Methods of making containers

Abstract

A hermetically sealed container is disclosed that may be produced by an effective and economical process for an in-plant system. The container comprises a coated unitary tray component having a base portion, a side wall portion, and a flange portion; and a lid component hermetically sealed to the flange portion of the tray component. A selected composite polymer film is blow-molded onto an interior surface of the pre-shaped unitary tray structure to provide the coated unitary tray component having its interior surface seamlessly, creaselessly and integrally bonded with the polymeric film.

1 - 7 . (canceled) 
     
     
         8 . A method of producing a hermetically sealed container, comprising:
 providing a pre-shaped unitary tray structure having interior and exterior surfaces and an internal space to contain packaged goods, the pre-shaped structure   comprising:   a base portion;   a side wall portion extending upward from the base portion; and   a flange portion extending peripherally from the side wall portion;   inserting the pre-shaped unitary structure against a blow mold cavity wall;   extruding a blow mold parison of polymeric film into the blow mold cavity;   blowing the polymeric film against the interior surface of the pre-shaped unitary tray structure to seamlessly, creaselessly, and integrally bond the polymeric film to the interior surface of the pre-shaped unitary tray structure, creating a coated unitary tray component; and   hermetically sealing a lid component to the flange portion of the coated unitary tray component.   
     
     
         9 . The method of  claim 8 , wherein providing the pre-shaped unitary tray structure further comprises providing a pre-shaped unitary tray structure made from paperboard. 
     
     
         10 . The method of  claim 8 , forming the pre-shaped unitary tray structure using a press-molding process. 
     
     
         11 . The method of  claim 8 , wherein blowing the polymeric film further comprises blowing a polymeric film comprising a polymer selected from a group consisting of PET, LDPE, nylon, EVOH, polypropylene, and combinations thereof. 
     
     
         12 . The method of  claim 8 , wherein the lid component comprises a polymer including PET polymer. 
     
     
         13 . The method of  claim 8 , further comprising depositing a heat-sealable layer onto at least a portion of the flange portion of the coated unitary tray component prior to hermetically sealing the lid component to the flange portion of the coated tray component. 
     
     
         14 . (canceled) 
     
     
         15 . A method for producing a container, comprising:
 forming a pre-shape unitary tray structure comprising an interior surface;   blow-molding a polymer film over the interior surface of the pre-shape unitary tray structure;   
     
     
         16 . The method of  claim 15 , wherein forming the pre-shape unitary tray structure comprises forming the pre-shape unitary tray structure from a material selected from the group consisting of paper, paperboard, cardboard, fiberboard, paper/plastic composites and aluminum. 
     
     
         17 . The method of  claim 15 , wherein forming the pre-shape unitary tray structure comprises forming the pre-shape unitary tray structure from paperboard having a thickness between 250 micron and 750 micron. 
     
     
         18 . The method of  claim 15 , wherein forming the pre-shape unitary tray structure comprises forming the pre-shape unitary tray structure using a press-molding process. 
     
     
         19 . The method of  claim 15 , wherein forming the pre-shape unitary tray structure comprises forming a pre-shape unitary tray structure comprising fillet corners. 
     
     
         20 . The method of  claim 15 , further comprising filling the pre-shape unitary tray structure with a food-stuff. 
     
     
         21 . The method of  claim 20 , further comprising adhering a lid to the pre-shape unitary tray structure. 
     
     
         22 . The method of  claim 21 , wherein adhering a lid to the pre-shape unitary tray structure further comprises adhering a sealing film to the pre-shape unitary tray structure about the flange portion. 
     
     
         23 . The method of  claim 21 , wherein adhering a lid to the pre-shape unitary tray structure further comprises creating a hermetic seal between the lid and the pre-shape unitary tray structure. 
     
     
         24 . A method for producing a container [for foodstuffs], comprising:
 press-molding a pre-shape unitary tray structure, the pre-shape unitary tray structure comprising:   a base portion;   side wall portions extending up from the base portion;   a flange portion extending peripherally from the side wall portions; and   wherein the base portion and side wall portions define an interior surface of the pre-shape unitary tray structure;   blow-molding a polymer film onto the interior surface and flange portion of the pre-shape unitary tray structure; and   trimming the polymer film coated flange portion of the pre-shape unitary tray structure.   
     
     
         25 . The method of  claim 24 , wherein the pre-shape unitary tray structure further comprises a fillet between the side wall portions and the base portion. 
     
     
         26 . The method of  claim 24 , wherein the pre-shape unitary tray structure further comprises a round transition between the side wall portions and the flange portion. 
     
     
         27 . The method of  claim 24 , wherein blow-molding a polymer film onto the interior surface and flange portion of the pre-shape unitary tray structure further comprises:
 inserting the pre-shaped unitary tray structure against a blow mold cavity wall;   extruding a blow mold parison of polymeric film into the blow mold cavity; and   blowing the polymeric film against the interior surface and flange portion of the pre-shape unitary tray structure.   
     
     
         28 . The method of  claim 24 , further comprising hermetically sealing a lid component to the polymer film on the flange portion of the pre-shape unitary tray structure.