WO2017072007A1 - A liquid food package, a method for producing the same and a machine - Google Patents

A liquid food package, a method for producing the same and a machine Download PDF

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Publication number
WO2017072007A1
WO2017072007A1 PCT/EP2016/075126 EP2016075126W WO2017072007A1 WO 2017072007 A1 WO2017072007 A1 WO 2017072007A1 EP 2016075126 W EP2016075126 W EP 2016075126W WO 2017072007 A1 WO2017072007 A1 WO 2017072007A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
injection molding
packaging material
plastic material
packaging
Prior art date
Application number
PCT/EP2016/075126
Other languages
French (fr)
Inventor
Daniel CEDERSTRÖM
Bengt HÅKANSSON
Original Assignee
Tetra Laval Holdings & Finance S.A.
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 Tetra Laval Holdings & Finance S.A. filed Critical Tetra Laval Holdings & Finance S.A.
Publication of WO2017072007A1 publication Critical patent/WO2017072007A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14336—Coating a portion of the article, e.g. the edge of the article
    • 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
    • B32B1/00—Layered products having a non-planar shape
    • 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
    • B32B27/32—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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • 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
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42—Details of containers or of foldable or erectable container blanks
    • B65D5/4212—Information or decoration elements, e.g. content indicators, or for mailing
    • B65D5/425—Decoration elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B29C2045/14319—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles bonding by a fusion bond
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B29C2045/14327—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles anchoring by forcing the material to pass through a hole in the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7162—Boxes, cartons, cases
    • B29L2031/7166—Cartons of the fruit juice or milk type, i.e. containers of polygonal cross sections formed by folding blanks into a tubular body with end-closing or contents-supporting elements, e.g. gable type 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • 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
    • 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
    • B32B2439/70—Food packaging
    • 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
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/02—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body
    • B65D5/06—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body with end-closing or contents-supporting elements formed by folding inwardly a wall extending from, and continuously around, an end of the tubular body
    • B65D5/064—Rectangular containers having a body with gusset-flaps folded outwardly or adhered to the side or the top of the container
    • 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
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42—Details of containers or of foldable or erectable container blanks
    • B65D5/56—Linings or internal coatings, e.g. pre-formed trays provided with a blow- or thermoformed layer
    • B65D5/563—Laminated linings; Coatings
    • 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
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42—Details of containers or of foldable or erectable container blanks
    • B65D5/62—External coverings or coatings

Definitions

  • the subject matter of this patent application generally relates to the field of packaging. More particularly, it relates to a package for liquid food products and a machine and a method for producing the same.
  • Carton based packages for liquid food products are well known in most parts of the world. For instance, Tetra Brik® packages are used in many parts of the world for milk, juice and other beverages.
  • carton based packages have gained such popularity. The environmental benefits of the packages, e.g. that the packages are to a large extent is produced by renewable material, and the efficient logistics of brick shaped packages are some examples to this popularity and also a reason why consumers today choose carton based packages instead of plastic bottles.
  • Another reason why carton based packages are popular is that the filling machines producing the packages are cost efficient compared to other alternatives and that the total cost for running a carton based filling machine is very competitive.
  • Tetra Brik® Edge a brick-shaped package with a slanted top panel, sold under the name Tetra Brik® Edge.
  • Tetra Prisma® and Tetra Gemina® both marketed by Tetra Pak® and being further developments of the Tetra Brik® concept.
  • the packaging material itself has been developed in order to make the packages stand out on the shelves.
  • the packaging material itself has been developed in order to make the packages stand out on the shelves.
  • printing technologies have been developed in order to provide packages made of metallic colored packaging material.
  • the claimed subject matter seeks to mitigate, alleviate or eliminate one or more of the above identified deficiencies in the art and disadvantages singly or in combination and solves at least the above mentioned problems according to any one of the aspects below.
