EP3848298A1

EP3848298A1 - Paper-based or paperboard-based container and related method

Info

Publication number: EP3848298A1
Application number: EP20151241.5A
Authority: EP
Inventors: Gerd Unni Kvam; Martin Kurt WIESER
Original assignee: Elopak AS
Current assignee: Elopak Asa
Priority date: 2020-01-10
Filing date: 2020-01-10
Publication date: 2021-07-14
Also published as: NO20200803A1; CA3163924A1; MA57425B1; MA57425A1

Abstract

A paper-based or paperboard-based container (100) for holding a pourable food product is described, the container comprising: a substantially planar bottom portion; a top portion arranged opposite the bottom portion and comprising a top panel and a top sealing region (126) forming a top seal of the container; and a wall portion extending between the bottom portion and the top portion and comprising a plurality of wall sections (108b, 108c) bordering the top panel and a longitudinal sealing band (14) extending between the bottom portion and the top portion and over at least one of the wall sections, wherein the top sealing region is folded onto said at least one of the wall sections comprising the longitudinal sealing band (14) and being attached thereto. A blank and a sleeve for producing the container is also described, as is a method for producing the container.

Description

Field of the invention

The present invention relates to a paper-based or paperboard-based container and a method for producing such a container.

Background

Within the art of paperboard-based packaging, it is known to produce a blank and fold and assemble the blank to produce a container. The container may then be utilised to hold a pourable food product, e.g. a liquid, e.g. dairy products, such as milk or yoghurt, or juices.
The blank is typically produced from a laminate packaging material, which typically comprises a multi-ply paperboard sheet on which is laminated one or a plurality of barrier layers for holding the food product and/or prevent migration of air and flavours through the paperboard. A barrier layer may typically comprise a polyethylene or an aluminium layer.
A method of producing the blank from the laminate packaging material typically comprises the steps of cutting the laminate packaging material to a predefined shape, and a method of producing the container from the blank typically comprises the step of folding the blank along predefined folding lines to produce the container.
The blank may be provided with crease lines in the laminate packaging material to aid folding of the blank along the folding lines. A crease line, or crease, may be defined as an embossed or impressed depression on one side of the laminate packaging material with a corresponding raised ridge or welt, also referred to as the bead, on the other side forming a line along which the laminate packaging material is structurally weakened and along which the laminate packaging material will bend or fold when pressure is applied.
The container may be provided with a closure allowing a consumer to open the container to access the food product
Within the art of paperboard-based containers, there is known to provide an extended top panel area of the container by folding down a top-fin onto the top panel at an off-centre position. The extended top panel area thus obtained can be used to provide the container with an enlarged closure. Such containers are known, for example, from EP2392517A1 and US20190106239A1 . Although positioned of-centre, the folded-down top-fin extending across the top panel will still restrict usage of the top panel.
US6182887B1 shows a container having an extended top panel produced by sealing the top panel and a rear wall of the container to one another at a sealing region that is coextensive with a top fin. Consequently, the top fin extends from the top panel in the plane of the rear wall, thus making essentially the whole top panel available for usage, e.g. positioning of a closure. However, the extending top-fin may still restrict access to the top panel. For example, a top-fin extending from the top panel in the plane of the rear wall may make it difficult for a consumer to drink directly from the container.

Summary of the invention

With the abovementioned challenges and known solutions in mind, and according to a first example aspect, the present disclosure provides a paper-based or paperboard-based container for holding a pourable food product, comprising:

a planar or substantially planar bottom portion;
a top portion arranged opposite the bottom portion and comprising a top panel and a top sealing region forming a top seal of the container; and
a wall portion extending between the bottom portion and the top portion and comprising a plurality of wall sections bordering the top panel and a longitudinal sealing band extending between the bottom portion and the top portion over at least one of the wall sections,

Consequently, instead of the top-fin being folded onto and attached to the top panel of the container, as is common in prior art containers, the top-fin, or top sealing region, is folded onto the wall portion comprising the longitudinal sealing band, i.e. the longitudinal seam running from the bottom to the top of the container. This leaves the top panel substantially free from sealing structures since the section of the longitudinal sealing band extending into the top sealing region will also be folded onto the wall portion and, consequently, will not extend onto the top panel. Such sealing structures may comprise permanently sealing structures such as welded, glued or otherwise permanently joined seams where panels of the laminate sheet material are permanently joined to each other. This allows the top panel to be utilised in an efficient manner. For example, a top closure can be positioned anywhere on the top panel since there will be no sealing structure to consider. Also, folding the top sealing region down onto the side wall portion comprising the longitudinal sealing band and attaching the sealing region thereto will give a consumer unrestricted access to the closure for accessing or dispensing the food product in an easy manner.
The top sealing region may be planar or substantially planar and arranged parallel or substantially parallel to said at least one of the wall sections comprising the longitudinal sealing band.
The top panel and the top sealing region may share a common border forming a top edge of the container.
The top edge may be rectilinear or substantially rectilinear and arranged parallel or substantially parallel to the bottom portion.
A closure may be arranged in the top panel for dispensing and/or accessing the food product. The closure, in contrast to the above-mentioned sealing structures, including the top sealing region and the longitudinal sealing band, is not arranged to permanently seal the container but may be opened by a consumer to allow the consumer to dispense or access the food product.
The closure may comprise an opening being arranged adjacent said top edge.
The opening may be arranged at an orthogonal distance of between 1 mm to 10 mm from the top edge.
The top panel may be planar or substantially planar. The wall section or wall sections comprising the longitudinal sealing band may also be planar or substantially planar and the top panel may form an angle to said wall section or wall sections that is of any one of: within the range of 10 degrees to 90 degrees; within the range of 30 degrees to 80 degrees, within the range of 45 degrees to 75 degrees; and 60 degrees.
The top sealing region may comprise a plurality of sealed sealing band panels, all of which may be arranged parallel or substantially parallel and/or coplanar or substantially coplanar in the container.
The sealing band panels may comprise a central sealing band panel extending over the wall section or the wall sections comprising the longitudinal sealing band and having a longitudinal extent being any one of: at least 15 mm, at least 20 mm and at least 30 mm.
According to a second example aspect, the present disclosure provides a paper-based or paperboard-based sleeve for producing the container according to the first example aspect.
According to a third example aspect, the present disclosure provides a paper-based or paperboard-based blank for producing the sleeve according to the second example aspect.
The blank may be mirror-symmetric about a longitudinal central axis of the blank.
The blank may comprise first and second rectilinear or substantially rectilinear and parallel or substantially parallel boundary edges forming lateral or longitudinal boundary edges of the blank. The blank may also a third rectilinear or substantially rectilinear boundary edge extending orthogonally or substantially orthogonally between the latera boundary edges and forming a bottom boundary edge of the blank. Further, the blank may comprise a fourth, non-rectilinear boundary edge extending between the lateral boundary edges and forming a top boundary edge of the blank.
The top boundary edge may be mirror-symmetric about a longitudinal central axis of the blank.
The top boundary edge may comprise a plurality of individually rectilinear top boundary edge sections.
According to a fourth example aspect, the present disclosure provides a method of producing a paper-based or paperboard-based container for holding a pourable food product comprising the steps of:

