WO2016016237A1

WO2016016237A1 - Filled and sealed beverage container

Info

Publication number: WO2016016237A1
Application number: PCT/EP2015/067263
Authority: WO
Inventors: Kendall Norman PALAZZI
Original assignee: Unistraw Holdings Pte. Ltd.; Schlich
Priority date: 2014-07-28
Filing date: 2015-07-28
Publication date: 2016-02-04

Abstract

A filled and sealed beverage container comprising an outlet for insertion of a drinking straw, the outlet comprising one or more inward-pointing supporting flaps fixed to and covering at least part of a flexible sealing membrane located at the internal aspect of the outlet, which one or more flaps are configured to be deformable into the container by insertion of the straw and the membrane is rupturable to form a hole upon insertion of the straw to the container. In use, the flaps support and shield the membrane, reducing unwanted rupturing during processing, handling and storage, and the outlet shape ensures that a seal is not formed between the straw and outlet.

Description

Filled and Sealed Beverage Container

This invention relates to filled and sealed beverage containers comprising outlets for insertion of a drinking straw sealed by a rupturable membrane.

Beverage containers may be sealed by a membrane, e.g. a laminated plastic- aluminium foil, which is fixed to the inside and/or outside of the container on and around an outlet. The outlet may be sealed by a removable strip, which is designed to be either removed by pulling to reveal an opening for pouring or accommodating a drinking straw, for example a tapered or rectangular hole, or punctured with a drinking straw. US 3,900,155 discloses a container with a pouring opening which is sealed by an external closure strip. To open the container the closure strip is removed. Known beverage containers, often referred to as "juice boxes" or cartons and pouches, are made of paperboard sealed with a laminated plastic-aluminium foil fixed to the internal surface of the paperboard or a thicker plastic laminate with a thinner plastic laminate over the internal surface. The paperboard layer or thicker plastic laminate comprises a round outlet dimensioned for a drinking straw to pass through, whereas the plastic-aluminium foil is continuous and effectively seals the container and in particular seals the outlet. The foil covering the hole is deformable such that forcing the straw through the outlet punctures and tears the foil, opening the container and allowing the straw to pass into the container. Outlets of this type are commonly known as straw holes due to their structure and intended function.

US 6,579,390 discloses a container with a round straw hole covered by an internal patch of a plastic-foil material.

US 5,873,656 relates to a beverage container including a circular straw hole covered by a tamper-evident, seal strip that is attached by a patterned heat seal. When a straw is inserted through the seal strip, the seal strip seals tightly all the way around the straw. Thus, beverage is prevented from being pushed up around the straw during piercing and drinking. US 4,553,693 relates to a beverage container including a straw hole with an outer sealing tab, and a complex arrangement of two inner seals, consisting of an innermost seal and an intermediate seal. The innermost seal optionally has a hole or weakened region to make opening easier. The presence of an intermediate inner seal and the positioning of the innermost seal with respect to the straw hole and/or the intermediate seal prevents interaction between the innermost seal and the material and any decorative finish at the straw hole. The diameter of the outlet of known containers is usually sized to be similar to the outside diameter of a straw, which is often supplied with the container. However, if the straw and outlet are sized too closely the straw may form a tight seal with the outlet, particularly with the paperboard part of the outlet, which makes drinking inconvenient due to the negative pressure generated in the container as liquid is drawn out through the straw. Additionally, overflow may occur if the container is accidentally squeezed while the straw end is in the liquid in the container, thus forcing the liquid up though the straw and out of the end of the straw.

The risk of ejecting liquid out of the straw by inadvertently squeezing the beverage container is higher with alternative known containers, often referred to as "juice pouches", which are typically made of a plastic film that is more flexible than paperboard.

To avoid a tight seal being formed between the straw and the outlet, it is known to use a straw that is narrower than the outlet. Narrow straws have poor flow properties, particularly with more viscous liquids. It is therefore desirable to have outlets with large diameters to accommodate adequately wide straws. Additionally, even if the outlet is larger than the straw, there remains a risk that a seal may form between the straw and the membrane. Other container contents make the use of wider straws desirable.

The membranes that seal larger diameter outlets, say 8 mm and above or 9 mm or above, are at higher risk of mechanical damage, for example, by accidental puncturing or rupturing due to squeezing during processing, handling and storage. For example, during processing the containers may be filled with beverage at a temperature of around 130°C, which can temporarily weaken the plastic seal, then the beverage subsequently contracts on cooling, producing negative pressure in the container, thus causing a rupture risk, particularly with larger outlets. Some of these larger diameter outlets cannot safely be made at present. Additionally, the larger the exposed membrane the more likely is unwanted rupture during the packaging and processing of the beverage. Manufacturing of containers with outlets that are sealed with a removal strip requires more complex and thus more expensive machinery taking up more space on the production line.

