Thermoformed packages and methods of making same

Abstract

The present invention relates to thermoformed containers and processes of making thermoformed containers. The containers are cost effective, can be produced from post-consumer recycled material and, in many cases, can be classified as recyclable.

What is claimed is:  
     
         1 . A process for producing a heat sealed plastic package comprising the steps of: 
 thermoforming a container from co-extruded nulti-layered sheet, said sheet including a first layer of a substantially non-heat sealable polymeric material and a second layer of heat sealable polymeric material, said container having a cavity for storage therein, said container including a first flange, said first flange having an engaging surface disposed to engage a cover, said container being thermoformed such that said second layer of heat sealable polymeric material forms the engaging surface of said first flange;    providing a cover including a flange engaging surface having a layer of heat sealable polymeric material; and    sealing said cover to said container so as to enclose said cavity by heat sealing at least a portion of said flange engaging surface of said cover to said engaging surface of said first flange.    
     
     
         2 . The process of producing the heat sealed plastic package of    claim 1   , wherein said cover is composed of a co-extruded multi-layered sheet, said sheet including a first layer of a substantially non-heat sealable polymeric material and a second layer of heat sealable polymeric material, wherein said second layer forms said flange engaging surface.  
     
     
         3 . The process of producing the heat sealed plastic package of    claim 1   , wherein said cover is a second thermoformed container composed of a co-extruded multi-layered sheet, said sheet having a first layer of a substantially non-heat sealable polymeric material and a second layer of heat sealable polymeric material, said second container having a cavity for storage formed therein, said second container including a second flange, said second flange having a flange engaging surface disposed to engage said engaging surface of said first flange, and said second container being thermoformed such that said second layer of heat sealable polymeric material forms the flange engaging surface of said second flange.  
     
     
         4 . The process of producing the heat sealed plastic package of    claim 1   , wherein said cover is composed of a co-extruded multi-layered sheet, said sheet including a first layer of a substantially non-heat sealable polymeric material and a second layer of heat sealable polymeric material, said sheet being substantially flat.  
     
     
         5 . The process of producing the heat sealed plastic package of    claim 1   , wherein said cover is composed of a co-extruded multi-layered sheet, said sheet including a first layer of a substantially non-heat sealable polymeric material and a second layer of heat sealable polymeric material, said cover is connected to said container along at least one side to provide a hinge.  
     
     
         6 . The process of producing the heat sealed plastic package of claims  1  through  5 , wherein said first layer has a thickness of between about 4 and about 40 mils.  
     
     
         7 . The process of producing the heat sealed plastic package of    claim 6   , wherein said first layer has a thickness of between about 6 and about 25 mils.  
     
     
         8 . The process of producing the heat sealed plastic package of    claim 7   , wherein said first layer has a thickness of between about 8 and about 15 mils.  
     
     
         9 . The process of producing the heat sealed plastic package of    claim 1   , wherein said second layer has a thickness of between about 0.5 and about 20 mils.  
     
     
         10 . The process of producing the heat sealed plastic package of    claim 9   , wherein said second layer has a thickness of between about 1 and about 4 mils.  
     
     
         11 . The process of producing the heat sealed plastic package of    claim 10   , wherein said second layer has a thickness of between about 1 and about 2 mils.  
     
     
         12 . The process of producing the heat sealed plastic package of    claim 1   , wherein said first layer is composed of PET.  
     
     
         13 . The process of producing the heat sealed plastic package of    claim 1   , wherein said first layer is composed of a mixture of virgin PET and post consumer recycled PET.  
     
     
         14 . The process of producing the heat sealed plastic package of    claim 13   , wherein said mixture or contains greater than about 10 percent post-consumer recycled PET.  
     
     
         15 . The process of producing the heat sealed plastic package of    claim 14   , wherein said mixture contains greater than about 25 percent post-consumer recycled PET.  
     
     
         16 . The process of producing the heat sealed plastic package of    claim 15   , wherein said mixture contains greater at least about 50 percent post-consumer recycled PET.  
     
     
         17 . The process of producing the heat sealed plastic package of    claim 15   , wherein said first layer is composed of about 100 percent post-consumer recycled PET.  
     
     
         18 . The process of producing the heat sealed plastic package of    claim 1   , wherein said second layer is composed of PETG.  
     
