Patent Application
20170129679
Described herein are an opening and closure device, a method of manufacturing an opening and closure device and a packaging container for liquid or semi-liquid food, said packaging container having such an opening and closure device.
Packaging containers of the single use disposable type for liquid foods are often produced from a packaging material based on paperboard or carton. One such commonly occurring packaging container is marketed under the trademark Tetra Fino® Aseptic and is principally employed for aseptic packaging of liquid foods such as milk, fruit juices etc, marketed and sold for long term ambient storage. The packaging material in this known packaging container is typically a laminate comprising a bulk layer of paper or paperboard and outer, liquid-tight layers of thermoplastics. In order to render the packaging container gas-tight, in particular oxygen gas-tight, for example for the purpose of aseptic packaging such as packaging of milk or fruit juice, the laminate in these packaging containers normally comprises at least one additional such gas barrier layer, most commonly an aluminium foil.
On the inside of the laminate, i.e. the side intended to face the filled food contents of a container produced from the laminate, there is an innermost layer, applied onto the aluminium foil, which innermost, inside layer may be composed of one or several part layers, comprising heat-sealable adhesive polymers and/or heat-sealable polyolefins. Also on the outside of the paper or paperboard bulk layer, there is an outermost heat-sealable polymer layer (decor layer). The heat-sealable polymer layers are often based on low density polyethylene or blends thereof.
The packaging containers are generally produced by means of modern, high-speed packaging machines of the type that continuously form, fill and seal packages from a web or from prefabricated blanks of packaging material, e.g. Tetra Fino® Aseptic-type packaging machines. Packaging containers may thus be produced by the so-called form-fill-seal technology basically including continuous reforming a web of the laminated packaging material by means of a filling machine which forms, fills and seals the web into packages. More specifically, a continuous tube is formed from the web-fed packaging material; the web of packaging material is sterilized by applying a chemical sterilizing agent, such as a hydrogen peroxide solution, which, once sterilization is completed, is removed from the surfaces of the packaging material, e.g. evaporated by heating; and the web of packaging material so sterilized is maintained in a closed, sterile environment, and is formed into a vertical tube by sealing the longitudinal edges of the tube in an overlapping seal. The tube is filled with the food product, and is sealed and subsequently cut along equally spaced transverse seal zones to form cushion-shaped or pillow-shaped packing containers.
An aspect of the Tetra Fino®-type packaging method is, as stated above, the possibility of continuous high-speed packaging, which has considerable impact on cost efficiency. Typically many thousands of packages may be prepared per hour. For example the Tetra Pak® A1 may manufacture about 10 000 packaging containers per hour (packaging containers of 0.5 litres or more), and about 15 000 packaging containers per hour (portion packages)
The Tetra Fino® Aseptic packaging containers are, as mentioned above, cushion-shaped or pillow shaped and commonly such packaging containers have an opening and closure device that is generally provided in the form of a straw hole, or simply as a cut indicator, which is facilitated by a rather thin and thus tearable packaging material being used. Using conventional opening and closure devices such as for example those comprising screw caps or pull-tabs would in most cases be fully functional. However, the type of packaging container is a high-volume (in terms of packaging containers per time unit) and low-cost packaging container (due to the properties of the packaging material), and such opening and closure devices might hamper the production speed and be detrimental for the cost of the packaging container.
For this reason there is a need for an opening and closure device having a high efficiency in regard of the amount of material used and the time needed for production of each opening and closure device. It should be emphasized that even if the present invention was developed to solve a specific problem, the outcome may be applied to packages in a general sense and it should not be limited to a particular type of packages in this respect.
At least the above described need is solved by the present invention.
In one or more embodiments the first opening line portion is arranged to substantially coincide with the second opening line portion when the opening and closure device is folded along the first fold line.
In one or more embodiments each of the first and second opening line portions is angled an angle with respect to the first fold line, and the second opening line portion is a mirror of the first opening line portion around the first fold line.
In one or more embodiments the second fold line is parallel to the opening line, and the intersection point divides the second fold line into a first fold line portion and a second fold line portion.
In one or more embodiments the opening device has a fold edge that is at least partly aligned along the first fold line and arranged on a first side of the fold line.
In one or more embodiments the opening edge is toothed or serrated.
