WO2023007149A1

WO2023007149A1 - Book-Opening Carton and Carton Blank

Info

Publication number: WO2023007149A1
Application number: PCT/GB2022/051958
Authority: WO
Inventors: Martin Myerscough
Original assignee: Splyt-Pak Limited
Priority date: 2021-07-27
Filing date: 2022-07-26
Publication date: 2023-02-02
Also published as: GB202110800D0; WO2023007150A1; GB2609401A; CN117836212A; CN117836213A; WO2023007148A1

Abstract

A carton blank, reel of carton blanks, and a method for manufacturing the carton blank or reel of carton blanks. The carton blank is for use in a vertical form fill sealing machine to form a carton. The carton blank includes a card outer and a liner. The card outer is perforated to define a tear line. The tear line extends from at or adjacent a top edge of the card outer to at or adjacent a bottom edge of the card outer. The liner is attached to the card outer by an adhesive disposed about a periphery of the liner.

Description

BOOK-OPENING CARTON AND CARTON BLANK

Field

The present invention relates to a recyclable carton for liquids, including a carton blank, a reel of carton blanks, and a method of manufacturing a carton blank.

Background

Cartons for liquid, for example juice, are typically made from a laminate material formed of a card layer and a polymeric inner layer laminated onto the card to provide a sealed inner surface and prevent contact of the liquid contents with the card.

In such cartons it is not possible to easily separate the card layer of the laminate material from the polymeric inner layer. The laminate material also cannot be easily recycled because the polymeric layer prevents the card recycling process (usually mixing the card with water) from working on the card component. Because conventional cartons cannot typically be recycled, it is common practice for Materials Recovery Facilities (MRFs) to reject any such cartons when sorting and processing waste material. The sorting is typically done by a visual inspection of the material, and MRFs will typically therefore reject any item that appears similar to a conventional laminate carton.

Summary of Invention

According to a first aspect of the present invention, there is provided a carton blank for use in a vertical form fill sealing machine, the carton blank comprising: a card outer having a top edge, a bottom edge opposing the top edge, two opposing side edges, a plurality of crease lines defining a plurality of panels, a tear line defined by a line of perforations, the tear line extending from at or adjacent the top edge, through one or more of the plurality of panels that are not adjacent to either of the two opposing side edges, to at or adjacent the bottom edge, and a liner attached to the card outer by an adhesive disposed about a periphery of the liner. By providing the carton blank with a tear line, it enables the carton that is formed from the carton blank to be easily recycled. The user is able to open the carton in a book-like manner via the tear line, and easily remove the liner from the opened carton, whereby both the card outer and liner can be recycled.

By arranging the line of perforations such that the tear line extends through one or more of the plurality of panels that are not adjacent to either of the two opposing side edges, when the carton blank is formed into a carton, the liner can be separated from the card outer more easily since the tear line is located away from a side seam of a resulting carton formed from the carton blank, where the liner and card outer are most difficult to separate.

In one example, the top edge is arranged to form a top seam of a carton, the bottom edge is arranged to form a bottom seam of the carton, and the two opposing side edges are arranged to be joined together to form the side seam of the carton extending between the top seam and the bottom seam.

In one example, the tear line is arranged such that, when the carton blank is formed into a carton, the tear line extends through a panel on the opposite side of the carton to a side seam of the carton.

Providing the tear line such that it extends, in the carton formed from the carton blank, through a panel on the opposite side of the carton to the side seam is advantageous, as this can achieve the maximum separation between the side seam and the tear line. This can make it easier for the user to open the carton.

In one example, the line of perforations is a single, continuous line of perforations.

Providing the line of perforations as a single, continuous line of perforations is advantageous because it allows the carton to be easily opened from the top seam to the bottom seam in a “book-like” manner, which makes it easier for the user to separate the card outer from the liner.

In one example, the line of perforations comprises a straight line of perforations. Providing the line of perforations comprising a straight line of perforations is advantageous, because a straight line of perforations is easier for a user to tear. Lines of perforations that are tightly curved can make it more difficult to tear the liner, because tears will tend to preferentially continue in a straight line through the card outer material, rather than follow a tightly curved line of perforations.

In one example, the line of perforations comprises two or more segments, wherein each of the two or more segments is a straight line, the two or more segments being joined to form a continuous line of perforations.

Providing the line of perforations comprising two or more straight line segments is advantageous, because, when the carton blank is rolled into a tube during a subsequent forming and filling process, this can prevent the carton blank from becoming kinked along the line of perforations, which would be detrimental to the forming and filling process.

In one example, the line of perforations comprises a first segment and a second segment, wherein the first and second segments are straight lines of perforations.

In one example, the line of perforations forms a rounded v-shape extending from at or adjacent the top edge to at or adjacent the bottom edge.

Providing the line of perforations as a rounded v-shape can be advantageous because it can make it easier for a user to open the carton. The rounded tip of the v-shaped line of perforations can provide a convenient starting point for the user to begin opening the line of perforations.

In one example, the adhesive is disposed about the entire periphery of the liner.

In one example, the adhesive is disposed only about the periphery of the liner.

According to a further aspect of the invention, there is provided a carton blank for use in a vertical form fill sealing machine, the carton blank comprising: a card outer having a top edge, a bottom edge opposing the top edge, and two opposing side edges, the top edge being arranged to form a top seam of a carton, the bottom edge being arranged to form a bottom seam of the carton, and the two opposing side edges are arranged to be joined together to form a side seam of the carton extending between the top seam and the bottom seam; a tear line defined by a line of perforations, the tear line extending from at or adjacent the top edge, to at or adjacent the bottom edge; wherein the tear line is arranged such that, when the carton blank is formed into a carton, it extends through a side of the carton that does not include the side seam.

In one example, the tear line is arranged such that, when the carton blank is formed into a carton, it extends through the opposite side of the carton to the side seam.

In one example, the line of perforations comprises a straight line of perforations.

In one example, the adhesive is disposed only about the periphery of the liner.

According to a further aspect of the present invention, there is provided a reel of carton blanks for use in a vertical form fill sealing machine, the reel of carton blanks comprising a plurality of carton blanks according to the present invention.

In one example, the reel comprises a web of carton blanks having a plurality of carton blanks arranged longitudinally along the web and a plurality of carton blanks arranged laterally across the web.

According to a further aspect of the present invention, there is provided a carton comprising a card outer and a liner formed from a carton blank according to the present invention. According to a further aspect of the present invention, there is provided a carton comprising: a card outer comprising a line of perforations defining a tear line; a liner adhered to an inside of the card outer; and a top seam, a bottom seam, and a side seam extending between the top seam and the bottom seam; wherein the tear line extends from at or adjacent the top seam to at or adjacent the bottom seam on a side of the carton that does not contain the side seam.

In one example, the tear line extends through an opposite side of the carton to the side seam.

In one example, the liner extends into one or more of the top seam, bottom seam, and side seam.

In one example, the liner extends into all of the seams of the carton.

According to a further aspect of the present invention, there is provided a method of manufacturing a carton according to any embodiment of the present invention using a carton blank according to any embodiment of the present invention, the method comprising: adhering the two opposing side edges together to form the side seam; adhering the top edge to itself to form the top seam; adhering the bottom edge to itself to form the bottom seam; folding the carton blank along the crease lines to shape the carton.

According to a further aspect of the present invention, there is provided a method of processing a carton according to any embodiment of the present invention, the method comprising: tearing the card outer along the tear line defined by the line of perforations; opening the top seam and bottom seam; and separating the liner from the card outer.

