WO2012064478A1 - Récipients en carton dotés d'une couche barrière à double paroi - Google Patents

Récipients en carton dotés d'une couche barrière à double paroi Download PDF

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Publication number
WO2012064478A1
WO2012064478A1 PCT/US2011/057008 US2011057008W WO2012064478A1 WO 2012064478 A1 WO2012064478 A1 WO 2012064478A1 US 2011057008 W US2011057008 W US 2011057008W WO 2012064478 A1 WO2012064478 A1 WO 2012064478A1
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WO
WIPO (PCT)
Prior art keywords
wall
container
longitudinal
end portion
layer
Prior art date
Application number
PCT/US2011/057008
Other languages
English (en)
Inventor
Zhiquan Q. Yan
Original Assignee
Meadwestvaco Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Meadwestvaco Corporation filed Critical Meadwestvaco Corporation
Publication of WO2012064478A1 publication Critical patent/WO2012064478A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D3/00—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines
    • B65D3/10—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines characterised by form of integral or permanently secured end closure
    • B65D3/12—Flanged discs permanently secured, e.g. by adhesives or by heat-sealing
    • B65D3/14—Discs fitting within container end and secured by bending, rolling, or folding operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D3/00—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines
    • B65D3/22—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines with double walls; with walls incorporating air-chambers; with walls made of laminated material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/38—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
    • B65D81/3865—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation drinking cups or like containers
    • B65D81/3874—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation drinking cups or like containers formed of different materials, e.g. laminated or foam filling between walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B32B2255/102—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer synthetic resin or rubber layer being a foamed layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/31—Heat sealable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B32B2307/7244—Oxygen barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2435/00—Closures, end caps, stoppers
    • B32B2435/02—Closures, end caps, stoppers for containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B32B2439/40—Closed containers
    • B32B2439/62—Boxes, cartons, cases

Definitions

  • This application relates to paperboard containers and, more particularly, to double wall paperboard containers and, even more particularly, to hermetically sealed, double wall paperboard containers.
  • Paperboard containers with barrier properties are typically formed from a paperboard blank comprising a paperboard substrate and one or more functionalized layers, such as oxygen and/or moisture barrier layers.
  • the paperboard blank is die cut to the desired silhouette and then formed into a container body by wrapping the paperboard blank around a mandrel.
  • the overlapping ends of the paperboard blank form a straight seam having an underlying portion and an overlying portion.
  • FIG. 1 shows a cross-sectional view of a container body 10 made by overlapping the longitudinal ends of the blank 12 into a straight, longitudinal seam 14 having an underlying portion 16 and an overlying portion 18.
  • the raw edge 20 of the underlying portion 16 is exposed to the container content, resulting in a reduction in the barrier performance of the container.
  • Several techniques have been reported to prevent the raw edge 20 of the seam 14 from being exposing to the packaged content.
  • barrier tape examples include metal foils, such as aluminum foil and tin foil, low density polyethylene (LDPE), ethylene-vinyl alcohol copolymer (EVOH),
  • PET polyethylene terephthalate
  • nylon polyamide
  • U.S. Patent No. 5,620,135 discloses a technique for covering the raw edge of the body with a protective covering tape.
  • the container body is formed from a blank having one longitudinal edge enclosed by a U-shaped protective covering.
  • the protective covered region of the blank Prior to formation of the container body, the protective covered region of the blank is compressed to a reduced thickness such that the entire sheet segment, including the protective region, has roughly the same thickness.
  • PCT Application No. WO 2003/106277 discloses a single wrap container having the exposed underlying edge of the paper-based container body enclosed by a tape that comprises a layer of metalized PET interposed between layers of LDPE.
  • the container body is made from a blank comprising layers of, from the inside out, polyolefin, paper stock, polyolefin, metal foil, polyolefin, printed paper and overprint varnish.
  • Another approach commonly used in multi-ply tubular container processes is to fold the underlying edge portion of the barrier liner ply into an "anaconda" fold, wherein the underlying edge is folded back on itself and adhere to the overlying edge.
  • An example of such a fold is illustrated in U.S. Patent No. 5,084,284.