In one or more embodiments the opening and closure device is made of a polymeric material and the opening and closure device is injection molded onto the packaging container before forming of the packaging container.
In one or more embodiments one of the first or second closure device parts forms part of the opening device.
In one or more embodiments the first closure device part forms part of the opening device.
In one or more embodiments the first closure device part is a first lockable member formed as at least one protrusion. The second closure device part comprises a second lockable member provided with a loop portion and an attachment portion. The at least one protrusion of the first lockable member is adapted to be inserted into at least one opening of the loop portion of the second lockable member for locking the first and the second lockable members together.
In one or more embodiments the loop portion and the first lockable member are freely suspended from or detachable from the packaging material of the packaging container.
In one or more embodiments the opening device is provided in between the first opening line portion and the first fold line portion, on a first side of the second fold line, and at least the first lockable member extends past the second fold line to a second side of the second fold line.
In one or more embodiments the loop portion is distanced from the second fold line a distance corresponding to the distance between the opening line and the second fold line, by means of the attachment portion, which attachment portion is attached to the packaging container.
In one or more embodiments there is provided a hinge area between the loop portion and the attachment portion.
In one or more embodiments the first lockable member is formed as a protrusion extending past the second fold line to a second side of the second fold line.
According to a second aspect the invention comprises a method of manufacturing a packaging container with an opening and closure device. Said method comprises the steps of providing a packaging material comprising a bulk layer, which on a first side has a polymer layer, moulding the opening and closure device onto the first side of the packaging material, said opening and closure device comprises an opening device and a closure device, wherein the opening device and a first closure device part of the closure device is arranged on a first side of a first fold line of the packaging container, and a second closure device part of the closure device is arranged on a second side of the first fold line, thereby obtaining a packaging material comprising the opening and closure device, forming the packaging material into a tube by sealing overlapping longitudinal edges thereof, filling the tube with a liquid or semi-liquid food product, sealing the tube along transverse seal zones to form a cushion-shaped packaging container, said sealing being made such that the packaging material is folded around the first fold line in the seal zones, and such that the opening and closure device is positioned in one corner of the packaging container.
In one or more embodiments the step of moulding comprises the steps of: arranging, on the first side of the packaging material, a first mould portion comprising at least a first mould cavity, arranging a second mould portion on the other side of the packaging material, positioned opposite the first mould portion, injecting a plastic melt into the first mould cavity, and removing the first and the second mould portions.
In one or more embodiments the packaging material is a web for forming more than one packaging container, and the step of sealing comprises sealing the tube along transverse mutually apart seal zones to form cushion-shaped packaging containers, and the method further comprises the step of separating the packaging containers from the tube by incisions in the seal zones.
According to a third aspect the invention comprises a packaging container for liquid or semi-liquid food. Said packaging container is made of a longitudinal tube of packaging material which has been sealed off in the ends by top and bottom transverse seal zones to form a cushion-shape, has a first fold line and an opening line, said first fold line and opening line intersect in an intersection point, said intersection point divides the opening line into a first opening line portion and a second opening line portion, and is provided with an opening and closure device. The opening and closure device comprises an opening device adapted for facilitating rupture of the packaging material along the opening line, said opening device has an opening edge that is at least partly aligned along the first opening line portion and arranged on a first side of the opening line. A second side of the opening line comprises an openable area of the packaging container, such that a consumer can fold the opening and closure device at the first fold line and force the packaging material of the opening line against the opening edge to facilitate rupture of the packaging material along the opening line. The opening and closure device further comprises a closure device adapted for re-closing the packaging container after opening along the opening line, said closure device comprises at least a first closure device part and a second closure device part, said first and second closure device parts are provided on different sides of the first fold line, and said first and second closure device parts are provided with mutual lockable members such that the first and second closure device parts may be releasably locked to each other, after folding the opening device along a second fold line.
In one or more embodiments the packaging container has a top transverse seal zone, the first fold line forms a side edge of the packaging container, such that the second closure device part is arranged on a first face of the packaging container and the first closure device part and the opening device are arranged on a second face of the packaging container.
In one or more embodiments the opening device extends between the first fold line and the top transverse seal zone.
In one or more embodiment the openable area is a corner of the packaging container.