The present invention relates to a carton blank, that can be formed into a recyclable carton. The carton blank comprises a card outer layer, and a liner attached to the inside of the card outer layer. The card outer predominantly provides the structural rigidity and strength of the carton while the inner liner holds the liquid inside and can provide a barrier to bacteria and contaminants. The carton blank according to the present invention includes a tear line. When disposing of the carton after use, a user can open the carton via the tear line, whereby the carton opens in a “book-like” manner. Peeling open the card outer layer reveals the inner liner, which can then easily be separated from the card outer. The card outer and inner liner can be disposed of and recycled separately. Advantageously, after the carton of the present invention has been opened via the tear line and separated from the liner, the two components do not resemble a conventional laminate carton, and will not be rejected by an MRF.

Brief Description of the Drawings The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 shows a carton.

FIG. 2 shows a rotated view of the carton of FIG. 1.

FIG. 3 shows a further rotated view of the carton of FIG. 1. FIGS. 4A, 4B and 4C show the carton of FIG. 1 being unfolded, opened along a tear line, and a liner being removed.

FIG. 5 shows a card outer blank for a carton blank for the carton of FIGS. 1 to 4C.

FIG. 6 shows a carton blank for the carton of FIGS. 1 to 4C.

FIG. 7 shows a web of the carton blank of FIG 6. FIG. 8 shows a schematic diagram of a vertical form fill sealing apparatus.

FIG. 9 shows a cross-section A-A of the web of carton blanks during a part of the vertical form fill sealing apparatus of FIG. 8.

FIG. 10 shows a reverse side (outside) of the carton blank of FIG. 6.

FIG. 11 shows a carton according to an alternative embodiment of the invention. FIG. 12 shows a card outer blank for a carton blank for the carton of FIG. 11.

FIG. 13 shows a carton according to a further alternative embodiment of the invention.

FIG. 14 shows a card outer blank for a carton blank for the carton of FIG. 13.

FIG. 15 shows a carton according to a further alternative embodiment of the invention.

FIG. 16 shows a card outer blank for a carton blank for the carton of FIG. 15. FIG. 17 shows a carton according to a further alternative embodiment of the invention.

FIG. 18 shows a card outer blank for a carton blank for the carton of FIG. 17.

FIG. 19 shows a carton according to a further alternative embodiment of the invention.

FIG. 20 shows a card outer blank for a carton blank for the carton of FIG. 19. Detailed Description

FIG. 1 shows a carton 1 for liquids, for example juice. The carton 1 is a brick-type carton, having a cuboidal shape. The carton 1 is formed of a card outer 2 and a liner 17 (not visible in FIG. 1). The liner 17 is within the card outer 2 and holds the contents of the carton, e.g. the liquid.

The card outer 2, as illustrated, has an opening 3. In some examples, the opening 3 is an insert, for example a plastics insert that includes a re-closable flap or screw lid. In other examples, the opening 3 may have a pierceable membrane that can be pierced to provide access into the carton. In other examples, the opening may have a peelable membrane adhered over the opening 3 that can be peeled away to expose the opening 3.

The carton 1 shown in FIG. 1 is cuboidal, having a top end 4 and a bottom end 5, opposing major sides 6, 7, and opposing minor sides 8, 9, the major sides 6, 7 being larger in area than the minor sides 8, 9. However, it will be appreciated that in alternative arrangements the minor sides 8, 9 may be the same size as the major sides 6, 7, providing a carton with a square cross- section. In various examples, the relative sizes of the major sides 6, 7 and minor sides 8, 9 can vary to provide a carton of any size or shape. Other sizes and shapes of carton will be described with reference to FIGs 11-20 below.

The opening 3 is formed in the top end 4 of the carton 1 , although the opening 3 could be formed in the bottom end 5 or on a side of the carton 1. The carton 1 is formed from a carton blank (10, see FIG. 6) that is folded and sealed to form the carton 1 , which has three seams: a top seam 11 disposed on the top end 4 of the carton 1 , a bottom seam 110 (shown in FIG. 3) disposed on the bottom end 5 of the carton 1 , and a side seam 12 (shown in FIG. 1 ) extending between the top seam 11 and the bottom seam 110 through one of the major sides 6, 7 or minor sides 8, 9, in this example through major side 7. The formation of the top seam 11 creates a pair of top flaps 13 on the top end 4 of the carton 1 , one of which is visible in FIG. 1. The top flaps 13 are folded over onto the opposing major sides 6, 7 or minor sides 8, 9, as illustrated. Similarly, the formation of the bottom seam 110 creates a pair of bottom flaps 130 on the bottom end 5 of the carton. The bottom flaps 130 are folded over onto the bottom end 5 of the carton 1. The top flaps 13 and the bottom flaps 130 are glued, or otherwise attached, into their folded positions.

As noted above, the carton blank 10 comprises a card outer 2 and a liner 17. To form the carton blank 10, the liner 17 is attached to the carton blank 10 using an adhesive. The liner 17 covers the majority of the surface of the card outer 2. In preferred embodiments, multiple edges of the liner 17 are aligned with corresponding edges of the card outer 2, and the remaining edges of the liner 17 are spaced from the corresponding edges of the card outer 2 to allow these edges of the card outer 2 to be glued when forming a carton. Preferably, the liner 17 is attached to the card outer 2 using adhesive that is disposed about the entire periphery of the liner 17. By adhering the liner 17 to the card outer 2 around the entire periphery, the space between the liner 17 and the card outer 2 is sealed against ingress of fluid, such as sterilisation fluid in which the carton blank 10 is immersed prior to forming, filling, and sealing. By adhering the liner 17 to the card outer 2 around the periphery of the liner 17, the liner 17 is secured within the resulting carton 1 within the top seam 11 and bottom seam 110, although this is only the case in embodiments wherein the corresponding edges of the liner 17 are aligned with the edges of the card outer 2 that are used to form the top seam 11 and bottom seam 110. It will be appreciated therefore that the top and bottom seams each have a sandwiched construction comprising card outers that sandwich two layers of liner material.

As illustrated in FIGS. 1 , 2, and 3, the card outer includes a tear line 14. The tear line 14 is defined by a line of perforations 15 in the card outer 2 that can be broken by a user. The line of perforations extends, in a carton formed from the blank, from at or adjacent the top seam 11 to at or adjacent the bottom seam 110 across one or more of the sides. In one example, the line of perforations 15 extends, in a carton formed from the blank, from at or adjacent the top seam 11 , across major side 6, and to at or adjacent the bottom seam 110. The tear line 14 thereby defines a line that, in a carton formed from the blank, extends substantially along the length of the carton along which the card outer may be broken and the carton opened by a user. In alternative embodiments, the tear line may extend from at or adjacent the top seam 11 across either of the minor sides 8, 9, to at or adjacent the bottom seam 110. The line of perforations 15 may extend from at or adjacent the top seam, across multiple sides of the card outer before extending to at or adjacent the bottom seam 110. As discussed in some embodiments, the line of perforations 15 may extend from a point adjacent to the top seam 11 , to a point adjacent to the bottom seam 110. In such embodiments, the line of perforations does not extend into either the top seam 11 or bottom seam 110. When opening the carton 1 , a user can tear the carton blank along the line of perforations 15, and then open the top seam 11 and bottom seam 110 to remove the liner. In some alternative embodiments, the line of perforations 15 may extend from a point spatially separated from the top seam 11 , to a point spatially-separated from the bottom seam 110. In such embodiments, when opening the carton 1 the user may tear the carton blank 10 along the line of perforations 15, and is then able to tear the remainder of the carton blank to the top seam 11 or bottom seam 110 which may subsequently be peeled apart to open the carton and allow the user to remove the liner 17.

