WO2000012394A1

WO2000012394A1 - Improved packaging

Info

Publication number: WO2000012394A1
Application number: PCT/GB1999/002817
Authority: WO
Inventors: Sean Patrick Fortune
Original assignee: Siebert Head Limited
Priority date: 1998-08-27
Filing date: 1999-08-26
Publication date: 2000-03-09
Also published as: AU5525599A

Abstract

A packaging container (40) is formed from a blank (32) cut from a sheet of semi-rigid material such as cardboard which forms an outer layer of the package (40). The outer layer blank (32) is secured to an inner film layer (34) so that at least part of the outer layer blank (32) is adhered to the inner film layer (34). The inner film layer (34) is of dimensions such that it extends beyond at least one edge of the outer layer blank (32). The blank is formed into a tubular construction by folding with the film layer (34) innermost. The ends of the tubular construction are closed by forming a transverse seam across the portion of the film layer (34) which extends beyond the tubular construction or by folding in flaps formed around the periphery of the end of the tubular construction. The flaps are secured together by gluing or welding. The resulting package is sift-proof and, at the same time, capable of being formed in a single manufacturing procedure. The packaging container (40) may additionally be formed so that folding out apart of the outer layer exerts a force on the transverse seam formed in the film layer (34) to facilitate opening of the container.

Description

IMPROVED PACKAGING

The present invention relates to improved packaging and to a method for manufacturing such packaging.

Many products, in particular, foodstuffs, are supplied in sealed packaging so as to meet hygiene rules and to prevent tampering. One method of providing such sealed packages is to use so-called 'flow wrap' techniques.

In a conventional flow wrap arrangement a generally tubular run of packaging material is sealed across its width by, for example, gluing or welding, the packaging contents being enclosed between pairs of widthwise seals. The individual packages can then be separated by cutting between the seals or welds which close adjacent packages.

The disadvantage of flow wrap packaging is that it tends to be relatively fragile, because of the relatively thin materials used, and goods which have been packaged by this method cannot, in many cases, readily be stacked for display or storage. In addition, products packaged in this way are generally not self-supporting; they will not stand up but must be laid down on the shelf. This means that they do not readily advertise themselves, a consideration of importance where the product is to be displayed for sale alongside a number of competing products on, for example, a supermarket shelf.

These disadvantages are overcome, in practice by 'over packing' , that is, by placing the flow wrap package inside another container of more rigid construction, usually a cardboard box or the like, so that it is self supporting. The outer box protects the relatively fragile contents and, since it will stand in an upright position on a shelf, is 'self-merchandising' ; it advertises its presence, unlike a horizontally arranged flow wrap package .

The need to over pack flow wrap packages, however, makes the packaging relatively expensive and the packaging process relatively complex.

In accordance with the invention, there is provided a method for making a packaging container, the method comprising cutting from a sheet of semi-rigid material an outer layer blank, securing the outer layer blank to an inner film layer so that at least a part of the outer layer blank is adhered to the inner film layer; the inner film layer being of dimensions such that it extends beyond at least one edge of the outer layer blank; forming a generally tubular construction with the film layer innermost, the portion of the film layer which extends beyond the outer layer blank projecting from the periphery of the tubular construction at one end thereof and forming a generally transverse seam across the portion of the film layer which extends beyond the said tubular construction to close the said end thereof.

Utilising the method of the invention, it is possible to manufacture a sealed container of a kind suitable for preserving the integrity and freshness of a food product, without the need for a separate over-packing operation, as a single in-line process.

The invention further provides a packaging container comprising an outer layer of semi-rigid material, and an inner film layer; the outer layer and inner film layer being secured together so that at least a part of the outer layer is adhered to the inner film layer, the two layers together forming a generally tubular construction ^' with the film layer innermost; the inner film layer being of dimensions such that it extends beyond at least one edge of the outer layer with the portion of the film layer which extends beyond the outer layer blank projecting from the periphery of the tubular construction at one end thereof; a generally transverse seam being formed across the portion of the film layer which extends beyond the said tubular construction to close the said end thereof.

In a preferred embodiment, the outer layer has formed in it at least one opening which, in the tubular construction formed therefrom, extends from side to side thereof so that the film layer in the region of the opening can be caused to collapse onto itself by folding the outer layer adjacent the opening, the film layer being adhered to the outer layer over at least a part of the region of the outer layer to be folded so that folding of the outer layer exerts a force which tends to pull apart the transverse seam formed in the film layer to re-open the container. This preferred constructions facilitates reopening of the container by the final consumer.

