Paper packaging

Abstract

There is provided a paper packaging (100) for holding an object, the paper packaging comprising a paper sheet (101) with a displaced section (103) defining a cavity (102), wherein the displaced section is a section of the paper sheet that is displaced relative to a surrounding flat section of the paper sheet, wherein the paper sheet is made from paper having a weight of at least 150 g per square meter. There is also provided a method of manufacturing a paper packaging, the method comprising: pressing a paper sheet to displace a section of the paper sheet relative to a flat surrounding section of the paper sheet so as to form a cavity; wherein the paper sheet is made from paper having a weight of at least 150 gram per square meter.

Description

TECHNICAL FIELD

[0001] The present invention relates to a paper packaging, in particular a paper packaging made from a heavy paper sheet in which a cavity has been formed by displacing a section of the paper sheet, and methods of manufacturing the same.BACKGROUND

[0002] Packaging plays a crucial role in protecting and preserving products throughout their lifecycle, from manufacturing to consumption. Historically, plastic has been a dominant material in the packaging industry due to its versatility, durability, and cost-effectiveness. As an example, thin-walled packaging with small cavities or recesses shaped to conform to the object to be packaged (e.g. small objects such as medicines, buttons, USB memory sticks, batteries) often consist of plastics, e.g. in the form of blister packs or the like.

[0003] However, the widespread use of plastic packaging has raised significant environmental concerns, primarily due to its non-biodegradable nature and the detrimental impact it has on ecosystems and marine life when improperly disposed of.

[0004] Paper packaging has emerged as a promising alternative to plastic. However, there are significant challenges in manufacturing packaging from paper, since paper is generally not as moldable or configurable as plastics. In particular, paper packaging often requires complex manufacturing processes and consume significant amounts of energy and resources.

[0005] For example, known paper packaging manufacturing techniques may only achieve adequate results using relatively thin paper, e.g. paper with a grammage below 80 g per square meter which yields a packaging with relatively low strength and durability.

[0006] Other known paper packaging manufacturing techniques are based on molding wet paper pulp to the intended shape of the packaging. An example of this is the manufacturing of egg cartons, which are produced by forming the pulp on sieves and then dewatering it. Although, such manufacturing methods allow great flexibility in packaging shape, the paper surface is not very attractive and unsuitable for many purposes.

[0007] Yet other known paper packaging manufacturing techniques require the addition of moisture and / or heat to the paper during the manufacturing process to allow the paper to obtain the desired shape. Hence, the manufacturing process requires complex apparatuses and consumes a significant amount of energy.

[0008] There is therefore a need for a packaging solution that is environmentally friendly while maintaining the necessary strength, durability, and functionality required for packaging various products.

[0009] Embodiments of the present invention seek to provide enhanced packaging, manufacturing methods and other implementations that improve the scope of packaging to address aspects of environmental impact, strength, durability, and flexibility, as well as providing new functionality and methods.SUMMARY

[0010] The invention is defined by the appended independent claims. Additional features and advantages of the concepts disclosed herein are set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the described technologies. The features and advantages of the concepts may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the described technologies will become more fully apparent from the following description and appended claims, or may be learned by the practice of the disclosed concepts as set forth herein.

[0011] In a first aspect there is provided a paper packaging for holding an object, the paper packaging comprising: a paper sheet comprising a displaced section defining a cavity, wherein the displaced section is a section of the paper sheet that is displaced relative to a surrounding flat section of the paper sheet, wherein the paper sheet is made from paper having a weight of at least 150 g per square meter.

[0012] The paper packaging according to the first aspect is an environmentally friendly packaging while achieving the necessary strength, durability, and functionality required for packaging various products. Furthermore, the packaging is very compact, and its shape can be flexibly determined in dependence on the object to be packaged.

[0013] Optionally, the paper sheet comprises at least one imprinted groove extending from an edge of the cavity towards an outer edge of the paper sheet.

[0014] The presence of one or more imprinted grooves significantly reduces the risk of flaws in the paper packaging which might otherwise occur when pressing heavy paper to form a cavity. These flaws may include creases, air bubbles, cracks, tears, blisters, or the like caused by the fairly significant deformation of the paper sheet to form the cavity. The grooves are increasingly advantageous as the paper wright increases, as the likelihood of such flaws increases for heavier and / or thicker paper.

[0015] Optionally, the at least one imprinted groove extends in a direction at an angle of between 30 and 150 degrees relative to the edge of the cavity, optionally between 45 and 135 degrees relative to the edge of the cavity, optionally between 60 and 120 degrees relative to the edge of the cavity, optionally between 75 and 105 degrees relative to the edge of the cavity, optionally substantially perpendicular to the edge of the cavity. It has been found that grooves orientated at an angle, and in an angle around 90 degrees, to the edge of the cavity reduces the risk of flaws even further. It is believed that such grooves, which have an extension along a radial direction, reduce the stress in the paper sheet along the radial or outwards axis, which is the direction or axis along which many of the above-described flaws often appear (e.g. cracks or tears extending perpendicularly away from the edge of the cavity).

[0016] Optionally, the paper sheet comprises a plurality of imprinted grooves spaced apart along the edge of the cavity. Hence, a distribution of grooves is present which can effectively provide stress relief around the cavity.

[0017] Optionally, the groove has: a width of at least 0.1 millimeters, optionally at least 0.2 millimeters; and / or a depth of at least 0.1 millimeters, optionally at least 0.2 millimeters.

[0018] Optionally, the cavity has a depth of at least 0.5 millimeters, optionally at least 1 mm, optionally at least 2 mm, optionally wherein the depth of the cavity is up to 15 millimeters, optionally up to 10 mm, optionally up to 7 mm, optionally up to 5 mm.

[0019] Optionally, the paper packaging further comprises a cover for enclosing the cavity. The cover may comprise a corresponding cavity such that the cavity in the paper sheet and the cavity in the cover jointly forms an enclosed cavity. Hence, an effective depth of the cavity may be increased, e.g. doubled.

[0020] Optionally, the paper sheet comprises one or more additional cavities. Thus, the paper packaging may be used for holding a plurality of objects, each object of the plurality of objects being held in a respective cavity.

[0021] In a second aspect there is provided a method of manufacturing a paper packaging, the method comprising: pressing a paper sheet to displace a section of the paper sheet relative to a flat surrounding section of the paper sheet so as to form a cavity; wherein the paper sheet is made from paper having a weight of at least 150 gram per square meter.

[0022] The paper packaging can thus be formed directly from a paper sheet, rather than from wet paper pulp. Hence, the manufacturing method for producing the packaging is accordingly streamlined and energy-efficient, utilizing fewer resources and generating less waste compared to conventional paper packaging methods. This results in a more cost-effective and environmentally friendly packaging solution that meets the growing demand for sustainable alternatives in the packaging industry.

[0023] Optionally, the method further comprises a step of imprinting the paper sheet with one or more grooves extending from an edge of the cavity towards an outer edge of the paper sheet.

[0024] Optionally, the step of pressing and the step of imprinting is performed in a single pressing motion. Thus, the complexity of the manufacturing process is reduced.

[0025] Optionally, the paper sheet is a dry paper sheet during the step of pressing the paper sheet. The method according to the second aspect, thus does not require any moisture (e.g. steam) to be introduced during the manufacturing process thus reducing manufacturing complexity and cost.

[0026] Optionally, the step of pressing the paper sheet is performed at room temperature. The method according to the second aspect, thus does not require any heat to be introduced during the manufacturing process, thus reducing manufacturing complexity and cost.

[0027] Optionally, the method further comprises a step of placing an object in the cavity.