  • a package comprising a main body for holding a product, said main body being formed by a packaging material, said packaging material comprising a first layer, said first layer facing an outside of said main body, and an element attached to said first layer of said main body, said element being formed by injection molding using an injection molding plastic material, wherein said first layer is affected by heat generated by said injection molding plastic material when injection molding said element such that said element and said first layer is bonded together when said injection molding material has solidified.
  • the first layer may be made of a first plastic material and that said first layer is affected by heat generated by said injection molding plastic material in that said first layer is at least partly melted.
  • the first plastic material may be polyethylene.
  • the injection molding plastic material may be polyethylene, such as low-density polyethylene.
  • the packaging material may comprise a carton layer.
  • the packaging material may be penetrated when injection molding said element.
  • the packaging material may comprise a weakened portion for facilitating penetration of said packaging material in said weakened portion.
  • the packaging material may comprise a carton layer and said weakened portion may be free from said carton layer.
  • a method for producing a package comprises providing a web of packaging material comprising a first layer, placing said web between a number of moulds, forming an element by injecting molten material of an injection molding plastic material into a cavity formed between said moulds, and attaching said element to said first layer by affecting said first layer using said molten material, such that said element and said first layer is bonded together when said injection molding plastic material solidify.
  • the first layer may be made of a first plastic material and that said first layer is affected by heat generated by said injection molding plastic material in that said first layer is at least partly melted.
  • the first plastic material may be polyethylene.
  • the injection molding plastic material may be polyethylene, such as low-density polyethylene.
  • the packaging material may comprise a carton layer.
  • the packaging material may be penetrated when injection molding said element.
  • the packaging material may comprise a weakened portion for facilitating penetration of said packaging material in said weakened portion.
  • the packaging material may comprise a carton layer and said weakened portion may be free from said carton layer.
  • a packaging machine comprising a packaging material station for housing packaging material comprising a first layer, an injection molding station for forming an element by injecting molten material of injection molding plastic material into a cavity formed between a number of molds, wherein a web of packaging material is placed between said molds, and attaching said element to said first layer by affecting said first layer using said molten material, such that said element and said first layer is bonded together when said injection molding plastic material solidify.
  • Fig 1 generally illustrates a roll fed carton based system for continuous packaging of liquid food products.
  • Fig 2a-c illustrates three stages of an injection molding process for providing details on an outer surface of packages according to a first embodiment.
  • Fig 3a-c illustrates three stages of an injection molding process for providing details on an outer surface of packages according to a second embodiment.
  • Fig 4 illustrates a first example of molds and packaging material.
  • Fig 5 illustrates a second example of molds and packaging material.
  • Fig 6 illustrates a third example of molds and packaging material.
  • Fig 7 illustrates a first example of a package having an element made using injection molding.
  • Fig 8 illustrates a second example of a package having an element made using injection molding.
  • Fig 9 illustrates a third example of a package having an element made using injection molding.
  • Fig 10 illustrates a flow chart of a method for producing a package.
  • Fig 1 generally illustrates the basic principle of a roll fed carton based packaging system for continuous packaging of liquid food products used in Tetra Brik® packaging systems.
  • the packaging material is delivered in packaging material reels 100 to the dairy or other site where the filling machine is placed. Before being delivered the packaging material has been produced and printed in a so-called converting factory.
  • the packaging material After unwinding the packaging material this is fed into a bath 102 in order to sterilize the packaging material, i.e. kill unwanted microorganisms. There are different ways to achieve this, but today one of the most commonly used methods is to use hydrogen peroxide.
  • the packaging material After being sterilized the packaging material is formed into a tube 104. More particularly, longitudinal ends are attached to each other continuously in a process often referred to as longitudinal sealing. When having formed a tube, this is filled with product, such as milk.
  • Packages 106 are formed from the tube by making transversal sealings in an end of the tube and cutting off sealed portions as they are formed. In order to shape the packages different measures can be made during the transversal sealing as well as after the transversal sealing.
