Product package having multi-layer labeling cover assembly

[0001] The invention relates to vacuum sealed packaging using film layers of differing gas permeabilities to control the internal gas composition of the package. The invention includes both a new product package and a new packaging method. This invention is applicable in all packaging situations, but is most applicable to packaging perishable items, such as meat.

[0002] Vacuum sealed packaging is known in the industry as a superior method for preserving items during shipping and display. Vacuum sealed packaging allows a supplier to control the internal gas composition of the package and stabilize the item during shipping. These advantages protect and preserve an item, increasing the items' shelf life and eye-appeal to consumers.

[0003] There are various forms of vacuum sealed packaging, and vacuum sealing is particularly popular for packaging perishable items. Previous packages used a rigid, preformed base for holding meat, fish or produce, with a plastic layer closing the top of the container base. While the layer was heat sealed onto the container, gas could be evacuated from the container around the perishable item. In some instances, the evacuated gas would be replaced with a more preferable inert gas, for example Nitrogen, which helped preserve the perishable item.

[0004] For some items, packagers needed a preservative gas in the packaging during shipment and a different gas when the package was on display. For example, when packaging red meat, the presence of oxygen during shipping would spoil the meat, but the absence of oxygen during presentation would make the meat appear blue and unappetizing to consumers. The oxygen content of the packaging had to be manipulated to provide both a long shelf life and a consumer preferred presentation. The answer to this oxygen dilemma was a dual-layer laminate with differing gas permeabilities.

[0005] The dual-layer laminate had a gas impermeable top layer that prevented oxygen from entering the packaging during shipment. Once the vacuum sealed meat reached the retailer, the top layer was peeled off to expose the gas permeable bottom layer. This bottom layer allowed air to pass through, thereby exposing the meat to oxygen and turning the meat red.

[0006] While the dual film layer laminate is a definite advantage and improvement over previous perishable item containers, it has a significant drawback for retailers. Labels for the item are placed on the packages' top layers when they leave the supplier's packaging plant. When the retailer removes the top layer to expose the meat to oxygen, the label is also removed. The packages must be re-labeled before they can be set out for consumers. Re-labeling requires extra expense and extra time on the part of the retailer.

[0007] FIG. 1 is a perspective view of a product package according to the present invention;

[0008] FIG. 2 is an exploded, perspective view of the product package of FIG. 1 with a cover assembly exploded from a container base;

[0009] FIG. 3 is a top view of an alternative product package according to the present invention and utilizing a labeling laminate cover;

[0010] FIG. 4 is a cross-sectional view of the product package of FIG. 3 taken along line 4-4;

[0011] FIG. 5 is a fragmentary, cross-sectional view of the product package of FIG. 3 taken along line 5-5; and

[0012] FIG. 6 is a fragmentary, exploded, cross-sectional view of the laminate of FIG. 3.

[0013] There is, therefore, provided in the practice of the invention a novel labeling cover assembly, which reduces re-labeling by retailers while protecting a packaged product from decay and other damage. The cover assembly includes a bottom film layer and a top film layer positioned over the bottom film layer. A label is positioned between the top and bottom film layers.

[0014] In one embodiment, the bottom film layer is gas permeable, and the top film layer is gas impermeable. Thus, the packaged item is protected during shipment from decay by the top film layer, but during display and after removal of the top film layer, the label is exposed to the consumer. Further, the packaged item is exposed to desirable gases transmitted through the bottom layer to enhance the packaged item's color for display. To further protect the packaged item during shipment by removing any oxygen left after packaging, an oxygen absorber is adhered to the inner side of the top layer and rests on the display layer.

[0015] The labeling cover assembly is used to complete a package according to the present invention. The cover assembly is used to cover and close the open top of a container base containing a packaged item.

[0016] In one embodiment, the container base is made from an insulated material, and the top layer extends beyond the perimeter of the container base, so that the top layer can be easily peeled from the display layer, label, and container.

[0017] The labeling cover assembly according to the present invention is also used in methods for packaging and displaying items. The method includes introduction of a packaged item into the container base, closing the container base with the bottom film layer, positioning a label on the display layer, and placing the protective top film layer over the label and display layer.

[0018] In one embodiment, an oxygen absorber is positioned between the bottom layer and the top layer. For display, the protective layer and oxygen absorber are removed from the package.

[0019] In an alternate embodiment, the container base is closed with a tri-layer laminate, which includes the bottom film layer, label positioned on the bottom film layer, and a top film layer covering the label and bottom film layer. In the method of assembly, the constructed laminate is then used to close the container base.

