GB2628457A

GB2628457A - Container

Info

Publication number: GB2628457A
Application number: GB2400357.6A
Authority: GB
Inventors: Guy Stevens Henry
Original assignee: Individual
Current assignee: Individual
Priority date: 2023-03-20
Filing date: 2024-01-10
Publication date: 2024-09-25
Also published as: GB202400357D0; GB2628350A

Abstract

A container 10 for a product, formed of a laminate material folded as a container body having a first end wall 16 of the laminate material, a second end wall (18, fig 2), and at least one side wall 20, the at least one side wall connecting the first and second end walls together, in which the first end wall, the second end wall and the at least one side wall define a chamber. An aperture 14 is provided in the at least one side wall, the aperture spanning at least about half of a distance across the apertured side wall in an orthogonal direction from the first end wall to the second end wall, and the container body includes at least one seal 30 for sealing the folded laminate material as the container body, the at least one seal being disposed: a) at least on the first end wall or the second end wall but not the apertured side wall, or b) on the at least one side wall and offset from the aperture.

Description

CONTAINER

The present invention relates to a container of folded laminate material for containing a product such as food.

BACKGROUND TO THE INVENTION

Folded laminate packaging such as a Tetra Pak (RTM) carton has many advantages.

For example, the laminate may be constructed to form aseptic containers which allow foods to stay fresher for longer. The laminate is relatively lightweight which minimises transport costs. Indicia can be printed onto the laminate material through various printing processes.

A conventional Tetra Pak (RTM) carton is formed from a single sheet of laminate material, with two opposing edges connected together. Adjacent edges of the laminate container are then sealed at both the top and bottom of the container. This leaves a seal disposed at the top of the container. Excess material at the top is typically folded towards sides adjacent to the top face, whereas excess material at the bottom is folded towards the bottom of the container. In some cases, a flat bottom seal may be used.

A small opening is typically provided on the top face, offset from the top seal. The small opening is ideal for carefully pouring liquids such as milk and juices stored in the container.

However, this type of container is not appropriate for storing solids, viscous liquids or powders. This is because they cannot be easily removed from the carton via the opening, hence why they are still sold in glass jars or plastic containers which can be formed open-topped. Glass jars and plastic containers are typically shipped empty from the manufacturer for subsequent filling, with a large volume per container thus resulting in a higher transport cost and a significant carbon footprint which is not environmentally sustainable. Glass jars in particular are relatively expensive to manufacture and heavy, which exacerbates the transport and environmental costs.

In the case of Tetra Pak (RTM), their carton material has six individual layers. The first layer is a polyethylene layer to seal against water. The second layer is a second polyethylene layer, which is used as an adhesive layer to bond the first layer to a third layer of aluminium foil for keeping the contents fresh. The fourth layer is a third polyethylene layer, used as an adhesive layer to bond the third layer to a fifth layer of paperboard which can be used to show information about product content and/or branding, for example. The sixth layer is a fourth polyethylene layer which seals the material against water. Other manufacturers may provide different carton or laminate material.

While the structure of laminate material provided by various manufacturers is generally effective in extending the shelf-life of food in a corresponding laminate container, it tends to require specialised disposal because the separate layers in the laminate material are difficult to separate during the recycling process. In addition, some local recycling collection services in the UK do not accept various types of laminate material as part of paper recycling, instead requiring consumers to take containers of such material to a recycling centre which does accept laminate containers for recycling.

Where there is a lack of convenient means to recycle the laminate material via domestic recycling collection (i.e. without needing to leave home), some people may therefore dispose of the laminate material as general waste. Globally, in 2022, about 1.2 million tonnes of paper-based cartons were recycled, so even a relatively small fraction of cartons which are binned rather than recycled constitutes a very large amount of material.

It is an object of the present invention to reduce or substantially obviate the aforementioned problems.

STATEMENT OF INVENTION

According to a first aspect of the present invention, there is provided a container for a product, the container formed of a laminate material folded as a container body having a first end wall provided by the laminate material, a second end wall provided by the laminate material, and at least one side wall provided by the laminate material connecting the first and second end walls together, in which the first end wall, the second end wall and the at least one side wall define a chamber for holding the product, in which an aperture is provided through the laminate material of the at least one side wall, the aperture spanning at least about half of a distance across the apertured side wall in an orthogonal direction from the first end wall to the second end wall, and the container body including at least one seal for sealing the folded laminate material in the form of the folded container body, the at least one seal being: a) disposed on the first end wall or the second end wall (thereby being on a different container wall to the aperture), or b) on the at least one side wall and offset from the aperture.

A container according to the invention provides a lightweight, low logistical cost alternative to glass and plastic bottles, jars and containers. The container can advantageously be formed from a single piece of laminate material folded into shape to form the various walls of the container (including the container base opposite the apertured side wall). It has the added advantage of not shattering under impact, unlike glass and some plastic containers.

The aperture in the present invention is relatively wide to allow for easier and/or faster passage of product through the aperture.

A middle region (or a centre) of the aperture may be disposed in a centre of the side wall. The arrangement in which the middle region (or a centre) of the aperture is disposed in a centre of the side wall, with the seal offset or disposed on an adjacent end wall, can provide more space to accommodate a large or wide aperture. This can maximise the size of the opening relative to the size of the container. This has particular application in the pre-formed bottle and jar packaging industry and the invention enables an important shift towards more useful and more sustainable packaging.

In another aspect of the invention, the at least one seal may be disposed on the at least one side wall and offset from the aperture, instead of being on a different wall to the aperture.

The container may have first and second central planes which are orthogonal to each other. A middle of the aperture may be disposed on the side wall at a position where the first and second central planes intersect.

Put another way, the container may have two orthogonal planes where one plane is parallel to the end walls and the other plane is orthogonal to the end walls, and the middle of the aperture may be located about where the planes cross each other. The central planes may be longitudinal planes passing through the centres of opposing side walls.

The aperture may be located substantially centrally on the apertured side wall.

However, it will be appreciated that the aperture may be offset from the centre of the apertured side wall in some embodiments. For example, the aperture may be located towards a middle of one edge of the apertured side wall, or towards a corner of the apertured side wall, or in any location on the apertured side wall which accommodates the full aperture within the perimeter of the apertured side wall.

The term "folded" may be interpreted to mean that the container is formed from a single piece of the laminate material, which has one or more folds. The piece of laminate material may be provided as a discrete piece or may be cut or isolated from a continuous piece of the laminate material. The container body may comprise any suitable number of folds. A given fold may be disposed between two adjacent walls of the container body, such that those walls meet at a distinct angle.

The container may be considered to be a carton, particularly a re-closeable carton.

The container may be used for any one or more of retort, aseptic, ambient or chilled applications. That is, for food storage in various scenarios. It will be appreciated that the container is not limited in any way solely to food container applications and it can be used for a variety of other container purposes as discussed further below.

The first end wall may be considered to be opposite the second end wall.

The aperture may have diameter which extends substantially across a majority of a width of its host side wall.

There may not be a seal in the laminate material provided on or across on the apertured side wall. That is, a join between separate parts of the laminate material may not be provided on the apertured side wall.