In a yet further embodiment, the invention, provides a packaging container comprising an outer layer of semi-rigid material, and an inner film layer; the outer layer and inner film layer being secured together so that at least a part of the outer layer is adhered to the inner film layer, the two layers together forming a generally tubular construction with the film layer innermost; and at least one open end of the tubular construction being closed by flaps formed around the periphery of said open end being folded inwards and secured together.

A preferred form of combined package in accordance with the invention will now be described in detail, by way of example, with reference to the drawings, in which:

^' Figure 1 shows a blank for_t forming into a first package in accordance with a first aspect of the invention; Figure 2 shows the pattern of adhesive to be applied to the film used to form the packaging blank of Figure 1;

Figure 3 shows a blank for forming a second, modified package in accordance with the invention;

Figures 4(a), (b) and (c) illustrate folding and completion of the package constructed from the blank of Figure 3.

A packaging blank shown in Figures 1 and 2 comprises two layers, an outer layer 12, typically of cardboard or other semi-rigid material of the kind used in packaging applications, and an inner layer 14 of thin film of, for example, plastics material of the kind conventionally used in flow wrap packaging.

The outer layer 12 is cut to shape and scored along the fold lines 16 in the same manner as the blank for conventional box packaging. In the example shown, the box would be formed by folding along the parallel fold lines 18 and welding or gluing the blank along the edges 20 parallel to the fold lines 18 to form a generally rectangular section tube with the seam down the centre of one of the rectangular faces of the resulting tubular construction. The bottom of the box would then be formed by folding in, and gluing, the four rectangular flaps 24 defined by transverse fold lines 22. It will be noted that there is no provision, in the embodiment shown, in the outer layer 12 for the finished box to be closed at its upper end; there are no flaps at the other end of the blank similar to the flaps 24 which would close the bottom of the box.

However, the outer layer 12 may, in an alternative embodiment, not shown, be provided with rectangular flaps 24 at both ends of the tubular structure, so that both ends of the packaging container are closed by folding flaps 24 inwards.

The inner layer 14 of the blank 10 is simply a generally rectangular piece of plastics film. The overall dimensions of the film are chosen to be such, however, that the film layer 14 extends beyond the edges of the outer cardboard layer 12 at the edges which run around the periphery of the box-like tubular construction formed as an intermediate stage of construction of the finished box- like container. At the lower end, where the flaps 24 are defined by the fold lines 22, the film layer 14 extends only a short distance beyond the edge of the cardboard layer 12. At the upper end, remote from the flaps 24, the film layer 14 extends quite a distance beyond the cardboard layer 12.

The outer cardboard layer 12 and inner film layer 14 are secured together by gluing. The glue extends over the whole of the outer cardboard layer 12 except for four triangular areas 26 adjacent the edges of the flaps 24, shown by cross hatching in Figure 1, where the cardboard layer 12 is not fixed to the film layer 14. The area 28 to which glue is applied on the film layer 14 is shown in Figure 2. Where the container is to be closed by flaps similar to flaps 24 at both of its ends, there will be similar unadhered areas 26 adjacent both sets of flaps.

The blank 10 is assembled by folding, as in the assembly of a conventional box, to form a rectangular tube, and the longitudinal seam required to close the tube is glued closed. The flaps 24 are then folded in to close the bottom of the tube; this is possible because of the unglued regions 26 where the film layer 14 can move away from the cardboard layer 12 to allow the flaps 24 to overlap one another. The bottom of the container is secured by gluing the flaps or by welding the film layer 14 to itself. It will be appreciated that this produces an open-topped, box-like structure which is completely lined by the film layer 14 and which has an upstanding collar projecting above its upper edge formed by the 'extension' of the film layer 14 which extended beyond the cardboard layer of the blank 12.

The end of the container which is closed by means of the folded-in flaps 24 can be made liquid-proof and, in the case of powdered products, sift-proof, using conventional techniques for folding and gluing the flaps. This is due to the fact teat the inner film layer 14 is continuous across the gaps between the flaps 2, the unadhered areas 26 permitting the flaps 24 to be folded inward so that they overlap one another, while maintaining the continuity of the inner film.