[0020] In another embodiment, the tri-layer laminate or the cover assembly is closed over an item placed on a plastic substrate. Again, the tri-layer laminate includes the bottom film layer, a label positioned on the bottom film layer, and a top film layer covering the label and bottom film layer. In the method of assembly, the tri-layer laminate is used to cover and enclose a packaged item positioned on the plastic substrate.

[0021] Accordingly, it is as an object of the present invention to provide an improved cover assembly for packaging items.

[0022] It is a further object of the present invention to provide an improved laminate for packaging items.

[0023] It is still a further object of the present invention to provide improved methods for packaging and displaying items.

[0024] Referring to the drawings in greater detail, FIGS. 1 and 2 illustrate a product package 10 assembled according to an embodiment of the present invention. The product package 10 includes a container base 20 and a labeling cover assembly 26. The cover assembly is attached to the base 20 to seal and protect a perishable item 36 in the package.

[0025] The container base 20 is generally rigid and is made from insulating materials, including Styrofoam, Polyethylene, PVC and other formable materials. The container base is generally rigid in that it substantially holds its shape under the application of minimal external forces. In another embodiment, the container base is flexible. The container base 20 has a rectangular shape with a generally flat bottom 11 (FIG. 2), a plurality of sidewalls 13, four sidewalls in one embodiment, extending up from the bottom, and a top perimeter lip 18 extending outwardly from the upper perimeter of the four sidewalls 13. The four sidewalls 13 extend up from the bottom of the container base 20 at a slight outward angle. The container lip 18 has a depressed outer ridge 16 formed by dropping down the outermost portion of the container lip 18. The corners of the container lip 18 are rounded and the interior of the container base 20 is hollow for receiving the packaged item 36.

[0026] In one embodiment, as shown in FIG. 2, the cover assembly 26 is comprised of a bottom display layer 34, a label 32, an oxygen absorber 30, and a top protective layer 28. The bottom display layer 34 is a transparent, gas permeable film layer. The display layer is flexible in that it easily deforms under the application of minimal external forces, and it is gas permeable in that it permits the transmission of oxygen. The label 32, which is adhered to an outer side of the top layer, can include marketing and scale information about the perishable item 36 and can include freshness and pricing details if desired. In one embodiment, the oxygen absorber 30 or oxygen scavenger is adhered to an inner side of the protective layer 28. The oxygen absorber 30 is a small packet enclosing a material that absorbs oxygen. The protective layer 28 is a transparent, gas impermeable film layer. The protective layer is flexible and is gas impermeable in that it inhibits the transmission of oxygen and microbes. In one embodiment, the protective layer substantially prohibits the transmission of oxygen, and if desired, the protective layer is opaque.

[0027] The cover assembly 26 is constructed, as shown in FIG. 2, by placing the display layer 34 on the container lip 18. The label 32 is placed onto the display layer 34 and the oxygen absorber 30 is spaced from the label 32 on the display layer 34. The top protective layer 28 is positioned over the oxygen absorber 30, the label 32, and the display layer 34. When the top protective layer 28 is positioned over the label and oxygen absorber, it may or may not contact the display layer 34.

[0028] The display layer can be attached to the container lip, the interior face of the sidewalls 13, or both. The display layer is made of a shrink material that reduces in size when heated and attached to the container base 20. In one embodiment, the display layer shrinks so that it does not extend to the edge of the container lip 18. The shrinking process also pulls the display layer taut over the top of the container base 20. The top layer can be attached to the container either on top of the display layer on the container lip 18 or attached directly to the container lip, without contacting the display layer. In one embodiment, the top layer 28 extends beyond the container lip over at least part of its perimeter. In another embodiment, the top layer 28 extends beyond the container lip 18 around its entire top layer perimeter. The bottom layer is heat sealed onto the container's lip 18, and the protective layer 28 is attached at the perimeter lip 18 with an adhesive strong enough to keep the protective layer 28 on the package during shipping but weak enough to allow the protective layer 28 to be peeled off the package 10 without removing the display layer 34 or the label 32. In one embodiment, the display layer and the top layer have space between them that is filled with gas which is atmospheric gas or air in one embodiment. In another embodiment, the gas is an inert preservative gas. The label is attached to the bottom layer, so that it stays attached to the bottom layer when the top layer is removed. In one embodiment, the label is attached with an adhesive. Because the oxygen absorber is adhered to the protective layer 28, the oxygen absorber 30 will be automatically discarded when the protective layer 28 is removed.