     
         19 . The process of producing the heat sealed plastic package of    claim 18   , wherein said second layer is a mixture of virgin PETG and recycled PETG.  
     
     
         20 . The process of producing the heat sealed plastic package of    claim 1    further comprising a third layer of a polymeric material co-extruded with said multi-layered sheet, said third layer being disposed such that said first layer is sandwiched between said second and said third layer.  
     
     
         21 . The process of producing the heat sealed plastic package of    claim 20   , wherein said third layer is composed of heat sealable polymeric material.  
     
     
         22 . The process of producing the heat sealed plastic package of    claim 21   , wherein said second layer of heat sealable polymeric material and said third layer of heat sealable polymeric material are composed of the same polymeric material.  
     
     
         23 . The process of producing the heat sealed plastic package of    claim 21   , wherein said third layer has a thickness of between about 0.5 and about 20 mils.  
     
     
         24 . The process of producing the heat sealed plastic package of    claim 23   , wherein said third layer has a thickness of between about 1 and about 4 mils.  
     
     
         25 . The process of producing the heat sealed plastic package of    claim 24   , wherein said third layer has a thickness of between about 1 and about 2 mils.  
     
     
         26 . The process of producing the heat sealed plastic package of    claim 21   , wherein said third layer is composed of PETG.  
     
     
         27 . The process of producing the heat sealed plastic package of    claim 26   , wherein said third layer is a mixture of virgin PETG and recycled PETG.  
     
     
         28 . The process of producing the heat sealed plastic package of    claim 1   , wherein said cover is sealed to said package using high frequency RF.  
     
     
         29 . The process of producing the heat sealed plastic package of    claim 13   , wherein said PET was produced using a post-consumer recycled material extruded directly from flake into a sheet.  
     
     
         30 . The process of producing the heat sealed plastic package of    claim 4   , wherein said substantially flat cover is composed of a colored co-extruded multi-layered sheet.  
     
     
         31 . The process of producing the heat sealed plastic package of    claim 4    further comprising the step of imprinting letters or figures on said substantially flat cover.  
     
     
         32 . A process for producing a heat sealed plastic package comprising the steps of: 
 thermoforming a container from co-extruded multi-layered sheet, said sheet including a first layer of PET and a second layer of PETG, said container having a cavity for storage therein, said container including a first flange, said first flange having an engaging surface disposed to engage a cover, said container being thermoformed such that said second layer forms the engaging surface of said first flange;    providing a cover including a flange engaging surface having a layer of PETG; and    sealing said cover to said container so as to enclose said cavity by heat sealing at least a portion of said flange engaging surface of said cover to said engaging surface of said first flange.    
     
     
         33 . The process of producing the heat sealed plastic package of    claim 32   , wherein said cover is composed of a co-extruded multi-layered sheet, said sheet including a first layer of PET and a second layer of PETG, wherein said second layer forms said flange engaging surface.  
     
     
         34 . The process of producing the heat sealed plastic package of    claim 32   , wherein said cover is a second thermoformed container composed of a co-extruded multi-layered sheet, said sheet having a first layer of PET and a second layer of PETG, said second container having a cavity for storage formed therein, said second container including a second flange, said second flange having a flange engaging surface disposed to engage said engaging surface of said first flange, and said second container being thermoformed such that said second layer of PETG forms the flange engaging surface of said second flange.  
     
     
         35 . The process of producing the heat sealed plastic package of    claim 32   , wherein said cover is composed of a co-extruded multi-layered sheet, said sheet including a first layer of PET and a second layer of PETG, said sheet being substantially flat.  
     
     
         36 . The process of producing the heat sealed plastic package of    claim 32   , wherein said cover is composed of a co-extruded multi-layered sheet, said sheet including a first layer of PET and a second layer of PETG, said cover being connected to said container along at least one side so as to provide a hinge.  
     
     
         37 . A heat sealable plastic package comprising: 
 a thermoformed container, said container being constructed from a co-extruded multi-layered sheet, said sheet including a first layer of a substantially non-heat sealable polymeric material and a second layer of heat sealable polymeric material, said container having a cavity for storage therein, said container including a first flange, said first flange having an engaging surface disposed to engage a cover, said container being thermoformed such that said second layer of heat sealable polymeric material forms the engaging surface of said first flange; and    a cover including a flange engaging surface, said flange engaging surface including a layer of heat sealable polymeric material; so that said cover and said container can be heat sealed together to enclose said cavity by heat sealing at least a portion of said flange engaging surface of said cover to said engaging surface of said first flange of said container.    
     