sealing a paper-based or paperboard-based laminate sheet material along a longitudinal sealing band forming a tubular proto-container;
bottom-sealing the laminate sheet material to form a bottom-sealed and open-top proto-container;
filling the bottom-sealed and open-top proto-container with the portable food product;
top-sealing the proto-container at a top sealing region; and
folding the top sealing region onto at least one wall section of the proto-container comprising said longitudinal sealing band and attaching the top sealing region to said at least one wall section.

The method may comprise a step of providing a top panel of the container free from sealing structures. Such sealing structures may comprise permanently sealing structures such as welded, glued or otherwise permanently joined seams where panels of the laminate sheet material are permanently joined to each other.
The method may comprise arranging the top sealing region planar or substantially planar and parallel or substantially parallel to said at least one of the wall sections comprising the longitudinal sealing band.
The method may comprise arranging the top panel and the top sealing region such that they share a common border forming a top edge of the container.
The method may comprise a step of arranging the top edge rectilinear or substantially rectilinear and the step of arranging the top edge parallel or substantially parallel to a planar or substantially planar bottom portion of the container.
The method may comprise a step of arranging a closure for dispensing or accessing the food product in the top panel of the container.
The method may comprise a step of arranging an opening of the closure adjacent said top edge forming a border between the top panel and the top sealing region.
The method may comprise a step of arranging the opening at an orthogonal distance of between 1 mm to 10 mm from the top edge.
The method may comprise a step of arranging the top panel planar or substantially planar. The method may also comprise a step of arranging the wall section or wall sections comprising the longitudinal sealing band planar or substantially planar, and a step of arranging the top panel at an angle to said wall section or wall sections that is of any one of: within the range of 10 degrees to 90 degrees; within the range of 30 degrees to 80 degrees, within the range of 45 degrees to 75 degrees; and 60 degrees.
The step of top-sealing the proto-container at the top sealing region may comprise a sub-step of sealing a plurality of sealing band panels to each other. This sub-step may comprise arranging the sealed sealing band panels parallel or substantially parallel and/or coplanar or substantially coplanar in the container. This sub-step may comprise arranging a central sealing band panel of said sealing band panels such that it extends over the wall section or the wall sections comprising the longitudinal sealing band and has a longitudinal extent being any one of: at least 15 mm, at least 20 mm and at least 30 mm.
Above-discussed preferred and/or optional features of each aspect of the invention may be used, alone or in appropriate combination, in the other aspects of the invention.

Description of the drawings

Following drawings are appended to facilitate the understanding of the invention:

Fig. 1 show an embodiment of a blank.
Figs. 2 and 3 show the blank according to Fig. 1 folded and sealed to form a sleeve.
Fig. 4 is a perspective view of the sleeve according to Figs. 2 and 3 after having been erected to tubular form.
Fig. 5 shows a bottom-view of the sleeve according to Fig. 4 after having been bottom-sealed.
Fig. 6 is a perspective view of the sleeve according to Fig. 4 after having been bottom-sealed.
Figs. 7 and 8 illustrate top-sealing of the sleeve according to Fig. 4.
Figs. 9 is a front view of a container produced from the blank according to Fig. 1.
Figs. 10 is a perspective view of the container produced from the blank according to Fig. 1.
Figs. 11 and 12 are side views of the container produced from the blank according to Fig. 1.
Fig. 13 is a front view of the container in an open position.
Figs. 14a and 14b illustrate the cross-section of the container.
Fig. 15 is an alternative embodiment of a blank.
Figs. 16 and 17 show the blank according to Fig. 15 folded and sealed to form a sleeve.
Figs. 18-21 are front, side and rear views of a container produced from the blank according to Fig. 15.

It should be understood that the drawings are not intended to limit the invention to the subject-matter depicted in the drawings.
In the drawings, like reference numerals have been used to indicate common parts, elements or features unless otherwise explicitly stated or implicitly understood by the context.