The present invention seeks to provide an alternative filled and sealed beverage container and especially to overcome one or more, preferably all of the above- mentioned problems.

Accordingly, the invention provides a filled and sealed beverage container comprising an outlet for insertion of a drinking straw, the outlet comprising one or more inward- pointing flaps fixed to at least part of a flexible sealing membrane located at the internal aspect of the outlet, which one or more flaps are configured to be deformable into the container by insertion of the straw and the membrane is rupturable to form a hole upon insertion of the straw into the container. Thus, according to the invention, the sealing membrane of the container is located at the internal aspect of the outlet, on the inside of the container and adjacent container contents, and the flaps are on the outside of the container.

In embodiments of the invention described herein, the flaps support the membrane. In use, membrane fixed to and around the flaps is reinforced and as a result protected from mechanical deformation and thus rupture during processing, handling and storage. In addition, since the flaps fold into the hole produced by the straw the resultant outlet is generally not round and the straw does not then form a seal with the outlet, thus preventing the development of negative pressure within the container and also preventing ejection of the beverage when the container is squeezed. The flaps point inwardly towards, and hence cover or partially cover, the centre of the outlet - the hole formed when the membrane has been punctured.

In an embodiment, the container comprises a further sealing membrane, and the outlet comprises the sealing membrane located at the internal aspect of the outlet and the further sealing membrane located at the external aspect of the outlet.

In a preferred embodiment, the one or more flaps cover only part of the membrane in the region of the outlet, thereby leaving a gap, generally a central gap, around or between the one or more flaps. Thus, where the membrane is located on the internal aspect of the container, part of the membrane will be visible and exposed through the gap. This provides a clearer visual clue as to the location of the outlet, and can enable the straw to initially directly pierce the membrane, thus making pushing the straw though the outlet easier. Flat ended straws may press on multiple flaps more or less simultaneously. The point of straws with a pointed end portion may pass between flaps and pierce the membrane directly before the remainder of the straw pushes flaps into the container, enlarging the hole.

In an alternative embodiment, the one or more flaps of the outlet cover substantially all of the membrane, thus providing the membrane a maximum level of stabilisation and protection. In this form of outlet, where the outlet comprises two or more flaps, the flaps are typically separated by slits cut between the flaps.

The outlet of the container may take one of many forms. In an embodiment, the gap and/or the slits form a trefoil, preferably a Y shape. Alternatively, the gap and/or the slits form a quatrefoil, preferably a cross. In another embodiment, the gap and/or the slits form a pentafoil. The gap and/or the slits may form a shape with 5 or 6 or more arms, preferably a star. Preferably, the arms of the gap or slits are of equal lengths, thus focusing the opening force on the centre of the outlet and balancing the stresses on the membrane thus limiting the possibility for unwanted rupture. The arms of the gap or slits may be rotationally equally distributed around the arm meeting point, to better focus the opening force on the centre of the outlet and balancing the stresses on the membrane thus limiting the possibility for unwanted rupture. In another embodiment, the gap or slit is curved, preferably a horseshoe shape or an arc, preferably a circular arc.

In preferred embodiments, the shape formed by the gap or slit additionally has no sharp points, e.g. is rounded, for example at the external or internal ends of the arms, to limit the stress concentration at these points, which may increase the resistance of the outlet to rupture in processing, handling and storage.

The outlet of the container may be configured to accommodate a drinking straw of 6 mm or less, 7 mm or less, 8 mm or less, 9 mm or less, 10 mm or less, 1 1 mm or less, 12 mm or less, or greater than 12 mm.

The outlet of the invention is particularly suitable for larger straws. Thus, the vertices of the slits or the vertices of the shape formed by or left between the flaps (e.g. the points of the trefoil or star, etc.) may fall on the circumference of a circle of diameter 8 mm or greater, 9 mm or greater, 10 mm or greater, 1 1 mm or greater, 12 mm or greater, or 13 mm or greater. In particular embodiments, described in examples below, the outlet accommodates straws of diameter 9 mm or greater or 10 mm or greater. For manufacturing simplicity, the flaps may be integral to a wall of the container. Thus, the outlet may be punched out or cut into the wall of the container, the resultant aperture being subsequently sealed by the membrane. Also for manufacturing simplicity, the sealing membrane may be integral to a membrane that seals a wall of the container. This enables the sealing membrane and membrane that seals a wall of the container to be applied in one process step. Having the flaps integral to a wall of the container and/or the sealing membrane integral to a membrane that seals a wall of the container enables a simpler and thus more cost effective manufacturing method. As will be appreciated, however, the sealing membrane may alternatively seal locally in the region of the outlet. The outlet can also be preformed as an insert for the container. Thus, the outlet may be fitted to a container with a simpler, e.g. round or rectangular outlet design.