  • an injection molding station 200,300 can be added before the packaging material 100 is transferred through the bath 102.
  • fig 2a-c it is illustrated a first general example of how such details can be formed.
  • the details are formed without perforating the packaging material 202 in this example comprising a carton layer 204, an outer plastic layer 206 and an inner plastic layer 208.
  • molten plastic material 210 e.g. low-density polyethylene
  • a cavity 212 formed between a first mould 214 and a second mould 21 6.
  • the second mould 21 6 is provided with a flat surface facing the packaging material such that the cavity is formed on only one side of the packaging material 202 and thus that no perforation of the packaging material is taking place.
  • the molten plastic material 210 has been heating the outer plastic layer 206 such that this has at least partly been melted, illustrated by that a dotted area, illustrating a solid material, has been transferred to a dashed area, illustrating melted material.
  • a third stage of this example illustrated in fig 2c, the plastic material 210 and the outer plastic layer 206 have both solidified, and the first mold 214 and the second mold 21 6 have been removed. In this stage the details have been formed. The details and the outer layer are bonded together due to that the outer plastic layer was at least partly melted during the injection molding of the details.
  • fig 3a-c it is illustrated a second general example of how such details can be formed. Unlike the example illustrated in fig 2a-c the details in this example are formed by penetrating a packaging material 302 here comprising a carton layer 304, an outer plastic layer 306 and an inner plastic layer 308.
  • a packaging material 302 here comprising a carton layer 304, an outer plastic layer 306 and an inner plastic layer 308.
  • molten plastic material 310 e.g. low-density polyethylene
  • two weakened portions of the packaging material 303 are provided such that the molten plastic material 310 can penetrate the packaging material 303 such that molten plastic material is placed on both sides of the packaging material.
  • a second stage is illustrated. As in the second stage illustrated in the example above and illustrated in fig 2b the outer plastic layer is melted, herein illustrated by that dotted areas are replaced by dashed areas. However, in this example, since the molten plastic material is also present on an inner side of the packaging material 302 the inner plastic layer 306 is also melted at least partly.
  • the molten plastic material has solidified and also the outer plastic layer 308 and the inner plastic layer 306. Due to that the three elements, the plastic material 310, the inner plastic layer 306 and the outer plastic layer 308, solidify together a bonding between the three elements are formed, thereby providing that the details formed by the plastic material 310 is securely attached to the package. In addition to that three elements are bonded together the plastic material 310 placed on the inner side of the packaging material provide for that that details are even further secured to the packaging material.
  • Fig 4 illustrates a first example of a molding station 400 for providing details to an outside of a package.
  • Packaging material 402 is placed between a first mold 404 and a second mould 406.
  • melted plastic material is fed into a cavity from below.
  • a weakened portion is provided in order to penetrate the packaging material.
  • Fig 5 illustrates a second example of a molding station 500.
  • packaging material 502 is placed between a first mold 504 and a second mould 506.
  • a weakened portion is wider than an inlet to a cavity between the first and second molds.
  • Fig 6 illustrates a third example of a molding station 600. Also in this example packaging material 602 is placed between a first mold 604 and a second mould 606. Unlike the two examples illustrated in fig 4 and 5, respectively, molten plastic material is fed into a cavity between the molds from above and without penetrating the packaging material 602.
  • Fig 7, 8 and 9 illustrate three examples of details, respectively, made using injection molding processes.
  • the details are made to distinguish the packages from other package via new design elements.
  • injection molded details may also be used for providing improved grippability by having details with tactile patterns.
  • Another example for providing extra functionality is having an injection moulded ring such that the package can easily be hanged to a rucksack or similar.
  • Fig 10 illustrates a flow chart 1000 of a method for producing a package.
  • a web of packaging material comprising a first layer of a first plastic material is provided.
  • the web is placed between a number of molds.
  • an element is formed by injecting molten material of an injection molding plastic material into a cavity formed between said moulds, and in a fourth step 1008 the element is attached to said first layer by affecting said first layer using said molten material, such that said element and said first layer is bonded together when said first layer and said element solidify.
