This application is the National Stage of International Application No. PCT/GB 2009/002462, which designates the U.S., filed Oct. 14, 2009, which claims the benefit of GB 0819200.7, filed Oct. 20, 2008, and GB 0821354.8, filed Nov. 21, 2008, the contents of which are incorporated by reference herein.
The present invention relates to packaging, and in particular to improved packaging for generally block-shaped products. The present invention is also directed to a method of packaging such products and to the combination of a substantially rigid, generally block shaped product and a flexible wrapper encasing the product.
It is known to package generally block-shaped products, including food products such as chocolate bars and other snack type confectionery products, in a wrapper that is fabricated from a substantially gas and moisture impervious material, such as a metal foil, or a plastics material (including a laminate of either or both materials), in order to protect the product.
Such known wrappers may be formed from a length of flat, foldable material having an inner surface directed to the food product and an outer surface. The outer surface may be printed on or otherwise be provided with information for the consumer. The material is folded about the product and the longitudinal side edges are bonded together to form a longitudinal sealed seam, sometimes referred to as a “fin seal” or “fin seam”. The material extends beyond the ends of the product and opposing edge regions at either end of the wrapper are bonded together to form transverse end seams. The seams may be formed using an adhesive to bond the opposing surfaces of the wrapper or by heating the material under pressure so that the opposing surfaces melt and fuse together to form a welded seam.
Packaging of this nature can be produced using a flow-wrap method in which a film of material is supplied in a roll to package a number of products in a substantially continuous process. The material is fed through a machine which folds it about each product in turn so that opposing side edges are brought into contact and bonded together to form the longitudinal seam, which usually extends along a rear face of the product. The material is crimped at either end of the product to form the end seams and the material is cut to separate each package from the remainder of the film. Alternatively, packaging may also be formed by envelope or sheet feeding and sealing is effected by means of pressure and/or heat.
The known packaging forms a fully sealed container for the product, which is substantially gas and moisture impervious. However, the material used to form such packages is typically quite tough it can be difficult to open as it does not easily tear in a controlled fashion, often requiring multiple tears to get the product out of the wrapper.
Furthermore, the known packaging is not re-closable once opened. This limits the shelf life of the product after opening and allows spillage of the remaining contents. Many larger chocolate bars are divided into portions with the intention that a consumer will break off one or more portions at a time and keep the reminder for later use. Typically, a consumer has to push the remaining bar back into the wrapper after a portion has been removed and fold the open end of the wrapper over. When the consumer wishes to break off some more of the bar, the wrapper has to be unfolded and the remaining bar pushed back out. This can be a cumbersome procedure and does not ensure the remaining contents are kept secure. This arrangement can also be rather messy for the consumer as small parts of the bar may break-off but are not securely retained in the wrapper when it is folded over.
In order to make this type of packaging easier to open, it has been proposed in GB 1, 107, 200 A to use a peelable and re-sealable adhesive coating to form the longitudinal seam and to provide folded tabs that can be grasped by a consumer and pulled apart to peel open the longitudinal seam. This arrangement helps in making the packaging easier to open and enables the packaging to be reclosed after opening. However, it has been found that the packaging is not wholly effective in securely retaining the remaining contents as it relies on the re-sealable coating to hold the longitudinal seam together. This is a particular problem with packaging for larger portioned bars which may be opened and re-sealed a number of times, as the resealable coating tends to become less effective with continued opening over time compromising the integrity of the packaging.
Other known types of packaging for generally blocked shaped products are formed from one or more sheets of flexible material. In one such known arrangement, a sheet of flexible material is folded about the product along one edge and opposing portions of the sheet are bonded or welded together along the other three edges to enclose the product. A further known form of flexible packaging comprises two sheets of flexible material positioned one on either side of the product and bonded/welded together along all four edges to form a sealed package. Where the material used to form the packages is a metal foil, laminate or other tough material, these can suffer from similar problems in terms of being difficult to open and not being re-closable.
It is an object of the invention to provide an improved packaging for a generally block-shaped product which overcomes or at least mitigates some or all of the above problems.