As described herein, and with reference to specific examples, flaps across the membrane form an outlet which is opened in use when pierced from the outside of the container by a drinking straw pressed against the flaps and through the membrane.

A further aspect of the invention thus provides a filled and sealed beverage container comprising a wall portion having a hole sealed by a membrane located at the internal aspect of the outlet which can be pierced from outside by a straw thereby allowing access to drink in the container, wherein the membrane is reinforced across the hole by one or more flaps fixed to the membrane and extending inwardly from the hole circumference, which flap or flaps is or are deformed into the container by the straw when the straw pierces the membrane.

A typical container has walls comprising a laminate of multiple layers, including at least the wall and the membrane, and optionally other layers. These may be other supporting or sealing layers, layers to accept printed labelling, etc. The hole in the wall portion may be approximately circular. It can hence be used with circular straws which when pushed through the wall break the membrane and open an aperture that is approximately circular. The hole diameter suitably has a diameter of 8 mm or more, preferably 9 mm or more, preferably 10 mm or more. Other embodiments provide for even greater diameter holes, allowing use of still larger straws. The reinforcement by flaps adhered to the membrane, e.g. as part of the laminated wall, means risk of accidental rupture in storage is reduced. Pressing the straw on the flaps tends to break the membrane in such a way that the aperture opened is not perfectly circular and does not seal tightly around the straw - avoiding problems associated with the prior sealing of the straw to the container.

A preferred container comprises 2 or more, or 3 or more, or 4 or more reinforcing flaps that partially cover the hole, leaving an exposed area of membrane having 2 or more or 3 or more or 4 or more lobes radiating from a common centre. The lobes can be regularly spaced. They can form an exposed portion of membrane in the shape of a trefoil or quatrefoil, or a 3 or more pointed star, with sharp or more usually rounded tips or vertices. Other optional and preferred features of this aspect are as described in relation to previous aspects of the invention.

A related aspect of the invention provides a filled and sealed drink container, comprising a laminate of:

an inner sealing membrane, and

an outer wall, a portion of which is cut in slits or is cut away to allow piercing of the inner sealing membrane from the outside of the container by a straw,

wherein the cut away portion comprises 2 or more lobes radiating from a common centre.

In this aspect, the cut away portion of the wall exposes an area of membrane of shape corresponding to the cut away portion. The cut away portion can comprise 3 or more lobes, and may be in the form of a trefoil, a quatrefoil or a star having 3 or more vertices.

The vertices of the lobes may fall on the circumference of a circle of diameter 8 mm or greater, 9 mm or greater, or 10 mm or greater.

The wall portion can comprise 2 or more slits that allow piercing of the inner sealing membrane by a straw of diameter 8 mm or greater, 9 mm or greater or 10 mm or greater. Other optional and preferred features of this related aspect are as described in relation to previous aspects of the invention.

In the invention, there is also provided a beverage container outlet for insertion of a drinking straw comprising one or more inward-pointing resilient flaps fixed to and covering at least part of a flexible sealing membrane located at the internal aspect of the outlet, which one or more flaps are configured to be deformable into the container by insertion of the straw and the membrane is rupturable to form a hole upon insertion of the straw to the container. The outlet can be used with a container to produce a filled and sealed container of the invention as elsewhere described herein.

The containers can be filled with various beverages, including milk, water, juice etc. Features of the filling and sealing do not form aspects of the invention. Methods of reinforcing and / or supporting a beverage container outlet for insertion of a drinking straw are also provided. One such method comprises fixing to and covering at least part of a flexible sealing membrane located at the internal aspect of the outlet with one or more inward-pointing protective flaps, which one or more flaps are configured to be deformable into the container by insertion of the straw and the membrane is rupturable to form a hole upon insertion of the straw to the container.

In a particular embodiment, the method comprises:

(i) punching out or cutting a structural layer, e.g. a wall, for the beverage container to form the one or more flaps thus forming an insertion point for the straw; and

(ii) fixing an inner sealing membrane to the structural layer, wherein the insertion point allows piercing of the sealing membrane from the outside of the container by the straw.

