Patent ID: 12258185

It should be understood that the drawings are not intended to limit the invention to the subject-matter depicted in the drawings.

In the drawings, like reference numerals have been used to indicate common parts, elements or features unless otherwise explicitly stated or implicitly understood by the context.

DETAILED DESCRIPTION

In the following, specific embodiments of a blank and a container produced therefrom will be described in more detail with reference to the drawings. However, it is specifically intended that the invention as defined in the following claims is not limited to the embodiments and illustrations contained herein but includes modified forms of the embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the claims.

FIG.1shows a first embodiment of a blank10for producing a sleeve and, subsequently, a container for holding a pourable food product.

The blank10can comprise several layers of different materials, for example paper, paperboard, plastic or metal, in particular aluminium. Typically, the blank10may be made from a paper-based or paperboard-based laminate sheet material comprising a multi-ply paperboard sheet on which is laminated one or a plurality of barrier layers for holding the food product and/or prevent migration of air and flavours through the paperboard sheet.

The blank10has several crease or fold lines which are intended to facilitate the folding of the blank10when produced to form a container and which divide the blank10into several regions and sub-regions.

The blank10comprises rectilinear or substantially rectilinear first12and second14boundary edges which are parallel or substantially parallel to a longitudinal direction L of the blank10. The boundary edges12and14are parallel or substantially parallel, of equal or substantially equal length and form lateral boundary edges of the blank10.

A central axis Caof the blank10extends parallel to the longitudinal direction L equidistant from the lateral boundary edges12and14.

The blank10also comprises a rectilinear or substantially rectilinear third boundary edge16which is parallel or substantially parallel to a transversal direction T of the blank10extending perpendicular to the longitudinal direction L. The boundary edge16extends between first, bottom endpoints18,20of the lateral boundary edges12,14and forms a bottom boundary edge of the blank10.

The blank10further comprises a fourth boundary edge22extending between second, top endpoints24,26of the lateral boundary edges12,14and forming a top boundary edge of the blank10.

The bottom endpoints18and20form bottom corner points of the blank10and the top endpoints24and26form top corner points. Since the lateral boundary edges12and14are parallel or substantially parallel, and since the bottom boundary edge16is perpendicular or substantially perpendicular to the lateral boundary edges12,14, the corner points18,20,24,26define a rectangular or substantially rectangular shape. In contrast to the bottom boundary edge16, however, the top boundary edge22is non-rectilinear and extend beyond the rectangular shape defined by the corner points18,20,24,26.

The top boundary edge22comprises a plurality of individually rectilinear or substantially rectilinear sections22a-22i.

The top boundary edge sections22aand22iare colinear or substantially colinear and extend, starting from the top corner points24and26, respectively, parallel or substantially parallel to the transversal direction T, i.e. parallel or substantially parallel to the bottom boundary edge16. The edge sections22aand22iare of equal or substantially equal length. The edge sections22band22hextend from edges sections22aand22i, respectively, and angle away from the bottom boundary edge16. The edge sections22band22hform an angle of approximately 45 degrees to the transversal direction T. The edge sections22cand22gextend from edges sections22band22i, respectively, and form an angle of approximately 20 degrees to the transversal direction T. The edge sections22dand22fextend from edges sections22cand22g, respectively, and form an angle of approximately 45 degrees to the transversal direction T. The edge section22e, finally, extends between edge sections22dand22fparallel or substantially parallel to the transversal direction T, i.e. parallel or substantially parallel to the bottom boundary edge16. However, due to the inclined orientations of edge sections22b-22dand22f-22h, edge section22eis arranged further from the bottom boundary edge16than are the edge sections22aand22i.

The top boundary edge22is reflection-symmetric about the central axis Ca. In other words, using the central axis Caas an axis of symmetry, the sections of the top boundary edge22located on one side of the central axis Cais mirrored by the corresponding sections located on the other side. Consequently, edge sections22a,22b,22cand22dare mirrored by edge sections22i,22h,22gand22f, respectively, and the central axis Carun centrally through the edge section22e.

The blank10comprises first28and second30crease lines, each extending across the blank10, i.e. between the lateral boundary edges12,14. The crease lines28and30divide the blank10into:a bottom region32having a bottom crease line pattern and being configured to form a bottom portion of the container formed from the blank10;a top region34having a top crease line pattern and being configured to form a top portion of the container; andan intermediate region36contained between said first28and second30crease lines, interposed between the bottom region32and the top region34and being configured to form an intermediate, wall portion of the container.

The crease line28is rectilinear or substantially rectilinear and extends parallel or substantially parallel to the transversal direction T across the panel10.

Partitioned from the intermediate region36by crease line28, the bottom region32comprises a plurality of rectangular or substantially rectangular bottom panels40a,40fand40kand a plurality of triangular or substantially triangular gusset panels40b-40eand40g-40j. The gusset panels40b-40eand40g-40jare arranged in two rectangular or substantially rectangular sub-regions arranged in file with the bottom panels40a,40fand40k. When a container is produced from the blank10, the bottom and gusset panels40a-40kare configured to be folded to form a substantially planar bottom of the container in a manner which is, as such, known in the art.

The bottom region32also comprises a plurality of rectangular or substantially rectangular bottom sealing band panels38a-38gextending between the lateral boundary edges12,14. The sealing band panels38a-38gare partitioned, in the transversal direction T, by longitudinal or substantially longitudinal crease lines. The sealing band panels38a-38gform a bottom sealing band38that extends along the bottom boundary edge16and is partitioned from the bottom and gusset panels40a-40kby a rectilinear or substantially rectilinear crease line42extending across the blank10parallel or substantially parallel to the transversal direction T. When a container is produced from the blank10, the sealing band panels38a-38gare configured to be sealed to each other to form a bottom seal of the container in a manner which is, as such, known in the art.

