Fibre-based packaging container, circular base part, quadrilateral wall blank, method for manufacturing fiber-based packaging container and container obtainable from said method

Abstract

The present invention provides a fiber-based packaging container for containing a liquid, the packaging container comprising: a tubular wall member having an inner wall surface and an outer wall surface opposite the inner wall surface, the inner wall surface being provided with a liquid impermeable layer and having a base sealing portion at one end of the tubular wall member; and a circular base member having an outer edge, an inner base surface and an outer base surface opposite the inner base surface, the inner base surface being provided with a liquid impermeable layer and having: a circumferential region of the inner base surface, the inner base surface has a circumferential region having a sealable lacquer coating, a fold line extending circumferentially around the inner base surface within the circumferential region of the inner base surface, and a wall sealing portion located on the inner base surface between the outer edge of the base and the fold line wherein the wall sealing portion is folded about the fold line at 80 degrees to 100 degrees to form a folded portion, the folded portion and at least a portion of the base sealing portion are sealed from each other to form a base seam and provide a three-dimensional container profile such that the sealable lacquer coating is present within the base seam between the wall member and the base member.

Description

TECHNICAL FIELD

[0001] The present invention relates generally to paperboard containers, such as disposable cups, components thereof, and methods of forming paperboard containers. More particularly, the present invention relates to containers, such as beverage cups, formed from paperboard having a liquid-impermeable layer and a sealable lacquer coating within the base seam, as well as bases and walls that can be used to produce such cups. BACKGROUND

[0002] Initially, disposable beverage cups and drinking vessels were generally formed from fiber-based board that included a layer of polyethylene or other polymeric material to provide a liquid barrier. However, in recent times, due to the environmental impact of polymeric waste having come under intense scrutiny, many countries have banned the use of polyethylene and certain other polymers. As a result, there has been a significant move in the disposable packaging industry toward manufacturing using alternative, more environmentally friendly materials. In particular, it is known to manufacture disposable cups and drinking vessels using fiber-based materials that are coated with a material other than polyethylene to provide a water-impermeable layer.

[0003] During the manufacture of such containers, a thin barrier layer is applied to the surface of the fiber-based material prior to winding the coated material into a roll. Such barrier coatings can be organic (e.g., polymers or monomers other than those identified as having environmental concerns, such as polyethylene) or inorganic (e.g., including mineral materials) or a mixture of both. The roll is printed to apply any desired external decoration, and then carefully mechanically cut into accurately measured cup sidewall blanks. The blanks are inserted into a cup former, which wraps the sidewall blanks into a cup shape and seals them, and subsequently adds a cup bottom and heat seals it into place. The seams of the cup are sealed to make the cup liquid-tight. In some cases, the seams between the wall and the base are folded or crimped to further strengthen the outer shape of the cup. Additionally, the upper edge of the wall is often rolled to provide a more comfortable rim for the user when drinking from the cup.

[0004] Such processes are based on and largely replicate the processes used to manufacture cups with polyethylene barrier coatings. However, many more environmentally friendly liquid barrier materials have a lower degree of elasticity than polyethylene. As a result, when substrates coated with these alternative barriers are subjected to the manufacturing processes developed for substrates coated with polyethylene, the different tolerances of the materials can cause problems (e.g., cracking of the coating when the coated substrate is folded or crimped), thus reducing the liquid barrier function. Additionally, flexing of the cup caused by filling the cup with liquid and subsequent manipulation by the user can create cracks in the coating located within the seam, thus causing liquid to be absorbed into the wall of the cup, causing it to become saturated and prone to leaking, or even the complete failure of the seam.

[0005] Accordingly, there is a need for improved container designs that are suitable for use with less elastic liquid barrier coatings to avoid the above-mentioned loss of liquid barrier function and potential seam failure. SUMMARY

[0006] The present invention seeks to address the problems of the prior art.

[0007] Aspects of the present invention are set out in the appended claims.

[0008] According to aspects of the present invention, there is provided a fibre-based packaging container for containing a liquid, the packaging container comprising: a. a tubular wall component comprising an inner wall surface and an outer wall surface opposite the inner wall surface, the inner wall surface comprising a liquid impermeable layer and a base seal portion at one end of the tubular wall component; and b. a circular base component comprising an outer edge, an inner base surface and an outer base surface opposite the inner base surface, the inner base surface comprising a liquid impermeable layer and further comprising: a circumferential region comprising a sealable lacquer coating, a fold line extending circumferentially around the inner base surface within the circumferential region of the inner base surface, and a wall seal portion located on the inner base surface between the outer edge of the circular base component and the fold line, wherein the circular base component is folded about the fold line to form a folded portion comprising the wall seal portion, wherein at least a portion of the wall seal portion and the base seal portion are sealed to each other to form a base seam and provide a three-dimensional container profile, such that the sealable lacquer coating is present within the base seam.

[0009] As the circumferential region of the inner base surface comprising the sealable lacquer coating extends beyond the fold line in a direction away from the outer edge of the base, a portion of the sealable lacquer coating extends across and beyond the fold line. Advantageously, the inventors have identified that by providing the sealable lacquer coating across and beyond the fold line, the sealable lacquer coating, which is inherently more elastic in nature than the liquid impermeable layer, minimises cracking of the less elastic liquid impermeable layer on the inner base surface at the fold line. This strengthens the container at the fold line and also prevents weeping of the liquid into the wall and leakage of the liquid from the container during use.

[0010] In one embodiment, the base seal portion of the tubular wall component further comprises a sealable lacquer coating. This provides an additional layer of sealable lacquer coating between the tubular wall and the circular base component.

[0011] The inner wall surface and / or the inner base surface can comprise the liquid impermeable layer over the entirety or at least substantially all of the entirety of that surface / surfaces.

[0012] Examples of liquid impermeable layer materials and details regarding their properties will now be discussed. These example materials and properties can include in the following: a liquid impermeable layer included on one or more of the inner wall surface, the inner base surface, and / or one or more of the second, third, and / or fourth edges of the quadrilateral blank; a second liquid impermeable layer applied to the rolled edge; a further liquid impermeable layer applied to the inner wall surface and / or the inner base surface; or any other liquid impermeable layer applied to any portion of the container obtainable from the processes of the present invention.

[0013] The liquid impermeable layer included on the inner wall surface and / or the inner base surface can be polymeric and / or monomeric. In certain embodiments, the polymer and / or monomer is of natural origin, i.e. the polymer and / or monomer is produced by an organism (e.g. a microorganism, a plant, or an animal) that is optionally not genetically modified. For example, the liquid impermeable layer can include micro- or nano-cellulose, polyhydroxybutyrate (PHB), polyhydroxyalkanoate (PHA), a plant-derived protein, a plant-derived polysaccharide, a fatty acid (such as stearic acid), or a mixture thereof. In embodiments of the present invention, the liquid impermeable layer does not include polyethylene.

[0014] Additionally or alternatively, the liquid impermeable layer included on the inner wall surface and / or the inner base surface can be inorganic, e.g. it can be a mineral liquid impermeable layer, e.g. it can include a mineral material such as silica, a silica-based material (e.g. a ceramic), an alkoxysilane, calcium carbonate, and / or kaolin. In embodiments, the mineral material is provided in particulate form in an aqueous and / or ethanol solution that can be in the form of a gel (e.g. a sol-gel), which is then applied to the inner wall surface and / or the inner base surface. Examples of materials that can be used to provide a mineral liquid impermeable layer include the materials listed in International Patent Publication Nos. WO2022 / 171893, WO2023 / 285499, WO2022 / 112566, and WO2021 / 019220.

