GB2545720A

GB2545720A - Packaging

Info

Publication number: GB2545720A
Application number: GB1522773.9A
Authority: GB
Inventors: Tarrant Stephen
Original assignee: Glowcroft Ltd
Current assignee: Glowcroft Ltd
Priority date: 2015-12-23
Filing date: 2015-12-23
Publication date: 2017-06-28
Also published as: GB201522773D0

Abstract

A packaging container 10 includes a flexible film 28, the film being a laminate with at least two layers of a plastics material. A first layer is a continuous barrier layer, and the film includes at least two score lines 32 in a second layer, the score lines defining a region of weakness 30 in the film. The score lines converge towards or at a puncture point 34 such that when sufficient force is applied to the film in the region of weakness, the film breaks at the puncture point and tears along the score lines thereby forming at least one flap in the film and creating an opening in the container. The film may cover a tray 12 and have a matrix of multiple regions of weakness, or instead form part of a bag (240, fig 5).

Description

Packaging

BACKGROUND a. Field of the Invention

This invention relates to packaging containers and in particular to packaging containers comprising a flexible film. The flexible film includes at least two score lines forming a region of weakness that allows the film to be broken by applying a force to the film in the region of weakness. b. Related Art

There are numerous designs of packaging containers used to contain a wide variety of different materials and products. Typically these containers will be opened by a user near one end of the container so as to provide access to the interior volume of the container.

In some cases, however, it is desirable to provide an opening in the packaging that is at a distance from an end or edge of the container. For example, it is often desirable to provide an opening in a box of tissues or packet of wipes that is substantially centrally positioned in one face of the container. In these containers a portion of the packaging is removable to form the opening. This portion may be provided with an adhesive area to allow the container to be resealed again, for example if it is desirable to retain moisture in the container.

It is also known to provide multi-compartment trays that are covered by a thin foil layer. These containers may be used, for example, to package medication or tablets. Similar, larger containers may be used to house chocolates or gifts in an advent calendar. In each of these examples the product, for example the tablet or chocolate, is removed by pushing the product against the foil layer to tear the foil. In these containers, therefore, the foil layer must be thin enough to enable it to be torn without damaging the product or without the application of a large force.

Due to the thinness of the foil layer, these containers are often retained within a outer sleeve or box to protect the foil layer from damage during transportation and storage.

It is an object of the present invention to provide an alternative packaging container that overcomes some of the problems with prior art containers whether mentioned herein or otherwise.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a packaging container comprising a flexible film, the film being a laminate comprising at least two layers of a plastics material, a first layer being a continuous barrier layer, and the film including at least two score lines in a second layer, the score lines defining a region of weakness in the film, wherein the score lines converge at or towards a puncture point such that, in use, when sufficient force is applied to the film in the region of weakness the film breaks at the puncture point and tears along the score lines, thereby forming at least one flap in the film and creating an opening in the container.

Each of the flaps that is created remains attached to the rest of the flexible film. A proximal end or edge of the or each flap defines an edge or extent of the opening that is formed.

The score lines are preferably formed by laser scoring.

At least a part of a first score line and a part of a second score line extend in intersecting directions so that the first and second score lines converge. In some embodiments the first score line may intersect the second score line. The first and second score lines may form a cross shape. In preferred embodiments at least one of the score lines is linear.

In embodiments in which the score lines converge but do not intersect, the puncture point is the point at which the score lines are closest to each other. In embodiments in which the score lines intersect, the puncture point is at the point of intersection.

In preferred embodiments of the packaging container, the film includes a plurality of distinct regions of weakness; each region of weakness comprising at least two converging or intersecting score lines. The regions of weakness may be in a matrix arrangement.

The score lines and regions of weakness are located so as to form one or more openings in the packaging container at a distance from an end or edge of the container. Accordingly the score lines preferably do not intersect an edge of the film. Additionally, it is preferable if the score lines are located at a distance from an edge of the packaging container.

The packaging container may be in the form of a bag. In these embodiments the or each region of weakness is preferably located at a distance from first and second ends of the bag.