Turning now to the top region34of the blank10, the crease line30comprises a plurality of crease line sections30a-30e, of which crease line sections30a,30b,20dand30eare individually rectilinear or substantially rectilinear and crease line section30cis curvilinear. The crease line sections30aand30eare colinear or substantially colinear and extend, starting from lateral boundary edges12and14, respectively, parallel or substantially parallel to the transversal direction T, i.e. parallel or substantially parallel to the edge sections22aand22i. The crease line sections30aand30eare of equal or substantially equal length. The crease line sections30band30dextend from crease line sections30aand30e, respectively, and angle towards the bottom boundary edge16. The crease line sections30band30dform an angle of approximately 30 degrees to the transversal direction T. Crease line sections30band30dare of equal or substantially equal length. Finally, crease line section30cextends between crease line sections30band30dand has a convex side facing the intermediate region36.

Similar to the top boundary edge22, the crease line30is reflection-symmetric about the central axis Ca. In other words, using the central axis Caas an axis of symmetry, the sections of the crease line30located on one side of the central axis Cais mirrored by the corresponding sections located on the other side. Consequently, crease line sections30aand30bare mirrored by crease line sections30eand30d, respectively, and the central axis Carun centrally through the crease line section30c.

Partitioned from the intermediate region36by crease line30, the top region34comprises triangular or substantially triangular gusset panels44aand44barranged on one side of the central axis Caand corresponding triangular or substantially triangular gusset panels44cand44d, partitioned by a rectilinear or substantially rectilinear crease line48, arranged on the other side. The gusset panels44aand44bare partitioned by a rectilinear or substantially rectilinear crease line46. The gusset panels44cand44dare partitioned by a rectilinear or substantially rectilinear crease line48. Crease line46connects to crease line30at the intersection of crease line sections30band30c, and crease line48connects to crease line30at the intersection of crease line sections30dand30e. Gusset panels44aand44bare equilateral and configured to be folded onto each other when the blank10is folded to form the container. Consequently, gusset panels44aand44bare reflection-symmetric with respect to crease line46, i.e. using crease line46as an axis of symmetry. Likewise, gusset panels44cand44dare equilateral and reflection-symmetric with respect to crease line48, thus allowing gusset panels44cand44dto be folded onto each other when the container is formed.

Gusset panels44aand44care partitioned from the intermediate region36by crease line sections30band30e, respectively.

The top region34also comprises a top panel50arranged between gusset panels44band44d. Top panel50is partitioned from gusset panel44bby a rectilinear or substantially rectilinear crease line52and from gusset panel44dby a rectilinear or substantially rectilinear crease line54. Crease line52connects to crease line30at the intersection of crease line sections30band30c, and crease line54connects to crease line30at the intersection of crease line sections30dand30e. Crease lines52and54are not perfectly parallel to the central axis Cabut converge slightly when moving along the crease lines52and54towards the intermediate region36. Crease lines52and54form an angle to the central axis Caof approximately 3 degrees.

The top panel50is partitioned from the intermediate region36by crease line30c. Consequently, the bottom boundary of the top panel50, i.e. the boundary of the top panel50facing the intermediate region36, is convex.

The gusset panels44a-44dand the top panel50are arranged reflection-symmetric or substantially reflection-symmetric about the central axis Ca. In other words, using the central axis Caas an axis of symmetry, gusset panels44aand44bare mirrored by gusset panels44cand44d, respectively, and the central axis Caruns centrally through the top panel50.

The top region34further comprises top sealing band panels56a-56gforming a top sealing band56extending along the top boundary edge22of the blank10. When a container is formed from the blank10, the top sealing band panels56a-56gare configured to be sealed to each other to form a top seal of the container, as will be discussed in more detail later in the disclosure.

Sealing band panel56aextends from lateral boundary edge12and runs between crease line section30aand boundary edge section22a. In a corresponding manner, sealing band panel56gextends from lateral boundary edge14and runs between crease line section30eand boundary edge section22i.

Sealing band panel56bextends from sealing band panel56aand runs between gusset panel44aand boundary edge section22b. In a corresponding manner, sealing band panel56fextends from sealing band panel56gand runs between gusset panel44cand boundary edge section22h. Sealing band panel56bis partitioned from gusset panel44aby a rectilinear or substantially rectilinear crease line section58aand from the neighbouring sealing band panel56aby a rectilinear or substantially rectilinear crease line60. Crease line60extends between the intersection of boundary edge sections22aand22band the intersection of crease line sections30aand30b. Crease line60forms an angle of approximately 15 degrees to the longitudinal direction L. Crease line section58aforms an angle of approximately 30 degrees to the longitudinal direction L. Sealing band panel56fis partitioned from gusset panel44cby a rectilinear or substantially rectilinear crease line section58eand from the neighbouring sealing band panel56gby a rectilinear or substantially rectilinear crease line70. Crease line70extends between the intersection of boundary edge sections22iand22hand the intersection of crease line sections30eand30d. As crease line60, crease line70forms an angle of approximately 15 degrees to the longitudinal direction L but angled in the opposite direction as compared to crease line60. Crease line section58eforms an angle of approximately 30 degrees to the longitudinal direction L but angled in the opposite direction as compared to crease line section58a.

Sealing band panel56cextends from sealing band panel56band runs between gusset panel44band the combined extent of boundary edge sections22cand22d. In a corresponding manner, sealing band panel56eextends from sealing band panel56fand runs between gusset panel44dand the combined extent of boundary edge sections22gand22f. Sealing band panel56cis partitioned from gusset panel44bby a rectilinear or substantially rectilinear crease line section58band from the neighbouring sealing band panel56bby a rectilinear or substantially rectilinear crease line62. Crease line62extends between the intersection of boundary edge sections22band22cand the intersection of crease line sections58aand58b. Crease lines62and46are collinear or substantially collinear and form an angle of approximately 25 degrees to the longitudinal direction L. Crease line section58bforms an angle of approximately 85 degrees to the longitudinal direction L. Sealing band panel56eis partitioned from gusset panel44dby a rectilinear or substantially rectilinear crease line section58dand from the neighbouring sealing band panel56fby a rectilinear or substantially rectilinear crease line68. Crease line68extends between the intersection of boundary edge sections22hand22gand the intersection of crease line sections58eand58d. Crease lines68and48are collinear or substantially collinear and form an angle of approximately 25 degrees to the longitudinal direction L but angled in the opposite direction as compared to crease lines62and46. Crease line section58dforms an angle of approximately 85 degrees to the longitudinal direction L but angled in the opposite direction as compared to crease line section58b.