[0028] Optionally, the method further comprises a step of providing a cover for enclosing the cavity. The method may further comprise fastening the cover onto the paper sheet so as to enclose the cavity.BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to best describe the manner in which the above-described embodiments are implemented, as well as define other advantages and features of the disclosure, a more particular description is provided below and is illustrated in the appended drawings. Understanding that these drawings depict only exemplary embodiments of the invention and are not therefore to be considered to be limiting in scope, the examples will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: Fig. 1ashows a schematic perspective view of a paper packaging according to embodiments; Fig. 1bshows a cross-sectional side view of a paper packaging according to embodiments; Fig. 2shows exemplary shapes of cavities according to embodiments; Fig. 3ashows a cross-sectional side view of a paper packaging with a separate cover according to embodiments; Fig. 3bshows a cross-sectional side view of a paper packaging with a folded cover according to embodiments; Fig. 3cshows a cross-sectional side view of a paper packaging with a cover provided with a corresponding cavity according to embodiments; Fig. 4shows a method of manufacturing a paper packaging according to embodiments; Fig. 5ashows a schematic perspective view of a paper packaging with imprinted grooves according to embodiments; Fig. 5bshows a cross-sectional side view of a paper packaging with imprinted grooves according to embodiments; and Fig. 6shows a method of manufacturing a paper packaging with grooves according to embodiments.

[0030] Further, in the figures like reference characters designate like or corresponding parts throughout the several figures. The first digit in the reference character denotes the first figure in which the corresponding element or part appears.DETAILED DESCRIPTION

[0031] Various embodiments of the disclosed methods and arrangements are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components, configurations, and steps may be used without parting from the spirit and scope of the claimed invention.

[0032] Hereinafter, certain embodiments will be described more fully with reference to the accompanying drawings. It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the inventive concept. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice disclosed herein. It is to be understood that elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed or omitted, certain features may be utilized independently, and embodiments or features of embodiments may be combined, all as would be apparent to the skilled person in the art.

[0033] The embodiments herein are provided by way of example so that this disclosure will be thorough and complete, and will fully convey the scope of the inventive concept, and that the claims be construed as encompassing all modifications, equivalents and alternatives of the present inventive concept which are apparent to those skilled in the art to which the inventive concept pertains. If nothing else is stated, different embodiments may be combined with each other.

[0034] Although reference may be made to directions (e.g. left, right, up, down, upper, lower) as shown in the figures, it will be appreciated that these references are purely for illustrative purposes, and that embodiments are not limited to such directions.

[0035] Figs. 1a and 1b show different views of a packaging 100 according to embodiments. In particular, Fig. 1a shows a perspective view while Fig. 1b shows a side view in cross-section. The dashed lines in Fig. 1a are provided for illustrative purposes to show the curved 3D shape of the displaced section 103.

[0036] The packaging 100 is at least partly made from paper. The packaging 100 may accordingly also be referred to as a paper packaging 100.

[0037] The term paper in this context refers to a sheet material made from (paper) pulp comprising cellulose fibres. The term paper will be understood to include paperboard, card, carboard, or the like. The paper may be single-ply or multi-ply. In some embodiments, paper does not include carboard with corrugated layers.

[0038] The packaging 100 comprises a paper sheet 101 which has been pressed to form a cavity 102. Prior to the pressing (i.e. prior to forming the cavity 102), the paper sheet 101 is an essentially flat sheet made from paper. The cavity 102 is typically shaped to conform to an object 302 to be packaged. Hence, the packaging 100 is functionally similar to known thin-walled paper packaging (e.g. made from plastics), and the packaging 100 may accordingly also be referred to as a thin-walled packaging.

[0039] However, compared to known thin-walled packaging made from plastics, the paper packaging 100 according to embodiments ensures that the packaging is recyclable, compostable, and biodegradable, thereby reducing its environmental footprint compared to traditional plastic packaging.

[0040] The paper sheet 101 may be made from paper having a weight, which may also be referred to as grammage, of at least 150 gram per square meter (g / m 2< ), optionally at least 175 gram per square meter, optionally at least 200 gram per square meter, optionally at least 250 gram per square meter, optionally at least 300 gram per square meter, optionally at least 325 gram per square meter. Additionally or alternatively the paper may have a weight of less than 700 g per square meter, optionally less than 600 gram per square meter, optionally less than 500 gram per square meter. For example, the paper sheet 101 may have a weight of about 380 gram per square meter.

[0041] By employing this relatively heavy paper, the packaging 100 has an increased strength and durability. Hence, the paper packaging 100, with its enhanced structural integrity, can withstand the rigors of handling, transportation, and storage.

[0042] Simultaneously, the paper packing made from the relatively heavy paper can be formed with cavities to allow the packaging 100 to be used for various different objects 302 and object shapes. Hence, the paper packaging 100 uses less material and has smaller dimensions (e.g. volume, size) than known cardboard boxes or the like.

[0043] The cavity 102 is defined by a displaced section 103 of the paper sheet 101. The displaced section 103 has been displaced relative to a surrounding flat section of the paper sheet 101. In particular, the displaced section 103 may be displaced in a direction perpendicular to the main plane of the paper sheet 101. The displaced section 103 thus projects from one side of the paper sheet 101.

[0044] The cavity 102 is intended to hold an object 302 or item (as shown in Figs. 3a to 3c). The shape and size of the cavity 102 may accordingly be determined based on the object 302 for which the packaging 100 will be used. For example, the cavity 102 may be conformal with the object 302 to be placed therein. Exemplary cavity shapes may be seen in Fig. 2, although it will be appreciated that embodiments are not limited to the shown shapes. In particular, the shape may be round, circular, ringshaped, or elliptical (as seen in the first row of Fig. 2); square, rectangular, or rectangular with rounded corners (as seen in the second row of Fig. 2); triangular, hexagonal, or otherwise polygonal (as seen in the third row of Fig. 2); other shape with one or more straight edges (as seen in the fourth row of Fig. 2); or other shape with one or more rounded edges (as seen in the fifth row of Fig. 2). In particular, the shape of the cavity 102 may include one or more curved edges or sides and / or one or more straight edges or sides.

[0045] Returning to Figs. 1a and 1b, a depth of the cavity 102 may be at least 0.5 mm, optionally at least 1 mm, optionally at least 2 mm. Additionally, or alternatively, the depth may be up to 10 mm, optionally up to 7 mm, optionally up to 5 mm. For some shapes without sharp corners (e.g. rounded shapes or the like) and / or with large cross-section (e.g. a cross-section exceeding about 7 cm 2< ), the depth of the cavity 102 may be up to 15 mm.

[0046] The cavity 102 may have a tapered shape where a cross-sectional area of the cavity 102 may decrease away from the main plane of the paper sheet 101. Alternatively, or additionally, the cavity 102 may have a rounded shape such as a dome-shape. Yet alternatively, or additionally, the cavity 102 may have one or more walls that are perpendicular to the main plane of the paper sheet 101. Accordingly, the cross-sectional area of the cavity 102 may be constant for at least part of the depth of the cavity 102.

[0047] The cavity 102 may have a width of at least 5 mm, optionally between 5 mm and 15 cm, optionally between 8 mm and 10 cm, optionally between 1 cm and 5 cm. Additionally, or alternatively, the cavity 102 may have a length of at least 5 mm, optionally between 5 mm and 15 cm, optionally between 8 mm and 10 cm, optionally between 1 cm and 5 cm.

[0048] The cavity 102 may have a complex shape such as a complex 3D shape which may include several different sides, edges, corners and the like. For example, the cavity 102 may be shaped after an item or object 302 with a complex 3D shape such as a USB memory stick, a safety razor, a toy, a pair of scissors, a pen or other stationary, or the like.

[0049] The cavity 102 may be surrounded by a flat section of the paper sheet 101. In other words, the cavity 102 may be surrounded by a flat rim section. The flat rim may extend for at least 1 cm, optionally at least 2 cm, around the cavity 102.