The line of perforations 15 may comprise one or more segments. Each of the segments is preferably a straight line of perforations. When forming lines of perforations in the card outer, it is preferable to form the lines of perforations of each segment as straight lines, because straight lines of perforations can be more easily torn by the user, whereas tightly curved or angled lines of perforations can be more difficult to tear as the tear in the card material will preferentially continue in a straight line, rather than following the line of perforations 15. Therefore, it is preferable that the line of perforations 15 comprises a straight line of perforations. The line of perforations of each segment may extend in a different direction to the line of perforations in an adjacent segment. The line of perforations may comprise a number of segments of perforations. For example, the line of perforations may comprise a first segment, and a second segment, wherein both the first and second segments are straight lines of perforations. The first segment may be parallel, and offset from, the second segment, and joined to the second segment by a third segment. In some examples the third segment joining the first and second segments may be formed as a curved line of perforations. In this case, the curved line is preferably relatively short compared to the segments to minimize adversely affecting the tearing of the line of perforations 15. In other examples, the two segments may be arranged at an angle with respect to each other. The segments may be joined end-to-end. The inventors have appreciated that providing the line of perforations 15 as a single straight line of perforations can be problematic if the single straight line of perforations is arranged lengthwise, or substantially lengthwise (i.e. parallel or substantially parallel to the direction of the side seam 12). During the forming and filling process, the carton blanks that form the cartons are rolled into a cylinder. If the line of perforations 15 is formed as a single straight line of perforations arranged lengthwise along the carton blanks, this can cause the cylinder to become kinked along the line of perforations 15 which can cause problems during the forming and filling process. In view of this, the inventors have appreciated that if a single, straight line of perforations is used, this should be oriented at an angle to the lengthwise direction, such that the line of perforations 15 extends diagonally across one or more of the major and minor sides of the carton. As set out above, this problem may also be overcome by providing a line of perforations comprised of two or more segments, where these are arranged at an angle, or an offset, with respect to each other.

In some embodiments the line of perforations 15 that defines the tear line 14 form a rounded V- shape along the length of the carton, as shown in FIG. 2. The V-shaped line of perforations is formed by a first and second segment, which are each formed as a straight line of perforations. The first and second segment may be joined end-to-end, or may be joined by a third, curved, segment. In some embodiments the third, curved segment is oriented in the same direction as the V-shaped arrangement of the first and second segments. In other embodiments, such as those shown in FIGs. 11-19, the third segment may be oriented in the opposite direction to the V- shaped arrangement of the first and second segments. The V-shaped configuration is particularly advantageous, since this can be formed using straight line segments, and enables the line of perforations to be formed in a roll of card outer blanks as a continuous line. Furthermore, during a process by which the cartons are formed and filled, a continuous roll of carton blanks are formed into a smooth tube, as will be described in more detail below. By forming the perforations in a V-shape, it allows the continuous roll of cartons to be formed into a smooth tube without distortions. Other configurations of the line of perforations that comprise one or more straight line segments may also provide these same advantages. It will be appreciated that the line of perforations 15 may form any other suitable shape in the card outer, and extends from at or adjacent the top seam to at or adjacent the bottom seam 110, such that the carton 1 can be opened by the user when the line of perforations 15 are broken and the top seam 11 and bottom seam 110 are peeled apart. It will be appreciated that in some alternative embodiments, the line of perforations may not extend all the way to one or both of the top edge 22 or bottom edge 23, such that the user can tear the carton blank 10 along the line of perforations 15, then peel apart the top seam 11 and bottom seam 110 in order to open the carton 1 and remove the liner 17.

Additionally, the line of perforations may be arranged such that the starting point of the line of perforations (for example on the top or bottom edge), and the finishing point of the line of perforations (for example on the bottom or top edge) are the same distance from the side edge of the carton blank. By arranging the line of perforations in this way, the manufacturing process of the carton blanks can be simplified. By way of example, when the carton blanks are formed as a continuous reel of carton blanks, the apparatus that perforates the card outer to form the line of perforations may form the line of perforations as a single line, that extends continuously long the reel of card outers. The perforations that form the line of perforations 15 can be defined by a perforation length, perforation width and a perforation spacing. The inventors have appreciated that if the length or width of the perforations is too great, liquid can ingress through the perforations. If the size of the perforations is such that liquid could ingress through the perforations, additional adhesive may be used to seal the perforations to prevent this from occurring. However, this may make the liner 17 more difficult to separate from the card outer 2. Accordingly, the inventors have determined that in preferred embodiments, the perforations should have a perforation width of 0.6mm, a perforation length in the range of 1 mm to 1.5mm, and a perforation spacing in the range of 1 mm to 1.5mm. It will be appreciated that this is merely an exemplary configuration, and that other configurations of perforations that prevent ingress of liquid may also be used. Alternatively, a configuration of perforations that does allow ingress of liquid may be used, and in such examples the perforations are sealed using adhesive or other suitable means.

After the carton 1 has been used (i.e. the liquid emptied from the carton 1 ) the user can open the carton 1 , and separate the card outer 2 from the liner 17. An example of a process by which the user can separate the card outer 2 and liner 17 is illustrated in FIGS. 4A, 4B, and 4C. Firstly, the user may break the glue holding the top flaps 13 and bottom flaps 130 in position. The user may then unfold the top flaps 13 and bottom flaps 130 as shown in FIG 4A. The user can then slightly compress the carton in order to unfold the top seam 11 and bottom seam 110. Then, the user can break the line of perforations 15. This can be achieved starting at a central point. In embodiments where the line of perforations 15 is formed in a V-shape, the central point may be the centre of the V-shape. Forming the line of perforations in such a way can assist the user in breaking the line of perforations. The user may start tearing the line of perforations at the centre of the V-shape, and then tear the line of perforations in a straight line towards either seam. The user can break the line of perforations 15 and open the carton at the tear line 14. When opening the carton, the user can peel open the top seam 11 and bottom seam 110. In a preferred example, the liner 17 can be peeled away from the associated surfaces of the card outer 2 to open the seam. By peeling open the seams, the liner is freed from the card outer 2 along the top and bottom edge of the card outer 2, or can easily be peeled away from the card outer 2. For this reason, it is not necessary to provide the line of perforations across the seams. Once the line of perforations has been broken, and the top and bottom seams 11 , 110 peeled open, the carton can be opened in a book-like manner. The liner 17 remains fixed to the card outer 2 along the side seam 12. The user can pull the liner to separate it from the card outer 2. The two pieces can then be processed for recycling separately.

It will be appreciated that the card outer and liner may be separated by performing some of the steps of the above method in a different order, or by omitting one or more of the above steps and/or substituting one or more alternative steps.

As explained hereinafter, when the carton 1 is formed by folding and sealing a carton blank (10, see FIG. 6) the edges of the liner 17 are incorporated into the sealed seams 11, 12 of the card outer 2.

As a result, as illustrated in FIG. 2, the liner 17 comprises sealed seams corresponding to the sealed seams of the card outer 2. In particular, the liner 17 comprises a top seam 11 , a bottom seam 110, and a side seam 12, the side seam 12 extending between the top and bottom seam

11 , 110.

As explained further hereinafter, the liner 17 is only adhered to the card outer 2 in certain locations so that the user can separate the liner 17 from the card outer 2 after use. In one alternative, the liner 17 is adhered to the card outer 2 by a glue that is weak and/or that is applied with a low weight (i.e. only a thin layer), so that the user can separate the liner 17 from the card outer 2 after use.

FIG. 5 shows a card outer blank 21 for a carton blank (10, see FIG. 5) for making the carton 1 described with reference to FIGS. 1 to 4C. The card outer blank 21 is rectangular and has a top edge 22, a bottom edge 23, and opposing side edges 24, 25. The top edge 22 and bottom edge 23 are arranged to form the top seam 11 and bottom seam 110 of a carton, respectively. The opposing side edges 24, 25 are arranged to form the side seam 12 of a carton, extending between the top seam 11 and bottom seam 110.