A planar wall may be provided at the base of the chamber. The planar wall may be opposite the aperture or opposite the apertured side wall. In other words, the base of the container may be substantially planar (which may be either or both of an internal or chamber-facing surface of the base and an external surface of the base).

An internal surface of the planar base may be substantially flat across its entire area. The internal surface of the planar base may be free from protrusions or recesses. The planar wall may lack a recess or well.

This can facilitate simpler container manufacture, since the laminate material may require fewer modifications in the process of folding / forming the container body using the laminate.

The planar wall may include a seal. This may help to mitigate the risk of product leaking out of the chamber via the laminate material, e.g. through the base.

The aperture may be a wide enough aperture for accepting a utensil such as a spoon which is of lesser width than the aperture, for removing the product or products from the chamber by manual insertion and removal of the utensil through the aperture.

The aperture may span at least about two thirds of the distance across the apertured side wall in the orthogonal direction from the first end wall to the second end wall. The aperture may span up to about 90% or 95% of that distance.

The aperture may be considered a wide neck aperture. The aperture may be able to receive or permit entry of a utensil such as a spoon for removing the product or products. That is, the aperture may be a wide-neck aperture for accepting a utensil such as a spoon which is of lesser width than the aperture, for removing the product or products from the chamber by manual insertion and removal of the utensil through the aperture.

The wide-neck aperture may include a neck or neck portion for receiving a closure.

The neck may be bonded or connected to the laminate material. The neck may extend away from the chamber by a neck height. The neck height may be up to around 3cm or 4cm in height, for example. The neck height may be around 1cm or 2cm in height.

The neck may have a neck width which spans at least about half or at least about two thirds of the distance across the apertured side wall in the orthogonal direction from the first end wall to the second end wall. The neck width may be at least three or at least four times greater than the neck height.

The neck may define a disc-shaped or cylindrical aperture which has a greater diameter than height.

The neck may include at least one flange or lip. The at least one flange may be bonded to the laminate material at corners of a chamber-facing side of the side wall.

This maximises the area of the apertured side wall which can be taken up by the aperture, whilst allowing for the neck to be suitably secured to the laminate material at various corners of the side wall.

The seal between the at least one flange and the side wall may be a circumferential seal around the aperture.

The neck may be bonded to an inside portion or outside portion of the container. If bonded to an inside portion, this should be done prior to the container being formed by folding the laminate.

The aperture may be at least 3cm in width, or at least 4cm or at least 5cm in width. In some embodiments, other diameter apertures of any integer or half integer value may be provided between 3cm and 15cm, for example 8.5cm in width.

The aperture may be at least 3cm in both length and width (or diameter), for example. The aperture may around 4cm or 5cm in both length and width (or diameter), in other examples. The aperture may be around 6cm or 8cm or 10cm in both length and width (or diameter), in further examples.

The apertured side wall may have an external perimeter defining a side wall area (or enclosed area). That is, folds at the boundary of the sidewall may define the area of the side wall.

The aperture may cover an area which is at least 40% (or more) of the side wall area. For example, the aperture area may be at least 45% or 50% (or more) of the side wall area. In another example, the aperture area may be at least 55% or 60% (or more) of the side wall area. The aperture area may be up to about 75% of the side wall area.

That is, the area bounded by the side wall perimeter.

The aperture may cover an area which is at least 40% or at least 50% or at least 60% of the area defined by the apertured side wall perimeter, whilst also having a diameter of any one of at least about: 3cm, 4cm, 5cm, 6cm, 8cm, 10cm.

The aperture is preferably as large as possible whilst fitting within the side wall area but without compromising overall structure of the sidewall.

Put another way, the aperture or neck may approach being an inscribed aperture (e.g. inscribed circle) in the apertured sidewall, except that the perimeter of the aperture is slightly inset from the perimeter of the side wall to the extent needed for maintaining structural integrity of the container body. For example, it may be inset by a few millimetres or up to about 1cm or 2cm (taken orthogonal to the perimeter edge of the sidewall). If a neck or closure-receiving portion is to be attached to the container, then the inset may accommodate suitable connection of the neck or closure-receiving portion to the laminate material.

The laminate container with a wide aperture can be used instead of glass jars and wide neck glass bottles, for example. This allows the benefits of a laminate container to be realised for additional products where logistical, transportation and storage costs for the packaging are reduced.

A midpoint between a centre of a first edge of the apertured side wall and a centre of an opposing edge of the apertured side wall may lie within the aperture.

A chamber-facing side of the apertured side wall may have an area which is less than the area of the aperture. Most of the area of the chamber-facing side of the apertured side wall may be disposed at or adjacent to corners of the apertured side wall.

The area of the chamber-facing side of the apertured side wall may be up to about 60% of the total area defined by the external perimeter of the apertured side wall. The area of the chamber-facing side of the apertured side wall may be about 22% to 50% of the total area enclosed by the external perimeter of the apertured side wall. For example, about 25% or about 30% or about 35% or about 40% or about 45% of the total area may be formed of a side wall area as opposed to an aperture area.

Opposing first and second points on the perimeter of the aperture may each be closer to the perimeter of the apertured side wall than they are to each other. Opposing third and fourth points on the perimeter of the aperture may each be closer to the perimeter of the apertured side wall than they are to each other. The first, second, third and fourth points may be equidistantly spaced around the aperture perimeter.

For a circular aperture, for example, there may be two points offset around the aperture perimeter by 90 degrees, and one or both of those points may be closer to the side wall perimeter than they are to the aperture centre.

An average distance (e.g. mean distance) between the apertured side wall perimeter and the aperture perimeter may be less than an average distance (e.g. mean distance) between the aperture perimeter and the aperture centre.

A first distance between a centre of the apertured side wall and the aperture centre may be less than a second distance between the aperture centre and a point on the perimeter of the apertured side wall, when the point, the aperture centre and the centre of the apertured side wall are colinear.

The aperture may be a circular aperture.

The aperture may be a single aperture in the apertured side wall. That is, it may be the sole aperture through which product can be removed from the container.

The laminate material may provide a barrier to odour, oxygen, UV light, and moisture.

The laminate material may comprise any combination of one or more polymer or plastic layers such as polyethylene; one or more metal layers such as aluminium layers; one or more paperboard layers. The laminate material may be conventional Tetra Pak (RTM) laminate material, for example. The laminate material may instead be the material of the fifth aspect of the present invention.

The at least one seal may be formed or provided where different parts or edges of the laminate material are connected together (such as heat sealed or glued together by adhesive) to form the container body. The at least one seal may include overlapping portions of the laminate material.

A first seal may be provided at or on the first end wall for sealing the folded laminate at the first end wall. A second seal may be provided at or on the second end wall for sealing the folded laminate at the second end wall.

The seal(s) may be disposed on container faces which are adjacent to and/or on opposite sides of the apertured face.

One or more folded tabs (or flaps) may be provided on or sealed to the first end wall. However, it will be appreciated that a flat seal may be used.

One or more folded tabs (or flaps) may be provided on or sealed to the second end wall. However, it will be appreciated that a flat seal may be used.

