GB2581159A

GB2581159A - Method of manufacturing a paper straw with scoop-like end

Info

Publication number: GB2581159A
Application number: GB1901593.2A
Authority: GB
Inventors: Goldfinch Paul; Cao Bill
Original assignee: Northumbrian Ice Cream Co Ltd T/a
Current assignee: Northumbrian Ice Cream Co Ltd T/a
Priority date: 2019-02-05
Filing date: 2019-02-05
Publication date: 2020-08-12
Also published as: GB201901593D0

Abstract

A method of manufacturing a paper straw 101 with a scoop-like end comprises providing a paper tube and at least one laser emission source. The laser emission source is suitable for emitting at least one laser beam to a surface of the paper tube so as to form a scoop-like end on the paper tube. The laser beam may penetrate the surface of the paper tube to form a cut in the surface of the paper tube. There may be relative movement between the laser beam and the paper tube. The at least one laser beam may simultaneously contact at least two surfaces of the paper tube. The scoop-like end may comprise a neck portion 103 and a scoop-like portion 104, wherein the neck portion is narrower than the paper tube body 102and the scoop-like portion is wider than the neck portion. The laser emission source may be a carbon dioxide laser emission source.

Description

Method of manufacturing a paper straw with scoop-like end

Technical Field

The present invention relates to a method of manufacturing paper straws with a scoop-like end and the resulting product.

Background

It is estimated that there are over 150 million tonnes of plastic in the oceans and according to a 2018 report published by the UK Government Office for Science, this is set to treble by 2025. One way in which many governments are planning to address this issue is by restricting the use of single use plastics such as plastic cutlery and plastic straws.

Despite these restrictions, there is still widespread demand for disposable tableware such as straws. One disposable alternative to plastic tableware such as straws is manufacturing them from paper to provide a biodegradable substitute.

Plastic straws with scoop-like ends are widely used for drinking beverages containing solid pieces, such as iced slush-type drinks and fruit smoothies. Given the environmental concerns over single-use plastics, there is a need for a biodegradable alternative to plastic straws with scoop-like ends, such as a paper substitute.

The manufacture of goods from paper as opposed to plastic presents some challenges due to the inherent properties of paper. For example, in the production of plastic straws, mechanical cutting is performed to cut different shapes into the plastic. This can include mechanically cutting a scoop shape in the end of the plastic straw. Following mechanical cutting, the natural resilience of the plastic material means that the plastic straw will return to a hollow cylindrical shape. However, the application of such mechanical cutting to paper straws results in the crushing of the straws and the properties of paper prevent it from returning to the hollow cylindrical shape required for a drinking straw.

One method employed to cut paper items utilises laser cutting. Whilst more commonly used to cut other materials, laser cutting can be used to cut paper products such as cards and flat paper goods which are largely two-dimensional.

The application of traditional lasers to cut paper does have limitations. Firstly, these lasers are largely used for cutting planar paper goods such as cards. Secondly, the application of high-powered laser cutting to paper goods can leave scorch marks around the cut area. The appearance of scorch marks for food-related goods is especially undesirable as it can make goods appear unhygienic.

The present invention aims to obviate or mitigate limitations associated with the prior art.

Summary of the Invention

The present invention addresses issues with the prior art by providing a method of manufacturing paper straws with a scoop-like end.

According to an aspect of the present invention, there is provided a method of making a paper straw with a scoop-like end, the method comprising: providing a paper tube and at least one laser emission source, capable of emitting at least one laser beam to a surface of said paper tube; applying said at least one laser beam to a surface of said paper tube; resulting in the formation of a scoop-like end on the paper tube.

Advantageously, this method provides a means of manufacturing a biodegradable paper straw with a scoop-like end without crushing and/or misshaping the paper tube. By applying and focusing the laser beam onto a surface of the paper tube, the required scoop-like shape can be cut.

Preferably, relative movement is provided between the at least one laser beam and the paper tube.

Advantageously, this allows the at least one laser beam to contact multiple different areas of the paper tube.

Preferably, the at least one laser beam penetrates the surface of the paper tube resulting in a cut in a surface of said paper tube.