As shown, the card outer blank 21 includes a major side panel 26 corresponding to the major side 6 of the carton 1 of FIGS. 1 to 4C. The card outer blank 21 also includes first and second side panels 27, 28 corresponding to the opposing minor sides 8, 9 of the carton 1 of FIG. 1. The card outer blank 21 also has two major sub panels 29, 30 adjacent to opposing side edges 24,

25 that are later joined together at the side seam (12, see FIG. 1 ) to form the major side panel 7 of the carton 1 of FIG. 1.

The card outer blank 21 also includes a major top end panel 31 , and top end sub-panels 32, 33, 34, 35 that after the carton 1 has been formed provide the top end 4 of the carton of FIG. 1. The card outer blank 21 also includes a major bottom end panel 36, and bottom end sub-panels 37, 38, 39, 40 that after the carton 1 has been formed provide the bottom end 5 of the carton of FIG.

1. The top end sub-panels 34, 35 and the bottom end sub-panels 39, 40 are folded diagonally on forming the carton of FIG. 1 to provide the top flaps (13, see FIG. 1) 5 and bottom flaps 130. The card outer blank 21 also includes an opening 3, as previously described. The opening 3 in this example is a through-hole in the card outer blank 21. The opening 21 is formed in the top end sub-panel 33 so that the opening 3 is formed in the position shown in FIGS. 1 to 4C.

As illustrated, the card outer blank 21 comprises a plurality of crease lines 41 along the edges of each of the panels and along other fold lines (i.e. diagonally across the top end panels 34, 35 and the bottom end panels 39, 40 that form the top flaps and bottom flaps 130 of the carton 1). These crease lines 41 are preferably embossed lines formed by pressing the card material to form a crease to ease folding of the card outer blank 21 along those lines during assembly of the carton 1. However, the crease lines 41 might alternatively be other lines of weakness or variations in material to permit folding of the card outer blank 21.

Crease lines 42 are also provided adjacent to the top edge 22 and bottom edge 23 of the card outer blank 21 , where the top seam (11, see FIG. 1 ) and bottom seam 110 are formed on assembly of the carton 1.

The card outer blank includes the line of perforations 15. The line of perforations defines the tear line 14 illustrated in FIGS. 1 to 4C.

In this example, the line of perforations 15 extends from the top edge 22 of the card outer blank 21 , in the region of the major top end panel 31 near to the intersection of the major top end 31 and top-end sub panel 35, across the intersection of the major side panel 26 and major top end panel 31 , and into the major side panel 26. From there, the line of perforations 15 defines a v- shape in the major side panel 26, with a center-point located at the mid-line of the card outer blank 25. The line of perforations 15 then extends to the intersection of the major side panel 26 and major bottom end panel 36. The line of perforations 15 then extends into the major bottom end panel 36, and then extends to the bottom edge 23 of the card outer blank 21 in the region of the major bottom end panel 36, near to the intersection between the major bottom end panel 36 and the bottom end sub panel 40. It will be appreciated that the configuration of the tear line 14 defined by line of perforations 15 shown in FIG. 5 is one preferred example. In other embodiments, the tear line 14 may be defined by alternative means other than by a line of perforations, such as by a variation in material, material thickness, or by scoring lines. The tear line 14 may be configured in other shapes. In some alternative embodiments, the tear line 14 may be provided with a section to assist the user in opening the tear line. This additional section may be provided as a “pull-tab” or any other suitable means for assisting the user in opening the tear line 14.

The tear line 14 as illustrated in FIGS. 1 to 6 is shown extending into major side panel 26. It will be appreciated that the tear line 14 may be configured so as to extend into the other panels of the carton blank 21 that are not adjacent to either side edge 24, 25. In some embodiments, the tear line may extend from the top edge through either of first or second sub panels 27, 28.

The line of perforations does not extend across the major sub panels 29, 30 of the card outer blank 21 that are later joined to form the side seam of the assembled carton.

Preferably, the line of perforations 15 defining the tear line 14 extends from the top edge 22 at point that is distanced from the mid-point of the top end sub-panel 35, or the mid point of the top end sub-panel 34. When the top end sub panels 34, 35 are folded to provide the top flaps 13, the stiffness and rigidity of the resulting carton in this region is increased. Ensuring that the line of perforations 15 are distanced from this region can assist the user in breaking the line of perforations 15 when opening the carton 1.

In preferred embodiments, the top edge 22 and bottom edge 23 of the card outer blank 21 are parallel. The line of perforations 15 defining the tear line 14 extends from the top edge 22 to the bottom edge 23. In preferred embodiments, the line of perforations 15 includes at least one portion that is not perpendicular to the top edge 22 or bottom edge 23. For example, the line of perforations 15 may include at least a portion that is oriented at an acute, or obtuse angle relative to the top edge 22 and bottom edge 23. As discussed above, it has been appreciated by the present inventors that by providing a line of perforations 15 with at least one portion arranged non-perpendicular to the top edge 22 or bottom edge 23, this prevents any kink forming in the resulting carton blank (formed from the card outer blank 21 ) when it is formed into a tube (with side edge 24 joined to side edge 25) during a subsequent forming and filling process. In some examples, the line of perforations 15 defining the tear line 14 may include only one portion that is oriented non-perpendicular to the top edge 22 and bottom edge 23. In other embodiments, the line of perforations 15 may include multiple portions that are oriented non-perpendicular to the top edge and bottom edge 23.

In some embodiments, the line of perforations 15 defining the tear line 14 may be formed as a single, straight line of perforations that is oriented non-perpendicular to the top edge 22 and bottom edge 23.

In embodiments where at least a portion of one or both of the opposing side edges 24, 25 are perpendicular to the top edge 22 and/or bottom edge 23, the line of perforations 15 defining the tear line 14 may be arranged such that at least a portion of the line of perforations is not parallel to the portion of one or both of the opposing side edges 24, 25 that is perpendicular to the top edge 22 and/or bottom edge 23. Similarly, where one or more of the crease lines 41 are arranged perpendicular to the top edge and/or bottom edge, the line of perforations 15 may be configured such that at least a portion of the line of perforations 15 is not parallel to the one or more of the crease lines 41 that are perpendicular to the top edge 22 and/or bottom edge 23.

In some embodiments, the orientation of the line of perforations 15 defining the tear line may be defined by reference to an axial direction, where the axial direction is aligned with the central axis of the resulting carton blank when it is subsequently rolled into a tube during a forming and filling process. Accordingly, the line of perforations 15 defining the tear line 14 is preferably arranged such that it is not parallel with the axial direction of the card outer blank 21.

It will be appreciated that the line of perforations 15 defining the tear line 14 may be arranged in any suitable way such that the resulting carton blank formed from the card outer blank 21 does not kink or buckle when formed into a tube during a subsequent forming and filling process. In preferred embodiments, the line of perforations 15 defining the tear line 14 extends through a panel, such as major side panel 26, that is not adjacent either of the opposing side edges 24, 25. In the embodiment of card outer blank 21 shown in FIG. 5, major sub panel 30, bottom end sub panel 38, and top end sub panel 33 are adjacent to side edge 25. Similarly, major sub panel 29, bottom end sub panel 37, and top end sub panel 32 are adjacent to side edge 24. The line of perforations 15 defining the tear line 14 preferably does not extend through any of the panels that are adjacent to either side edge 25 or 24. The inventors have appreciated that providing the line of perforations 15 defining the tear line 14 such that it does not extend through any panels adjacent to either side edge 24 or side edge 25 provides a resulting carton that is easier for a user to open in order to separate the liner 17 from the card outer 2. This is because the adhesive in the side seam 12 causes the card outer 2 and liner 17 to be strongly adhered in the region proximal to the side seam 12, thus making it more difficult to begin separating the liner 17 and the card outer 2 in this region. Therefore, arranging the line of perforations 15, and therefore the tear line 14, such that it is spaced from the side seam 12 of the resulting carton means a user can open the carton and begin separating the card outer 2 from the liner 17 in a region having less adhesive holding the liner 17 and card outer 2 together.

