Sealed single-dose paper package with improved break opening

Description

[0001] The present invention relates to the field of packaging and in particular to the field of sealed single-dose packages with a break opening of the "one hand opening" type, i.e. which may be opened by bending the package with one hand. Such packages are known e.g. from IT 2018 0001 0275 A1 or US 2011 / 170938 A1.

[0002] These packages, by virtue of the indisputable practicality of use thereof, have become considerably widespread; currently, several hundreds of millions of packages of this type are marketed every year in many industries, for example for food products, such as sauces and other condiments, and pharmaceutical products, such as eye drops and dermatological creams.

[0003] Given the enormous diffusion of such packages and a profound change in the attitudes of the consumer towards the issues of sustainability and environmental protection, the problem of the correct disposal of used packages is now particularly felt. Such packages are substantially made from film consisting of a plastics material, and therefore the consumer is now particularly careful when it comes to the purchasing thereof. Furthermore, after use, it is necessary that they be disposed of in a differentiated manner.

[0004] The object of the present invention is to provide a predominantly paper, cardboard or cellulose-based package that may be recycled amongst paper packages, whilst also providing for an adequate barrier to gas and vapors.

[0005] The object of the present invention is to provide a sealed single-dose package with a break opening which meets the needs of the field and at the same time overcomes the aforementioned drawbacks.

[0006] Such an object is achieved by a sealed single-dose package with a break opening according to claim 1. The dependent claims disclose further advantageous embodiments of the invention.

[0007] The features and advantages of the package according to the present invention will appear more clearly from the following description, given by way of non-limiting example with reference to the drawings of the accompanying figures, in which: Figure 1 shows a sealed single-dose package according to an embodiment of the present invention, shown from the front; Figure 2 shows an example diagram of the multi-layer structure of a semi-rigid sheet of the package according to one embodiment of the invention; Figure 3 shows the front face of a semi-rigid sheet of the package, according to one embodiment of the invention; Figure 4 shows the rear face of a semi-rigid sheet of the package, according to one embodiment of the invention; Figures 5a to 5b show further embodiments of the rear face of the semi-rigid sheet of the package; Figures 6a to 6c show some embodiments of the semi-rigid sheet of the package; Figures 7a to 7c show further embodiments of the semi-rigid sheet of the package; Figures 8a and 8b show still further embodiments of the rear face of the semi-rigid sheet of the package.

[0008] With reference to the figures of the accompanying tables, reference numeral 1 denotes a sealed single-dose package with a break opening.

[0009] The package 1 comprises a semi-rigid sheet 2, delimited by a peripheral edge 3 and having a rear face 2a and an opposite front face 2b, and a flexible sheet 4, having an inner face 4a and an outer face 4b. The flexible sheet 4 is superimposed on the semi-rigid sheet 2, in such a way that the inner face 4a is facing the front face 2b, and is welded thereto, so as to form an inner pocket 6 for containing one dose of a product, generally a creamy or thick or gel-like product, such as a hand sanitizing gel.

[0010] For example, according to one embodiment, the semi-rigid sheet 2 has a rectangular shape and has opposite long sides 3' and opposite short sides 3''; the semi-rigid sheet 2 extends along a longitudinal axis X parallel to the long sides 3'.

[0011] The semi-rigid sheet 2, which for example has a thickness of between 300 - 750 microns overall, is a multi-layer laminate comprising a carrier layer 10 having said rear face 2a. The carrier layer 10, which is mono-layer or multi-layer, is made of paper, cardboard or another material mainly based on cellulose (i.e. based on cellulose for at least 50% by weight). The carrier layer 10 has, for example, a thickness of between 250 - 700 microns.

[0012] Preferably, internally, the semi-rigid sheet 2 comprises a barrier layer 12 suitable for providing a barrier against the passage of gas, for example oxygen, and vapor.

[0013] For example, the barrier layer 12 is mono-layer or multi-layer, in aluminum or EVOH (ethylene vinyl alcohol), or combinations thereof. In those variants wherein the barrier layer is multi-layer, some films may be made from non-barrier materials.

[0014] Alternatively, the carrier layer 10 has a film coated onto the face opposite the front face 2a, wherein said coated film has barrier properties.

[0015] Alternatively, the carrier layer 10 is subjected to chemical treatment so as to cause it to assume barrier properties, at least upon the face opposite to the rear face 2a. Alternatively, a metallized film, for example metallized PET or metallized PE, is bonded to the carrier layer 10, wherein the metallization faces towards the paper.

[0016] On the opposite side of the rear face 2a, and preferably between the carrier layer 10 and the barrier layer 12, the semi-rigid sheet 2 also comprises at least one intermediate layer 14, which is mono-layer or multi-layer, comprising an adhesive or an extruded polymer, for example polyethylene or polypropylene, or another material that binds with the carrier layer 10.