  • the main drawback of an anaconda fold is the undesired increase in thickness of the seam, as it is three times the thickness of the blank. Cracks tend to form with such high thickness, resulting in a leakage of the contents, an influx of the outside air, and a reduction in barrier performance of the containers.
  • U.S. Patent No. 6,190,485 teaches a technique of manufacturing a hermetically sealed spiral-wound multi-ply container without using an "anaconda" fold.
  • the hollow body component of the hermetically-sealed container comprises a paperboard body ply and a liner ply on the inner surface of the body ply, wherein the inner ply includes a barrier layer and a layer of adhesive that is activatable at a predetermined activated temperature.
  • a continuous body ply formed of paperboard having first and second side edges is advanced to a shaping mandrel, while a continuous polymeric liner ply having first and second side edges is advanced adjacent to one surface of the paperboard body ply.
  • the liner ply and the body ply are passed in face-to-face contact through a pair of nip rollers with the adhesive layer of the liner ply adjacent to the body ply, such that the first marginal edge of the liner ply extends beyond the first marginal edge of the body ply.
  • the adhesive layer is then heated above its activating temperature such that the liner ply becomes adhered directly to the inner surface body ply.
  • the resulting adhered multi-ply is wrapped around the shaping mandrel such that the second marginal edge of the body ply engages the first marginal edge of the body ply, and the second marginal edge of the liner ply engages the first marginal edge of the liner ply.
  • the first marginal edge of the liner ply is heated to a temperature above the activating temperature of the adhesive such that the second marginal edge adheres to the first marginal edge, resulting in a tubular shape that is subsequently cut into discrete lengths to provide the hollow body component of the hermetically sealed paperboard container.
  • This process of producing a hermetically sealed container uses continuous webs of paperboard ply and liner ply, which require rather intensive handling and relatively high shipping and storage costs.
  • Achieving a hermetically sealed barrier paperboard cup using the "skiving and hemming" approach is difficult on the paperboard cup forming machine, which is typically designed to produce liquid-tight container with a top rim not designed for a gas tight seal.
  • the increased thickness of the skived/hemmed edge area over the original paperboard provides an additional challenge in producing a hermetically sealed bottom in the area where the thick skived/hemmed seam meets the bottom in the overlapped area.
  • the skived edge also substantially increases the abrupt step at the seam of the top rim formed by the overlapped ends of the blank, and the non-planar hill-like surface of the rim makes hermetically sealing the lidding membrane (film or paper) more difficult.
  • GB Patent Application No. 2055743 discloses a paper-based container comprising a hollow container body having a recessed structure on the upper and lower ends, a top lip positioning on the recessed top of the container body, and a bottom positioning on the recessed bottom.
  • the hollow container body is produced by skiving one longitudinal end of a paper-based blank to substantially half its thickness for a predetermined width and then forming a longitudinal groove substantially at the center of the skived portion.
  • a heat-resistant adhesive such as vinyl acetate emulsion or the like, is applied to the skived portion, and the adhesive is irradiated with infrared rays to evaporate water contained therein.
  • the skived portion is then folded about the groove so that the end face of the skived paper and the end face of the unskived portion contact each other.
  • the container body is formed by adhering both longitudinal ends of the blank together in overlapping relation with the folded longitudinal end inside the other longitudinal end.
  • the paper-based blank consists of, from the outside: a thermo plastic synthetic resin layer, a paper layer, an adhesive layer, a metal layer, a heat-resistant adhesive layer, and a thermoplastic synthetic resins layer.
  • the top lid and bottom components may be made of the same or similar material as that for the body component. This process of producing a barrier container is, however, rather complicated and high cost due to the use of adhesives and the recessed structure of the upper and lower ends.
  • the disclosed double wall paperboard container may include a container body that includes an inner wall panel and an outer wall panel connected to the inner wall panel along a longitudinal fold, the inner wall panel having a first longitudinal edge opposed from the longitudinal fold and the outer wall panel having a second longitudinal edge opposed from the longitudinal fold, wherein the first and second longitudinal edges overlap the longitudinal fold to define a seam having an overlying portion and an underlying portion including the longitudinal fold, the overlying portion being sealed to the underlying portion.