Detailed description

In the following, specific embodiments of a blank and a container produced therefrom will be described in more detail with reference to the drawings. However, it is specifically intended that the invention as defined in the following claims is not limited to the embodiments and illustrations contained herein but includes modified forms of the embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the claims.
Fig. 1 shows a first embodiment of a blank 10 for producing a sleeve and, subsequently, a container for holding a pourable food product.
The blank 10 can comprise several layers of different materials, for example paper, paperboard, plastic or metal, in particular aluminium. The blank 10 has several crease or fold lines which are intended to facilitate the folding of the blank 10 when produced to form a container and which divide the blank 10 into several regions and sub-regions.
The blank 10 comprises rectilinear or substantially rectilinear first 12 and second 14 boundary edges which are parallel or substantially parallel to a longitudinal direction L of the blank 10. The boundary edges 12 and 14 are parallel or substantially parallel, of equal or substantially equal length and form lateral boundary edges of the blank 10.
A central axis Ca of the blank 10 extends parallel to the longitudinal direction L equidistant from the lateral boundary edges 12 and 14.
The blank 10 also comprises a rectilinear or substantially rectilinear third boundary edge 16 which is parallel or substantially parallel to a transversal direction T of the blank 10 extending perpendicular to the longitudinal direction L. The boundary edge 16 extends between first, bottom endpoints 18, 20 of the lateral boundary edges 12, 14 and forms a bottom boundary edge of the blank 10.
The blank 10 further comprises a fourth boundary edge 22 extending between second, top endpoints 24, 26 of the lateral boundary edges 12, 14 and forming a top boundary edge of the blank 10.
The bottom endpoints 18 and 20 form bottom corner points of the blank 10 and the top endpoints 24 and 26 form top corner points. Since the lateral boundary edges 12 and 14 are parallel or substantially parallel, and since the bottom boundary edge 16 is perpendicular or substantially perpendicular to the lateral boundary edges 12, 14, the corner points 18, 20, 24, 26 define a rectangular or substantially rectangular shape. In contrast to the bottom boundary edge 16, however, the top boundary edge 22 is non-rectilinear and extend beyond the rectangular shape defined by the corner points 18, 20, 24, 26.
The top boundary edge 22 comprises a plurality of individually rectilinear or substantially rectilinear sections 22a-22i.
The top boundary edge sections 22a and 22i are colinear or substantially colinear and extend, starting from the top corner points 24 and 26, respectively, parallel or substantially parallel to the transversal direction T, i.e. parallel or substantially parallel to the bottom boundary edge 16. The edge sections 22a and 22i are of equal or substantially equal length. The edge sections 22b and 22h extend from edges sections 22a and 22i, respectively, and angle away from the bottom boundary edge 16. The edge sections 22b and 22h form an angle of approximately 45 degrees to the transversal direction T. The edge sections 22c and 22g extend from edges sections 22b and 22i, respectively, and form an angle of approximately 20 degrees to the transversal direction T. The edge sections 22d and 22f extend from edges sections 22c and 22g, respectively, and form an angle of approximately 45 degrees to the transversal direction T. The edge section 22e, finally, extends between edge sections 22d and 22f parallel or substantially parallel to the transversal direction T, i.e. parallel or substantially parallel to the bottom boundary edge 16. However, due to the inclined orientations of edge sections 22b-22d and 22f-22h, edge section 22e is arranged further from the bottom boundary edge 16 than are the edge sections 22a and 22i.
The top boundary edge 22 is reflection-symmetric about the central axis C_a. In other words, using the central axis C_a as an axis of symmetry, the sections of the top boundary edge 22 located on one side of the central axis Ca is mirrored by the corresponding sections located on the other side. Consequently, edge sections 22a, 22b, 22c and 22d are mirrored by edge sections 22i, 22h, 22g and 22f, respectively, and the central axis Ca run centrally through the edge section 22e.
The blank 10 comprises first 28 and second 30 crease lines, each extending across the blank 10, i.e. between the lateral boundary edges 12, 14. The crease lines 28 and 30 divide the blank 10 into:

a bottom region 32 having a bottom crease line pattern and being configured to form a bottom portion of the container formed from the blank 10;
a top region 34 having a top crease line pattern and being configured to form a top portion of the container; and
an intermediate region 36 contained between said first 28 and second 30 crease lines, interposed between the bottom region 32 and the top region 34 and being configured to form an intermediate, wall portion of the container.