In other embodiments the packaging container may comprise a tray, and the flexible film may cover at least a part of the tray. In preferred embodiments the tray includes a plurality of compartments, each compartment having an opening, and the flexible film extends over and covers the opening of each of the compartments. In these embodiments a region of weakness in the film is typically aligned with each of said openings.

According to a second aspect of the present invention there is provided a method of manufacturing a packaging container, the container comprising a flexible film, the film being a laminate comprising at least two layers of a plastics material and a first layer being a continuous barrier layer, and the method comprising: scoring a first line in a second layer of the film; and scoring a second line in the second layer of the film, the score lines defining a region of weakness in the film, and the score lines being arranged such that the score lines converge at or towards a puncture point, so that, in use, when sufficient force is applied to the film in the region of weakness the film breaks at the puncture point and tears along the score lines, thereby forming at least one flap in the film and creating an opening in the container.

The method preferably comprises laser scoring the first line and laser scoring the second line.

The first score line may intersect the second score line.

In preferred embodiments the method comprises forming a plurality of distinct regions of weakness in the flexible film, each of the regions of weakness comprising a first score line and a second score line.

The or each region of weakness is preferably formed at a distance from an end or an edge of the packaging container.

The container may be in the form of a bag. In other embodiments the container comprises a multi-compartment tray, each compartment having an opening, and the method comprises: attaching the flexible film to the tray so that the film extends over and covers the opening of each compartment; and forming a plurality of distinct regions of weakness in the flexible film, each of the regions of weakness comprising a first score line and a second score line, and each of the regions of weakness being aligned with one of the openings.

Preferably the flexible film is oriented so that the first layer of the film is closest to or in contact with the tray.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be further described by way of example only and with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a packaging container in the form of a tray including a flexible film lid comprising regions of weakness according to a preferred embodiment of the present invention;

Figure 2 is a perspective view of the flexible film of Figure 1, with one of the regions of weakness broken;

Figure 3 is a plan view of the flexible film of Figure 1;

Figure 4 is a perspective view of a packaging container in the form of a bag including a flexible film comprising a region of weakness according to a preferred embodiment of the present invention;

Figure 5 is a perspective view of a packaging container in the form of a bag including a flexible film comprising a plurality of regions of weakness according to a further preferred embodiment of the present invention;

Figure 6 illustrates an arrangement of score lines forming a region of weakness;

Figure 7 illustrates an alternative arrangement of score lines forming a region of weakness; and

Figure 8 illustrates a further arrangement of score lines forming a region of weakness.

DETAILED DESCRIPTION

Figure 1 shows a packaging container 10 in the form of a covered tray according to a first preferred embodiment of the present invention. The container 10 comprises a tray 12 having multiple compartments or receptacles 14. In this example the tray 12 includes an array of six compartments 14 in a matrix configuration; however, it will be appreciated that the tray 12 may include any number of compartments 14 in any configuration, and that the compartments 14 may be all the same size and shape or may be different sizes and shapes.

Each compartment 14 has a base and a plurality of side walls defining an interior volume of the compartment 14. An opening 16 of each compartment 14 is formed in an upper surface 18 of the tray 12. In this example each of the openings 16 has a substantially square or rectangular shape. Bridging portions 20 of the tray 12 extend between adjacent openings 16 and a lip region 22 defines a perimeter edge 24 of the tray 12. The tray 12 may be substantially rigid or at least a part of the tray 12 may be flexible. A cover 26 of the container 10 is made of a flexible sheet or film 28. The film 28 is a laminate and includes at least two layers of a suitable plastics material. In preferred embodiments the film 28 comprises layers of low density polyethylene (LDPE) and/or polyethylene terephthalate (PET). The laminate film 28 may also include one or more layers of a metal foil. Each layer of the film 28 is preferably between 10 pm and 20 pm thick, and more preferably between 10 pm and 15 pm thick.

