Paper-based or paperboard-based container and related method

Abstract

To provide a paper-based or paperboard-based container and a related method.SOLUTION: There is provided a paper-based or paperboard-based container (100) for holding a pourable food product, the container including: an approximately flat bottom portion; a top portion arranged opposite the bottom portion and including a top panel and a top seal area (126) that forms a top seal of the container; wall portions (108b, 108c) extending between the bottom and top portions and contacting the top panel; and a longitudinal seal strip (14) extending between the bottom and top portions across at least one of the wall portions, in which the top seal area includes the longitudinal sealing strip (14) and is folded over at least one of the wall portions attached thereto. Blank and sleeve for producing the container are also described, as are methods for producing the container.SELECTED DRAWING: Figure 10

Description

[Technical Field]

[0001] The present invention relates to a container for holding a tiltable food product comprising a paper-based or paperboard-based laminated sheet material. Specifically, the present invention relates to such a container with an opening device or closure for dispensing and / or accessing the food product. The present invention also relates to a method for producing such a container and a container precursor for such a container. [Background technology]

[0002] It is known in the art of paperboard-based packaging to produce blanks, fold the blanks, and assemble them to produce containers that can then be utilized to hold pourable food products, for example, dairy products such as milk or yogurt, or liquids such as juice.

[0003] The blanks are typically produced from laminated packaging materials, typically comprising multi-layer paperboard sheets laminated with one or more barrier layers to retain the food product and / or prevent air and flavor migration through the paperboard. The barrier layers may typically comprise polyethylene or aluminum layers.

[0004] Methods of producing blanks from laminated packaging material typically include cutting the laminated packaging material to a predetermined shape, and methods of producing containers from the blanks typically include folding the blank along predetermined fold lines to produce the containers.

[0005] The blank may include fold lines in the laminated packaging material to assist in folding of the blank along the fold lines. A fold line or crease may be defined as an embossed or stamped depression on one side of the laminated packaging material with a corresponding raised ridge or welt, also called a bead, and on the other side forming a line along which the laminated packaging material is structurally weak and along which the laminated packaging material will bend or fold when pressure is applied.

[0006] The blanks may be produced in a converting process in which the blanks are cut from a web of laminated material having generally parallel and straight lateral boundary edges. The converting process typically involves feeding the web of laminated material through one or more nips formed between a pair of cutting or creasing rollers to produce blanks that are cut from the web and formed with creases, notches, and / or holes for subsequent folding, e.g., to fit a closure into the blank material when a container is produced therefrom.

[0007] The layout of the blank pattern on the web is known as a "nesting pattern." A nesting pattern is not a physical pattern visible on the web, but is a pattern that illustrates how the blanks are going to be cut from the web and / or how the blanks are going to be stamped. In other words, the nesting pattern illustrates the layout of the blanks on the web and, as a result, how the available web material is utilized.

[0008] The container may include an opening device or closure that allows the consumer to open the container and access the food product. The opening device may be reclosable, allowing the consumer to reclose the container in a sealed or unsealed state once the container is opened. Alternatively, the opening device cannot be reclosed once opened. A commonly used opening device comprises a patch defined by a small sheet of heat-sealable plastic material that is heat-sealed to the inner surface of the packaging material, covering a hole in the packaging material, and a pull-off tab that is applied to the opposite side of the packaging material and heat-sealed to the patch. The tab and patch are adhered to each other such that when the tab is pulled and removed, the portion of the patch that was heat-sealed to it is also removed, uncovering the hole. This configuration is often referred to as a pre-laminated hole (PLH). While this configuration may provide an acceptable opening device, there exists a general need for improvements to known opening devices or closures to provide a more enjoyable drinking experience, particularly when drinking directly from the container.

[0009] In the technical field of paperboard-based containers, it is known to provide an extended top panel area of ​​a container by folding an upper fin downward onto the top panel in an acentric position. The extended top panel area thus obtained can be used to provide a container with an enlarged opening device or closure. Such containers are known, for example, from EP2392517A1 and US20190106239A1. Although positioned acentrically, a downwardly folded upper fin extending across the top panel would still limit the use of the top panel.

[0010] US6182887B1 shows a container with an extended top panel produced by sealing the top panel and rear wall of the container to one another in a seal area coextensive with the top fin. As a result, the top fin extends from the top panel in the plane of the rear wall, thus essentially making the entire top panel available for use, such as positioning an opening device or closure. However, the extended top fin may still limit access to the top panel. For example, a top fin extending from the top panel in the plane of the rear wall may make it difficult for a consumer to drink directly from the container. [Prior art documents] [Patent documents]

[0011] [Patent Document 1] U.S. Patent No. 6,182,887 Summary of the Invention [Means for solving the problem]

[0012] With the above-mentioned problems and known solutions in mind, according to a first exemplary aspect, the present disclosure provides a paper- or paperboard-based container for holding a pourable food product, comprising: a planar or substantially planar bottom portion; a top portion arranged opposite the bottom portion and comprising a top panel and a top seal area forming a top seal of the container; a wall portion comprising a plurality of wall sections extending between the bottom and top portions and abutting the top panel, and a longitudinal sealing strip extending between the bottom and top portions across at least one of the wall sections; Equipped with the upper sealing area is folded over and attached to at least one of the wall sections comprising the longitudinal sealing strip; A paper-based or paperboard-based container is provided.

[0013] As a result, instead of the upper seal area or upper fin being folded over and attached to the top panel of the container, as is common in prior art containers, the upper fin or upper seal area is folded over a longitudinal seal strip, i.e., a wall portion with a longitudinal seam extending from the bottom to the top of the container. Because the section of the longitudinal seal strip extending into the upper seal area is also folded over the wall portion and thus would not extend over the top panel, this leaves the top panel free or substantially free of a seal structure. Such a seal structure may comprise a permanent seal structure, such as a welded, glued, or otherwise permanently joined seam where panels of laminated sheet material are permanently joined to each other. This allows the top panel to be utilized in an efficient manner. For example, an opening device or top closure can be positioned anywhere on the top panel, since there would be no sheet structure to consider. Also, the step of folding the top seal area over the sidewall portion with the longitudinal seal strip and attaching the seal area thereto will give the consumer unrestricted access to the opening device or closure for accessing or dispensing the food product in an easy manner.

[0014] The container may advantageously comprise gusset panels that, when the container is formed, are folded onto each other directly below the top panel, allowing the top seal area as a whole to be folded down onto and attached to the wall sections comprising the longitudinal seal strip. In other words, the entire top seal area may advantageously be folded down onto and attached to said at least one of the wall sections comprising the longitudinal seal strip. The top seal area may typically be formed by the top seal strip, and the entire top seal strip may be folded down onto and attached to the wall section comprising the longitudinal seal strip.

[0015] The container may include an opening device or closure disposed within the top panel for dispensing and / or providing access to the food product. The opening device may be reclosable, allowing the container to be reclosed after the first opening step.

[0016] The container may be made from a paper-based or paperboard-based laminated sheet material, including a multi-layer paperboard sheet laminated with one or more barrier layers to hold the food product thereon and / or prevent air and flavor migration through the paperboard sheet.

[0017] The upper sealing area may be planar or substantially planar and aligned parallel or substantially parallel to the at least one of the wall sections comprising the longitudinal sealing strip.

[0018] The top panel and the top seal area may share a common boundary that forms the top edge of the container.

[0019] The top edge may be straight or substantially straight and aligned parallel or substantially parallel to the bottom portion.

[0020] An opening device or closure for dispensing and / or accessing the food product may be arranged within the top panel. In contrast to the seal structures described above, the opening device or closure, including the top seal area and longitudinal seal strip, is arranged to permanently seal the container, but can be opened by the consumer to allow the consumer to dispense or access the food product.

[0021] The opening device or closure may include an opening disposed adjacent said upper edge.

[0022] The openings may be arranged at an orthogonal distance of 1 mm to 10 mm from the upper edge.

[0023] The top panel may be planar or substantially planar. The wall section or sections comprising the longitudinal seal strip may also be planar or substantially planar, and the top panel may form an angle therewith that is any one of the following: 10 degrees to 90 degrees, 30 degrees to 80 degrees, 45 degrees to 75 degrees, and 60 degrees.