Finally, sealing band panel56dextends between sealing band panels56cand56eand runs between top panel50and boundary edge section22e. Sealing band panel56dis partitioned from top panel50by a rectilinear or substantially rectilinear crease line section58cand from the neighbouring sealing band panels56cand56eby rectilinear or substantially rectilinear crease lines64and66, respectively. Crease line64is parallel or substantially parallel to the longitudinal direction L and extends between the intersection of boundary edge sections22dand22eand the intersection of crease line sections58band58c. Crease line66is also parallel or substantially parallel to the longitudinal direction L but extends between the intersection of boundary edge sections22fand22eand the intersection of crease line sections58dand58c. Crease line section58cand boundary edge section22eare parallel or substantially parallel.

The sealing band56is reflection-symmetric about the central axis Ca. In other words, using the central axis Caas an axis of symmetry, sealing band panels56a,56b,56care mirrored by sealing band panels56g,56f,56e, respectively, and the central axis Caruns centrally through sealing band panel56d.

The top panel50comprises a removable section72delimited by a loop of weakness74allowing section72to be removed from the container formed from the blank10when the container is initially opened. This opening action will be discussed in more detail later in the disclosure. The loop of weakness74may, for example, be a so-called “half-cut”, i.e. a cut made partially through the laminated substrate of the blank10from the outside surface thereof leaving one or a plurality of inner layers of the laminated substrate intact to provide, prior to a first opening of the container produced from the blank10, an uninterrupted barrier against a food product to be contained in the container.

Turning now to the intermediate region36of the blank10, this region comprises panels76a-76epartitioned by crease lines82a-82d.

Panel76cis configured to form a front wall panel of a container produced from the blank10. Neighbouring panel76c, the intermediate region36comprises panels76band76dwhich are configured to form side wall panels of the produced container. The panel76cis partitioned from the panel76dby a rectilinear or substantially rectilinear crease line82cand from panel76bby a rectilinear or substantially rectilinear crease line82b.

The intermediate region36further comprises panel76aneighbouring panel76band a fifth panel76eneighbouring panel76d. Panels76aand76eare configured to form rear wall panel sections of the produced container. Panel76ais partitioned from panel76bby a rectilinear or substantially rectilinear crease line82aand panel76eis partitioned from panel76dby a rectilinear or substantially rectilinear crease line82d.

Crease line82cextends between crease line28and the intersection of crease line sections30cand30d. Crease line82bextends between crease line28and the intersection of crease line sections30band30c. Starting from the top region34and moving towards the bottom region32, crease lines82band83cconverge. Consequently, the width of panel76c, i.e. the distance between the crease lines76cand76din the traversal direction T, continuously decreases when moving from the top region34to the bottom region32. Using the central axis Caas an axis of symmetry, crease line82bis mirrored by crease line82cand both crease lines82band82cform an angle to the central axis Caof approximately 2 degrees, although diverging from the central axis Cain opposite directions.

Crease line82aextends between crease line28and the intersection of crease line sections30aand30b. Starting from the top region34and moving towards the bottom region32, crease lines82aand82bdiverge. Consequently, the width of panel76bincreases continuously when moving from the top region34to the bottom region32. Crease line82dextends between crease line28and the intersection of crease line sections30dand30e. Starting from the top region34and moving towards the bottom region32, crease lines82dand82cdiverge. Consequently, similar to panel76b, the width of panel76dincreases continuously when moving from the top region34to the bottom region32. Crease lines82aand82dboth form an angle to the central axis Caof approximately 3 degrees, although diverging from the central axis Cain opposite directions. Consequently, using the central axis Caas an axis of symmetry, panel76bis mirrored by panel76d.

The blank10also comprises two rectilinear or substantially rectilinear crease lines92and94extending over the whole length of the blank10, i.e. between the bottom boundary edge16and the top boundary edge22, parallel or substantially parallel to the central axis Ca. Crease lines92and94extend centrally or substantially centrally in panels76band76d, respectively, and, consequently, divide panels76band76dinto two panel sections76b-I,76b-II and76d-I,76d-II, respectively. Also, in the bottom region32, the crease lines92and94extend centrally or substantially centrally in the gusset panel sub-regions formed by gusset panels40b-40eand40g-40j, respectively.

FIG.2shows a sleeve96produced from the blank10ofFIG.1in a rear view andFIG.3shows the sleeve96in a front view. Features of the sleeve already described with reference toFIG.1are provided with corresponding reference numbers inFIGS.2and3.

The sleeve63is created from the blank10by folding the blank10along the two crease lines92and94, bringing panel76eto overlap panel76a. In the overlapping region, panels76aand76eare then sealed to one another, e.g. welded together, to form a longitudinal sealing band14forming a planar or substantially planar rear wall section. The sleeve96thus obtains a circumferential structure, closed in the circumferential direction, with an opening in the region of the bottom boundary edge16and with an opening in the region of the top boundary edge22. The lateral boundary edge ending up inside the sleeve, i.e. boundary edge12in this case, is covered, either prior to folding the blank10along the crease lines92and94or after the overlapping regions of panels76aand76ehave been connected to one another. The covering of the open cut edge of the composite material has the purpose of preventing any contact between the contents of the container and this layer, in particular the paper or paperboard layer contained therein. As is known in the art, the covering of the cut edge can be achieved by stripping composite layers from the edge and folding a remaining, impermeable layer over the edge. Alternatively, as is also known in the art, a strip of sealing material (not shown) can be applied over the lateral boundary edge ending up inside the sleeve.