The flexible film 28 is attached or bonded to the upper surface 18 of the tray 12 so that the film 28 extends over and covers each of the openings 16. The film 28 may be heat welded to the tray 12 or the film 28 may be adhered to the tray 12 using a suitable adhesive.

The flexible film 28 includes a plurality of regions of weakness 30, each region of weakness 30 being aligned with one of the openings 16 in the tray 12 when the film 28 is attached to the tray 12. Each region of weakness 30 comprises two score lines 32 that are configured so that a user can easily break the film 28 in these regions.

In this example each region of weakness 30 includes two score lines 32 that intersect each other to form a cross shape. The ends of each of the score lines 32 define the extent of the region of weakness 30, as shown most clearly in Figure 3. It will be appreciated that in other embodiments a region of weakness 30 may be formed by score lines 32 having a different arrangement or configuration, as will be explained in more detail below.

The point of intersection or convergence of the score lines 32 is referred to as a puncture point 34. Typically the puncture point 34 will be substantially centrally located within the region of weakness 30; however, in some embodiments the puncture point 34 may be located closer to one end of one of the score lines 32.

The score lines 32 are formed by cutting through or removing material from at least one of the layers of the laminate film 28. In preferred embodiments the score lines 32 are formed by laser scoring. In particular a movable laser scoring head is programmed with the desired arrangement of score lines 32, and the laser scores the film 28 along the pre-programmed lines 32 to the required depth.

The film 28 is scored to a depth such that at least one layer of the laminate film 28 remains intact. This continuous film layer, therefore, provides a barrier layer that seals the compartments 14 of the tray 12.

To construct the container illustrated in Figure 1, an item or product is first placed into each of the compartments 14. The item or product may be, for example, a chocolate or other foodstuff, or a medicament. A pre-scored flexible film 28 is then bonded to the upper surface 18 of the tray 12 so that the film 28 extends over and covers each of the compartments 14. The flexible film 28 is preferably bonded to the upper surface 18 around the full perimeter of each of the openings 16 such that each of the compartments 14 is independently sealed by the film. The film 28 is preferably oriented such that an intact, unscored layer is closest to or in contact with the tray 12, and a scored layer is furthest from the tray 12.

To remove an item from its compartment 14 a user presses on the region of weakness 30 aligned with the compartment 14. At least a part of the force exerted on the film 28 will be substantially perpendicular to the plane of the film 28. Once a sufficient force is applied, the film 28 will break at the puncture point 34 where the score lines 32 converge or intersect. The film 28 will tear along the score lines 32 causing flaps 36 of film 28 to be formed; the edges of the flaps 36 being defined by the score lines 32. Pushing the flaps 36 apart or into the interior volume of the compartment 14 creates an opening 38 in the film 28 and permits access to the compartment 14. This is illustrated in Figure 2, in which the arrow represents an approximate direction of application of force to the film 28 by a user.

Because each of the compartments 14 is independently sealed by the film cover 28 and because, in this embodiment, each region of weakness 30 does not extend beyond the perimeter edge of the associated compartment opening 16, this allows each compartment 14 to be opened or accessed independently. Furthermore, due to the fact that the laminate film 28 has a reduced thickness along the score lines 32, tearing of the film 28 will stop at the ends of the tear lines 32, which minimises the risk of breaking the seal of a neighbouring compartment 14.

It is envisaged that such a covered tray may be used as part of an advent calendar, as a holder of medicaments, or as a means of storing pre-measured amounts or limited volumes of other materials. A second preferred embodiment of the present invention is illustrated in Figure 4. In this embodiment the packaging container 110 is in the form of a bag 140. The bag 140 is made of a flexible, laminate sheet or film 128 including at least two layers of a suitable plastics material. In preferred embodiments the film 128 comprises layers of low density polyethylene (LDPE) and/or polyethylene terephthalate (PET). The laminate film 128 may also include one or more layers of a metal foil. Each layer of the film 128 is preferably between 10 pm and 20 pm thick, and more preferably between 10 pm and 15 pm thick.

The bag 140 is sealed closed along first and second edges 142, 144 at opposing ends to define an interior volume of the bag 140.