[0024] The upper seal area may comprise a plurality of sealed seal strip panels, all of which may be arranged parallel or nearly parallel and / or coplanar or nearly coplanar within the container.

[0025] The seal strip panel may comprise a central seal strip panel extending across the wall section or sections comprising the longitudinal seal strip and may have a longitudinal extent that is any one of at least 15 mm, at least 20 mm, and at least 30 mm.

[0026] According to a second exemplary aspect, the present disclosure provides a paper- or paperboard-based sleeve for producing a container according to the first exemplary aspect.

[0027] According to a third exemplary aspect, the present disclosure provides a paper- or paperboard-based blank for producing a sleeve according to the second exemplary aspect.

[0028] The blank may be mirror symmetric about the central longitudinal axis of the blank.

[0029] The blank may include first and second straight or substantially straight and parallel or substantially parallel border edges that form the lateral or longitudinal border edges of the blank. The blank may also include a third straight or substantially straight border edge that extends orthogonally or substantially orthogonally between the lateral border edges and forms the bottom border edge of the blank. Additionally, the blank may include a fourth non-linear border edge that extends between the lateral border edges and forms the top border edge of the blank.

[0030] The blank may include a top region having an upper fold pattern and configured to form the top portion of the container. The top region may include a top panel and a gusset panel configured to fold over one another beneath the top panel when the container is formed from the blank.

[0031] The upper boundary edge may be mirror symmetric about the central longitudinal axis of the blank.

[0032] The upper border edge may comprise a plurality of individual straight upper border edge segments.

[0033] According to a fourth exemplary aspect, the present disclosure provides a method of producing a paper-based or paperboard-based container for holding a pourable food product, the method comprising: - sealing the paper-based or paperboard-based laminated sheet material along a longitudinal sealing strip to form a tubular protocontainer; - top sealing the proto-container in the top sealing area; - folding the upper sealing area onto at least one wall section of a protocontainer provided with a longitudinal sealing strip and attaching the upper sealing area to said at least one wall section; The present invention provides a method comprising:

[0034] The method may include forming a top portion of the container by folding gusset panels of the laminated sheet material over one another beneath a top panel of the laminated sheet material. The method may further include arranging an opening device or closure within the top portion for dispensing or accessing the food product. The opening device may be reclosable, thus allowing the container to be reclosed after the first opening step.

[0035] The method comprises: - bottom sealing the laminated sheet material to form a bottom sealed open top protocontainer; - filling a bottom-sealed, open-top protocontainer with a pourable food product; wherein the step of top-sealing the laminated sheet material is performed after the step of filling the bottom-sealed open-top proto-container with the pourable food product. In other words, the method may include filling the proto-container from the top side.

[0036] Alternatively, the step of top-sealing the proto-container at the top sealing region may produce a proto-container that is top-sealed but open at the bottom, the method comprising: - filling a top-sealed, open-bottom protocontainer with a pourable food product; - bottom sealing the laminated sheet material; may include:

[0037] As a result, instead of filling the protocontainer from the top side, the method may include filling the protocontainer from the bottom side.

[0038] The method may include providing a top panel of the container that is free of a seal structure. Such a seal structure may comprise a permanent seal structure, such as a welded, glued, or otherwise permanently joined seam where panels of laminated sheet material are permanently joined to one another.

[0039] The method may include aligning a planar or substantially planar upper sealing area parallel or substantially parallel to the at least one of the wall sections comprising the longitudinal sealing strip.

[0040] The method may include arranging the top panel and the top seal area so that they share a common boundary that forms a top edge of the container.

[0041] The method may include aligning the top edge in a straight or substantially straight line, and aligning the top edge parallel or substantially parallel to a planar or substantially planar bottom portion of the container.

[0042] The method may include arranging an opening device or closure within the top panel of the container for dispensing or accessing the food product.

[0043] The method may include aligning an opening of an opening device or closure adjacent the upper edge that forms a boundary between the top panel and the upper seal area.

[0044] The method may include arranging the openings at an orthogonal distance of 1 mm to 10 mm from the top edge.

[0045] The method may include arranging a planar or substantially planar top panel. The method may also include arranging a wall section or a plurality of wall sections with a planar or substantially planar longitudinal seal strip, and arranging the top panel at an angle relative to the wall section or plurality of wall sections that is any one of the following: 10 degrees to 90 degrees, 30 degrees to 80 degrees, 45 degrees to 75 degrees, and 60 degrees.

[0046] The step of top-sealing the protocontainer at the top seal region may include the substep of sealing a plurality of seal strip panels to one another. This substep may include arranging the sealed seal strip panels parallel or nearly parallel and / or coplanar or nearly coplanar within the container. This substep may include arranging a central seal strip panel of the seal strip panels to extend across the wall section or sections comprising the longitudinal seal strip and have a longitudinal extent of any one of at least 15 mm, at least 20 mm, and at least 30 mm.

[0047] According to a fifth exemplary aspect, the present disclosure provides a method for manufacturing a semiconductor device, comprising: a substantially planar bottom portion; a top portion arranged opposite the bottom portion and comprising a top panel and a top seal area forming a top seal of the container; a wall portion comprising a plurality of wall sections extending between the bottom and top portions and abutting the top panel, and a longitudinal sealing strip extending between the bottom and top portions across at least one of the wall sections; The present invention provides a container for holding a tiltable food item, comprising a paper-based or paperboard-based laminated sheet material forming:

[0048] The container may include a barrier disposed within the top panel for providing a seal within the opening in the top panel, and an opening device or closure disposed to break the seal during a first step of opening the container and dispensing and / or accessing the food product. The top seal area is folded over and attached to at least one of the wall sections.

[0049] The opening device or closure is a first sheet extending across and attached to at least a section of the top panel, the first sheet having a through opening aligned with the barrier; a second sheet releasably attached at its outer surface to at least a section of the first sheet, the second sheet being configured to be attached to the barrier via the through opening prior to the first opening step and to tear open the barrier during the first opening step; may also be provided.

[0050] The second sheet may be manually operable from a closed position, in which the second sheet covers the through opening, to an open position, in which the second sheet exposes the through opening and allows the pourable food product to be dispensed or accessed through the through opening.

[0051] As a result, instead of the upper seal area being folded over the top panel of the container or extending from the top panel to form an upper fin, as is the case in prior art containers, the present upper seal area is folded downward in its entirety onto one or more wall portions. This leaves the top panel free of an upper seal structure, allowing for free positioning of the dispenser seal structure and opening device or closure. Also, because the section of the longitudinal seal strip extending into the upper seal area will also be folded over the wall portion or portions, the longitudinal seal strip will also not extend over the top panel.

[0052] After the first opening step, the second sheet may be manually operable from an open position to a closed position to re-close the through opening.

[0053] The first sheet may extend across and be attached to at least a portion of the upper seal area.

[0054] The first sheet may comprise a drinking surface extending from the through opening to a distance of any one of at least 20 mm, at least 25 mm, and at least 30 mm from the through opening. The drinking surface may extend across and into the upper seal area.

[0055] The top panel and top seal area may share a common border that forms the uppermost boundary of the top panel and the top edge of the container, and the first sheet may extend across said top edge.

[0056] The through opening may be located within 2 to 10 mm of the uppermost boundary of the top panel.

[0057] The first sheet and the second sheet may each include a first lateral edge positioned at or adjacent the lowermost boundary of the top panel.

[0058] The first sheet may include a second lateral edge positioned at or adjacent the lowermost boundary of the upper seal area.

[0059] The outer surface of the first sheet and / or the inner surface of the second sheet may comprise an adhesive, and the inner surface of the second sheet may comprise an area of ​​reduced adhesiveness in an area facing the through opening when the second sheet is in the closed position.

