Improvements in or relating to packaging

Abstract

A hybrid packaging article is provided and comprises an inner container formed from a plastics material and an outer wrap or sleeve which is formed from a paper or paper-based material and which is securable to the container. The wrap or sleeve is secured to the container only by mechanical fixing such that the container and the wrap or sleeve are separable.

Description

[0001] IMPROVEMENTS IN OR RELATING TO PACKAGING

[0002] The present invention relates generally to packaging and particularly, although not exclusively, to hybrid material packaging.

[0003] A combination of plastic and cardboard gives packaging with the best of both worlds in one and the same packaging. For example an outer part is made of cardboard, providing for light barrier protection and ensuring a lightweight pack; and an inner part comprises a thermoformed plastic sheet, protecting the edible content and making the pack grease resistant. The combination of cardboard and plastic maximises the strengths of each component and enables a reduction in the use of fossil-based materials of up to 50 per cent.

[0004] CombiPac® and CombiRound® are two differently shaped packs for the food industry based on the principle of combining the best properties of cardboard with the ones of plastic.

[0005] The current CombiPac is, for example, made from cardboard and thermoformed plastic that are fixed together with wax. CombiPacs can be manually separated; however, because not all end-users separate the materials, after using the CombiPac, the tubs are not sorted and recycled. Furthermore the wax used destroys the cardboard fibers, so that they are not suited for recycling. Other mono-material packaging is easy to sort and recycle, but can have a higher carbon footprint, compared to CombiPac, because of the materials used.

[0006] The present invention seeks to provide improvement in or relating to packaging.

[0007] Some aspects and embodiments provide or relate to packs of the general class of a combination product such as CombiPac or CombiRound, but with mechanical separation i.e. separable without a requirement for the end-user.

[0008] An aspect of the present invention provides a hybrid packaging article comprising an inner container formed from a plastics material and an outer wrap or sleeve which is formed from a paper or paper-based material and which is securable to the container, in which the wrap or sleeve is secured to the container only by mechanical fixing and whereby the container and the wrap or sleeve are separable. In some embodiments the article is formed as a tub. In other embodiments the article is formed as a pot or a cup, for example.

[0009] Current products have a cardboard wrap lined with wax, that functions as a glue between the cardboard and the plastic. Some embodiments of the present invention do not have wax (or glue) on; the only thing connecting the cardboard and plastic are mechanical fixation.

[0010] An article formed in accordance with the present invention could, for example, be used for yellow fats like butter, spreadable and margarine. It could also be relevant, for example, to use for other foods e.g., ice cream, cream cheese, white dairy (like cottage cheese, creme fraiche, and yogurt, among others), soup, ready-made meals (like: pasta Bolognese, instant noodles, chicken fried rice, among others), salads, and candy. Some embodiment could also be used in other industries than food, e.g., for washing powder, skin cream, hair wax, and nutritional supplements.

[0011] Pots may, for example, be suitable for any type of dairy product, confectionery, snacks, nuts and more.

[0012] The container may, for example, be formed from one or more of: polyethylene (PE), polypropylene (PP), polystyrene (PS) and polyethylene terephthalate (PET).

[0013] The wrap or sleeve may, for example, be formed from paperboard or cardboard.

[0014] In some embodiment a cardboard material is used and is unwaxed / waxless.

[0015] Some embodiments are provided with no (or substantially no) adhesive between the cardboard and the plastic insert.

[0016] The inner container and / or the wrap or sleeve may contain at least some recycled content.

[0017] Articles may further comprise a lid.

[0018] The shape of articles may, for example, be generally square, rectangular, triangular, or round. Some embodiments are provided as a tub comprising a cardboard wrap with thermoformed plastic inside.

[0019] In some embodiments the wrap or sleeve is configured as a foldable blank. In some embodiments, underneath the foldings the plastic is formed, and locks the two components together.

[0020] Blanks may, for example, include one or more panels and / or folding flaps / tab and / or corner link panels.

[0021] In some embodiments a blank comprises: a central panel; a first side panel; a second side panel; a first end panel; and a second end panel.

[0022] In some embodiments a blank comprises: a central panel; a first side panel, with a terminal folding flap / tab; a second side panel, with a terminal folding flap / tab; a first end panel, with a terminal folding flap; first and second fan-shape corner link panels at either side of the first end panel, with respective first and second lateral end panels; a second end panel, with a terminal folding flap; and first and second fan-shape corner link panels at either side of the second end panel, with respective first and second lateral end panels.

[0023] In some embodiments the article is configured to be stiff and stable for use, but fragile enough for it to separate, by itself, when in a waste handling system.

[0024] The outer wrap may, for example, be configured to be a tight fit on the inner container.