It is a further object of the invention to provide improved methods of packaging a generally block-shaped product which overcomes or at least mitigates some or all of the above problems.
It is a still further object of the invention to provide a combination of a substantially rigid, generally block-shaped product and a flexible wrapper encasing the product which overcomes or at least mitigates some or all of the problems of the prior art.
In accordance with a first aspect of the invention, there is provided packaging for a generally block shaped product, the packaging comprising a wrapper of flexible material encasing the product, the wrapper having a foldable flap portion adjacent an end of the package, the free edges of the flap overlapping a further portion of the wrapper and being bonded thereto by means of a peelable and re-sealable adhesive, the flap extending fully across one face of the package and at least partially down opposing sides to form a sealed and re-closable closure for the package.
The packaging may be configured such that in use, the free edges of the flap can be peeled away from the further portion of the wrapper and the flap folded back to expose an opening or aperture at one end of the package through which the product can be removed. The flap may be configured to enable the product to be removed through the opening in a longitudinal direction.
The wrapper may be sealed along its length by means of a longitudinal fin seam, which may be positioned on the opposite side of the package from the flap.
The wrapper may be closed at either end by means of a sealed transverse seam.
The flap may be foldably connected along one edge adjacent one of the transverse seams and may be rotatable about the transverse seam. The one or more seams may be located in a central portion of the package, or may be off-set from a central portion.
In one embodiment, the packaging is a flow-wrap film packaging.
The re-sealable adhesive may be a cold seal adhesive.
The seal between the flap and the further portion of the wrapper may comprise a tamper-evident seal. Alternatively, a temper-evident label may be employed. The free edges of the flap may be sealed to the further portion of the wrapper by means of two seals, a first breakable seal and a second, peelable and re-sealable seal.
The packaging may comprise at least one peelable panel portion formed in a face of the packaging, which peelable panel portion can be peeled away from the remainder of its respective face to increase the depth of the opening after the flap has been opened. The packaging may comprise a first peelable panel portion formed in a face of the package across which the flap extends, the first peelable panel portion extending part way along the face from an edge of the face which defines the opening. In addition or alternatively, the packaging may comprise a second peelable panel portion in a second face of package opposite from the face across which the flap extends. The, or each, peelable panel portion may have edge regions which overlap corresponding edge regions of the remainder of their respective packaging face, the overlapping edge regions being releasably bonded together. The overlapping edge regions may be bonded together using a peelable and re-sealable adhesive.
The packaging may be for a generally blocked shaped food product, which may be a confectionery bar.
The generally blocked shaped product may comprise two or more generally block shaped portions.
In accordance with a second aspect of the invention, there is provided a combination of packaging in accordance with the first aspect and a generally blocked shaped product enclosed by the packaging.
The product may be a food product which may be a chocolate or other confectionery bar.
In accordance with a third aspect of the invention, there is provided a method of packaging a generally blocked shaped product, the method comprising:
The step of folding the wrapper about a generally block shaped product and bonding opposed surfaces of the material to form sealed seams so as to encase the product may comprise forming a longitudinal sealed seam and a transverse sealed seam at either end of the product, the re-sealable flap being foldably connected along one edge adjacent one of the transverse seams.
The method may comprise forming the longitudinal seam along a rear face of the package, the flap being positioned to extend across a front face opposite the rear face. Alternatively, the method may comprise forming the longitudinal seam along a front face of the package, the flap being positioned to traverse at least part of the rear face.
The packaging may be produced using a flow-wrap method, the wrapper being provided as part of a roll of material having a plurality of re-sealable flap portions spaced along its length, the material being folded about the product so that opposing longitudinal edge regions of the material are brought into contact and bonded together to form the longitudinal seam, opposing regions of the material at either end of the product being brought into contact and bonded to form the transverse end seams and the material being cut to separate the package from the remainder of the film.
The method may comprise providing a wrapper having at least one peelable panel portion and positioning the wrapper so that the panel portion is positioned on a face of the packaging.