In the front view (FIG.3), panel76cis visible as are panel sections76b-II and76d-I. The loop of weakness74encircling the removable section72of the top panel50is also visible in the front view. However, the loop of weakness is not visible in the rear view (FIG.2) since the inside layer of the laminated material of the top panel50is unbroken, providing said uninterrupted barrier. In the rear view (FIG.2), panels76aand76eare visible as are panel sections76b-I and76d-II.

FIG.4shows the sleeve96fromFIGS.2and3in an erected state. The erected state is arrived at by reversing the previous folding along the crease lines92and94and folding the sleeve96back along the crease lines92and94by approximately 180 degrees. The folding back along the crease line92has the consequence that the two panel sections76b-I and76b-II no longer lie on top of one another but become arranged in the same or substantially the same plane. In a corresponding manner, the folding back along the crease line94has the consequence that the two panel sections76d-I and76d-II no longer lie on top of one another but become arranged in the same or substantially the same plane. The folding back action also involves folding the sleeve96along crease lines82a,82b,82cand82dby approximately 90 degrees, thus forming side edges of the container-to-be.

Next, the bottom region of the erected sleeve is folded and sealed. This involves bringing the bottom sealing band panels38fand38binto sealing engagement with sealing band panels38eand38c, respectively, and bringing bottom sealing band panels38gand38sinto sealing engagement with sealing band panel38d. The sealing engagement may be effectuated by welding in a manner which is, as such, known in the art. Folding and sealing the bottom region also involves folding gusset panels40jand40ginwards onto gusset panels40iand40h, respectively, and folding corresponding gusset panels40band40einwards onto gusset panels40dand40c, respectively. It further involves folding down the now sealed sealing band onto bottom panel40fand gusset panels40eand40gand connecting the sealing band thereto, e.g. by welding, and, finally, folding in lugs formed by the previously folded gusset panels, thus arriving at the sealed and substantially planar configuration illustrated inFIG.5. It is to be understood, however, that other configurations of a sealed and planar bottom region are known in the art and may be used instead of the one described above.

Erecting and bottom sealing the sleeve may be effectuated in a packaging machine (not shown), where the sleeve96may be supplied from a magazine and erected on a mandrel. The bottom region may be formed and sealed on the mandrel and the proto-container, i.e. the partially-formed container as shown inFIG.6, may then be discharged from the mandrel to a conveyor. The conveyor may transport the partially-formed container to a sterilization station and then to a filling station. In the filling station, a food product may be dispensed into the partially-formed container through the open top.

The filled and partially-formed container may then be conveyed to a top-folding and sealing station for folding and sealing the top region.

When folding the top region, the slanted top panels44cand44dare pushed inward at crease line48to fold panel44dover panel44cand to fold panel56eover56f(seeFIG.6). A similar operation is carried out on panels44a,44band56c,56b(see alsoFIG.1). At the end of this folding operation, the top panel50will have assumed a slanted orientation, as shown inFIG.7. In this position, the gusset panels44a-44dare folded onto each other underneath the top panel50and the panels of the sealing band56may be sealed to each other, e.g. in a welding operation, thereby sealing the top region. The folded and sealed sealing band56is then folded down onto and attached to the rear wall panels76aand76e, as is shown inFIG.8.

Since the top sealing band panels56b,56c,56eand56fare pushed inwards when the top seal is formed, the top sealing band panels56b,56c,56eand56fwill be contained between top sealing band panel56dand the joined top sealing band panel56gand56a. Consequently, the folded and sealed sealing band56will have a lateral extent corresponding to the lateral extent of the top sealing band panel56d, thus allowing the whole sealing band56to be folded down onto and attached to the rear wall panels76aand76e.

Consequently, the folded and sealed sealing band56forms a top sealing region that is folded onto and is attached to a rear wall section of the container formed from the rear wall panels76aand76e, i.e. the wall section containing the longitudinal sealing band14. The consequence of this arrangement, as will be discussed in more detail later, is that a top panel of the container124(seeFIG.13), formed from panel50(seeFIG.3), will be free from sealing structures, such as welded, glued or otherwise permanently joined seams where panels of the laminate sheet material are permanently joined to each other. This allows the top panel to be utilised in an efficient manner.

A tear-flap may be arranged over and attached to the removable section72of the top panel50(seeFIG.3) to allow easy removal of the removable section72.

FIGS.9-12show a container100produced from the blank10disclosed above. The container100comprises a substantially planar bottom portion102, a top portion104and a wall portion106. The wall portion106comprises a front wall section108aformed from panel76cand a rear wall section108cformed from panels76aand76e. Further, the wall portion106comprises side wall sections108band108dformed from panels76dand76b, respectively. An edge116, formed by crease line82b, defines an intersection of the front wall section108aand the side wall section108d, and an edge118, formed by crease line82c, defines an intersection of the front wall section108aand the side wall section108b. Further, an edge120, formed by crease line82a, defines an intersection of the rear wall section108cand the side wall section108d, and an edge122, formed by crease line82d, defines an intersection of the rear wall section108cand the side wall section108b.

The top portion104comprises a top panel124, formed from panel50, and a sealing region126, formed from the sealed sealing band56, i.e. the folded and sealed top sealing band panels56a-56g, forming a top seal of the container100. A slanted side edge128, formed by crease line52, defines an intersection of the top panel124and the side wall section108d, and a slanted side edge130, formed by crease line54, defines an intersection of the top panel124and the side wall section108b. A front edge132, formed by crease line section30c, defines an intersection of the top panel124and the front wall section108a. The container100also comprises a rear edge134, formed by crease line section58c, corresponding to the intersection of the top panel124and the sealing region126. Consequently, the top panel124extends between the top edges128,130,132and134.

As previously discussed, the sealing region126is folded down onto and attached to the rear wall section108c, i.e. the wall section formed by the panels76aand76eand containing the longitudinal sealing band14.