Advantageously, this means that the contact between the laser beam and paper tube is sufficient to easily manufacture a paper straw with a scoop-like end.

Optionally, the at least one laser beam substantially simultaneously contacts at least two surfaces of the paper tube.

Advantageously, this allows the substantially simultaneous cutting of two surfaces of said paper tube.

Preferably, the scoop-like end comprises; a neck portion and a scoop-like portion; said neck portion being narrower than the body of the paper tube; and said scoop-like portion being wider than said neck portion.

Advantageously, this configuration forms a scoop-like end of the paper straw allowing liquids to be sucked through the straw body and solids to be collected using the scoop-like end for consumption.

Typically, the paper tube is a paper straw.

Advantageously, beginning the method with a paper straw results in a finished product with appropriate dimensions for a paper straw with a scoop-like end.

Preferably, the at least one laser beam moves in a pattern on one end of a paper straw, resulting in an excised portion leaving said end of the paper straw with an open scoop-like end comprising a narrower neck portion and a wider scoop-like portion.

Advantageously, this provides an efficient method which produces a paper straw with a scoop-like end by controlling movement of the at least one laser beam over the surface of the paper tube.

Preferably, the paper tube is made of 3 ply paper.

Advantageously, using paper of this thickness conveys the properties desirable for a paper straw that will withstand use in liquid for an appropriate amount of time.

Typically, the paper tube is made from food grade standard paper.

Advantageously, using paper of a food grade standard results in a product which is suitable for using as a tool for consumption without requiring further treatment.

Typically, the laser emission source is a carbon dioxide laser emission source.

S

Preferably, a method of producing a paper straw with a scoop-like end wherein the at least one laser beam has a power density of greater than SOW, preferably between 50 and SOOW.

Advantageously, using a laser beam with a power density between SO and SOOW provides enough power to cut the paper tube smoothly.

More preferably, the at least one laser beam has a power density of 300W.

Advantageously, using a laser beam with a power density of 300W provides enough power to optimally cut the paper tube without leaving scorch marks on the newly formed edge.

Optionally, the relative movement between the at least one laser beam and the paper tube is controlled by software present on a control module.

Preferably, controlling the relative movement of the at least one laser beam and the paper tube by means of software present on a control module allows the precise control of the pattern of the laser beam emission onto the paper tube. This means that the shape of the laser beam path on the paper tube can be precise and is alterable through the software. This leads to increased reproducibility between individual products.

Optionally, a method of producing a paper straw with a scoop-like end further comprising applying compressed air from a compressed air source to substantially prevent scorching of the paper tube.

Advantageously, this further reduces the risk of leaving scorch marks on the paper tube. This is particularly advantageous for goods to be sold into the food and drink sector as the appearance of scorch marks can appear unhygienic to consumers.

Preferably, the laser emission source is located 10 to 50 centimetres from the surface of the paper tube.

More preferably, the laser emission source is located 30 centimetres from the surface of the paper tube.

Preferably, the method of producing a paper straw with a scoop-like end is a method for mass production.

Advantageously, this provides an efficient method for mass production of paper straws with a scoop-like end.

Optionally, the scoop-like portion is configured to flare outwardly from the neck portion.

Advantageously, this provides a scoop-like portion capable of gathering more material.

According to another embodiment of the present invention, there is provided a paper straw with a scoop-like end comprising a paper tube wherein one end of said paper tube comprises an integral scoop-like portion; the edges of said scoop-like portion being laser-cut edges.

Advantageously, the edges of said scoop-like portion having been formed by the application of a laser to the paper tube provides a biodegradable paper straw with a scoop-like end which has maintained its tubular shape.

Various further features and aspects of the invention are defined in the claims.

Brief Description of the Drawings

Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings where like parts are provided with corresponding reference numerals and in which:

S

Figure 1 shows a system for use in a method of manufacturing a paper straw with a scoop-like end according to an embodiment of the present invention; Figure 2 is a drawing showing a paper straw with a scoop-like end, according to one embodiment of the present invention; Figure 3 is a drawing showing an alternative view of a paper straw with a scoop-like end according to one embodiment of the present invention; Figure 4 is a drawing showing a paper straw with a scoop-like end according to an alternative embodiment of the present invention.