Another method of the invention, for making a filled and sealed beverage container, comprises forming a hole in a wall portion of the container, sealing the hole by a membrane located at the internal aspect of the outlet which (in the end product) can be pierced from outside by a straw thereby allowing access to drink in the container, wherein the membrane is supported across the hole by one or more flaps fixed to the membrane and extending inwardly from the hole circumference, which flap or flaps is or are deformed into the container by the straw when the straw pierces the membrane.

The hole is typically formed by punching or cutting out the hole from a wall or wall precursor. The hole may then be sealed by the membrane and the wall then formed into a container, which is then filled and sealed. Hence the nature and shape of the punched out portion yields the form of flaps that extend across and support the portion of membrane that covers the hole and is exposed in the final container.

Other optional and preferred features of this method of the invention are mutatis mutandis as described elsewhere herein. A further method of the invention, for making a filled and sealed drink container, comprises (i) providing an outer wall for a container, (ii) cutting slits in a portion of the outer wall or cutting away a portion of the outer wall wherein the cut away portion comprises 2 or more lobes radiating from a common centre, (iii) forming a laminate of the cut wall of (ii) and an inner sealing membrane, and forming a container from the laminate, which container is then filled and sealed. The slits / cut away portion allow piercing of the inner sealing membrane from the outside of the container by a straw.

Other optional and preferred features of this method of the invention are mutatis mutandis as described elsewhere herein.

The invention is now illustrated with references to the accompanying drawings, in which:

Fig. 1 shows a juice box with a prior art round outlet;

Fig. 2 shows an enlarged section of Fig. 1 ;

Fig. 3 shows a juice pouch with a prior art round outlet; Fig. 4 shows a selection of shapes of container outlets formed according to the invention; Fig. 5 shows a further selection of shapes of container outlets formed according to the invention;

Fig. 6 shows a juice box comprising an outlet according to the invention; Fig. 7 shows an enlarged section of Fig. 6; and

Fig. 8 shows a juice pouch comprising an outlet according to another example of the invention. Known beverage containers, such as rectangular prism juice boxes 10, have a foil- sealed round straw hole located near the corner of their top wall 1 1 (Fig. 1 and Fig. 2). Alternative prior art beverage containers, such as juice pouches 20, have a foil- sealed round straw hole centrally located near the top of their side wall 21 (Fig. 3). A container comprising an outlet according to the invention 41 was incorporated into a rectangular prism juice box 40 comprising a paperboard core layer with a polymer external sealing layer, and a laminated polymer-aluminium-polymer internal sealing layer. The method used to make the container was similar to that used to make prior art juice boxes with round holes, modified to punch out holes of the form shown in Fig. 4(a).

In more detail, a sheet of paperboard laminated with polymer on the intended external surface was fed into a standard juice box-forming machine. Holes of the form shown in Fig. 4(a) were punched using a through punch into the sheet in positions that correspond to around 7 mm from a corner of the top of the finally formed juice box 40 (Fig. 6 and Fig. 7). The through punch comprises a punch and correspondingly shaped and positioned die, and the punching motion deposits the scrap slug from the hole into the die, thus ensuring that the slug is removed from the piece and so will not remain in the packaging.

The use of a through punch requires precise alignment of the punch and die in the X- Y plane and precise rotational alignment.

The holes formed a Y shape with three substantially equally distributed, straight arms 31 of substantially equal lengths radiating from a single central point, as shown in Fig. 4(a). The tips of the arms fell on a circle with a diameter of 10 mm with the same central point as the Y.

The arms 31 of the hole had a width of 2 mm. The material between two arms formed a flap 32. Thus, the holes, which had the form shown in Fig. 4(a), formed three flaps 32.

The punched paperboard was then further laminated by applying a laminated polymer-aluminium-polymer internal sealing layer using conventional means. Thus, the holes were sealed with a rupturable membrane forming the internal sealing layer.

The laminated sheet was then cut into templates for forming the filled and sealed finished juice box 40 (Fig. 6 and Fig. 7). Thus, the flaps of the hole, being fixed to and covering the sealing layer, stabilised the membrane and formed a protective barrier to impact.

In use, as a standard round straw is forced through the membrane, the membrane tears along each arm 31 of the Y and the three flaps 32 bend and deform inwards progressively. The bending action propagates the tears in the membrane along the arms 31 and enlarges the hole to accommodate the straw. The resulting hole is not round due to the non-round shape of the punched hole of the outlet. This helps avoid the formation of a seal between the straw and the paperboard and/or membrane, thus avoiding an overflow issue if the carton is inadvertently squeezed by the consumer.

Alternatively, outlets of one of the forms shown in Fig. 4(b)-(i) are punched into the laminated paperboard. The portion 33 is removed by the punch.