  • the disclosed double wall paperboard container may include a container body that defines a longitudinal axis, an upper end portion and a lower end portion.
  • the upper end portion is longitudinally spaced from the lower end portion and defines a first sealing structure having a lid sealingly connected thereto.
  • the lower end portion defines a second sealing structure having a bottom sealingly connected thereto.
  • the container body includes an inner wall having a first edge and a second edge and an outer wall having a first edge and a second edge.
  • the first edge of the inner wall is connected to the first edge of the outer wall along a longitudinal fold.
  • the inner and outer walls extend about the longitudinal axis such that the second edges of the inner and outer walls overlap the longitudinal fold to form a longitudinal seam.
  • a method for assembling a double wall paperboard container may include the steps of (1) providing a blank formed as a layered structure including a paperboard layer, a sealing layer, and barrier layer positioned between the paperboard layer and the sealing layer, (2) folding the blank to define an inner wall panel and an outer wall panel connected to the inner wall panel along a longitudinal fold, the inner wall panel having a first longitudinal edge opposed from the longitudinal fold and the outer wall panel having a second longitudinal edge opposed from the longitudinal fold, wherein the blank is folded to approximate the paperboard layer of the inner wall panel with the paperboard layer of the outer wall panel, (3) wrapping the folded blank such that the first and second longitudinal edges overlap the longitudinal fold, the overlap defining an overlying portion and an underlying portion, and (4) sealing the overlying portion to the underlying portion.
  • FIG. 1 is a top plan view, in section, of a container body having a seam formed in accordance with the prior art
  • FIG. 2 is a front elevational view of one aspect of the disclosed double wall paperboard container
  • FIG. 3 is a front elevational view, in section, of the double wall paperboard container of Fig. 2;
  • Fig. 4 is a top plan view of a blank used to form the container body of the double wall paperboard container of Fig. 2;
  • Fig. 5 is a cross-sectional view of a portion of the blank of Fig. 4;
  • Fig. 6 is a top plan view of the blank of Fig. 4 shown in a folded configuration
  • Fig. 7 is a cross-sectional view of a portion of the folded blank of Fig. 6;
  • Fig. 8 is a top plan view of the folded blank of Fig. 6 formed into a container body.
  • one aspect of the disclosed double wall paperboard container may include a container body 102, a lid 104 and a bottom 106.
  • the container body 102 may define a longitudinal axis A and an internal volume 108, and may include an open first (upper) end portion 110 longitudinally opposed from an open second (lower) end portion 112.
  • the lid 104 may be sealed to the upper end portion 110 to enclose the upper end portion 110.
  • the bottom 106 may be sealed to the lower end portion 112 to enclose the lower end portion 112.
  • the lid 104 and/or the bottom 106 may be hermetically sealed to the container body 102.
  • the lid 104 may be hermetically sealed to the upper end portion 110 of the container body 102.
  • the container body 102 may be formed from a double wall structure 114 that includes a first, inner wall 116 and a second, outer wall 118.
  • the inner wall 116 of the double wall structure 114 may be connected to the outer wall 118 along a longitudinal fold 146, as is described in greater detail below.
  • the double wall structure 114 of the container body 102 may be formed from a blank, such as the blank 120 shown in Fig. 4.
  • the blank 120 may be die cut from a sheet of stock material to define an outer periphery 122 of the blank 120.
  • a preformed fold line 124 may divide the blank 120 into a first wall panel 126, which may form the inner wall 116 of the double wall structure 114, and a second wall panel 128, which may form the outer wall 118 of the double wall structure 114.
  • the blank 120 may include a first major surface 130 and a second major surface 132, and may be formed as a layered structure 134.
  • the layered structure 134 may include a paperboard layer 136, a barrier layer 138, and a sealing layer 140. Additional layers may be included in the layered structure 134 of the blank 120 without departing from the scope of the present disclosure.
  • the layered structure 134 may be formed by applying the barrier layer 138 and the sealing layer 140 to the paperboard layer 135 using any available technique.