Each tab or flap may be substantially triangular in shape. However, it will be appreciated that a different tab or flap shape may be provided.

At least one folded tab portion may be provided on or sealed to both of the first and second end walls.

The folded tab portions may be formed of laminate material. The laminate material forming the folded tab portions may be considered excess portions of laminate material not used to form the walls defining the chamber of the container body. The folded tab portions may be formed by folding a substantially rectangular piece of laminate material into the container body.

At least one edge seal may be formed substantially along overlapping edges of the laminate material. The edge seal may extend along a direction perpendicular to the first and second seal. The edge seal may be disposed on at least one side wall. The edge seal may be disposed substantially centrally on the side wall. The edge seal may be disposed offset from a centre of the side wall.

A first seal may be provided on the first end wall and a second seal may be provided on the seal end wall. The seals may be disposed opposite each other about the apertured side wall. Where one or more additional side walls are provided, the additional side wall(s) may lack seal(s). That is, the one or more additional side walls may each be an 'unbroken' wall or a wall that is not interrupted by a seal formed by bonding or securing two different parts of the laminate together, although the wall itself presents a barrier that resists or prevents product leaking from the container.

At least four side walls may be provided. The container may be substantially cuboidal or prismatic.

The container may be constructed using laminate material in the form of a net. That is, a shape for folding into the desired container body. The net may be a single net which is foldable to provide all of the side walls and end walls of the container. The net may have two or more pairs of edges which each have a first edge that is substantially parallel to an opposing second edge. For example, the container may be constructed with a substantially square or rectangular net.

The apertured side wall may be disposed between and connect together the first end wall and the second wall. That is, the first and second end walls may be disposed on opposite sides of the apertured side wall. The apertured side wall may be disposed between and connect together those end walls as part of the net.

The apertured side wall may be connected to the first end wall by a fold and/or may be connected to the second end wall by a fold.

The container body may be a square-based substantially cuboidal container or a square prism container. The square base of the container may oppose the apertured side wall.

The apertured side wall may have a square or rectangular perimeter.

The container body may have a height to width ratio relative to the apertured side wall, the height to width ratio being substantially in the range of 2:1 to 1:2.

The container may be at least half as tall as it is wide. The container may be up to twice as tall as it is wide. The height of the container may be taken along an axis which is parallel to a central axis of the aperture. The width of the container may be taken along an axis which is orthogonal to a central axis of the aperture.

This can provide a relatively short / squat container. Put another way, the container can have a low centre of mass and be at relatively lower risk of being tipped over accidentally, if knocked.

The container may have a minimum chamber volume of about 25 ml. The container may have a maximum chamber volume of about 5000 ml.

The unit ml may instead be cm3. The chamber volume may have an integer value in the range 25 ml to 5000 ml, such as 50 ml, 75 ml, 100 ml, 125m1, 150 ml, 200 ml, 250 ml, 300 ml, 400 ml, 500 ml, 750 ml, 1000 ml, 1500 ml, 2000 ml, 2500 ml, 3000 ml, 3500 ml, 4000 ml, or 4500 ml, for example. The range of chamber volumes may be selected to have lower and upper limits which are each independently selected from any of the values mentioned herein.

The container may be substantially empty for receiving the product. The container may receive a volume of the product which is substantially the same as the chamber volume of the container, or approaching the chamber volume (optionally with an amount of gas such as nitrogen gas filling the remaining volume).

The container may comprise a plurality of side walls of the laminate material. That is, one or more additional side walls may be provided, in addition to the apertured sidewall. Each of the plurality of side walls may connect the first and second end walls together. Each of the plurality of side walls may be respectively connected at either side to a different side wall. The aperture may be provided through the laminate material of one of the plurality of side walls.

At least one side wall may be formed of a continuous uninterrupted portion of the folded laminate. That is to say the folded laminate material may extend continuously in a single plane without interruption by the at least one seal. The aperture may be disposed through the continuous portion of the folded laminate of the side wall. Absence of the seal on that side wall can provide space to accommodate a larger aperture such as the wide neck aperture.

Put another way, the apertured side of the container may lack a seal where two different portions of the laminate material are sealed to each other.

Where at least four side walls are provided, at least two side walls or at least three side walls may not comprise a seal. One side wall may comprise a seal or edge seal. The edge seal may be formed along a longitudinal side of the container.

The aperture may be disposed through a planar portion of the folded laminate material.

Indicia such as branding and/or images of container contents/product (such as food or tablets) may be printed or otherwise provided on the laminate material. Indicia may be provided on one or both of the first and second end walls. Indicia may be provided on one, some or all of the side walls. Indicia may be provided on the at least one folded tab portion, where provided.

Indicia provided on the at least one folded tab portion may align with corresponding indicia provided on at least one of the respective end walls for providing any of continuous image(s), logo(s) or letter(s), for example. Where a folded tab is disposed over indicia on one of the first and second end walls, indicia on the folded tab may be substantially the same as the concealed or covered indicia on the first or second end wall.

Aligning the indicia provided on the folded tab(s) with the indicia on the respective end wall(s) allows indicia across the folded tab(s) and respective end wall(s) to form a substantially continuous appearance to the indicia. This provides a more aesthetically pleasing container.

The aperture may be sealed by a metal foil lid or metal foil laminate. For example, the metal foil may be aluminium. The metal foil lid may be preferred for aseptic packaging applications. The metal foil lid may prevent ingress of one or more of moisture, light, oxygen and bacteria.

The laminate lid seal may be foiled paper. A discrete closure may be provided over the lid seal for protecting the seal prior to chamber opening, and for allowing re-closure of the aperture after lid seal is broken.

The aperture may be re-closeable or substantially re-sealable by a closure or cap or lid. For example, the closure may be a screw-threaded lid or push-fit lid. The closure or lid may be suitable for sealing the aperture against egress of product from the chamber and/or sealing the aperture against ingress of air from outside the chamber.

The closure or cap or lid may include a top wall having a top wall area which is equal to or larger than the aperture for covering the aperture. The top wall may be a planar top wall. The closure or cap or lid may include a circumferential rim on the wall. The closure or cap or lid may include a screw thread around the circumferential rim for cooperating with a corresponding screw thread provided on the container. The corresponding screw thread may be provided on a neck attached to the container body,

for example.

The closure or lid may include branding or image(s) corresponding to the product in the container. The branding or image(s) may be provided on the (preferably planar) top wall.

The closure may lie substantially above the aperture. The closure may lie at an edge of the container. In order words, the closure may not penetrate substantially into the container. Positioning the closure at an edge or outside of the container provides a substantially empty internal volume for receiving product.

To dispense the product, the closure or cap may be detached or moved away from the container. For example, a screw threaded lid may be removed.

The container may not include a pump dispenser. That is, a pump dispenser may not form part of the closure or lid or other device used to close or seal the aperture. A pump dispenser is particularly unsuitable where the product is a solid or powder or where the product is viscous, for example.

In addition, it should be noted that a pump dispenser requires a small aperture area to facilitate a comparatively large bonding area for the part of the pump dispenser bonded to the container. Alongside the small aperture and large bonding area, a pump dispenser needs to be used on a relatively rigid container structure, or else the pressure applied to a pump dispenser during use will excessively deform the container walls and may split them, causing product leakage.