The panel76chas a length LFalong the central axis Ca(seeFIG.1). The panels76aand76ehave a length LBin the direction of the central axis Cathat is less than LF. Consequently, the front wall section108ahas a length that is less than the length of the rear wall section108c(when viewed in the longitudinal direction of the carton100). This difference in the lengths, i.e., LF<LB, creates an extended configuration of the top panel124. Thus, the front edge132is lower than the rear edge134when the container100is in an upright position as shown. The top panel124is at a predetermined angle α to the rear wall section108c(seeFIGS.11and12). The angle α can be about 10 degrees to about 90 degrees, and preferably, about 30 degrees to about 80 degrees. Most preferably, the angle α is about 45 degrees to about 75 degrees. In the present embodiment, the angle is approximately 60 degrees, as is dictated by the angle between the crease line sections30band30dand crease lines82aand82d, respectively (seeFIG.1).

Referring now toFIGS.14aand14b, the planar bottom portion102is substantially square-shaped, i.e. it has a width and a breadth of substantially equal length, as is illustrated inFIG.14a(see alsoFIG.5). At the top portion104, however, the cross-section of the container100, when viewed in a plan parallel to the plane of the bottom portion102, is rectangular. In other words, above the bottom portion102the width of the container100is larger than the breadth of the container100, as is illustrated inFIG.14b. This asymmetry increases when moving from the bottom portion102towards the top portion104.

Referring now toFIGS.9,10and13, the container100comprises an opening device or closure136having a tear-flap138that covers and is attached to the removable section72of the top panel50(see alsoFIG.1). As previously discussed, the removable section72is delimited by a line of weakness74allowing the section72to be removed from the container100together with the tear-flap138when the container is initially opened. Until this first opening, however, section72forms, together with the rest of the top panel124, an uninterrupted barrier for the food product contained in the package. The line of weakness74may, for example, be a so-called “half-cut”, i.e. a cut made partially through the laminated substrate of the blank from the outside surface thereof leaving one or a plurality of inner layers of the laminated substrate intact to provide an uninterrupted barrier against the contained food product. When the tear-flap and the attached section72is removed from the container100, an opening140(seeFIG.13) will be revealed in the top panel124through which the food product in the container100can be dispensed or accessed. The tear-flap138may extend down onto the rear wall section108ccrossing the sealing region126. The tear-flap138may be attached to the container100after the container100has been filled and top-sealed. Alternatively, the tear-flap138may be attached to the proto-container upstream of the filling station.

It is to be understood, however, that the container, in principle, can be fitted with any type of opening device or closure known in the art, e.g. an opening device or closure comprising a pour spout and a cap resealably arranged on the pour spout. Alternatively, the opening device or closure may be implemented using so called pre-laminated hole (PLH) technology to provide the uninterrupted barrier. As is known in the art, such technology involves making a through-hole in the blank, i.e. in the paper-based or paperboard-based laminate sheet material of the container, and covering the hole, preferably from the inside surface of the container, with a suitable barrier layer, e.g. a polymer film, which barrier layer is attached to a tear-flap to be removed from the hole together with the tear-flap at a first opening.

The opening140is positioned close to the rear edge134substantially equidistant from slanted edges128and130. The opening140may be arranged at an orthogonal distance D of between 1 mm to 10 mm from the fourth top edge134. In other words, with reference toFIG.1, the removable section72may be arranged at an orthogonal distance D of between 1 mm to 10 mm from the crease line section58c. Since the sealing region126is folded down onto the rear wall containing the longitudinal sealing band14and is attached thereto, the top panel124will be free from sealing structures and there will be no obstructions extending above the surface of the top panel124. In particular, the longitudinal sealing band14and the top sealing region126will be confined to the rear wall section108cof the container. Therefore, when tear-flap138and section72are removed, the then revealed opening140will become easily accessible, in particular from the rear wall section108cside of the container100, allowing a consumer to position his or her lower lips on the sealing region126and the upper lips over the opening140. The longitudinal extent of the sealing band panel56d, i.e. the distance A between the crease line section58cand the top boarder section22e(seeFIG.1), defining the length of the sealing region126in the longitudinal direction of the container100, may be at least 15 mm, or more preferably at least 20 mm, or even more preferably at least 30 mm, to comfortably accommodate the lower lips of a consumer and thereby cater for an enjoyable drinking experience. By having the tear-flap138extending down onto the rear wall section108ccrossing the sealing region126, the outer surface of the sealing region126intended to come into contact with the mouth of a consumer will be protected until the container100is opened. The slanted top panel124and the position of the opening140close to the rear edge134allow for an ergonomically advantageous drinking position, thus making it easy for a consumer to drink directly from the container100. Consequently, the disclosed container100may be suitable to be used as a so-called portion pack, i.e. a type of container configured to hold a liquid intended to be consumed on the go, without the container necessarily having to be reclosed after once having been opened.

Because to the gusset panels44a,44b,44c,44dare folded inwards during the top sealing of the container (seeFIG.6), the gusset panels44a,44b,44c,44dwill end up underneath the top panel50(e.g. seeFIG.3) in the filled and sealed container. Consequently, when designing the opening, due account of the gusset panels44a,44b,44c,44dmust be taken. In the present embodiment, the opening140is positioned such that the gusset panels44a,44b,44c,44ddo not interfere with drinking or dispensing from the container.

FIG.15shows another embodiment of a blank10′ according to the invention.FIGS.16and17show a sleeve96′ produced from the blank10′ andFIGS.18-21illustrates a container100′ produced from the sleeves96′.

The blank10′ differs from the previously disclosed blank10in that the blank10′ comprises two rectilinear or substantially rectilinear crease line sections30c′-I and30c′-II instead of the curvilinear crease line30cof blank10.

Furthermore, the blank10′ comprises a semi-circular line of weakness74′ instead of the loop of weakness74of blank10, which semi-circular line of weakness74′ defines a panel section72′ arranged to be folded out from the plane of panel50′ during the first opening. Also, the line of weakness74′ is positioned further from the crease line section58c′ than the loop of weakness74from crease line section58c. Similar to the loop of weakness74of blank10, the semi-circular line of weakness74′ may be a so-called “half-cut”, i.e. a cut made partially through the laminated substrate of the blank from the outside surface thereof leaving one or a plurality of inner layers of the laminated substrate intact to provide an uninterrupted barrier against the contained food product.

