Patent Publication Number: US-11643263-B2

Title: Unit of packaged product, and method of packaging a product

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This claims priority from Italian Application No. 102020000000226, filed Jan. 9, 2020, the disclosure of which is hereby incorporated by reference in its entirety. 
     FIELD OF INVENTION 
     This invention concerns a packaged product unit. The invention has been developed with particular regard to a packaged product unit which includes a straw that remains sealed in the package until the product is used. The invention also concerns a method of packaging a product. 
     TECHNOLOGICAL BACKGROUND 
     Units of packaged product are known, which include a straw that remains sealed in the package until the product is used. The straw remains protected inside the package until the package is opened and the straw is partially exposed so that, for example, the product can be sipped therethrough. The products can be of various types, although in this sector most products are edible. Examples of products typically packaged in units of the above type are edible liquids or pastes, such as fruit juices, syrups, milk-based drinks, and the like. 
     An example of packaging units of the above type is described in document WO 96/32342 by this Applicant. 
     The production of such a straw packaging unit is satisfactory, but rather complex. The use of the edible product is not very easy, because the user has to push the straw into the container to activate the communication of the straw with the liquid in the package. In addition, there is a risk of product spillage due to the pressure exerted on the straw. 
     SUMMARY OF THE INVENTION 
     The aim of the invention is to solve the problems of the known technique, and to provide a product unit of the above mentioned type, which is easy and economical to produce, reliable to fill and store and comfortable in use. In particular, the aim of the invention is to provide a packaged product unit in which it is not necessary to manoeuvre the straw in order to use the packaged product, which can therefore be easily accessed. Another aim is to avoid in a simple way that the product inside the container leaks externally along the straw. 
     Another purpose of the invention is to create a method for packaging a product in a product unit of the type indicated above, which is simple, economical and effective. 
     These and other purposes are achieved by the invention as discussed below. 
     According to a first aspect, a packaged product unit that includes a package with an inner cavity is described. The inner cavity can be formed by a pocket portion containing a product. The inner cavity can comprise an elongated portion. The pocket portion can communicate with the elongated portion. The elongated portion can contain a straw. The straw can have a proximal end that can lead into the pocket portion. The inner cavity of the straw can be in communication with the pocket portion. The product can fill the inner cavity of the straw. The distal end of the straw can be closed by a cap portion of the package, so that the product does not get out of the pack. The cap portion can be removed from the rest of the package to enjoy the product, for example, to sip it through the straw. The outer wall of the straw can be welded perimetrically to the package in a proximal sealing area. The proximal sealing area can be substantially at the proximal end of the straw. This can prevent the product from leaking from the pocket portion along the outer surface of the straw. The welding between the packaging and the straw makes them fully integral to each other, continuously sealedly along an annular portion of the straw. 
     According to one particular aspect, the outer wall of the straw can have a corrugation at its proximal end. The corrugation can facilitate the hold of the welding in the proximal sealing area between the outer wall of the straw and the packaging. 
     In another particular aspect, the package can comprise a weakening that defines at least one line of separation of the cap portion from the remainder of the package. In use, it is possible, for example, to twist the cap portion to open the package by exposing the distal end of the straw and thus enjoy the product, e.g. to sip it through the straw. The weakening can be interposed between the proximal sealing area and the distal end of the straw, so that when the package is opened the proximal sealing area remains intact and retains its sealing function, preventing leakage of the product from the pocket portion along outside of the straw. The weakening can be adjacent to the proximal sealing area so that as much of the straw as possible is exposed when the package is opened without compromising the sealing in the proximal sealing area. 
     In another respect, the distal end of the straw can include a breakable portion. The breakable portion can be welded perimetrically to the cap portion of the package in a distal sealing area to seal the distal end of the straw. Sealing the distal end of the straw can prevent the product from leaking out of the inner cavity of the straw. In use, the cap portion of the package can be removed along with the breakable portion of the straw that is welded to the cap portion, leaving the remaining portion of the straw exposed for use. 