[0050] The paper sheet 101 may comprise a plurality of cavities. That is, the paper sheet 101 may comprise a plurality of displaced sections 103, each section 103 defining a cavity 102. Each cavity 102 of the plurality of cavities may be substantially similar to the previously described cavity 102. However, it will be appreciated that the plurality of cavities 102 may have different sizes and / or shapes.

[0051] The paper packaging 100 may further comprise a cover 301, as shown in Figs. 3a to 3c. The cover 301 is configured to enclose the cavity 102. Hence, the cover 301 is positioned on top of the paper sheet 101 (i.e. superimposed on the paper sheet 101) on a side of the paper sheet 101 opposite to the side from which the displaced section 103 projects. Thus, the cavity 102 is enclosed by, on one side, the cover 301, and, on the other side, the displaced section 103 of the paper sheet 101.

[0052] The cover 301 may be fastened to the paper sheet 101. For example, the cover 301 may be fastened to the paper sheet 101 by an adhesive (e.g. glue), a heat seal and / or other suitable fastening methods. The flat rim surrounding the cavity 102 may thus provide a surface onto which the cover 301 may be fastened, e.g. by applying an adhesive to the flat rim.

[0053] The cover 301 may be formed by a separate paper sheet (i.e. an additional paper sheet), as can be seen in Fig. 3a. That is, the paper sheet 101 may be a first paper sheet while the cover 301 is formed by a second paper sheet.

[0054] Alternatively, the cover 301 may be formed by folding of the paper sheet 101, such that the folded portion forms the cover 301, as can be seen in Fig. 3b. Thus, the cover 301 may be an integral part of the paper sheet 101. The paper sheet 101 may be provided with a folding line for facilitation of the folding. The folding line may be located where the fold to form the cover 301 is intended to occur. That is, in the folded state, the folding line may form a connection between the cover 301 and the portion of the paper sheet 101 with the cavity 102. The folding line may comprise a pre-fold, a perforation, a crease, or the like. In other words, the folding line may be a pre-folded line, a perforated line, a creased line, or the like.

[0055] In addition to the cavity 102 in the paper sheet 101 as previously described, the cover 301 may be provided with a cavity 303 in a corresponding position, as can be seen in Fig. 3c. The cavity 303 formed in the cover 301 may be substantially similar or identical to the cavity 102 formed in the paper sheet 101. In particular, the cover cavity 303 may have a shape and size corresponding to the shape and size of the cavity 102 in the paper sheet 101. The cover cavity 303 is preferably formed in a corresponding location to the cavity 102 in the paper sheet 101, such that, when the cover 301 is placed on the paper sheet 101, the cavity 102 and the cover cavity 303 jointly forms a combined cavity. Hence a depth of the cavity 102 may be increased up to twice the above-described depth.

[0056] Although the cover 301 has been described in relation to Figs. 3a to 3c as a paper cover 301, it will be appreciated that the cover 301 may alternatively be made from a different material.

[0057] Fig. 4 shows a method of manufacturing a paper packaging. The paper packaging may be a paper packaging 100 as described in relation to Figs. 1 to 3.

[0058] In step 401, a paper sheet is provided. The paper sheet may be a paper sheet 101 as previously described. The paper sheet 101 is then pressed so as to displace a section of the paper sheet 101 relative to a surrounding section of the paper sheet 101. Hence, a cavity 102 is formed.

[0059] The pressing may be performed by a pair of dies, i.e. with male and female dies. The dies preferably have a shape with corresponds to the intended cavity shape. The paper sheet 101 may be placed between the dies, after which the dies may be pressed against each other to deform the paper sheet 101. For example, the paper sheet 101 may be placed on the female die and against which the male die may be pressed, or vice versa. Hence, the paper sheet 101 will deform to the shape of the dies.

[0060] The pressing motion (by the dies) may be a pressing motion in a single direction, i.e. the dies being moved towards and against and / or into each other. This may also be referred to as a translational pressing motion. For example, one or more of the dies may be moved along a straight line, such as one of the dies being moved vertically down against the other die. Such pressing has been found to be advantageous when pressing relatively thick paper, reducing the risk of the paper tearing.

[0061] Alternatively, the pressing may be performed using one or more rollers between which the paper sheet 101 is fed, e.g. one roller provided with protrusions and one roller provided with indents.

[0062] Importantly, the pressing step may be performed without the need for heating of the paper sheet 101 and / or the dies. In other words, the pressing step may be performed at ambient temperature and / or at room temperature, e.g. at around 15 to 30 degrees Celsius. In particular, the paper sheet 101 and / or the dies may be at ambient or room temperature during the pressing step.

[0063] Furthermore, the pressing step may be performed without the need to introduce moisture (such as steam or water) to the paper sheet 101 during the pressing motion. That is, the paper sheet 101 may be a dry paper sheet during and / or throughout the pressing motion. A dry paper sheet may be defined as a paper sheet 101 that is not, or has not recently been, subject to external moisture and / or a paper sheet 101 that does not contain a layer which is wet or moist such that the paper has to be dried after the pressing step. In particular, a moisture content of the paper sheet 101 during the pressing step may be substantially the same as the moisture content of the paper sheet 101 before the pressing step and / or of the manufactured paper packaging 100.

[0064] In step 403, an object 302 or item is placed in the cavity 102. The object 302 or item may be a consumer goods, a household item, a food item, a goods for sale in a supermarket, department store, grocery store or the like, or any other item that is normally placed in a packaging 100.

[0065] In step 405, a cover 301 is provided for enclosing the cavity 102. The method may further comprise placing the cover 301 on the paper sheet 101 so as to enclose the cavity 102. The cover 301 may be a cover 301 as previously described in relation to Figs 3a to 3c. Hence, the object 302 or item may be enclosed or contained in the packaging 100.

[0066] The step of providing a cover 301 may include providing an additional paper sheet and optionally placing the additional paper sheet on the paper sheet 101. The step of providing a cover 301 may alternatively include folding the paper sheet 101 so as to form the cover 301.

[0067] It is noted that step 405 may be performed before or after step 401 and / or step 403.

[0068] In step 407, the cover 301 is fastened to the paper sheet 101. The fastening of the cover 301 to the paper sheet 101 may include applying an adhesive (e.g. glue or resin) to section of the paper sheet 101 at least partially surrounding the cavity 102. The fastening may alternatively, or additionally, comprise heat sealing the cover 301 to the paper sheet 101.

[0069] It will be understood that embodiments include methods where one or more of steps 403 to 405 are omitted.

[0070] Fig. 5 shows a paper packaging 100 comprising one or more imprinted grooves 501. The paper packaging 100 shown in Fig. 5 may be substantially similar or identical to the paper packaging 100 described in relation to Figs. 1 to 4, but with the addition of imprinted grooves 501.

[0071] When pressing relatively heavy paper, such as paper with a weight of at least 150 gram per square meter, to form a cavity 102 as described above, there is a risk that flaws appear in the paper sheet 101. These flaws may include creases, air bubbles, cracks, tears, blisters, or the like caused by the fairly significant deformation of the paper sheet 101. The prominence or likelihood of such flaws increases as the weight of the paper sheet 101 increases (i.e. the heavier the paper, the more likely it is that one or more flaws occur).

[0072] The inventors have realised that this risk is reduced by introducing imprinted grooves 501 in the paper sheet 101. Hence, the paper sheet 101 according to embodiments may comprise one or more grooves 501 imprinted in the paper sheet 101 and / or in a surface of the paper sheet 101.