The closure may be made of metal such as aluminium. The closure may be made of plastic.

The closure and the metal foil seal may both be provided as part of the container.

Where a screw-threaded lid is used, a neck portion or lid receiving portion may be secured or sealed to the side wall for screwing the lid in place.

Where a push-fit lid is used, the lid may substantially form a seal to the aperture rim by virtue of the push-fit connection. The push-fit lid may extend into the chamber to some extent.

The closure or lid may be colour-matched or pattern-matched or colourway-matched to indicia on the container. This can assist in pairing or matching a correct lid to a container where there are multiple containers of similar size open at the same time, and may assist if there are multiple container of different size but which have equally-sized closures. This can avoid cross contamination of product between containers.

The closure may be a childproof cap. A childproof cap may be preferred where the container contains medicinal and/or nutraceutical products. The closure may be provided in addition to the metal foil lid. The closure may allow the container to be substantially resealable for prolonging the shelf-life of the product in the container, e.g. after a metal seal (if provided) has been broken.

The container may include or be used to package products such as fast-moving consumer goods. The product may include wet or dry goods. The product may include solid or semi-solid product (where a semi-solid product includes at least some solids or is a flowable solid, or contains some solid and some liquid portions). The product may include liquid.

The container may include or be suitable for receiving viscous liquid products.

The container may comprise liquid or product which cannot be easily poured and/or pumped. For example, the product may include a solid product stored in/under a liquid (for example, gherkins in vinegar or pickling brine).

The products may include any one or more of the following: A food or beverage such as any of mayonnaise, peanut butter, chocolate spread, nuts, baby food, coffee beans or coffee granules/powder (or any other granules/powder), pasta sauce, mustard, jam, double cream, pickled food, flour, salt, microwaveable food, and confectionary; -A health and beauty product (or cosmetic product) such as any of baby formula, lotion, gel, cream, and powder or another solid; -A medicinal product such as a digestant (for digestive health), a plurality of capsules (or tablets/pills), oral medicine, and ointment; -A nutraceutical product such as a plurality of vitamin tablets, supplements, and protein powder.

The container may be used to package a product such as any of pet food, oil and/or grease, and industrial powder.

The container or laminate material may be suitable for irradiation by microwaves for heating the product therein. (i.e. it may be a microwaveable container). For example, if the container contains microwaveable food or contents, then the laminate material and the closure should be made of microwave-safe materials.

The container may be a chemical container for containing solid chemicals such as laboratory chemicals. The container chamber (or the surface(s) of the laminate material facing into the chamber) may be lined with an inert or passivating layer such as a polymer layer or metal layer, such as polytetrafluoroethylene (PTFE) or platinum, for example. It will be appreciated that other polymer(s) or metal(s) (or material) may be used to the extent that they are compatible for use with the product in the chamber.

For example, the container may be suitable for containing an inedible chemical product or a household chemical. In some examples, the container may contain any of: washing powder, washing capsules, dishwasher capsules/tablets, or an industrial chemical. For example, soda crystals or another pipe-unblocking chemical could be provided.

The container therefore provides a safer way to store household products, when compared to simple cardboard boxes that can be opened relatively easily by a child, whilst providing a more environmentally friendly option to conventional glass and plastic packaging.

The container is preferred for use where the chemical product involved does not require specific protective packaging. For example, a spill absorbent, or garden fertiliser could be provided in the container.

According to a second aspect of the present invention, there is provided a method of manufacturing a folded laminate container. The method may comprise the steps of: folding a sheet of laminate material into a container body which has a first end wall, a second end wall, and at least one side wall connecting the first and second end walls together, a chamber in the container body being defined by the first end wall, the second end wall and the at least one side wall, and an aperture being provided through the laminate material of the at least one side wall, the aperture spanning at least about half of a distance across the apertured side wall in an orthogonal direction from the first end wall to the second end wall; ii. sealing the laminate material in the shape of the container body so that the chamber is suitable for retaining a product, including at least one seal: a) on the at least one side wall and offset from the aperture, or b) disposed on the first end wall or the second end wall (but not the apertured side wall).

The advantages are similar to those discussed with respect to the first aspect of the invention.

Folding the sheet of laminate material may include folding one or more portions of the sheet into a plurality of folded tabs.

The laminate material may be pre-creased, or the method may include the step of providing creases or pre-folds in the laminate material.

The aperture may be provided or formed through the laminate material prior to the folding step.

The closure, or neck portion thereof, may be applied to the laminate material prior to the folding step.

The laminate material may be folded into a tubular-type structure initially, followed by folding respective portions of the material into the end walls. An edge seal may be formed longitudinally by overlapping the material and sealing along the overlap.

Sealing the laminate material in the form of the container may include sealing the folded portions at the end walls for preventing product spillage or leakage.

Sealing the laminate material may include sealing some of the folded tabs to the container body at the first end wall.

Sealing the laminate material may include sealing some of the folded tabs to the container body at the second end wall, opposite the first end wall.

A seal in the laminate material may not be provided on or across the apertured side wall.

In another aspect of the method, the at least one seal may be disposed on the at least one side wall and offset from the aperture, instead of being on a different wall to the aperture.

According to a third aspect of the present invention, there is provided a container for a product, the container formed of a laminate material folded as a container body having a first end wall of the laminate material, a second end wall of the laminate material, and at least one side wall of the laminate material connecting the first and second end walls together, in which the first end wall, the second end wall and the at least one side wall define a chamber for holding the product, in which an aperture is provided through the laminate material of the at least one side wall, a middle of the aperture being disposed on a first central plane of the container and also on a second central plane of the container, the second central plane being orthogonal to the first central plane, and the container body including at least one seal for sealing the folded laminate material as the container body, the at least one seal being: a) disposed on the first end wall or the second end wall, or b) on the at least one side wall and offset from the aperture.

Any feature or independently selected combination of features presented with respect to the first aspect of the invention may be provided in the third aspect of the invention.

According to a fourth aspect of the present invention, there is provided a method of manufacturing a folded laminate container. The method may comprise the steps of: i. folding a sheet of laminate material into a container body which has a first end wall, a second end wall, and at least one side wall connecting the first and second end walls together, a chamber in the container body being defined by the first end wall, the second end wall and the at least one side wall, and an aperture being provided through the laminate material of the at least one side wall, in which a middle of the aperture is disposed on a first central plane of the container body and also on a second central plane of the container body which is orthogonal to the first central plane; ii. sealing the laminate material in the shape of the container body so that the chamber is suitable for retaining a product, including at least one seal: a) on the at least one side wall and offset from the aperture, or b) disposed on the first end wall or the second end wall.

Any feature or independently selected combination of features presented with respect to the second aspect of the invention may be provided in the fourth aspect of the invention.