  • techniques suitable for applying the barrier layer 138 and/or the sealing layer 140 to the paperboard layer 136 include, but are not limited to, extrusion coating, extrusion lamination, curtain coating and adhesive lamination.
  • the paperboard layer 136 may be formed from various paperboard substrates.
  • suitable paperboard substrates include, but are not limited to, coated natural kraft board (CNK), solid bleached sulfate board (SBS), solid unbleached sulfate board (SUS), coated recycled board (CRB), coated white lined chipboard (WLC) and folding boxboard (FBB).
  • any paper-based substrate suitable for forming containers such as cups, may be used to form the paperboard layer 136.
  • the barrier layer 138 may be formed from various materials having moisture and/or oxygen barrier properties.
  • suitable barrier materials include, but are not limited to, nylon polymers, ethylene-vinyl alcohol copolymer (EVOH), polyethylene terephthalate (PET), materials derived from water-based barrier coatings, polyamide, polyvinylidene chloride, cyclic olefin copolymer, metalized polymer film and combinations thereof.
  • a water-based barrier coating composition may include a polymeric binder, an amine stabilizer and, optionally, filler particles, wherein the water-based
  • composition has a pH of greater than or equal to pKa of the amine stabilizer.
  • suitable fillers include, but are not limited to, layered fillers capable of being at least partially exfoliated such as bentonite, vermiculite, montmorillonite, smectite, kaolin, nanoparticle filler such as nanotalc particle; conventional low-cost fillers commonly used for the paper coating such as kaolin clay, talc, calcined clay, structured clay, ground calcium carbonate, precipitated calcium carbonate, titanium dioxide, aluminum trihydrate, satin white, silica, zinc oxide, and barium sulfate; and mixtures thereof.
  • a variety of polymeric binders known for paper coating applications may be used. These include, but are not limited to, polyesters, styrene-acrylic polymers, styrene- butadiene polymers, vinyl-acrylic polymers, polyvinyl acetate,
  • the water-based barrier coating composition may further include processability or functional additives which include, but are not limit to, colorants, pigments, defoaming agents, dispersing agents, tackifiers, surfactants, emulsifiers, coalescing agents, plasticizers, buffers, neutralizers, wetting agents, leveling agents, thickeners, rheology modifiers, biocides, waxes, water repellants, slip or mar aids, antioxidants, additive fillers, starch and combinations thereof.
  • processability or functional additives include, but are not limit to, colorants, pigments, defoaming agents, dispersing agents, tackifiers, surfactants, emulsifiers, coalescing agents, plasticizers, buffers, neutralizers, wetting agents, leveling agents, thickeners, rheology modifiers, biocides, waxes, water repellants, slip or mar aids, antioxidants, additive fillers, starch and combinations thereof.
  • the water-based barrier composition may be applied to the paperboard layer 136 either on-line during the paperboard making process or off-line.
  • Suitable coating techniques include, but are not limited to, size press application, brushing, spraying, roll coating, rod- coatings, dipping, spreading, printing methods, air knife coating, and curtain coating.
  • the application of the water-based barrier coating composition during the papermaking process may reduce both production cost and complexity.
  • the sealing layer 140 may be formed from various materials capable of being activated, such as with heat, ultrasonic energy, radiation or the like, to form a seal.
  • suitable sealing materials include, but are not limited to, polyester, low density polyethylene (LDPE), high density polyethylene (HDPE), ethylene-vinyl acetate copolymer (EVA), ethylene methyl acrylate (EMA) copolymer, ionomer polymers such as poly(ethylene-co-methacrylic acid) (EMAA) copolymer which is commercially available from DuPont under the trademark SURLYN ® , and combinations thereof.
  • LDPE low density polyethylene
  • HDPE high density polyethylene
  • EVA ethylene-vinyl acetate copolymer
  • EMA ethylene methyl acrylate copolymer
  • ionomer polymers such as poly(ethylene-co-methacrylic acid) (EMAA) copolymer which is commercially available from DuPont under the trademark SURLYN ® , and
  • the layered structure 134 of the blank 120 may include a layer of SBS paperboard having a basis weight of 310 grams per square meter (i.e., the paperboard layer 136).
