Multilayer packaging element, packaging comprising such element and process for making such packaging element

Abstract

The invention concerns a process for making a packaging element (1) for containing and displaying a product, featuring a seat (2) shaped to house a respective product. The packaging element (1) is obtained by forming a multilayer comprising a plurality of paper layers made using a wet process, where the multilayer is formed by pressing in a mould at a temperature between 20°C and 300°C.

Description

[0001] The present invention relates to a packaging element for containing and displaying a product and to a package comprising such a packaging element.

[0002] The present invention also relates to a process for making a packaging element.

[0003] The present invention finds useful use in the paper industry and, specifically, is aimed at packages, wrappings, boxes, covered boxes, cases, cases and / or similar for the containment, display and marketing of various types of products.

[0004] The present invention applies particularly to packaging for high-quality and luxury products such as perfumes, creams, alcoholic products, high-end cosmetic products, accessories and / or high fashion items, jewellery and / or similar, but also to packaging for food products such as trays sealed with plastic films.

[0005] As is well known, the presentation and display, as well as the marketing, of high-quality and luxury products require the use of equally high-quality and well-made packaging which is taken care of down to the smallest details.

[0006] For this purpose, packages of various shapes and sizes have been created which can be simple or foldable, covered with special materials, such as particular papers and / or canvas and / or any other high-quality material, or silk-screened and / or planographically printed, or provided with plastic elements which are appropriately created using thermoforming processes.

[0007] An example of a known packaging normally used for the sale and / or display of perfumes, beauty products, alcoholic beverages and / or similar products involves the presence of at least three elements, i.e. an external box-like body, a housing element, suitable for accommodating the product to be contained and / or displayed, and a support inserted in the box-like body and suitable for supporting the housing element.

[0008] In particular, the box-shaped body is provided with a bottom from which a plurality of side walls extend perpendicularly so as to define a respective housing compartment, in which the support is inserted. The housing element rests on the support and on the bottom of the box-shaped body and has one or more seats, or cavities, each shaped to house a respective product. The support, which supports the housing element, has openings shaped similarly to the seats of the housing element for insertion of the same into the support.

[0009] In some known packages, the box body and the support are made of cardboard or a similar paper-like material. Instead, the housing element is made of plastic, using an appropriate thermoforming process.

[0010] In order to visually cover a large part of the structure of the support and the housing element, and at the same time allow for the aesthetic decoration of the packaging, it is common practice to glue onto the same a decorative mask appropriately made of a high-quality paper material. The decorative mask covers the support and the housing element with the exception of the seats, in such a way as to allow the placement or removal of the products to be contained and / or displayed. The decorative mask is therefore provided, for each of the seats, with a corresponding through opening having the same shape.

[0011] In order to solve the problems due to the excessive use of plastic in known packaging, such as the issues related to recycling and waste disposal, as well as the costs of producing plastic supports with configurations dedicated to particular combinations of products or items to be contained and / or displayed, a package has been designed, as described in Italian patent application no. 102016000068257 in the name of the same Applicant, in which the housing element is made of paper material, such as pressed cardboard pulp, thus completely eliminating the use of plastic. In this way, the package can be completely recycled without the need to separate components made of materials other than paper, such as plastic components.

[0012] The Applicant has however found that packages made entirely of paper material are not free from drawbacks and can be improved in various aspects.

[0013] In fact, the processes for working and modelling pressed cardboard pulp present greater limitations than the thermoforming processes adopted for the production of plastic housing elements.

[0014] In particular, the process of making the housing element from cardboard pulp requires a drying phase to remove water.

[0015] Disadvantageously, this drying phase requires high temperatures and this makes the manufacturing process of the housing element highly energy-intensive.

[0016] It is also known to produce packaging elements through so-called "dry molding" processes. These processes are used to produce packaging elements for food use, such as trays for cooked or pre-cooked foods, cup covers for coffee products and more.

[0017] These processes are carried out starting from a cellulose raw material which is free of water, obtained by compacting paper "fluff" (i.e. dry and shredded cellulose fibres to form a sort of wadding) into sheets.

[0018] In particular, the packaging element is made by forming by pressing the sheet-like blank into a mould, thus imparting the shape of the mould to it.

[0019] Disadvantageously, this process is not suitable for the production of packaging elements with complex shapes. In fact, it has been found that the blank described above, due to its nature, does not allow the shape of the mold to be followed in correspondence with detailed elements having sharp angles or particularly small or fine, and therefore tears.

[0020] The main purpose of the present invention is to propose a packaging element for containing and displaying a product, and a related packaging, capable of solving the problems encountered in the known art.