The crease line 28 is rectilinear or substantially rectilinear and extends parallel or substantially parallel to the transversal direction T across the panel 10.
Partitioned from the intermediate region 36 by crease line 28, the bottom region 32 comprises a plurality of rectangular or substantially rectangular bottom panels 40a, 40f and 40k and a plurality of triangular or substantially triangular gusset panels 40b-40e and 40g-40j. The gusset panels 40b-40e and 40g-40j are arranged in two rectangular or substantially rectangular sub-regions arranged in file with the bottom panels 40a, 40f and 40k. When a container is produced from the blank 10, the bottom and gusset panels 40a-40k are configured to be folded to form a substantially planar bottom of the container in a manner which is, as such, known in the art.
The bottom region 32 also comprises a plurality of rectangular or substantially rectangular bottom sealing band panels 38a-38g extending between the lateral boundary edges 12, 14. The sealing band panels 38a-38g are partitioned, in the transversal direction T, by longitudinal or substantially longitudinal crease lines. The sealing band panels 38a-38g form a bottom sealing band 38 that extends along the bottom boundary edge 16 and is partitioned from the bottom and gusset panels 40a-40k by a rectilinear or substantially rectilinear crease line 42 extending across the blank 10 parallel or substantially parallel to the transversal direction T. When a container is produced from the blank 10, the sealing band panels 38a-38g are configured to be sealed to each other to form a bottom seal of the container in a manner which is, as such, known in the art.
Turning now to the top region 34 of the blank 10, the crease line 30 comprises a plurality of crease line sections 30a-30e, of which crease line sections 30a, 30b, 20d and 30e are individually rectilinear or substantially rectilinear and crease line section 30c is curvilinear. The crease line sections 30a and 30e are colinear or substantially colinear and extend, starting from lateral boundary edges 12 and 14, respectively, parallel or substantially parallel to the transversal direction T, i.e. parallel or substantially parallel to the edge sections 22a and 22i. The crease line sections 30a and 30e are of equal or substantially equal length. The crease line sections 30b and 30d extend from crease line sections 30a and 30e, respectively, and angle towards the bottom boundary edge 16. The crease line sections 30b and 30d form an angle of approximately 30 degrees to the transversal direction T. Crease line sections 30b and 30d are of equal or substantially equal length. Finally, crease line section 30c extends between crease line sections 30b and 30d and has a convex side facing the intermediate region 36.
As the top boundary edge 22, the crease line 30 is reflection-symmetric about the central axis Ca. In other words, using the central axis Ca as an axis of symmetry, the sections of the crease line 30 located on one side of the central axis Ca is mirrored by the corresponding sections located on the other side. Consequently, crease line sections 30a and 30b are mirrored by crease line sections 30e and 30d, respectively, and the central axis C_a run centrally through the crease line section 30c.
Partitioned from the intermediate region 36 by crease line 30, the top region 34 comprises triangular or substantially triangular gusset panels 44a and 44b arranged on one side of the central axis C_a and corresponding triangular or substantially triangular gusset panels 44c and 44d, partitioned by a rectilinear or substantially rectilinear crease line 48, arranged on the other side. The gusset panels 44a and 44b are partitioned by a rectilinear or substantially rectilinear crease line 46. The gusset panels 44c and 44d are partitioned by a rectilinear or substantially rectilinear crease line 48. Crease line 46 connects to crease line 30 at the intersection of crease line sections 30b and 30c, and crease line 48 connects to crease line 30 at the intersection of crease line sections 30d and 30e. Gusset panels 44a and 44b are equilateral and configured to be folded onto each other when the blank 10 is folded to form the container. Consequently, gusset panels 44a and 44b are reflection-symmetric with respect to crease line 46, i.e. using crease line 46 as an axis of symmetry. Likewise, gusset panels 44c and 44d are equilateral and reflection-symmetric with respect to crease line 48, thus allowing gusset panels 44c and 44d to be folded onto each other when the container is formed.
Gusset panels 44a and 44c are partitioned from the intermediate region 36 by crease line sections 30b and 30e, respectively.
The top region 34 also comprises a top panel 50 arranged between gusset panels 44b and 44d. Top panel 5 is partitioned from gusset panel 44b by a rectilinear or substantially rectilinear crease line 52 and from gusset panel 44d by a rectilinear or substantially rectilinear crease line 54. Crease line 52 connects to crease line 30 at the intersection of crease line sections 30b and 30c, and crease line 54 connects to crease line 30 at the intersection of crease line sections 30d and 30e. Crease lines 52 and 54 are not perfectly parallel to the central axis Ca but converge slightly when moving along the crease lines 52 and 54 towards the intermediate region 36. Crease lines 52 and 54 form an angle to the central axis Ca of approximately 3 degrees.
The top panel 50 is partitioned from the intermediate region 36 by crease line 30c. Consequently, the bottom boundary of the top panel 50, i.e. the boundary of the top panel 50 facing the intermediate region 36, is convex.
The gusset panels 44a-44d and the top panel 50 are arranged reflection-symmetric or substantially reflection-symmetric about the central axis C_a. In other words, using the central axis Ca as an axis of symmetry, gusset panels 44a and 44b are mirrored by gusset panels 44c and 44d, respectively, and the central axis Ca runs centrally through the top panel 50.
The top region 34 further comprises top sealing band panels 56a-56g forming a top sealing band 56 extending along the top boundary edge 22 of the blank 10. When a container is formed from the blank 10, the top sealing band panels 56a-56g are configured to be sealed to each other to form a top seal of the container, as will be discussed in more detail later in the disclosure.
Sealing band panel 56a extends from lateral boundary edge 12 and runs between crease line section 30a and boundary edge section 22a. In a corresponding manner, sealing band panel 56g extends from lateral boundary edge 14 and runs between crease line section 30e and boundary edge section 22i.
Sealing band panel 56b extends from sealing band panel 56a and runs between gusset panel 44a and boundary edge section 22b. In a corresponding manner, sealing band panel 56f extends from sealing band panel 56g and runs between gusset panel 44c and boundary edge section 22h. Sealing band panel 56b is partitioned from gusset panel 44a by a rectilinear or substantially rectilinear crease line section 58a and from the neighbouring sealing band panel 56a by a rectilinear or substantially rectilinear crease line 60. Crease line 60 extends between the intersection of boundary edge sections 22a and 22b and the intersection of crease line sections 30a and 30b. Crease line 60 forms an angle of approximately 15 degrees to the longitudinal direction L. Crease line section 58a forms an angle of approximately 30 degrees to the longitudinal direction L. Sealing band panel 56f is partitioned from gusset panel 44c by a rectilinear or substantially rectilinear crease line section 58e and from the neighbouring sealing band panel 56g by a rectilinear or substantially rectilinear crease line 70. Crease line 70 extends between the intersection of boundary edge sections 22i and 22h and the intersection of crease line sections 30e and 30d. As crease line 60, crease line 70 forms an angle of approximately 15 degrees to the longitudinal direction L but angled in the opposite direction as compared to crease line 60. Crease line section 58e forms an angle of approximately 30 degrees to the longitudinal direction L but angled in the opposite direction as compared to crease line section 58a.
