WO2025006392A1

WO2025006392A1 - Compostable packaging, packages, and containers

Info

Publication number: WO2025006392A1
Application number: PCT/US2024/035263
Authority: WO
Inventors: Jeffrey C. Minnette; Ryan P. Davidson; Eric Kost
Original assignee: Jabil Inc.
Priority date: 2023-06-27
Filing date: 2024-06-24
Publication date: 2025-01-02

Abstract

Compostable packaging, packages, and containers and manufacturing thereof. A method includes positioning a die line on a cavity plate. A cavity plate has multiple cavity sections, the die line has multiple film sections, and a film section is positionally aligned with a cavity section. A clamp plate is positioned on the die line to maintain a tension on the die line. The clamp plate has multiple openings and an opening is aligned with the cavity section. A core plate is placed on the clamp plate. The core plate has multiple core portions and a core portion is aligned with the cavity section to punch the film section into a cavity in the cavity section on the cavity plate. A structure forming material is injected into an assembled cavity plate, clamp plate, and core plate to form multiple frames. Each frame fuses with a corresponding film section to form a container.

Description

Attorney Docket No. JABI-212-A-WO COMPOSTABLE PACKAGING, PACKAGES, AND CONTAINERS TECHNICAL FIELD [0001] This disclosure relates to packaging and in particular, containers having compostability. BACKGROUND [0002] Plastic containers are difficult to recycle and use materials that are not environmentally friendly. Moreover, they are not easily compostable. SUMMARY [0003] Disclosed herein are compostable packaging, packages, and containers and methods of manufacturing thereof. BRIEF DESCRIPTION OF THE DRAWINGS [0004] The disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings and are incorporated into and thus constitute a part of this specification. It is emphasized that, according to common practice, the various features of the drawings are not to-scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. [0005] FIG.1 is a perspective view of a container in accordance with implementations. [0006] FIG.2 is a top view of the container of FIG.1 in accordance with implementations. [0007] FIG. 3 is a cross-sectional view of the container of FIG. 1 in accordance with implementations. [0008] FIG.4 is a view of a molded part of the container in accordance with implementations. [0009] FIG.5 is a die line diagram of films used with molding equipment to form containers as shown in FIG.1 in accordance with implementations. [0010] FIG.6 is a zoomed in view of a film in accordance with implementations. [0011] FIG.7 is a perspective view of a container with a lid accordance with implementations. [0012] FIG. 8 is a diagram of molding equipment for making the container of FIG. 1 in accordance with implementations. [0013] FIG. 9 is a top view of a diagram of a cavity plate of molding equipment for making Attorney Docket No. JABI-212-A-WO the container of FIG.1 in accordance with implementations. [0014] FIG.9A is a bottom view of a diagram of the cavity plate of FIG.9 in accordance with implementations. [0015] FIG.10 is a perspective view of a diagram of a clamp plate of molding equipment for making the container of FIG.1 in accordance with implementations. [0016] FIG.11 is a top view of a diagram of a core plate of molding equipment for making the container of FIG.1 in accordance with implementations. [0017] FIG.11A is a bottom view of a diagram of the core plate of FIG.11 in accordance with implementations. [0018] FIG.12 is a perspective view of a diagram of an assembled molding equipment using the cavity plate of FIG.9, the clamp plate of FIG.10, and the core plate of FIG.11 in accordance with implementations. [0019] FIG.13 is a die line diagram of films used with molding equipment to form containers as shown in FIG.1 in accordance with implementations. [0020] FIG.14 is a zoomed in view of the film of FIG.13 in accordance with implementations. [0021] FIG.14A is a diagram of a film with a scalloped texture to increase top load capacity in accordance with implementations. [0022] FIG.15 is a view of the die line in the molding equipment to form containers as shown in FIG.1 in accordance with implementations. [0023] FIG.15A and 15B are views of the die line 13000 on the cavity plate 9000, the clamp plate on the die line, and the core plate on the clamp plate in accordance with implementations. [0024] FIG. 16 is a cross-section view of the assembled molding equipment of FIG. 12 in accordance with implementations. [0025] FIG.16A and 16B are cross-sectional views of the of the assembled molding equipment of FIG.12 in accordance with implementations. [0026] FIG. 17 is a zoomed view of the cross-section view of the assembled molding equipment of FIG.12 in accordance with implementations. DETAILED DESCRIPTION [0027] The figures and descriptions provided herein may be simplified to illustrate aspects of the described embodiments that are relevant for a clear understanding of the herein disclosed Attorney Docket No. JABI-212-A-WO processes, machines, manufactures, and/or compositions of matter, while eliminating for the purpose of clarity other aspects that may be found in typical similar devices, systems, compositions, and methods. Those of ordinary skill may thus recognize that other elements and/or steps may be desirable or necessary to implement the devices, systems, compositions, and methods described herein. However, because such elements and steps are well known in the art, and because they do not facilitate a better understanding of the disclosed embodiments, a discussion of such elements and steps may not be provided herein. However, the present disclosure is deemed to inherently include all such elements, variations, and modifications to the described aspects that would be known to those of ordinary skill in the pertinent art in light of the discussion herein. [0028] Embodiments are provided throughout so that this disclosure is sufficiently thorough and fully conveys the scope of the disclosed embodiments to those who are skilled in the art. Numerous specific details are set forth, such as examples of