The blank10′ differs from blank10also in that the intermediate region of the blank10′ comprises slanted crease lines82a′-82g′ instead of the substantially longitudinally extending crease lines82a-82dof blank10. The slanted crease lines82a′-82h′ partition slanted panels76a′-76i′.

The blank10′ is otherwise identical to blank10and the sleeve96′ (seeFIGS.16and17) is produced in substantially the same manner as sleeve96. The container100′ is produced from sleeve96′ in substantially the same manner as container100from sleeve96. However, when the sleeve96′ is erected and folded, the slanted panels76a′-76i′ will form a pattern of slanted and slightly warped wall sections108a′-108h′ in the wall portion106′ of the container100′. Wall sections108a′,108g′,108e′ and108c′ extend diagonally across the front wall, the first side wall, the rear wall and the second side wall, respectively, of the container100′. When the carton100′ is produced, the sealing region126′ is folded down onto wall section108d′ and wall section108e′ (i.e. the wall section containing the longitudinal sealing band14′) and is attached to the same. Consequently, as the previously discussed container100, the container100′ comprises a top panel124′ that is free from sealing structures.

Also, instead of being provided with a tear-flap, the carton100′ is provided with an opening device or closure136′ comprising a cap142′ and a pour spout having a flange144′ attached to the top panel124′ above the line of weakness74′. The opening device or closure136′ is configured to break the line of weakness74′ during a first opening of the container100′ in a manner that is, as such, known in the art. For example, the opening device or closure136′ may comprise a seal-breaking member (not shown) arranged inside the pour spout which is activated during the first opening to push down onto panel section72′ and force the panel section72′ into the container so that an opening in the top panel substrate is created. However, the section72′ will not separate from the rest of the top panel substrate but will remain attached to the same via the uncut substrate region located between the endpoints of the line of weakness74′.

FIG.22shows a blank10″ which is substantially identical to the blank10shown inFIG.1except that the top boundary edge sections22a″,22e″ and22i″ are curvilinear and the top panel50″ is provided with a circular, pre-cut opening140″ in the paper-based or paperboard-based laminate sheet material of the blank10″. The opening140″ is positioned adjacent the crease line section58c″ and may, similarly to the removable section72inFIG.1, be arranged at an orthogonal distance D of between 1 mm to 10 mm from the crease line section58c″. Also, as compared to the blank10shown inFIG.1, the panel76a″ is somewhat wider than the panel76e″ allowing the boundary edge14″ to become positioned substantially equidistant from the edges120″ and122″ in a container100″ produced from the blank10″ (seeFIGS.23-27).

In the region of the opening140″, the inside surface of the blank10′ is provided with a sheet membrane (not shown) covering the opening140″, thus providing a pre-laminated hole (PLH) configuration forming a barrier separating the opening140″ from the food product prior to a first opening of the container. It is understood, however, that the barrier, instead of being formed by a pre-laminated hole (PLH) configuration, may comprise, as in the embodiment disclosed inFIGS.1-13, a removable section delimited by a half-cut, i.e. a cut made partially through the top panel from an outside surface thereof leaving one or a plurality of inner layers of the laminated substrate or sheet material intact to provide said barrier.

FIGS.23-27show the container100″ produced from the blank10″. The container100″ is produced substantially in the same way as has been described above with reference toFIGS.2-8. Due to the curvilinear nature of the top boundary edge sections22a″,22e″ and22i″, the sealing region126″ displays a curvilinear edge127″ in this embodiment of the container.

The container100″ comprises an opening device or closure136″ arranged over the opening140″ allowing a consumer to break the PLH barrier, open the container and dispense or access the food product.

The opening device or closure136″ comprises a first sheet150and a second sheet160. The first sheet150is attached to the outside surface of the paper-based or paperboard-based laminate sheet material of the container100″. The second sheet160is releasably attached to the outside surface of the first sheet150, allowing the second sheet160to be brought from a first position, in which the opening device or closure136″ is closed (seeFIGS.23-25) to a second position, in which the opening device or closure136″ is open (seeFIGS.26and27).

The first sheet150is generally rectangular and extends between longitudinal edges151,152and transversal edges153,154(seeFIG.28, which shows the first sheet150prior to having been mounted to the laminate sheet material). The first sheet150displays a through-opening155having substantially the same size and shape as the opening140″ (seeFIG.22). In other words, the opening140″ and the through-opening152are congruent. The first sheet150is attached to the outside surface of the laminate sheet material of the container100″ so that the through opening155is aligned with the opening140″. Consequently, in the present embodiment, in which the opening140″ and the through-opening155are circular, the opening140″ and the through-opening155are coaxially arranged.

The first sheet150comprises a first sheet section150athat extends over the top panel124″ between the top edge134″ of the container100″ and a region close to the edge132″ (seeFIG.26). In the disclosed embodiment, the first sheet150also comprises a second sheet section150bthat extends from the top edge134″ down onto the sealing region126″ to a region close to the edge127″ (seeFIG.27). Consequently, due to the transversal edge153of first sheet150being arranged adjacent the edge132″ and the transversal edge154being arranged adjacent the edge127″, the first sheet150extends over the uppermost edge134″ of the container100″ and over substantially the whole length of the top panel124″ and the sealing region126″, respectively.

In the present embodiment, the width of the first sheet150is somewhat smaller than the width of the top panel124″. In other words, the sheet150does not extend all the way to the edges128″ and130″ (seeFIG.26). In alternative embodiments, the first sheet150may have a width that is substantially equal to the width of the top panel124″. The extent of the first sheet150should, however, be sufficient to encircle the opening140″.

The second sheet160is also generally rectangular and extends between longitudinal edges161,162and transversal edges163,164(seeFIG.29, which shows the second sheet160prior to having been mounted to from the opening device or closure136″). The second sheet160has substantially the same width as the first sheet150. The length of the second sheet160, however, is substantially twice the length of the first sheet150.

