Patent Description:
The applicant markets food packaging containers of the "carton bottle" type under the names TETRA TOP® and TETRA APTIVA®. Containers of this type are described in <CIT> and <CIT> of the applicant. The containers are used for example to package liquid dairy products, juices, nectars and still drinks.

"Carton bottle" containers have a lower portion including base and side walls formed of packaging laminate (also referred to as the "bulb") and a plastics top portion (also referred to as the "dome") including an opening. In some cases a pre-formed opening device such as a screw top is included. Carton bottle containers can combine the advantages of packaging laminate based containers (e.g. use of renewal plant-based materials, good printability) with the advantages of plastics containers (e.g. design freedom in container shape, use of opening devices).

The packaging laminate typically comprises a core layer of paper or paperboard and one or more barrier layers of, for example, plastics (e.g. low density polyethylene LDPE) and/or aluminium foil. A sleeve of packaging laminate is prepared, either from a flat-laid tube-shaped blank or by forming a sheet around a mandrel and induction sealing to form a tube as the lower portion. The plastics top portion may be injection moulded directly onto a sleeve of packaging laminate. Alternatively, the plastics top portion may be pre-formed and sealed to the sleeve of packaging laminate. The plastics is typically a thermoplastic material such as polyethylene or polypropylene (e.g. high density polyethylene HDPE).

After the injection moulding step, the packaging container is conveyed with its open base directed upwards and is filled through the base in a subsequent filling station. The packaging container may be passed through one or several sterilisation stations before filling if required. After the filling step, the open base of the packaging container is folded and sealed to form a filled sealed container having a flat base.

During the filling and sealing steps, the container is supported with the open base uppermost within a sleeve-like cassette. The plastics top portion of the container is supported from beneath by a member referred to as a "volume plate" which engages the cassette. The volume plate contacts the plastics top portion.

Current carton bottles generally have planar and/or convex surfaces. The present applicant has appreciated that it is desirable to form carton bottles of different designs, and in particular to include concave portions.

Existing solutions are mentioned in the following patent documents.

<CIT> relates to a method and an apparatus for preventing the occurrence of bulging in gable top packages. During sealing of the gable top container, the container is squeezed, which creates a partial vacuum inside the container. After a certain period of time, the partial vacuum will release creating a gable top container with essentially straight walls. <CIT> relates to a method and an apparatus for injection moulding a shoulder section of an almost finished packaging container, where the shoulder section is located between the carton-based sleeve part and a polymer top part.

<CIT>, although not related to filling of gable-top containers, is similar to <CIT>. It discloses a product holding puck which holds a container from the bottom up to certain part of the body portion in place during the filling of the container.

In a first aspect, the invention relates to a method of filling and/or sealing a packaging container according to claim <NUM>.

As the skilled person will understand, the term "top portion" and "lower portion" as used herein relate to the normal orientation of the packaging container when filled, sealed and positioned on its closed base. During filling and sealing the container is inverted.

The term "dimensional stability" refers to maintaining the size and shape of the packaging container through filling and/or sealing so that the final container is substantially unchanged in size and shape compared with the container before filing and/or sealing except for its base being closed. In some preferred embodiments, an important aspect of dimensional stability is maintaining the shape of concave portions of the packaging container.

Preferably, the packaging container is filled with liquid food product. Preferred products including liquid dairy products, juices, nectars and still drinks e.g. water and milk drinks.

Preferably, the sealing step involves folding and sealing of packaging laminate using a transverse seal as known to the skilled person.

The top portion of the packaging container is of plastics and the lower portion of the packaging container is of packaging laminate (i.e. the container is a carton bottle), and the support engages the plastics top portion and the upstanding portion of the support engages part of the side walls(s) of the packaging laminate lower portion. The materials of the carton bottle may generally be as described in connection with known carton bottles above.

Preferably, the top portion includes an opening device (also referred to as a "lid" or "top") e.g. a screw or press fit opening device.

Preferably, the support engages the full perimeter of the top portion of the packaging container e.g. with the contact area forming a ring-like shape. This is useful in preventing rotation of the container.