According to a fifth aspect of the present invention, there is provided a laminate material for aseptic or retort packaging, the laminate material including a first layer, adhesive layer, and a second layer for rigidity, the first and second layers being made from different materials, the first and second layers being substantially coextensive, and the first and second layers being releasably attached together, in which: the first layer is made of a metal or metal alloy bounding the chamber for preventing oxygen and/or light from passing through the laminate material into the chamber; and the second layer is made of a cellulosic material.

Advantageously, the laminate material is easier to recycle than currently available laminate materials. The releasably connected layers can be separated to facilitate recycling. This can improve recycling compliance rates, where a person chooses to recycle the laminate (or container thereof) instead of putting it into a general refuse receptacle.

The laminate material may not comprise a polyethylene adhesive (or in other words may lack a polyethylene-based or polyethylene-derived adhesive). Laminate materials constructed using a polyethylene adhesive are more difficult to recycle.

The laminate material may be provided in or folded into the form of either a carton or a bottle body.

The bottle body may be the container described in the first, second or third aspects of the present invention.

The first layer may form a terminal layer. The metal or metal alloy may include any one or more of: aluminium, stainless steel, copper, iron, brass, tin, silver, titanium, nickel and bronze.

At least one of the first and second layer may comprise a tab for facilitating the separation of the first and second layers.

The laminate material may comprise a third layer including glassine for forming a terminal glassine layer. The third layer may be releasably attached to at least one of the first and second layer.

A profile of the first layer may not be coterminous with a profile of the second layer. The laminate material may have a first edge. The laminate material may have a second edge opposing the first edge. The first and second layers may each have a first lateral extent at the first edge and a second lateral extent at the second edge. The lateral extent of the first layer at the first edge may be greater than the lateral extent of the second layer at the first edge. The lateral extent of the second layer at the second edge may be greater than the lateral extent of the first layer at the second edge.

When the container is folded, the different lateral extents of the layers may allow a portion of one side of the first layer to bond to an opposing side of the first layer. A portion of one side of the second layer may bond to an opposing side of the second layer.

A portion of a first face of each layer may be bonded to a portion of a second face of said layer.

An aperture may or may not be provided through the laminate material. That is, the laminate material may be used to form a container according to the first aspect, for example, or may be used to form a different container.

Any aspect of the invention may include any feature or features presented with respect to any other aspect of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example only to the accompanying drawings, in which: Figure 1 shows a perspective view of a first embodiment of a container according to the present invention; Figure 2 shows a perspective view of a second embodiment of a container according to the present invention; Figure 3 shows a perspective view of a third embodiment of a container according to the present invention; Figure 4 shows a perspective view of a fourth embodiment of a container according to the present invention; Figure 5 shows a perspective view of a fifth embodiment of a container according to the present invention; Figure 6 shows a second perspective view of the fifth container of Figure 5, depicting orthogonal central planes of the container; Figure 7 shows a top perspective view of a sixth embodiment of container according to the present invention; Figure 8 shows a cross-section of a first embodiment of a laminate material. Figure 9 shows a plan view of the laminate material of Figure 8; Figure 10 shows a perspective view of a first edge of the laminate material of Figure 8 bonded to a second edge of the laminate material; Figure 11 shows a cross-section of the first edge of the laminate material of Figure 8 bonded to the second edge of the laminate material; Figure 12 shows a cross-section of a second embodiment of a laminate material.

Figure 13 shows a plan view of the laminate material of Figure 12; and Figure 14 shows a perspective view of a first edge of the laminate material of Figure 12 bonded to a second edge of the laminate material.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring firstly to Figure 1, a container according to the present invention is generally indicated at 10. The container 10 may be used to hold a product such as viscous liquid or powder.

The container is formed from a folded laminate material 12. The folded laminate material 12 defines a chamber for receiving a product.

Whilst the container 10 is shown in partial view, it will be appreciated that the container 10 has six main faces which provide a substantially cuboidal body. The laminate material 12 provides a barrier against oxygen, moisture and UV from entering the container 10.

A wide aperture (or wide neck aperture) 14 is provided. The wide neck aperture 14 is disposed through a top face of the container 10 in the orientation shown, as described below. The aperture 16 is substantially circular in this embodiment, although other shapes of aperture may be used in other embodiments.

A first face is provided at a first end wall 16. The first face can be considered a left-side face of the container. A second face is provided at a second end wall (18, see Figures 2 to 5). The second face can be considered a right-side face. The second end wall 18 is disposed opposite to the first end wall 16. The second end wall 18 is substantially similar to the first end wall 16.

A third face of the container 10 is provided at a first side wall 20. The third face can be considered a top face. The first side wall 20 is disposed adjacent to the first end wall 16 and the second end wall 18. The first side wall 20 connects or extends between the first end wall 16 and the second end wall 18.

A fourth face of the container 10 is provided at a second side wall 22. The fourth face can be considered a bottom face. The second side wall 22 is disposed adjacent to the first end wall 16 and second end wall 18. The second side wall 22 is disposed opposite to the first side wall 20.

A fifth face of the container 10 is provided at a third side wall 24. The fifth face can be considered a front face. The third side wall 24 is disposed adjacent to the first end wall 16 and second end wall 18. The third side wall 24 is disposed adjacent to the first side wall 20 and second side wall.

A sixth face of the container 10 is provided at a fourth side wall (not shown). The sixth face can be considered a rear face. The fourth side wall is disposed adjacent to the first end wall 16 and second end wall 18. The fourth side wall is disposed adjacent to the first side wall 20 and second side wall 22. The fourth side wall is disposed opposite to the third side wall 24.

In this embodiment, the container 10 may be constructed from a single sheet of the laminate material 12. During manufacture, first and second opposing edges of the laminate material sheet are connected together. The first and second opposing edges are overlapped and are sealed together to form an overlap seal. The laminate sheet at that stage forms a tube-like structure with a substantially square cross-section.

The laminate material 12 can be folded and sealed at either end of the tube structure to form the first end wall 16 and second end wall 18 respectively. The first end wall 16 has a first end wall seal 30. The second end wall 18 has a second end wall seal (36, see Figures 2 to 5).

Folded tab portions 32 are provided on the first end wall 16 and the second end wall 18. The folded tab portions 32 in this embodiment are formed from excess material at the first and second end wall 18 as is conventional when constructing cuboidal containers from a substantially rectangular sheet of material. The folded tab portions 32 are folded onto the first end wall 16 and second end wall 18. The folded tab portions 32 are sealed to the first end wall 16 and second end wall 18. That is, the folded tab portions for the first end wall are disposed opposite the second end wall, and vice versa.

The container 10 has three faces which are substantially free from seals 30 or folded tab portions 32. In this embodiment, the first side wall 20 (i.e. top face), second side wall 22 (i.e. bottom face), and third side wall 24 (i.e. front face) are substantially free from seals 30 or folded tab portions 28. In other words, these faces are formed of continuous, uninterrupted portions of the laminate material 12.

The aperture 14 is provided through the first side wall 20. In other words, the aperture 14 is provided through the top face of the container 10. It will be appreciated that in other embodiments the aperture 14 may be disposed one or both of the second side wall 22 and the third side wall 24. The aperture 14 is disposed on a centre of the first side wall 20. In other embodiments, the aperture 14 may be disposed offset from the centre of the first side wall 20.