[0073] The grooves 501 may be defined as shallow, elongated depressions in the surface of the paper sheet 101. The imprinted grooves 501 (i.e. the depressions) may be formed on the same side of the paper sheet 101 as the cavity 102. The grooves 501 may be sufficiently deep so as to project or protrude through the paper sheet 101. That is, the grooves 501 may project or protrude from the same side of the paper sheet 101 as the displaced section 103 defining the cavity 102. The grooves 501 may thus form embossed lines on the side of the paper sheet 101 with the displaced section 103 defining the cavity 102.

[0074] The grooves 501 may have a rounded, square or otherwise rectangular, or triangular profile (which may also be referred to as cross-section).

[0075] The grooves 501 are preferably shallow and elongate. That is, a longitudinal extension of the grooves 501 in the plane of the paper sheet 101 far exceeds their lateral extension as well as their extension in the direction perpendicular to the paper sheet 101, or, in other words, the length of the grooves 501 far exceeds their depth and width. The grooves 501 may have a uniform depth and / or thickness along their length. In particular, the grooves 501 may have a depth of at least 0.1 mm, optionally at least 0.2 mm. For example, the grooves 501 may have a depth between 0.1 and 2 mm, optionally between 0.15 and 1 mm, optionally between 0.2 and 0.5 mm.

[0076] The grooves 501 may additionally or alternatively have a width of at least 0.1 mm, optionally at least 0.2 mm. For example, the grooves 501 may have a width between 0.1 and 2 mm, optionally between 0.15 and 1 mm, optionally between 0.2 and 0.5 mm. It has been found that such elongate and shallow grooves 501 significantly reduce the risk of flaws.

[0077] The grooves 501 may extend outwards from the cavity 102. In other words, the grooves 501 may extend outwards from the edge of the cavity 102, such as in a direction at an angle to the edge of the cavity 102. For example, each groove may extend outwards from the edge of the cavity 102 in a direction substantially perpendicular to the edge of the cavity 102. For example, the grooves 501 may extend radially from the cavity 102. The grooves 501 may extend at least 5 mm, optionally at least 1 cm, optionally at least 2 cm, outwards from the edge of the cavity 102.

[0078] A flat paper section may be provided around the grooves 501. That is, the grooves 501 may extend between the cavity 102 and the flat paper section. In particular, the flat paper section may comprise no imprints, grooves, undulations or the like. The flat paper section may thus be particularly suitable for application of e.g. an adhesive used for fastening the cover 301 to the paper sheet 101.

[0079] The grooves 501 may be substantially straight. In other words, the grooves 501 may extend along straight lines. Alternatively, the grooves 501 may be curved.

[0080] A plurality of spaced apart grooves 501 may be provided along the edge of the cavity 102. That is, there may extend a plurality of spaced apart grooves 501 from the edge of the cavity 102. The grooves 501 (i.e. a first end of the grooves 501) may be located at regular intervals along the edge of cavity 102. For example, for a circular, round, or elliptical cavity 102, the grooves 501 may extend radially from the edge of the cavity 102 at regular angular intervals.

[0081] A spacing between adjacent grooves 501, at or along the edge of the cavity 102, may be less than 25 mm, optionally less than 15 mm, optionally less than 10 mm, optionally less than 5 mm.

[0082] It will be appreciated that the cover 301 may be provided with similar imprinted grooves 501.

[0083] Fig. 6 shows a method of manufacturing a paper packaging 100 with imprinted grooves 501. The method is substantially similar to the method described in relation to Fig. 4, but with the addition of step 601. In particular, steps 401 to 407 of the method in Fig. 6 may be substantially the same or identical to steps 401 to 407 of the method in Fig. 4. Furthermore, similarly to the method of Fig. 4, one or more of steps 403 to 407 may be omitted. For conciseness, steps 401 to 407 will therefore not be described again in relation to Fig. 6.

[0084] In step 601 of the method of Fig. 6, one or more grooves 501 are imprinted in the surface of the paper sheet 101. The one or more grooves 501 may be formed by imprinting or pressing the paper sheet 101 so as to form shallow, elongated depressions in the surface thereof. The grooves 501 may be formed in a similar manner to the formation of the cavity 102 in step 401. That is, the grooves 501 may be formed using a pair of dies (i.e. a male and a female die) with are pressed against each other with the paper sheet 101 in between. The dies may be shaped to create the grooves 501, i.e. the dies may create corresponding protrusions and depressions (i.e. indentations) as the grooves 501 to be imprinted.

[0085] Step 601 may be performed before the cavity 102 is formed in step 401. That is, the paper sheet 101 may comprise the imprinted grooves 501 before the paper sheet 101 is pressed so as to form the cavity 102.

[0086] Alternatively, step 601 may be performed simultaneously with step 401 to reduce the manufacturing complexity and cost. The grooves 501 and the cavity 102 may accordingly be formed using a single pressing motion. To form the grooves 501 simultaneously with the cavity 102, a single pair of dies may comprise protrusions and depressions for creating both the cavity 102 and the grooves 501.

[0087] The various embodiments described above are provided by way of illustration only and should not be construed to limit the invention. For example, the principles herein may be applied to any packaging irrespective of shape or size. Those skilled in the art will readily recognize various modifications and changes that may be made to the present invention without following the example embodiments and applications illustrated and described herein, and without departing from the scope of the present disclosure.

[0088] Throughout this specification, the word "may" is used in a permissive sense (i.e. meaning having the potential to), rather than in the mandatory sense (i.e. meaning must).

[0089] Throughout this specification, the words "comprise", "include", and variations of the words, such as "comprising" and "comprises", "including", "includes", do not exclude other elements or steps.

[0090] As used throughout this specification, the singular forms "a", "an", and "the", include plural referents unless explicitly indicated otherwise. Thus, for example, reference to "an" element includes a combination of two or more elements, notwithstanding use of other terms and phrases for one or more elements, such as "one or more" or "at least one".

[0091] The term "or" is, unless indicated otherwise, non-exclusive, i.e. encompassing both "and" and "or". For example, the feature "A or B" includes feature "A", feature "B" and feature "A and B".

[0092] Unless otherwise indicated, statements that one value or action is "based on", "in response to" and / or "in dependence on" another condition or value or action, encompass both instances in which the condition or value or action is the sole factor and instances where the condition or value or action is one factor among a plurality of factors.

[0093] Unless otherwise indicated, statements that "each" instance of some collection have some property should not be read to exclude cases where some otherwise identical or similar members of a larger collection do not have the property, i.e. each does not necessarily mean each and every.

Examples

Embodiment Construction

[0031]Various embodiments of the disclosed methods and arrangements are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components, configurations, and steps may be used without parting from the spirit and scope of the claimed invention.

[0032]Hereinafter, certain embodiments will be described more fully with reference to the accompanying drawings. It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the inventive concept. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice disclosed herein. It is to be understood that elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed or omitted, certain features may be utilized independ...

TECHNICAL FIELD

[0001] The present invention relates to a paper packaging, in particular a paper packaging made from a heavy paper sheet in which a cavity has been formed by displacing a section of the paper sheet, and methods of manufacturing the same.BACKGROUND

[0002] Packaging plays a crucial role in protecting and preserving products throughout their lifecycle, from manufacturing to consumption. Historically, plastic has been a dominant material in the packaging industry due to its versatility, durability, and cost-effectiveness. As an example, thin-walled packaging with small cavities or recesses shaped to conform to the object to be packaged (e.g. small objects such as medicines, buttons, USB memory sticks, batteries) often consist of plastics, e.g. in the form of blister packs or the like.

[0003] However, the widespread use of plastic packaging has raised significant environmental concerns, primarily due to its non-biodegradable nature and the detrimental impact it has on ecosystems and marine life when improperly disposed of.

[0004] Paper packaging has emerged as a promising alternative to plastic. However, there are significant challenges in manufacturing packaging from paper, since paper is generally not as moldable or configurable as plastics. In particular, paper packaging often requires complex manufacturing processes and consume significant amounts of energy and resources.