[0015] In preferred embodiments of the present invention, the liquid impermeable layer included on the inner wall surface and / or the inner base surface is biodegradable. In some embodiments, the liquid impermeable layer included on the inner wall surface and / or the inner base surface includes a biodegradable monomer and / or polymer.

[0016] The liquid-impermeable layer included on the inner wall surface and / or the inner base surface can be metallic, for example, it can include metallic particles or a metallic film. However, it is preferred to avoid the use of metals in the liquid-impermeable layer in view of the fact that the inclusion of metals would adversely affect the recyclability of the container to which these metals are applied as well as the need to use mined metals thereby increasing the carbon footprint of the container. Thus, in some embodiments, the liquid-impermeable layer included on the inner wall surface and / or the sealable lacquer coating is free of metallic films. In embodiments, the liquid-impermeable layer included on the inner wall surface and / or the sealable lacquer coating is free of metallic particles. In some embodiments, the liquid-impermeable layer included on the inner base surface and / or the sealable lacquer coating is free of metallic films. In certain embodiments, the liquid-impermeable layer included on the inner base surface and / or the sealable lacquer coating is free of metallic particles.

[0017] In preferred embodiments of the present application, the liquid-impermeable layer included on the inner wall surface and / or the inner base surface is recyclable. In some embodiments, the liquid-impermeable layer included on the inner wall surface and / or the inner base surface includes recyclable monomers and / or polymers.

[0018] The liquid-impermeable layer included on the inner wall surface and / or the inner base surface can be less elastic than polyethylene. LDPE (low-density polyethylene) has an elastic modulus of 0.13 GPa to 0.30 GPa, which has been conventionally used to provide a liquid-impermeable layer to fiber-based containers such as paper cups. Thus, in embodiments of the present application, the liquid-impermeable layer included on the inner wall surface and / or the inner base surface can have an elastic modulus equal to or greater than about 0.3 GPa, equal to or greater than about 0.5 GPa, equal to or greater than about 1 GPa, equal to or greater than about 5 GPa, or equal to or greater than about 10 GPa. In some embodiments, the liquid-impermeable layer included on the inner wall surface and / or the inner base surface can have an elastic modulus of about 1 GPa to about 1000 GPa, about 5 GPa to about 500 GPa, or about 10 to about 100 GPa.

[0019] Where reference is made herein to quantified elastic modulus values, these elastic modulus values are calculated in accordance with ASTM D638 - Standard Test Methods for Plastics: Tensile Properties.

[0020] In embodiments, the liquid-impermeable layer included on the inner wall surface and the inner base surface is the same. In alternative embodiments, the liquid-impermeable layer included on the inner wall surface and the inner base surface is different. As discussed below, whether the liquid-impermeable layer included on the inner wall surface and the inner base surface is the same or different, a sealable lacquer coating can be included on the sealed portions of those surfaces.

[0021] The liquid impermeable layer included on the inner wall surface and / or the inner base surface can have any thickness so long as it provides effective liquid barrier properties. The effective thickness of the layer depends to some extent on the material used to form the layer. However, in embodiments of the present application, the liquid impermeable layer included on the inner wall surface and / or the inner base surface can have a thickness from about 1 to about 100 pm, from about 5 to about 50 pm, from about 10 to about 25 pm, or from about 12 to 20 pm.

[0022] Additionally or alternatively, the liquid impermeable layer can have a weight from about 1 g / m2 2 to about 20 g / m2 2 , from about 2 g / m2 2 to about 12 g / m2 2 , or from about 3 g / m2 2 to about 8 g / m2 2 .

[0023] In some embodiments, the weight / thickness of the liquid impermeable layer applied to the inner wall surface can be greater than the weight / thickness of the liquid impermeable layer applied to the inner base surface. In certain embodiments, the weight / thickness of the liquid impermeable layer applied to the inner base surface can be greater than the weight / thickness of the liquid impermeable layer applied to the inner wall surface. In other embodiments, the weight / thickness of the liquid impermeable layer applied to the inner wall surface can be the same as the weight / thickness of the liquid impermeable layer applied to the inner base surface.

[0024] The liquid impermeable layer can be applied in liquid form (e.g., in aqueous form and / or in solution or emulsion form) and then dried (air dried, via application of heat, etc.) to provide the liquid impermeable barrier. In such embodiments, the liquid impermeable barrier can be applied to the inner wall surface and / or the inner base surface using any technique known to those skilled in the art (e.g., by printing, brushing, spraying, etc.).

[0025] As explained herein, the function of the liquid impermeable layer is to provide a barrier to moisture and liquid that is transferred into the cup wall or base, which would cause the wall and / or base paper fibers to saturate and liquid to leak from. In embodiments, the liquid impermeable layer included on the inner wall surface and / or the inner base surface can provide a Cobb 2 value of less than about 10 g / m2 2 , less than about 5 g / m2 2 , less than about 2 g / m2 2 , less than about 1 g / m2 2 , or about 0 g / m2 60 to the wall and / or base, respectively. The Cobb 60 value is measured according to ISO Standard 535 (Paper and Paperboard).

[0026] In further embodiments, the liquid-impermeable layer comprises an inorganic mineral.

[0027] The outer wall surface and / or the outer base surface can or can not comprise a liquid-impermeable layer.

[0028] In embodiments, the outer wall surface and / or the outer base surface can comprise a varnish (e.g., a whole-body protective varnish). This can be the same material as the sealable lacquer employed in aspects of the present invention or a different material.

[0029] In certain embodiments of the present invention, a sealable lacquer coating is provided on top of the liquid-impermeable layer, e.g., on the wall sealing portion, the base sealing portion, the first edge sealing portion, and / or the second edge sealing portion.

[0030] In some embodiments, the base sealing portion of the wall component can also comprise a sealable lacquer coating to further strengthen the seal of the circular base component to the wall component. In such embodiments, the sealable lacquer coating can be provided on top of the liquid-impermeable layer.

[0031] The inventors have advantageously found that providing a sealable lacquer coating on both surfaces of the circular base component greatly contributes to preventing liquid from entering into the circular base component. Accordingly, in some embodiments, the outer base surface of the circular base component comprises a second wall sealing portion having a sealable lacquer coating. The second wall sealing portion can be positioned circumferentially around the edge of the outer base surface of the circular base component. In such embodiments, the outer base surface of the circular base component can comprise a fold line corresponding to the fold line provided on the inner base surface of the circular base component, and the second wall sealing portion can be located on the outer base surface between the fold line and the outer edge of the circular base component. In such embodiments, the base sealing portion of the wall component can be sealed to both the wall sealing portion and the second wall sealing portion, e.g., by folding around the outer edge of the circular base component.

[0032] Any type of food-approved sealable lacquer coating can be employed in the present invention, so long as it is capable of providing a liquid-resistant seal upon activation. In some embodiments, the lacquer coating can be heat-sealable (e.g., at temperatures of about 100 °C to about 250 °C), e.g., it can be sealable via contact with hot pressurized air. Additionally or alternatively, the lacquer coating can be ultrasonically sealable (e.g., at frequencies of about 20 mHz to about 40 mHz). Other types of sealable lacquer coatings can also be employed, e.g., pressure-sealable lacquer coatings.