In this embodiment, the aperture 14 is not disposed on a face comprising the overlap seal. Positioning the aperture 14 on a side wall 20 substantially free from seals or folded tabs 32 allows the aperture 14 to occupy a comparatively larger area of the container side without crossing a seal 20, which could adversely affect the seal and the closure means. The aperture 14 can be much larger than the aperture provided in conventional cartons. In this embodiment, the aperture 14 occupies approximately 5060% of the total area of the first side wall 20.

It will be appreciated that slightly smaller apertures (e.g. around 40% side wall area) may be provided in other embodiments, or that relatively larger apertures may be used in further embodiments.

The aperture should be large enough to permit a utensil to be used to scoop or spoon out the product from the container, rather than by a 'pouring' motion. Larger apertures can be preferred for ease of doing so, and so that the occluded or 'overhung' region of the chamber (in the upper chamber corners) is more easily accessible, e.g. in some cases to minimise the amount of product left adhered to the chamber corner(s).

The aperture 14 is closed by a closure 34. In this embodiment, the closure 34 is a screw cap. In other embodiments, alternative closures 34 may be provided. The closure 34 provides a means of opening and substantially resealing or re-closing the aperture 14.

Referring now to Figures 2 to 5, the container 10 can be sized to accommodate or provide chambers of different relative shapes or sizes. Identical reference numerals will be used to refer to equivalent features across the embodiments.

Referring to Figure 2, a second embodiment of the container according to the present invention is generally shown at 100. The container 100 is intended as a replacement container for a conventional pasta sauce jar. Hence, the surface indicia include images of tomatoes, which are substantially aligned across between the tabs and the walls. The closure is red to substantially match the indicia.

In this embodiment, the container 100 could be sized to accommodate approximately 300 ml to 5 litres of product, for example.

Referring to Figure 3, a third embodiment of container according to the present invention is generally shown at 200. The container 200 is intended as a replacement for a jam jar. Hence, the surface indicia include images of strawberries, which are substantially aligned across between the tabs and the walls. The closure is red to substantially match the indicia.

In this embodiment, the container 200 could be sized to accommodate approximately ml to 700 ml of product.

Referring to Figure 4, a fourth embodiment of container according to the present invention is generally shown at 300. The container 300 is intended as a replacement container for ground coffee packaging or coffee granule/bean container. Hence, the surface indicia include images of coffee beans, the images being substantially aligned across between the tabs and the walls. The closure is brown to substantially match the indicia.

In this embodiment, the container 300 could be sized to accommodate approximately 200 ml to 1000 ml of product.

Referring to Figure 5, a fifth embodiment of container according to the present invention is generally shown at 400. The container 400 is a replacement for a pharmaceutical or nutraceutical bottle/container. Hence, the surface indicia include images of tablets or capsules, the images being substantially aligned across between the tabs and the walls. The closure is beige or tan to substantially match the indicia. This container could also be suited for holding chewing gum, for example.

In this embodiment, the container 400 could be sized to accommodate approximately ml to 150 ml of product.

In the embodiments of Figures 2 to 5, indicia 40 are provided on the exterior or outward-facing surfaces of the laminate material 12. The indicia 40 give an indication of the product stored in the container 100, 200, 300, 400. It will be appreciated that in other embodiments the indica 40 may include branding material and/or textual information about the product, for example. The indicia may provide partial container surface coverage or may fully cover the container body.

In these embodiments, each of the closures 36 are colour-coded to indicia 40. This facilitates identification of the product in the container 100, 200, 300, 400.

As can be seen most clearly in Figure 2, the indicia 40 are provided on the folded tabs 32 as well as the main container body. The indicia 40 on the folded tabs 32 align with corresponding indicia 40 disposed on the second end wall 18. The alignment of the indica 40 on the folded tabs 32 and second end wall 18 produces a consistent image across the right-side face of the container 100. In other words, a full image can be displayed on the right-side face despite the folded tabs 32 covering portions of the second end wall 18.

Referring also to Figure 6, a first plane 50 is shown. The first plane 50 passes through a centre of the first end wall (at the left side of Figure 6) and a centre of the second end wall 18. A second plane 52 is shown passing through a centre of the third side wall 24 and the fourth side wall (at the rear of the container seen in Figure 6). In other words, the planes 50, 52 each pass through an opposing pair of end/side walls. The second plane 52 is orthogonal to the first plane 50. The aperture 14 is positioned such that it is centred on both the first plane 50 and the second plane 52. That is, a centre of the aperture 14 is disposed at a point in which the first plane 50 intersects the second plane 52.

Referring to Figure 7, another embodiment of a container is indicated generally at 500.

The container 500 is similar to the containers in the previous embodiments.

A large or wide-neck aperture 514 is provided, which in this example is nearly as wide as the side wall through which the aperture 514 is provided. The aperture 514 in this embodiment takes up a majority of the area of the apertured side of the container 500.

The aperture 514 diameter for this container could be in the range 7cm to 14cm, for example, although integer values inside and outside this range are also contemplated.

A planar wall 522 is provided at the base of the chamber, opposite the aperture 514. The planar wall 522 is substantially planar or flat across its full length and width. There is no recess or well in the planar wall 522.

A seal 535 on the chamber-facing side of the laminate is visible running across the base.

A neck or neck portion 534a is provided at the aperture perimeter for receiving a closure or screw-threaded lid 534. A corresponding screw thread is provided around the exterior of the neck 534a. Similar necks may be provided in other embodiments, or a push-fit type closure may be used, or any other suitable seal or closure may be provided. That is, a screw-threaded lid is not essential, although it may be preferred.

The screw-threaded lid 534 of this embodiment is shown unscrewed from the container in Figure 7. The lid 534 includes a top wall (seen face-on in Figure 7) which has a top wall area that is about equal to or slightly larger than the aperture 514. This area allows the top wall to cover the whole aperture 514 when the lid 534 is connected to the neck 534a. There is a rim around the top wall, and a screw thread around the inside of the circumferential rim which cooperates with the screw thread on the neck 534a.

It will be appreciated from the overhead view in Figure 7 that the neck is much wider than it is tall (in the direction away from the chamber defined by the laminate walls). For example, the neck may only be about 2-3cm high, but may be 3-4 times or more wider than that.

An important advantage of the present invention is having an easily recyclable container with a large aperture through which to easily remove a custom amount of product. Whilst each of the preceding embodiments of container is closed by a screw-threaded lid, it will be appreciated that other types of closure or lid or aperture seal may be provided as needed. However, a pump dispenser type closure is not provided in any of the embodiments because a pump dispenser is not suitable for withdrawing a custom amount of product such as solid food or viscous food or another solid from the container.

It will also be appreciated that various other embodiments of container are possible and features from these different embodiments of container may be provided in any combination. The shape of the aperture is preferably circular, but may be another suitable shape if desired. Whilst cubic or cuboidal containers have been described above, it will be appreciated that any suitable shape of container may be provided by folding and sealing the laminate material appropriately.