[0017] Furthermore, the semi-rigid sheet 2 comprises a final layer 16 having said front face 2b. The final layer 16, which is mono-layer or multi-layer, comprises polyethylene or polypropylene or a solder varnish or another material that is adapted to be welded to the flexible film 4.

[0018] The flexible sheet 4 is a multi-layer laminate comprising an inner layer having said inner face 4a. The inner layer, which is mono-layer or multi-layer, comprises polyethylene or polypropylene or a solder varnish or another material suitable for being welded to the semi-rigid film 2.

[0019] Externally, the flexible sheet 4 comprises an outer layer having said outer face 4b. The outer layer 32, which is mono-layer or multi-layer, comprises paper, cardboard or another material mainly based on cellulose.

[0020] Furthermore, the flexible sheet 4 preferably comprises an intermediate layer arranged between the inner layer and the outer layer. For example, the intermediate layer, which is mono-layer or multi-layer, has barrier properties and comprises aluminum or EVOH, and / or has binding properties with the inner layer 30 and with the outer layer 32. Alternatively, the outer layer has a film coated upon the face opposite the outer face 4b, wherein said coated film has barrier properties. According to an embodiment variant, the flexible sheet 4 has no intermediate layer and the inner layer is directly in contact with the outer layer.

[0021] Overall, the package 1 provides that the paper, cardboard or other mainly cellulose-based material of the semi-rigid sheet and the paper, cardboard or other mainly cellulose-based material of the flexible sheet together constitute at least 60% by weight of the entire (empty) package.

[0022] The semi-rigid sheet 2 has a weakened portion, and in particular at least one incision, in order to allow the package to be opened. When the sealed package is bent, controlled breakage of the semi-rigid sheet 2 is determined along this weakened portion so as to determine the formation through said sheet of an opening for the product to escape.

[0023] As shown in Figure 3, on the front face 2b of the semi-rigid sheet 2, namely the face that at least partially defines the inner pocket 6 in which the product is contained, there is an inner incision 20 that extends along an incision direction Y which is for example transversal, i.e., in the above embodiment, along a direction incident to the longitudinal axis X, preferably orthogonal thereto.

[0024] With reference to Figure 2, the inner incision 20 impacts upon the final layer 16, without affecting the barrier layer 12. The inner incision 20 may be a cut passing through the layers or else a localized deformation of the layers themselves.

[0025] In one embodiment, the inner incision 20, as the depth varies, has a constant cross section.

[0026] In one embodiment, the inner incision 20 has a tapered cross section, wherein it has a triangular cross section with the point towards the carrier layer 10.

[0027] According to the present invention, the barrier layer 12 has an interruption, i.e., it has a micro-hole 201 of extremely small dimensions.

[0028] Preferably, the micro-hole 201 realizes an opening in all of the layers of the semi-rigid sheet 2, with the exception of the paper layer. Referring to Figure 2, the micro-hole 201 is formed in the layers 14, 12, and 16.

[0029] Preferably, the micro-hole 201 at least partially follows the geometry of the inner incision 20.

[0030] Advantageously, the micro-hole 201 serves to trigger the breaking of the barrier layer 12, and to promote the breaking of any further elastic layers (the intermediate layer 14 and final layer 16 where present) of the rigid sheet 2, during the bending of the package. In fact, unlike the paper carrier layer 10, the barrier layer 12 is elastic and tends to elongate rather than break, such as to prevent in some cases the correct opening of the package. The micro-hole 201, during the bending of the package, therefore ensures the propagation of the cracking of the barrier layer 12 which then opens correctly.

[0031] Preferably, the micro-hole 201 has an extension along the incision direction Y of at most 15 mm, and an extension along the longitudinal axis X of less than 35 microns.

[0032] Preferably, as in Figures 6a and 7a, the micro-hole 201 crosses all of the layers of the semi-rigid sheet 2 except the paper carrier layer 10. For example, the micro-hole 201 passes through the final layer 16, the barrier layer 12 and the intermediate layer 14.

[0033] In one embodiment, the micro-hole 201 extends in such a way as to also partially act upon the paper carrier layer 10.

[0034] Preferably, the micro-hole 201 is separated from the external environment by the interposition of a portion of the barrier layer 10, referred to as the barrier portion 101. The barrier portion 101 is therefore the portion of the barrier layer 10 that is interposed between the micro-hole 201 of the barrier layer 12 and the external environment.

[0035] Preferably, the barrier portion 101 of the barrier layer 10 has a minimum thickness of 10 microns.