[0033] In certain embodiments, the sealable lacquer coating and / or the liquid impermeable layer can be free of fluorinated compounds. In some embodiments, the sealable lacquer coating and / or the liquid impermeable layer can be free of polyfluoroalkyl and perfluoroalkyl substances (PFAS), such as perfluorooctane sulfonic acid (PFOS) and perfluorooctanoic acid (PFOA).

[0034] In embodiments of the present application, the sealable lacquer coating material that can be employed is an environmentally friendly (e.g., biodegradable) material. Advantageously, unlike conventional fiber-based containers that include a polyethylene-based liquid impermeable layer, this permits the container to be composted at home or industrially after disposal of the container. Particular lacquer coating materials that can be utilized include polyolefins, polyurethanes, polyvinyls (e.g., polyvinyl acetate), polyesters, and / or acrylic lacquers. The lacquers can be provided in the form of a solution (e.g., an aqueous solution), which is then applied to the wall and / or base components at the desired location(s). The sealable lacquer coating can be applied at a coating weight of about 1 g / m2to about 50 g / m2, about 3 g / m2to about 30 g / m2, about 5 g / m2to about 25 g / m2, about 6 g / m2to about 22 g / m2, about 8 g / m2to about 20 g / m2, about 10 g / m2to about 15 g / m2, or about 12 g / m2to about 14 g / m2. 2 to about 50 g / m2 2 , about 3 g / m2 2 to about 30 g / m2 2 , about 5 g / m2 2 to about 25 g / m2 2 , about 6 g / m2 2 to about 22 g / m2 2 , about 8 g / m2 2 to about 20 g / m2 2 , or about 10 g / m2 2 to about 15 g / m2 2 .

[0035] In embodiments where both the base sealing portion and the wall sealing portion are provided with sealable lacquer, the weight of the sealable lacquer provided in the wall sealing portion can be greater than the weight of the sealable lacquer provided in the base sealing portion. For example, the weight of the sealable lacquer provided in the wall sealing portion can be about 5 g / m2 2 to about 20 g / m2 2 , about 6 g / m2 2 to about 15 g / m2 2 , or about 10 g / m2 2 to about 15 g / m2 2 . Additionally or alternatively, the weight of the sealable lacquer provided in the base sealing portion can be about 3 g / m2 2 to about 15 g / m2 2 , about 5 g / m2 2 to about 10 g / m2 2 , or about 6 g / m2 2 to about 8 g / m2 2 .

[0036] In certain embodiments, the thickness of the sealable lacquer coating applied to the inner base surface is uniform. For example, the thinnest portion of the sealable lacquer coating applied to the inner base is not less than about 20%, not less than about 30%, not less than about 40%, not less than about 50%, not less than about 60%, not less than about 70%, or not less than about 80% of the thickness of the thickest portion of the sealable lacquer coating applied to the inner base surface.

[0037] The sealable lacquer coating is preferably elastic. In preferred embodiments, the sealable lacquer coating is more elastic than the liquid impermeable layer, i.e., it has a lower modulus of elasticity than the liquid impermeable layer. For example, the sealable lacquer coating can have a modulus of elasticity of less than about 5 GPa, less than about 2 GPa, less than about 1 GPa, less than about 0.5 GPa, less than about 0.2 GPa, or less than about 0.1 GPa. In some embodiments, the sealable lacquer coating has a modulus of elasticity of about 0.01 GPa to about 1 GPa, about 0.012 GPa to about 0.5 GPa, or about 0.015 GPa to about 0.1 GPa.

[0038] Where reference is made herein to a sealable lacquer coating being included over or in a region or portion of a component, the sealable lacquer coating can be included over the entirety or a substantial portion of that region or portion.

[0039] In embodiments of the present application, in a container of the present application, the circumferential region disposed on the inner base surface of the circular base component includes a sealable lacquer coating, and the sealable lacquer coating extends from the outer edge of the circular base component and beyond the base seam. Thus, in an assembled container, a portion of the circumferential region including the sealable lacquer coating extends across the inner surface of the circular base component and beyond the base seam in a direction away from an adjacent tubular wall component. Preferably, the sealable lacquer coating extends at least 2 mm beyond the base seam. In certain embodiments, the sealable lacquer coating extends at least 4 mm beyond the base seam. In some embodiments, the sealable lacquer coating extends at least 6 mm beyond the base seam. Additionally or alternatively, the sealable lacquer coating extends less than 15 mm beyond the base seam. In embodiments, the sealable lacquer coating extends less than 10 mm beyond the base seam. In some embodiments, the sealable lacquer coating extends less than 8 mm beyond the base seam. In certain embodiments, the sealable lacquer coating extends less than 6 mm beyond the base seam.

[0040] In embodiments, the sealable lacquer coating extends over the base seam by about 1 mm to about 10 mm or about 2 mm to about 6 mm. However, it will be appreciated that extending the sealable lacquer coating over the base seam by any distance means that the sealable lacquer coating extends over the fold line. Thus, the sealable lacquer coating protects the base seam from failure due to cracking of the liquid-impermeable layer and / or the seam during filling or flexing of the container, particularly given the less elastic nature of the liquid-impermeable layer.

[0041] In embodiments, the entirety of the inner base surface does not comprise the sealable lacquer coating, i.e. the inner base surface comprises a central portion that does not comprise the sealable lacquer coating.

[0042] In some embodiments, the inner base surface can comprise a second liquid-impermeable layer that covers the sealable lacquer coating extending over the base seam and, optionally, the first liquid-impermeable layer.

[0043] The second liquid-impermeable layer can comprise the same barrier material as the first liquid-impermeable layer applied to the inner base surface of the base.

[0044] In alternative embodiments, the second liquid-impermeable layer can comprise a different barrier material to the liquid-impermeable layer applied to the inner base surface of the base.

[0045] The second liquid-impermeable layer can comprise any of the liquid-impermeable barrier materials and / or have any of the properties of the liquid barrier materials discussed herein.

[0046] The wall component and / or the circular base component of the fibre-based packaging container can comprise any suitable fibre-based substrate, but preferably comprises a paperboard substrate, such as but not limited to cupstock and the like. In embodiments of the present application, the material forming the wall component and the base component can be the same or different.

[0047] In some embodiments, the fibre-based substrate is coated with clay, optionally on the inner wall surface.

[0048] The wall component and the circular base component can have any thickness that provides sufficient structural strength to the assembled container. In embodiments, the wall component and / or the circular base component can have a thickness of about 200 pm to about 2000 pm, about 250 pm to about 1000 pm, about 300 pm to about 500 pm or about 350 pm to about 500 pm (not including the liquid-impermeable layer and any sealable lacquer coating).

[0049] Additionally or alternatively, the wall component and / or the circular base component can have a grammage of about 150 g / m2to about 500 g / m2, about 200 g / m2to about 400 g / m2, about 250 g / m2to about 350 g / m2, or about 300 g / m2. 2 about 500 g / m2.2 , about 180 g / m 2 to about 350 g / m 2 , about 200 g / m 2 to about 330 g / m 2 or about 250 g / m 2 to about 300 g / m 2 of weight. In embodiments, the circular base component is formed of a fiber-based substrate having a weight of greater than 250 g / m 2 , greater than 255 g / m 2 or greater than 260 g / m 2 of weight.