The second sheet160comprises a first sheet section160awhich, prior to a first opening of the container100″, extends over the first sheet150between the top edge134″ of the container100″ and a region close to the edge132″ (seeFIGS.24and29). The transversal edge163of the second sheet160is substantially aligned with the transversal edge153of the first sheet150. The second sheet160also comprises a second sheet section160bwhich, prior to the first opening of the container100″, extends from the top edge134″ down onto the second sheet section150bof the first sheet150, over the edge127″ of the sealing region126″ and down onto the wall section108c″ of the container100″ (seeFIG.25).

The outside surface of the first sheet150may comprise an adhesive (indicated by a dotted pattern inFIG.28). The inside surface of the second sheet160, i.e. the surface which is configured to contact the first sheet150and the laminate sheet material of the container100″ at the side wall section108c″ prior to the first opening, may also comprise an adhesive. However, in one embodiment the inside surface of the sheet160may comprise a region165, arranged to cover the through-opening155of the first sheet150, in which the adhesiveness is reduced as compared to surrounding sections166and167(seeFIG.29).

Prior to the first opening of the container100″, the second sheet160is attached to the outside surface of the first sheet150. Also, to ensure that the second sheet160is kept flush to the container100″ prior to the first opening, the second sheet160may be attached to the side wall section108c″. As stated above, the inside surface of the blank10′ is provided with a sheet membrane (not shown) covering the opening140″ and forming a barrier prior to the first opening. The outside surface of the sheet membrane, which is exposed via the opening140″ and the through-opening155, is attached to the inside surface of the second sheet160. However, if the barrier comprises a removable section delimited by a half-cut instead of being formed by a PLH configuration, the inside surface of the second sheet material160would instead be attached to the outside surface of the removable section, which is exposed via the through-opening155in a similar manner as the PLH membrane.

In order to perform the first opening, a consumer manually grips the transversal edge164of the second sheet160and pulls the second sheet160upward over the top edge134″ and then downwards towards the edge132″, thereby bringing the second sheet160to the position shown inFIG.26. The downward pulling action will reveal the through-opening155and break the sheet membrane covering the opening140″. If the barrier comprises a removable section delimited by a half-cut, as is discussed above, the downward pulling action will break the half-cut, lift the removable section and reveal an opening similar to the opening140″. When the second sheet160has been brought to the position showed inFIG.26, the consumer will be able to dispense or access the food product through the opening140″ and the through-opening155.

Due to the first sheet150extending from the through-opening155, over the top edge134″ and down onto the sealing region126″ to the region close to the edge127″ (seeFIG.27), a drinking surface, which prior to the first opening was covered by the second sheet160, will be available to the consumer should he or she chose to drink from the container100″ from the side of the wall section108c″. In order to prevent the mouth of the consumer from coming into contact with the outside surface of the container laminate sheet material during such a drinking operation, and thereby provide an enjoyable drinking experience, the first sheet150should preferably extend from the through-opening155to a distance A from the through-opening155of at least at 20 mm and more preferably at least 25 mm, and even more preferably at least 30 mm (seeFIG.28).

According to one embodiment, the second sheet160may be configured to allow the consumer to reclose the opening device or closure136″ after the first opening. This may be effectuated by the consumer bringing the second sheet160back to its original, first position, and allowing the second sheet160to adhere to the first sheet region150aof the first sheet150in the sealing region126″. While this may not necessarily be sufficient to provide a liquid tight seal, it may be sufficient to prevent foreign object from entering the through-opening155.

At the region of the edges153and163, the first and second sheets150,160may be permanently joined, e.g. heat sealed to each other, thereby ensuring that the second sheet160remains attached to the first sheet150also after the first opening.

The first sheet150may be heat-sealed to the outside surface of the container100″. Alternatively, the first sheet150may be permanently attached to the outside surface of the container100″ by other means, e.g. using a suitable adhesive.

The first and second sheets150,160may comprise a polymer sheet, e.g. a sheet comprising a polyethylene layer or a polypropylene layer or both. At least the second sheet160may be a laminate sheet, e.g. comprising a plurality of polymer layers and/or a layer comprising cellulose fibres, e.g. a paper layer. In one embodiment, the second sheet160may comprise an aluminium layer.

During production of the container100″, the first and second sheets150and160may be attached to each other to form a sheet aggregate. The sheet aggregate may subsequently be attached to the outside surface of the container laminate sheet material. Alternatively, the first sheet150may attached to the outside surface of the container laminate sheet material in a first step and the second sheet160may be attached to the first sheet150in a second, subsequent step. The sheet aggregate, or the first sheet150and subsequently the second sheet160, may be attached to the container laminate sheet material after the container has been folded, filled and top-sealed. In an alternative embodiment of producing the container100″, the first sheet150may be attached to the blank10″ prior to the blank10″ is folded to form the sleeve.

As previously stated, blanks are produced in a converting process in which the blanks are cut from a web of laminate material having substantially parallel and rectilinear lateral boundary edges. The converting process typically comprises feeding the web of laminate material through one or a plurality of nips formed between a pair of cutting and/or creasing rollers to produce blanks cut from the web and formed with creases lines for subsequent folding and/or with cuts and/or with holes, e.g. for fitting a closure to the blank material when a carton is produced therefrom.

FIG.30shows an embodiment of a nesting pattern of blanks laid out on a web204of laminate material. Such a pattern is sometimes referred to as a nesting pattern. The blanks are identical to the one previously discussed with reference toFIG.1andFIG.31is a detailed view of the nesting pattern ofFIG.30showing some of the crease lines and the loop of weakness previously discussed with reference toFIG.1.

As is known in the art, a nesting pattern is not a physical pattern that is visible on the web but a pattern that illustrates how the blanks are intended to be cut from the web and/or how the blanks are impressed. In other words, the nesting pattern illustrates the layout of the blanks on the web and, consequently, how the available web material is utilised.