[0036] It should be noted that the paper that makes up the carrier layer 10 does not have barrier properties as regards the passage of gas and vapor, or in any case not significant properties thereto. The extremely small size of the micro-hole 201 does however mean that the surface of the carrier layer 10, which in effect remains without a barrier layer 12, is so small that it is irrelevant to the shelf life of the product.

[0037] The package according to the present invention is particularly suitable for dense fluid products, insofar as they are not absorbed by the paper, cardboard or cellulose barrier layer 10. For example, the package according to the present invention is particularly suitable for fluid products with a dynamic density of between 10 and 4,000 Pose (P), i.e. of between 1 and 400 Poiseuille (PI).

[0038] As shown in Figure 4, the rear face 2a of the semi-rigid sheet 2, at the pocket 6, has an outer incision 8 extending along an incision direction Y which is for example transversal, i.e., in the aforementioned embodiment, along a direction incident to the longitudinal axis X, preferably orthogonal thereto. The outer incision 8 is suitable for guiding, upon a bending of the package 1, a controlled breakage of the semi-rigid sheet 2 along the incision itself so as to determine the formation, through said semi-rigid sheet, of an opening for the product contained in the pocket 6 to escape.

[0039] For example, the outer incision 8 joins two opposite points 3a, 3b of the peripheral edge 3; in the aforementioned embodiment, this means that it extends over the entire width of the rectangular semi-rigid sheet.

[0040] According to a further embodiment variant, the outer incision 8 is interrupted before the perimeter edge 3, or it starts from a point on the peripheral edge 3 and is interrupted before reaching the other point of the peripheral edge 3.

[0041] The outer incision 8, where present as in Figures 6a and 7a, partially crosses the carrier layer 10 of the semi-rigid sheet 2.

[0042] Said incision has a depth H with respect to the front face 2a that is typically variable transversely along the outer incision 8. For example, the depth is greatest in a central segment of the incision. Advantageously, this variation in depth along the incision ensures the opening at breakage in a controlled manner, preventing the break from being sudden and therefore preventing the product from being projected outwards in a damaging manner.

[0043] According to an embodiment shown in Figures 6b and 7b, the outer incision 8 is aligned, i.e. completely superimposed, with the inner incision 20.

[0044] According to an embodiment shown in Figures 6c and 7c, the outer incision 8 is misaligned, i.e. not completely superimposed, with the inner incision 20.

[0045] In one embodiment, the outer incision 8 has a constant cross section as the depth varies, as in the examples of Figures 6a to 6c, in which it has a rectangular or square cross section.

[0046] In one embodiment, the outer incision 8 has a tapered cross section, as in the examples of Figures 7a to 7c, in which it has a triangular cross section with the point towards the carrier layer 10.

[0047] According to the present invention, the term "incision" refers exclusively to a cut that leads to the breaking of the structural continuity of the layers or films that make up a sheet.

[0048] According to a further embodiment variant (Figures 5a and 5b), the semi-rigid sheet 2, in order to facilitate the bending of the package, has at least one weakened portion that is separate and preferably aligned with the inner incision 20.

[0049] Preferably, the rear face 2a of the semi-rigid sheet 2 has at least one weakened portion; for example, the rear face 2a has two weakened portions 40', 40" placed side by side with the inner incision 20. Where the outer incision 8 is present, the two weakened portions 40', 40" are aligned with the outer incision 8. In such an example, the outer incision 8 is interrupted before the perimeter edge 3. Said weakened portions have a depth less than or equal to that of the outer incision 8.

[0050] Preferably, each weakened portion consists of an incision (Figure 5a). According to one embodiment variant, each weakened portion consists of a plurality of holes.

[0051] Alternatively (Figure 5b), each weakened portion consists of a recess obtained along the perimeter edge 3 of the semi-rigid sheet 2. For example, two recesses 42', 42" are provided, side-by-side with the inner incision 20. Where the outer incision 8 is present, the two recesses 42', 42" are aligned with the outer incision 8. In such an example, the outer incision 8 is interrupted before the perimeter edge 3.

[0052] Further embodiments of the invention are now described.

[0053] According to one embodiment, the inner incision of the carrier layer has a constant depth.

[0054] According to one embodiment, the outer incision of the carrier layer has a constant depth.

[0055] According to an embodiment variant of the package according to the invention, the semi-rigid sheet has a circular or oval shape or a regular or mixed polygonal shape, i.e. consisting of rectilinear sections and arched sections.

[0056] According to one embodiment, the outer incision 8 extends along a broken line 85, i.e. a line consisting of an ordered set of segments oriented consecutively (i.e. the second end of a segment coincides with the first end of the next segment) and not adjacently (i.e. a segment and the next segment do not belong to the same line).