  • the paperboard layer 136 may be coextrusion-coated with (1) a layer of LDPE having a basis weight of 13 grams per square meter, (2) a layer of EVOH having a basis weight of 10 grams per square meter (i.e., the barrier layer 138), (3) a tie-layer having a basis weight of 6.5 grams per square meter, and (4) a layer of LDPE having a basis weight of 35 grams per square meter (i.e., the sealing layer 140).
  • the blank 120 may be folded along the preformed fold line 124 such that the first wall panel 126 of the blank 120 forms the inner wall 116 of the double wall structure 114 and the second wall panel 128 of the blank 120 forms the outer wall 118 of the double wall structure 114, as shown in Figs. 6 and 7.
  • the second wall panel 128 of the blank 120 may be folded over the first wall panel 126 such that the first major surface 130 of the first wall panel 126 is adjacent to (i.e., in face-to-face alignment with) the first major surface 130 of the second wall panel 128, thereby exposing the second major surface 132 (i.e., the surface defined by the sealing layer 140) on both major sides of the double wall structure 114.
  • the first and second wall panels 126, 128 of the folded blank 120 may define a first, folded longitudinal edge 142 and second longitudinal edges 144, as well as the upper end portion 110 and the lower end portion 112 of the container body 102.
  • a longitudinal fold 146 may extend along the first longitudinal edge 142 of the folded blank 120 and may connect the first wall panel 126 to the second wall panel 128.
  • the second wall panel 128 may have a circumferential length that is slightly greater than the circumferential length of the first wall panel 126. Therefore, the second longitudinal edge 144 of the second wall panel 128 may extend slightly beyond the second longitudinal edge 144 of the first wall panel 126.
  • first wall panel 126 may have a longitudinal length that is greater than the longitudinal length of the second wall panel 128. Therefore, the upper and lower end portions 110, 112 of the first wall panel 126 may extend slightly beyond the upper and lower end portions 110, 112 of the second wall panel 128.
  • the container body 102 may be formed by wrapping the folded blank 120 (Fig. 6) about a longitudinal axis A such that the second longitudinal edge 144 of the folded blank 120 overlaps the first longitudinal edge 142 to define an underlying portion 148 and an overlying portion 150.
  • the underlying portion 148 may be sealed to the overlying portion 150 to form a longitudinal seam 152 wherein only the longitudinal fold 146 is exposed to the internal volume 108 of the container body 102.
  • the container body 102 may be formed by wrapping the folded blank 120 (Fig. 6) about a mandrel such that the second longitudinal edge 144 of the folded blank 120 overlaps the first longitudinal edge 142.
  • the mandrel may be a mandrel associated with a high speed cup forming machine, such as a model 1001 from Paper Machinery Corporation. With the longitudinal edges 142, 144 overlapping, heat and pressure may be applied along the overlapping edges 142, 144 to form a heat-sealed longitudinal seam 152.
  • the second longitudinal edge 144 of the second wall panel 128 may extend circumferentially beyond the second longitudinal edge 144 of the first wall panel 126.
  • the second longitudinal edge 144 of the second wall panel 128 may be sealed directly to the underlying portion 148, thereby concealing the second longitudinal edge 144 of the first wall panel 126. Furthermore, sealing the second longitudinal edge 144 of the second wall panel 128 directly to the underlying portion 148 may prevent the second wall panel 128 from separating from the first wall panel 126, thereby eliminating the need for an adhesive between the first and second wall panels 126, 128, which may significantly reduce
  • container body 102 is shown in the drawings as being a frustoconical container body (i.e., circumferential, with the upper end portion 110 having a greater diameter than the lower end portion 112), those skilled in the art will appreciate that container bodies having various shapes and configurations may be constructed without departing from the scope of the present disclosure.
  • the container body 102 may be formed as a generally cylindrical container body.
  • the upper end portion 110 of the container body 102 may define a first sealing structure 160 having a first sealing surface 161 for connecting the lid 104 to the container body 102.
  • the lower end portion 112 of the container body 102 may define a second sealing structure 162 having a second sealing surface 163 for connecting the bottom 106 to the container body 102.