Detailed Description

In Figure 1 there is depicted a system used in a method of manufacturing a paper straw with a scoop-like end according to an embodiment of the present invention; comprising a laser emission source, wherein the laser emission source is a CO2 (carbon dioxide) laser emission source 106.

In the present invention, "paper" includes materials manufactured from the pulp of wood, grasses, rags or any other fibrous substances. For the purposes of the present invention, "paper" also includes fibrous substance-based materials which have embedded short wire bristles such as card. The term "paper" also encompasses, but is not limited to, materials derived from bamboo, corn and polylactic acid (PLA) and related paper-type products such as paperboard and cardboard.

The CO2 laser emission source 106 is positioned above a surface 108 holding a paper tube, wherein the paper tube is a paper straw body 102, the paper straw body 102 is manufactured from 3 ply food-grade standard paper. The paper straw body 102 is positioned on the surface 108 as such that one end of the paper straw body 102 protrudes over the edge of the surface 108. The end of the paper straw body 102 protruding over the edge of the surface 108 is optionally positioned over a waste bin 109.

The CO2 laser emission source 106 is capable of emitting a moveable CO2 laser beam 107. The CO2 laser beam 107 is emitted from the laser emission source 106 at 300 watts. The CO2 laser beam 107 is focussed on a surface of the paper straw body 102 which protrudes the surface 108. The CO2 laser emission source 106 is located approximately 30 centimetres from the surface of the paper straw body 102.

The term "cut" in the context of the present invention means any action resulting in the formation of a new edge in by removal of a part of the paper tube body. This could be achieved by cutting, melting, burning or vaporising at least part of the paper tube body and so on.

Relative movement between the CO2 laser beam 107 and the paper straw body 102 is provided by movement of the CO2 laser beam 107. The CO2 laser beam 107 moves across the surface of the paper straw body 102. This movement is controlled by software present on a control module for example by software on a computer controlling the movement of the laser beam 107 via the laser emission source 106. The rate of movement of the laser beam 107 as well as the pattern and direction of movement of the laser beam 107 can be controlled through the software.

As the CO2 laser beam 107 continuously moves along the paper straw body 102 following the laser beam path 105, the CO2 laser beam 107 cuts through a surface of the paper straw body 102. The laser beam path 105 is determined by the software present on a computer.

Once the CO2 laser beam 107 reaches the end of the laser beam path 105 at the terminal end of the paper straw body 102, the CO2 laser emission source 106 ceases to emit the CO2 laser beam 107.

The excised portion of the paper straw body 111 becomes detached from the paper straw body 102 as a result of the cut made by the CO2 laser beam 107. The excised portion of the paper straw body 111 falls from the paper straw body 102 and into the waste bin 109 positioned directly below the protruding end of the paper straw body 102.

The resulting paper straw with a scoop-like end is moved from its position on the surface 108 by a moving element present on the surface 108 such as a belt conveyor. The moving element present on the surface 108 subsequently brings another paper straw body 102 into position underneath the CO2 laser emission source 106.

In one embodiment, the method works as described above however there are two laser emission sources positioned proximate to the straw and in use there are two laser beams which are both applied to surfaces of the paper straw to achieve cuts resulting in a paper straw having a scoop-like end.

In an alternative embodiment, the method is as above however instead of performing a single cut, the CO2 laser beam 107 cuts through a first surface of the paper straw body 102 and a second surface of the paper straw body 102 directly opposite the first surface substantially simultaneously.

In another embodiment, the method is as described above however the relative movement between the at least one laser beam and the paper straw is provided by movement of the paper straw body. Typically, this movement is controlled by software present on a control module which controls the movement of a moving element present on the surface 108.

In an alternative embodiment, no relative movement is provided between the laser beam and the paper straw body, instead an array of laser beams is applied to the paper straw body in an arrangement which results in the production of a paper straw with a scoop-like end.

Figures 2 and 3 depict different views of a paper straw with a scoop-like end 101 manufactured using a laser according to one embodiment of the present invention. The paper straw body 102 has a scoop-like end comprising a narrow neck portion 103 and a wider scoop-like portion 104.