The nesting pattern200shown inFIG.30comprises two rows202a,202bof congruent blanks10a,10b, each row comprising blanks arranged side by side with the first lateral boundary edge12adjoining the second lateral boundary edge14of a neighbouring blank and vice-versa. Consequently, in the nip of the cutting rollers (not shown) adjoining lateral boundary edges12and14in each row can be produced simultaneously using the same cutting tool utilising a single cutting edge.

The blanks10aof the first row202aare arranged facing the blanks10bof the second row202bso that the top boundary edge22of the blanks of the first row202aadjoins the top boundary edge22of the blanks of the second row202b. In the longitudinal direction Lw of the web of laminate material204, the rows202a,202bare offset so that the top boundary edge section22eof the blanks of the first row202aadjoins the top boundary edge sections22aand22iof the blanks of the second row202band vice-versa (seeFIG.31). Consequently, in the nip of the cutting rollers (not shown) the adjoining top boundary edges22of oppositely arranged blanks can also be produced simultaneously using the same cutting tool utilising a single cutting edge.

In each row202a,202b, the bottom boundary edges16are arranged substantially parallel to the lateral boundary edges204a,204bof the web204, either substantially colinear the lateral boundary edges of the web204or within a small distance from the lateral boundary edges of the web204, e.g. within 1 mm to 5 mm from the lateral boundary edges204a,204b. This will provide a nesting pattern allowing substantially the whole area of web204to be covered with no or very little web material being wasted. Consequently, the disclosed nesting pattern is very effective in that substantially all available web material is utilised to form blanks.

In the nesting pattern200, the fourth boundary edges22form a non-rectilinear line222extending substantially centrally in the longitudinal direction Lw of the web204. The line22display a two-fold rotational symmetry with respect to a plurality of centres220located on the line222. In other words, the line222, when rotated 180 degrees about any one of the centres220, will assume the same orientation as before the rotation. This symmetry allows the rows202aand202bto be arranged adjacent each other without any intermediate gaps, thus providing the efficient nesting.

An efficient nesting can also be achieved by arranging a plurality of such row-pairs adjacent to each other, e.g. as is disclosed inFIG.32, which shows two row-pairs in such a configuration.

FIG.33illustrates the geometry of the blank allowing the above-discussed efficient nesting pattern. The blank10is the same blank as previously shown inFIG.1. The top boundary edge22is reflection symmetric with respect to the central axis Ca. In other words, using the central axis Caas an axis of symmetry, the top boundary edge22on one side of the axis Cais mirrored by the top boundary edge22on the other side of the axis Ca.

The top boundary edge22is inscribed in a right rectangle206. In other words, the top boundary edge22is enclosed by and “fits snugly” inside the rectangle206. The rectangle206has a first pair of sides208,210being parallel to the longitudinal direction L of the blank and a second pair of sides212,214being parallel to the transversal direction T. The central axis Cadivides the rectangle206into two congruent right sub-rectangles216and218. In other words, the sub-rectangles216and218are identical in size and shape.

The sub-rectangle216has a centre220, i.e. a position where diagonals of the sub-rectangle216intersect. Within the sub-rectangle216, the top boundary edge22displays a two-fold rotational symmetry with respect to an axis running through the centre220and being orthogonal to the plane of the blank10. In other words, the part of the top boundary edge22inscribed in the sub-rectangle216assumes the same orientation after a rotation of 180 degrees (360/2 degrees) about the centre220.

The above is equally true for the part of the top boundary edge22that is inscribed in the sub-rectangle218—within the sub-rectangle218the top boundary edge22displays a two-fold rotational symmetry with respect to an orthogonal axis running through the centre222of the sub-rectangle218. This follows directly from the fact that the top boundary edge22is reflection-symmetric with respect to the central axis Ca—such reflection symmetry implies equal rotational symmetry about the respective centre in the sub-rectangles216and218. In other words, if the top boundary edge22is reflection-symmetric with respect to the central axis Ca, and if the part of the top boundary edge22inscribed in one of the sub-rectangles displays a two-fold rotational symmetry with respect to the centre of that sub-rectangle, the part of the top boundary edge22inscribed in the other sub-rectangle will also display a two-fold rotational symmetry with respect to the centre of that other sub-rectangle.

Arranging the top boundary edge22of the blank10reflection symmetric with respect to the central axis Caand, for the part of the top boundary edge22being inscribed in respective sub-rectangle, two-fold rotational symmetric with respect to the centre of the sub-rectangle, as described above, will allow the effective nesting pattern disclosed inFIG.30. In particular, it will allow laying out the pattern of the blanks on the web204such that the top boundary edge22of the row of blanks202acoincides with the top boundary edge22of the row of blanks202b, thus resulting in that there will be no non-used web material between the rows202aand202b.

InFIG.31, the top boundary edge sections22aand22iare equally long and top boundary edge section22eis twice as long as any one of edge sections22aand22i. However, it is understood that an efficient nesting pattern can be achieved also with other geometries.FIG.34shows a further embodiment of a nesting pattern of blanks laid out on a web of a laminate material andFIG.35shows a blank10″ cut and embossed according to the nesting pattern shown inFIG.34. In this embodiment, the top boundary edge22″ comprises curvilinear edge sections22a″ and22e″ and22i″ having an extend and a curvature allowing the nesting patter to be laid out with the top boundary edges of the blanks adjoining each other without an intermediate gap, as is illustrated inFIG.34. Once cut out from the laminate material web, the blank10″ can be folded, filled and sealed in a manner similar to the blank10disclosed inFIG.1.FIG.36shows a container100″ produced from the blank10″ according toFIG.35.

It is appreciated that certain features of the invention, which, for clarity, have been described above in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which, for brevity, have been described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

In the preceding description, various aspects of the blank and container according to the invention have been described with reference to the illustrative embodiment. For purposes of explanation, specific numbers, systems and configurations were set forth in order to provide a thorough understanding of the apparatus and its workings. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiment, as well as other embodiments of the apparatus, which are apparent to person skilled in the art to which the disclosed subject-matter pertains, may lie within the scope of the present invention as defined by the following claims.