Sealing band panel 56c extends from sealing band panel 56b and runs between gusset panel 44b and the combined extent of boundary edge sections 22c and 22d. In a corresponding manner, sealing band panel 56e extends from sealing band panel 56f and runs between gusset panel 44d and the combined extent of boundary edge sections 22g and 22f. Sealing band panel 56c is partitioned from gusset panel 44b by a rectilinear or substantially rectilinear crease line section 58b and from the neighbouring sealing band panel 56b by a rectilinear or substantially rectilinear crease line 62. Crease line 62 extends between the intersection of boundary edge sections 22b and 22c and the intersection of crease line sections 58a and 58b. Crease lines 62 and 46 are collinear or substantially collinear and form an angle of approximately 25 degrees to the longitudinal direction L. Crease line section 58b forms an angle of approximately 85 degrees to the longitudinal direction L. Sealing band panel 56e is partitioned from gusset panel 44d by a rectilinear or substantially rectilinear crease line section 58d and from the neighbouring sealing band panel 56f by a rectilinear or substantially rectilinear crease line 68. Crease line 68 extends between the intersection of boundary edge sections 22h and 22g and the intersection of crease line sections 58e and 58d. Crease lines 68 and 48 are collinear or substantially collinear and form an angle of approximately 25 degrees to the longitudinal direction L but angled in the opposite direction as compared to crease lines 62 and 46. Crease line section 58d forms an angle of approximately 85 degrees to the longitudinal direction L but angled in the opposite direction as compared to crease line section 58b.
Finally, sealing band panel 56d extends between sealing band panels 56c and 56e and runs between top panel 50 and boundary edge section 22e. Sealing band panel 56d is partitioned from top panel 50 by a rectilinear or substantially rectilinear crease line section 58c and from the neighbouring sealing band panels 56c and 56e by rectilinear or substantially rectilinear crease lines 64 and 66, respectively. Crease line 64 is parallel or substantially parallel to the longitudinal direction L and extends between the intersection of boundary edge sections 22d and 22e and the intersection of crease line sections 58b and 58c. Crease line 66 is also parallel or substantially parallel to the longitudinal direction L but extends between the intersection of boundary edge sections 22f and 22e and the intersection of crease line sections 58d and 58c. Crease line section 58c and boundary edge section 22e are parallel or substantially parallel.
The sealing band 56 is reflection-symmetric about the central axis C_a. In other words, using the central axis Ca as an axis of symmetry, sealing band panels 56a, 56b, 56c are mirrored by sealing band panels 56g, 56f, 56e, respectively, and the central axis Ca runs centrally through sealing band panel 56d.
The top panel 50 comprises a removable section 72 delimited by a loop of weakness 74 allowing section 72 to be removed from the container formed from the blank 10 when the container is initially opened. This opening action will be discussed in more detail later in the disclosure. The loop of weakness 74 may, for example, be a so-called "half-cut", i.e. a cut made partially through the laminated substrate of the blank 10 from the outside surface thereof leaving one or a plurality of inner layers of the laminated substrate intact to provide an uninterrupted barrier against a food product to be contained in the container produced from the blank 10.
Turning now to the intermediate region 36 of the blank 10, this region comprises panels 76a-76 partitioned by crease lines 82a-82d.
Panel 76c is configured to form a front wall panel of a container produced from the blank 10. Neighbouring panel 76c, the intermediate region 36 comprises panels 76b and 76d which are configured to form side wall panels of the produced container. The panel 76c is partitioned from the panel 76d by a rectilinear or substantially rectilinear crease line 82c and from panel 76b by a rectilinear or substantially rectilinear crease line 82b.
The intermediate region 36 further comprises panel 76a neighbouring panel 76b and a fifth panel 76e neighbouring panel 76d. Panels 76a and 76e are configured to form rear wall panel sections of the produced container. Panel 76a is partitioned from panel 76b by a rectilinear or substantially rectilinear crease line 82a and panel 76e is partitioned from panel 76d by a rectilinear or substantially rectilinear crease line 82d.
Crease line 82c extends between crease line 28 and the intersection of crease line sections 30c and 30d. Crease line 82b extends between crease line 28 and the intersection of crease line sections 30b and 30c. Starting from the top region 34 and moving towards the bottom region 32, crease lines 82b and 83c converge. Consequently, the width of panel 76c, i.e. the distance between the crease lines 76c and 76d in the traversal direction T, continuously decreases when moving from the top region 34 to the bottom region 32. Using the central axis C_a as an axis of symmetry, crease line 82b is mirrored by crease line 82c and both crease lines 82b and 82c form an angle to the central axis Ca of approximately 2 degrees, although diverging from the central axis Ca in opposite directions.
Crease line 82a extends between crease line 28 and the intersection of crease line sections 30a and 30b. Starting from the top region 34 and moving towards the bottom region 32, crease lines 82a and 82b diverge. Consequently, the width of panel 76b increases continuously when moving from the top region 34 to the bottom region 32. Crease line 82d extends between crease line 28 and the intersection of crease line sections 30d and 30e. Starting from the top region 34 and moving towards the bottom region 32, crease lines 82d and 82c diverge. Consequently, similar to panel 76b, the width of panel 76d increases continuously when moving from the top region 34 to the bottom region 32. Crease lines 82a and 82d both form an angle to the central axis Ca of approximately 3 degrees, although diverging from the central axis Ca in opposite directions. Consequently, using the central axis C_a as an axis of symmetry, panel 76b is mirrored by panel 76d.
The blank 10 also comprises two rectilinear or substantially rectilinear crease lines 92 and 94 extending over the whole length of the blank 10, i.e. between the bottom boundary edge 16 and the top boundary edge 22, parallel or substantially parallel to the central axis Ca. Crease lines 92 and 94 extend centrally or substantially centrally in panels 76b and 76d, respectively, and, consequently, divide panels 76b and 76d into two panel sections 76b-I, 76b-II and 76d-I, 76d-II, respectively. Also, in the bottom region 32, the crease lines 92 and 94 extend centrally or substantially centrally in the gusset panel sub-regions formed by gusset panels 40b-40e and 40g-40j, respectively.
Fig. 2 shows a sleeve 96 produced from the blank 10 of Fig. 1 in a rear view and Fig. 3 shows the sleeve 96 in a front view. Features of the sleeve already described with reference to Fig. 1 are provided with corresponding reference numbers in Figs. 2 and 3.
The sleeve 63 is created from the blank 10 by folding the blank 10 along the two crease lines 92 and 94, bringing panel 76e to overlap panel 76a. In the overlapping region, panels 76a and 76e are then sealed to one another, e.g. welded together, to form a longitudinal sealing band 14 forming a planar or substantially planar rear wall section. The sleeve 96 thus obtains a circumferential structure, closed in the circumferential direction, with an opening in the region of the bottom boundary edge 16 and with an opening in the region of the top boundary edge 22. The lateral boundary edge ending up inside the sleeve, i.e. boundary edge 12 in this case, is covered, either prior to folding the blank 10 along the crease lines 92 and 94 or after the overlapping regions of panels 76a and 76e have been connected to one another. The covering of the open cut edge of the composite material has the purpose of preventing any contact between the contents of the container and this layer, in particular the paper or paperboard layer contained therein. As is known in the art, the covering of the cut edge can be achieved by stripping composite layers from the edge and folding a remaining, impermeable layer over the edge.