This part-formed container can then be filled and the open end of the container closed by pinching together the opposite sides of the upstanding collar formed by the extension of the film layer 14 and gluing or welding the film material to form a transverse seam in a similar manner to the method of closing conventional flow wrap packaging.

Other forms of closure may, if appropriate, be used to form the transverse seam in the inner film layer 14, in particular, for example, resealable closures of the kind known as 'zip' seals formed by two interengageable strips which overlap one another. Alternatively such a zip seal might be provided in the film layer 14 for use by the ultimate purchaser while a conventional welded or glued seam is used to close the film layer 14 after the packaging contents have been added to fill the container.

In an alternative embodiment to that shown in the drawings, the inner film layer 14 may be left detached around the periphery of the tubular structure so that the upper part of the sealed inner package formed by closing the inner film layer 14 may be pushed into the end of the tubular structure formed by the outer rigid layer 12. The open end of the tubular structure may then be closed by folding in flaps similar to flaps 24 but free of adhered inner film layer 14.

The resulting package is relatively robust, sufficiently rigid to be self supporting, and lined throughout with plastics film which serves to seal in the contents of the package and protect them against deterioration or contamination. The package can, additionally, be erected, filled and sealed as part of a single, in-line process avoiding the need for a first flow wrap operation followed by over wrapping of the flow wrap packages in boxes or other containers. The process is simpler that the double process it replaces and cheaper.

It is well-known that packaging which is closed by gluing or welding plastic sheet or film can be difficult to open and Figures 3 and 4 show a modified package 40 which can be erected and filled as described above but which is provided with means for opening the package after it has been filled and sealed.

Figure 3 shows a blank 30 for forming the package 40 which, again, comprises two layers, a generally semi-rigid layer 32 of, for example, cardboard and a plastics film layer 34. The two layers 32 and 34 are glued together much as described in connection with Figures 1 and 2. The outer layer 32 is scored to form fold lines 36 which allow the blank to be erected into an open-topped, box-like container similar to that described above.

The blank 30 of Figure 3 is similar to that of Figures 1 and 2 in other respects. The film layer 34 again extends beyond the overall rectangular outline of the outer layer 34 to form an upstanding collar in the part-finished container and the blank is cut to form flaps 42 which can be folded in to close the bottom of the package 40.

However, the outer layer 32 is cut, prior to gluing to the film layer 34, so that it has two openings 35 formed therein. The openings may be chosen to be of any preferred shape provided that they extend across the whole width of two opposite walls of the box-like container 40. The outer layer 32 is, additionally, scored to form extra, transverse fold lines 37 which extend across the regions of the outer layer between the openings 35. The purpose of these additional fold lines 37 will be described in greater detail below.

As in the embodiment of Figures 1 and 2, the outer layer 32 is not glued to the film layer 34 over its whole surface area. The areas in which there is no glue are shown by crosshatching in Figure 3. Again, triangular areas 39 are left free of glue adjacent the flaps 42 to allow the flaps to overlap one another when folded inwards during erection of the box. There are, however, additional areas 41 left free of glue adjacent the edges of the openings 35.

The package 40 is assembled as described above; the blank 30 is folded as shown in Figure 4(a) to form a generally tubular construction which is closed by forming a longitudinally extending seam down one wall of the tubular assembly. The flaps 42 are then folded inwards to close the bottom of the box-like construction.

The package 40 is then filled and the top end closed by forming a transverse seam by gluing or welding across the upstanding collar of plastics film formed by the extension on the film layer 34, as shown in Figure 4(b) . When the package 40 is to be opened, the user inserts a finger between the outer layer 32 and the film layer 34 at the edge of one or both openings 35. This is possible due to the unglued areas 39 in the packaging blank 30 shown in Figure 3. The outer layer 34 is eased outwards and tends to fold along the pre-scored fold lines 37. By pinching together the outer layer along the fold lines 37 as shown in Figure 4(c), the wall of the package 40 is caused to protrude outward, a movement which is facilitated by the openings 35 which extend across the walls of the package 40 between the areas formed with the fold lines 37.

The film layer 34 is fixed to the outer layer 32 over most of the area between the openings 35 and so, as the outer layer is forced outwards around the fold line 37, the film layer 34 folds with it. This tends to exert a force on the film layer 34 in the region of the seam which closes the package 40, splitting the seam open around the contents of the package. The package 40 of Figures 3 and 4 is thus easily provided during the single in-line manufacturing process with means to facilitate opening of the package by the ultimate consumer.