  • the first layer can be a plastic layer, but also a carton layer or a layer of any other material affected by the heat such that bonding is improved.
  • polyethylene is mentioned as an example of a plastic that can be used in the first layer
  • polypropylene or polyester could be used as well.
  • materials for injection molding and in the first layer that are compatible, i.e. having similar melting temperatures.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

A package comprising a main body for holding a product, wherein the main body is formed by a packaging material comprising a first layer, and the first layer is facing an outside of the main body. The package further comprises an element attached to the first layer of the main body, wherein the element is formed by injection molding using an injection molding plastic material. The first layer is affected by heat generated by said injection molding plastic material when injection molding said element such that said element and said first layer is bonded together when said injection molding material has solidified.

Description

A LIQUID FOOD PACKAGE, A METHOD FOR
PRODUCING THE SAME AND A MACHINE
Technical field
The subject matter of this patent application generally relates to the field of packaging. More particularly, it relates to a package for liquid food products and a machine and a method for producing the same.
Background
Carton based packages for liquid food products are well known in most parts of the world. For instance, Tetra Brik® packages are used in many parts of the world for milk, juice and other beverages. There are several reasons why carton based packages have gained such popularity. The environmental benefits of the packages, e.g. that the packages are to a large extent is produced by renewable material, and the efficient logistics of brick shaped packages are some examples to this popularity and also a reason why consumers today choose carton based packages instead of plastic bottles. Another reason why carton based packages are popular is that the filling machines producing the packages are cost efficient compared to other alternatives and that the total cost for running a carton based filling machine is very competitive.
There are generally two different types of filling machines for carton packages, blanks fed packaging machines and roll fed packaging machines. For blanks fed packaging machines, blanks, being pieces of packaging material with two ends welded together such that a folded sleeve is formed, are fed to the filling machine, erected into an open sleeve, folded and sealed such that bottoms are formed, filled with product and sealed and folded such that a package filled with product is achieved. For roll fed packaging machines a tube is formed from a web of packaging material by continuously directing the web and making a longitudinal sealing. The tube is filled with product and then by making successive transversal sealings and cuttings in a lower end of the tube, packages are formed. By providing means for holding the tube in position during the transversal sealing and cutting, and by providing subsequent folding means different forms may be obtained.
In order to provide for that the packages stand out on the shelf at the retailers a number of different shapes have been developed. For instance, based on the Tetra Brik® concept a brick-shaped package with a slanted top panel, sold under the name Tetra Brik® Edge, has been developed. Further examples are Tetra Prisma® and Tetra Gemina®, both marketed by Tetra Pak® and being further developments of the Tetra Brik® concept.
In addition to having a number of different shapes the packaging material itself has been developed in order to make the packages stand out on the shelves. For instance, in order to make a package stand out printing technologies have been developed in order to provide packages made of metallic colored packaging material.
Even though it today exist a number of different possibilities to make a package stand out on the shelf, customers, e.g. being brand owners, are continuously looking for new ways to provide for that the packages of their products catch the attention of consumers in grocery stores. In order to meet this request from customers, there is a need for new ways to provide packages with new functionality such that these are distinguished from other packages.
Summary
Accordingly the claimed subject matter seeks to mitigate, alleviate or eliminate one or more of the above identified deficiencies in the art and disadvantages singly or in combination and solves at least the above mentioned problems according to any one of the aspects below.
According to a first aspect it is provided a package comprising a main body for holding a product, said main body being formed by a packaging material, said packaging material comprising a first layer, said first layer facing an outside of said main body, and an element attached to said first layer of said main body, said element being formed by injection molding using an injection molding plastic material, wherein said first layer is affected by heat generated by said injection molding plastic material when injection molding said element such that said element and said first layer is bonded together when said injection molding material has solidified.