[0005] For example, known paper packaging manufacturing techniques may only achieve adequate results using relatively thin paper, e.g. paper with a grammage below 80 g per square meter which yields a packaging with relatively low strength and durability.

[0006] Other known paper packaging manufacturing techniques are based on molding wet paper pulp to the intended shape of the packaging. An example of this is the manufacturing of egg cartons, which are produced by forming the pulp on sieves and then dewatering it. Although, such manufacturing methods allow great flexibility in packaging shape, the paper surface is not very attractive and unsuitable for many purposes.

[0007] Yet other known paper packaging manufacturing techniques require the addition of moisture and / or heat to the paper during the manufacturing process to allow the paper to obtain the desired shape. Hence, the manufacturing process requires complex apparatuses and consumes a significant amount of energy.

[0008] There is therefore a need for a packaging solution that is environmentally friendly while maintaining the necessary strength, durability, and functionality required for packaging various products.

[0009] Embodiments of the present invention seek to provide enhanced packaging, manufacturing methods and other implementations that improve the scope of packaging to address aspects of environmental impact, strength, durability, and flexibility, as well as providing new functionality and methods.SUMMARY

[0010] The invention is defined by the appended independent claims. Additional features and advantages of the concepts disclosed herein are set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the described technologies. The features and advantages of the concepts may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the described technologies will become more fully apparent from the following description and appended claims, or may be learned by the practice of the disclosed concepts as set forth herein.

[0011] In a first aspect there is provided a paper packaging for holding an object, the paper packaging comprising: a paper sheet comprising a displaced section defining a cavity, wherein the displaced section is a section of the paper sheet that is displaced relative to a surrounding flat section of the paper sheet, wherein the paper sheet is made from paper having a weight of at least 150 g per square meter.

[0012] The paper packaging according to the first aspect is an environmentally friendly packaging while achieving the necessary strength, durability, and functionality required for packaging various products. Furthermore, the packaging is very compact, and its shape can be flexibly determined in dependence on the object to be packaged.

[0013] Optionally, the paper sheet comprises at least one imprinted groove extending from an edge of the cavity towards an outer edge of the paper sheet.

[0014] The presence of one or more imprinted grooves significantly reduces the risk of flaws in the paper packaging which might otherwise occur when pressing heavy paper to form a cavity. These flaws may include creases, air bubbles, cracks, tears, blisters, or the like caused by the fairly significant deformation of the paper sheet to form the cavity. The grooves are increasingly advantageous as the paper wright increases, as the likelihood of such flaws increases for heavier and / or thicker paper.

[0015] Optionally, the at least one imprinted groove extends in a direction at an angle of between 30 and 150 degrees relative to the edge of the cavity, optionally between 45 and 135 degrees relative to the edge of the cavity, optionally between 60 and 120 degrees relative to the edge of the cavity, optionally between 75 and 105 degrees relative to the edge of the cavity, optionally substantially perpendicular to the edge of the cavity. It has been found that grooves orientated at an angle, and in an angle around 90 degrees, to the edge of the cavity reduces the risk of flaws even further. It is believed that such grooves, which have an extension along a radial direction, reduce the stress in the paper sheet along the radial or outwards axis, which is the direction or axis along which many of the above-described flaws often appear (e.g. cracks or tears extending perpendicularly away from the edge of the cavity).

[0016] Optionally, the paper sheet comprises a plurality of imprinted grooves spaced apart along the edge of the cavity. Hence, a distribution of grooves is present which can effectively provide stress relief around the cavity.

[0017] Optionally, the groove has: a width of at least 0.1 millimeters, optionally at least 0.2 millimeters; and / or a depth of at least 0.1 millimeters, optionally at least 0.2 millimeters.

[0018] Optionally, the cavity has a depth of at least 0.5 millimeters, optionally at least 1 mm, optionally at least 2 mm, optionally wherein the depth of the cavity is up to 15 millimeters, optionally up to 10 mm, optionally up to 7 mm, optionally up to 5 mm.

[0019] Optionally, the paper packaging further comprises a cover for enclosing the cavity. The cover may comprise a corresponding cavity such that the cavity in the paper sheet and the cavity in the cover jointly forms an enclosed cavity. Hence, an effective depth of the cavity may be increased, e.g. doubled.

[0020] Optionally, the paper sheet comprises one or more additional cavities. Thus, the paper packaging may be used for holding a plurality of objects, each object of the plurality of objects being held in a respective cavity.

[0021] In a second aspect there is provided a method of manufacturing a paper packaging, the method comprising: pressing a paper sheet to displace a section of the paper sheet relative to a flat surrounding section of the paper sheet so as to form a cavity; wherein the paper sheet is made from paper having a weight of at least 150 gram per square meter.

[0022] The paper packaging can thus be formed directly from a paper sheet, rather than from wet paper pulp. Hence, the manufacturing method for producing the packaging is accordingly streamlined and energy-efficient, utilizing fewer resources and generating less waste compared to conventional paper packaging methods. This results in a more cost-effective and environmentally friendly packaging solution that meets the growing demand for sustainable alternatives in the packaging industry.

[0023] Optionally, the method further comprises a step of imprinting the paper sheet with one or more grooves extending from an edge of the cavity towards an outer edge of the paper sheet.

[0024] Optionally, the step of pressing and the step of imprinting is performed in a single pressing motion. Thus, the complexity of the manufacturing process is reduced.

[0025] Optionally, the paper sheet is a dry paper sheet during the step of pressing the paper sheet. The method according to the second aspect, thus does not require any moisture (e.g. steam) to be introduced during the manufacturing process thus reducing manufacturing complexity and cost.

[0026] Optionally, the step of pressing the paper sheet is performed at room temperature. The method according to the second aspect, thus does not require any heat to be introduced during the manufacturing process, thus reducing manufacturing complexity and cost.

[0027] Optionally, the method further comprises a step of placing an object in the cavity.

[0028] Optionally, the method further comprises a step of providing a cover for enclosing the cavity. The method may further comprise fastening the cover onto the paper sheet so as to enclose the cavity.BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to best describe the manner in which the above-described embodiments are implemented, as well as define other advantages and features of the disclosure, a more particular description is provided below and is illustrated in the appended drawings. Understanding that these drawings depict only exemplary embodiments of the invention and are not therefore to be considered to be limiting in scope, the examples will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: Fig. 1ashows a schematic perspective view of a paper packaging according to embodiments; Fig. 1bshows a cross-sectional side view of a paper packaging according to embodiments; Fig. 2shows exemplary shapes of cavities according to embodiments; Fig. 3ashows a cross-sectional side view of a paper packaging with a separate cover according to embodiments; Fig. 3bshows a cross-sectional side view of a paper packaging with a folded cover according to embodiments; Fig. 3cshows a cross-sectional side view of a paper packaging with a cover provided with a corresponding cavity according to embodiments; Fig. 4shows a method of manufacturing a paper packaging according to embodiments; Fig. 5ashows a schematic perspective view of a paper packaging with imprinted grooves according to embodiments; Fig. 5bshows a cross-sectional side view of a paper packaging with imprinted grooves according to embodiments; and Fig. 6shows a method of manufacturing a paper packaging with grooves according to embodiments.

[0030] Further, in the figures like reference characters designate like or corresponding parts throughout the several figures. The first digit in the reference character denotes the first figure in which the corresponding element or part appears.DETAILED DESCRIPTION

[0031] Various embodiments of the disclosed methods and arrangements are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components, configurations, and steps may be used without parting from the spirit and scope of the claimed invention.

[0032] Hereinafter, certain embodiments will be described more fully with reference to the accompanying drawings. It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the inventive concept. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice disclosed herein. It is to be understood that elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed or omitted, certain features may be utilized independently, and embodiments or features of embodiments may be combined, all as would be apparent to the skilled person in the art.

