FIBER-BASED MOISTURE RESISTANT PACKAGING ARTICLE AND METHOD OF MANUFACTURE

1 . A method for making a food packaging article comprising the steps of:

a. providing a compressed fiber web of unwoven fiber material, the compressed fiber web having a first surface and a second surface;

b. applying an upper film to the first surface of the compressed fiber web, the upper film being a multi-layer film;

c. applying a lower film to the second surface of the compressed fiber web;

d. thermoforming the compressed fiber web, upper film and lower film into a three-dimensional thermoformed food packaging article;

wherein the total film content of the thermoformed food packaging article is less than 15 wt % as compared to the total weight of thermoformed food packaging article.

2 . The method of claim 1 wherein the upper film comprises at least one layer comprising a barrier polymer.

3 . The method of claim 2 wherein the barrier polymer is chosen from ethylene-vinyl alcohol copolymer or polyvinyl alcohol copolymer.

4 . The method of claim 1 wherein at least one of the steps of applying an upper film to the first surface of the compressed fiber web or applying a lower film to the second surface of the compressed fiber web includes passing the compressed fiber web along with one of, or both of the upper film and the lower film through a pair of heated nip rollers.

5 . The method of claim 4 wherein the heated nip rollers are at a temperature of at least any of 40° C., 50° C., 60° C. or 80° C.

6 . The method of claim 1 wherein the lower film is a monolayer film.

7 . The method of claim 1 wherein the compressed fiber web is formed by providing an airlaid web of unwoven fiber and compressing the airlaid web into the compressed fiber web.

8 . The method of claim 1 further comprising the step of placing a food product in the thermoformed food packaging article.

9 . The method of claim 8 further comprising the steps of overwrapping the thermoformed food packaging article and food product with a polymeric film and shrinking the polymeric film.

10 . The method of claim 1 wherein the total thickness of the upper film and the lower film is less than any of 60 microns, 55 microns, 50 microns, 45 microns or 40 microns and the compressed fiber core has a basis weight of between any of the following ranges, 300 to 1100 grams per square meter (gsm), 350 to 900 gsm, 400 to 700 gsm, 450 to 600 gsm measured in accordance with ASTM D-3776 with the sample size being adjusted to a 7 cm by 7 cm square.

11 . The method of claim 1 wherein the thermoformed food packaging article is a tray comprising a base and at least one sidewall extending upward from the base to an upper periphery of the tray.

12 . A three-dimensional thermoformed food packaging article comprising:

a. an upper film portion;

b. a lower film portion; and

c. a compressed fiber core disposed between the upper film portion and the lower film portion;

wherein the upper film portion is a multi-layer film,

wherein the total film content of the thermoformed food packaging article is less than 15 wt % as compared to the total weight of thermoformed food packaging article.

13 . The three-dimensional thermoformed food packaging article of claim 12 wherein the total film content of the thermoformed food packaging article is less than 10 wt % as compared to the total weight of thermoformed food packaging article

14 . The three-dimensional thermoformed food packaging article of claim 12 wherein the thermoformed food packaging article is a tray comprising a base and at least one sidewall extending upward from the base to an upper periphery of the tray.

15 . The three-dimensional thermoformed food packaging article of claim 12 wherein the upper film portion is a multi-layer film comprising at least three layers:

a. a food contact layer;

b. a barrier layer comprising at least one barrier polymer; and

c. a sealant layer bonded to the dry laid compressed fiber core.

16 . The three-dimensional thermoformed food packaging article of claim 15 wherein the upper film portion further comprises a first tie layer situated between the food contact layer and the barrier layer and a second tie layer situated between the barrier layer and the sealant layer.

17 . The three-dimensional thermoformed food packaging article of claim 15 wherein the barrier polymer of the barrier layer is chosen from an ethylene-vinyl alcohol copolymer or a polyvinyl alcohol copolymer.

18 . The three-dimensional thermoformed food packaging article of claim 12 wherein the lower film portion is a monolayer polymeric film and the compressed fiber core has a basis weight of between any of the following ranges, 300 to 1100 grams per square meter (gsm), 350 to 900 gsm, 400 to 700 gsm, 450 to 600 gsm measured in accordance with ASTM D-3776 with the sample size being adjusted to a 7 cm by 7 cm square.

19 . The three-dimensional thermoformed food packaging article of claim 12 wherein the compressed fiber core further comprises up to 15 wt % of a moisture resistant binder selected sol-gel, natural wax (aqueous or 100% solid), polymer latex, hot melt adhesive coatings, starch-wax emulsions, and blends thereof.

20 . A food packaging article comprising:

a. a tray comprising a base and at least one sidewall extending upward from the base to an upper periphery of the tray, the tray comprising:

i. an upper film portion being a multi-layer film;

ii. a lower film portion; and

iii. a compressed fiber core disposed between the upper film portion and the lower film portion;

b. a food product situated on the upper film portion;

c. a polymeric film situated over the food product and in contact with the upper periphery of the tray, sealing the food product within;

wherein the total film content of the tray is less than 15 wt % as compared to the total weight of tray.