[0021] It is a particular aim of the present invention to provide a packaging element that is suitable for obtaining even complex shapes, whilst maintaining its structural integrity.

[0022] A further aim of the present invention is to provide a package suitable for containing and / or displaying luxury and high-quality products according to a predefined position, and a process for producing a packaging element which allows for obtaining packaging elements even having complex shapes.

[0023] It is also the aim of the present invention to reduce environmental costs, both those related to plastic recycling and energy costs, linked to the production of packaging elements from cardboard pulp.

[0024] The purposes specified above and others are substantially achieved by a packaging element, by a package comprising such a packaging element and by a process for making a packaging element as set forth in the accompanying claims.

[0025] Further features and advantages will become more apparent from the description of preferred, but not exclusive, embodiments of a packaging element, a package and a process, illustrated by way of example and not by way of limitation with the aid of the attached drawings in which: – figures 1a and 1b schematically show two different phases of a process for making a packaging element according to the present invention; – figure 2 shows a packaging element according to the present invention; – figure 2a shows a section of a detail of the packaging element of figure 2; – figure 3 shows a perspective view of an embodiment of a package comprising a packaging element according to the present invention; – figure 4 shows an exploded view of the package of figure 3.

[0026] With reference to the figures cited, a packaging element 1 for the containment and display of a product is described below.

[0027] In the remainder of this description, the term packaging element 1 refers to the structural element of a package having a shape suitable for containing a specific product.

[0028] The packaging element 1 has at least one seat 2 shaped to house a respective product.

[0029] The packaging element 1 according to the present invention is applicable for the creation of packaging for various sectors, from the luxury and quality sectors to the food sector.

[0030] In the case of food packaging, the packaging element 1 takes the form, for example, of a tray for containing the food.

[0031] In the case of packaging for luxury and high-quality products, packaging element 1 corresponds to what is described above as the housing element, i.e. the packaging element designed to accommodate a respective luxury and high-quality product having a specific shape, such as a perfume or a cream.

[0032] Particularly in the case of packaging for high-quality and luxury products, the packaging element optionally has two or more seats 2, each shaped to house a respective product. The seats 2, and therefore the products intended to be inserted therein, can have different shapes.

[0033] Note that, in accordance with the present invention, the packaging element 1 is obtained by forming a multilayer 10 comprising a plurality of paper layers 11. In particular, the paper layers 11 are made with a wet process.

[0034] In other words, in accordance with the present invention, the packaging element 1 is made from paper plies 11 based on cellulose pulp mixed with water, i.e. obtained with wet paper production processes.

[0035] For example, the packaging element 1 can be made from a plurality of paper layers 11 such as those used to make toilet paper, kitchen paper, handkerchiefs, napkins.

[0036] In detail, with reference to figures 1a and 1b, the multilayer 10 is formed by pressing in a mould 200 at a temperature between 20 and 300 °C.

[0037] Advantageously, thanks to the presence of a plurality of paper layers 11, during the forming phase in the mould 200 the paper layers 11 can slide with respect to each other, giving rise to a structure capable of adapting to the shapes of the mould 200, thus preventing the formation of tears and defects and allowing a compact and intact packaging element 1 to be obtained.

[0038] Advantageously, it is possible to form the multilayer 10 not only with simple shapes but also with complex shapes, thus obtaining packaging elements 1 that can be used in various fields, from the food sector which uses simpler shapes to the luxury and luxury sector, which requires more complex shapes, as shown for example in figure 2.

[0039] Note that, in accordance with the present invention, preferably each paper ply 11 faces and is in direct contact with its entire face with an adjacent paper ply 11. In other words, in the multilayer 10 there are no elements or substances previously interposed between one paper ply 11 and the other.

[0040] In fact, the paper layers 11 in the packaging element 1 which is formed in the mould 200 are held together only by the pressure applied in the mould 200, without the prior use of glues.

[0041] Always preferably, the multilayer 10 comprises a number of paper layers 11 between five and fifty.

[0042] More preferably, the number of paper plies 11 is between five and ten.

[0043] Furthermore, preferably, each layer of paper 11 has a weight between 10 and 80 g / m <2> . More preferably, each ply of paper 11 has a weight between 10 and 30 g / m <2> .

[0044] Even preferably, the paper layers 11 of the multilayer 10 are identical to each other, in part or completely. For example, the paper layers 11 have the same weight, however falling within the range indicated above.

[0045] The paper layers 11 used to make a packaging element 1 according to the present invention can be subjected, prior to forming, to a humidification step with water and / or other additives. In this way, the paper layers 11 used to make a packaging element 1 according to the present invention can comprise water and / or other additives.