[0033] The embodiments herein are provided by way of example so that this disclosure will be thorough and complete, and will fully convey the scope of the inventive concept, and that the claims be construed as encompassing all modifications, equivalents and alternatives of the present inventive concept which are apparent to those skilled in the art to which the inventive concept pertains. If nothing else is stated, different embodiments may be combined with each other.

[0034] Although reference may be made to directions (e.g. left, right, up, down, upper, lower) as shown in the figures, it will be appreciated that these references are purely for illustrative purposes, and that embodiments are not limited to such directions.

[0035] Figs. 1a and 1b show different views of a packaging 100 according to embodiments. In particular, Fig. 1a shows a perspective view while Fig. 1b shows a side view in cross-section. The dashed lines in Fig. 1a are provided for illustrative purposes to show the curved 3D shape of the displaced section 103.

[0036] The packaging 100 is at least partly made from paper. The packaging 100 may accordingly also be referred to as a paper packaging 100.

[0037] The term paper in this context refers to a sheet material made from (paper) pulp comprising cellulose fibres. The term paper will be understood to include paperboard, card, carboard, or the like. The paper may be single-ply or multi-ply. In some embodiments, paper does not include carboard with corrugated layers.

[0038] The packaging 100 comprises a paper sheet 101 which has been pressed to form a cavity 102. Prior to the pressing (i.e. prior to forming the cavity 102), the paper sheet 101 is an essentially flat sheet made from paper. The cavity 102 is typically shaped to conform to an object 302 to be packaged. Hence, the packaging 100 is functionally similar to known thin-walled paper packaging (e.g. made from plastics), and the packaging 100 may accordingly also be referred to as a thin-walled packaging.

[0039] However, compared to known thin-walled packaging made from plastics, the paper packaging 100 according to embodiments ensures that the packaging is recyclable, compostable, and biodegradable, thereby reducing its environmental footprint compared to traditional plastic packaging.

[0040] The paper sheet 101 may be made from paper having a weight, which may also be referred to as grammage, of at least 150 gram per square meter (g / m 2< ), optionally at least 175 gram per square meter, optionally at least 200 gram per square meter, optionally at least 250 gram per square meter, optionally at least 300 gram per square meter, optionally at least 325 gram per square meter. Additionally or alternatively the paper may have a weight of less than 700 g per square meter, optionally less than 600 gram per square meter, optionally less than 500 gram per square meter. For example, the paper sheet 101 may have a weight of about 380 gram per square meter.

[0041] By employing this relatively heavy paper, the packaging 100 has an increased strength and durability. Hence, the paper packaging 100, with its enhanced structural integrity, can withstand the rigors of handling, transportation, and storage.

[0042] Simultaneously, the paper packing made from the relatively heavy paper can be formed with cavities to allow the packaging 100 to be used for various different objects 302 and object shapes. Hence, the paper packaging 100 uses less material and has smaller dimensions (e.g. volume, size) than known cardboard boxes or the like.

[0043] The cavity 102 is defined by a displaced section 103 of the paper sheet 101. The displaced section 103 has been displaced relative to a surrounding flat section of the paper sheet 101. In particular, the displaced section 103 may be displaced in a direction perpendicular to the main plane of the paper sheet 101. The displaced section 103 thus projects from one side of the paper sheet 101.

[0044] The cavity 102 is intended to hold an object 302 or item (as shown in Figs. 3a to 3c). The shape and size of the cavity 102 may accordingly be determined based on the object 302 for which the packaging 100 will be used. For example, the cavity 102 may be conformal with the object 302 to be placed therein. Exemplary cavity shapes may be seen in Fig. 2, although it will be appreciated that embodiments are not limited to the shown shapes. In particular, the shape may be round, circular, ringshaped, or elliptical (as seen in the first row of Fig. 2); square, rectangular, or rectangular with rounded corners (as seen in the second row of Fig. 2); triangular, hexagonal, or otherwise polygonal (as seen in the third row of Fig. 2); other shape with one or more straight edges (as seen in the fourth row of Fig. 2); or other shape with one or more rounded edges (as seen in the fifth row of Fig. 2). In particular, the shape of the cavity 102 may include one or more curved edges or sides and / or one or more straight edges or sides.

[0045] Returning to Figs. 1a and 1b, a depth of the cavity 102 may be at least 0.5 mm, optionally at least 1 mm, optionally at least 2 mm. Additionally, or alternatively, the depth may be up to 10 mm, optionally up to 7 mm, optionally up to 5 mm. For some shapes without sharp corners (e.g. rounded shapes or the like) and / or with large cross-section (e.g. a cross-section exceeding about 7 cm 2< ), the depth of the cavity 102 may be up to 15 mm.

[0046] The cavity 102 may have a tapered shape where a cross-sectional area of the cavity 102 may decrease away from the main plane of the paper sheet 101. Alternatively, or additionally, the cavity 102 may have a rounded shape such as a dome-shape. Yet alternatively, or additionally, the cavity 102 may have one or more walls that are perpendicular to the main plane of the paper sheet 101. Accordingly, the cross-sectional area of the cavity 102 may be constant for at least part of the depth of the cavity 102.

[0047] The cavity 102 may have a width of at least 5 mm, optionally between 5 mm and 15 cm, optionally between 8 mm and 10 cm, optionally between 1 cm and 5 cm. Additionally, or alternatively, the cavity 102 may have a length of at least 5 mm, optionally between 5 mm and 15 cm, optionally between 8 mm and 10 cm, optionally between 1 cm and 5 cm.

[0048] The cavity 102 may have a complex shape such as a complex 3D shape which may include several different sides, edges, corners and the like. For example, the cavity 102 may be shaped after an item or object 302 with a complex 3D shape such as a USB memory stick, a safety razor, a toy, a pair of scissors, a pen or other stationary, or the like.

[0049] The cavity 102 may be surrounded by a flat section of the paper sheet 101. In other words, the cavity 102 may be surrounded by a flat rim section. The flat rim may extend for at least 1 cm, optionally at least 2 cm, around the cavity 102.

[0050] The paper sheet 101 may comprise a plurality of cavities. That is, the paper sheet 101 may comprise a plurality of displaced sections 103, each section 103 defining a cavity 102. Each cavity 102 of the plurality of cavities may be substantially similar to the previously described cavity 102. However, it will be appreciated that the plurality of cavities 102 may have different sizes and / or shapes.

[0051] The paper packaging 100 may further comprise a cover 301, as shown in Figs. 3a to 3c. The cover 301 is configured to enclose the cavity 102. Hence, the cover 301 is positioned on top of the paper sheet 101 (i.e. superimposed on the paper sheet 101) on a side of the paper sheet 101 opposite to the side from which the displaced section 103 projects. Thus, the cavity 102 is enclosed by, on one side, the cover 301, and, on the other side, the displaced section 103 of the paper sheet 101.

[0052] The cover 301 may be fastened to the paper sheet 101. For example, the cover 301 may be fastened to the paper sheet 101 by an adhesive (e.g. glue), a heat seal and / or other suitable fastening methods. The flat rim surrounding the cavity 102 may thus provide a surface onto which the cover 301 may be fastened, e.g. by applying an adhesive to the flat rim.

[0053] The cover 301 may be formed by a separate paper sheet (i.e. an additional paper sheet), as can be seen in Fig. 3a. That is, the paper sheet 101 may be a first paper sheet while the cover 301 is formed by a second paper sheet.