     The distal end of the straw can be externally corrugated to facilitate the hold of the welding at the cap portion of the package. The straw can in any case be symmetrical with respect to its median transverse plane, to favour the manufacturing process of the product unit, without the need to mark or select an orientation to introduce the straw into the package cavity. 
     According to another aspect, the package can be formed by two opposing shells. The opposing shells can be welded to each other along a continuous seal. The continuous seal can advantageously incorporate the proximal sealing area between the proximal end of the straw and the package. In case the distal sealing area between the distal end of the straw and the cap portion of the package is provided, the continuous seal between the two opposing shells can advantageously incorporate the distal sealing area of the straw. 
     The package and the straw can both be made of a plastic material, e.g. a thermoplastic material, which facilitates easy and complete welding between the package and the straw where it is required. 
     In another aspect, a method of packaging a product is described. The method can involve the preparation of a package according to one or more of the above mentioned aspects. The package can then include an inner cavity formed by a pocket portion that communicates with an elongated portion. The package can include an access opening for access to the internal cavity. The packaging method can involve inserting a straw into the elongated portion of the inner cavity, so that a proximal end of the straw leads into the pocket portion and a distal end of the straw is closed by a cap portion of the package. The method can also involve welding perimetrically the outer wall of the straw to the package in a proximal sealing area at the proximal end of the straw to prevent subsequent leakage of product from the pocket portion along the outer surface of the straw. The method can also involve filling the pocket portion with a product through the access opening to the inner cavity. The method can also include welding the access opening to close the internal cavity in which the product is packaged. 
     According to one particular aspect, the distal end of the straw can include a breakable portion. This breakable portion can be welded perimetrically to the cap portion of the package in a distal sealing area before the pocket portion is filled with the product. 
     In another particular aspect, the package can be formed by welding two opposing shells against each other along a continuous sealing. The welding of the package to the straw in the proximal sealing area can be incorporated into the continuous seal of the package, thus forming a whole therewith. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further characteristics and advantages will be evident from the following detailed description of a preferred embodiment, with reference to the attached drawings, given by way of non-limiting examples: 
         FIG.  1    is a perspective view of a group of packaged product units, incorporating one or more aspects of the present invention, 
         FIG.  2    is a longitudinal section of the packaged product unit group in  FIG.  1   , 
         FIG.  3    is a front view of a straw used in each of the packaged product units shown in  FIGS.  1  and  2   , 
         FIG.  4    is a longitudinal section of the straw of  FIG.  3   , 
         FIG.  5    is a longitudinal section of one of the packaged product units of  FIGS.  1  and  2   , in the configuration where the straw is partially exposed for use, 
         FIG.  6    is a longitudinal section, similar to  FIG.  2   , of a variant of the packaged product unit group of  FIG.  1   , 
         FIG.  7    is a front view of a straw used in each of the packaged product units of  FIG.  6   , 
         FIG.  8    is a longitudinal section of the straw of  FIG.  7   , 
         FIG.  9    is a longitudinal section of one of the packaged product units in  FIG.  6   , in the configuration where one end section of the straw is removed together with a cap portion of the pack, leaving the remaining part of the straw partially exposed for use. 
     
    
    
     DETAILED DESCRIPTION 
     With reference now to  FIGS.  1  and  2   , a group  1  of units of a packaged product P is shown. Each unit comprises a package  2  inside which a straw  3  is closed and remains sealed in the package  2  until someone wishes to enjoy the product, for example by sipping it through the straw  3  in case of an edible product. Other possible non-food uses can involve a pharmaceutical or parapharmaceutical product, for example eye drops or a disinfectant, or an industrial product, for example a lubricating oil, which can be dispensed through the straw  3 . It is convenient to produce the various units of product packaged in groups  1  in which the various units are made, for example, from a long plastic film, and are joined to each other along one or more portions of their edges. The units of product packaged in this way can then be supplied to the market either individually, after separating them from each other, or in groups, keeping them together in a determined number. 