In some embodiments, the line of perforations 15 extends from a point at or adjacent to halfway along the top seam 11 of the resulting carton, to a point at or adjacent halfway along the bottom seam 110 of the resulting carton.

In some alternative embodiments, the line of perforations 15 defining the tear line 14 may extend from a point at or adjacent to one end of the top seam 11 of the resulting carton, to a point at or adjacent to one end of the bottom seam 110 of the resulting carton. The inventors have appreciated that such an arrangement can allow a user to begin peeling apart the top seam 11 and/or bottom seam 110 to separate the liner 17 from the card outer 2 from one side of the respective seam, thus making it easier and simpler to peel apart the seam and separate the liner

17 from the card outer 2. Where the resulting carton has a non-square cross-section, such as the brick-type carton 1 illustrated in FIG. 1. The brick-type carton 1 has wide major sides 6,7 and narrower minor sides 8, 9. Preferably, the line of perforations 15 defining the tear line 14 extends through a major side. It has been appreciated that providing the line of perforations 15 defining the tear line 14 extending through a major side of the carton 1 makes it easier for a user to open the carton 1 and separate the liner 17 from the card outer 2.

In preferred embodiments, the line of perforations 15 defining the tear line 14 is arranged such that it extends through a side of the carton 1 that is opposite the side seam 12. As discussed above, it may be more difficult to separate the liner 17 from the card outer 2 when opening the carton 1 in a region close to the side seam. Therefore, providing the line of perforations 15 extending through a side of the carton 1 opposite the side seam 12 ensures that the tear line 14 is suitably distanced from the side seam 12. In a preferred example, the card material of the card outer blank 21 is uncoated on its inner surface to permit conventional recycling of the card outer 2. Specifically, the card outer blank 21 preferably comprises a liquid packaging board. A liquid packaging board preferably comprises a multi-ply paperboard with strong wet sizing. Preferably, the edge or edges of the card outer blank 21 are resistant to the wicking of water or other liquids.

FIG. 6 illustrates a carton blank 43 that is formed by attaching a liner 17 to the card outer blank 21 of FIG. 5. The liner 17 is adhered to the card outer blank 21 to form a carton blank 43. The opening 3 is shown as a hidden detail as it is underneath the liner 17 as illustrated. In a preferred example, the liner 17 is a film material having a polymeric component. More preferably, the liner 17 is a laminate film material having a polymeric layer and a metallic layer, for example foil. However, in other examples the liner can be made of other materials, for example the metallic layer could be replaced by an ethylene vinyl alcohol (EVOH) film, which gives similar barrier properties. If EVOH were used as the barrier layer then a heat sealing system could be used to seal the liner, as described further hereinafter. As shown in FIG. 4, in this example the liner 17 is rectangular and has a top edge 44, a bottom edge 45 that are coincident, i.e. in line with, the top and bottom edges 22, 23 of the card outer blank 21 , respectively. The liner 17 also has a first side edge 46 that is coincident with a side edge 25 of the card outer blank 21. The liner 17 also has a second side edge 47. In preferred examples, the second side edge 47 is spaced from the corresponding side edge 24 of the card outer blank 21 , as illustrated. The liner 17 covers the majority of the surface area of the card outer blank 21.

The liner 17 is attached to the card outer blank 21 by adhesive about the periphery of the liner 17. As illustrated, bands of adhesive 48 are disposed along the first and second side edges 46, 47 of the liner 17, and bands of adhesive 49 are disposed along the top and bottom edges 44, 45 of the liner 17. In this example, the bands of adhesive 48, 49 extend about the entire periphery of the liner 17.

As shown in FIG. 6, an area of adhesive 50 is also provided over an area that surrounds the opening 3. By arranging the adhesive 48, 49 in this way, when the liner 17 is attached to the card outer blank 21 the area of card covered by the liner 17 is sealed. The bands of adhesive 48, 49 about the periphery of the liner 17 provide a seal to prevent liquids entering between the liner 17 and the card outer blank 21 at the edges 44, 45, 46, 47 of the liner 17. In the absence of sealing between the liner 17 and the card outer blank 21 , liquid may penetrate the card outer blank 21 during a sterilisation process in which the combined liner 17 and card outer blank 21 are immersed in a reservoir of sterilising fluid. The inventors have ascertained that adhesive need not be applied to cover the line of perforations 15 defining the tear line 14. The particular configuration of perforations used does not permit any significant ingress of sterilising fluid during the sterilisation process. Therefore, adhesive need only be applied around the periphery of the liner 17 and around the opening 3. Also shown in FIG. 4, a band of adhesive 52 is provided along the side edge 24 of the card outer blank 21. The adhesive may be a heat-reactivated glue that can be applied to the card outer blank. When the heat-reactivated glue is applied, the glue is absorbed into the card material. When the two opposing side edges 24,25 are brought together and the glue is subsequently heated, this causes the glue to activate and adhere the card outer material to form the side seam 12. The adhesive is preferably applied after the liner 17 is adhered to the card. Preferably, the band of adhesive 52 overlaps the side edge 47 of the liner 17, so that none of the material of the card outer 2 is exposed between the liner 17 and the adhesive 52. In alternative examples, the band of adhesive 52 is positioned adjacent to the side edge 47 of the liner 17. The adhesive 52 covers this area of the card outer blank 21 and so protects this part of- 11 -the card outer blank 21 against contact with the liquids or contamination. The adhesive 52 is provided to form the side seam (12, see FIG. 1 ) of the carton (1 , see FIG.1 ).

The inventors have appreciated that the in embodiments wherein the adhesive 52 is a heat- reactivated glue, the glue should preferably be applied along both side edge 24 and side edge 25. The heat-reactivated glue applied along side edge 25 should be applied on the opposite surface of the card outer blank to the heat-reactivated glue applied along side edge 24, such that when the card outer blank is subsequently formed into a tube, the glued surfaces meet. The inventors have appreciated that if the heat-reactivated glue is only applied to one of the side seams, the heat-reactivated glue 52 may not have sufficient time, when subsequently forming the carton on a high-speed form-filling machine, to re-flow and adhere the side seam 12.

In preferred embodiments, no adhesive is provided between the liner 17 and the card outer blank 21 over the region 53 covering the majority of their overlapping surface area -only in the bands 48, 49 extending about the periphery of the liner 17. In this way, the liner 17 can be separated from the card outer blank 21 with a manageable pulling force when the carton is opened via the tear line 14.

As explained above, once the liner 17 is adhered to the card outer blank 21 the adhesive 48, 49 provides a seal between the liner 17 and the side of the card outer blank 21 that the liner 17 is attached to. The carton blank 43 can then be sterilised, for example in a peroxide bath, without allowing ingress of sterilisation substances in between the liner 17 and the card outer blank 21, from where it would be difficult to remove before forming the carton 1. Sterilisation fluid may also damage the card outer blank 21 if it gets underneath the liner 17. It will be appreciated that by providing a carton 1 with a tear line 14 that allows the user to open the carton in a “book-like” manner, it is not necessary to form weak points in the liner 17 along the top edge 22 or bottom edge 23, for example to ensure that the liner 17 breaks at these points if a user were to try and remove the liner 17 from the carton 1 through the opening 3 without opening the carton 1. As explained further hereinafter, and as shown in FIGS. 1 to 4C, the carton 1 is formed by folding the carton blank 43 and forming sealed seams 11 , 12 between at edges of the carton blank 43.