specific aspects, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. Nevertheless, it will be apparent to those skilled in the art that certain specific disclosed details need not be employed, and that embodiments may be embodied in different forms. As such, the exemplary embodiments set forth should not be construed to limit the scope of the disclosure. [0029] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. For example, as used herein, the singular forms "a", "an" and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. [0030] The steps, processes, and operations described herein are thus not to be construed as necessarily requiring their respective performance in the particular order discussed or illustrated, unless specifically identified as a preferred or required order of performance. It is also to be understood that additional or alternative steps may be employed, in place of or in conjunction with the disclosed aspects. [0031] Yet further, although the terms first, second, third, etc. may be used herein to describe various elements, steps or aspects, these elements, steps, or aspects should not be limited by these terms. These terms may be only used to distinguish one element or aspect from another. Thus, Attorney Docket No. JABI-212-A-WO terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, step, component, region, layer, or section discussed below could be termed a second element, step, component, region, layer, or section without departing from the teachings of the disclosure. [0032] The non-limiting embodiments described herein are with respect to packages, including but not limited to, containers. The packages and methods for making the packages may be modified for a variety of applications and uses while remaining within the spirit and scope of the claims. The embodiments and variations described herein, and/or shown in the drawings, are presented by way of example only and are not limiting as to the scope and spirit. The descriptions herein may be applicable to all embodiments of the packages and the methods for making the packages. [0033] Disclosed herein are implementations of sustainable and compostable packaging. The implementations shown are illustrative and other implementations are within the scope of the specification and claims described herein. For purposes of illustration, certain aspects, features, and the like are described with respect to implementations. These aspects, features, and the like are appropriately applicable to and interchangeable with other implementations described herein. [0034] In implementations, the containers can use injection molding (IM), in-mold labeling (IML), die cutting, compression blow molding, continuous compression molding, thermoform molding, thermoforming, and the like processing (collectively “structure forming process”) to form a frame, a ribbed frame, a vertical frame, container body, body, and the like (collectively “structure” or “molded part or portion”) of the container. In implementations, injection molding (IM), in-mold labeling (IML), heat, induction, mechanical, staking, ultrasonic, adhesive bonding, chemical bonding, and the like processing (collectively “join processing”) can be used to fuse, weld, or bond (collectively “fuse”) the structure with a label, film, shell, seal, and/or the like (collectively “flexible part”) to create a container which can hold content or materials. In implementations, the fusing can include application of pressure, temperature, and/or combinations thereof. In implementations, the container, after placement of content and sealed with a lid as described herein, is an integrally, hermetically sealed package. In implementations, the container can be configured to contain liquid or non-dry content or materials. [0035] In implementations, the structure is fused with the flexible part using the join processing to create the container. The fusing of the flexible part with the structure results in edge(s) of the flexible part being intermingled, impregnated, encapsulated, embedded, or coated with the Attorney Docket No. JABI-212-A-WO material of the structure to form a sealed edge at junctions between the structure and the flexible part. The sealed edges prevent leakage of content from the container. [0036] In implementations, the structure or molded part or portion can be made from compostable materials, compostable materials in accordance with European Standard EN 13432, compostable materials in accordance with Vincotte certification for home composting, polymers, sustainable materials, recyclable materials, biodegradable materials, bio-based resins, weight- optimized biodegradable plastic, paperboard, pressed pulp, fiber based, pressed fiber, paper, starch, cellulose, recycled plastic film, metals, metalized film, biodegradable resins such as Polylactic acid (PLA), Polyhydroxyalkanoates (PHA), Polyhydroxybutyrate (PHB), Polyethylene Furanoate (PEF), High Density Poly Ethylene (HDPE), and the like (collectively “structure forming materials”). [0037] In implementations, the European Standard EN 13432 for packaging recoverable through composting and biodegradation requires at least 90% disintegration after twelve weeks, 90% biodegradation (CO₂ evolvement) in six months, and includes tests on ecotoxicity and heavy metal content. In implementations, certified compostable plastic products are converted into CO2, water, and biomass within 6 to 12 weeks. [0038] In implementations, the structure or molded part or portion can have a rectangular, square, oval, circular, conical, conical frustum, and/or like profile or footprint. In implementations, the structure or molded part or portion can have any number of legs or ribs connecting a base portion and a neck portion. [0039] In implementations, the flexible part can be or can be made from compostable materials, compostable materials in accordance with European Standard EN 13432, compostable materials in accordance with Vincotte certification for home composting, heavy film, paperboard, pressed pulp, compostable coated paper, recyclable materials, sustainable materials, degradable materials, biodegradable materials, fiber, compressed fiber, and the like (collectively “flexible forming materials”). [0040] In implementations, after content placement, join processing can be used to fuse a lid, membrane, film, or cover (collectively “lid”) to a content filled container to create a sealed package or container. In implementations, the lid can be made using the structure forming processes from the structure forming materials, or can be made from flexible forming materials. In implementations, the fusing of the lid with the structure results in edge(s) of the lid being Attorney Docket No. JABI-212-A-WO intermingled, impregnated, encapsulated, embedded, or coated with the material of the structure to form a sealed edge at junctions between the structure and the lid. The sealed edges prevent leakage of content from the container. [0041] In implementations, the container including the structure or molded part or portion and the flexible part, and the lid can include a barrier layer or film on an internal or inside surface, where the barrier layer is impervious or substantially impervious to the content or material in the container and/or chemically inert or substantially chemically inert with respect to the content or material in the container. In implementations, the container and/or lid can include an integrated or integrally formed barrier layer or film. In implementations, the materials used for the container and/or lid can include barrier layer or film materials. In implementations, the flexible part can include an integrated or integrally formed barrier layer or film. In implementations, the container and/or lid can be coated, laminated, or otherwise with the barrier layer or film. In some implementations, the barrier layer can include or be one or more of an oxygen barrier, a moisture barrier, a grease barrier, a gas barrier, an oil barrier, and other barrier relevant to the content or material in the container. In some implementations, the oxygen barrier, the moisture barrier, the grease barrier, the gas barrier, the oil barrier, and the other barrier can be separate layers formed on the barrier layer. [0042] In implementations, the containers and/or the components of the containers can be of structure forming material and/or flexible material construction, which can be sustainable materials, recyclable materials, degradable materials, degradable plastic, biodegradable materials, bio-based resins, and/or weight-optimized biodegradable plastic. The containers and/or the components of the containers can efficiently use recyclable, biodegradable, and the like materials for improved sustainability. [0043] The containers and components thereof described herein provide structural integrity to the package at minimal weight cost and permits the container to flex, stretch, and the like during pressure and temperature variations. The containers and components thereof are stackable and nestable during shipping. In implementations, the containers can efficiently use recyclable, biodegradable, and the like materials for improved sustainability. [0044] FIG.1 is a perspective view of a container 1000 in accordance with implementations, FIG.2 is a top view of the container 1000 of FIG.1 in accordance with implementations, and FIG. 3 is a cross-sectional view of the container 1000 of FIG.1 in accordance with implementations. Attorney Docket No. JABI-212-A-WO [0045] The container 1000 includes a structure such as a frame 1100 and a flexible part such as a film 1200. The frame 1100 can be formed from structure forming materials using structure forming processes as described herein. The film 1200 can be made from flexible forming materials as described herein. In implementations, the frame 1100 and the film 1200 can have a barrier layer on an internal surface or content facing surface 1110 and 1210, respectively, as described herein. In implementations, the frame 1100 and the film 1200 can have an integrated barrier layer as described herein. The frame 1100 and the film 1200 can be fused using join processing as described herein. The fusing of the film 1200 with the frame 1100 results in edge(s) of the film 1200 being intermingled, impregnated, encapsulated, embedded, or coated with the material of the frame 1100 to form sealed edges 1300 at junctions between the frame 1100 and the film 1200. The sealed edges 1300 prevent leakage of content from the container. [0046] Referring now also to FIG.4, the frame 1100 includes a base 1120, a collar 1130, and legs 1140 for connecting the base 1120 and the collar 1130. In implementations, the base 1120, the collar 1130, and the legs 1140 can be a unitary component or fused together using join processing as described herein. The base 1120 can include an extended portion 1122 for fusing with the film 1200 as described herein. The collar 1130 can include an extended portion 1132 for fusing with a lid as described herein. [0047] Referring now also to FIG.5, a die line 2000 of films 2100 is shown in accordance with implementations. FIG. 6 shows a zoomed in view of a film 2100 in accordance with implementations. The film 2100 can include a base 2110 connected to a pair of wing portions 2120 and 2130. [0048] Referring now also to FIG.7, after the container 1000 is filled with content (not shown), a lid 3000 can fused to the collar 1130 of the container 1000 using join processing as described herein. In implementations, the fusing of the lid 3000 with the collar 1130 of the container 1000 results in edge(s) of the lid 3000 being intermingled, impregnated, encapsulated, embedded, or coated with the material of the collar 1130 to form a sealed edge 3100 at junction between the lid 3000 and the collar 1130. The sealed edge 3100 prevents leakage of content from the container. [0049] FIG.8 is a diagram of molding equipment 4000 for making the container of FIG.1 in accordance with implementations. In implementations, the molding equipment 4000 can include a cavity side or portion 4100 and a clamping side or portion 4200. A film 4300, such as the film 1100 or 2100, can be placed between the cavity side 4100 and the clamping side 4200. The cavity side Attorney Docket No. JABI-212-A-WO 4100 and the clamping side 4200 are pressed together such that the film 4300 is situated