The flexible film 128 includes a region of weakness 130 comprising two score lines 132 that intersect each other to form a cross shape. The ends of each of the score lines 132 define the extent of the region of weakness 130, as shown by the dashed line in Figure 4. It will be appreciated that in other embodiments a region of weakness 130 may be formed by score lines 132 having a different arrangement or configuration, as will be explained in more detail below.

The score lines 132 are formed by cutting through or removing material from at least one of the layers of the laminate film 128. In preferred embodiments the score lines 132 are formed by laser scoring. In particular a movable laser scoring head is programmed with the desired arrangement of score lines 132, and the laser scores the film along the pre-programmed lines to the required depth. The film 128 is scored to a depth such that at least one layer of the laminate film 128 remains intact.

The score lines 132 are formed in a face of the bag 140 at a distance from the edges 142, 144 or ends of the bag 140. The score lines 132 may be formed in the film 128 before or after filling of the bag 140; however, in preferred embodiments the flexible film 128 is pre-scored before the bag 140 is formed and filled.

It is envisaged that a bag 140 according to the present invention may be used to hold compost. To allow a user to plant directly into the compost while it is still in the bag 140, a user can press on the region of weakness 130 to break the film 128 at the puncture point 134 where the score lines 132 converge or intersect. The film 128 will tear along the score lines 132 causing flaps of film 128 to be formed; the edges of the flaps 136 being defined by the score lines 132. The user can then pull the flaps apart to create an opening in the film 128 of the bag 140 so that a seed or seedling, for example, may be planted in the compost in the bag 140. A bag 140 according to the present invention, including a large region of weakness in a face of the bag 140, may be used to hold any suitable product where it is desirable to form a large opening to access the product. Such products may include, for example, building sand or cement, or various horticultural products.

In other embodiments a plurality of regions of weakness 230 may be formed in a bag 240, as illustrated in Figure 5, for example. The regions of weakness 230 may be arranged in an array, for example in a matrix configuration. The provision of a plurality of regions of weakness 230 allows a user to form a plurality of openings in the bag 240. In embodiments in which the bag 240 is filled with compost, this allows the user to form openings to receive individual plants in a spaced apart arrangement, while the rest of the compost remains covered to reduce moisture loss and suppress weeds.

In the embodiments described above the regions of weakness 30, 130, 230 each included intersecting first and second score lines 32, 132 forming a cross shape. It will be appreciated, however, that the score lines may not be straight or linear, and the score lines may converge but not intersect, as long as a puncture point is formed. A number of alternative shapes and arrangements of score lines forming regions of weakness are shown in Figures 6 to 8. The score lines are indicated by solid lines and the corresponding region of weakness is indicated by a dashed line.

As shown in Figures 6 and 7, the score lines may be curved, and each score line may include one or more points of curvature. The score lines in Figure 6 intersect to form a substantially central puncture point, i.e. the point at which the score lines intersect, relative to the region of weakness. When this region of weakness is broken, four substantially identical shark fin shaped flaps are formed, a tip of each flap being formed at the puncture point.

In the configuration shown in Figure 7 the two score lines do not intersect. The two score lines are curved and converge to form a puncture point. In this case the puncture point is the point at which the two score lines are closest to each other. The gap or spacing between the score lines at the puncture point should be as small as possible to minimise the force required to break the film in this area.

Figure 8 illustrates a region of weakness comprising four score lines. None of the score lines intersect. The score lines are arranged in a cross shape such that a first end of each score line is located at a central puncture point, and the score lines extend radially from this puncture point.

In embodiments in which the score lines converge at the puncture point but do not intersect, the distance between the score lines at the puncture point is preferably less than 1 mm, and more preferably less than 500 pm.

Although all of the examples above have included substantially square or rectangular regions of weakness, it will be appreciated that the number of score lines, the shape of the score lines and their arrangement may result in a region of weakness having a shape other than a square or rectangle.