[0060] The barriers are - pre-laminate holes; a removable section of the laminated sheet material of the top panel, bounded by a cutout made from an outer surface of the top panel partially through the top panel, the cutout providing for leaving one or more inner layers of the laminated sheet material intact prior to the first opening step; It may comprise any one of the following:

[0061] According to a sixth exemplary aspect, the present disclosure provides a method of producing paper-based or paperboard-based blanks for producing containers for holding pourable food products, each blank comprising: a first substantially linear boundary edge and a second substantially linear boundary edge, each extending substantially parallel to a first longitudinal direction of the blank between a first end point and a second end point; a third border edge extending generally parallel to the second transverse direction of the blank between the first end point of the first border edge and the first end point of the second border edge; a fourth non-linear boundary edge extending between the second end point of the first boundary edge and the second end point of the second boundary edge; Equipped with - spreading a first row and a second row of blank patterns on a web of laminate material, each row comprising a plurality of blank patterns arranged side by side with a first boundary edge of one blank pattern adjacent to a second boundary edge of a neighboring blank pattern and a fourth boundary edge of a blank pattern in the first row adjacent to a fourth boundary edge of a blank pattern in the second row; - cutting the web along the expanded first border edge, the second border edge, the third border edge, and the fourth border edge to form the blank; The present invention provides a method comprising:

[0062] According to a seventh exemplary aspect, the present disclosure provides a nesting pattern for producing paper-based or paperboard-based blanks from a web of laminate material, each blank comprising: a first substantially linear boundary edge and a second substantially linear boundary edge, each extending substantially parallel to a first longitudinal direction of the blank between a first end point and a second end point; a third border edge extending generally parallel to the second transverse direction of the blank between the first end point of the first border edge and the first end point of the second border edge; a fourth non-linear boundary edge extending between the second end point of the first boundary edge and the second end point of the second boundary edge; A nested pattern is provided, comprising:

[0063] The nested pattern comprises a first row and a second row of blank patterns arranged side by side with a first boundary edge of one blank pattern adjacent to a second boundary edge of a neighboring blank pattern and a fourth boundary edge of a blank pattern in the first row adjacent to a fourth boundary edge of a blank pattern in the second row.

[0064] The fourth boundary edge may form a non-linear line exhibiting two-fold rotational symmetry with respect to a center located on the line.