In one or more embodiments the closure device extends along the opening line and the second fold line a substantial portion, particularly more than 80%, of the distance from the first fold line to the upper transverse seal zone.
Further advantages and favorable characterizing features will be apparent from the following detailed description. Equal or corresponding elements are denominated by the same reference numbers in all figures. The features described in connection with the different embodiments can be combined as far as technically possible. The embodiments will be described with reference to the appended figures, in which:
The opening line 13, the first fold line 16 and the second fold line 22 are imaginary lines not necessarily shown on the packaging container, but used herein for facilitating description of the invention.
The opening device 12 is arranged on a first, left side of the first fold line 16. Further it is arranged on a first, lower side of the opening line 13. Said opening device 12 has an opening edge 12a that is at least partly aligned along, and on the lower side of, the first opening line portion 13a. A second side of the opening line 13 comprises an openable area 19 of the packaging container (better shown in
The opening device 12 is elongate and parallel to the first opening line portion 13a. The opening edge 12a, which is provided in the vicinity of the opening line portion 13a, is serrated or toothed for facilitating rupture of the packaging material.
The closure device 14 comprises a first closure device part 17 and a second closure device part 18. Said first and second closure device parts 17, 18 are provided on different sides of the first fold line 16.
Said first and second closure device parts 17, 18 are provided with mutual lockable members 20, 21 such that the first and second closure device parts 17, 18 may be releasably locked to each other.
As mentioned the opening line 13 is an imaginary line along which the opening and closure device 10 will be opened, i.e. along which the packaging material of the packaging container will be ruptured or torn. The first fold line 16 is a longitudinal imaginary line along which the opening and closure device 10 can be folded during opening. It will also be described later that the first fold line 16 constitutes a side edge of the packaging container 100.
In this first embodiment the first opening line portion 13a is angled an angle a in relation to the first fold line 16. Similarly, the second opening line portion 13b is angled an angle a in relation to the first fold line 16. The angle may be in the range 20-90°, particularly 45-90°. Together the first and second opening line portions 13a, 13b together form an obtuse V-shape.
In the first embodiment the opening device 12 is further comprising a fold edge 12b. The fold edge 12b is aligned along the first fold line 16, i.e. it is parallel to the first fold line 16. Further, the fold edge 12b is arranged at a first distance from the first fold line 16. The distance is in the range of 1-2 mm. The distance facilitates folding of the opening and closure device 10 around the first fold line 16.
Furthermore, the opening edge 12a of the opening device 12 is arranged at a second distance from the opening line 13. The distance is in the range of 0.2-1 mm. The distance facilitates rupture of the packaging material along the opening line 13.
Furthermore, the opening device 12 is provided in between the first opening line portion 13a and the first fold line portion 22a, on a first side of the second fold line 22.
The closure device 14 comprises, as mentioned above, first and second closure device parts 17, 18. In this embodiment the first closure device part 17 forms part of the opening device 12. The first closure device part 17 is a first lockable member 20 formed as at least one protrusion. Hence, the first closure device part 17 forms an integrated portion of the opening device 12, and protrudes from the opening device 12. It extends, or protrudes, past the second fold line 22 to a second side of the second fold line 22.
As can be seen from
The second closure device part 18 is provided on a second side of the first fold line 16 and on a second side of the second fold line 22. It comprises a second lockable member 21 provided with a loop portion 21a and an attachment portion 21b. The loop portion 21a is freely suspended from or detachable from the packaging material of the packaging container, i.e. it is not adhered or attached to the packaging material as much as the attachment portion 21b.
A first edge 23 of the attachment portion 21b is aligned, and parallel to, the second fold line 22. The loop portion 21a is distanced from the second fold line 22 a distance corresponding to the distance between the opening line 13 and the second fold line 22, by means of the attachment portion 21b. The attachment portion 21b is attached or adhered to the packaging container 100.
Further, there is provided a hinge area 21c between the loop portion 21a and the attachment portion 21b. The hinge area 21c is parallel to the first edge 23 of the attachment portion 21b.
The loop portion 21a is provided with a through-going opening 24. In this embodiment the opening 24 is oblong, and designed such that the protrusion of the first lockable member 20 is adapted to be inserted into said opening 24 for locking the first and the second lockable members 20, 21 together.