The term "upstanding" includes a portion which extends in a direction substantially perpendicular to the main body of the support and/or substantially in the axial direction of the support, in particular in the upwards direction in use. Preferably, the upstanding portion of the support is at least one upstanding peg. For example one, two, three or four upstanding pegs may be present. In this and other preferred embodiments, the upstanding portion may engage only a part of the perimeter (around the side walls) of the packaging laminate lower portion. More preferably, the upstanding portion engages one or more corners of the lower portion of the packaging container.

Suitably, the lower portion is formed of a sleeve/tube of packaging laminate. The sleeve will typically have a longitudinal seal. The sleeve may be cylindrical with a constant cross-section e.g. square or rectangular in cross-section. "Cross-section" as used herein refers to a cross-section parallel to the base i.e. horizontal when the container is in the normal orientation supported on its closed base discussed above. A brick-like packaging container has a constant rectangular cross-section. Alternatively the sleeve may have a varying cross-section along its length e.g. it may be frustopyramidal or of a more complicated design.

Preferably, at least part of the lower portion of the packaging container is not rectangular in cross-section. This may be desirable for aesthetic reasons and/or to make the container easier or more comfortable to hold. The packaging container may for example have a rectangular e.g. square base but a non-rectangular cross-section away from the base. It is also preferred for the top portion not to be rectangular in cross-section. <NUM>, <NUM>, <NUM> or <NUM> right-angled corners may be present through some or all of the height of the packaging container. "Corner" as used herein refers to a change in direction within a cross-section of the container. Thus, a corner corresponds generally to an edge between side walls. A corner may have a sharp angle (which may be defined by a fold) or be rounded, including having a concave/inwards curve as explained below.

The packaging container may have planar or curved surfaces (including side walls, top and base). The packaging container may have a polyhedral cross-section so as to define multiple side walls e.g. it may be octagonal in cross-section or be of another shape with more than <NUM> sides. Where the packaging container has a curved cross-section only and no identifiable corners, a single side wall may be present. Curved surfaces of the packaging container may be convex and/or concave.

In a particularly preferred embodiment, the top portion and/or the lower portion of the packaging container comprises a concave portion and the support engages at least part of the concave portion. A concave portion is inwardly curved with respect to the container as a whole. A concave portion may help to make the packaging container easier to hold. Preferably, the concave portion is such that a cross-section of the packaging container has an inward curve. Preferably, the packaging container has a concave portion at one or more corners of the top portion and/or the lower portion; this profile need not extend for the full height of the top or bottom portion. However, a cross-section in the upper surface of the packaging container is also possible. Where a concave portion is present, support during filling and/or sealing is particularly important in ensuring dimensional stability, as explained below.

Alternatively or additionally, the packaging container may have one or more rounded corners in the top portion and/or at least part of the lower portion. Again, this profile need not extend for the full height of the top or bottom portion.

The packaging container may have a larger maximum cross-sectional dimension within its top portion than within its lower portion. The term "maximum cross-sectional dimension" refers to the longest linear distance across any cross-section (as defined above) within the specified portion.

The top portion and lower portion of the packaging container may be separable for recycling.

Preferably, the support is removably mounted to a cassette, the cassette providing further support for the packaging container during the filling and/or sealing step. The cassette is preferably of metal. The cassette may be cylindrical in shape, and may be a sleeve with the packaging container being inserted in use into the cassette, e.g. from above, and being held in place by friction fit. This is in contrast to the support which supports the packaging container from underneath. In some cases the packaging container may be loosely held within the cassette.

The cassette may comprise mounting means for the support e.g. rails. The cassette may have more than one mounting means such that the support can be mounted at different positions. The method may include steps of mounting the support to the cassette and/or removing the support from the cassette.

In a second aspect, the invention relates to an apparatus for use in a method as described above, the apparatus defined according to claim <NUM>.

Preferably the support is formed in a single piece. The support may be prepared by additive manufacturing (3D printing) or by moulding or casting. Preferably, the support is formed of polyoxymethylene (POM) or POE (polyoxyethylene).