  • the sealing surfaces 161, 163 may be defined by a sealing layer 140 of the container body 102.
  • suitable sealing structures 160, 162 include, but are not limited to, a flange, a rolled rim or bead, and an annular recess.
  • the first sealing structure 160 at the upper end portion 110 of the container body 102 may include a circumferential flange 164.
  • the flange 164 may be formed by shaping the upper end portion 110 of the container body 102 such that the upper end portion 110 of the container body 102 extends radially outward, as shown in Fig. 3, thereby exposing the sealing layer 140 of the container body 102 for engagement with the lid 104.
  • the upper end portion 110 of the first wall panel 126 may extend slightly beyond the upper end portion 110 of the second wall panel 128. Therefore, in a specific implementation, the flange 164 may be formed from only a single layer (i.e., the inner layer 116 (first wall panel 126) of the container body 102).
  • the lid 104 may be connected to the container body 102 by connecting the lid 104 to the sealing surface 161 of the first sealing structure 160, thereby enclosing the upper end portion 110 of the container body 102.
  • the connection between the lid 104 and the first sealing structure 160 may be achieved by heating the sealing surface 161 of the first sealing structure 160 to melt or tackify the sealing layer 140 and then applying the lid 104 to the heated sealing structure 160 with sufficient pressure to achieve a hermetic seal.
  • Other sealing techniques are also contemplated, and may or may not require a heating step.
  • the lid 104 may be formed as a layered structure 166, similar to the blank 120 (Fig. 5), and may include a paperboard layer 168, a barrier layer 170 and a sealing layer 172, as shown in Fig. 3. Therefore, the lid 104 may be connected to the container body 102 such that the sealing layer 172 of the lid 104 is engaged with the sealing surface 161 of the sealing structure 160.
  • the lid 104 may be a plastic rim, a film or the like.
  • the second sealing structure 162 at the lower end portion 112 of the container body 102 may include an annular recess 174 that defines the sealing surface 163 of the second sealing structure 162.
  • the annular recess 174 may be formed by shaping the lower end portion 112 of the container body 102 such that the lower end portion 112 of the container body 102 extends radially inward in a hook or U-shape in cross-section, as shown in Fig. 3.
  • the lower end portion 112 of the first wall panel 126 may extend slightly beyond the lower end portion 112 of the second wall panel 128. Therefore, in a specific implementation, the annular recess 174 may be formed from only a single layer (i.e., the inner layer 116 (first wall panel 126) of the container body 102).
  • the bottom 106 may include an annular rim 176. Therefore, the bottom 106 may be connected to the container body 102 by positioning the annular rim 176 into the annular recess 174 such that the annular rim 176 is engaged with, and sealed to, the sealing surface 163 of the annular recess 174.
  • the connection between the annular rim 176 and the sealing surface 163 of the second sealing structure 162 may be achieved by heating the sealing surface 163 to melt or tackify the sealing layer 140 and then inserting the annular rim 176 into the annular recess 174 with sufficient pressure to achieve a hermetic seal.
  • the sealing material may completely fill any gaps between the annular rim 176 and the annular recess 174.
  • the bottom 106 may be formed as a layered structure 178 that includes a paperboard layer 180, a barrier layer 182 and a sealing layer 184, as shown in Fig. 3. Therefore, the bottom 106 may be connected to the container body 102 such that the sealing layer 184 of the bottom 106 is engaged with the sealing surface 163 of the second sealing structure 162.
  • the disclosed double wall paperboard container 100 includes a container body 102 having a double wall structure 114, which may provide increased strength (rigidity) and improved thermal insulation compared to single wall containers.
  • the seam 152 used to form the container body 102 does not include an underlying portion 148 that exposes raw paperboard to the internal volume 108 of the container body 102. Rather, the underlying portion 148 of the seam 152 is the folded edge 146 of a folded blank 120.