[0050] In some embodiments, the fiber-based substrate included in the wall component has a greater weight than the fiber-based substrate included in the circular base component. In certain embodiments, the fiber-based substrate included in the circular base component has a greater weight than the fiber-based substrate included in the wall component. In other embodiments, the fiber-based substrate included in the wall component has the same weight as the fiber-based substrate included in the circular base component.

[0051] In embodiments of the invention, the circular base component is substantially planar, except for a folded portion that is folded at an angle from the rest of the circular base component. The circular base component can have a diameter of from about 30 mm to about 100 mm, from about 35 mm to about 80 mm, or from about 40 mm to about 65 mm.

[0052] In some embodiments, the end of the tubular wall component opposite the end including the base seal can be rolled, for example, to provide a more comfortable rim for the user when drinking from the cup.

[0053] In embodiments of the invention, a portion of the inner wall surface or the outer wall surface that extends from the fourth edge of the quadrilateral blank / the upper edge of the tubular wall component along the surface partially can include an additional layer of liquid-impermeable barrier material and / or sealable lacquer. In some embodiments, the portion includes a layer of sealable lacquer and an additional layer of liquid-impermeable barrier material applied thereon. The portion can extend from some portion or substantially all of the fourth edge. In embodiments, the portion extends from the entirety of the fourth edge.

[0054] The inventors have found that providing such a portion that extends from the fourth edge of the quadrilateral blank / the upper edge of the tubular wall component advantageously improves the resistance of the container to moisture ingress, in particular from steam if the container of the invention includes a hot beverage. Including the portion can also be advantageous for containers in which a foil or film is sealed over the rim of the container.

[0055] As will be appreciated by those skilled in the art, the tubular wall component can be perfectly cylindrical. In other embodiments, the tubular wall component can not be perfectly cylindrical. For example, it can be tapered, e.g., in the form of a truncated cone and / or such that the diameter of the tubular wall component at the end where the base seal is formed is less than the diameter of the tubular wall component at its opposite end.

[0056] In the assembled container of the present application, the wall seal portion is folded about the fold line towards the outer surface and away from the inner surface substantially perpendicular to the plane of the circular base component. By "substantially perpendicular" it is meant that the wall seal portion is folded about the fold line from the plane of the circular base component by about 80° to about 100°, about 85° to about 95°, or about 90°.

[0057] The fold line can or can not be marked and / or visible prior to folding the wall seal portion. In some embodiments, the fold line can be scored or marked to facilitate reliable and repeatable positioning of the fold.

[0058] By configuring the circular base component as explained herein, this advantageously permits production of containers having liquid impermeable layers formed of materials having low elasticity. Accordingly, according to a further aspect of the present application, there is provided a circular base component having an outer edge, an inner base surface and an outer base surface opposite the inner base surface, the inner base surface being provided with a liquid impermeable layer and having a circumferential region of the inner base surface comprising a sealable lacquer coating.

[0059] In embodiments, the circumferential region (and thus the sealable lacquer coating provided thereon) can extend from the outer edge of the circular base component towards the centre by a distance of at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 10 mm, at least about 11 mm, at least about 12 mm, at least about 13 mm, at least about 14 mm or at least about 15 mm. In certain embodiments, the circumferential region can extend from the outer edge of the circular base component towards the centre by a distance of about 5 mm to about 20 mm, about 7 mm to about 15 mm or about 8 mm to about 12 mm.

[0060] The circular base component of this aspect of the present application can comprise a fold line extending circumferentially around the inner base surface within the circumferential region of the inner base surface. In embodiments, the fold line is visible, e.g., it can be marked or scored.

[0061] The outer base surface of the circular base component can or can not comprise a liquid impermeable layer.

[0062] The circular base component of this aspect of the application can include any of the features of the circular base component included within the container of the application as disclosed herein.

[0063] For example, in embodiments of the application, the outer base surface can include a circumferential region that includes a sealable lacquer coating optionally positioned between the outer edge of the circular base component and the fold line. The fold line can be positioned to correspond to the position of the fold line on the inner base surface, i.e., such that when the circular base component is folded about the fold line on the inner base surface, it is also folded about the fold line in the outer base surface.

[0064] In embodiments in which the outer base surface includes a circumferential region that includes a sealable lacquer coating, the weight of the sealable lacquer coating provided in the circumferential region can be greater than the weight of the sealable lacquer coating provided in the circumferential region of the inner base surface.

[0065] In embodiments, the circumferential region on the outer base surface can extend at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 10 mm, at least about 11 mm, at least about 12 mm, at least about 13 mm, at least about 14 mm, or at least about 15 mm from the outer edge of the circular base component toward the center. In certain embodiments, the circumferential region on the outer base surface can extend a distance from the outer edge of the circular base component toward the center that is less than the distance that the circumferential region on the inner base surface extends from the outer edge of the circular base component toward the center.

[0066] In embodiments of the application, the circular base component of this aspect of the application can be formed by cutting (e.g., die cutting) the circular base component from a web. Accordingly, according to a further aspect of the application, there is provided a web comprising an inner surface and an outer surface opposite the inner surface, the inner surface comprising a liquid impermeable layer and a plurality of circular regions comprising a sealable lacquer coating around a circumferential region of the circular regions and a region free of sealable lacquer coating at the center of the circular regions.

[0067] In embodiments, the sealable lacquer coating can extend at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 10 mm, at least about 11 mm, at least about 12 mm, at least about 13 mm, at least about 14 mm, or at least about 15 mm from the circumference of the circular region toward the center of the circular region. In certain embodiments, the sealable lacquer coating can extend a distance from the circumference of the circular region toward the center of the circular region of about 5 mm to about 20 mm, about 7 mm to about 15 mm, or about 8 mm to about 12 mm.

[0068] In some embodiments, the outer surface of the web can include circular regions positioned on the web to correspond to the locations of the circular regions on the inner surface of the web, wherein the circular regions on the outer surface of the web include a sealable lacquer coating around the circumference of the circular regions, and a region free of the sealable lacquer coating at the center of the circular regions on the outer surface of the web.

[0069] In such embodiments, the sealable lacquer coating included on the outer surface can extend at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 10 mm, at least about 11 mm, at least about 12 mm, at least about 13 mm, at least about 14 mm, or at least about 15 mm from the circumference of the circular regions on the outer surface of the web toward the center of the circular regions. In certain embodiments, the sealable lacquer coating can extend from about 5 mm to about 20 mm, from about 7 mm to about 15 mm, or from about 8 mm to about 12 mm from the circumference of the circular regions toward the center of the circular regions. In certain embodiments, the sealable lacquer coating included on the outer surface can extend a distance from the circumference of the circular regions toward the center of the circular regions that is less than the distance that the sealable lacquer coating on the inner surface of the web extends from the circumference of the circular regions toward the center of the circular regions.

[0070] In embodiments, the circular regions can have a diameter from about 30 mm to about 100 mm, from about 35 mm to about 80 mm, or from about 40 mm to about 65 mm.

[0071] The circular regions provided on the web in this aspect of the application can include any of the features of the circular base components disclosed herein in connection with other aspects of the application.

[0072] According to a further aspect of the application, there is provided a method of producing circular base components for containers, the method comprising: providing a web as discussed herein; and die cutting a plurality of circular regions from the web to provide the circular base components.