     The packages  2  are made with two opposing shells  2   a ,  2   b , e.g. symmetrically opposed shells of any shape, preferably made of plastic, e.g. from a folded film or two opposing films, welded together according to techniques generally known in the field, as described for example in document WO 96/32342 of this Applicant. Opposite shells  2   a ,  2   b  can be joined together by continuous sealing  4 , preferably hot sealing, along part of their outer edge, e.g. in the longitudinal median plane of the package  2   
     The package  2  of each unit of packaged products defines a respective inner cavity  5 , large enough to contain the product and preferably, but not limited to, larger than the quantity of product so as to take into account the increase in volume of the product if it is to be subsequently frozen. The inner cavity  5  is formed within a pocket portion  6  and has an opening  2 A through which product exits. The pocket portion  6  extends downwards into an elongated portion  7  package  2  which serves as a seat for the straw  3 , the proximal end  3   a  of which is in communication with the inner cavity  5  of the pocket portion  6  via the opening  2 A. 
     The straw  3  is completely inserted into the elongated portion  7  so that the distal end  3   b  of straw  3  is plugged by the continuous sealing  4  of package  2 . The straw  3  is preferably press-fitted into the elongated portion  7  through an opening  8  which is sealed, as shown in the drawings, after the product P has been introduced into cavity  5 . The elongated portion  7  can also be made slightly narrower or tapered with respect to the outer diameter of the straw, creating a slightly interfering fit so that the straw is planted in the elongated portion  7  so that product P does not escape from the distal end  3   b  before the container  2  is opened. 
     To open the container  2 , a weakening  9  is provided along the continuous sealing  4 , which can be made with a V notch that reduces the width of the continuous sealing, as shown in the figures. Another solution to make the weakening  9  is to make a fracture line or pre-cut on the material of the container  2 . The weakening  9  defines a portion of cap  10  in the package  2 , which in the example of the figures includes an end tab  10   a . As can be seen in  FIG.  5   , the weakening  9  allows one to break the package  2  at the weakening  9 , e.g. by twisting the cap portion  10  by grasping it on the end tab  10   a , so that the distal portion  3   b  and a large part of the straw  3  through which the product P contained in the package  2  can be enjoyed is exposed. 
     The straw  3  can be made of a plastic material, and in particular of the same plastic material as the shells  2   a ,  2   b , or in any case of a material that can be easily welded to them, preferably heat-welded. In this respect, the package  2  is welded to the straw  3  at its proximal end  3   a . More precisely, the shells  2   a ,  2   b  of the package  2  are welded to the outer wall of the straw  3  along its entire periphery, thus forming a proximal sealing area  11  where the material of the straw  3  blends with that of shells  2   a ,  2   b  to form a sealing ring that extends from the proximal end  3   a  of straw  3  along a certain length, e.g. about a third of its length. In this way, leakage of product P from the pocket portion  6  along the outer surface of the straw  3  is prevented. In the case of an edible product P to be sipped through the straw  3 , it is advantageous to design the container  2  in such a way that the weakening  9  is just below the proximal sealing area  11 , so that the portion of straw  3  which remains exposed after the breakage of the cap portion  10  is long enough to allow the product P to be comfortably sipped without getting the lips too close to the remaining portion of container  2  after the breakage of the weakening  9  and the removal of the cap portion  10 . 
     To facilitate welding of straw  3  to container  2 , the upper end  3   a  of the straw has a corrugation  12   a , as can also be seen in  FIGS.  3  and  4   . The corrugation  12   a  can be shaped as a series of ridges and/or annular grooves, or as a knurling, or other design that creates a certain roughness on the outer wall of the straw  3  at the top end  3   a.    