Alternatively, outlets of one of the forms shown in Fig. 5(a)-(f) are punched, or punched/cut into the laminated paperboard - again, indicated by 33 in each case. In this context, the gaps will typically be formed by punching, and the slits typically formed by cutting. However, methods of producing the shapes of outlets of the invention in typical packaging materials will be known to the skilled person. Alternatively, outlets according to the invention 51 are incorporated into a juice pouch 50 (Fig. 8), in which the containers are prepared by standard methods and the round holes are replaced with outlets of the invention. In the present example, the outlet was formed as a cross with four substantially equally distributed, straight arms of substantially equal lengths radiating from a single central point, as shown in Fig. 4(b). The tips of the arms fell on a circle with a diameter of 10 mm with the same central point as the cross.

The containers are filled with beverage and sealed. Hence the invention provides filled and sealed beverage containers.

Claims

1. A filled and sealed beverage container comprising an outlet for insertion of a drinking straw, the outlet comprising one or more inward-pointing supporting flaps fixed to and covering at least part of a flexible sealing membrane located at the internal aspect of the outlet, which one or more flaps are configured to be deformable into the container by insertion of the straw and the membrane is rupturable to form a hole upon insertion of the straw to the container.

2. The container according to claim 1 , wherein the one or more flaps cover part of the membrane, leaving a central gap between the one or more flaps.

3. The container according to any preceding claim, comprising two or more flaps, wherein the flaps are separated by slits.

4. The container according to claim 2 or claim 3, wherein the gap and/or the slits form a trefoil, preferably a Y shape.

5. The container according to claim 2 or claim 3, wherein the gap and/or the slits form a quatrefoil, preferably a cross.

6. The container according to any preceding claim comprising an outlet configured to accommodate a drinking straw of 8 mm or greater.

7. The container according to any of claims 2 to 6 wherein the vertices of the gap or slits fall on the circumference of a circle of diameter 8 mm or greater, 9mm or greater, preferably 10 mm or greater.

8. A container according to any preceding claim, wherein the flaps are integral to a wall of the container.

9. A filled and sealed beverage container comprising a wall portion having a hole sealed by a membrane located at the internal aspect of the hole, which can be pierced from outside by a straw, thereby allowing access to a beverage in the container, wherein the membrane is supported across the hole by one or more flaps fixed to the membrane and extending inwardly from the hole circumference, which flap or flaps is or are deformed into the container by the straw when the straw pierces the membrane.

10. A container according to claim 9, wherein the hole is approximately circular with a diameter of 9 mm or more.

1 1 . A container according to claim 9 or 10, comprising 3 or more reinforcing flaps that partially cover the hole, leaving an exposed area of membrane having 3 or more lobes radiating from a common centre.

12. A filled and sealed drink container, comprising a laminate of

an inner sealing membrane, and

13. A container according to claim 12, wherein the cut away portion comprises 3 or more lobes.

14. A container according to claim 13, wherein the cut away portion is in the form of a trefoil, a quatrefoil or a star having 3 or more vertices.

15. A container according to claim 12, 13 or 14, wherein the vertices of the lobes fall on the circumference of a circle of diameter 9 mm or greater.

16. A method of supporting a beverage container outlet for insertion of a drinking straw, comprising fixing to and covering at least part of a flexible sealing membrane located at the internal aspect of the outlet with one or more inward-pointing protective flaps, which one or more flaps are configured to be deformabie into the container by insertion of the straw and the membrane is rupturable to form a hole upon insertion of the straw to the container.

17. The method according to claim 16, comprising:

(i) punching out or cutting a structural layer for the beverage container to form the one or more flaps thus forming an insertion point for the straw; and

(ii) fixing an inner sealing membrane to the structural layer,

wherein the insertion point allows piercing of the sealing membrane from the outside of the container by the straw.

18. A method for making a filled and sealed beverage container, comprising forming a hole in a wall portion of the container, and

sealing the hole by a membrane located at the internal aspect of the hole which can be pierced from outside by a straw thereby allowing access to drink in the container,

wherein the membrane is supported across the hole by one or more flaps fixed to the membrane and extending inwardly from the hole circumference, which flap or flaps is or are deformed into the container by the straw when the straw pierces the membrane.

19. A method for making a filled and sealed drink container, comprising

(i) providing an outer wall for a container,

(ii) cutting slits in a portion of the outer wall or cutting away a portion of the outer wall wherein the cut away portion comprises 2 or more lobes radiating from a common centre,

(iii) forming a laminate of the cut wall of (ii) and an inner sealing membrane, and forming a container from the laminate, which container is then filled and sealed.

20. A filled and sealed beverage container comprising an outlet substantially as hereinbefore described with reference to any of figures 4 to 8.