[0073] In further embodiments, the tubular wall component can be formed from a quadrilateral wall blank defining four edges. In embodiments, the first edge and the second edge are opposite one another, wherein the first edge seal portion extends partially across the inner wall surface from the first edge, and the second edge seal portion extends partially across the outer wall surface from the second edge. One or both of the first edge seal portion and the second edge seal portion can include a sealable lacquer coating. Optionally, the outer wall surface can include a portion that includes a sealable lacquer coating extending from the first edge. In embodiments, the first edge and the second edge of the quadrilateral wall blank are not parallel.

[0074] In embodiments, the lengths of the first and second edges of the quadrilateral wall blank are equal to one another. As will be appreciated by the skilled person, the use of quadrilateral wall blanks to produce containers is well known, including quadrilateral wall blanks in which notches or other portions are cut out in order to facilitate manufacture of the container (for example, as shown in the second edge 20 in Figure 1 and Figure 2 . For the avoidance of doubt, where reference is made herein to the lengths of the first and second edges of a quadrilateral wall blank being equal to one another, the lengths of these edges are measured without taking into account the effect of such notches or other cut-out portions on the edge lengths, i.e. as if the notches or cut-out portions were not present.

[0075] As noted above, in the container of the present application, the tubular wall component comprises an inner wall surface and an outer wall surface opposite the inner wall surface. The inner wall surface comprises a liquid-impermeable layer. Further, the tubular component comprises a base seal portion at one end of the tubular wall component.

[0076] The tubular wall component can be formed from a quadrilateral blank. Accordingly, according to a further aspect of the present application, there is provided a quadrilateral wall blank comprising an inner wall surface and an outer wall surface opposite the inner wall surface, the inner wall surface comprising a liquid-impermeable layer, the quadrilateral wall blank further comprising: a first edge and a second edge opposite the first edge, wherein the first and second edges are linear; and a third edge and a fourth edge opposite the third edge, each of the third and fourth edges defining an arc, wherein a first edge seal portion extends partially across the inner wall surface from the first edge, and a second edge seal portion extends partially across the outer wall surface from the second edge, and the first and / or second edge seal portions comprise a sealable lacquer coating, and wherein a base seal portion extends partially across the inner wall surface from the third edge.

[0077] In such embodiments, the base seal portion can comprise a sealable lacquer coating.

[0078] The quadrilateral wall blank can be substantially planar.

[0079] The outer wall surface of the quadrilateral blank can or can not comprise a liquid-impermeable layer. Additionally or alternatively, the outer wall surface of the quadrilateral blank can comprise a varnish, which can or can not be the same as the sealable lacquer coating.

[0080] The base seal portion (and optionally the sealable lacquer coating) can extend from some or substantially all of the third edge. In embodiments, the base seal portion (and optionally the sealable lacquer coating) extends from the entirety of the third edge.

[0081] In embodiments, the first edge seal portion (and optionally the sealable lacquer coating) can extend from some portion or substantially all of the first edge. In embodiments, the first edge seal portion (and optionally the sealable lacquer coating) extends from the entirety of the first edge.

[0082] In embodiments, the second edge seal portion (and optionally the sealable lacquer coating) can extend from some portion or substantially all of the second edge. In embodiments, the second edge seal portion (and optionally the sealable lacquer coating) extends from the entirety of the second edge.

[0083] The quadrilateral blank of this aspect of the application can include any of the features of the tubular wall component as disclosed herein included within the container of the application, and vice versa.

[0084] In some embodiments, a portion of the inner wall surface or the outer wall surface that extends partially along the surface from the fourth edge of the quadrilateral blank can include an additional layer of liquid impermeable barrier material and / or sealable lacquer. This portion can extend from some portion or substantially all of the fourth edge. In embodiments, this portion extends from the entirety of the fourth edge. In certain embodiments, this portion can extend from the fourth edge along the surface of the quadrilateral blank a distance of about 5 mm to about 30 mm, about 7 mm to about 20 mm, or about 10 mm to about 15 mm.

[0085] In certain embodiments, the first edge seal portion contacts the base seal portion. For example, the sealable lacquer coating can extend continuously from the first edge and the third edge of the inner wall surface of the quadrilateral blank. Additionally or alternatively, the portion including the sealable lacquer coating can extend continuously from the fourth edge, the first edge (e.g., the first edge seal portion), and / or the third edge (e.g., the base seal portion) of the inner wall surface of the quadrilateral blank. In some embodiments, the portion including the sealable lacquer coating can extend continuously from the fourth edge, the first edge (e.g., the wall seal portion), and the third edge (e.g., the base seal portion) of the inner wall surface of the quadrilateral blank.

[0086] In embodiments of the application, the outer wall surface of the first edge of the quadrilateral blank or tubular component of the container can include a portion of the sealable lacquer coating that extends partially or entirely across the outer wall and can extend from some portion, substantially all, or the entirety of the first edge. Additionally or alternatively, the inner wall surface of the second edge of the quadrilateral blank or tubular component of the container can include a portion of the sealable lacquer coating that extends partially across the inner wall and can extend from some portion, substantially all, or the entirety of the second edge.

[0087] In certain embodiments, one or more of the second edge, the third edge, or the fourth edge of the quadrilateral blank includes a liquid impermeable layer and / or a sealable lacquer coating.

[0088] The first and second edge seal portions can overlap and seal together to form a wall juncture and provide a three-dimensional tubular shape, such that the sealable lacquer coating is present within the wall juncture between the first and second edges.

[0089] Further aspects of the present application provide a method of manufacturing a fibre-based packaging container, the method comprising the steps of: a. providing a quadrilateral blank (optionally, a quadrilateral blank as described herein), the quadrilateral blank comprising an inner wall surface and an outer wall surface opposite the inner wall surface, the inner wall surface comprising a liquid impermeable layer, the quadrilateral wall blank further comprising: a first edge and a second edge opposite the first edge, wherein the first and second edges are linear; and a third edge and a fourth edge opposite the third edge, each of the third and fourth edges defining an arc, wherein a first edge seal portion extends partially across the inner wall surface from the first edge, and a second edge seal portion extends partially across the outer wall surface from the second edge, and wherein a base seal portion extends partially across the inner wall surface from the third edge; b. providing a circular base component (optionally, a circular base component as described herein), the circular base component comprising an outer edge, an inner base surface and an outer base surface opposite the inner base surface, the inner base surface comprising a liquid impermeable layer and a circumferential region comprising a sealable lacquer coating, and a wall seal portion located on the inner base surface within the circumferential region; c. flexing the quadrilateral blank to overlapingly engage the first and second edges with each other and seal (optionally, ultrasonically) them to each other to form a tubular wall component having a wall juncture; d. folding the circular base component at a fold line extending within the circumferential region around the entire circular base component to produce a circumferentially folded edge, the edge comprising the wall seal portion extending from the remainder of the circular base component by 80 to 100 degrees; and e. sealing (optionally, heat sealing) the wall seal portion and the base seal portion to each other to produce a base juncture between the tubular wall component and the circular base component, wherein the sealable lacquer coating is present within the base juncture.

[0090] In an embodiment, the base seal portion of the quadrilateral blank comprises the sealable lacquer coating.

[0091] In an embodiment, the base seal portion of the tubular wall component can be folded around the circumferentially folded edge region, optionally prior to step e and / or after step d.