The first layer may be made of a first plastic material and that said first layer is affected by heat generated by said injection molding plastic material in that said first layer is at least partly melted.
The first plastic material may be polyethylene.
The injection molding plastic material may be polyethylene, such as low-density polyethylene.
The packaging material may comprise a carton layer.
The packaging material may be penetrated when injection molding said element.
The packaging material may comprise a weakened portion for facilitating penetration of said packaging material in said weakened portion.
The packaging material may comprise a carton layer and said weakened portion may be free from said carton layer.
According to a second aspect it is provided a method for producing a package, said method comprises providing a web of packaging material comprising a first layer, placing said web between a number of moulds, forming an element by injecting molten material of an injection molding plastic material into a cavity formed between said moulds, and attaching said element to said first layer by affecting said first layer using said molten material, such that said element and said first layer is bonded together when said injection molding plastic material solidify.
The first layer may be made of a first plastic material and that said first layer is affected by heat generated by said injection molding plastic material in that said first layer is at least partly melted.
The first plastic material may be polyethylene.
The injection molding plastic material may be polyethylene, such as low-density polyethylene.
The packaging material may comprise a carton layer.
The packaging material may be penetrated when injection molding said element. The packaging material may comprise a weakened portion for facilitating penetration of said packaging material in said weakened portion.
The packaging material may comprise a carton layer and said weakened portion may be free from said carton layer.
According to a third aspect it is provided a packaging machine comprising a packaging material station for housing packaging material comprising a first layer, an injection molding station for forming an element by injecting molten material of injection molding plastic material into a cavity formed between a number of molds, wherein a web of packaging material is placed between said molds, and attaching said element to said first layer by affecting said first layer using said molten material, such that said element and said first layer is bonded together when said injection molding plastic material solidify. Brief description of the drawings
The above, as well as additional objects, features and advantages of the present invention will be better understood through the following illustrative and non-limiting detailed description of different embodiments of the present invention, with reference to the appended drawings, wherein:
Fig 1 generally illustrates a roll fed carton based system for continuous packaging of liquid food products.
Fig 2a-c illustrates three stages of an injection molding process for providing details on an outer surface of packages according to a first embodiment.
Fig 3a-c illustrates three stages of an injection molding process for providing details on an outer surface of packages according to a second embodiment.
Fig 4 illustrates a first example of molds and packaging material.
Fig 5 illustrates a second example of molds and packaging material. Fig 6 illustrates a third example of molds and packaging material.
Fig 7 illustrates a first example of a package having an element made using injection molding. Fig 8 illustrates a second example of a package having an element made using injection molding.
Fig 9 illustrates a third example of a package having an element made using injection molding.
Fig 10 illustrates a flow chart of a method for producing a package.
Detailed description
Fig 1 generally illustrates the basic principle of a roll fed carton based packaging system for continuous packaging of liquid food products used in Tetra Brik® packaging systems. The packaging material is delivered in packaging material reels 100 to the dairy or other site where the filling machine is placed. Before being delivered the packaging material has been produced and printed in a so-called converting factory.
After unwinding the packaging material this is fed into a bath 102 in order to sterilize the packaging material, i.e. kill unwanted microorganisms. There are different ways to achieve this, but today one of the most commonly used methods is to use hydrogen peroxide. After being sterilized the packaging material is formed into a tube 104. More particularly, longitudinal ends are attached to each other continuously in a process often referred to as longitudinal sealing. When having formed a tube, this is filled with product, such as milk. Packages 106 are formed from the tube by making transversal sealings in an end of the tube and cutting off sealed portions as they are formed. In order to shape the packages different measures can be made during the transversal sealing as well as after the transversal sealing.
In order to add details to an outer surface of the packages an injection molding station 200,300 can be added before the packaging material 100 is transferred through the bath 102.