[0029] To complete a package 10, the perishable item 36 is placed inside the container base 20, and the bottom layer 34 is heat sealed to the lip 18. The container is then weighed, and the label is printed. The printed label 32 is then attached to the bottom layer 34, and the top layer, which is slightly longer and wider than the lip 18 is attached to the bottom layer at least at the container's lip 18. Thus, the container base 20 is closed with the cover assembly 26, so that the top layer extends slightly beyond the container lip 18 perimeter on all four sides. If desired air is removed from the container base 20 as the display layer is heat sealed, and in one embodiment, a preserving gas or a refrigerant gas is introduced into the base 20. The oxygen absorber removes any oxygen remaining in the package after the protective layer is adhered to the display layer. Thus, the oxygen absorber provides extra protection from decay for perishable items such as meat including beef and poultry.

[0030] The container base 20 and the cover assembly 26 are used in a packaging and display method. A perishable item 36, beef in one embodiment, is introduced into a container base 20. The cover assembly 26 is heat sealed onto the container lip 18 while the air around the perishable item 36 inside the container base 20 is evacuated. The container base 20 is back-filled with an inert gas, preferably Nitrogen, as a preservative. The cover assembly is heat sealed to the container lip 18 around the entire perimeter of the container base 20. In the absence of 02 the beef turns blue.

[0031] After the product package 10 is shipped to its intended destination, it is prepared for display. The top protective layer 28 of the cover assembly 26 is removed by peeling from the rest of the cover assembly 26, namely the label 32 and the bottom display layer 34. The oxygen absorber 30 is discarded. The removal of the gas impermeable protective layer 28 and the oxygen absorber 30 allows oxygen to reach the display layer 34. The display layer 34 permits the newly present oxygen to pass through and enter the space in the container base 20. The oxygen infuses into the beef, causing the meat tissue to take up the oxygen and change from a bluish color to a more consumer-friendly red color.

[0032] When the consumer purchases the packaged meat, and wishes to take the meat out of the package, the remaining portion of the cover assembly 26 is removed by removing the display layer 34 from the container base 20. The bottom display layer 34 and the label 32 are removed when the consumer peels off the bottom display layer 34. Thus, the present invention places the label, either a marketing label or a scale label, between the display and protective layers during packaging. The label contains information including weight, price, advertising, promotions, and freshness dates. If desired, other information is added to the label. This innovation eliminates the need for a re-labeling step when the retailer removes the protective layer before displaying the product.

[0033] An alternative product package 12 including a substrate layer 38 and a laminate 40 as illustrated in FIGS. 3 and 4. The substrate layer 38 can be made from any type of plastic. The laminate as shown in FIG. 6 comprises a bottom, gas permeable film layer 46, a middle label layer 44, and a top, gas impermeable film layer 42. As in the cover assembly, the label layer 44 is adhered to the bottom film layer 46. The perimeter of the top film layer 42 is adhered over the label layer 44 to the bottom film layer 46. The top film layer 42 is adhered strong enough to remain on the bottom film layer 46 during shipping, but weak enough that it can be removed by peeling from the bottom layer 46. In one embodiment, the oxygen absorber 30 (FIG. 5) is also positioned between the top and bottom layers, and the absorber 30 is adhered to the top layer 46.

[0034] A method for creating product package 12 includes forming a substrate layer 38 and a laminate 40. The item 36 is placed in the middle of a rectangular piece of the substrate layer 38. A piece of laminate 40, slightly larger than the substrate layer 38 piece, is draped over the item 36 and the substrate layer 38. The edges of the substrate layer 38 and the laminate 40 are heat sealed together on all four sides, as the air around the item 36 is evacuated.

[0035] Once the product package 12 is shipped to its intended destination, the top, gas impermeable layer is peeled off the product package 12, leaving the middle label layer and the bottom gas permeable layer remaining on the product package 12. If desired, the laminate is used to form a bag, which is vacuum heat sealed along its open side with product inside. Further, the laminate 40 is used with the container base 20 if desired. When forming the laminate, the packaged items are weighed and the labels printed. The printed labels are then formed into the laminate. The printed labels are then applied to the corresponding item.

[0036] Thus, a product package is disclosed which utilizes a multi-layer labeling cover assembly to vacuum seal packages with a label that does not have to be replaced for display purposes. While preferred embodiments and particular applications of this invention have been shown and described, it is apparent to those skilled in the art that many other modifications and applications of this invention are possible without departing from the inventive concepts herein. It is, therefore, to be understood that, within the scope of the appended claims, this invention may be practiced otherwise than as specifically described, and the invention is not to be restricted except in the spirit of the appended claims. Though some of the features of the invention may be claimed in dependency, each feature has merit if used independently.