In order to permit the laminate film to tear cleanly and consistently along the score lines the score lines are continuous. Furthermore, each score line preferably has the same depth along its length to ensure consistent tearing of the film and to ensure the integrity of the continuous barrier layer of the film.

The present invention, therefore, provides an alternative packaging container that allows one or more openings to be easily formed by hand at a distance from the ends or edges of the container.

Claims

1. A packaging container comprising a flexible film, the film being a laminate comprising at least two layers of a plastics material, a first layer being a continuous barrier layer, and the film including at least two score lines in a second layer, the score lines defining a region of weakness in the film, wherein the score lines converge at or towards a puncture point such that, in use, when sufficient force is applied to the film in the region of weakness the film breaks at the puncture point and tears along the score lines, thereby forming at least one flap in the film and creating an opening in the container.

2. A packaging container as claimed in Claim 1, wherein the score lines are formed by laser scoring.

3. A packaging container as claimed in Claim 1 or Claim 2, wherein a part of a first score line and a part of a second score line extend in intersecting directions.

4. A packaging container as claimed in Claim 1 or Claim 2, wherein a first score line intersects a second score line.

5. A packaging container as claimed in Claim 3 or Claim 4, wherein the first and second score lines form a cross shape.

6. A packaging container as claimed in any preceding claim, wherein at least one of the score lines is linear.

7. A packaging container as claimed in any preceding claim, the film including a plurality of distinct regions of weakness and each region of weakness comprises at least two converging score lines.

8. A packaging container as claimed in Claim 7, wherein the regions of weakness are in a matrix arrangement.

9. A packaging container as claimed in any preceding claim, wherein the score lines do not intersect an edge of the film.

10. A packaging container as claimed in any preceding claim, wherein the score lines are located at a distance from an edge of the packaging container.

11. A packaging container as claimed in any preceding claim, wherein the container is in the form of a bag and the or each region of weakness is located at a distance from first and second ends of the bag.

12. A packaging container as claimed in any one of Claims 1 to 10, wherein the container comprises a tray and the flexible film covers at least a part of the tray.

13. A packaging container as claimed in Claim 12, wherein the tray includes a plurality of compartments, each compartment having an opening, and the flexible film extends over and covers the opening of each of the compartments, and wherein a region of weakness in the film is aligned with each of said openings.

14. A method of manufacturing a packaging container, the container comprising a flexible film, the film being a laminate comprising at least two layers of a plastics material and a first layer being a continuous barrier layer, and the method comprising: scoring a first line in a second layer of the film; and scoring a second line in the second layer of the film, the score lines defining a region of weakness in the film, and the score lines being arranged such that the score lines converge at or towards a puncture point, so that, in use, when sufficient force is applied to the film in the region of weakness the film breaks at the puncture point and tears along the score lines, thereby forming at least one flap in the film and creating an opening in the container.

15. A method as claimed in Claim 14, wherein the method comprises laser scoring the first line and laser scoring the second line.

16. A method as claimed in Claim 14 or Claim 15, wherein said first score line intersects said second score line.

17. A method as claimed in any of Claims 14 to 16, wherein the method comprises forming a plurality of distinct regions of weakness in the flexible film, each of the regions of weakness comprising a first score line and a second score line.

18. A method as claimed in any of Claims 14 to 17, wherein the or each region of weakness is formed at a distance from an end or an edge of the packaging container.

19. A method as claimed in any of Claims 14 to 18, wherein the container is in the form of a bag.

20. A method as claimed in any of Claims 14 to 18, wherein the container comprises a multi-compartment tray, each compartment having an opening, and the method comprises: attaching the flexible film to the tray so that the film extends over and covers the opening of each compartment; and forming a plurality of distinct regions of weakness in the flexible film, each of the regions of weakness comprising a first score line and a second score line, and each of the regions of weakness being aligned with one of the openings.

21. A method as claimed in Claim 20, wherein the first layer of the film is closest to the tray.

22. A packaging container substantially as herein described with reference to the accompanying drawings.

23. A method of manufacturing a packaging container substantially as herein described with reference to the accompanying drawings.