Alternatively conventional means for breaking the seal in the inner film layer 14 may be provided, for example, a rigid insert within the film layer with a pointed or comblike end against which the film layer 1 4 may be pulled to split the seam.

It will be appreciated from the above description that the packages describes above are only to be regarded as exemplifying the invention. A number of modifications which might be made are readily apparent. For example, the outer semi-rigid layer might be omitted at both ends of the package, both ends being closed by forming a glued or welded seam in a film layer extension. Additionally, the outer layer might be cut and scored with a view to forming a container of other than rectangular shape, for example a cylindrical or polygonal columnar shape. Further, in the modified version which includes means for facilitating opening of the sealed package, only a single opening might be formed at one side of the package and inclined 'out folds' formed to exert a pull at one side only of the seam.

Claims

1. A method for making a packaging container, the method comprising cutting from a sheet of semi-rigid material an outer layer blank, securing the outer layer blank to an inner film layer so that at least a part of the outer layer blank is adhered to the inner film layer; the inner film layer being of dimensions such that it extends beyond at least one edge of the outer layer blank; forming a generally tubular construction with the film layer innermost, the portion of the film layer which extends beyond the outer layer blank projecting from the periphery of the tubular construction at one end thereof and forming a generally transverse seam across the portion of the film layer which extends beyond the said tubular construction to close the said end thereof.

2. A method according to claim 1 wherein the outer layer blank is so shaped that it can be folded to form an open- topped box-like construction, the end opposite the open end being closed following forming of the tubular construction by folding in flaps formed around the periphery of the said end.

3. A method for making a packaging container, the method comprising cutting from a sheet of semi-rigid material and outer layer blank, securing the outer layer blank to an inner film layer so that at least a part of the outer layer blank is adhered to the inner film layer; forming a generally tubular construction with the film layer innermost; and closing at least one open end of the tubular construction by folding in flaps formed around the periphery of the said end and securing said flaps to one another .

4. A method according to claim 1 wherein the flaps are secured together by gluing or welding.

5. A method according to any preceding claim wherein the outer layer blank is scored to form fold lines for facilitating formation of the tubular construction prior to being adhered to the film layer.

6. A method according to claim 1 or 2 wherein the outer layer blank is cut to form at least one opening which in the tubular construction formed therefrom extends from side to side thereof so that the film layer in the region of the opening can be caused to collapse onto itself by folding the outer layer adjacent the opening, the film layer being adhered to the outer layer over at least a part of the region of the outer layer to be folded so that folding of the outer layer exerts a force which tends to pull apart the transverse seam formed in the film layer to re-open the container.

7. A packaging container comprising an outer layer of semi-rigid material, and an inner film layer; the outer layer and inner film layer being secured together so that at least a part of the outer layer is adhered to the inner film layer, the two layers together forming a generally tubular construction with the film layer innermost; the inner film layer being of dimensions such that it extends beyond at least one edge of the outer layer with the portion of the film layer which extends beyond the outer layer blank projecting from the periphery of the tubular construction at one end thereof; a generally transverse seam being formed across the portion of the film layer which extends beyond the said tubular construction to close the said end thereof.

8. A packaging container according to claim 7 wherein the outer layer is folded to form an open-topped box-like construction, the end opposite the open end being closed following forming of the tubular construction by folding in flaps formed around the periphery of the said end.

9. A packaging container comprising an outer layer of semi-rigid material, and an inner film layer; the outer layer and inner film layer being secured together so that at least a part of the outer layer is adhered to the inner film layer, the two layers together forming a generally tubular construction with the film layer innermost; and at least one open end of the tubular construction being closed by flaps formed around the periphery of said open end being folded inwards and secured together.

10. A packaging container according to claim 9 in which the said flaps are secured together by gluing or welding.

11. A packaging container according to claim 7 or 8 wherein the outer layer has formed in it at least one opening which, in the tubular construction formed therefrom, extends from side to side thereof so that the film layer in the region of the opening can be caused to collapse onto itself by folding the outer layer adjacent the opening, the film layer being adhered to the outer layer over at least a part of the region of the outer layer to be folded so that folding of the outer layer exerts a force which tends to pull apart the transverse seam formed in the film layer to re-open the container.