Preferably, the opening and closure device 10 is injection-moulded or glued onto the packaging material, preferably to what will become the outside surface of a packaging container. The material thickness t of the opening and closure device 10, in a direction perpendicular to the packaging material surface, is in the range of approximately 0.2-2 mm. However, the thickness may be made larger than 2 mm, but the opening and closure device would then require more material, thereby increasing cost. The corresponding packaging material thickness used for this type of opening and closure device is today in the range of approximately 0.2-1.5 mm. However, the opening and closure device may be provided on thinner as well as thicker packaging materials.
The packaging container 100 is made of a longitudinal tube of packaging material which has been sealed off in the ends by first and second transverse seal zones 26 to form a cushion-shape. In the seal zones inner heat sealable layers of the packaging material have been sealed together to form a tight seal. As the packaging containers are of the pouch type it does not have any defined longitudinal edges. However, at outermost edges 38 of the transverse seal zones 26 the packaging material is folded, since the transverse sealing is made transverse to a tube. The first fold line 16 previously referred to is an imaginary line extending longitudinally from an upper outermost edge 38a of a first transverse seal zone 26a to a corresponding, lower outermost edge 38b of a second transverse seal zone 26b. The first fold line 16 extends the shortest possible distance between the edges 38a, 38b. The second closure device part 18 is arranged on a first, front face 28 of the packaging container 100 and the first closure device part 17 and the opening device 12 are arranged on a second, back face 30 of the packaging container 100.
The packaging container 100 is filled with a liquid or semi-liquid food product. The term “liquid or semi-liquid food” generally refers to food products having a flowing content that optionally may contain pieces of food. Dairy and milk, soy, rice, grains and seed drinks, juice, nectar, still drinks, energy drinks, sport drinks, coffee or tea drinks, coconut water, tea drinks, wine, soups, jalapenos, tomatoes, sauce (such as pasta sauce), beans and olive oil are some example of food products contemplated.
With reference to
Upon opening a consumer will typically grip above the opening line 13, around the first fold line 16, with the index finger and the thumb of one hand, i.e. gripping on the opening device 12 with the index finger, and similarly grip around the first fold line 16, below the opening line 13, with the other hand. By doing so the consumer can fold the opening and closure device 10 at the first fold line 16. By further forcing the packaging material of the front and back face 28, 30 towards the serrated edge 12a, the packaging material is initially broken in the intersection point. The serrated edge 12a will then facilitate rupture of the packaging material along the opening line 13. Hence, opening along the opening line 13 will open the packaging container 100 cross one of the upper corners thereof, and the corner piece may be removed. An opened state of the packaging container 100 is shown in
To further facilitating the rupture along the opening line 13 it may be considered to provide the opening line as a weakening line, such as for example a line at which one or more of the packaging material layers have been perforated or in other way been weakened.
Re-closure of the opened packaging container 100 will now be made in relation to
The lockable members 20 can be any of a large variety of types, for example the locking function can be mechanical such as for example as a snap lock, or snap fit, solution, either in points or along a line, the latter being similar to a conventional zip lock. Further, it can be chemical or a combination of mechanical and chemical such for example a locking function based on surface friction or surface adherence. In this embodiment the lockable members are shaped for mechanical locking. The protrusion is insertable in the loop and will stay there until released.
Although the opening and closure device 10 is attached to the packaging material of the packaging container it is advantageous if the protrusion and the loop portion 21a is easily detachable from the packaging material such that the consumer can easily pull the loop over the protrusion. If the opening and closure device is moulded, which will be described later, onto the packaging material the mould may be cooled locally at the lockable members. Another alternative is that the packaging material is locally coated with a material that will cause less adhesion between the packaging material and the lockable members.
Going back to
In the following, and with reference to
Similar to the first embodiment, the second embodiment is opened by folding the opening and closure device 10 at the first fold line 16, and by then forcing the packaging material of the front and back face 28, 30 towards the serrated edge 12a. The serrated edge 12a will facilitate rupture of the packaging material along the opening line 13, and the corner of the packaging container may be removed such that the packaging container is ready for pouring.
Re-closure of the opened packaging container 100 is also made in a similar way, see
In the following manufacturing of the packaging container with the opening and closure device will be described.