     
         38 . The heat sealable plastic package of    claim 37   , wherein said cover is composed of a co-extruded multi-layered sheet, said sheet including a first layer of a substantially non-heat sealable polymeric material and a second layer of heat sealable polymeric material, said second layer forming said flange engaging surface.  
     
     
         39 . The heat sealable plastic package of    claim 37   , wherein said cover is a second thermoformed container, said container being constructed of a co-extruded multi-layered sheet, said sheet having a first layer of a substantially non-heat sealable polymeric material and a second layer of heat sealable polymeric material, said second container having a cavity for storage formed therein, said second container including a second flange, said second flange having a flange engaging surface disposed to engage said engaging surface of said first flange, said second container being thermoformed such that said second layer of heat sealable polymeric material forms the flange engaging surface of said second flange.  
     
     
         40 . The heat sealable plastic package of    claim 37   , wherein said cover is composed of a co-extruded multi-layered sheet, said sheet including a first layer of a substantially non-heat sealable polymeric material and a second layer of heat sealable polymeric material, said sheet being substantially flat.  
     
     
         41 . The heat sealable plastic package of    claim 37   , wherein said cover is composed of a co-extruded multi-layered sheet, said sheet including a first layer of a substantially non-heat sealable polymeric material and a second layer of heat sealable polymeric material, wherein said cover is connected to said container through a hinge.  
     
     
         42 . The heat sealable plastic package of    claim 37   , wherein said first layer has a thickness of between about  4  and about 40 mils.  
     
     
         43 . The heat sealable plastic package of    claim 42   , wherein said first layer has a thickness of between about  6  and about 25 mils.  
     
     
         44 . The heat sealable plastic package of    claim 43   , wherein said first layer has a thickness of between about  8  and about 15 mils.  
     
     
         45 . The heat sealable plastic package of    claim 37   , wherein said second layer has a thickness of between about 0.5 and about 20 mils.  
     
     
         46 . The heat sealable plastic package of    claim 45   , wherein said second layer has a thickness of between about 1 and about 4 mils.  
     
     
         47 . The heat sealable plastic package of    claim 46   , wherein said second layer has a thickness of between about 1 and about 2 mils.  
     
     
         48 . The heat sealable plastic package of    claim 37   , wherein said first layer is composed of PET.  
     
     
         49 . The heat sealable plastic package of    claim 37   , wherein said first layer is composed of a mixture of virgin PET and post-consumer recycled PET.  
     
     
         50 . The heat sealable plastic package of    claim 49   , wherein said mixture contains greater than about 10 percent post consumer recycled PET.  
     
     
         51 . The heat sealable plastic package of    claim 50   , wherein said mixture contains greater than about 25 percent post consumer recycled PET.  
     
     
         52 . The heat sealable plastic package of    claim 51   , wherein said mixture contains at least about 50 percent post consumer recycled PET.  
     
     
         53 . The heat sealable plastic package of    claim 52   , wherein said first layer is composed of about 100 percent post-consumer recycled PET.  
     
     
         54 . The heat sealable plastic package of    claim 37   , wherein said second layer is composed of PETG.  
     
     
         55 . The heat sealable plastic package of    claim 54   , wherein said second layer is a mixture of virgin PETG and recycled PETG.  
     
     
         56 . The heat sealable plastic package of    claim 37    further comprising a third layer of a polymeric material co-extruded with said multi-layered sheet, said third layer being disposed such that said first layer is sandwiched between said second and said third layer.  
     
     
         57 . The heat sealable plastic package of    claim 56   , wherein said third layer is composed of heat sealable polymeric material.  
     
     
         58 . The heat sealable plastic package of    claim 57   , wherein said second layer of heat sealable polymeric material and said third layer of heat sealable polymeric material are composed of the same polymeric material.  
     
     
         59 . The heat sealable plastic package of    claim 57   , wherein said third layer has a thickness of between about 1 and about 20 mils.  
     