[0057] In an embodiment variant, the broken line 85 comprises two lateral segments 86 which are identical in size and aligned with each other (i.e. one segment lies on the extension of the other). The broken line 85 further comprises a main line 87 which is substantially offset with respect to the two lateral segments 86 and by two joining segments 88 which are substantially parallel to each other and preferably are substantially perpendicular to the two lateral segments 86. In other words, each joining segment 88 connects an end of the lateral segment 86 to an end of the main line 87.

[0058] In one embodiment (Figure 8a), the main line 87 is a straight segment substantially parallel to the two lateral segments 86 and substantially perpendicular to the joining segments 88. In a further embodiment (Figure 8b), the main line 87 comprises two straight segments 87', 87" which form therebetween an acute or obtuse angle, i.e. they are not aligned. Said straight segments 87', 87" also form an acute or obtuse angle with the joining segments 88. In a further embodiment, the main line 87 is an arc of circumference. In a further embodiment variant, the broken line 85 comprises two lateral segments 86 which are identical in size and aligned therebetween (i.e. one lies upon the extension of the other). The broken line 85 further comprises an arc of circumference, preferably a semi-circle, which connects an end of a first lateral segment 86 to an end of a second lateral segment 86. According to different embodiments, the two lateral segments 86 and / or the joining segments 88 may be linear, angled or curved.

[0059] Innovatively, the package according to the present invention overcomes the drawbacks mentioned with reference to the prior art, insofar as it makes it possible to have a package having very low environmental impact, and that is in particular recyclable together with paper and capable of always opening itself correctly whilst providing an adequate barrier against the passage of gases, for example oxygen, and vapor.

[0060] It is clear that a person skilled in the art, in order to satisfy contingent needs, could make modifications to the package described above, said modifications all being contained within the scope of protection defined in the following claims.

Claims

1. A sealed single-dose package (1) with break opening, comprising: - a multilayer semi-rigid sheet (2) having a rear face (2a) and an opposite front face (2b), said semi-rigid sheet (2) comprising: -- a carrier layer (10) having said rear face (2a); -- a barrier layer (12) adapted to provide a barrier against the passage of gas and vapor; -- a final layer (16) having said front face (2b); - a flexible sheet (4), having an inner face (4a) and an outer face (4b), superimposed on the semi-rigid sheet (2) so that the inner face (4a) faces the front face (2b), and welded to the front face (2b) of the semi-rigid sheet (2) so as to form an inner pocket (6) for containing one dose of a product; - an outer incision (8) extending along an incision direction (Y), made in the rear face (2a) of the semi-rigid sheet (2), adapted to guide, upon a bending of the package (1), a breakage of the first sheet (2) to form an opening for the product contained in the pocket (6) to escape; - on the front face (2b), at the pocket (6), an inner incision (20) extending along an incision direction (Y), wherein said inner incision (20) does not indent the barrier layer (12); characterized in that the barrier layer (12) has an interruption (201) aligned with said outer incision (8), wherein the interruption (201) partially follows the geometry of said inner incision (20), and in that the carrier layer (10) is made of paper, cardboard or other cellulose-based material.

2. Sealed single-dose package (1) according to claim 1, wherein a portion of the barrier layer (10), referred to as the barrier portion (101), is present between the interruption (201) of the barrier layer (12) and the external environment.

3. Sealed single-dose package (1) according to claim 2, wherein said barrier portion (101) of the barrier layer (10) has a minimum thickness of 10 microns.

4. Sealed single-dose package (1) according to any one of the preceding claims, wherein the paper, cardboard or other cellulose-based material of the carrier layer (10) has no gas and vapor barrier properties.

5. Sealed single-dose package (1) according to any one of the preceding claims, wherein said pocket (6) contains a dense product with dynamic density between 1 and 400 Poiseuille (PI).

6. Sealed single-dose package (1) according to any one of the preceding claims, wherein the interruption (201) forms an opening in all the layers of the semi-rigid sheet (2), with the exception of the carrier layer (10).

7. Sealed single-dose package (1) according to any one of the preceding claims, wherein the interruption (201) has - an extension of 15 mm maximum along the incision direction (Y), and / or - an extension along a longitudinal axis (X) transverse to the incision direction (Y) less than 35 microns.

8. Sealed single-dose package (1) according to any one of the preceding claims, wherein said outer incision (8) partially crosses the carrier layer (10) of the semi-rigid sheet (2).

9. Sealed single-dose package (1) according to any one of the preceding claims, wherein the outer incision (8) is aligned with the inner incision (20).

10. Sealed single-dose package (1) according to any one of the preceding claims, wherein the semi-rigid sheet (2) has at least one weakened portion, separate from and aligned with the inner incision (20) and / or the outer incision (8).

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