     Preferably, the distal end  3   b  of the straw  3  also has a similar corrugation  12   b , thus being symmetrical with respect to its median transverse plane. In this way, it is not necessary to specifically mark or orient the straws  3  in the production of pack  2 , which can thus be introduced into the elongated portion  7  indifferently oriented in either direction, without the need to select their introduction orientation in advance. In other words, the ends of the straw  3  are equal and undifferentiated before the introduction of the straw  3  into the elongated portion  7  of the inner cavity  5 , while they assume the roles of proximal portion  3   a  and distal portion  3   b  respectively, after the straw  3  has been inserted firmly and permanently into the elongated portion  7 . The presence of the corrugation  12   b  on the distal end  3   b  of the straw  3  also favours the holding of the sealing in correspondence of the cap portion  10  of the package. 
     In the manufacture of the packaged product units described above, the packages  2  are made from, for example, two opposing plastic films or a plastic film folded to form two opposing flaps. The opposing films or flaps form the half-shells  2   a ,  2   b  of the package  2 , and are heat-welded along predefined contour lines to form most of the continuous sealing  4 , except in the upper area which remains open to form opening  8 . By a known method, e.g. pressure forming, the inner cavity  5  is made which includes the pocket portion  6  and the elongated portion  7 . From the upper opening  8 , the straw  3  is introduced, which is inserted deeply into the elongated portion  7 . After the straw  3  is in place, the package  2  is heat-welded onto the straw  3  in the sealing area  11  located at the proximal end  3   a  of the straw, preferably just above the weakening  9 , for the reasons mentioned above. The welding in the sealing area  11  is preferably carried out with the aid of a hot pressing mould or vice. Subsequently, the product P is introduced into the cavity  5  through the upper opening  8 , which is then heat-welded to restore the integrity of the continuous sealing  4  along the entire contour of package  2 . 
       FIGS.  6  and  9    show a variant of product unit P, comprising a package  22  inside which a straw  23  is closed and which, as in the case described above, remains sealed in the package  22  until the product is used. This variant is subject to the same considerations as previously described, except for the differences that will be expressly indicated or will be evident to a technician in the field reading the present description. Identical reference numbers identify features which are identical to those described above. 
     Again, the packages  22  are preferably made with two opposing shells, joined together by a continuous sealing  4 . A straw  23  is inserted completely into the elongated portion  7  so that the distal end  23   b  of the straw  23  is plugged by the continuous sealing  4  of pack  22 . As can also be seen in  FIGS.  7  and  8   , the distal end  23   b  of the straw  23  includes a breakable section  24   b  defined for example by a weakening annular groove  25  on the wall of the straw  23 . The corrugation  12   b  preferably extends from the distal end  23   b  along the entire breakable section  24   b  and beyond the weakening annular groove  25  to continue on a section of the outer wall of the straw  23  beyond the breakable section  24   b . For reasons of symmetry, as described above, there is also a breakable section  24   a  at the proximal end  23   a  of the straw  23  defined by a similar weakening annular groove  25  and affected by corrugation  12   a  which also extends over a section of the outer wall of the straw  23  beyond the breakable section  24   a.    
     In the container  22 , the welding of the distal end  23   b  of the straw  23  to the cap portion  10 , particularly in the area of the tab  10   a , is carried out in the same way and preferably at the same time of the sealing area  11  near or at the proximal end  23   a  of the straw  23 . In this way a distal sealing area  26  is formed which only affects the breakable section  24   b  of the straw  23 . The welding of the material of straw  23  to that of the container  22  in the distal sealing area  26  ensures the sealed plugging of the distal end  23   b  of the straw  23 , so that the product P in the inner duct of the straw  23  does not leak outside the distal end  23   b  of the straw  23 . 
     When using the container  22 , a twist on the cap portion  10 , and in particular on the tab  10   a , causes both the fracture of the weakening  9  previously described and the fracture of the distal breakable section  24   b  of the straw  23 , which remains attached to the cap portion  10  as shown in  FIG.  9   , exposing the end of the straw  23  starting from the weakening annular groove  25  where the straw  23  broke when the container  22  was opened. 
     Naturally, without prejudice to the principle of the invention, the embodiments and the details of realisation can vary widely with respect to what has been described and illustrated, without departing from the scope of the present invention.