In particular, the heat-reactivated glue 52 on the card outer blank 21 is joined to the heat- reactivated glue 52 on the opposing side edge 25 of the card outer blank 21 to form the side seam 12. After that, the top edges 22, 44 of the card outer blank 21 and the liner 17 are sealed to themselves to form the top sealed seam 11 , and the bottom edges 23, 45 of the card outer blank 21 and the liner 17 are sealed to themselves to form the bottom sealed seam. When forming the top and bottom sealed seams, the liner 17 is sandwiched between the card outer blank 21 , so that the edges 44, 45 of the liner 17 are incorporated into the top and bottom seams. Forming the top and bottom seams 11 creates the top and bottom flaps 13, which are then folded over, as shown in FIG. 1. In this way, the weight of liquid contained in the container is supported from the top seam. The increased thickness of card material, and adhesive, present in the top and bottom seams (and side seam) provide the majority of the structural rigidity of the resulting carton.

In an alternative example, the liner 17 also extends to, or towards, the side edge 24 of the card outer blank 21 , and so the edge 47 of the liner 17 is also trapped in the side seam 12 of the carton 1. In this example, an additional line of weakness may be provided in the liner 17 adjacent to the side edge 47. In some embodiments, a thin strip of sealing material may be positioned to overlay the edge 47 of the liner 17, the side edge 24 of the card outer blank 21 , or both prior to forming the carton 1. Preferably, the thin strip of sealing material is position so that approximately half of the strip overlaps the side edge 24 of the card outer blank 21 , the edge 47 of the liner, or both. When the carton blank 43 is formed into a tube during the process of forming the carton 1 , the overhanging piece of sealing material overlaps the opposite edge of the carton blank 43 and is affixed using adhesive. Thereby, the sealing material can act to seal the side seam 12. The sealing material may be polyethylene (PE) material, or any other suitable alternative. It will be appreciated that the sealing material can be initially fixed to either side of the carton blank 43. As shown in FIG. 7, when the carton blanks 43 are produced they are joined end-to-end in a web 57 that can be rolled into a reel. Specifically, in the web 57 of carton blanks 43 illustrated in FIG.

7 the individual blanks 43 are joined to each other along their top and bottom edges. In particular, the card outer blanks 21 are joined along their top and bottom edges 22, 23, and the liner 17 of each carton blank 43 is joined along its top and bottom edges 44, 45. As explained further hereinafter, this is achieved by manufacturing the web 57 from a web of card and a liner web that are joined together by the adhesive. The band of adhesive 52 (which forms the side seam 12) runs constantly along the edge of the web 57. The adhesive is disposed in the web 57 in bands extending:

In a constant band 58 adjacent to, abutting, or overlapping the band of adhesive 52. This constant band 58 forms the bands of adhesive 48 adjacent to the adhesive 52 on each carton blank 43.

In a constant band 59 along the opposing side edge of the web. This constant band 59 forms the bands of adhesive 48 along the opposing side edge 52, 46 of each carton blank 43. In transversely extending bands 60 across the web 57 at the boundary between two carton blanks 43. These transversely extending bands 60 form the bands of adhesive 49 at the top edges 22, 44 and at the bottom edges 23, 45 of the carton blanks 43.

The transversely extending bands of adhesive 60 are disposed such that a part of each transversely extending band of adhesive 60 is applied to the top edge 22, 44 of one carton blank 43, and the rest of the band of adhesive 60 is applied to the bottom edge23, 45 of the adjacent carton blank 43.

FIG. 8 shows a schematic diagram of a vertical form fill sealing apparatus 74. The vertical form fill sealing apparatus 74 receives the carton blank web 57 described above and forms and fills it to produce cartons such as the carton 1 described with reference to FIGS. 1 to 4C.

As illustrated, the carton blank web 57 is provided to the vertical form fill sealing apparatus 74 and the carton blank web 57 is initially formed into a vertically moving tube 75 by deforming the carton blank web 57 until the opposing side edges of the card outer 24, 25 overlap, with the band or bands of adhesive 52 being disposed between the opposing side edges 24, 25, as shown in FIG. 9. The carton blank web 57 is formed into a tube by using guides and/or guide rollers.

Heat and pressure rollers (not shown) act on the overlapping side edges 24, 25 of the carton blank web 57 to activate the adhesive 52, thereby joining the opposing side edges 24, 25 together to form the side seam 12 of the carton 1 (see FIGS. 1 to 4C).

A filling tube (not shown) extends into the vertical web tube 75 from above and the contents of the carton (e.g. juice) are dosed through the filling tube into the vertical web tube 75. The liquid is dosed sequentially with the end sealer assembly 77 described below.

As illustrated in FIG. 8, an end sealer assembly 77 forms the top seam 11 of a first carton 1a and the bottom seam 110 of a second carton 1 b simultaneously, while the contents are sequentially dosed into the second carton 1b. Preferably, the end sealer assembly 77 comprises an induction sealer 78 that induces heat in a metal component of the liner 17 to fuse the opposing parts of the liner 17 together to create the seams 11. The induction sealer comprises induction sealing bars 79 that are wide enough to create the top seam 11 of a first carton 1a and the bottom seam 110 of a second carton 1b simultaneously. Several stages of induction sealing may be provided, to ensure an intact seal. As illustrated in FIG. 8, the apparatus 74 has two stages of induction sealers 78.

In other examples, the liner 17 may not comprise a metal component, in which case the end sealer assembly 77 may comprise heat sealer bars that heat the liner material to form the seams. Alternatively, the carton blanks 43 of the web 57 are manufactured using adhesive for the top and bottom seams that can be heated and cured via induction. In such examples, the sealer assembly 77 comprises induction sealer bars that heat and cure the adhesive to form the seams.

In other examples, different types of sealers may be used to form the sealed seams 11,12. In particular, the sealers may by heat sealers, induction sealers, ultrasonic sealers, or other types of sealers, depending on the materials of the card web 63 and the liner web 68. In some examples, the sealers may apply adhesive to the carton blank web 57to form the seams 11, 12.

The formed cartons 1a are then individually cut off through the sealed seams 11.Preferably, one of the sealing bars 79, for example a sealing bar 79 of the final induction sealer 78, includes a cutting blade that separates the cartons 1a, 1b. The formed cartonsl then pass into a folding machine (not shown) that folds the top and bottom end flaps (13, see FIG. 1 ) into position to provide a formed carton 1 such as that illustrated in FIG. 1.

Advantageously, the vertical form fill sealing apparatus 74 is existing technology for laminate cartons that can also be used to produce the carton 1 of FIGS. 1 to 4C, from the carton blank web 57 described with reference to FIG. 7. Even more advantageously, the carton blank web 57 is configured such that the carton blank web 57 can be spliced into a vertical form fill sealing apparatus 74 that is presently producing other laminate cartons without needing to pause the vertical form fill sealing apparatus 74 so as to adjust one or more settings of the apparatus 74 to produce new cartons according to FIGS. 1 to 4C.

FIG. 10 shows an outer surface of a carton blank 43 that is the opposite side to that shown in FIGS. 3 to 6. As illustrated, areas of adhesive 80 may be provided to each carton blank 43 on the opposite side to the liner 17, i.e. on the outside of the cartonl. The adhesive 80 may be a heat- reactivated glue. These areas of adhesive 80 are provided for fixing the top and bottom end flaps (13, see FIG. 1 ) in position on the erected carton 1. The adhesive 80 is provided at each end of both minor side panels 27, 28, and on the sub panels 34, 35, 39,40 adjacent to the ends of the minor side panels 27, 28. After folding the end flaps (13, see FIG. 1 ) the areas of adhesive 80 can be heated to activate them and adhere the end flaps (13, see FIG. 1) in place on the carton 1.