The method may comprise cutting the wrapper material to produce an integral flap portion. The wrapper may be cut to form the flap portion using a laser treatment. Alternatively, the wrapper may be cut to form a flap using mechanical means. A releasable adhesive may be at least partially applied to the integral wrapper portion. If desired, a releasable adhesive may be applied to the integral wrapper portion in discrete areas, resulting in some areas of the wrapper portion being free of adhesive. Where the packaging is produced using a flow-wrap method, the method may include producing a roll of material having a plurality of pre-cut flap portions.
In accordance with a fourth aspect of the invention, there is provided a combination of a substantially rigid, generally block shaped product and a wrapper of flexible material enclosing the product, the wrapper having an aperture and a foldable flap portion, the flap portion having one or more free edge regions overlapping a further portion of the wrapper and being bonded thereto by means of a peelable and re-sealable adhesive so as to form re-closable closure for the aperture, in which the aperture has a maximum width equal to or slightly larger than a side of the product.
The aperture may have a maximum width that is in the range of 1% to 15%, 1% to 14%, 1% to 13%, 1% to 12% or 1% to 11% larger than the side of the product.
The aperture may have a maximum width that is in the range of 1% to 10% larger than the side of the product. Alternatively, the aperture may have a maximum width that is in the range of 1% to 9%, 1% to 8%, 1% to 7% or 1% to 6% larger than the side of the product.
The aperture may have a maximum width that is in the range of 1% to 5% larger than the side of the product.
The product may be generally rectangular in plan having longer and shorter edges and the flap and aperture may be aligned with one of the longer side edges of the product.
The product may be generally rectangular in plan having longer and shorter edges and the flap and aperture may be aligned with one of the shorter side edges of the product.
The product could be potentially any shape in plan, such as rectangular or have undulating edges.
The wrapper may have two flap portions and two apertures, a first flap portion and aperture being aligned with one of the side edges of the product and a second flap portion and aperture being aligned with another one of the side edges of the product.
The wrapper may have a longitudinal fin seal, and a portion of the fin seal may form a tab that can be grasped to open the flap.
The wrapper may be a flow-wrapped wrapper.
The wrapper may comprise at least one peelable panel portion formed in a face of the packaging, which peelable panel portion can be peeled away from the remainder of its respective face to increase the depth of the aperture after the flap has been opened. The packaging may comprise a first peelable panel portion formed in a face of the package across which the flap extends, the first peelable panel portion extending part way along the face from an edge of the face which defines the aperture. In addition or alternatively, the packaging may comprise a second peelable panel portion in a second face of package opposite from the face across which the flap extends. The, or each, peelable panel portion has edge regions which overlap corresponding edge regions of the remainder of their respective packaging face, the overlapping edge regions being releasably bonded together. The overlapping edge regions may be bonded together using a peelable and re-sealable adhesive.
The product may be a food product, which may be a chocolate or other confectionery bar.
The product may comprise two or more substantially rigid, generally block shaped portions arranged in-line within the wrapper. The product could comprise two or more chocolate or other confectionary bars arranged in-line, or side-by-side within the wrapper.
In accordance with a fifth aspect of the invention, there is provided a method of packaging a substantially rigid, generally blocked shaped product with a wrapper of flexible material, the method comprising:
In accordance with a sixth aspect of the invention, there is provided a packaging for a generally block shaped product, the packaging comprising a wrapper of flexible material encasing the product, the wrapper having a foldable flap portion adjacent an end of the package, the free edges of the flap overlapping a further portion of the wrapper and being bonded thereto by means of a peelable and re-sealable adhesive, the flap extending at least partially across a first face of the package to form a sealed and re-sealable closure for the package, the package also having a first peelable panel portion formed in the first face of the packaging and a second peelable panel portion forming in a face of the packaging opposite from the first face, each of the first and second peelable panel portions being configured so that it can be peeled away from the remainder of its respective face to increase the depth of an opening in the packaging produced when the flap is opened.
Several embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
The same reference numerals but increased by 100 in each case are used in relation to the various embodiments described below.