[0092] In preferred embodiments, a portion of the circumferential portion including the sealable lacquer coating extends across the inner base surface of the circular base component beyond the base seam in a direction away from the adjacent tubular wall component. Preferably, the sealable coating extends beyond the base seam by at least about 2 mm, at least about 4 mm, or at least about 6 mm.

[0093] In further embodiments, one or both of the first and second edge seal portions include a sealable lacquer coating such that the sealable lacquer coating extends into the wall seam formed in step c).

[0094] In some embodiments, the method can further include the step of crimping a fourth edge of the quadrilateral blank or tubular wall component, for example, to provide a more comfortable rim for a user when drinking from the cup.

[0095] In certain embodiments, the method further includes the step of applying a second liquid impermeable layer to the inner base surface of the base. In such embodiments, the second liquid impermeable layer covers the sealable lacquer coating extending across the inner base surface, thus providing additional protection against moisture penetration.

[0096] The second liquid impermeable layer can include the same barrier material as the first liquid impermeable layer applied to the inner base surface of the base.

[0097] In alternative embodiments, the second liquid impermeable layer can include a different barrier material than the liquid impermeable layer applied to the inner base surface of the base.

[0098] The second liquid impermeable layer can include any of the liquid impermeable barrier materials, and / or have any of the properties of the liquid barrier materials discussed herein.

[0099] Those skilled in the art will be familiar with the techniques used to form rolled edges in containers. Typically, this step is performed in an edge forming station, and as part of the process, a lubricant (such as paraffin oil) is applied to facilitate edge curling / forming. However, the inventors have advantageously discovered that by applying a liquid-impermeable barrier instead of a lubricant, the liquid-impermeable barrier material effectively acts as a lubricant, but once dried, it acts as a barrier to provide additional resistance to moisture penetration. Therefore, in embodiments of the invention, no lubricant (other than the liquid-impermeable barrier material) may be applied during the step of rolling the fourth edge of the quadrilateral blank or the upper edge of the tubular wall component to form the rolled edge. In some embodiments, before or during the step of rolling the fourth edge of the quadrilateral blank or the upper edge of the tubular wall component to form the rolled edge, the liquid-impermeable barrier material may be applied to the inner or outer wall surface extending from the fourth edge of the quadrilateral blank or the upper edge of the tubular wall component. This may be a supplement to or alternative to applying a second liquid-impermeable layer to the rolled edge.

[0100] This application discloses various aspects of the invention, such as containers, components of containers, and methods of manufacturing containers. Unless otherwise stated, the disclosure of features in connection with one aspect of the invention is not limited to those features provided only in connection with that aspect. Conversely, where a feature of a component is disclosed in connection with one aspect of the invention, that feature may also be provided in a corresponding component in any other aspect of the invention. Attached Figure Description

[0101] Figure 1 This is a diagram of the outer surface of a container wall blank according to a first embodiment of the present invention; Figure 2 yes Figure 1 A diagram of the inner surface of the blank; Figure 3 This is an illustration of the upper surface of the web of a base blank (each of which is used for a container) according to a first embodiment of the present invention; and Figure 4 This is an illustration of an assembled container according to a first embodiment of the present invention; Figure 5 yes Figure 4 A cross-sectional view of the base portion of an embodiment of a container having a sealable paint coating with standard tolerance areas; Figure 6 yes Figure 4 A cross-sectional view of the base portion of a container of another embodiment, the container having a sealable paint coating with lower tolerance areas; and Figure 7 yes Figure 4A cross-sectional view of the base portion of a container of another embodiment, the container having a sealable paint coating with a high tolerance area.

[0102] Figure 8 This is an image of the container of the present invention after a liquid penetration test.

[0103] Figures 9A and 9B are images of the containers (the container of the present invention and the control container) after a liquid penetration test. Detailed Implementation

[0104] Embodiments of the invention will now be described with reference to, but not limited to, the accompanying drawings.

[0105] Figure 1 and Figure 2 The illustration shows a quadrilateral wall blank 10 comprising a cardboard substrate. The wall blank 10 has a substantially planar inner surface 12 and a substantially planar outer surface 14. The blank 10 defines four edges, namely, a first edge 16, a second edge 20, a third edge 22, and a fourth edge 18. The four edges 16, 18, 20, and 22 extend around the inner surface 12 and the outer surface 14.

[0106] The first edge 16 is opposite to the second edge 20, and both the first edge 16 and the second edge 20 are linear and of the same length. The fourth edge 18 is opposite to the third edge 22, and each of the third edge 22 and the fourth edge 18 defines an arc that extends parallel to each other. The first edge 16 and the second edge 20 are not parallel to each other and extend at an angle such that the length of the fourth edge 18 is greater than that of the third edge 22.

[0107] Once assembled, the inner surface 12 will form the interior of the beverage container, and the outer surface 14 will form the exterior of the beverage container. Therefore, the cardboard substrate of the inner surface 12 is coated with a suitable liquid-impermeable coating (in this case, a mineral barrier coating). As an alternative or supplement to the barrier coating of the embodiment shown in the figure, any suitable liquid-impermeable barrier coating suitable for use with liquids intended for human consumption can be used.

[0108] The outer surface 14 of the wall blank 10 is not provided with a liquid impermeable barrier coating because once assembled, the outer surface 14 forms the outer wall of the beverage container and therefore such a barrier coating is not required, since the outer surface 14 will not come into contact with liquid during use.

[0109] A first edge seal portion 24 is provided on the inner surface 12, which is adjacent to and extends from the full length of the first edge 16. A corresponding second edge seal portion 28 is provided on the outer surface 14, which is adjacent to and extends from the full length of the second edge 20. A base seal portion 26 is provided on the inner surface 12, which is adjacent to and extends from the full length of the third edge 22.

[0110] The base seal portion 26 is provided with a heat sealable lacquer coating applied over the barrier coating.

[0111] Figure 3 A web 30 of paperboard substrate is shown that includes a plurality of circular base components 32. Each base component 32 is circular in shape and includes an inner base surface 34 and an outer base surface (not shown) opposite the inner base surface 34. The inner base surface 34 is provided with a liquid impermeable coating. Each circular base component 32 defines a circular outer edge 36 that extends around the entire circular base component 32. A circumferential region 38 is provided on the base inner surface 34 and is adjacent to and extends from the full length of the outer edge 36. The circumferential region 38 is provided with a heat sealable lacquer coating applied over the liquid impermeable layer. Within the circumferential region 38, a wall seal portion is positioned between the fold line A and the outer edge 36.

[0112] During the assembly process, the quadrilateral wall blank 10 is bent so as to bring the first edge 16 and the second edge 20 toward and over each other, such that the first edge seal portion 24 is brought into engagement with the second edge seal portion 28. Once the first and second seal portions 24, 28 have been overlapped, ultrasonic energy is applied to seal the first and second edge seal portions 24, 28 to each other, thereby creating a sealed wall joint that will subsequently extend along the height of the resulting beverage container or cup. The quadrilateral wall blank 10 now forms a tubular shape and is ready to be assembled with a corresponding circular base component 32.

[0113] During the assembly process, the circular base component 32 is punched from the sheet 30 and inserted into a base mold of a cup forming machine (not shown). The fold line A is located within the circumferential portion and extends around the circular base component 32. The circular base component 32 is then folded along the fold line A at an angle of approximately 90 degrees, such that the heat sealable lacquer coating in the circumferential region extends across and beyond the fold line.