FIG. 11 shows a carton 1101 according to an alternative embodiment of the present invention. The carton 1101 is formed of a card outer 112 and a liner 1117 (not shown). The liner 1117 is within the card outer 112 and holds the content of the carton.

The carton shown in FIG. 11 is wedge shaped, having a top end 114 and a bottom end 115, and opposing major sides 116 and 117.

In the embodiment shown in FIG. 11 , the card outer 112 does not include an opening. In order to open the carton 1101 to extract the content, a user may cut, pierce, or tear the carton 1101. For example, the user may use scissors to cut one of the corners on the top end 114.

The carton 1101 has three seams: a top seam 1111 which forms the top end 114 of the carton 1101 , a bottom seam (not shown) disposed on the bottom end 115 of the carton 1101, and a side seam 1112 (not shown) extending between the top seam 1111 and bottom seam through one of the major sides 116, 117, in this example major side 117. The formation of the top seam 1111 forms the top end 114 of the carton. The formation of the bottom seam is similar to the that of the brick-type carton 1 , and creates a pair of bottom flaps on the bottom end of the carton 1101. The bottom flaps are folded over onto the bottom end 115 of the carton 1101, and glued into their folded position.

The carton 1101 includes a tear line 1114, defined by a line of perforations 1115 in the card outer 112, which corresponds to the tear line 14 of the brick-type carton 1. The line of perforations 1115 extends from the top seam 1111 to the bottom seam, across one or both of the major sides

116, 117.

FIG. 12 shows a card outer blank 1221 for a carton blank 1110 for making the carton 1101 shown in FIG. 11. The card outer blank 1221 is rectangular and has a top edge 1222, a bottom edge 1223, and opposing side edges 1224, 1225. As shown, the card outer blank 1221 includes major side panel 1226. Major side panel 1226 forms both major sides 116 and 117 of the carton 1101. Opposing side edges 1224, 1225 are later joined together to form side seam 1112. The card outer blank 1221 also includes major bottom end panel 1236, and bottom-end sub panels 1237, 1238, 1239, 1240 that after the carton 1101 has been formed provide the bottom end 115 of the carton 1101 of FIG. 11. The bottom- end sub-panels 1239, 1240 are folded diagonally on forming of the carton 1101 of FIG. 11 to provide the bottom flaps.

The carton 1101 of FIG. 11 is formed by attaching a liner 1117 to the card outer blank 1221 of FIG. 12 to create a carton blank, then subsequent folding and adhering the seams to form the carton. FIG. 13 shows a further alternative embodiment of a carton 131. The carton 131 is a tetrahedron shape, having a top end and bottom end, and major side 137. Similarly to carton 1101 of FIG. 11 , the card outer 132 does not include an opening.

The carton 131 has three seams: a top seam 1311 which forms the top end 134 of the carton, a bottom seam 13110 which forms the bottom end 135 of the carton 131 , and a side seam (not shown) extending between the top seam 1311 and bottom seam 13110 through the major side 137. The formation of the top and bottom seams 1311, 13110 forms the top end 134 and bottom end 135 of the carton 131. As shown in FIG. 13, the top seam and bottom seam are arranged to be substantially perpendicular to each other to form the tetrahedron-shaped carton 131. The carton 131 includes a tear line 1314, defined by a line of perforations 1315 in the card outer 132. The line of perforations 1315 extends from the top seam 1311 to the bottom seam 13110, across the major side 137.

FIG. 14 shows a card outer blank 1421 fora carton blank 1310 for making the carton 131 shown in FIG. 13. The card outer blank 1421 is rectangular and has a top edge 1422, a bottom edge 1423, and opposing side edges 1424, 1425. In some alternative embodiments, the card outer blank 1421 may be a square. As shown, the card outer blank 1421 does not include panels, or crease lines such as those of card outer blank 21 of the brick-type carton 1 or card outer blank 1321 of the wedge-shaped carton 131.

To form the carton 141 , a liner is adhered to the card outer blank 1421 , then the opposing sides are joined to create the side seam 1412. The top edge 1422 and bottom edge 1423 are then used to form the top seam 1411 and bottom seam.

FIG. 15 shows a further alternative embodiment of a carton 151. The carton 151 is an asymmetrical brick-type carton, having a top end 154, a bottom end 155, and major sides 156, 157, 158, 159. The four major sides 156, 157, 158, 159 are of equal width. The length of major side 156 is less than that of opposing major side 157. As a result, the top end 154 of carton 151 is sloped towards the major side 156. The carton 151 has an opening 153. It will be appreciated that in other embodiments the carton 151 may not include an opening 153, and in such embodiments the user may open the carton 151 by cutting, piercing, or tearing the carton, or by opening one of the sealed seams. FIG. 16 shows a card outer blank 1621 fora carton blank 1510 for making the carton 151 shown in FIG. 15. The card outer blank is rectangular and has a top edge 1622, a bottom edge 1623, and opposing side edges 1624, 1625.

The configuration of the card outer blank 1621 corresponds substantially to the card outer blank 21 of FIG. 5. The card outer blank 1621 includes a major side panel 1626 corresponding to major side 6 of the carton 151 of FIG. 15. The card outer blank 1621 also includes first and second side panels 1627, 1628, corresponding to opposing major sides 158, 159 of the carton 151 of FIG. 15. The card outer blank 1621 also has two major sub panels 1629, 1630 that are later joined together at the side seam 1512 to form the major side 157 of the carton 151. The card outer blank also includes a major top end panel 1631 , and top end sub-panels 1632, 1633, 1634, 1635 that after the carton 151 has been formed provide the top end 154 of the carton 151 of FIG. 15. The major top end panel 1631 extends between top edge 1622 and major side panel 1626. As shown in FIG. 16, the major top end panel is larger in the dimension parallel to side edges 1624, 1625 that major sub panels 1629, 1630. The top end sub panels 1634, 1635 are shaped such that where they abut major top end panel 1631 and top end sub-panels 1632, 1633, their dimension matches that of the panel to which they are adjacent.

The card outer blank 1621 also includes an opening 163, as previously described. The opening 163 is formed in major top end panel 1631 so that the opening is formed in the position shown in FIG. 15. As illustrated, the card outer blank 1621 comprises a plurality of crease lines 1641 along the edges of each of the panels and along other fold lines, as described in relation to other embodiments.

The card outer blank 1621 includes the line of perforations 1615 that defines the tear line 1614 illustrated in FIG. 15. In this embodiment, the line of perforations extends from the top edge 1622, along the crease line 1641 formed in top end sub-panel 1635, and into major side panel 1626. From there, the line of perforations 1615 form a V-shape, with a central pull-tab section. The line of perforations 1615 then extends to the intersection of the major side panel 1626 and along the crease line 1641 formed in bottom end sub panel 1640, to bottom edge 1623.

The carton 151 of FIG. 15 is formed by attaching a liner to the card outer blank 1621 of FIG. 16 to create a carton blank, then subsequent folding and adhering the seams to form the carton.

FIG. 17 shows a further alternative embodiment of a carton 171. The carton is a pillow shaped carton, having a top end 174, a bottom end 175, and opposing major sides 176, 177. Similarly to carton 1101 of FIG. 11 and carton 131 of FIG. 13, the card outer 172 does not include an opening. The configuration of the seams 1711, 1712, 17110 and tear line 1714 of carton 171 is the same as that of carton 131. However, when forming the carton 171 of FIG. 17, the top seam 1711 and bottom seam 17110 are formed parallel to each other.