     
         60 . The heat sealable plastic package of    claim 59   , wherein said third layer has a thickness of between about 1 and about 4 mils.  
     
     
         61 . The heat sealable plastic package of    claim 60   , wherein said third layer has a thickness of between about 1 and about 2 mils.  
     
     
         62 . The heat sealable plastic package of    claim 57   , wherein said third layer is composed of PETG.  
     
     
         63 . The heat sealable plastic package of    claim 62   , wherein said third layer is a mixture of virgin PETG and recycled PETG.  
     
     
         64 . The heat sealable plastic package of    claim 37   , wherein said cover is capable of being sealed to said package using high frequency RF.  
     
     
         65 . The heat sealable plastic package of    claim 49   , wherein said PET was produced using a post-consumer recycled material extruded directly from flake into a sheet.  
     
     
         66 . The heat sealable plastic package of    claim 40   , wherein said substantially flat cover is composed of a colored co-extruded multi-layered sheet.  
     
     
         67 . The heat sealable plastic package of    claim 40    further comprising imprinted letters or figures on said substantially flat cover.  
     
     
         68 . The heat sealable plastic package of    claim 37   , wherein said cover and said container are heat sealed together.  
     
     
         69 . A heat sealed plastic package manufactured in accordance with the process of    claim 1   .  
     
     
         70 . A heat sealable plastic package comprising: 
 a thermoformed container, said container being constructed from a co-extruded multi-layered sheet, said sheet including a first layer of a mixture of virgin PET and greater than about 10 percent post-consumer recycled PET and a second layer of PETG, said first layer having a thickness of between about 4 and about 40 mils and said second layer having a thickness of between about 0.5 and about 20 mils, said container having a cavity for storage therein, said container including a first flange, said first flange having an engaging surface disposed to engage a cover, said container being thermoformed such that said second layer of PETG forms the engaging surface of said first flange;    a cover including a flange engaging surface having a layer of PETG; and    said cover being sealable to said container so as to enclose said cavity by heat sealing at least a portion of said flange engaging surface of said cover to said engaging surface of said first flange.    
     
     
         71 . The heat sealable plastic package of    claim 70   , wherein said cover is composed of a co-extruded multi-layered sheet, said sheet including a first layer of a mixture of virgin PET and greater than about 10 percent post-consumer recycled PET and a second layer of PETG, said first layer having a thickness of between about 4 and about 40 mils and said second layer having a thickness of between about 0.5 and about 20 mils, said second layer forming said flange engaging surface.  
     
     
         72 . The heat sealable plastic package of claims  70  or  71 , further comprising a third layer of a polymeric material co-extruded with said multi-layered sheet, said third layer being disposed such that said first layer is sandwiched between said second and said third layer, said third layer being composed of PETG and having a thickness of between about 0.5 and about 20 mils.  
     
     
         73 . The heat sealable plastic package of    claim 72   , wherein said cover and said container are heat sealed together.  
     
     
         74 . A heat sealable plastic package comprising: 
 a thermoformed container having a cavity for storage therein, said container including a first flange, said first flange having an engaging surface disposed to engage a cover; and    a cover including a flange engaging surface;    said cover and said container being capable of being heat sealed together to enclose said cavity by heat sealing at least a portion of said flange engaging surface of said cover to said first flange of said container;    wherein at least one of said cover and said container is constructed from at least one layer of heat sealable polymeric material and the other of said cover and said container is constructed from a co-extruded multi-layered sheet, said sheet including a first layer of a substantially non-heat sealable polymeric material and a second layer of heat sealable polymeric material.    
     
     
         75 . The heat sealable plastic package of    claim 74   , wherein said container is constructed from said co-extruded multi-layered sheet and said cover is constructed from at least one layer of heat sealable polymeric material.  
     
     
         76 . The heat sealable plastic package of    claim 74   , wherein said cover is constructed from said co-extruded multi-layered sheet and said container is constructed from at least one layer of a heat sealable polymeric material.  
     
     
         77 . The heat sealable plastic package of    claim 74   , wherein said cover is a second thermoformed container having a cavity for storage formed therein, said second container including a second flange, and said second flange disposed to engage said first flange of said first container.  
     