[0025] The article may, for example, be configured to require deformation (e.g. crushing) to release the wrap or sleeve from the container. This could, for example, be conducted by a user and / or by the normal action of a waste recycling stream. A further aspect provides a recyclable food pack tub comprising an unwaxed cardboard outer wrap and thermoformed plastics inner, the tub is generally square or generally rectangular, in which there is no adhesive between the cardboard and the plastic inner, in which what keeps the cardboard and the plastic together is mechanical fixation made by four sides on the wrap that is folded towards the middle of the tub, in which underneath the wrap foldings the plastic is formed, and locks the two components together which makes the tub stiff and stable for use, but fragile enough for it to separate, by itself, when in the waste handling system.

[0026] A further aspect provides a multi-material pack comprising a paper-based outer part and thermoformed plastics inner part, the parts are formed separately from each other and assembled together in the absence of adhesive.

[0027] The parts may be configured to be separable following deformation.

[0028] Some embodiments relate to a combination of a plastics material and a paperboard (e.g. cardboard) material. Some embodiments use a PS / PET-Paperboard combination, for example.

[0029] A further aspect provides an article or tub as described herein and filled with product.

[0030] Example Features / Advantaqes

[0031] The present invention can be used to save money in the production of the packaging.

[0032] No fixing agent is used (on the cardboard) and thereby minimizes the price of the cardboard wrap significantly.

[0033] The elimination of the fixing agent will result in elimination of one process, when producing the cardboard wrap.

[0034] The present invention provides a more sustainable version of current likewise cardboard-plastic packaging.

[0035] When the two components the pack is made of (cardboard and plastic) is separated automatically, both components can each be recycled. The plastic part can be formed as clean plastic with no ink on - and would, therefore, not contaminate the current waste streams, like other packaging with print directly on the plastic would.

[0036] The cardboard is clean from any fixing agent, and can, therefore, be recycled without degradation of the fibers.

[0037] The combination of plastic and cardboard makes it possible to have very low use of plastic compared to other alike products on the market.

[0038] Embodiments of the present invention can have more use areas than current products (such as CombiPac):

[0039] Embodiments can have high barriers from the plastic and the cardboard, that makes it optimal for food.

[0040] The fixing system of the present invention makes it possible to use embodiments for hot-filling.

[0041] Thickness

[0042] Plastic:

[0043] The thickness of the plastic may vary considering how big the tub is, but it also varies across the tub, since the plastic are stretched more in some places than other.

[0044] Plastic sheet thickness:

[0045] The sheet thickness may vary from 250p (0,250 mm) to 600p (0,6 mm)

[0046] Plastic thickness in finished product:

[0047] When the plastic have been formed the thickness may vary from 80p to 600p in different places on the tub.

[0048] Cardboard:

[0049] The thickness of the cardboard varies considering how big the tub is.

[0050] Cardboard thickness: The cardboard thickness may be between 280 (0,280 mm) and 500 (0,5 mm)

[0051] Example Materials

[0052] Plastic:

[0053] The container may be produced in the plastic types: PP and PET - but could also be made in other types like PS. The tub can, for example, be made with or without recycled plastic in different proportions. E.g., 85% recycled plastic and 15% virgin plastic, and other.

[0054] Cardboard:

[0055] The cardboard can be made with or without recycled fibers in different proportions. 128,5, x 94x42

[0056] 129,6x92,7x36,7

[0057] 128,5x94x45

[0058] The present invention also provides a method of folding a cardboard wrap blank. The method may comprise the steps of:

[0059] 1. Push the cardboard blank down in a tool;

[0060] 2. Push top flaps of the cardboard wrap in; and 3. Push flaps of the cardboard wrap down.

[0061] Pushing top flaps of the cardboard wrap may be accomplished using four (for example) cylinders.

[0062] Pushing flaps of the cardboard wrap down may be accomplished using the last part of a stempie to pushes down too.

[0063] A two-part male tool part (e.g. a “stempie”) may be provided, for example with a first part being used to push a wrap blank into a female part of a tool and a second part being used to fold flaps.

[0064] The present invention also provides a pack substantially as described herein.

[0065] The present invention also provides a blank as described herein.

[0066] The present invention also provides a method of assembling a wrap blank as described herein.

[0067] The present invention also provides a folding tool for assembling a wrap blank as described herein.

[0068] The present invention also provides a pack substantially as described and shown in the accompanying drawings.

[0069] The present invention also provides a blank substantially as described and shown in the accompanying drawings.

[0070] The present invention also provides a method of assembling a wrap blank substantially as described and shown in the accompanying drawings.