The support portion may be in the form of a collar. The collar may include a ring from which the upstanding portion extends. As mentioned above, the upstanding portion is preferably a peg. The peg preferably has a convex cross-sectional profile towards the centre of the collar (i.e. where it will engage the packaging container) so as to complement a concave portion of the packaging container. The peg may have a straight, concave or convex cross-sectional profile toward the outside of the collar. For example, the peg may be oval in cross-section.

The mounting may comprise any suitable arrangement for removing engagement with the cassette. One example of the mounting is legs which co-operate with rails of the cassette.

The support may further comprise a grip member.

All features described in connection with any aspect of the invention can be used with any other aspect of the invention.

The invention will be further described with reference to a preferred embodiment, as shown in the drawings in which:.

A TT/<NUM>™ filling and sealing apparatus (not shown) is used to fill and seal a carton bottle <NUM> (also referred to herein as a "packaging container") prepared as described above.

The carton bottle <NUM> (<FIG>) has a lower portion formed of a sleeve of packaging laminate <NUM> and a plastics top portion <NUM> including a screw top opening device <NUM>. The sleeve of packaging laminate <NUM> will form the side walls <NUM> and closed base (not shown) of the final filled and sealed package as described in more detail below. The sleeve of packaging laminate <NUM> has a lower end (not shown) which is square in cross-section and an upper end <NUM> which is generally square in cross-section with rounded corners; at one corner <NUM> is a concave channel <NUM> starting near to the lower end and extending and widening to the upper end <NUM>. The cross-sectional dimensions of the sleeve of packaging laminate <NUM> at the upper end <NUM> are larger than at the lower end. The plastics top portion <NUM> is moulded and joins the sleeve of packaging laminate <NUM> at a seam <NUM>. The plastics top portion <NUM> generally extends the cross-section of the packaging laminate sleeve <NUM> including the concave channel <NUM> (also referred to herein as a "concave portion") via a shoulder region <NUM> to an upper surface <NUM> including an opening with screw threaded neck (not shown) to which the screw top opening device <NUM> is mounted.

The carton bottle <NUM> is formed up to the filling and sealing steps by the method described above.

The filling and sealing apparatus includes a metal cassette <NUM> (<FIG>) for conveying the carton bottle <NUM> with open base (not shown) uppermost. The cassette <NUM> comprises a cylindrical upper surround <NUM> with a flanged top edge <NUM> and a lower frame <NUM> having a C-shaped cross-section and being provided with several pairs of external rails <NUM> spaced along its height. The cassette <NUM> is sized such that a carton bottle <NUM> introduced into the cassette <NUM> via its flanged top edge <NUM> will be engaged by friction fit with the cylindrical upper surround <NUM> of the cassette <NUM>.

A support insert <NUM> (<FIG>); also referred to herein as a "support" and as a "volume plate") is mounted to the rails <NUM> of the cassette <NUM>.

The support insert <NUM> is formed in one piece of POM by three-dimensional printing. The support insert <NUM> includes a collar <NUM> (also referred to herein as a "support part") for supporting the carton bottle <NUM> and a mounting <NUM>. The collar <NUM> is in the form of a ring <NUM> which is approximately cylindrical but which narrows slightly in the downwards direction. The ring <NUM> is generally square with rounded corners; one corner <NUM> (front left in use when facing the apparatus) is concave and an upstanding peg <NUM> (also referred to herein as an "upstanding portion") of oval cross-section protrudes perpendicular from this corner <NUM> perpendicular to the ring <NUM> in the upwards direction so as to extend the concave profile. The inner profile <NUM> of the collar <NUM> is complementary to part of the outside profile of the carton bottle <NUM> such that when the carton bottle <NUM> is positioned on the collar <NUM> with its plastics top portion <NUM> downwards, the collar <NUM> engages the shoulder region <NUM> but not the upper surface <NUM> or opening device <NUM> of the plastics top portion <NUM>. The collar <NUM> also engages part of the packaging laminate sleeve <NUM>. More specifically, corner <NUM> engages the concave channel <NUM> of the plastics top portion <NUM> and upstanding peg <NUM> engages part of the length of the concave channel <NUM> of the packaging laminate sleeve <NUM>.