     
         78 . The heat sealable plastic package of    claim 74   , wherein said cover is substantially flat.  
     
     
         79 . The heat sealable plastic package of    claim 74   , wherein said cover is connected to said container through a hinge.  
     
     
         80 . The heat sealable plastic package of    claim 74   , wherein said at least one layer of heat sealable polymeric material is a single layer.  
     
     
         81 . The heat sealable plastic package of    claim 80   , wherein said single layer of heat sealable polymeric material is selected from the group consisting of PETG, chemically modified PET, PVC and urethane.  
     
     
         82 . The heat sealable plastic package of    claim 81   , wherein said at least one layer of heat sealable polymeric material is PETG.  
     
     
         83 . The heat sealable plastic package of    claim 80   , wherein said single layer of heat sealable material has a thickness of between about 4 and about 80 mils.  
     
     
         84 . The heat sealable plastic package of    claim 83   , wherein said single layer of heat sealable material has a thickness of between about 8 and about 30 mils.  
     
     
         85 . The heat sealable plastic package of    claim 74   , wherein said first layer has a thickness of between about 4 and about 40 mils.  
     
     
         86 . The heat sealable plastic package of    claim 85   , wherein said first layer has a thickness of between about 6 and about 25 mils.  
     
     
         87 . The heat sealable plastic package of    claim 86   , wherein said first layer has a thickness of between about 8 and about 15 mils.  
     
     
         88 . The heat sealable plastic package of    claim 74   , wherein said second layer has a thickness of between about 0.5 and about 20 mils.  
     
     
         89 . The heat sealable plastic package of    claim 88   , wherein said second layer has a thickness of between about 1 and about 4 mils.  
     
     
         90 . The heat sealable plastic package of    claim 89   , wherein said second layer has a thickness of between about 1 and about 2 mils.  
     
     
         91 . The heat sealable plastic package of    claim 74   , wherein said first layer is composed of PET.  
     
     
         92 . The heat sealable plastic package of    claim 74   , wherein said first layer is composed of a mixture of virgin PET and post-consumer recycled PET.  
     
     
         93 . The heat sealable plastic package of    claim 92   , wherein said mixture contains greater than about 10 percent post consumer recycled PET.  
     
     
         94 . The heat sealable plastic package of    claim 93   , wherein said mixture contains greater than about 25 percent post consumer recycled PET.  
     
     
         95 . The heat sealable plastic package of    claim 94   , wherein said mixture contains at least about 50 percent post consumer recycled PET.  
     
     
         96 . The heat sealable plastic package of    claim 95   , wherein said first layer is composed of about 100 percent post-consumer recycled PET.  
     
     
         97 . The heat sealable plastic package of    claim 74   , wherein said second layer is composed of PETG.  
     
     
         98 . The heat sealable plastic package of    claim 97   , wherein said second layer is a mixture of virgin PETG and recycled PETG.  
     
     
         99 . The heat sealable plastic package of    claim 74   , further comprising a third layer of a polymeric material co-extruded with said multi-layered sheet, said third layer being disposed such that said first layer is sandwiched between said second and said third layer.  
     
     
         100 . The heat sealable plastic package of    claim 99   , wherein said third layer is composed of heat sealable polymeric material.  
     
     
         101 . The heat sealable plastic package of    claim 100   , wherein said second layer of heat sealable polymeric material and said third layer of heat sealable polymeric material are composed of the same polymeric material.  
     
     
         102 . The heat sealable plastic package of    claim 101   , wherein said third layer has a thickness of between about 1 and about 20 mils.  
     
     
         103 . The heat sealable plastic package of    claim 102   , wherein said third layer has a thickness of between about 1 and about 4 mils.  
     
     
         104 . The heat sealable plastic package of    claim 103   , wherein said third layer has a thickness of between about 1 and about 2 mils.  
     
     
         105 . The heat sealable plastic package of    claim 100   , wherein said third layer is composed of PETG.  
     
     
         106 . The heat sealable plastic package of    claim 105   , wherein said third layer is a mixture of virgin PETG and recycled PETG.  
     
     
         107 . The heat sealable plastic package of    claim 37   , wherein said cover and said container are heat sealed together.  
     
     
         108 . The heat sealable plastic package of    claim 74   , wherein said cover and said container are heat sealed together.