Packaging in accordance with a first embodiment of the invention is indicated generally at 10. The packaging 10 in accordance with the present embodiment is particularly suited for packaging generally block shaped food products such as chocolate bars 12 or other similar confectionery products. However, the packaging 10 can be adapted for packaging other generally block shaped products. The packaging 10 can also be used to package products provided in two or more generally block shaped portions. For example, the packaging 10 could be used to package multiple chocolate or other confectionery bars arranged in-line.
The packaging 10 comprises a wrapper 14 of flexible material which is folded around the product and sealed to fully enclose the product. Overlapping longitudinal edge regions of the wrapper 14 are bonded together to form a longitudinal fin seam 16 which extends along a rear face 18 of the packaging. Opposing end edge regions of the material are bonded together to form transverse sealed seams 20, 22 at either end of the product.
The longitudinal seam 16 and the transverse seams 20, 22 can be formed using an adhesive to bond the opposing surfaces of the wrapper or by heating the material under pressure so that the opposing surfaces melt and fuse together to form a welded seam. Alternatively, an ultrasonic means of bonding the opposing surfaces together may be employed. In
The wrapper can be made of any foldable material suitable for packaging the product concerned. Where the product is a food product, the material may be substantially moisture and gas impervious so that when it is fully sealed, the packaging provides a hermetically sealed container for the product. Alternatively, the package may be vented so as to enable the food product to be stored for longer periods (for example, Turkish Delight products require venting so as to prevent microbial activity during storage). Examples of typical materials that can be used include: paper based materials, one or more polymeric materials, and metallic foils. The wrapper may also be a lamination comprising layers of the same or different materials, which may include any of those mentioned above in any suitable combination. In one embodiment, the material comprises a laminate of a metal foil, which may be an aluminium foil, on one side and a plastics material on the other side. When the material is formed into the package, the metallic foil is positioned on the inside facing the product and the plastics material is on the outside. The plastics material may be printed on or otherwise provided with information for the consumer.
The wrapper 14 has an aperture which is closed by a flap portion 24 near to one end which forms a sealed and re-closable end closure for the packaging. The flap 24 is foldably connected with the remainder of the wrapper 14 along one edge 26 adjacent to the transverse seam 20 at one end of the package. The flap has three free edges 28, 3032, which overlap a main body portion 34 of the wrapper. The free edges 28, 30, 32 of the flap are bonded to the overlapping region 36 of the main body portion by means of a peelable and re-sealable adhesive 37. In some instances, the re-sealable adhesive 37 only extends along part of the flap. The flap extends fully across the front face 38 of the package and at least partially down opposing sides 40, 42 so that when it is peeled back, it reveals an opening or aperture 44 at the end of the package through which the product 12 can be removed in a longitudinal direction as indicated by arrow A in
The peelable and re-sealable adhesive 37 may be a cold seal adhesive and may be applied to the free edges of the flap 24 or to the overlapping region 36 of the main body portion 34 or both. The flap seal may include a tamper evident seal arrangement which provides a visual indication when the flap has been opened. The flap arrangement could include two seals, a first seal which breaks when the flap is first opened and a second, peelable and re-sealable seal to enable the package to be re-closed after it has been opened. The first, breakable seal will usually be positioned outside the second peelable seal so that a clear visual indication is given to potential consumers if the flap 24 has been opened and re-closed.
Although the peelable seal on the flap 24 is referred to as being re-sealable, in practice the peelable seal will not usually be expected to form a hermetic seal when the flap is re-closed. However, when the flap 24 is re-closed it will hold the remaining contents securely in the package and will provide some protection for the product from the environment. References to the flap being “re-sealed” or “re-sealable” should be construed accordingly. However, where the packaging is used to package a food product such as a chocolate bar, it is expected that the flap 24 will be fully sealed when the package is formed prior to the first opening, so that the packaging initially forms a sealed package. Thus the first breakable seal may be arranged to hermetically seal the flap 24 whereas the second peelable seal may simply be arranged to hold the flap in position when re-closed without forming a perfect seal. Accordingly, the peelable adhesive forming the second seal may not be applied to the whole surface area of the free edges of the flap 24.