FIG. 18 shows a card outer blank 1821 fora carton blank 1710 for making the carton 171 shown in FIG. 17. The configuration of card outer blank 1621 is substantially the same as that of card outer blank 1421 of FIG. 14. FIG. 19 shows a further alternative embodiment of a carton 191. The carton 191 is an octagonal brick-type carton, having a top end 194, a bottom end 195, major sides 196, 197, 198, 199, and chamfered corner faces 1916a, 1916b, 1916c, 1916d . As illustrated, the carton 191 does not include an opening, however it will be appreciated that in alternative embodiments the carton 191 may include an opening. The carton includes a tear line 1914 defined by a line of perforations 1915. The configuration of the carton 191 including the seams and tear line 1914 is similar to that of the other carton embodiments described above.

FIG. 20 shows a card outer blank 2021 for a carton blank 2010 for making the carton 191 shown in FIG. 19. The configuration of the card outer blank 2021 is the same as the card outer blank 21 shown in FIG. 5, apart from the shape of the side panels. As shown in FIG. 20, major side panel 2026, side panels 2027, 2028, and major sub panels 2029, 2030 include a thinned section to accommodate the inclusion of minor chamfer panels 2043a, 2043b, 2043c, 2043d.

The carton 191 of FIG. 19 is formed by attaching a liner to the card outer blank 1921 of FIG. 16 to create a carton blank, then subsequent folding and adhering the seams to form the carton 191.

In this specification reference has been made to ‘adhesive’, ‘low tack glue’, and ‘heat-reactivated glue’. It will be appreciated that the ‘adhesive’ that joins the liner 17 to the card outer blank 21 about its periphery is a strong adhesive intended to provide a strong bond, not to be broken by the user during normal use of the carton 1. In preferred embodiments, the adhesive is intended to be stronger than the card material to which the adhesive is applied, so that when the user peals apart the top and bottom seam 110s to separate the liner 17, the adhesive also pulls away a top layer of the card material. In addition, the heat-reactivated adhesive is intended to provide a strong bond along the side seam 12 of the carton 1 , the bond not being intended to be broken a user during normal use. The low tack glue may have a low bonding strength, it may be applied onto to a small area of the liner 17/card outer blank 21 , or it may be a peel able or non permanent glue. Similarly, a ‘low weight’ adhesive is a thinner layer of adhesive, for example applied by a recessed gravure roller. The skilled person will be familiar with suitable adhesives, but preferred examples are acrylic emulsion adhesives or vinyl ethyl acetate adhesives. Preferably, the adhesives are heat activated.

It will be appreciated that the carton 1 described herein can be used to contain any liquid, including but not limited to juice, milk, water, and other foodstuffs.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for a superior carton, carton blank, and associated methods of manufacture. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.

Claims

1. A carton blank for use in a vertical form fill sealing machine, the carton blank comprising: a card outer having: a top edge, a bottom edge opposing the top edge, and two opposing side edges; a plurality of crease lines defining a plurality of panels; a tear line defined by a line of perforations, the tear line extending from at or adjacent the top edge, through one or more of the plurality of panels that are not adjacent to either of the two opposing side edges, to at or adjacent the bottom edge; and a liner attached to the card outer by an adhesive disposed about a periphery of the liner.

2. The carton blank of claim 1 , wherein the top edge is arranged to form a top seam of a carton, the bottom edge is arranged to form a bottom seam of the carton, and the two opposing side edges are arranged to be joined together to form a side seam of the carton extending between the top seam and the bottom seam.

3. The carton blank of claim 1 or claim 2, wherein the tear line is arranged such that, when the carton blank is formed into a carton, the tear line extends through a panel on the opposite side of the carton to a side seam of the carton.

4. The carton blank of any one of the preceding claims, wherein the line of perforations is a single, continuous line of perforations.

5. The carton blank of any one of the preceding claims, wherein the line of perforations comprises a straight line of perforations.

6. The carton blank of any one of the preceding claims, wherein the line of perforations comprises two or more segments, wherein each of the two or more segments is a straight line, the two or more segments being joined to form a continuous line of perforations.

7. The carton blank of any one of the preceding claims, wherein the line of perforations comprises a first segment and a second segment, wherein the first and second segments are straight lines of perforations.

8. The carton blank of any one of the preceding claims, wherein the line of perforations forms a rounded v-shape extending from at or adjacent the top edge to at or adjacent the bottom edge.

9. The carton blank of any one of the preceding claims, wherein the adhesive is disposed about the entire periphery of the liner.

10. The carton blank of any one of the preceding claims, wherein the adhesive is disposed only about the periphery of the liner.

11. A carton blank for use in a vertical form fill sealing machine, the carton blank comprising: a card outer having: a top edge, a bottom edge opposing the top edge, and two opposing side edges, the top edge being arranged to form a top seam of a carton, the bottom edge being arranged to form a bottom seam of the carton, and the two opposing side edges are arranged to be joined together to form a side seam of the carton extending between the top seam and the bottom seam; a tear line defined by a line of perforations, the tear line extending from at or adjacent the top edge, to at or adjacent the bottom edge; wherein the tear line is arranged such that, when the carton blank is formed into a carton, it extends through a side of the carton that does not include the side seam.

12. The carton blank of claim 11 , wherein the tear line is arranged such that, when the carton blank is formed into a carton, it extends through the opposite side of the carton to the side seam.

13. The carton blank of claim 11 or claim 12, wherein the line of perforations is a single, continuous line of perforations.

14. The carton blank of any one of claims 11 to 13, wherein the line of perforations comprises a straight line of perforations.

15. The carton blank of any one of claims 11 to 14, wherein the line of perforations comprises two or more segments, wherein each of the two or more segments is a straight line, the two or more segments being joined to form a continuous line of perforations.

16. The carton blank of any one of claims 11 to 15, wherein the line of perforations comprises a first segment and a second segment, wherein the first and second segments are straight lines of perforations.

17. The carton blank of any one of claims 11 to 16, wherein the line of perforations forms a rounded v-shape extending from at or adjacent the top edge to at or adjacent the bottom edge.

18. The carton blank of any one of claims 11 to 17, wherein the adhesive is disposed about the entire periphery of the liner.

19. The carton blank of any one of claims 11 to 18, wherein the adhesive is disposed only about the periphery of the liner.

20. A reel of carton blanks for use in a vertical form fill sealing machine, the reel of carton blanks comprising a plurality of carton blanks according to any one of claims 1 to 19.

21. The reel of carton blanks of claim 20, wherein the reel comprises a web of carton blanks having a plurality of carton blanks arranged longitudinally along the web and a plurality of carton blanks arranged laterally across the web.

22. A carton comprising a card outer and a liner formed from a carton blank according to any one of claims 1 to 19.

23. A carton comprising: a card outer comprising a line of perforations defining a tear line; a liner adhered to an inside of the card outer; and a top seam, a bottom seam, and a side seam extending between the top seam and the bottom seam; wherein the tear line extends from at or adjacent the top seam to at or adjacent the bottom seam on a side of the carton that does not contain the side seam.

24. The carton of claim 23, wherein the tear line extends through an opposite side of the carton to the side seam.

25. The carton of any one of claims 22 to 24, wherein the liner extends into one or more of the top seam, bottom seam, and side seam.

26. The carton of any one of claims 22 to 25, wherein the liner extends into all of the seams of the carton.

27. A method of manufacturing a carton according to any one of claims 22 to 26 using a carton blank according to anyone of claims 1 to 19, the method comprising: adhering the two opposing side edges together to form the side seam; adhering the top edge to itself to form the top seam; adhering the bottom edge to itself to form the bottom seam; folding the carton blank along the crease lines to shape the carton.

28. A method of processing a carton according to any one of claims 23 to 26, the method comprising: tearing the card outer along the tear line defined by the line of perforations; opening the top seam and bottom seam; and separating the liner from the card outer.