[0054] Alternatively, the cover 301 may be formed by folding of the paper sheet 101, such that the folded portion forms the cover 301, as can be seen in Fig. 3b. Thus, the cover 301 may be an integral part of the paper sheet 101. The paper sheet 101 may be provided with a folding line for facilitation of the folding. The folding line may be located where the fold to form the cover 301 is intended to occur. That is, in the folded state, the folding line may form a connection between the cover 301 and the portion of the paper sheet 101 with the cavity 102. The folding line may comprise a pre-fold, a perforation, a crease, or the like. In other words, the folding line may be a pre-folded line, a perforated line, a creased line, or the like.

[0055] In addition to the cavity 102 in the paper sheet 101 as previously described, the cover 301 may be provided with a cavity 303 in a corresponding position, as can be seen in Fig. 3c. The cavity 303 formed in the cover 301 may be substantially similar or identical to the cavity 102 formed in the paper sheet 101. In particular, the cover cavity 303 may have a shape and size corresponding to the shape and size of the cavity 102 in the paper sheet 101. The cover cavity 303 is preferably formed in a corresponding location to the cavity 102 in the paper sheet 101, such that, when the cover 301 is placed on the paper sheet 101, the cavity 102 and the cover cavity 303 jointly forms a combined cavity. Hence a depth of the cavity 102 may be increased up to twice the above-described depth.

[0056] Although the cover 301 has been described in relation to Figs. 3a to 3c as a paper cover 301, it will be appreciated that the cover 301 may alternatively be made from a different material.

[0057] Fig. 4 shows a method of manufacturing a paper packaging. The paper packaging may be a paper packaging 100 as described in relation to Figs. 1 to 3.

[0058] In step 401, a paper sheet is provided. The paper sheet may be a paper sheet 101 as previously described. The paper sheet 101 is then pressed so as to displace a section of the paper sheet 101 relative to a surrounding section of the paper sheet 101. Hence, a cavity 102 is formed.

[0059] The pressing may be performed by a pair of dies, i.e. with male and female dies. The dies preferably have a shape with corresponds to the intended cavity shape. The paper sheet 101 may be placed between the dies, after which the dies may be pressed against each other to deform the paper sheet 101. For example, the paper sheet 101 may be placed on the female die and against which the male die may be pressed, or vice versa. Hence, the paper sheet 101 will deform to the shape of the dies.

[0060] The pressing motion (by the dies) may be a pressing motion in a single direction, i.e. the dies being moved towards and against and / or into each other. This may also be referred to as a translational pressing motion. For example, one or more of the dies may be moved along a straight line, such as one of the dies being moved vertically down against the other die. Such pressing has been found to be advantageous when pressing relatively thick paper, reducing the risk of the paper tearing.

[0061] Alternatively, the pressing may be performed using one or more rollers between which the paper sheet 101 is fed, e.g. one roller provided with protrusions and one roller provided with indents.

[0062] Importantly, the pressing step may be performed without the need for heating of the paper sheet 101 and / or the dies. In other words, the pressing step may be performed at ambient temperature and / or at room temperature, e.g. at around 15 to 30 degrees Celsius. In particular, the paper sheet 101 and / or the dies may be at ambient or room temperature during the pressing step.

[0063] Furthermore, the pressing step may be performed without the need to introduce moisture (such as steam or water) to the paper sheet 101 during the pressing motion. That is, the paper sheet 101 may be a dry paper sheet during and / or throughout the pressing motion. A dry paper sheet may be defined as a paper sheet 101 that is not, or has not recently been, subject to external moisture and / or a paper sheet 101 that does not contain a layer which is wet or moist such that the paper has to be dried after the pressing step. In particular, a moisture content of the paper sheet 101 during the pressing step may be substantially the same as the moisture content of the paper sheet 101 before the pressing step and / or of the manufactured paper packaging 100.

[0064] In step 403, an object 302 or item is placed in the cavity 102. The object 302 or item may be a consumer goods, a household item, a food item, a goods for sale in a supermarket, department store, grocery store or the like, or any other item that is normally placed in a packaging 100.

[0065] In step 405, a cover 301 is provided for enclosing the cavity 102. The method may further comprise placing the cover 301 on the paper sheet 101 so as to enclose the cavity 102. The cover 301 may be a cover 301 as previously described in relation to Figs 3a to 3c. Hence, the object 302 or item may be enclosed or contained in the packaging 100.

[0066] The step of providing a cover 301 may include providing an additional paper sheet and optionally placing the additional paper sheet on the paper sheet 101. The step of providing a cover 301 may alternatively include folding the paper sheet 101 so as to form the cover 301.

[0067] It is noted that step 405 may be performed before or after step 401 and / or step 403.

[0068] In step 407, the cover 301 is fastened to the paper sheet 101. The fastening of the cover 301 to the paper sheet 101 may include applying an adhesive (e.g. glue or resin) to section of the paper sheet 101 at least partially surrounding the cavity 102. The fastening may alternatively, or additionally, comprise heat sealing the cover 301 to the paper sheet 101.

[0069] It will be understood that embodiments include methods where one or more of steps 403 to 405 are omitted.

[0070] Fig. 5 shows a paper packaging 100 comprising one or more imprinted grooves 501. The paper packaging 100 shown in Fig. 5 may be substantially similar or identical to the paper packaging 100 described in relation to Figs. 1 to 4, but with the addition of imprinted grooves 501.

[0071] When pressing relatively heavy paper, such as paper with a weight of at least 150 gram per square meter, to form a cavity 102 as described above, there is a risk that flaws appear in the paper sheet 101. These flaws may include creases, air bubbles, cracks, tears, blisters, or the like caused by the fairly significant deformation of the paper sheet 101. The prominence or likelihood of such flaws increases as the weight of the paper sheet 101 increases (i.e. the heavier the paper, the more likely it is that one or more flaws occur).

[0072] The inventors have realised that this risk is reduced by introducing imprinted grooves 501 in the paper sheet 101. Hence, the paper sheet 101 according to embodiments may comprise one or more grooves 501 imprinted in the paper sheet 101 and / or in a surface of the paper sheet 101.

[0073] The grooves 501 may be defined as shallow, elongated depressions in the surface of the paper sheet 101. The imprinted grooves 501 (i.e. the depressions) may be formed on the same side of the paper sheet 101 as the cavity 102. The grooves 501 may be sufficiently deep so as to project or protrude through the paper sheet 101. That is, the grooves 501 may project or protrude from the same side of the paper sheet 101 as the displaced section 103 defining the cavity 102. The grooves 501 may thus form embossed lines on the side of the paper sheet 101 with the displaced section 103 defining the cavity 102.

[0074] The grooves 501 may have a rounded, square or otherwise rectangular, or triangular profile (which may also be referred to as cross-section).

[0075] The grooves 501 are preferably shallow and elongate. That is, a longitudinal extension of the grooves 501 in the plane of the paper sheet 101 far exceeds their lateral extension as well as their extension in the direction perpendicular to the paper sheet 101, or, in other words, the length of the grooves 501 far exceeds their depth and width. The grooves 501 may have a uniform depth and / or thickness along their length. In particular, the grooves 501 may have a depth of at least 0.1 mm, optionally at least 0.2 mm. For example, the grooves 501 may have a depth between 0.1 and 2 mm, optionally between 0.15 and 1 mm, optionally between 0.2 and 0.5 mm.

[0076] The grooves 501 may additionally or alternatively have a width of at least 0.1 mm, optionally at least 0.2 mm. For example, the grooves 501 may have a width between 0.1 and 2 mm, optionally between 0.15 and 1 mm, optionally between 0.2 and 0.5 mm. It has been found that such elongate and shallow grooves 501 significantly reduce the risk of flaws.

[0077] The grooves 501 may extend outwards from the cavity 102. In other words, the grooves 501 may extend outwards from the edge of the cavity 102, such as in a direction at an angle to the edge of the cavity 102. For example, each groove may extend outwards from the edge of the cavity 102 in a direction substantially perpendicular to the edge of the cavity 102. For example, the grooves 501 may extend radially from the cavity 102. The grooves 501 may extend at least 5 mm, optionally at least 1 cm, optionally at least 2 cm, outwards from the edge of the cavity 102.