[0114] The quadrilateral wall blank 10 is also folded about the fold lines B and C to create a U-shaped profile (see Figure 5 to Figure 7 ).

[0115] The folded portion 40 of the circular base component 32 is then positioned within the U-shaped profile of the quadrilateral wall blank 10 such that, when the folded quadrilateral wall blank 10 and the folded circular base component 32 are brought into engagement with one another, the wall seal portion comprised within the circumferential region 38 between the outer edge 36 and the fold line A overlaps with the base seal portion 26 of the quadrilateral wall blank 10. Pressure and heat are then applied to cause the base seal portion 26 and the wall seal portion to heat seal with one another, thereby retaining a portion of the sealable lacquer coating within the resulting heat seal joint located at the base of the beverage container (see Figure 5 to Figure 7 ).

[0116] Thus, a portion of the circumferential region 38 and, therefore, the heat sealable lacquer coating applied to that portion will then extend beyond the fold in the base 32, such that there will be a small margin of heat sealable lacquer coating at the internal base surface of the fully assembled beverage container. This positioning of a portion of the circumferential region and, therefore, the heat sealable lacquer coating will provide for a positional fluctuation during the application of the heat sealable lacquer coating to the web 30 prior to the cutting out of the circular base component 32. This positioning also ensures that the heat sealable lacquer coating will protect the edges of the barrier coating which can crack during the folding process due to the less elastic nature of the liquid impermeable coating layer. This is illustrated in Figure 5 which shows a standard tolerance region of the heat sealable lacquer coating extending across the internal surface 34 of the circular base component of the assembled beverage container.

[0117] It will be appreciated that different tolerance regions of the sealable lacquer coating can arise due to positional fluctuation during the application of the sealable lacquer coating to the web 30 prior to the cutting out of the circular base component 32. Figure 6 a cross-section is shown in which there is a low tolerance region of the sealable lacquer coating extending across the internal surface 34 of the circular base component of the assembled beverage container, and Figure 7 a cross-section is shown in which there is a high tolerance region of the sealable lacquer coating extending across the internal surface 34 of the circular base component of the assembled beverage container.

[0118] The assembled beverage container is shown in Figure 4 and comprises an internal space defined by a portion of the internal surface 12 of the tubular component 10 and a portion of the circular base component internal surface 34, such that the entire exposed internal liner of the beverage container is provided with a liquid impermeable coating.

[0119] Therefore, when the circular base component 32 is folded, the sealable varnish coating prevents the liquid-impermeable layer from cracking at the fold line A. Additionally, the sealable varnish coating may also be applied to the first sealing portion 24 and the second sealing portion 28. The resulting seal will then contain the sealable varnish within it. Because the sealable varnish is elastic, this will also help maintain the integrity of the seal that extends along the height of the beverage container, even when it is flexed during liquid filling and / or during user manipulation.

[0120] Therefore, the combination of a liquid-impermeable layer and a sealable varnish coating contributes to the usability of the beverage container. The liquid-impermeable layer provides a liquid barrier to prevent liquid from approaching the cardboard substrate. The sealable varnish coating allows for sealing to form a seal that maintains the three-dimensional shape of the beverage container. Furthermore, because the sealable varnish coating is also elastic, the seal remains intact and leak-proof even when the beverage container is flexed (e.g., when filled with liquid and / or handled by a user). Therefore, the present invention provides a disposable beverage container that is reliable, leak-proof, and durable during use.

[0121] This is a significant advantage over conventional disposable cups of the prior art, where the heat-sealing operation relies on a liquid-impermeable barrier coating to form a heat-sealed portion at the sealing point (when heat and pressure are applied during the manufacturing process). It also advantageously permits the production of disposable cups that do not contain materials that would render the cup non-recyclable (such as polyethylene). In this application, the presence of a resilient sealant at the folds in the seal and the circular base portion of the cup will prevent seal failure and cup leakage.

[0122] It will be understood that the containers of the present invention are not limited to beverage containers (such as cups), but are equally applicable to any other food or liquid packaging, such as, but not limited to, bowls, jugs, paint cans, paper drums or any other similarly manufactured liquid-impermeable disposable containers.

[0123] The invention will now be illustrated by the following examples.

[0124] Example 1 - Test of liquid absorption rate entering the base of the container Paper cups are manufactured as discussed in this article. The walls and base of the cups are produced from standard weights of clay-coated paper cup paperboard. A mineral coating including silica is used as an emulsion at ~5 g / m³. 2 The coating weight is applied to the inner surface of the base and the inner wall surface of the quadrilateral blank, and then allowed to dry. For the first set of cups (control), the sealant is applied at ~10 g / m². 2only to a circumferential region of the inner base surface that extends from the fold line to the outer edge. For the second set of cups (inventive), the sealable lacquer (same coating weight) is applied at a circumferential region that extends from the outer edge of the container base beyond the fold line by a distance that spans 8 mm of the inner base surface from the fold line.

[0125] The cups were filled with coffee at a temperature of 95°C and left to stand for 60 minutes. After this time, the container base of the first set of cups had absorbed an unacceptable volume of fluid, whereas the container base of the second set of cups was resistant to moisture ingress as shown in Figure 8

[0126] Example 2 - Effect of sealable lacquer extending inwardly beyond the fold line Two sets of 12 oz paper cups were manufactured as discussed herein. Both sets comprised tubular wall components and circular base components that comprised a mineral coating including silica. The circular base components were formed from stock paper having a weight of 265 g / m2.

[0127] In the first set of cups (inventive), a circumferential region of the upper surface of the circular base component comprised sealable lacquer and extended from the outer edge of the circular base component towards the centre of the component, thereby crossing the fold line by 10 mm.

[0128] In the second set of cups (comparative), a circumferential region of the upper surface of the circular base component comprised sealable lacquer and extended from the outer edge of the circular base component to the fold line, but did not cross the fold line, in accordance with the configuration disclosed in EP4043362.

[0129] Both sets of cups were filled with coffee at a temperature of 93°C and the filled cups were then left to stand for one hour.

[0130] After one hour, the cups were emptied and their interiors inspected. An interior image of an example from a cup of the first set (inventive) is provided as Figure 9A. As can be seen, there is little visible penetration of coffee into the rim of the cup base, demonstrating that the mineral barrier is effectively functioning to prevent moisture ingress into the cup base. In contrast, as can be seen from Figure 9B (an interior image from a cup of the second set (comparative)), the lack of sealable lacquer extending inwardly from the fold line towards the centre of the upper surface of the base results in substantial penetration of coffee into the rim of the cup base. Additionally, the base of the comparative cup was softer and more friable to the touch than the corresponding inventive cup.​

Claims

1. A fiber-based packaging container for containing liquids, the packaging container comprising: a. A tubular wall component, comprising an inner wall surface and an outer wall surface opposite to the inner wall surface, the inner wall surface comprising a liquid-impermeable layer and a base sealing portion at one end of the tubular wall component; as well as b. A circular base component, comprising an outer edge, an inner base surface, and an outer base surface opposite to the inner base surface, the inner base surface comprising a liquid-impermeable layer, and further comprising: a circumferential region extending from the outer edge, the circumferential region comprising a sealable paint coating, a fold line extending circumferentially around the inner base surface within the circumferential region of the inner base surface, and a wall-sealing portion located on the inner base surface between the outer edge of the base and the fold line, wherein the circular base component is folded around the fold line at 80 to 100 degrees to form a folded portion including the wall-sealing portion. Wherein, at least a portion of the wall sealing portion and the base sealing portion seal each other to form a base joint and provide a three-dimensional container shape, such that the sealable paint coating exists within the base joint.