The mounting <NUM> of the support insert <NUM> takes the form of an integral mounting plate extending from the lower front edge (in use) of the collar <NUM> with a pair of legs <NUM> extending therefrom along the sides <NUM> of the collar <NUM>; the legs <NUM> are separated from the collar <NUM> by a pair of slots <NUM>. The front edge (in use) of the mounting plate <NUM> extends upwards into a grip member <NUM> having a semi-circular notch <NUM>.

In use, the support insert <NUM> is mounted to the cassette <NUM> by hand using grip member <NUM>. The slots <NUM> of the mounting <NUM> are slidably engaged with the C-shaped lower frame <NUM> of the cassette <NUM> such that the legs <NUM> are supported on one of the pairs of rails <NUM>.

A carton bottle <NUM> with open base uppermost is introduced into the cassette <NUM> via the flanged top edge <NUM> of the cassette <NUM> (<FIG>). The top portion <NUM> of the carton bottle <NUM> is engaged by friction fit with the cylindrical upper surround <NUM> of the cassette <NUM>. However, the packaging laminate sleeve <NUM>, of smaller cross-sectional dimensions, sits within the cylindrical upper surround <NUM> of the cassette <NUM> without close engagement.

The carton bottle <NUM> is orientated such that the concave channel <NUM> is aligned with the concave front corner <NUM> of the support insert <NUM> which has the upstanding peg <NUM>. Thus, the collar <NUM> of the support insert <NUM> engages the carton bottle <NUM>, with the ring <NUM> engaging the full perimeter of the plastics top portion <NUM> at the shoulder region <NUM> and the upstanding peg <NUM> engaging only the concave channel <NUM> of the packaging laminate sleeve <NUM>. The opening device <NUM> does not contact the support insert <NUM>. The open base of the packaging laminate sleeve <NUM> is held within the cylindrical upper surround <NUM> of the cassette <NUM>. The carton bottle <NUM> is thus well supported, particularly at its concave portions. The carton bottle <NUM> is prevented from rotating or moving vertically within the cassette <NUM>.

The carton bottle <NUM> is conveyed by cassette <NUM> to a filling station (not shown) and is filled through its open base with liquid food product (not shown). The support insert <NUM> provides counter pressure against the pressure of the filling liquid. This prevents filling from changing the shape of the carton bottle <NUM> by bulging, particularly at the concave channel <NUM>. In this way, dimensional stability of the carton bottle <NUM> is ensured.

The filled carton bottle <NUM> is conveyed by cassette <NUM> to a sealing station (not shown) and the open base is sealed with a transverse seal (not shown) and folded. Thus, side walls <NUM> and a closed base (not shown) are formed. Again, the support insert <NUM> provides counter pressure against the pressure of the liquid contents during volume displacement which may occur during sealing. This prevents sealing from changing the shape of the container by bulging, particularly at the concave channel <NUM>. In this way, dimensional stability of the carton bottle <NUM> is ensured.

In an alternative embodiment of the support insert <NUM> shown in <FIG>, upstanding peg <NUM> extends from a rear corner (in use) <NUM> of the support insert <NUM>.

The use of a support insert as in the preferred embodiments of the invention has the following advantages:.

Claim 1:
A method of filling and/or sealing a packaging container (<NUM>) comprising a packaging laminate and having a top portion (<NUM>) made of plastics and a lower portion (<NUM>) made of packaging laminate, including one or more side walls (<NUM>) and an open base, the method comprising:
- supporting the packaging container (<NUM>) with open base uppermost on a support (<NUM>) comprising an upstanding portion (<NUM>), wherein the support (<NUM>) engages the top portion (<NUM>) of the packaging container (<NUM>) and engages part of the one or more side walls (<NUM>) of the packaging container (<NUM>) via the upstanding portion (<NUM>) of the support (<NUM>); and
- filling the packaging container (<NUM>) via its open base and/or sealing the open base of the packaging container (<NUM>), wherein the support (<NUM>) ensures dimensional stability of the packaging container (<NUM>) during the filling and/or sealing step,
wherein the support (<NUM>) engages the plastic top portion (<NUM>) and the upstanding portion (<NUM>) of the support (<NUM>) engages part of the side wall(s) (<NUM>) of the packaging laminate lower portion (<NUM>).