[0065] The above-discussed preferred and / or optional features of each aspect of the invention may be used alone or in any suitable combination with other aspects of the invention. The present invention provides, for example, the following. (Item 1) A paper-based or paperboard-based container (100, 100') for holding a pourable food product, comprising: a substantially planar bottom portion (102); a top portion (104) arranged opposite the bottom portion (102) and including top panels (124, 124') and top seal areas (126, 126') that form a top seal for the container (100, 100'); a wall portion (106) including a plurality of wall sections (108a-108d, 108a'-108h') extending between the bottom portion (102) and the top portion (104) and contacting the top panel (124, 124'); and a longitudinal sealing strip (14, 14') extending between the bottom portion (102) and the top portion (104) across at least one of the wall sections (108c, 108d', 108e'); Equipped with A container (100, 100') characterized in that the upper seal area (126, 126') is folded over and attached to at least one of the wall sections (108c, 108d', 108e') comprising the longitudinal seal strip (14, 14'). (Item 2) Item 1. The container (100, 100') according to item 1, characterized in that the container (100, 100') has gusset panels (44a-44d, 44a'-44d') folded over each other directly below the top panel (124, 124'). (Item 3) 3. The container (100, 100') according to any one of items 1 and 2, wherein the top panel (124, 124') is characterized by the absence of a seal structure. (Item 4) A container (100, 100') according to any one of the preceding items, characterized in that the upper sealing area (126, 126') is substantially planar and aligned substantially parallel to at least one of the wall sections (108c, 108d', 108e') comprising the longitudinal sealing band (14). (Item 5) A container (100, 100') according to any one of the preceding items, characterized in that the upper panel (124, 124') and the upper seal area (126, 126') share a common boundary (58c) that forms the upper edge (134) of the container (100, 100'). (Item 6) 6. The container (100, 100') according to item 5, characterized in that the upper edge (134) is substantially straight and aligned parallel to the bottom portion (102). (Item 7) A container (100, 100') according to any one of the preceding items, characterized in that an opening device or closure (136, 136') is arranged within the top panel (124, 124') for dispensing and / or accessing the food product. (Item 8) 7. The container (100, 100') according to any one of items 5 and 6, characterized in that an opening device or closure (136) is arranged within the top panel (124, 124') for dispensing and / or accessing the food product, and the opening device or closure (136) has an opening (140) arranged adjacent to the top edge (134). (Item 9) Item 9. The container (100, 100') according to item 8, characterized in that the openings (140) are arranged at an orthogonal distance of 1 mm to 10 mm from the upper edge (134). (Item 10) A container (100, 100') according to any one of the preceding items, characterized in that the top panel (124, 124') and at least one of the wall sections (108c, 108e') comprising the longitudinal seal band (14) are substantially planar, and the top panel (124, 124') forms an angle (α) with respect to at least one of the wall sections (108c, 108e') comprising the longitudinal seal band (14) that is any one of the following: 10 degrees to 90 degrees, 30 degrees to 80 degrees, 45 degrees to 75 degrees, and 60 degrees. (Item 11) A container (100, 100') according to any one of the preceding items, characterized in that the upper seal area (126, 126') comprises a plurality of sealed seal strip panels (56a-56g), and all of the sealed seal strip panels (56a-56g) of the upper seal area (126, 126') are arranged in a generally parallel and / or generally coplanar manner. (Item 12) Item 12. The container (100, 100') according to item 11, characterized in that the sealing strip panels (56a-56g) comprise a central sealing strip panel (56d) having a longitudinal extent (A) that is any one of at least 15 mm, at least 20 mm, and at least 30 mm. (Item 13) A paper- or paperboard-based sleeve (96, 96') for producing a container (100, 100') according to any one of the preceding items. (Item 14) 14. A paper or paperboard blank (10, 10') for producing a sleeve (96, 96') according to item 13. (Item 15) Item 15. The blank (10, 10') according to item 14, wherein the upper region (34) is characterized by comprising an upper panel (50, 50') and gusset panels (44a-44d, 44a'-44d') configured to be folded over one another directly below the upper panel (50). (Item 16) The blank (10, 10') is aligned along a longitudinal center axis (C a 16. The blank (10, 10') according to any one of items 14 and 15, characterized by mirror symmetry about the center. (Item 17) 1. A method of producing a paper-based or paperboard-based container (100, 100') for holding a pourable food product, comprising: sealing the paper-based or paperboard-based laminated sheet material along a longitudinal sealing strip (14) to form a tubular protocontainer (96, 96'); top sealing the proto-container at a top sealing area (126, 126'); folding the upper seal area (126, 126') onto at least one wall section (108c, 108d', 108e') of the proto-container provided with the longitudinal seal strip (14) and attaching the upper seal area (126, 126') to the at least one wall section (108c, 108d', 108e'); A method comprising: (Item 18) Item 18. The method according to item 17, comprising forming a top portion (104) of the container by folding gusset panels (44a-44d, 44a'-44d') of the laminated sheet material over one another directly below a top panel (50, 50') of the laminated sheet material. (Item 19) Item 19. The method of item 18, comprising arranging within said top portion (104) an opening device or closure (136, 136') for dispensing or accessing said food product. (Item 20) bottom sealing the laminated sheet material to form a bottom-sealed open-top protocontainer; filling said bottom-sealed, open-top protocontainer with said pourable food product; Including, 20. The method of any one of items 17-19, wherein the step of top-sealing the laminated sheet material is performed after the step of filling the bottom-sealed open-top protocontainer with the pourable food product. (Item 21) The step of top-sealing the protocontainer produces a top-sealed open-bottom protocontainer, the method comprising: filling said top-sealed, open-bottom protocontainer with said pourable food product; bottom sealing the laminated sheet material; 20. The method according to items 17-19, further comprising: (Item 22) A container (100'') for holding a pourable food product, comprising: A paper-based or paperboard-based laminated sheet material, comprising: a substantially planar bottom portion (102); a top portion (104) disposed opposite the bottom portion (102), the top portion (104) including a top panel (124'') and a top seal area (126'') that forms a top seal of the container (100''); a wall portion (106) including a plurality of wall sections (108a''-108d'') extending between the bottom portion (102) and the top portion (104) and contacting the top panel (124''); and a longitudinal seal strip (14'') extending between the bottom portion (102) and the top portion (104) across at least one of the wall sections (108c''); forming a paper-based or paperboard-based laminated sheet material Equipped with the container (100'') comprising a barrier arranged within the top panel (124'') to provide a seal within an opening (140'') in the top panel (124''), and an opening device or closure (136'') arranged to break the seal during initial opening of the container (100'') and dispensing of and / or access to the food product; the upper sealing area (126'') is folded over and attached to at least one of the wall sections (108c''); The opening device or closure (136'') a first sheet (150) extending across and attached to at least a portion of the top panel (124''), the first sheet (150) having a through opening (155) aligned with the barrier; a second sheet (160), the second sheet (160) being releasably attached to at least a portion of the first sheet (150) on its outer surface, the second sheet (160) being attached to the barrier through the through opening (155) prior to the first opening, the second sheet (160) being configured to tear open the barrier during the first opening; and To have is characterized by The second sheet (160) is manually operable from a closed position in which the second sheet (160) covers the through opening (155) to an open position in which the second sheet (160) exposes the through opening (155) and allows the pourable food product to be dispensed through or accessed therethrough, container (100''). (Item 23) 23. The container (100'') according to item 22, characterized in that the second sheet (160) is manually operable from the open position to the closed position to reclose the through opening (155) after the first opening. (Item 24) 24. The container (100'') according to any one of items 22 and 23, characterized in that the first sheet (150) extends across and is attached to at least a portion of the upper seal area (126''). (Item 25) 25. The container (100'') according to any one of items 22-24, characterized in that the first sheet (150) has a drinking surface extending from the through opening (155) to a distance (A) of at least 20 mm, at least 25 mm, and at least 30 mm from the through opening (155). (Item 26) 26. The container (100'') according to item 25, characterized in that the drinking surface extends into the upper seal area (126''). (Item 27) A container (100'') according to any one of items 22-26, characterized in that the upper panel (124'') and the upper seal area (126'') share a common boundary (58c'') that forms the uppermost boundary of the upper panel (124'') and the upper edge (134'') of the container (100''), and the first sheet (150) extends across the upper edge (134''). (Item 28) 28. The container (100'') according to item 27, characterized in that the through opening (155) is positioned within 2 to 10 mm from the uppermost boundary of the top panel (124''). (Item 29) 29. The container (100'') according to any one of items 22-28, characterized in that each of the first sheet (150) and the second sheet (160) has a first lateral edge (153, 163) positioned at or adjacent to the lowermost boundary (132'') of the top panel (124''). (Item 30) Item 30. The container (100'') according to item 29, wherein the first sheet (150) has a second lateral edge (154) positioned at or adjacent to the lowermost boundary (127'') of the upper seal area (126''). (Item 31) Container (100'') according to any one of items 22-30, characterized in that the outer surface of the first sheet (150) and / or the inner surface of the second sheet (160) are provided with an adhesive. (Item 32) Item 32. The container (100'') according to item 31, characterized in that the inner surface of the second sheet (160) comprises an area of ​​reduced adhesiveness (165) in the area facing the through opening (155) when the second sheet (160) is in the closed position. (Item 33) The above barriers, a pre-lamination hole (140''); a removable section (72) of laminated sheet material of said top panel (124'') bounded by a cutout (74) made from the outer surface of said top panel partially through said top panel; 33. The container (100'') according to any one of items 22-32, characterized in that it comprises any one of the following: (Item 34) 1. A method for producing paper-based or paperboard-based blanks (10, 10') for producing containers (100) for holding tiltable food products, comprising the steps of: a first substantially linear boundary edge (12) and a second substantially linear boundary edge (14), each extending substantially parallel to a first longitudinal direction (L) of the blank (10, 10') between first end points (18, 20) and second end points (24, 26); a third border edge (16), the third border edge (16) extending generally parallel to a second transverse direction (T) of the blank (10, 10') between a first end point (18) of the first border edge (12) and a first end point (20) of the second border edge (14); a fourth non-linear boundary edge (22), the fourth non-linear boundary edge (22) extending between a second end point (24) of the first boundary edge (12) and a second end point (26) of the second boundary edge (14); Equipped with The above method is spreading a first row (202a) and a second row (202b) of blank patterns (200) on a web (204) of laminate material, each row (202a, 202b) comprising a plurality of blank patterns arranged side by side such that a first boundary edge (12) of one blank pattern is adjacent to the second boundary edge (14) of an adjacent blank pattern and a fourth boundary edge (22) of a blank pattern in the first row (202a) is adjacent to the fourth boundary edge (22) of a blank pattern in the second row (202b); cutting the web along the expanded first boundary edge (12), second boundary edge (14), third boundary edge (16), and fourth boundary edge (22) to form the blanks (10, 10'); A method characterized by (Item 35) A nesting pattern (200) for producing paper-based or paperboard-based blanks (10, 10') from a web (204) of laminated material, each blank (10, 10') comprising: a first substantially linear boundary edge (12) and a second substantially linear boundary edge (14), each extending substantially parallel to a first longitudinal direction (L) of the blank (10, 10') between first end points (18, 20) and second end points (24, 26); a third border edge (16), the third border edge (16) extending generally parallel to a second transverse direction (T) of the blank (10, 10') between a first end point (18) of the first border edge (12) and a first end point (20) of the second border edge (14); a fourth non-linear boundary edge (22), the fourth non-linear boundary edge (22) extending between a second end point (24) of the first boundary edge (12) and a second end point (26) of the second boundary edge (14); Equipped with A nested pattern (200) characterized by comprising a first row (202a) and a second row (202b) of blank patterns (200) arranged side by side, with the first boundary edge (12) of one blank pattern adjacent to the second boundary edge (14) of a neighboring blank pattern, and the fourth boundary edge (22) of a blank pattern in the first row (202a) adjacent to the fourth boundary edge (22) of a blank pattern in the second row (202b). (Item 36) Item 36. The nested pattern (400) according to item 35, characterized in that the fourth boundary edge (22) forms a non-linear line (222) exhibiting two-fold rotational symmetry with respect to a center (220) located on the line (222). [Brief explanation of the drawings]

[0066] The following drawings are included to facilitate understanding of the present invention.

[0067] [Figure 1] FIG. 1 shows one embodiment of the blank. [Figure 2] 2 and 3 show a blank according to FIG. 1 that is folded and sealed to form a sleeve. [Figure 3] 2 and 3 show a blank according to FIG. 1 that is folded and sealed to form a sleeve. [Figure 4] FIG. 4 is a perspective view of the sleeve according to FIGS. 2 and 3 after it has been erected into a tubular form. [Figure 5] FIG. 5 shows a bottom view of the sleeve according to FIG. 4 after it has been bottom sealed. [Figure 6] FIG. 6 is a perspective view of the sleeve according to FIG. 4 after it has been bottom sealed. [Figure 7] 7 and 8 illustrate the upper seal of the sleeve according to FIG. [Figure 8] 7 and 8 illustrate the upper seal of the sleeve according to FIG. [Figure 9] FIG. 9 is a front view of a container produced from the blank according to FIG. [Figure 10] FIG. 10 is a perspective view of a container produced from the blank according to FIG. [Figure 11] 11 and 12 are side views of a container produced from the blank according to FIG. [Figure 12] 11 and 12 are side views of a container produced from the blank according to FIG. [Figure 13]FIG. 13 is a front view of a container produced from the blank according to FIG. 1 in an open position. [Figure 14] 14a and 14b illustrate a cross section of a container produced from the blank according to FIG. [Figure 15] FIG. 15 is an alternative embodiment of the blank. [Figure 16] 16 and 17 show the blank according to FIG. 15 folded and sealed to form a sleeve. [Figure 17] 16 and 17 show the blank according to FIG. 15 folded and sealed to form a sleeve. [Figure 18] 18-21 are front, side and rear views of a container produced from the blank according to FIG. [Figure 19] 18-21 are front, side and rear views of a container produced from the blank according to FIG. [Figure 20] 18-21 are front, side and rear views of a container produced from the blank according to FIG. [Figure 21] 18-21 are front, side and rear views of a container produced from the blank according to FIG. [Figure 22] FIG. 22 shows an embodiment of the blank. [Figure 23] 23-25 ​​show a container formed from the blank according to FIG. [Figure 24] 23-25 ​​show a container formed from the blank according to FIG. [Figure 25] 23-25 ​​show a container formed from the blank according to FIG. [Figure 26] Figures 26 and 27 show the container according to Figures 23-25 ​​in the open position. [Figure 27] Figures 26 and 27 show the container according to Figures 23-25 ​​in the open position. [Figure 28] Figures 28 and 29 illustrate opening devices or closures for containers according to Figures 23-27. [Figure 29] Figures 28 and 29 illustrate opening devices or closures for containers according to Figures 23-27. [Figure 30] FIG. 30 shows an embodiment of a nesting pattern of blanks according to FIG. [Figure 31] FIG. 31 is a detailed view of the nested pattern according to FIG. [Figure 32] FIG. 32 shows a second embodiment of the nesting pattern of the blank according to FIG. [Figure 33] FIG. 33 shows a blank produced from the nested patterns of either of FIGS. [Figure 34] FIG. 34 shows one embodiment of a nesting pattern of blanks. [Figure 35] FIG. 35 shows a blank produced from the nested pattern of FIG. [Figure 36] FIG. 36 shows a container produced from the blank according to FIG.