The packaging 10 can be produced using a flow-wrap method in which a film of material having a number appropriately positioned flap portions 24 disposed along its length is supplied in a roll to package products 12 in a substantially continuous process. The material is fed through a machine which folds it about each product in turn so that opposing longitudinal edge regions are brought into contact and bonded together to form the longitudinal seam 16. The material is crimped at either end of the product to form the transverse end seams 20, 22 and the material is cut to separate each package from the remainder of the film.
In a preferred embodiment, the flap portion 24 is an integral part of the wrapper and is formed in the wrapper material by laser treatment (e.g. laser cutting /etching) or by mechanical means so as to produce overlapping regions 36 along the free edges 28, 30, 32 of the flap 24.
An alternative arrangement for producing the flap where the material is a laminate is shown in
The first and second cuts 58, 60 may be produced using one or more lasers as indicated by the arrows 62, 64 after the two layers 50, 52 have been laminated. Because the two layers 50, 52 are different materials, the lasers 62, 64 may be operated at different frequencies to produce the required depth of cut. In addition or as an alternative, the depth of cut produced by the lasers can be at least partly controlled by having at least one layer of material in the laminate which incorporates or is coated with a laser retardant additive having laser retarding properties. The laser retardant additive may be an ink and in particular a metallic ink. In one embodiment, the laminated material includes a continuous metallic foil bonded to a second layer of material which incorporates or is coated with the laser retardant additive.
The term “laser retardant additive” should be taken to mean any material which is capable of hindering, attenuating or mitigating the passage of electromagnetic radiation in the spectrum commonly used by laser (light amplification by simulated emission of radiation).
In an alternative method, the first and second cuts 58, 60 are produced by passing the laminated material between a pair of contra-rotating die cylinders, one of the cylinders contacting the outer layer 52 and one the inner layer 50, each of the cylinders having one or more blades which form a cut in the respective layer.
The first and second cuts or lines of weakness 58, 60 could be produced prior to the two layers 50, 52 being laminated. In this case, a line of perforations will be produced in the material forming each layer 50, 52 and the layers arranged so that when they are laminated, the lines of perforation 58, 60 are aligned as illustrated in the
The packaged product is supplied with the flap 24 in a closed and sealed condition. A consumer opens the package 10 by grasping the tab 46 and peeling the flap 24 away from the main body portion 34 to reveal an opening or aperture 44 through which the rigid bar 12 can be slid out of the main body portion 34 of the package in a longitudinal direction, as indicated by the arrow A in
The opening or aperture 44 is dimensioned to enable the product 12 to pass through when the flap 24 is opened. Accordingly, the aperture 44 has a width which is equal to or just slightly larger than the side 13 of the product 12 which is aligned with and faces the aperture. Typically, the aperture 44 will be dimensioned so that its maximum width Y is in the range of 1% to 10% larger than the side 13 of the product 12 which must pass through the aperture. In some embodiments, the aperture may have a maximum width that is in the range 1% to 5% larger than the side 13 of the product 12 which is aligned with the aperture.
Packaging 10 in accordance with the invention is particularly suitable for use in packaging chocolate or other confectionery bars as it allows the consumer to easily open the packaging periodically to remove one or more portions and holds the remaining contents in a secure and sealed container. However packaging in accordance with the invention may also be useful in packaging smaller “snack” size bars as it provides an easy to open package which produces less mess than the known packaging. In some cases, more than one bar may be contained in the package, with the bars arranged in-line or side-by-side. In this case, the package 10 can be opened and one of the bars removed before the flap is re-closed to hold the remaining bar or bars in that package. Indeed as has already been stated, packaging 10 in accordance with the invention can be adapted to pack any generally block shaped food or even non-food product where is it is desirable to have packaging which is easy to open and re-close.