in the cavity side 4100. The structure forming materials for forming the frame 1100 are injected and fuse with the film 4300 as described herein to form the container. In implementations, the molding equipment 4000 can be an in-mold labeling machine. [0050] In implementations, the die line 2000 of films 2100 can be separated into single films and placed into the molding equipment 4000. [0051] In implementations, the molding equipment 4000 can be an array of molding units, each unit having a cavity side 4100 and a clamping side 4200. The die line 2000 of films 2100 can be placed into the array of molding units. The structure forming materials for forming the frame 1100 can be injected such that multiple containers can be formed substantially at the same time. [0052] FIG. 9 is a top view of a diagram of a cavity plate 9000 of molding equipment for making the container of FIG.1 in accordance with implementations. FIG.9A is a bottom view of a diagram of the cavity plate 9000 of FIG.9 in accordance with implementations. The cavity plate 9000 may include cavities 9100, stand-offs 9200, and injection holes 9300. Each stand-off 9200 may include location pins or holes or fiduciary markers 9210 to assist in placement of the film as described herein. The stand-offs 9200 allow the film to have room to rotate into the cavity as described herein. The stand-offs 9200 also assist to keep loose ends of the web up and out of the cavity. Each cavity 9100 has a graduated or gradual lead-in region 9110 to assist placement of the film into the cavity. [0053] FIG. 10 is a perspective view of a diagram of a clamp plate 10000 of molding equipment for making the container of FIG. 1 in accordance with implementations. The clamp plate 10000 maintains tension on the die line and/or films after placement on the cavity plate 9000 and as the cores punch through the die line. As illustrated, the clamp plate 10000 is dimensioned with apertures 10100 that align with the cavity plate 9000. [0054] FIG. 11 is a top view of a diagram of a core plate 11000 of molding equipment for making the container of FIG.1 in accordance with implementations. FIG.11A is a bottom view of a diagram of the core plate 11000 of FIG.11 in accordance with implementations. The core plate 11000 has a lower core portion 11100 for placement in a cavity of the cavity plate 9000 and an upper core portion 11200 substantially a width of the clamp plate 10000. A juncture between the lower core portion 11100 and the upper core portion 11200 is a sealing edge 11300 which forms the collar 1130 and the extended portion 1132 as shown in FIG.4, for example. As illustrated, the Attorney Docket No. JABI-212-A-WO core plate 11000 is dimensioned to align with the cavity plate 9000 and the clamp plate 10000. [0055] FIG.12 is a perspective view of a diagram of an assembled molding equipment 12000 using the cavity plate 9000 of FIG.9, the clamp plate 10000 of FIG.10, and the core plate 11000 of FIG.11 in accordance with implementations. [0056] FIG.13 is a die line 13000 diagram of films 13100 and location holes 13200 used with molding equipment shown in FIGS. 9-120 to form containers as shown in FIG. 1 in accordance with implementations. FIG. 14 is a zoomed in view of the film 13100 of FIG. 13 in accordance with implementations. Each film 13100 may include a base 13110 connected to a pair of wing portions 13120 and 13130. Each film 13100 may include connecting web portions or perforated line portions 13140 between the base 13110 and the wing portions 13120 and 13130. Each of the wing portions 13120 and 13130 may include connecting web portions or perforated line portions 13150 proximate to placement of the location holes 13200. FIG.14A is a diagram of a film 14000 with a scalloped texture14100 to increase top load capacity in accordance with implementations. [0057] FIG. 15 is a view of the die line 13000 on the cavity plate 9000 in accordance with implementations. FIG.15A and 15 B are views of the die line 13000 on the cavity plate 9000, the clamp plate 10000 on the die line 13000, and the core plate 11000 on the clamp plate 10000 in accordance with implementations. The stand-offs 9200 assist in providing sufficient space for the film 13100 to fold into the cavity. The connecting web portions or perforated line portions 13140 and 13150 enable the film 13100 to break and fold into the cavity. The clamp plate 10000 and the core plate 11000 are positioned, respectively, onto the die line 13000 on the cavity plate 9000. Vacuum is applied to assist in positioning the film 13100 in the cavity. Material is injected in to form the frame and fused with the film to form the container as described herein. [0058] FIG. 16 is a cross-section view of the assembled molding equipment of FIG. 12 in accordance with implementations. FIG.16A and 16B are cross-sectional views of the assembled molding equipment of FIG.12 in accordance with implementations. [0059] FIG. 17 is a zoomed view of the cross-section view of the assembled molding equipment of FIG.12 which shows a sealing edge 17000. [0060] The construction and arrangement of the methods as shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use Attorney Docket No. JABI-212-A-WO of materials and components, colors, orientations, etc.). For example, the position of elements may be reversed or otherwise varied and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the exemplary embodiments without departing from the scope of the present disclosure. [0061] Although the figures may show a specific order of method steps, the order of the steps may differ from what is depicted. Also two or more steps may be performed concurrently or with partial concurrence. Such variation will depend on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure. Likewise, software implementations could be accomplished with standard programming techniques with rule-based logic and other logic to accomplish the various connection steps, processing steps, comparison steps, and decision steps. [0062] While the disclosure has been described in connection with certain embodiments, it is to be understood that the disclosure is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.