2. The fiber-based packaging container according to claim 1, wherein, The base sealing portion of the tubular wall component has a sealable paint coating.

3. The fiber-based packaging container according to claim 1 or 2, wherein, The liquid-impermeable layer comprises inorganic minerals, and the sealable coating is disposed on top of the inorganic mineral layer.

4. The fiber-based packaging container according to any one of claims 1 to 3, wherein, A portion of the circumferential area including the sealable paint coating extends across the inner base surface beyond the base joint in a direction away from the tubular wall component.

5. The fiber-based packaging container according to claim 4, wherein, The sealable coating extends across the inner base surface at least 2 mm beyond the base joint.

6. The fiber-based packaging container according to any of the preceding claims, comprising a cardboard substrate.

7. The fiber-based packaging container according to any of the preceding claims, wherein, The sealable paint coating, including the circumferential region on the surface of the inner base, is a heat-sealable paint coating.

8. The fiber-based packaging container according to any of the preceding claims, wherein, The liquid-impermeable layer included on the circular base component and / or the tubular wall component has an elastic modulus of about 1 GPa or greater.

9. The fiber-based packaging container according to claim 8, wherein, The sealable paint coating, including the circumferential region on the surface of the inner base, has a lower elastic modulus than the liquid-impermeable layer disposed on the surface of the inner base.

10. A fiber-based packaging container according to any of the preceding claims, wherein, The sealable paint coating, including the circumferential region on the surface of the inner base, has an elastic modulus of less than about 0.5 GPa.

11. A fiber-based packaging container according to any of the preceding claims, wherein, The sealable paint coating, including the circumferential region on the surface of the inner base, has an elastic modulus of less than about 0.1 GPa.

12. The fiber-based packaging container according to any of the preceding claims, wherein, The elastic modulus of the sealable coating on the inner base surface is higher than that of the liquid-impermeable layer disposed on the inner base surface.

13. The fiber-based packaging container according to any of the preceding claims, wherein, The outer base surface of the circular base component includes a circumferential region extending from the outer edge, the circumferential region including a sealable paint coating.

14. A circular base component having an outer edge, an inner base surface, and an outer base surface opposite to the inner base surface, the inner base surface being provided with a liquid-impermeable layer and having a circumferential region extending from the outer edge of the inner base surface, the circumferential region including a sealable paint coating.

15. The circular base component according to claim 14, wherein, The outer base surface has a circumferential region extending from the outer edge, the circumferential region including a sealable paint coating.

16. A quadrilateral wall blank, comprising an inner wall surface and an outer wall surface opposite to the inner wall surface, the inner wall surface comprising a liquid-impermeable layer, the quadrilateral wall blank further comprising: A first edge and a second edge opposite to the first edge, wherein the first edge and the second edge are linear; and a third edge and a fourth edge opposite to the third edge, each of the third edge and the fourth edge defining an arc, wherein: a. A first edge sealing portion extends partially across the inner wall surface from the first edge, and a second edge sealing portion extends partially across the outer wall surface from the second edge, wherein the first edge sealing portion and / or the second edge sealing portion comprises a sealable paint coating; and b. The base sealing portion extends partially from the third edge across the inner wall surface.

17. The quadrilateral wall blank according to claim 16, wherein, The base sealing portion includes a sealable paint coating.

18. The quadrilateral wall blank according to claim 16 or 17, wherein, The outer wall surface includes a portion of a sealable paint coating that extends partially across the outer wall surface from the first edge.

19. The quadrilateral wall blank according to any one of claims 16 to 18, further comprising a portion of a sealable paint coating extending partially from the fourth edge across the inner wall surface and / or the outer wall surface.

20. The fiber-based packaging container according to any one of claims 1 to 13 or the circular base component according to claim 14 or 15, wherein, The liquid-impermeable layer on the surface of the inner base does not include a metal film.

21. The fiber-based packaging container according to any one of claims 1 to 13 or the quadrilateral wall blank according to any one of claims 16 to 19, wherein, The liquid-impermeable layer on the inner wall surface does not include a metal membrane.

22. The fiber-based packaging container according to any one of claims 1 to 13, wherein, The tubular wall component is formed from a quadrilateral wall blank according to any one of claims 16 to 19 or 21, wherein the first edge sealing portion and the second edge sealing portion overlap and seal together to form a wall joint and provide a three-dimensional tubular shape, such that the sealable paint coating is present in the wall joint between the first edge and the second edge.

23. The fiber-based packaging container according to claim 22, wherein, The outer wall surface of the tubular component includes a sealable paint coating adjacent to the wall joint.

24. A method for manufacturing a fiber-based packaging container, wherein, The method includes the following steps: a. A quadrilateral blank comprising an inner wall surface and an outer wall surface opposite to the inner wall surface, the inner wall surface comprising a liquid-impermeable layer, the quadrilateral blank further comprising: a first edge and a second edge opposite to the first edge, wherein the first edge and the second edge are linear; and a third edge and a fourth edge opposite to the third edge, each of the third edge and the fourth edge defining an arc, wherein a first edge sealing portion extends partially from the first edge across the inner wall surface, and a second edge sealing portion extends partially from the second edge across the outer wall surface; and wherein a base sealing portion extends partially from the third edge across the inner wall surface; b. A circular base component is provided, the circular base component including an outer edge, an inner base surface and an outer base surface opposite to the inner base surface, the inner base surface including a liquid-impermeable layer and a circumferential region extending from the outer edge including a sealable paint coating, and a wall-sealing portion located in the circumferential region on the inner base surface; c. Flex the quadrilateral blank to make the first edge and the second edge overlap and join with each other, and seal them together to form a tubular wall component with a wall joint; d. Folding the circular base component at a fold line extending within the circumferential region to create a circumferentially folded edge, the edge including a wall-sealing portion extending at 80 to 100 degrees from the remainder of the circular base component; and e. Seal the wall sealing portion and the base sealing portion together to create a base joint between the tubular wall component and the circular base component, wherein the sealable paint coating is present within the base joint.

25. The method according to claim 24, wherein, A portion of the circumferential region including the sealable paint coating extends across the inner base surface beyond the base joint in a direction away from the adjacent tubular wall component.

26. The method of claim 25, wherein, The sealable coating extends at least 2 mm beyond the base joint.

27. The method according to any one of claims 24 to 26, wherein, One or both of the first edge sealing portion and the second edge sealing portion include a sealable paint coating such that the sealable paint coating is present within the wall joint formed in step c).

28. The method according to any one of claims 24 to 27, wherein, The quadrilateral wall blank is a quadrilateral wall blank according to any one of claims 16 to 19 or 21, and / or the circular base component is a circular base component according to any one of claims 14, 15 or 20.

29. The method according to any one of claims 24 to 28, wherein, The base sealing portion of the tubular wall component is folded around the circumferentially folded edge region prior to step e.

30. A container that can be obtained from the process according to any one of claims 24 to 29.

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