  • the double wall structure may provide enhanced strength and gas barrier performance to the paperboard container.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Cartons (AREA)

Abstract

La présente invention a trait à un récipient en carton à double paroi (100) qui comprend : un corps de récipient (102) qui est doté d'une première structure d'étanchéité (160) sur une partie d'extrémité supérieure (110) et d'une seconde structure d'étanchéité (162) sur une partie d'extrémité inférieure (112); un couvercle (104) qui est relié de façon à assurer l'étanchéité à la première structure d'étanchéité; et un fond (106) qui est relié de façon à assurer l'étanchéité à la seconde structure d'étanchéité. Le corps de récipient comprend : une paroi intérieure (116) qui est dotée d'un premier bord et d'un second bord et une paroi extérieure (118) qui est dotée d'un premier bord et d'un second bord, lequel premier bord de la paroi intérieure est relié au premier bord de la paroi extérieure le long d'un pli longitudinal (146). Les parois intérieure et extérieure s'étendent autour d'un axe longitudinal de manière à ce que les seconds bords des parois intérieure et extérieure chevauchent le pli longitudinal en vue de former une jonction longitudinale (152). La structure à double paroi permet de fournir une résistance améliorée et un effet barrière contre les gaz au récipient en carton.
PCT/US2011/057008 2010-11-08 2011-10-20 Récipients en carton dotés d'une couche barrière à double paroi WO2012064478A1 (fr)

Applications Claiming Priority (2)

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US41120710P 2010-11-08 2010-11-08
US61/411,207 2010-11-08

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10543665B2 (en) 2014-10-31 2020-01-28 Sig Technology Ag Container precursor, in particular for the manufacture of a food container, from a laminate with a plastic gas and aroma barrier and a peeled edge region, which is partially folded back on itself
US10625488B2 (en) 2014-10-31 2020-04-21 Sig Technology Ag Container precursor, in particular for the manufacture of a food container, from a laminate with a peeled edge region, which is partially folded back on itself
CN112639044A (zh) * 2018-09-07 2021-04-09 波士胶公司 可堆肥热熔性粘合剂
US11001403B2 (en) 2014-10-31 2021-05-11 Sig Technology Ag Device, in particular for closing a head region of a foodstuffs container made of a laminate having an edge region which is skived and partially folded over itself
WO2022026899A1 (fr) * 2020-07-31 2022-02-03 Westrock Mwv, Llc Récipients en carton à double paroi comportant des vernis de protection aqueux
EP3981699A1 (fr) * 2020-10-08 2022-04-13 Dart Container Corporation Procédé de formation d'un récipient en papier et matériaux associés
EP4043362A1 (fr) * 2021-02-16 2022-08-17 FLO - Societa' Per Azioni Récipient pour produits alimentaires et son procédé de fabrication
EP3995406A4 (fr) * 2019-07-02 2023-07-19 Tokan Kogyo Co., Ltd. Contenant en papier
EP4389411A1 (fr) * 2022-12-19 2024-06-26 Huhtamaki Flexible Packaging Germany GmbH & Co. KG Stratifie tubulaire multicouche comprenant une couche de papier et une couche de protection, corps tubulaire et tube

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WO1990009926A2 (fr) 1989-03-03 1990-09-07 Fbi Brands Ltd. Conditionnement de liquides perissables dans ces cartons a partie superieure en forme de toit
US5084284A (en) 1991-01-07 1992-01-28 The Pillsbury Company Container for refrigerated dough and method of forming a refrigerated dough product
US5236408A (en) 1992-07-21 1993-08-17 International Paper Box Machine Company, Inc. Method and apparatus for forming carton blanks with hemmed edges
US5620135A (en) 1994-04-07 1997-04-15 Ruediger Haaga Gmbh Container
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US6190485B1 (en) 1997-02-06 2001-02-20 Sonoco Development, Inc. Methods of manufacturing tubular containers having polymeric liner plies