A first step of the method is to provide a packaging material. The packaging material generally comprises a bulk layer, which on a first side has a polymeric layer. The bulk layer can be a paper or paperboard layer. The bulk layer is arranged to provide for the greatest contribution to the flexural rigidity of the laminate. The paper or paperboard used herein has a typical grammage between 50-250 g/m2, particularly between 60-220 g/m2, depending on the requirement for different types of packaging containers. The grammage of the paperboard is assessed in accordance with ISO 536. Grammage expresses weight per unit area and is measured in g/m2. The paper or paperboard normally has a thickness between 80-300 μm, particularly between 90-290 μm 80-660 μm, and is appropriately selected in order to obtain the desired stiffness suitable for the type of packaging container and the intended food product. The bulk layer thickness can be assessed by microscopy. It is however also conceivable that the bulk layer of the packaging material instead is a polyolefin bulk layer, made e.g. of polyethylene, polypropylene or copolymers of ethylene or propylene, such as, for example, ethylene-propylene, ethylene-butene, ethylene-hexene, ethylene-alkyl(meth)acrylate or ethylene-vinyl acetate copolymers, or PET (polyethylene terephthalate) bulk layer.
The polymeric layer is a decor layer which is to be the outer side of the filled and sealed packaging container. The side of the bulk layer, e.g. paper or paperboard, which is to be the outer side of the closed and sealed packaging container can contain a print covered by the decor layer. The decor layer is a heat-sealable polyolefin layer facing the surrounding environment of the resulting packaging container. Suitable polyolefins are polyethylene of the low density type, selected from the group consisting of LDPE, LLDPE, VLDPE, ULDPE or mLLDPE and blends of two or more thereof, optionally other polyolefins such as high density polyethylene (HDPE), polypropylene or propylene co- or ter-polymers are useful as the layer facing the surroundings. The decor layer provides additional protection and stability to the packaging container.
In addition, the packaging material comprises an innermost heat-sealable layer of a heat-sealable polyolefin polymer which is applied as a layer to be directed towards the inside of the packaging container, i.e. in direct food contact. The heat-sealable layer for the innermost layer may suitably be a polyethylene polymer of the low density type, selected from the group consisting of LDPE, LLDPE, VLDPE, ULDPE or mLLDPE and blends of two or more thereof. Depending on the type of packaging containers produced from the packaging material, also heat-sealable innermost layers of high density polyethylene, polypropylene or propylene co- or ter-polymers are conceivable.
Furthermore, the packaging material may comprise a barrier layer, such as an oxygen barrier, for instance aluminium foil, as well as suitable adhesion layers to increase adherence between the layers. The barrier layer is arranged by help of a laminate layer on the side opposite the bulk layer and has an adhesive on the side opposite the laminate layer. The adhesive depends on the type of bulk layer and the barrier layer and are within the capacity of those skilled in the art to select.
One exemplary packaging material comprises a decor layer which on one side of the layer has a paperboard layer, said paperboard layer, on the side opposite the decor layer has a laminate layer, said laminate layer, on the side opposite the paperboard layer has an oxygen barrier, said oxygen barrier, on the side opposite the laminate layer has an adhesive, and said adhesive, on the side opposite the oxygen barrier has a heat-sealable layer.
Laminated packaging materials are obtained by various methods for laminating layers together, such as extrusion lamination, dry adhesive lamination, heat-pressure lamination, and may also be including various coating methods. Although to achieve the benefits the particular lamination technique is not crucial it is considered to be of particular use in extrusion lamination to produce laminated packaging materials, in particular carton-based packages used for food such as liquid and semi-liquid food.
The term “heat-sealing” used above refers to the process of sealing of a thermoplastic material with another. Thus a heat-sealable material should be able to generate a seal when put in contact with another suitable thermoplastic material under the appropriate conditions such as when applying sufficient heating. Suitable heating can be achieved by induction heating or ultrasonic heating or other heating means.