[0071] The present invention also provides a folding tool for assembling a wrap blank substantially as described and shown in the accompanying drawings.

[0072] Different aspects and embodiments of the invention may be used separately or together. The present invention is more particularly shown and described, by way of example, in the accompanying drawings.

[0073] All orientational terms, such as upper, lower, radially and axially, are used in relation to the drawings and should not be interpreted as limiting on the invention or its connection to a closure.

[0074] Example embodiments are described in sufficient detail to enable those of ordinary skill in the art to embody and implement the systems and processes herein described. It is important to understand that embodiments can be provided in many alternate forms and should not be construed as limited to the examples set forth herein.

[0075] Accordingly, while embodiments can be modified in various ways and take on various alternative forms, specific embodiments thereof are shown in the drawings and described in detail below as examples. There is no intent to limit to the particular forms disclosed and as well as individual embodiments the invention is intended to cover combinations of those embodiments as well. On the contrary, all modifications, equivalents, and alternatives falling within the scope of the appended claims should be included. Elements of the example embodiments are consistently denoted by the same reference numerals throughout the drawings and detailed description where appropriate.

[0076] The terminology used herein to describe embodiments is not intended to limit the scope. The articles “a,” “an,” and “the” are singular in that they have a single referent; however, the use of the singular form in the present document should not preclude the presence of more than one referent. In other words, elements referred to in the singular can number one or more, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes,” and / or “including,” when used herein, specify the presence of stated features, items, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, items, steps, operations, elements, components, and / or groups thereof.

[0077] Unless otherwise defined, all terms (including technical and scientific terms) used herein are to be interpreted as is customary in the art. It will be further understood that terms in common usage should also be interpreted as is customary in the relevant art and not in an idealized or overly formal sense unless expressly so defined herein. Referring first to Figures 1 to 3 a tub 10 is shown and comprises a cardboard wrap 20 with thermoformed plastic tray 30 inside.

[0078] The drawings illustrate a generally rectangular pack, but other shapes (e.g. square, high, triangular, and round, among others) are contemplated.

[0079] The plastic from which the tray 30 is formed can be of any kind e.g. polyethylene (PE), polypropylene (PP), polystyrene (PS) and polyethylene terephthalate (PET).

[0080] The outer wrap part 20 may, for example, be formed from a paper or paper-based material such as paperboard e.g. virgin paperboard, recycled or FSC® paperboard.

[0081] Figure 4 shows a thermoformed plastics tray 130 and a cardboard wrap 140 formed according to a further embodiment.

[0082] In this embodiment the wrap 140 is erected from a blank 150, shown in Figures 5 (fully flat) and 6 (partially folded).

[0083] The blank 150 comprises: a central panel 152; a first (left) side panel 154, with a terminal folding flap / tab 155; a second (right) side panel 156, with a terminal folding flap / tab 157; a first (top) end panel 160, with a terminal folding flap 161 ; first 162 and second 163 fan-shape corner link panels at either side of the first end panel 160, with respective first and second lateral end panels / flaps 164, 165; a second (bottom) end panel 170, with a terminal folding flap 171 ; and first 172 and second 173 fan-shape corner link panels at either side of the second end panel 170, with respective first and second lateral end panels / flaps 174, 175.

[0084] The blank 150 is erected by folding to the configuration shown in Figure 4.

[0085] An example of how the blank wrap may be folded is described in Figures 7 to 10.

[0086] Figure 7 - three steps when folding a cardboard wrap: 1 . Push the cardboard down in the tool;

[0087] 2. Four (in this embodiment) cylinders pushes the top flaps of the cardboard wrap in; and

[0088] 3. The last part of a stempie pushes down too, to push the flaps of the cardboard wrap down.

[0089] Figures 8A to 8J is a sequence of images illustrating folding apparatus and a folding method.

[0090] Figures 9 & 10: example production setup for folding a cardboard wrap in a tool.

[0091] The function and shape of the blue parts (stempie, 180) are a new development. The blue parts (stempie) move up and down collecting the cardboard wraps and folding them into the tool.

[0092] A two-part male tool part (e.g. a “stempie”) 180 has a first part 185 which used to fold / push a wrap blank into a female part 190 of a tool and a second part 195 which is used to fold flaps. In this embodiment the stempie is spring operated.

[0093] Figures 11 to 13 illustrate how the cardboard attaches to the plastic insert by way of close up / exploded drawings of the relevant region(s) in order to show how they connect / stay attached.

[0094] There is no adhesive between the cardboard and the plastic.

[0095] In this embodiment, what keeps the cardboard and the plastic together is mechanical fixation made by 4 sides on the wrap 140 that is folded towards the middle of the tub.