In the front view (Fig. 3), panel 76c is visible as are panel sections 76b-II and 76d-I. The loop of weakness 74 encircling the removable section 72 of the top panel 50 is also visible in the front view. However, the loop of weakness is not visible in the rear view (Fig. 2) since the inside layer of the laminated material of the top panel 50 is unbroken. In the rear view (Fig. 2), panels 76a and 76e are visible as are panel sections 76b-I and 76d-II.
Fig. 4 shows the sleeve 96 from Figs. 2 and 3 in an erected state. The erected state is arrived at by reversing the previous folding along the crease lines 92 and 94 and folding the sleeve 96 back along the crease lines 92 and 94 by approximately 180 degrees. The folding back along the crease line 92 has the consequence that the two panel sections 76b-I and 76b-II no longer lie on top of one another but become arranged in the same or substantially the same plane. In a corresponding manner, the folding back along the crease line 94 has the consequence that the two panel sections 76d-I and 76d-II no longer lie on top of one another but become arranged in the same or substantially the same plane. The folding back action also involves folding the sleeve 96 along crease lines 82a, 82b, 82c and 82d by approximately 90 degrees, thus forming side edges of the container-to-be.
Next, the bottom region of the erected sleeve is folded and sealed. This involves bringing the bottom sealing band panels 38f and 38b into sealing engagement with sealing band panels 38e and 38c, respectively, and bringing bottom sealing band panels 38g and 38s into sealing engagement with sealing band panel 38d. The sealing engagement may be effectuated by welding in a manner which is, as such, known in the art. Folding and sealing the bottom region also involves folding gusset panels 40j and 40g inwards onto gusset panels 40i and 40h, respectively, and folding corresponding gusset panels 40b and 40e inwards onto gusset panels 40d and 40c, respectively. It further involves folding down the now sealed sealing band onto bottom panel 40f and gusset panels 40e and 40g and connecting the sealing band thereto, e.g. by welding, and, finally, folding in lugs formed by the previously folded gusset panels, thus arriving at the sealed and substantially planar configuration illustrated in Fig. 5. It is to be understood, however, that other configurations of a sealed and planar bottom region are known in the art and may be used instead of the one described above.
Erecting and bottom sealing the sleeve may be effectuated in a packaging machine (not shown), where the sleeve 96 may be supplied from a magazine and erected on a mandrel. The bottom region may be formed and sealed on the mandrel and the proto-container, i.e. the partially-formed container as shown in Fig. 6, may then be discharged from the mandrel to a conveyor. The conveyor may transport the partially-formed container to a sterilization station and then to a filling station. In the filling station, a food product may be dispensed into the partially-formed container through the open top.
The filled and partially-formed container may then be conveyed to a top-folding and sealing station for folding and sealing the top region.
When folding the top region, the slanted top panels 44c and 44d are pushed inward at crease line 48 to fold panel 44d over panel 44c and to fold panel 56e over 56f (see Fig. 6). A similar operation is carried out on panels 44a, 44b and 56c, 56b (see also Fig. 1). At the end of this folding operation, the top panel 50 will have assumed a slanted orientation, as shown in Fig. 7. In this position, the panels of the sealing band 56 may be sealed to each other, e.g. in a welding operation, thereby sealing the top region. The folded and sealed sealing band 56 is then folded down onto and attached to the rear wall panels 76a and 76e, as is shown in Fig. 8.
Consequently, the folded and sealed sealing band 56 forms a top sealing region that is folded onto and is attached to a rear wall section of the container formed from the rear wall panels 76a and 76e, i.e. the wall section containing the longitudinal sealing band 14. The consequence of this arrangement, as will be discussed in more detail later, is that a top panel of the container 124 (see Fig. 13), formed from panel 50 (see Fig. 3), will be free from sealing structures, such as welded, glued or otherwise permanently joined seams where panels of the laminate sheet material are permanently joined to each other. This allows the top panel to be utilised in an efficient manner.
A tear-flap may be arranged over and attached to the removable section 72 of the top panel 50 (see Fig. 3) to allow easy removal of the removable section 72.
Figs. 9-12 shown a container 100 produced from the blank 10 disclosed above. The container 100 comprises a substantially planar bottom portion 102, a top portion 104 and a wall portion 106. The wall portion 106 comprises a front wall section 108a formed from panel 76c and a rear wall section 108c formed from panels 76a and 76e. Further, the wall portion 106 comprises side wall sections 108b and 108d formed from panels 76d and 76b, respectively. An edge 116, formed by crease line 82b, defines an intersection of the front wall section 108a and the side wall section 108d, and an edge 118, formed by crease line 82c, defines an intersection of the front wall section 108a and the side wall section 108b. Further, an edge 120, formed by crease line 82a, defines an intersection of the rear wall section 108c and the side wall section 108d, and an edge 122, formed by crease line 82d, defines an intersection of the rear wall section 108c and the side wall section 108b.
The top portion 104 comprises a top panel 124, formed from panel 50, and a sealing region 126, formed from the sealed sealing band 56, i.e. the folded and sealed top sealing band panels 56a-56g, forming a top seal of the container 100. A slanted side edge 128, formed by crease line 52, defines an intersection of the top panel 124 and the side wall section 108d, and a slanted side edge 130, formed by crease line 54, defines an intersection of the top panel 124 and the side wall section 108b. A front edge 132, formed by crease line section 30c, defines an intersection of the top panel 124 and the front wall section 108a. The container 100 also comprises a rear edge 134, formed by crease line section 58c, corresponding to the intersection of the top panel 124 and the sealing region 126. Consequently, the top panel 124 extends between the top edges 128, 130, 132 and 134.
As previously discussed, the sealing region 126 is folded down onto and attached to the rear wall section 108c, i.e. the wall section formed by the panels 76a and 76e and containing the longitudinal sealing band 14.
The panel 76c has a length L_F along the central axis C_a (see Fig. 1). The panels 76a and 76e have a length L_B in the direction of the central axis C_a that is less than L_F. Consequently, the front wall section 108a has a length that is less than the length of the rear wall section 108c (when viewed in the longitudinal direction of the carton 100). This difference in the lengths, i.e., L_F < L_B, creates an extended configuration of the top panel 124. Thus, the front edge 132 is lower than the rear edge 134 when the container 100 is in an upright position as shown. The top panel 124 is at a predetermined angle α to the rear wall section 108c (see Figs. 11 and 12). The angle α can be about 10 degrees to about 90 degrees, and preferably, about 30 degrees to about 80 degrees. Most preferably, the angle α is about 45 degrees to about 75 degrees. In the present embodiment, the angle is approximately 60 degrees, as is dictated by the angle between the crease line sections 30b and 30d and crease lines 82a and 82d, respectively (see Fig. 1).