A second step in the manufacturing method is that of moulding the opening and closure device onto the first side of the packaging material. As described in relation to the various embodiments above said opening and closure device comprises at least an opening device 12 and a closure device 14. The opening device 12 is arranged on a first side of a fold line 16 of the packaging container, and the second closure device part 18 of the closure device 14 is arranged on a second side of the first fold line 16. The moulding step comprises the sub-steps of arranging, on the first side of the packaging material, a first mould portion comprising at least a first mould cavity, arranging a second mould portion on the other side of the packaging material, positioned opposite the first mould portion, injecting a plastic melt into the first mould cavity, and removing the first and the second mould portions. The material of the opening and closure device 10 is suitable for thermoplastic moulding, more specifically injection moulding, and may be polyethylene, polypropylene or another plastic suitable for injection moulding, for example polyethylene terephthalate. The first side of the packaging material is the side which will become the outer side of the packaging container, the first side having the decor layer. The heat of the melt will anchor or weld the opening and closure device to the outer decor layer of the packaging material.
The first mould portion, or mould half has, as described above, at least one mould cavity. The first mould portion may comprise several cavities depending on the opening and closure device, preferably one cavity per isolated part. The embodiment shown in
The dimensions of the opening and closure device 10 may be optimized to achieve an adequate opening of the packaging container only and any surplus use of material may be avoided. In this way only a relatively small amount of plastic is needed (compared to known opening devices). This has the beneficial effect that the time needed for injection is small, yet it also has the effect that the mould does not have to be closed for very long since the plastic will start to freeze (or solidify) immediately. The small amount of plastic vouches for that even if only a surface layer has started to freeze, this will be enough to retain the shape of the opening and closure device until it has fully frozen, which in turn implies that the mould will be opened basically as soon as the injection is finalized. An outermost skin layer of the plastic melt will freeze as soon as it contacts the walls of a mould cavity, or the outermost layer of the packaging material. For non-complex designs this vouches for that the mould may be opened as soon as it is filled. For more complex designs, e.g. designs incorporating steep edges or distinct ridges more time may have to be allocated for the plastic to freeze, such that the plastic is allowed to solidify from the skin and inwards before opening the mould. In this context it should be understood that the plastic will shrink (from the outside and inwards) as it freezes, and in a conventional injection molding process it is known to continue to inject plastic during the freezing, such that the finished detail is a replica of the mould cavity. It may also be important to realize that the longer the mould remains closed, the more heat will be transferred from the melt to the mould. This results in a need for installing a cooling arrangement, such as channels for leading cooling fluid through the mould portions. For the present invention such arrangements may not be necessary due to the inherently low cycle times.
Though there is no drawing of a mould or mould cavity the skilled person realizes that the shape of the mould cavity will correlate to the shape of the manufactured opening and closure device (or rather—vice versa), and since the present invention is not directed to the shaping of mould cavities this will not be described any further. Also, injection moulding is a well-established technique not the least for some of the suggested materials: PE, PP and PET. Therefore a disclosure of an injection moulding process or features thereof is not considered essential for the skilled person to apply the present invention, and it is therefore omitted.
After moulding, the packaging material comprises the opening and closure device and it is time to form the packaging material into packaging containers. The packaging material is formed into a tube by sealing overlapping longitudinal edges thereof. Either the packaging material is loaded into the filling machine as a continuous web which will be formed into several packaging containers, or the packaging material is loaded to the filling machine as blanks. In the latter case a sleeve-formed tube is formed by each blank.
The next steps are filling and sealing. In the case of a packaging material in the form of a blank, the sleeve-formed tube is in one end sealed along a transverse seal zone and thereby filled with the liquid or semi-liquid food product. The still open end is then sealed along a transverse seal zone. In the case of a web-based filling machine, like for instance the Tetra Fino® Aseptic-type packaging machine the tube is continuously filled and sealed along transverse mutually apart seal zones to form cushion-shaped packaging containers. In this case the method further comprises the step of separating the packaging containers from the tube by incisions in the seal zones.
Each transverse seal is made such that the packaging material is folded around the fold line 16 in the seal zones 26. Further, the position of the opening and closure devices in relation to the transverse sealing inductors are controlled such that an opening and closure device is positioned on each package and preferably in one corner of the finished packaging container, see
It is apparent to a person skilled in the art that with the advancement of technology, the basic idea may be implemented in various ways. The invention and its embodiments are thus not limited to the examples described above; instead they may vary within the scope of the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1450773-5 | Jun 2014 | SE | national |
| 1450774-3 | Jun 2014 | SE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2015/058622 | 4/22/2015 | WO | 00 |