In fig 2a-c it is illustrated a first general example of how such details can be formed. In this example the details are formed without perforating the packaging material 202 in this example comprising a carton layer 204, an outer plastic layer 206 and an inner plastic layer 208. In a first stage, illustrated in fig 2a, molten plastic material 210, e.g. low-density polyethylene, is transferred into a cavity 212 formed between a first mould 214 and a second mould 21 6.
In this example the second mould 21 6 is provided with a flat surface facing the packaging material such that the cavity is formed on only one side of the packaging material 202 and thus that no perforation of the packaging material is taking place.
In a second stage of this example, illustrated in fig 2b, the molten plastic material 210 has been heating the outer plastic layer 206 such that this has at least partly been melted, illustrated by that a dotted area, illustrating a solid material, has been transferred to a dashed area, illustrating melted material.
In a third stage of this example, illustrated in fig 2c, the plastic material 210 and the outer plastic layer 206 have both solidified, and the first mold 214 and the second mold 21 6 have been removed. In this stage the details have been formed. The details and the outer layer are bonded together due to that the outer plastic layer was at least partly melted during the injection molding of the details.
In fig 3a-c it is illustrated a second general example of how such details can be formed. Unlike the example illustrated in fig 2a-c the details in this example are formed by penetrating a packaging material 302 here comprising a carton layer 304, an outer plastic layer 306 and an inner plastic layer 308. In a first stage, illustrated in fig 3a, molten plastic material 310, e.g. low-density polyethylene, is transferred into a cavity 312 formed between a first mould 314 and a second mould 316. In this example two weakened portions of the packaging material 303 are provided such that the molten plastic material 310 can penetrate the packaging material 303 such that molten plastic material is placed on both sides of the packaging material.
In fig 3b, a second stage is illustrated. As in the second stage illustrated in the example above and illustrated in fig 2b the outer plastic layer is melted, herein illustrated by that dotted areas are replaced by dashed areas. However, in this example, since the molten plastic material is also present on an inner side of the packaging material 302 the inner plastic layer 306 is also melted at least partly. In fig 3c, illustrating a third stage, the molten plastic material has solidified and also the outer plastic layer 308 and the inner plastic layer 306. Due to that the three elements, the plastic material 310, the inner plastic layer 306 and the outer plastic layer 308, solidify together a bonding between the three elements are formed, thereby providing that the details formed by the plastic material 310 is securely attached to the package. In addition to that three elements are bonded together the plastic material 310 placed on the inner side of the packaging material provide for that that details are even further secured to the packaging material.
Fig 4 illustrates a first example of a molding station 400 for providing details to an outside of a package. Packaging material 402 is placed between a first mold 404 and a second mould 406. In this example melted plastic material is fed into a cavity from below. In order to penetrate the packaging material a weakened portion is provided.
Fig 5 illustrates a second example of a molding station 500. As in the the first example, packaging material 502 is placed between a first mold 504 and a second mould 506. Unlike the first example a weakened portion is wider than an inlet to a cavity between the first and second molds.
Fig 6 illustrates a third example of a molding station 600. Also in this example packaging material 602 is placed between a first mold 604 and a second mould 606. Unlike the two examples illustrated in fig 4 and 5, respectively, molten plastic material is fed into a cavity between the molds from above and without penetrating the packaging material 602.
Fig 7, 8 and 9 illustrate three examples of details, respectively, made using injection molding processes. In these three examples the details are made to distinguish the packages from other package via new design elements. However, injection molded details may also be used for providing improved grippability by having details with tactile patterns. Another example for providing extra functionality is having an injection moulded ring such that the package can easily be hanged to a rucksack or similar.
Fig 10 illustrates a flow chart 1000 of a method for producing a package. In a first step 1002 a web of packaging material comprising a first layer of a first plastic material is provided. In a second step 1004 the web is placed between a number of molds. In a third step 1006 an element is formed by injecting molten material of an injection molding plastic material into a cavity formed between said moulds, and in a fourth step 1008 the element is attached to said first layer by affecting said first layer using said molten material, such that said element and said first layer is bonded together when said first layer and said element solidify.