Claims

Attorney Docket No. JABI-212-A-WO What is claimed is: 1. A method for manufacturing a container, the method comprising: positioning a die line on a cavity plate, wherein the cavity plate has multiple cavity sections, the die line has multiple film sections, and a film section is positionally aligned with a cavity section; placing a clamp plate on the die line positioned on the cavity plate to maintain a tension on the die line, wherein the clamp plate has multiple openings and an opening is aligned with the cavity section; placing a core plate on the clamp plate, wherein the core plate has multiple core portions and a core portion is aligned with the cavity section to punch the film section into a cavity in the cavity section on the cavity plate; and injecting a structure forming material into an assembled cavity plate, clamp plate, and core plate to form multiple frames, wherein each frame fuses with a corresponding film section to form the container. 2. The method according to claim 1, wherein the positioning positions the film section on a stand-off in the cavity section. 3. The method according to claim 1, wherein the injecting is via injection holes in the cavity plate. 4. The method according to claim 1, wherein the positioning aligns the die line using fiducial markers on the cavity plate. 5. The method according to claim 1, wherein each cavity includes a graduated lead-in region to assist placement of the film section into the cavity. 6. The method according to claim 1, wherein a core portion has a lower core portion substantially fitting with the cavity and an upper core portion with a larger diameter to be a sealing edge which forms at least a collar of the container. Attorney Docket No. JABI-212-A-WO 7. The method according to claim 1, wherein each film section includes a base connected to a pair of wing portions. 8. The method according to claim 7, wherein each film section includes web portions between the base and the pair of wing portions. 9. The method according to claim 8, wherein the pair of wing portions includes web portions proximate to fiduciary markers on the cavity plate. 10. The method according to claim 7, wherein each film section includes perforated lines between the base and the pair of wing portions. 11. The method according to claim 10, wherein the pair of wing portions includes perforated lines proximate to fiduciary markers on the cavity plate. 12. The method according to claim 7, wherein each film section has a scalloped texture to increase top load capacity. 13. The method according to claim 1, further comprising: applying a vacuum to pull each film section into the cavity. 14. A device for manufacturing a container according to any one of claims 1-13.

FIG. 1 1200 1000 2/24

1200

FIG. 2 1000 3/24

1300 FIG. 3 4/24

FIG. 4 5/24

2000

FIG. 5 6/24

2100

FIG. 6 7/24

1000

FIG. 7 8/24

4200

FIG. 8 4100

FIG. 10

11000

FIG. 12

FIG. 13

FIG. 15B

FIG. 16

FIG. 16A

FIG. 16B