Referring now to Figs. 14a and 14b, the planar bottom portion 102 is substantially square-shaped, i.e. it has a width and a breadth of substantially equal length, as is illustrated in Fig. 14a (see also Fig. 5). At the top portion 104, however, the cross-section of the container 100, when viewed in a plan parallel to the plane of the bottom portion 102, is rectangular. In other words, above the bottom portion 102 the width of the container 100 is larger than the breadth of the container 100, as is illustrated in Fig. 14b. This asymmetry increases when moving from the bottom portion 102 towards the top portion 104.
Referring now to Figs. 9-11, the container 100 comprises a closure 136 having a tear-flap 138 that covers and is attached to the removable section 72 of the top panel 50 (see also Fig. 1). As previously discussed, the removable section 72 is delimited by a line of weakness 74 allowing the section 72 to be removed from the container 100 together with the tear-flap 138 when the container is initially opened. Until this first opening, however, section 72 forms, together with the rest of the top panel 124, an uninterrupted barrier for the food product contained in the package. The line of weakness 74 may, for example, be a so-called "half-cut", i.e. a cut made partially through the laminated substrate of the blank from the outside surface thereof leaving one or a plurality of inner layers of the laminated substrate intact to provide an uninterrupted barrier against the contained food product. When the tear-flap and the attached section 72 is removed from the container 100, an opening 140 (see Fig. 13) will be revealed in the top panel 124 through which the food product in the container 100 can be dispensed or accessed. The tear-flap 138 may extend down onto the rear wall section 108c crossing the sealing region 126. The tear-flap 138 may be attached to the container 100 after the container 100 has been filled and top-sealed. Alternatively, the tear-flap 138 may be attached to the proto-container upstream of the filling station.
It is to be understood, however, that the container, in principle, can be fitted with any type of closure known in the art, e.g. a closure comprising a pour spout and a cap resealably arranged on the pour spout. Alternatively, the closure may be implemented using so called pre-laminated hole (PLH) technology. As is known in the art, such technology involves making a through-hole in the blank and covering the hole with a suitable barrier layer, e.g. a polymer film, which barrier layer is attached to a tear-flap to be removed from the hole together with the tear-flap at a first opening.
The opening 140 is positioned close to the rear edge 134 substantially equidistant from slanted edges 128 and 130. The opening 140 may be arranged at an orthogonal distance D of between 1 mm to 10 mm from the fourth top edge 134. In other words, with reference to Fig. 1, the removable section 72 may be arranged at an orthogonal distance D of between 1 mm to 10 mm from the crease line section 58c. Since the sealing region 126 is folded down onto the rear wall containing the longitudinal sealing band 14 and is attached thereto, the top panel 124 will be free from sealing structures and there will be no obstructions extending above the surface of the top panel 124. In particular, the longitudinal sealing band 14 and the top sealing region 126 will be confined to the rear wall section 108c of the container. Therefore, when tear-flap 138 and section 72 are removed, the then revealed opening 140 will become easily accessible, in particular from the rear wall section 108c side of the container 100, allowing a consumer to position his or her lower lips on the sealing region 126 and the upper lips over the opening 140. The longitudinal extent of the sealing band panel 56d, i.e. the distance A between the crease line section 58c and the top boarder section 22e (see Fig. 1), defining the length of the sealing region 126 in the longitudinal direction of the container 100, may be at least 15 mm, or more preferably at least 20 mm, or even more preferably at least 30 mm, to comfortably accommodate the lower lips of a consumer and thereby cater for an enjoyable drinking experience. By having the tear-flap 138 extending down onto the rear wall section 108c crossing the sealing region 126, the outer surface of the sealing region 126 intended to come into contact with the mouth of a consumer will be protected until the container 100 is opened. The slanted top panel 124 and the position of the opening 140 close to the rear edge 134 allow for an ergonomically advantageous drinking position, thus making it easy for a consumer to drink directly from the container 100. Consequently, the disclosed container 100 may be suitable to be used as a so-called portion pack, i.e. a type of container configured to hold a liquid intended to be consumed on the go, without the container necessarily having to be reclosed after once having been opened.
Fig. 15 shows another embodiment of a blank 10' according to the invention. Figs. 16 and 17 show a sleeve 96' produced from the blank 10' and Figs. 18-21 illustrates a container 100' produced from the sleeves 96'.
The blank 10' differs from the previously disclosed blank 10 in that the blank 10' comprises two rectilinear or substantially rectilinear crease line sections 30c'-I and 30c'-II instead of the curvilinear crease line 30c of blank 10.
Furthermore, the blank 10' comprises a semi-circular line of weakness 74' instead of the loop of weakness 74 of blank 10. Also, the line of weakness 74' is positioned further from the crease line section 58c' than the loop of weakness 74 from crease line section 58c.
The blank 10' differs from blank 10 also in that the intermediate region of the blank 10' comprises slanted crease lines 82a'-82g' instead of the substantially longitudinally extending crease lines 82a-82d of blank 10. The slanted crease lines 82a'-82h' partition slanted panels 76a'-76i'.
The blank 10' is otherwise identical to blank 10 and the sleeve 96' (see Figs. 16 and 17) is produced in substantially the same manner as sleeve 96. The container 100' is produced from sleeve 96' in substantially the same manner as container 100 from sleeve 96. However, when the sleeve 96' is erected and folded, the slanted panels 76a'-76i' will form a pattern of slanted and slightly warped wall sections 108a'-108h' in the wall portion 106' of the container 100'. Wall sections 108a', 108g', 108e' and 108c' extend diagonally across the front wall, the first side wall, the rear wall and the second side wall, respectively, of the container 100'. When the carton 100' is produced, the sealing region 126' is folded down onto wall section 108d' and wall section 108e' (i.e. the wall section containing the longitudinal sealing band 14') and is attached to the same. Consequently, as the previously discussed container 100, the container 100' comprises a top panel 124' that is free from sealing structures.
Also, instead of being provided with a tear-flap, the carton 100' is provided with a closure 136' comprising a cap 142' and a pour spout having a flange 144' attached to the top panel 124' above the line of weakness 74'. The closure 136' is configured to break the line of weakness 74' during a first opening of the container 100' in a manner that is, as such, known in the art.
It is appreciated that certain features of the invention, which, for clarity, have been described above in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which, for brevity, have been described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.
In the preceding description, various aspects of the blank and container according to the invention have been described with reference to the illustrative embodiment. For purposes of explanation, specific numbers, systems and configurations were set forth in order to provide a thorough understanding of the apparatus and its workings. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiment, as well as other embodiments of the apparatus, which are apparent to person skilled in the art to which the disclosed subject-matter pertains, may lie within the scope of the present invention as defined by the following claims.