[0096] Underneath the foldings the plastic is formed, and locks the two components 120, 130 together. This makes the tub 110 stiff and stable for use in e.g. dairies and supermarkets, but fragile enough for it to separate, by itself, when in the waste handling system.

[0097] Also, with a tub without wax, the fibers are better, and can be recycled for other products. The strength of the mechanical fixation is proven by testing, which has shown that they are sturdy and keeps together, but also that they fall apart when simulating the waste handling system. The pack 110 has the same functions as current tubs for e.g. butter, but adds the feature of being able to separate the materials in the waste handling system. Every market where these current tubs are used now is relevant for this invention too.

[0098] Figures 14A to 14D illustrate separation of the components 120, 130.

[0099] A used tub (Figure 14A) is crushed (Figure 14B) and that allows the wrap 120 to be pulled away from the container 130 (Figure 14C and Figure 14D).

[0100] The wrap and the container are then separated (Figure 15). This action could either be performed by a user, or naturally / automatically by the action of the tub passing through a standard waste recycling stream.

[0101] Examples of some cardboard wrap blanks 250, 350, 450, 550, 650, 750 of different shapes are shown in Figures to 16 to 21 .

[0102] Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiments shown and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention.

Claims

CLAIMS1. A hybrid packaging article comprising an inner container formed from a plastics material and an outer wrap or sleeve which is formed from a paper or paper-based material and which is securable to the container, in which the wrap or sleeve is secured to the container only by mechanical fixing and whereby the container and the wrap or sleeve are separable.

2. An article as claimed in claim 1 , in which the article is formed as a tub.

3. An article as claimed in claim 1 , in which the article is formed as a pot.

4. An article as claimed in claim 1 , in which the article is formed as a cup.

5. An article as claimed in any preceding claim, in which the container is formed from one or more of: polyethylene (PE), polypropylene (PP), polystyrene (PS) and polyethylene terephthalate (PET).

6. An article as claimed in any preceding claim, in which the wrap or sleeve is formed from cardboard.

7. An article as claimed in claim 6, in which the cardboard material is unwaxed / waxless.

8. An article as claimed in any preceding claim, in which the inner container and / or the wrap or sleeve contains at least some recycled content.

9. An article as claimed in any preceding claim, further comprising a lid10. An article as claimed in any preceding claim, in which the article is generally square, rectangular, triangular, or round.

11. An article as claimed in any preceding claim, formed as a tub comprising of a cardboard wrap with thermoformed plastic inside.

12. An article as claimed in any preceding claim, in which the wrap or sleeve is configured as a foldable blank.

13. An article as claimed in claim 12, in which underneath the foldings the plastic is formed, and locks the two components together.

14. An article as claimed in claim 12 or claim 13, in which the blank comprises: a central panel; a first side panel; a second side panel; a first end panel; and a second end panel.

15. An article as claimed in any of claims 12 to 14, in which the blank comprises: a central panel; a first side panel, with a terminal folding flap / tab; a second side panel, with a terminal folding flap / tab; a first end panel, with a terminal folding flap; first and second fan-shape corner link panels at either side of the first end panel, with respective first and second lateral end panels; a second end panel, with a terminal folding flap; and first and second fan-shape corner link panels at either side of the second end panel, with respective first and second lateral end panels.

16. An article as claimed in any preceding claim, in which the article is configured to be stiff and stable for use, but fragile enough for it to separate, by itself, when in the waste handling system.

17. An article as claimed in any preceding claim, in which the outer wrap is configured to be a tight fit on the inner container.

18. An article as claimed in any preceding claim, configured to require deformation to release the wrap or sleeve from the container.

19. A recyclable food pack tub comprising an unwaxed cardboard outer wrap and thermoformed plastics inner, the tub is generally square or generally rectangular, in which there is no adhesive between the cardboard and the plastic inner, in which what keeps the cardboard and the plastic together is mechanical fixation made by four sides on the wrap that is folded towards the middle of the tub, in which underneath the wrapfoldings the plastic is formed, and locks the two components together which makes the tub stiff and stable for use, but fragile enough for it to separate, by itself, when in the waste handling system.

20. A multi-material pack comprising a paper-based outer part and thermoformed plastics inner part, the parts are formed separately from each other and assembled together in the absence of adhesive.21 . A pack as claimed in claim 20, in which the parts are configured to be separable following deformation.

22. An article or tub as claimed in any preceding claim and filled with product.

23. A tool for folding a packaging wrap blank of the type comprising one or more folding panels and one or more folding flaps, the tool comprising a male tool part and a female tool part, the male tool part comprises two parts: a first part which used to fold / push a wrap blank into the female tool part; and a second part which is used to fold flaps.

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