[0078] A flat paper section may be provided around the grooves 501. That is, the grooves 501 may extend between the cavity 102 and the flat paper section. In particular, the flat paper section may comprise no imprints, grooves, undulations or the like. The flat paper section may thus be particularly suitable for application of e.g. an adhesive used for fastening the cover 301 to the paper sheet 101.

[0079] The grooves 501 may be substantially straight. In other words, the grooves 501 may extend along straight lines. Alternatively, the grooves 501 may be curved.

[0080] A plurality of spaced apart grooves 501 may be provided along the edge of the cavity 102. That is, there may extend a plurality of spaced apart grooves 501 from the edge of the cavity 102. The grooves 501 (i.e. a first end of the grooves 501) may be located at regular intervals along the edge of cavity 102. For example, for a circular, round, or elliptical cavity 102, the grooves 501 may extend radially from the edge of the cavity 102 at regular angular intervals.

[0081] A spacing between adjacent grooves 501, at or along the edge of the cavity 102, may be less than 25 mm, optionally less than 15 mm, optionally less than 10 mm, optionally less than 5 mm.

[0082] It will be appreciated that the cover 301 may be provided with similar imprinted grooves 501.

[0083] Fig. 6 shows a method of manufacturing a paper packaging 100 with imprinted grooves 501. The method is substantially similar to the method described in relation to Fig. 4, but with the addition of step 601. In particular, steps 401 to 407 of the method in Fig. 6 may be substantially the same or identical to steps 401 to 407 of the method in Fig. 4. Furthermore, similarly to the method of Fig. 4, one or more of steps 403 to 407 may be omitted. For conciseness, steps 401 to 407 will therefore not be described again in relation to Fig. 6.

[0084] In step 601 of the method of Fig. 6, one or more grooves 501 are imprinted in the surface of the paper sheet 101. The one or more grooves 501 may be formed by imprinting or pressing the paper sheet 101 so as to form shallow, elongated depressions in the surface thereof. The grooves 501 may be formed in a similar manner to the formation of the cavity 102 in step 401. That is, the grooves 501 may be formed using a pair of dies (i.e. a male and a female die) with are pressed against each other with the paper sheet 101 in between. The dies may be shaped to create the grooves 501, i.e. the dies may create corresponding protrusions and depressions (i.e. indentations) as the grooves 501 to be imprinted.

[0085] Step 601 may be performed before the cavity 102 is formed in step 401. That is, the paper sheet 101 may comprise the imprinted grooves 501 before the paper sheet 101 is pressed so as to form the cavity 102.

[0086] Alternatively, step 601 may be performed simultaneously with step 401 to reduce the manufacturing complexity and cost. The grooves 501 and the cavity 102 may accordingly be formed using a single pressing motion. To form the grooves 501 simultaneously with the cavity 102, a single pair of dies may comprise protrusions and depressions for creating both the cavity 102 and the grooves 501.

[0087] The various embodiments described above are provided by way of illustration only and should not be construed to limit the invention. For example, the principles herein may be applied to any packaging irrespective of shape or size. Those skilled in the art will readily recognize various modifications and changes that may be made to the present invention without following the example embodiments and applications illustrated and described herein, and without departing from the scope of the present disclosure.

[0088] Throughout this specification, the word "may" is used in a permissive sense (i.e. meaning having the potential to), rather than in the mandatory sense (i.e. meaning must).

[0089] Throughout this specification, the words "comprise", "include", and variations of the words, such as "comprising" and "comprises", "including", "includes", do not exclude other elements or steps.

[0090] As used throughout this specification, the singular forms "a", "an", and "the", include plural referents unless explicitly indicated otherwise. Thus, for example, reference to "an" element includes a combination of two or more elements, notwithstanding use of other terms and phrases for one or more elements, such as "one or more" or "at least one".

[0091] The term "or" is, unless indicated otherwise, non-exclusive, i.e. encompassing both "and" and "or". For example, the feature "A or B" includes feature "A", feature "B" and feature "A and B".

[0092] Unless otherwise indicated, statements that one value or action is "based on", "in response to" and / or "in dependence on" another condition or value or action, encompass both instances in which the condition or value or action is the sole factor and instances where the condition or value or action is one factor among a plurality of factors.

[0093] Unless otherwise indicated, statements that "each" instance of some collection have some property should not be read to exclude cases where some otherwise identical or similar members of a larger collection do not have the property, i.e. each does not necessarily mean each and every.

Examples

Embodiment Construction

[0031]Various embodiments of the disclosed methods and arrangements are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components, configurations, and steps may be used without parting from the spirit and scope of the claimed invention.

[0032]Hereinafter, certain embodiments will be described more fully with reference to the accompanying drawings. It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the inventive concept. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice disclosed herein. It is to be understood that elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed or omitted, certain features may be utilized independ...

Claims

1. A paper packaging for holding an object, the paper packaging comprising: a paper sheet comprising a displaced section defining a cavity, wherein the displaced section is a section of the paper sheet that is displaced relative to a surrounding flat section of the paper sheet, wherein the paper sheet is made from paper having a weight of at least 150 g per square meter.

2. The paper packaging according to claim 1, wherein the paper sheet comprises at least one imprinted groove extending from an edge of the cavity towards an outer edge of the paper sheet.

3. The paper packaging according to claim 2, wherein the at least one imprinted groove extends in a direction at an angle of between 30 and 150 degrees relative to the edge of the cavity, optionally between 45 and 135 degrees relative to the edge of the cavity, optionally between 60 and 120 degrees relative to the edge of the cavity, optionally between 75 and 105 degrees relative to the edge of the cavity, optionally substantially perpendicular to the edge of the cavity.

4. The paper packaging according to claim 2 or 3, wherein the paper sheet comprises a plurality of imprinted grooves spaced apart along the edge of the cavity.

5. The paper packaging according to any of claims 2 to 4, wherein the groove has: a width of at least 0.1 millimeters, optionally at least 0.2 millimeters; and / or a depth of at least 0.1 millimeters, optionally at least 0.2 millimeters.

6. The paper packaging according to any preceding claim, wherein the cavity has a depth of at least 0.5 millimeters, optionally at least 1 mm, optionally at least 2 mm, optionally wherein the depth of the cavity is up to 15 millimeters, optionally up to 10 mm, optionally up to 7 mm, optionally up to 5 mm.

7. The paper packaging according to any preceding claim, wherein the paper packaging further comprises a cover for enclosing the cavity.

8. The paper packaging according to claim 7, wherein the cover comprises a corresponding cavity such that the cavity in the paper sheet and the cavity in the cover jointly forms an enclosed cavity.

9. A method of manufacturing a paper packaging, the method comprising: pressing a paper sheet to displace a section of the paper sheet relative to a flat surrounding section of the paper sheet so as to form a cavity; wherein the paper sheet is made from paper having a weight of at least 150 gram per square meter.

10. The method according to claim 9, wherein the method further comprises a step of imprinting the paper sheet with one or more grooves extending from an edge of the cavity towards an outer edge of the paper sheet.

11. The method according to claim 10, wherein the step of pressing and the step of imprinting is performed in a single pressing motion.

12. The method according to any of claims 9 to 11, wherein the method further comprises a step of providing a cover for enclosing the cavity.

13. The method according to claim 12, wherein the method further comprises fastening the cover onto the paper sheet so as to enclose the cavity.

14. The method according to any of claims 9 to 13, wherein the paper sheet is a dry paper sheet.

15. The method according to any of claims 9 to 14, wherein the step of pressing the paper sheet is performed at room temperature.

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