Claims

A paper-based or paperboard-based container (100, 100') for holding a pourable food product, comprising:
- a substantially planar bottom portion (102);

- a top portion (104) arranged opposite the bottom portion (102) and comprising a top panel (124, 124') and a top sealing region (126, 126') forming a top seal of the container (100, 100'); and

- a wall portion (106) extending between the bottom portion (102) and the top portion (104) and comprising a plurality of wall sections (108a-108d, 108a'-108h') bordering the top panel (124, 124') and a longitudinal sealing band (14, 14') extending between the bottom portion (102) and the top portion (104) over at least one of the wall sections (108c, 108d', 108e');
characterised by the top sealing region (126, 126') being folded onto said at least one of the wall sections (108c, 108d', 108e') comprising the longitudinal sealing band (14, 14') and being attached thereto.
The container (100, 100') according to claim 1, characterised by the top panel (124, 124') being free from sealing structures.
The container (100, 100') according to any one of the preceding claims, characterised by the top sealing region (126, 126') being substantially planar and arranged substantially parallel to said at least one of the wall sections (108c, 108d', 108e') comprising the longitudinal sealing band (14).
The container (100, 100') according to any one of the preceding claims, characterised by the top panel (124, 124') and the top sealing region (126, 126') sharing a common border (58c) forming a top edge (134) of the container (100, 100').
The container (100, 100') according to claim 4, characterised by the top edge (134) being substantially rectilinear and arranged parallel to the bottom portion (102).
The container (100, 100') according to any one of the preceding claims, characterised by a closure (136, 136') being arranged in the top panel (124, 124') for dispensing and/or accessing the food product.
The container (100, 100') according to any one of claims 4 and 5, characterised by a closure (136) being arranged in the top panel (124, 124') for dispensing and/or accessing the food product, and by the closure (136) comprising an opening (140) being arranged adjacent said top edge (134).
The container (100, 100') according to claim 7, characterised by the opening (140) being arranged at an orthogonal distance of between 1 mm to 10 mm from the top edge (134).
The container (100, 100') according to any one of the preceding claims, characterised by the top panel (124, 124') and said at least one of the wall sections (108c, 108e') comprising the longitudinal sealing band (14) being substantially planar, and by the top panel (124, 124') forming an angle (α) to said at least one of the wall sections (108c, 108e') comprising the longitudinal sealing band (14) that is of any one of: within the range of 10 degrees to 90 degrees; within the range of 30 degrees to 80 degrees, within the range of 45 degrees to 75 degrees; and 60 degrees.
The container (100, 100') according to any one of the preceding claims, characterised by the top sealing region (126, 126') comprising a plurality of sealed sealing band panels (56a-56g), all of the sealed sealing band panels (56a-56g) of the top sealing region (126, 126') being arranged substantially parallel and/or substantially coplanar.
The container (100, 100') according to claim 10, characterised by the sealing band panels (56a-56g) comprises a central sealing band panel (56d) having a longitudinal extent (A) being any one of: at least 15 mm, at least 20 mm and at least 30 mm.
A paper-based or paperboard-based sleeve (96, 96') for producing the container (100, 100') according to any one of the preceding claims.
A paper-based or paperboard-based blank (10, 10') for producing the sleeve (96, 96') according to claim 12.
The blank (10, 10') according to claim 13, characterised by the blank (10, 10') being mirror-symmetric about a longitudinal central axis (C_a) of the blank (10, 10').
A method of producing a paper-based or paperboard-based container (100, 100') for holding a pourable food product comprising the steps of:
- sealing a paper-based or paperboard-based laminate sheet material along a longitudinal sealing band (14) forming a tubular proto-container (96, 96');

- bottom-sealing the laminate sheet material to form a bottom-sealed and open-top proto-container;

- filling the bottom-sealed and open-top proto-container with the portable food product;

- top-sealing the proto-container at a top sealing region (126, 126'); and

- folding the top sealing region (126, 126') onto at least one wall section (108c, 108d', 108e') of the proto-container comprising said longitudinal sealing band (14) and attaching the top sealing region (126, 126') to said at least one wall section (108c, 108d', 108e').
The method according to claim 15, comprising the step of arranging a closure (136, 136') for dispensing or accessing the food product in a top panel (124, 124') of the container (100, 100').