.

20. The apparatus of claim 15, wherein the container further comprises:

fourth means for allowing the container to stand upright on a flat surface; and

fifth means for resealing the container after opening.