[0068] It should be understood that the drawings are not intended to limit the invention to the subject matter depicted in the drawings.

[0069] In the drawings, like reference numerals are used to designate common parts, elements, or features unless otherwise expressly stated or implicitly understood by context. DETAILED DESCRIPTION OF THE INVENTION

[0070] Detailed Description Specific forms of the blanks and containers produced therefrom will be described in more detail below with reference to the drawings. However, it is specifically intended that the invention as defined in the following claims is not limited to the embodiments and figures contained herein, but includes modified forms of embodiments, including portions of such embodiments and combinations of elements of different embodiments, that fall within the scope of the claims.

[0071] FIG. 1 shows a blank 10 for producing a sleeve and subsequently a first embodiment of a container for holding a tiltable food product.

[0072] The blank 10 can comprise several layers of different materials, such as paper, paperboard, plastic, or metal, particularly aluminum. Typically, the blank 10 can be made from a paper- or paperboard-based laminated sheet material, including a multi-layer paperboard sheet laminated with one or more barrier layers to retain the food product and / or prevent air and flavor migration through the paperboard sheet.

[0073] The blank 10 has several creases or fold lines that divide the blank 10 into several regions and sub-regions that are intended to facilitate folding of the blank 10 when produced to form a container.

[0074] Blank 10 comprises a straight or substantially straight first boundary edge 12 and a second boundary edge 14 that are parallel or substantially parallel to the longitudinal direction L of blank 10. Boundary edges 12 and 14 are parallel or substantially parallel and of equal or substantially equal length and form lateral boundary edges of blank 10.

[0075] Center axis C of blank 10 a extends parallel to the longitudinal direction L, equidistant from the lateral boundary edges 12 and 14.

[0076] The blank 10 also includes a straight or substantially straight third boundary edge 16 that is parallel or substantially parallel to a transverse direction T of the blank 10, which extends perpendicular to the longitudinal direction L. The boundary edge 16 extends between the first bottom end points 18, 20 of the lateral boundary edges 12, 14 and forms the bottom boundary edge of the blank 10.

[0077] The blank 10 further includes a fourth boundary edge 22 that extends between second upper endpoints 24 , 26 of the lateral boundary edges 12 , 14 and forms the upper boundary edge of the blank 10 .

[0078] Bottom terminal points 18 and 20 form bottom corner points, and top terminal points 24 and 26 form top corner points, of blank 10. Because side boundary edges 12 and 14 are parallel or nearly parallel, and bottom boundary edge 16 is perpendicular or nearly perpendicular to side boundary edges 12, 14, corner points 18, 20, 24, and 26 define a rectangular or nearly rectangular shape. However, in contrast to bottom boundary edge 16, top boundary edge 22 is non-linear and extends beyond the rectangular shape defined by corner points 18, 20, 24, and 26.

[0079] Upper boundary edge 22 comprises a plurality of individual straight or substantially straight segments 22a-22i.

[0080] Upper boundary edge segments 22a and 22i are collinear or nearly collinear, originating from upper corner points 24 and 26, respectively, and extending parallel or nearly parallel to the lateral direction T, i.e., parallel or nearly parallel to the bottom boundary edge 16. Edge segments 22a and 22i are equal or substantially equal in length. Edge segments 22b and 22h extend from edge segments 22a and 22i, respectively, and angle away from the bottom boundary edge 16. Edge segments 22b and 22h form an angle of approximately 45 degrees with the lateral direction T. Edge segments 22c and 22g extend from edge segments 22b and 22i, respectively, and form an angle of approximately 20 degrees with the lateral direction T. Edge segments 22d and 22f extend from edge segments 22c and 22g, respectively, and form an angle of approximately 45 degrees with the lateral direction T. Edge section 22e finally extends between edge sections 22d and 22f parallel or substantially parallel to the lateral direction T, i.e., parallel or substantially parallel to bottom boundary edge 16. However, due to the oblique orientation of edge sections 22b-22d and 22f-22h, edge section 22e is arranged farther from bottom boundary edge 16 than edge sections 22a and 22i.

[0081] The upper boundary edge 22 is aligned with the central axis C a It is reflectively symmetric about the central axis C. a as the axis of symmetry, and the central axis C aThe sections of upper boundary edge 22 located on one side of the center axis C are mirrored by the corresponding sections located on the other side. As a result, edge sections 22a, 22b, 22c, and 22d are mirrored by edge sections 22i, 22h, 22g, and 22f, respectively, and are aligned with the center axis C. a extends centrally through edge section 22e.

[0082] The blank 10 includes a first fold line 28 and a second fold line 30, each of which extends across the blank 10, i.e., between the lateral boundary edges 12, 14. The fold lines 28 and 30 define the blank 10 as follows: a bottom region 32 having a bottom fold pattern and configured to form a bottom portion of a container formed from the blank 10; an upper region 34 having an upper fold line pattern and configured to form an upper portion of the container; an intermediate region 36 contained between said first fold line 28 and said second fold line 30, interposed between the bottom region 32 and the top region 34, and configured to form an intermediate wall portion of the container; Divide into.

[0083] The fold lines 28 are straight or substantially straight and extend parallel or substantially parallel to the transverse direction T across the panel 10 .

[0084] Partitioned from intermediate region 36 by fold line 28, bottom region 32 comprises a plurality of rectangular or generally rectangular bottom panels 40a, 40f, and 40k and a plurality of triangular or generally triangular gusset panels 40b-40e and 40g-40j. Gusset panels 40b-40e and 40g-40j are arranged in two rectangular or generally rectangular subregions that are arranged in a row with bottom panels 40a, 40f, and 40k. When a container is produced from blank 10, bottom and gusset panels 40a-40k are therefore configured to be folded in a manner known in the art to form a generally planar bottom of the container.

[0085] The bottom region 32 also includes a plurality of rectangular or generally rectangular bottom seal strip panels 38a-38g extending between the lateral boundary edges 12, 14. The seal strip panels 38a-38g are partitioned in the transverse direction T by longitudinal or generally longitudinal fold lines. The seal strip panels 38a-38g extend along the bottom boundary edge 16 and form a bottom seal strip 38 that is partitioned from the bottom and gusset panels 40a-40k by straight or generally straight fold lines 42 extending across the blank 10 that are parallel or generally parallel to the transverse direction T. When a container is produced from the blank 10, the seal strip panels 38a-38g are thus configured to be sealed to one another to form a bottom seal for the container in a manner known in the art.