It will be appreciated that the shape of the flap 24 can be varied from that shown in the first embodiment. For example, the flap 24 could be hemispherical or have some other curved shape so that it does not exhibit three distinct side edges but has what could be regarded as a single continuous free edge. Indeed the flap 24 can have any suitable shape and can have one, two, three or more free edge regions. Furthermore, the flap 24 need not be positioned adjacent a longitudinal end as shown. In some cases the pack may be oversized so that it is longer than the product. In this case, the flap 24 could be positioned in-board from the end provided the product can be manoeuvred through the opening 44.
The invention is not limited to packaging comprising a longitudinal seam or which is formed using a flow-wrap method and apparatus.
A further embodiment of a packaging 500 in accordance with the invention is illustrated in
The packaging 500 is similar to the packaging 10 of the first embodiment described above with reference to
The packaging 500 has a re-closable flap 524 positioned adjacent to one longitudinal end of the packaging 500 to form a re-closable end closure. The flap 524 is essentially the same as the flap 24 in the first embodiment and can be produced using any of the methods discussed above. However, the flap 524 is somewhat smaller in length than the flap 24 in the first embodiment so that the opening 544 formed when the flap 524 is opened is shallower in depth than the opening 44 produced in the first embodiment 10 when the flap 24 is opened. This can be seen by comparing
The first or front panel portion 584 extends from an upper (as shown) edge 588 of the main panel portion 534 adjacent the opening 544 partway down a front wall region or face 538 of the man in body portion 534. The front panel portion 584 has a tab 590 on its upper edge that is exposed once the flap 524 is opened. The tab can be grasped by a user to peel the front panel portion down as shown in
The second or rear panel portion 586 extends from an upper (as shown) region of a rear wall or face 518 of the main body 534 which is approximately level with the upper (as shown) edge of the front wall partway down the rear wall. At its upper end, the rear panel portion extends around the sides of the packaging to connect with the front wall of the main body at a position substantially in line with the upper edge of the front wall. This arrangement enables the rear panel portion 586, the flap 524 and the end seal 520 to be peeled downwardly as shown in
The front and rear panel portions 584, 586 can be formed in a manner similar to the flap 524 so that each panel portion has one or more free edge region which overlaps an edge region of the main body portion 534, with the overlapping edge regions being bonded together by means of a peelable adhesive which may be a re-sealable or re-closable adhesive. Where the packaging 500 is produced from a laminated material, the front and rear panel portions 584, 586 could be produced using the method of off set cuts as described above in relation to
If desired, the packaging 500 may have only one of the front and rear peelable panel portions 584, 586.
The packaging 500 can be produced using a flow-wrap method as described above from a roll or web of material in which flaps 524 and the peelable panel portions 584, 586 are pre-formed.
The packaging 600 is identical to the packaging 500 except that the flap 624 is formed solely in the front face of the packaging and does not extend down the opposing sides in accordance with the presently claimed invention. As a consequence, when the package is opened and the front and rear panel portions 684, 686 are peeled open, the side portions 694 between the front and rear panel portion encase the side regions of the product. To access the product, the user also peels the side portions downwardly.
Whilst the packaging 600 is not in accordance with the presently claimed invention, patent protection for this arrangement may be sort in due course.
It will be appreciated from the forgoing description that the flap 24, 124, 224, 324, 424, 524 and corresponding aperture 44, 144, 544 can be positioned in any suitable location on the package provided the rigid block shaped product 20, 120, 520 can be manoeuvred through the aperture once the flap is opened. Indeed, packaging in accordance with the invention may be provided with two or more flaps and corresponding apertures so that the consumer has the option of opening the package in different positions. For example, a package in accordance with the invention may be provided with a flap near one longitudinal end and a second flap along one of the longer sides to provide an option for side opening.
The foregoing embodiments are not intended to limit the scope of protection afforded by the claims, but rather to describe an example as to how the invention may be put into practice.
Number | Date | Country | Kind |
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0819200.7 | Oct 2008 | GB | national |
0821354.8 | Nov 2008 | GB | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/GB2009/002462 | 10/14/2009 | WO | 00 | 7/5/2011 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2010/046623 | 4/29/2010 | WO | A |
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Number | Date | Country | |
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20110253771 A1 | Oct 2011 | US |