US6196454B1 (en) * 1998-11-30 2001-03-06 Insulair, Inc. Insulated cup and method of manufacture
US6460759B1 (en) * 2000-05-02 2002-10-08 Sonoco Development, Inc. Multi-ply composite container with regions of weakened strength and method for manufacturing same
WO2003106277A1 (fr) 2002-06-12 2003-12-24 Sonoco Development, Inc. Joint de serti metallise pour contenant en une couche
WO2008025996A2 (fr) 2006-08-30 2008-03-06 Elopak Systems Ag Améliorations apportées ou associées à des applications d'emballage
WO2010072791A1 (fr) * 2008-12-22 2010-07-01 Huhtamäki Oyj Emballage à plusieurs couches ayant un joint

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GB2055743A (en) 1979-06-26 1981-03-11 Toppan Printing Co Ltd A paper container
DE3228437A1 (de) * 1982-03-10 1984-02-02 Michael Hörauf Maschinenfabrik, 7334 Süssen Verfahren zum herstellen eines papierbehaelters aus heisssiegelfaehig beschichtetem oberflaechengeschuetztem karton
WO1990009926A2 (fr) 1989-03-03 1990-09-07 Fbi Brands Ltd. Conditionnement de liquides perissables dans ces cartons a partie superieure en forme de toit
US5084284A (en) 1991-01-07 1992-01-28 The Pillsbury Company Container for refrigerated dough and method of forming a refrigerated dough product
US5236408A (en) 1992-07-21 1993-08-17 International Paper Box Machine Company, Inc. Method and apparatus for forming carton blanks with hemmed edges
US5620135A (en) 1994-04-07 1997-04-15 Ruediger Haaga Gmbh Container
US5810243A (en) 1995-04-03 1998-09-22 International Paper Company Paperboard cartons having protected board raw edges surfaces and method of manufacture
US6190485B1 (en) 1997-02-06 2001-02-20 Sonoco Development, Inc. Methods of manufacturing tubular containers having polymeric liner plies
US6196454B1 (en) * 1998-11-30 2001-03-06 Insulair, Inc. Insulated cup and method of manufacture
US6460759B1 (en) * 2000-05-02 2002-10-08 Sonoco Development, Inc. Multi-ply composite container with regions of weakened strength and method for manufacturing same
WO2003106277A1 (fr) 2002-06-12 2003-12-24 Sonoco Development, Inc. Joint de serti metallise pour contenant en une couche
WO2008025996A2 (fr) 2006-08-30 2008-03-06 Elopak Systems Ag Améliorations apportées ou associées à des applications d'emballage
WO2010072791A1 (fr) * 2008-12-22 2010-07-01 Huhtamäki Oyj Emballage à plusieurs couches ayant un joint

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10543665B2 (en) 2014-10-31 2020-01-28 Sig Technology Ag Container precursor, in particular for the manufacture of a food container, from a laminate with a plastic gas and aroma barrier and a peeled edge region, which is partially folded back on itself
US10625488B2 (en) 2014-10-31 2020-04-21 Sig Technology Ag Container precursor, in particular for the manufacture of a food container, from a laminate with a peeled edge region, which is partially folded back on itself
US11001403B2 (en) 2014-10-31 2021-05-11 Sig Technology Ag Device, in particular for closing a head region of a foodstuffs container made of a laminate having an edge region which is skived and partially folded over itself
CN112639044A (zh) * 2018-09-07 2021-04-09 波士胶公司 可堆肥热熔性粘合剂
US11661537B2 (en) 2018-09-07 2023-05-30 Bostik, Inc. Compostable hot melt adhesive
EP3995406A4 (fr) * 2019-07-02 2023-07-19 Tokan Kogyo Co., Ltd. Contenant en papier
WO2022026899A1 (fr) * 2020-07-31 2022-02-03 Westrock Mwv, Llc Récipients en carton à double paroi comportant des vernis de protection aqueux
EP3981699A1 (fr) * 2020-10-08 2022-04-13 Dart Container Corporation Procédé de formation d'un récipient en papier et matériaux associés
EP4043362A1 (fr) * 2021-02-16 2022-08-17 FLO - Societa' Per Azioni Récipient pour produits alimentaires et son procédé de fabrication
EP4389411A1 (fr) * 2022-12-19 2024-06-26 Huhtamaki Flexible Packaging Germany GmbH & Co. KG Stratifie tubulaire multicouche comprenant une couche de papier et une couche de protection, corps tubulaire et tube

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