The narrow neck portion 103 is formed by the removal of a larger proportion of the circumference of the paper straw, leaving behind an area equivalent to or less than half of the circumference of the paper straw. The wider scoop-like portion 104 is formed by the removal of a smaller proportion of the circumference of the paper straw resulting in a wider portion remaining.

Due to the inherent properties of paper, the wider scoop-like portion 104 of the scoop-like end unfurls from the narrow neck portion 103. The narrower width of the narrow neck portion 103 further induces the unfurling of the wider scoop-like portion 104. This unfurling of the wider scoop-like portion results in a more planar surface at the distal end of the wider scoop-like portion 104.

S

Figure 4 depicts a paper straw with a scoop-like end manufactured using a laser according to an alternative embodiment of the present invention. There is provided a paper straw with a scoop-like end 101 comprising a paper straw body 102 and a scoop-like end.

The scoop-like end comprising: a narrow neck portion 103, the narrow neck portion being narrower than the paper straw body 102; and a wider flared scoop-like portion 110 being wider than the narrow neck portion 103. The wider flared scoop-like portion 110 having its most narrow point proximal to the narrow neck portion 103 and becoming wider in a flared manner towards the terminal end of the paper straw with a scoop-like end 101.

The wider flared scoop-like portion 110 is formed by the removal of a higher proportion of the circumference of the paper straw at the proximal end of the wider flared scoop-like portion closest to the narrow neck portion 103, and removal of a smaller proportion of the circumference the paper straw towards the distal terminal end. The resulting wider flared scoop-like portion being narrower at the end proximal to the narrow neck-portion 103 and wider at the distal terminal end of the wider flared scoop-like portion 110.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations).

It will be appreciated that various embodiments of the present disclosure have been described herein for purposes of illustration, and that various modifications may be made without departing from the scope of the present disclosure. Accordingly, the various embodiments disclosed herein are not intended to be limiting, with the true scope being indicated by the following claims.

Claims

CLAIMS1. A method of making a paper straw with a scoop-like end, the method comprising: providing a paper tube and at least one laser emission source, capable of emitting at least one laser beam to a surface of said paper tube; applying said at least one laser beam to a surface of said paper tube; resulting in the formation of a scoop-like end on the paper tube.
2. A method according to claim 1 wherein relative movement is provided between the laser beam and the paper tube.
3. A method according to any previous claim wherein the at least one laser beam penetrates the surface of the paper tube resulting in a cut in a surface of said paper tube.
4. A method according to any previous claim wherein the at least one laser beam substantially simultaneously contacts at least two surfaces of the paper tube.
5. A method according to any previous claim wherein the scoop-like end comprises; a neck portion and a scoop-like portion; said neck portion being narrower than the body of the paper tube; and said scoop-like portion being wider than said neck portion.
6. A method according to any previous claim wherein the paper tube is a paper straw.
7. A method according to claims 2 to 6 wherein the at least one laser beam moves in a pattern on one end of said paper tube, resulting in an excised portion leaving said end of the paper tube with an open scoop-like end comprising a narrower neck portion and a wider scoop-like portion.
8. A method according to any previous claim utilising a paper tube made from food grade standard paper.
9. A method according to any previous claim wherein the laser emission source is a carbon dioxide laser emission source.
10. A method according to any previous claim wherein the at least one laser beam has a power density of greater than 50W, preferably between 50 and 500W.
11. A method according to any previous claim wherein the at least one laser beam has a power density of 300W.
12. A method according claims 2 to 11 wherein the relative movement between the at least one laser beam and the paper tube is controlled by software present on a control module.
13. A method as in any of the previous claims wherein the laser emission source is located at a distance between 10 and 50 centimetres from the surface of the paper tube.
14. A method as in any of the previous claims wherein the laser emission source is located 30 centimetres from the surface of the paper tube.
15. A paper straw with a scoop-like end comprising a paper tube wherein one end of said paper tube comprises an integral scoop-like portion; the edges of said scoop-like portion having been formed by the application of a laser to the paper tube.