[0086] Turning now to the top region 34 of the blank 10, the fold line 30 comprises a plurality of fold line segments 30a-30e, with fold line segments 30a, 30b, 30d, and 30e individually being straight or substantially straight, and fold line segment 30c being curved. Fold line segments 30a and 30e are collinear or substantially collinear, originating from the side boundary edges 12 and 14, respectively, and extending parallel or substantially parallel to the transverse direction T, i.e., parallel or substantially parallel to edge segments 22a and 22i. Fold line segments 30a and 30e are of equal or substantially equal length. Fold line segments 30b and 30d extend from fold line segments 30a and 30e, respectively, and angle toward the bottom boundary edge 16. Fold line segments 30b and 30d form an angle of approximately 30 degrees with respect to the transverse direction T. Fold line sections 30b and 30d are of equal or substantially equal length. Finally, fold line section 30c extends between fold line sections 30b and 30d and has a convex side facing intermediate region 36.

[0087] Like the upper boundary edge 22, the fold line 30 is aligned with the central axis C a It is reflectively symmetric about the central axis C. a as the axis of symmetry, and the central axis C aThe segments of fold line 30 located on one side of central axis C are mirrored by the corresponding segments located on the other side. As a result, fold line segments 30a and 30b are mirrored by fold line segments 30e and 30d, respectively, and the central axis C a extends centrally through fold line section 30c.

[0088] Partitioned from the middle region 36 by the fold line 30, the upper region 34 is aligned along a central axis C a The blank 10 includes triangular or approximately triangular gusset panels 44a and 44b arranged on one side thereof and corresponding triangular or approximately triangular gusset panels 44c and 44d arranged on the other side thereof, partitioned by a straight or approximately straight fold line 48. Gusset panels 44a and 44b are partitioned by a straight or approximately straight fold line 46. Gusset panels 44c and 44d are partitioned by a straight or approximately straight fold line 48. Fold line 46 connects to fold line 30 at the intersection of fold line sections 30b and 30c, and fold line 48 connects to fold line 30 at the intersection of fold line sections 30d and 30e. Gusset panels 44a and 44b are equilateral and configured to fold over one another when blank 10 is folded to form the container. As a result, gusset panels 44a and 44b are reflectively symmetrical about fold line 46, i.e., they use fold line 46 as an axis of symmetry. Similarly, gusset panels 44c and 44d are equilateral and reflectively symmetrical about fold line 48, thus allowing gusset panels 44c and 44d to fold onto one another when the container is formed.

[0089] Gusset panels 44a and 44c are partitioned from intermediate region 36 by fold line sections 30b and 30e, respectively.

[0090] Upper region 34 also includes a top panel 50 disposed between gusset panels 44b and 44d. Top panel 50 is partitioned from gusset panel 44b by a straight or nearly straight fold line 52 and from gusset panel 44d by a straight or nearly straight fold line 54. Fold line 52 connects to fold line 30 at the intersection of fold line segments 30b and 30c, and fold line 54 connects to fold line 30 at the intersection of fold line segments 30d and 30e. Fold lines 52 and 54 are aligned along central axis C. a , but converge slightly as one moves along fold lines 52 and 54 toward intermediate region 36. Fold lines 52 and 54 are spaced approximately 3 degrees from central axis C a forms an angle with respect to

[0091] The top panel 50 is partitioned from the intermediate region 36 by the fold line 30c, such that the bottom boundary of the top panel 50, i.e., the boundary of the top panel 50 facing the intermediate region 36, is convex.

[0092] The gusset panels 44a-44d and the top panel 50 are aligned along a central axis C a In other words, the central axis C a as an axis of symmetry, gusset panels 44a and 44b are mirrored by gusset panels 44c and 44d, respectively, and are aligned about central axis C a extends centrally through the top panel 50.

[0093] The upper region 34 further includes upper seal strip panels 56a-56g that form an upper seal strip 56 that extends along the upper boundary edge 22 of the blank 10. When a container is formed from the blank 10, the upper seal strip panels 56a-56g are configured to seal to one another to form a top seal of the container, as will be discussed in more detail later in this disclosure.

[0094] Seal strip panel 56a extends from side boundary edge 12 and extends between fold line section 30a and boundary edge section 22a. In a corresponding manner, seal strip panel 56g extends from side boundary edge 14 and extends between fold line section 30e and boundary edge section 22i.

[0095] Seal strip panel 56b extends from seal strip panel 56a and extends between gusset panel 44a and boundary edge section 22b. In a corresponding manner, seal strip panel 56f extends from seal strip panel 56g and extends between gusset panel 44c and boundary edge section 22h. Seal strip panel 56b is partitioned from gusset panel 44a by a straight or nearly straight fold line section 58a and from adjacent seal strip panel 56a by a straight or nearly straight fold line 60. Fold line 60 extends between the intersection of boundary edge sections 22a and 22b and the intersection of fold line sections 30a and 30b. Fold line 60 forms an angle of approximately 15 degrees with respect to longitudinal direction L. Fold line section 58a forms an angle of approximately 30 degrees with respect to longitudinal direction L. Seal strip panel 56f is partitioned from gusset panel 44c by straight or nearly straight fold line segment 58e and from adjacent seal strip panel 56g by straight or nearly straight fold line 70. Fold line 70 extends between the intersection of boundary edge segments 22i and 22h and the intersection of fold line segments 30e and 30d. Like fold line 60, fold line 70 forms an angle of approximately 15 degrees with respect to longitudinal direction L, but is angled in the opposite direction compared to fold line segment 60. Fold line segment 58e forms an angle of approximately 30 degrees with respect to longitudinal direction L, but is angled in the opposite direction compared to fold line segment 58a.

[0096] Seal strip panel 56c extends from seal strip panel 56b and extends between gusset panel 44b and the combined extent of boundary edge sections 22c and 22d. In a corresponding manner, seal strip panel 56e extends from seal strip panel 56f and extends between gusset panel 44d and the combined extent of boundary edge sections 22g and 22f. Seal strip panel 56c is partitioned from gusset panel 44b by a straight or nearly straight fold line section 58b and from adjacent seal strip panel 56b by a straight or nearly straight fold line 62. Fold line 62 extends between the intersection of boundary edge sections 22b and 22c and the intersection of fold line sections 58a and 58b. Fold lines 62 and 46 are collinear or nearly collinear and form an angle of approximately 25 degrees with respect to longitudinal direction L. Fold line section 58b forms an angle of approximately 85 degrees with respect to longitudinal direction L. Seal strip panel 56e is partitioned from gusset panel 44d by straight or nearly straight fold line segment 58d and from adjacent seal strip panel 56f by straight or nearly straight fold line 68. Fold line 68 extends between the intersection of boundary edge segments 22h and 22g and the intersection of fold line segments 58e and 58d. Fold lines 68 and 48 are collinear or nearly collinear and form an angle of approximately 25 degrees with respect to longitudinal direction L, but are angled in the opposite direction compared to fold lines 62 and 46. Fold line segment 58d forms an angle of approximately 85 degrees with respect to longitudinal direction L, but is angled in the opposite direction compared to fold line segment 58b.

[0097] Finally, seal strip panel 56d extends between seal strip panels 56c and 56e and between top panel 50 and border edge section 22e. Seal strip panel 56d is partitioned from top panel 50 by straight or nearly straight fold line section 58c and from adjacent seal strip panels 56c and 56e by straight or nearly straight fold lines 64 and 66, respectively. Fold line 64 is parallel or nearly parallel to longitudinal direction L and extends between the intersection of border edge sections 22d and 22e and the intersection of fold line sections 58b and 58c. Fold line 66 is also parallel or nearly parallel to longitudinal direction L but extends between the intersection of border edge sections 22f and 22e and the intersection of fold line sections 58d and 58c. Fold line section 58c and border edge section 22e are parallel or nearly parallel.

[0098] The sealing band 56 is a It is reflectively symmetric about the central axis C. a as an axis of symmetry, the seal strip panels 56a, 56b, 56c are mirrored by the seal strip panels 56g, 56f, 56e, respectively, and are aligned with the central axis C a extends centrally through the sealing strip panel 56d.