Although it has been described above that an element made using injection molding technology is bonded to a plastic layer due to that this plastic layer is at least partly melted because of heat generated when injection molding, it has also been seen that if injection molding an element and having a carton layer, instead of the plastic layer, bonding will still occur due to that the heat affects the carton layer in a way such that the element is securely bonded to the carton layer. Thus the first layer can be a plastic layer, but also a carton layer or a layer of any other material affected by the heat such that bonding is improved.
Further, although polyethylene is mentioned as an example of a plastic that can be used in the first layer, also polypropylene or polyester could be used as well. In short, it has been proven advantageous to use materials for injection molding and in the first layer that are compatible, i.e. having similar melting temperatures.
The invention has mainly been described above with reference to a few embodiments. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the claimed subject matter according to the appended claims.

Claims

1 . A package comprising
a main body for holding a product, said main body being formed by a packaging material, said packaging material comprising a first layer, said first layer facing an outside of said main body, and
an element attached to said first layer of said main body, said element being formed by injection molding using an injection molding plastic material, wherein said first layer is affected by heat generated by said injection molding plastic material when injection molding said element such that said element and said first layer is bonded together when said injection molding material has solidified.
2. The package according to claim 1 , wherein said first layer is made of a first plastic material and that said first layer is affected by heat generated by said injection molding plastic material in that said first layer is at least partly melted.
3. The package according to claim 2, wherein said first plastic material is polyethylene.
4. The package according to any one of the preceding claims, wherein said injection molding plastic material is polyethylene, such as low- density polyethylene.
5. The package according to any one of the preceding claims, wherein said packaging material comprises a carton layer.
6. The package according to any one of the preceding claims, wherein said packaging material is penetrated when injection molding said element.
7. The package according to claim 6, wherein said packaging material comprises a weakened portion for facilitating penetration of said packaging material in said weakened portion.
8. The package according to claim 7, wherein said packaging material comprises a carton layer and said weakened portion is free from said carton layer.
9. A method for producing a package, said method comprises providing a web of packaging material comprising a first layer, placing said web between a number of moulds,
forming an element by injecting molten material of an injection molding plastic material into a cavity formed between said moulds, and
attaching said element to said first layer by affecting said first layer using said molten material, such that said element and said first layer is bonded together when said injection molding plastic material solidify.
10. The method according to claim 9, wherein said first layer is made of a first plastic material and that said first layer is affected by heat generated by said injection molding plastic material in that said first layer is at least partly melted.
1 1 . The method according to claim 10, wherein said first plastic material is polyethylene.
12. The method according to any one of claims 9 to 1 1 , wherein said injection molding plastic material is polyethylene, such as low-density polyethylene.
13. The method according to any one of the claims 9 to 12, wherein said packaging material comprises a carton layer.
14. The method according to any one of the claims 9 to 13, wherein said packaging material is penetrated when injection molding said element.
15. The method according to claim 14, wherein said packaging material comprises a weakened portion for facilitating penetration of said packaging material in said weakened portion.
1 6. The method according to claim 15, wherein said packaging material comprises a carton layer and said weakened portion is free from said carton layer.
17. A packaging machine comprising
a packaging material station for housing packaging material comprising a first layer,
an injection molding station for forming an element by injecting molten material of injection molding plastic material into a cavity formed between a number of molds, wherein a web of packaging material is placed between said molds, and
attaching said element to said first layer by affecting said first layer using said molten material, such that said element and said first layer is bonded together when said injection molding plastic material solidify.
PCT/EP2016/075126 2015-10-27 2016-10-19 A liquid food package, a method for producing the same and a machine WO2017072007A1 (en)

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SE1551383 2015-10-27

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WO2015101427A1 (en) * 2013-12-30 2015-07-09 Tetra Laval Holdings & Finance S.A. Package material blank, package with such device and method for manufacturing an opening device
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