[0046] Such additives are those commonly used in the production of cellulose products, such as starch compounds, gelatin, calcium, silicon, wax, rosin, AKD (alkyl ketene dimer), ASA (alkenyl succinic anhydride), and more.

[0047] Also forming part of the present invention is a package 100 comprising a package element 1 as described above.

[0048] In the case of applications for food trays, not illustrated, the package 100 may comprise, in contact with the multilayer 10 and i.e. with the paper layers 11, at least one external barrier layer, for example suitable for contact with the food product. The package 100 may also comprise a covering plastic film.

[0049] According to a preferred embodiment, as shown in figures 3 and 4, the package 100 is a package for premium and luxury products.

[0050] In accordance with this embodiment, the package 100 comprises a box-like body 110 having a bottom 111 and at least one side wall 112 extending transversely from the bottom 111. In this way, the bottom 111 and the side wall 112 delimit, at least partially, at least one housing compartment 113 open on the side opposite the bottom 111. The box-like body 110 is preferably made of paper material.

[0051] The package 100 also includes a support structure 120 made of a paper material, which can be inserted inside the housing compartment 113 of the box-shaped body 110.

[0052] In particular, in the package 100, the packaging element 1 is engaged with the support structure 120. According to this embodiment, the package 100 is designed to contain and / or display a luxury or valuable product in a predefined position. Consequently, the seat 2 of the packaging element 1 is shaped to house a luxury or valuable product to be contained and / or displayed in a predefined position. The package 100 may also comprise multiple packaging elements 1 and / or multiple seats 2, each shaped to house a respective luxury or valuable product.

[0053] The support structure 120, which supports the packaging element 1, has through openings 121 shaped in a similar way to the seats 2 of the housing element for inserting them into the support.

[0054] Optionally, the package 100 includes a decoration mask 130. The decoration mask 130 is placed to cover the support structure 120 and the packaging element 1 with the exception of the seats 2, so as to allow the placement or removal of the products to be contained and / or displayed. The decoration mask 130 therefore has through openings 131 having the same shape as the seats 2 and in a number equal to the number of seats 2.

[0055] Preferably, the area defined by the shape of each of the through openings 131 is smaller than the area defined by the shape of the corresponding seat 2.

[0056] In particular, each through opening 131 has the same shape as the corresponding seat 2. In other words, the shapes of the through openings 131 and those of the respective seats 2 have the same form, but the areas defined by the shapes of the through openings 131 are smaller than those of the shapes of the corresponding seats 2 so that the product is retained by the decoration mask 130 inside the seat 2.

[0057] Preferably, the decoration mask 130 has a visible surface 132 which is designed to remain facing away from the bottom 111 of the box-shaped body 110 when the support structure 120 is inserted inside the housing compartment 113.

[0058] This visible surface 132 may include an aesthetic decoration and / or a high-quality surface finish.

[0059] Even more preferably, the decoration mask 130 can be associated with the packaging element 1 and / or the support structure 120 by means of at least one gluing substance or a similar joining substance.

[0060] The present invention also includes a process for producing a packaging element 1 having a seat 2 shaped to house a respective product.

[0061] The process according to the present invention comprises a first step of providing a multilayer 10 of paper plies 11, where such paper plies 11 are made by a wet process.

[0062] The process then comprises a step of arranging the multilayer 10 in a mold 200 having a predefined shape.

[0063] In accordance with the present invention, this process further comprises a step of forming the multilayer 10 by pressing it in the mold 200 at a temperature between 20 and 300 °C, to produce a packaging element 1 having a seat having the predefined shape of the mold 200 and shaped to house a respective product.

[0064] Preferably, the press is a 30-300 ton mechanical or hydraulic isostatic press. More preferably, the press is a 50 ton press.

[0065] Note that the forming phase can take place at room temperature or by heating the mold 200.

[0066] Optionally, then, the process comprises a step of heating the mold 200 to a temperature between 100°C and 300°C.

[0067] The mold 200 is made of metallic material such as steel or aluminum.

[0068] Generally, the mold 200 is composed of a female mold 201 having a cavity 210 having the predefined shape to be imparted to the multilayer 10. Furthermore, the mold 200 comprises a male mold 202 shaped in a complementary way to the female mold 201 and which can be coupled to the female mold 201 for the forming phase.

[0069] In accordance with one embodiment, the male mold 202 comprises a removable piston (not shown) which is adapted to push the plywood 10 into the cavity 210 of the respective female mold 201 in the forming step. Advantageously, it is possible to adhere the plywood 10 to the cavity 210 of the female mold 201 and form the plywood 10 by accurately reproducing the predefined shape of the mold 200.