[0099] Top panel 50 includes a removable section 72 bounded by a loop of weakness 74 that allows section 72 to be removed from a container formed from blank 10 when the container is initially opened. This opening action will be discussed in more detail later in this disclosure. Loop of weakness 74 may, for example, be a so-called "half-cut" - i.e., a cut made partially through the laminated substrate of blank 10 from its outer surface, leaving one or more inner layers of the laminated substrate intact and providing an uninterrupted barrier to the food product to be contained within the container prior to the first opening step of the container produced from blank 10.

[0100] Turning now to intermediate region 36 of blank 10, this region comprises panels 76a-76e partitioned by fold lines 82a-82d.

[0101] Panel 76c is configured to form the front wall panel of a container produced from blank 10. Adjacent to panel 76c, intermediate region 36 includes panels 76b and 76d, which are configured to form the side wall panels of the container produced. Panel 76c is partitioned from panel 76d by straight or nearly straight fold line 82c and from panel 76b by straight or nearly straight fold line 82b.

[0102] Intermediate region 36 further includes panel 76a adjacent to panel 76b and fifth panel 76e adjacent to panel 76d. Panels 76a and 76e are configured to form rear wall panel sections of the produced container. Panel 76a is partitioned from panel 76b by a straight or nearly straight fold line 82a, and panel 76e is partitioned from panel 76d by a straight or nearly straight fold line 82d.

[0103] Fold line 82c extends between fold line 28 and the intersection of fold line segments 30c and 30d. Fold line 82b extends between fold line 28 and the intersection of fold line segments 30b and 30c. Starting from top region 34 and moving toward bottom region 32, fold lines 82b and 83c converge. As a result, the width of panel 76c, i.e., the distance between fold lines 76c and 76d in transverse direction T, continuously decreases when moving from top region 34 to bottom region 32. Central axis C a as an axis of symmetry, fold line 82b is mirrored by fold line 82c, and both fold lines 82b and 82c are aligned approximately 2 degrees from central axis C a forms an angle with the central axis C a It branches off in the opposite direction from

[0104] Fold line 82a extends between fold line 28 and the intersection of fold line segments 30a and 30b. Starting from top region 34 and moving toward bottom region 32, fold lines 82a and 82b diverge. As a result, the width of panel 76b continuously increases as one moves from top region 34 to bottom region 32. Fold line 82d extends between fold line 28 and the intersection of fold line segments 30d and 30e. Starting from top region 34 and moving toward bottom region 32, fold lines 82d and 82c diverge. As a result, similar to panel 76b, the width of panel 76d continuously increases as one moves from top region 34 to bottom region 32. Fold lines 82a and 82d are both approximately 3 degrees from central axis C. a forms an angle with the central axis C a As a result, the central axis C a Using as an axis of symmetry, panel 76b is mirrored by panel 76d.

[0105] The blank 10 also has a length along the entire length of the blank 10, i.e., the central axis C a In bottom region 32, fold lines 92 and 94 extend centrally or approximately centrally within panels 76b and 76d, respectively, thereby dividing panels 76b and 76d into two panel sections 76b-I, 76b-II, and 76d-I, 76d-II, respectively. Also in bottom region 32, fold lines 92 and 94 extend centrally or approximately centrally within gusset panel sub-regions formed by gusset panels 40b-40e and 40g-40j, respectively.

[0106] Figure 2 shows, in a rear view, a sleeve 96 produced from the blank 10 of Figure 1, and Figure 3 shows, in a front view, the sleeve 96. Features of the sleeve already described with reference to Figure 1 are provided with corresponding reference numerals in Figures 2 and 3.

[0107] The sleeve 63 is produced from the blank 10 by folding the blank 10 along the two fold lines 92 and 94, overlapping the panel 76e over the panel 76a. In the overlapping region, the panels 76a and 76e are then sealed to one another, e.g., welded together, to form a longitudinal seal strip 14 that defines a planar or substantially planar rear wall section. The sleeve 96 is thus closed in the circumferential direction and acquires a circumferential structure with an opening in the region of the bottom boundary edge 16 and an opening in the region of the top boundary edge 22. The lateral boundary edges, i.e., in this case, boundary edge 12, that terminate on the inside of the sleeve are covered either prior to the step of folding the blank 10 along the fold lines 92 and 94 or after the overlapping regions of the panels 76a and 76e are connected to one another. Covering the open cut edges of the composite material has the purpose of preventing any contact between the contents of the container and the layers, in particular the paper or paperboard layers contained therein. As is known in the art, covering the cutting edge can be accomplished by peeling the composite layer from the edge and folding the remaining impermeable layer over the edge. Alternatively, as is also known in the art, strips of sealing material (not shown) can be applied over the lateral boundary edges that terminate on the inside of the sleeve.

[0108] In the front view (FIG. 3), panel 76c is visible, as are panel sections 76b-II and 76d-I. The weakened loops 74 surrounding the removable section 72 of top panel 50 are also visible in the front view. However, the weakened loops are not visible in the back view (FIG. 2) because the inner layer of laminated material of top panel 50 is not broken, providing the uninterrupted barrier. In the back view (FIG. 2), panels 76a and 76e are visible, as are panel sections 76b-I and 76d-II.

[0109] FIG. 4 shows the sleeve 96 from FIGS. 2 and 3 in an erected state. The erected state is reached by reversing the previous fold along fold lines 92 and 94 and folding the sleeve 96 approximately 180 degrees along fold lines 92 and 94. The folding along fold line 92 has the result that the two panel sections 76b-I and 76b-II are no longer on top of each other but are now aligned in the same or substantially the same plane. In a corresponding manner, the folding along fold line 94 has the result that the two panel sections 76d-I and 76d-II are no longer on top of each other but are now aligned in the same or substantially the same plane. The folding action also involves folding the sleeve 96 approximately 90 degrees along fold lines 82a, 82b, 82c, and 82d, thus forming the side edges of the future container.

[0110] The bottom region of the erected sleeve is then folded and sealed. This involves bringing bottom seal strip panels 38f and 38b into sealing engagement with seal strip panels 38e and 38c, respectively, and bottom seal strip panels 38g and 38s into sealing engagement with seal strip panel 38d. Sealing engagement, therefore, may be accomplished by welding in a manner known in the art. The step of folding and sealing the bottom region also involves folding gusset panels 40j and 40g inwardly over gusset panels 40i and 40h, respectively, and folding corresponding gusset panels 40b and 40e inwardly over gusset panels 40d and 40c, respectively. This further involves folding the now sealed sealing strip downwardly onto bottom panel 40f and gusset panels 40e and 40g, connecting the sealing strip thereto, for example by welding, and finally folding it into the lugs formed by the previously folded gusset panels, thus arriving at the sealed, generally planar configuration illustrated in Figure 5. However, it should be understood that other configurations of sealed, planar bottom regions are known in the art and may be used instead of those described above.

[0111] The sleeve erection and bottom sealing steps may be accomplished in a packaging machine (not shown), where sleeves 96 may be fed from a magazine and erected on a mandrel. The bottom region may be formed and sealed on the mandrel, and the proto-container, i.e., a partially formed container as shown in FIG. 6, may then be ejected from the mandrel onto a conveyor. The conveyor may transport the partially formed container to a sterilization station and then to a filling station, where food products may be dispensed into the partially formed container through the open top.

[0112] The filled, partially formed containers may then be conveyed to a top folding and sealing station for folding and sealing the top region.

[0113] As the upper region is folded, angled upper panels 44c and 44d are forced inward at crease line 48, folding panel 44d over panel 44c and panel 56e over 56f (see FIG. 6). Similar operations are performed on panels 44a, 44b and 56c, 56b (see also FIG. 1). At the end of this folding operation, upper panel 50 will assume an angled orientation as shown in FIG. 7. In this position, gusset panels 44a-44d are folded over one another beneath upper panel 50, and the panels of sealing strip 56 may be sealed to one another, for example, in a welding operation, thereby sealing the upper region. The folded and sealed sealing strip 56 is then folded downward onto and attached to rear wall panels 76a and 76e, as shown in FIG. 8.