Referring now to Figure 8, a laminate material is generally shown at 1010. The laminate 1010 can be used to form a container. The container may be a carton or a bottle for example. The container may be any of the containers 10, 100, 200, 300, 400, 500 described above, if an aperture is cut, stamped or otherwise provided in a suitable position in the laminate.

In a preferred embodiment, the container is an aseptic container for containing food, beverages, health and beauty products, medicinal products, nutraceutical products, household products such as cleaning products are garden chemicals, or automotive products such as oils, lubricants and waxes.

The laminate material 1010 has two layers releasably connected together by adhesive. This facilitates separation of different material layers for recycling. The relative thicknesses of the layers and adhesive in Figure 7 are not necessarily shown to scale.

The laminate material includes a first layer 1012 and a second layer 1016. The first layer 1012 and second layer 1016 are attached by adhesive 1014. The adhesive 1014 provides a degree of adhesion. The degree of adhesion is sufficient to keep the first and second layers 1012, 1016 attached during use. The degree of adhesion can be overcome by an individual manually peeling the first layer 1012 from the second layer 1016, described in more detail below.

The first layer 1012 is made from aluminium or aluminium foil. The first layer 1012 provides a barrier. When formed into a container, the first layer 1012 mitigates against the ingress of light, oxygen, moisture and bacteria through the laminate material 1010. It will be appreciated that in other embodiments, the first layer 1012 may be made from other suitable materials such as another metal or a metal alloy (which may be selected from aluminium, stainless steel, copper, iron, brass, tin, silver, titanium, nickel, and bronze). In this embodiment, the aluminium / foil has a thickness of 20-30 microns. The first layer 1012 is a terminal layer.

The second layer 1016 is made from paperboard. The second layer 1016 provides the laminate with strength and/or rigidity. When used to form the container, the second layer 1016 should provide the container with structural integrity.

The laminate material 1010 can be used to form a container. A plan view of the laminate material 1010 used to form a container is shown in Figure 9. The first layer 1012 is shown disposed over the second layer 1016. The laminate material 1010 is substantially rectangular. The laminate 1010 has a first edge region 1018 and second edge region 1020. The first and second edges 1018, 1020 are disposed opposite each other. The laminate has a third edge region 1022 and fourth edge region 1024. The third and fourth edges 1022, 1024 are disposed opposite each other. The third and fourth edges 1022, 1024 are disposed adjacent to the first and second edges 1018, 1020.

It will be appreciated that the laminate material 1010 in Figure 9 has a rectangular first layer which overlays and is slightly offset from a rectangular second layer. This means that the second edge 1020 of the first layer does not overlie the second layer 1016 (e.g. as viewed in plan), but the other three edges of the first layer do overlie the second layer 1016. In this example, the first layer 1012 is about the same length as the second layer 1016, albeit offset from the second layer, and the first layer is also less wide than the second layer.

In other words, the second layer 1016 overlaps the first layer 1012 at the first edge 1018, and also at the two lateral third and fourth edges. The first layer 1012 overlaps the second layer 1016 at the second edge 1020.

The difference in the lateral extent at the first edge 1018 and second edge 1020 facilitates bonding of the first edge 1018 to the second edge 1020, to form a seal 1030. As part of the seal 1030, part of the first layer 1012 bonds to another part of the first layer 1012, and part of the second layer 1016 bonds to another part of the second layer 1016.

Figures 10 and 11 depict the seal 1030 between the first and second edge 1018, 1020. The first layer 1012 at the second edge 1020 wraps around or is folded over/about the second layer 1016. The second edge region 1020 is brought into contact with the first edge region 1018 when forming the seal 1030.

To form the seal 1030 a first face of the first layer 1012 at the first edge 1018 is brought into contact with a second face of the first layer 1012 at the second edge 1020. A first face of the second layer 1016 at the first edge 1018 is brought into contact with a second face of the second layer 1016 at the second edge 1020.

In other words, a portion of the first layer 1012 at one edge bonds with a further portion of the first layer 1012 at the other opposing edge, indicated generally at 1042 on Figure 5. A portion of the second layer 1016 at one edge bonds with a further portion of the second layer 1016 at the other opposing edge, indicated generally at 1044 on Figure 5.

The bond between the first layer 1012 at the first edge 1018 and the first layer 1012 at the second edge 1020 may be stronger than the connection between the first layer 1012 and second layer 1016. The bond between the second layer 1012 at the first edge 1018 and the second layer 1012 at the second edge 1020 may be stronger than the connection between the first layer 1012 and second layer 1016.

In this embodiment, the bond 1042 between each face of the first layer 1012 is formed by heat sealing. The bond 1044 between each face of the second layer 1016 is formed by heat sealing. It will be appreciated that in other embodiments the bonds 1042, 1044 may be formed via adhesive, for example.

The seal 1030 is an air-tight seal. The seal 1030 mitigates the ingress of moisture, air/oxygen and bacteria. The seal 1030 prevents the container's contents from leaking out of the container.

Folded tab portions can be formed and sealed as needed in order to close ends of the tube formed by the laminate.

The laminate material 1010 includes creases 1032, which can be preformed creases. In this embodiment, the creases 1032 allow the laminate material 1010 to be folded into the shape of a carton. It will be appreciated that, in other embodiments, the laminate material 1010 may be formed with creases 1032 in any position necessary to allow folding of the laminate material 1010 into the shape of a container of a desired shape and/or size.

Labelling and printing processes can be performed prior to construction of the container. That is, the laminate may be provided with suitable indicia such as label(s) and/or other print prior to folding / forming it into a container.

Referring to Figure 12, a second embodiment of laminate material is generally shown at 1300. The laminate material 1300 is substantially similar to that of the first embodiment except as now described.

The laminate material 1300 of the second embodiment includes a third layer 1302.The third layer 1302 includes or is made of glassine. The third layer 1302 is a terminal layer.

The third layer 1302 is releasably connected to the second layer 1016 by a second adhesive layer 1304 providing a degree of adhesion. The adhesive may be the same as the first adhesive or may be a different adhesive. Similar to the layers of the first embodiment of laminate material, the degree of adhesion between the second layer 1016 and third layer 1302 can be overcome by an individual manually peeling those layers apart.

As shown in Figures 13 and 14, a container may be made from the second embodiment of the laminate material 1300 in a similar manner to that described for the first embodiment of the laminate material 1010.

It will be appreciated that the laminate material 1010 in Figure 13 has a rectangular first layer which overlays and is slightly offset from a rectangular second layer, and that there is a rectangular third layer which overlays and is slightly offset from the first layer. This means that the second edge 1020 of the first layer does not overlie the second layer 1016 and the neighbouring edge of the third layer does not overlie the first layer (e.g. as viewed in plan). However, the other three edges of the first layer do overlie the second layer 1016, and the corresponding other three edges of the third layer do overlie the first layer. In this example, the first layer 1012 is about the same length as the second layer 1016, albeit offset from the second layer, and the first layer is also less wide than the second layer. Similarly, in this example, the third layer 1302 is about the same length as the first layer 1012, albeit offset from the first layer, and the third layer 1302 is also less wide than the first layer.