[0070] Preferably, the process comprises a step of moistening the multilayer 10, carried out prior to the forming step.

[0071] Always preferably, the step of humidifying the plywood 10 is preferably carried out in a humidification station separate from the mould 200, in which water is vaporised.

[0072] In particular, the step of humidifying the plywood 10 is carried out by supplying water to the plywood 10 until a moisture content in the plywood 10 of between 30% and 50% is reached. More preferably, the desired moisture content is 40%.

[0073] The step of humidifying the multilayer 10 can be carried out with water or even additives designed to facilitate the cohesion of the paper layers 11 between them in the forming process.

[0074] Accordingly, preferably the step of humidifying the plywood 10 involves supplying water and / or additives to the plywood 10.

[0075] Preferably, the process comprises, subsequent to the step of forming the multilayer 10, a step of cutting the multilayer 10, to shape the packaging element 1 according to a predetermined shape.

[0076] In this way, a packaging element 1 is obtained which is suitable for use in a specific package 100.

[0077] The packaging element, the packaging comprising such packaging element and the process for making a packaging element so conceived are susceptible to numerous modifications and variations all of which fall within the scope of the inventive concept.

[0078] Furthermore, all details may be replaced by other technically equivalent elements.

[0079] In practice, the materials used, provided they are compatible with the specific use, as well as the contingent dimensions and shapes, may be any according to the needs.

Claims

1. Packaging element (1) for containing and displaying a product, having at least one seat (2) shaped to house a respective product; said packaging element (1) being obtained by forming a multilayer (10) comprising a plurality of paper layers (11) made using a wet process, said multilayer (10) being formed by pressing in a mould (200) at a temperature between 20 and 300 °C.

2. Packaging element (1) according to the previous claim, wherein each paper layer (11) faces and is in direct contact with the adjacent paper layer (11).

3. Packaging element (1) according to any of the preceding claims, wherein said multilayer (10) comprises a number of paper plies (11) between five and fifty, preferably between five and ten.

4. Packaging element (1) according to any of the preceding claims, wherein each paper ply (11) has a weight between 10 and 80 g / m <2> , preferably between 10 and 30 g / m <2> .

5. Packaging element (1) according to any of the preceding claims, wherein the paper layers (11) are equal to each other.

6. Package (100) comprising a packaging element (1) according to any of the preceding claims.

7. Packaging (100) according to claim 6, comprising: – a box-shaped body (110) having a bottom (111) and at least one side wall (112) extending transversely from the bottom (111); the bottom (111) and the side wall (112) delimiting, at least partially, at least one housing compartment (113) open on the opposite side to the bottom (111); – a support structure (120) made of a paper material, insertable inside said at least one housing compartment (113) of the box-shaped body (110); wherein said packaging element (1) is engaged with the support structure (120); said packaging (100) being suitable for containing and / or displaying a luxury product according to a predefined position, said seat (2) being shaped to house a luxury product to be contained and / or displayed according to a predefined position.

8. Packaging (100) according to claim 7, comprising a decoration mask (130) placed to cover the support structure (120) and the packaging element (1) with the exception of the seats (2), in such a way as to allow the placement or removal of the products to be contained and / or displayed; said decoration mask (130) presenting through openings (131) having the same shape as the seats (2) and in a number equal to the number of seats (2).

9. Package (1) according to claim 8, wherein the area defined by said shape of each of said through openings (131) is smaller than the area defined by the shape of the corresponding seat (2).

10. Packaging (1) according to claim 8 or 9, wherein said decoration mask (130) has a visible surface (132) capable of remaining facing away from the bottom (111) of the box-shaped body (110) when the support structure (120) is inserted inside the housing compartment (113); said visible surface (132) comprising an aesthetic decoration and / or a high-quality surface finish.

11. Process for making a packaging element (1) having a seat (2) shaped to house a respective product, said process comprising the steps of: – providing a multilayer (10) comprising a plurality of paper layers (11) made using a wet process; – placing the multilayer (10) in a mould (200) having a predefined shape; – forming said multilayer (10) by pressing in said mould (200) at a temperature between 20 and 300 °C to make a packaging element (1) having a seat (2) having said predefined shape and shaped to house a respective product.

12. Process according to the preceding claim, comprising, prior to the step of forming the multilayer (10), a step of humidifying the multilayer (10) by supplying water and / or additives to said multilayer (10).

13. Process according to claim 11 or 12, comprising, subsequent to the step of forming the multilayer (10), a step of cutting the multilayer (10) to shape the packaging element (1) according to a predetermined shape.