In other words, the lateral extent of the first layer 1012 and second layer 1016 is greater than that of the third layer 1302 at the first edge region 1018. The lateral extent of the third layer 1302 is greater than the lateral extent of the first layer 1012 and second layer 1016 at the second edge region 1020.

The layers are connected in a similar manner to the previous embodiment of laminate material 1010. In addition, a first face of the third layer 1302 bonds to a second face of the third layer 1302 at the second edge 1020. The bond between the two faces of the third layer 1302 may be stronger than the degree of adhesion provided by the second adhesive 1304.

When constructed or provided as a container, the third layer 1302 may form a glassine pouch. The glassine pouch may be peeled away from the rest of the container. The glassine pouch is suitable for microwaving. The glassine pouch can contain microwavable food.

The laminate materials 1010, 1300 have the advantage of being more easily processed for recycling. The layers 1012, 1016, 1302 are releasably attached, allowing the layers to be readily separated into paper and metal recycling receptacles for example. In other embodiments, one or more of the layers may include a tab or tabs to facilitate the separation of the various layers.

Note that the laminate materials 1010, 1300 do not comprise polyethylene. This can further simplify the process of recycling the laminate material 1010, 1300.

The embodiments described above are provided by way of example only, and various changes and modifications will be apparent to persons skilled in the art without departing from the scope of the present invention as defined by the appended claims.

Claims

CLAIMS1. A container for a product, the container formed of a laminate material folded as a container body having a first end wall of the laminate material, a second end wall of the laminate material, and at least one side wall of the laminate material connected to the first end wall at a first fold and connected to the second end wall at a second fold, the at least one side wall connecting the first and second end walls together, in which the first end wall, the second end wall and the at least one side wall define a chamber for holding the product, in which an aperture is provided through the laminate material of the at least one side wall, the aperture spanning at least about half of a distance across the apertured side wall in an orthogonal direction from the first end wall to the second end wall, and the container body includes at least one seal for sealing the folded laminate material as the container body, the at least one seal being disposed: a) at least on the first end wall or the second end wall but not the apertured side wall, or b) on the at least one side wall and offset from the aperture.
2. A container as claimed in claim 1, in which the container has first and second central planes which are orthogonal to each other, and a middle of the aperture is disposed on the apertured side wall at a position where the first and second central planes intersect.
3. A container as claimed in claim 1 or claim 2, in which a planar wall is provided at the base of the chamber, opposite the aperture.
4. A container as claimed in claim 3, in which the planar wall lacks a recess or well.
5. A container as claimed in any preceding claim, in which opposing first and second points on the periphery of the aperture are each closer to the perimeter of the apertured side wall than they are to each other.
6. A container as claimed in any preceding claim, in which the aperture is a wide enough aperture for accepting a utensil such as a spoon which is of lesser width than the aperture, for removing the product or products from the chamber by manual insertion and removal of the utensil through the aperture, the aperture spanning at least about two thirds of the distance across the apertured side wall in the orthogonal direction from the first end wall to the second end wall.
7. A container as claimed in any preceding claim, in which the aperture is a wide-neck aperture for accepting a utensil such as a spoon which is of lesser width than the aperture, for removing the product or products from the chamber by manual insertion and removal of the utensil through the aperture, the wide-neck aperture including a neck for receiving a closure, the neck being bonded or connected to the laminate material and extending away from the chamber by a neck height, the neck having a neck width which spans at least about two thirds of the distance across the apertured side wall in the orthogonal direction from the first end wall to the second end wall, and the neck width being at least four times greater than the neck height.
8. A container as claimed in claim 7, in which the neck includes at least one flange, and the at least one flange is bonded to the laminate material at least at corners of a chamber-facing side of the side wall.
9. A container as claimed in any preceding claim, in which the aperture is substantially circular and at least about 5 cm wide.
10. A container as claimed in any preceding claim, in which the laminate material includes: a first layer of metal or metal alloy for bounding the chamber to prevent oxygen and/or light from passing through the laminate material into the chamber, an adhesive layer, and a second layer of cellulosic material or paperboard for rigidity, the second layer being substantially coextensive with the first layer, and the first and second layers being releasably attached together by the adhesive layer.
11. A container as claimed in claim 10, in which the laminate material lacks polyethylene adhesive.
12. A container as claimed in claim 10 or claim 11, in which the first layer forms a terminal layer of the laminate material.
13. A container as claimed in any of claims 10 to 12, in which the metal or metal alloy may include one or more of: aluminium, stainless steel, copper, iron, brass, tin, silver, titanium, nickel, and bronze.
14. A container as claimed in any of claims 10 to 13, in which at least one of the first layer and the second layer comprises a tab for facilitating manual separation of the first and second layers.
15. A container as claimed in any of claims 10 to 14, in which the laminate material comprises a third layer or third terminal layer including glassine, which is releasably attached to at least one of the first layer and the second layer.
16. A container as claimed in any of claims 10 to 15, in which part of a first side of the first layer is bonded to part of an opposing second side of the first layer, and/or part of a first side of the second layer is bonded to part of an opposing second side of the second layer.
17. A container as claimed in any preceding claim, in which one or more additional side walls of the laminate material connect the first and second end walls together.
18. A container as claimed in any preceding claim, in which the at least one seal includes a first seal for sealing the folded laminate which is provided on the first end wall and a second seal for sealing the folded laminate which is provided on the second end wall.
19. A container as claimed in any preceding claim, in which the apertured side wall has an external perimeter defining a side wall area, and the aperture covers an area which is at least 40% of the side wall area.
20. A container as claimed in claim 19, in which the aperture area is at least 50% or at least 60% of the side wall area.
21. A container as claimed in any preceding claim, in which the container body is a square-based substantially cuboidal container or a square prism container.
22. A container as claimed in any preceding claim, in which four side walls are provided and at least three of those side walls do not comprise a seal.
23. A container as claimed in any preceding claim, in which the aperture is sealed by a metal foil lid or foil paper or closed by a closure or cap but not a pump dispenser.
24. A container as claimed in any of claims 1 to 22, in which the aperture is closed by a screw threaded lid including a top wall having a top wall area which is equal to or larger than the aperture for covering the aperture, a circumferential rim on the wall, and a screw thread around the circumferential rim for cooperating with a corresponding screw thread provided on the container.
25. A container as claimed in any of claims 1 to 22, in which the aperture is closed by a push-fit lid for sealing the aperture against egress of product from the chamber.
26. A method of manufacturing a folded laminate container, comprising the steps of: i. folding a sheet of laminate material into a container body which has a first end wall, a second end wall, and at least one side wall connected to the first end wall at a first fold and connected to the second end wall at a second fold, the at least one side wall connecting the first and second end walls together, a chamber in the container body being defined by the first end wall, the second end wall and the at least one side wall, and an aperture being provided through the laminate material of the at least one side wall, the aperture spanning at least about half of a distance across the apertured side wall in an orthogonal direction from the first end wall to the second end wall; ii. sealing the laminate material in the shape of the container body so that the chamber is suitable for retaining a product, including at least one seal disposed: a) at least on the first end wall or the second end wall but not the apertured side wall, or b) on the at least one side wall and offset from the aperture.