[0114] Because the upper seal strip panels 56b, 56c, 56e, and 56f are forced inward as the upper seal is formed, the upper seal strip panels 56b, 56c, 56e, and 56f will be contained between the upper seal strip panel 56d and the joined upper seal strip panels 56g and 56a. As a result, the folded and sealed seal strip 56 will have a lateral extent that corresponds to the lateral extent of the upper seal strip panel 56d, thus allowing the entire seal strip 56 to be folded downwardly onto and attached to the rear wall panels 76a and 76e.

[0115] As a result, the folded and sealed seal strip 56 forms an upper seal area that is folded over and attached to rear wall panels 76a and 76e, i.e., the rear wall section of a container formed from the wall section containing longitudinal seal strip 14. The result of this arrangement, as will be discussed in more detail below, is that the top panel (see FIG. 13) of container 124 formed from panel 50 (see FIG. 3) will be free of seal structures, such as welded, glued, or otherwise permanently joined seams, where panels of laminated sheet material are permanently joined to one another. This allows the top panel to be utilized in an efficient manner.

[0116] A tear flap may be disposed over and attached to the removable section 72 (see FIG. 3) of the top panel 50 to allow for easy removal of the removable section.

[0117] 9-12 show a container 100 produced from the blank 10 disclosed above. Container 100 includes a generally planar bottom portion 102, a top portion 104, and a wall portion 106. Wall portion 106 includes a front wall section 108a formed from panel 76c and a rear wall section 108c formed from panels 76a and 76e. Wall portion 106 further includes side wall sections 108b and 108d formed from panels 76d and 76b, respectively. An edge 116, formed by fold line 82b, defines the intersection of front wall section 108a and side wall section 108d, and an edge 118, defined by fold line 82c, defines the intersection of front wall section 108a and side wall section 108b. Additionally, an edge 120 formed by fold line 82a defines the intersection of rear wall section 108c and side wall section 108d, and an edge 122 formed by fold line 82d defines the intersection of rear wall section 108c and side wall section 108b.

[0118] The top portion 104 includes a top panel 124 formed from panel 50 and a sealed seal strip 56, i.e., a seal area 126 formed from folded and sealed top seal strip panels 56a-56g that form the top seal of the container 100. A beveled side edge 128 formed by fold line 52 defines the intersection of the top panel 124 and side wall section 108d, and a beveled side edge 130 formed by fold line 54 defines the intersection of the top panel 124 and side wall section 108b. A front edge 132 formed by fold line section 30c defines the intersection of the top panel 124 and front wall section 108a. The container 100 also includes a back edge 134 formed by fold line section 58c that corresponds to the intersection of the top panel 124 and seal area 126. As a result, top panel 124 extends between top edges 128 , 130 , 132 , and 134 .

[0119] As discussed above, the seal area 126 is folded downwardly onto and attached to the rear wall section 108c, i.e., the wall section formed by panels 76a and 76e and containing the longitudinal seal strip 14.

[0120] The panel 76c is aligned with the central axis C a along the length L F (See FIG. 1.) The panels 76a and 76e have a central axis C a In the direction of L F is less than the length L B As a result, the front wall section 108a has a length that is less than the length of the rear wall section 108c (when viewed in the longitudinal direction of the box 100). This difference in length, i.e., L F <L B creates an extended configuration for the top panel 124. Thus, the front edge 132 is lower than the rear edge 134 when the container 100 is in the upright position, as shown. The top panel 124 is at a predetermined angle α relative to the rear wall section 108c (see FIGS. 11 and 12). The angle α can be from about 10 degrees to about 90 degrees, preferably from about 30 degrees to about 80 degrees. Most preferably, the angle α is from about 45 degrees to about 75 degrees. In this embodiment, the angle is approximately 60 degrees, as indicated by the angle between fold line sections 30b and 30d and fold lines 82a and 82d, respectively (see FIG. 1).

[0121] 14a and 14b, the planar bottom portion 102, as illustrated in FIG. 14a, is generally square-shaped, i.e., it has a length and width that are substantially equal (see also FIG. 5). However, at the top portion 104, when viewed in a plane parallel to the plane of the bottom portion 102, the cross-section of the container 100 is rectangular. In other words, across the bottom portion 102, the width of the container 100 is greater than the width of the container 100, as illustrated in FIG. 14b. This asymmetry increases when moving from the bottom portion 102 toward the top portion 104.

[0122] 9, 10, and 13, container 100 includes an opening device or closure 136 covering removable section 72 of top panel 50 and having tear flap 138 attached thereto (see also FIG. 1). As discussed above, removable section 72 is demarcated by a line of weakness 74, which allows section 72, along with tear flap 138, to be removed from container 100 when the container is initially opened. However, until this first opening step, section 72, along with the remainder of top panel 124, forms an uninterrupted barrier for the food product contained within the package. Line of weakness 74 may be, for example, a so-called "half-notch," i.e., a notch made from the outer surface of the blank laminated substrate partially through the blank laminated substrate, leaving one or more inner layers of the laminated substrate intact to provide an uninterrupted barrier for the contained food product. When the tear flap and attached section 72 are removed from the container 100, an opening 140 (see FIG. 13) will be revealed in the top panel 124, through which the food product in the container 100 may be dispensed or accessed. The tear flap 138 may extend downwardly onto the rear wall section 108c across the seal area 126. The tear flap 138 may be attached to the container 100 after it has been filled and top-sealed. Alternatively, the tear flap 138 may be attached to a proto-container upstream of the filling station.

[0123] However, it should be understood that the container can in principle be equipped with any type of opening device or closure known in the art, for example, an opening device or closure comprising a spout and a cap arranged on the spout so as to be resealable. Alternatively, the opening device or closure can be implemented using the so-called pre-laminated hole (PLH) technique to provide an uninterrupted barrier. As known in the art, such a technique involves creating a through-hole in the blank, i.e., in the paper- or paperboard-based laminated sheet material of the container, and preferably covering the hole from the inner surface of the container with a suitable barrier layer, for example, a polymer film attached to a tear flap so that the barrier layer is removed from the hole together with the tear flap in the first opening step.

[0124] The opening 140 is positioned proximate the rear edge 134, substantially equidistant from the beveled edges 128 and 130. The opening 140 may be disposed at an orthogonal distance D of 1 mm to 10 mm from the fourth upper edge 134. In other words, with reference to FIG. 1 , the removable section 72 may be disposed at an orthogonal distance D of 1 mm to 10 mm from the fold line section 58c. Because the seal area 126 is folded downward onto the rear wall, which contains and is attached to the longitudinal seal strip 14, the top panel 124 will be free of any seal structure and will not have any obstructions extending above the surface of the top panel 124. In particular, the longitudinal seal strip 14 and the top seal area 126 will be confined to the rear wall section 108c of the container. Thus, when tear flap 138 and section 72 are removed, the exposed opening 140 will be easily accessible, particularly from the rear wall section 108c side of container 100, allowing a consumer to position their lower lip over sealing area 126 and their upper lip over opening 140. The longitudinal extent of seal strip panel 56d, i.e., the distance A between fold line section 58c and upper boundary section 22e (see FIG. 1), which defines the length of sealing area 126 in the longitudinal direction of container 100, is at least 15 mm, or more preferably at least 20 mm, or even more preferably at least 30 mm, to comfortably fit the consumer's lower lip and thereby provide an enjoyable drinking experience. By extending tear flap 138 downward onto rear wall section 108c across sealing area 126, the outer surface of sealing area 126 that is intended to contact the consumer's mouth will be protected until container 100 is opened. The location of the opening 140 adjacent the sloped top panel 124 and the back edge 134 therefore allows for an ergonomic drinking position that facilitates a consumer drinking directly from the container 100. As a result, the disclosed container 100 may be suitable for use as a so-called portion pack, i.e., a type of container configured to hold liquids intended for consumption on the go without necessarily having to be reclosed once the container has been opened.

[0125] Because gusset panels 44a, 44b, 44c, and 44d fold inward during the top seal of the container (see FIG. 6), gusset panels 44a, 44b, 44c, and 44d will terminate directly below top panel 50 within the filled and sealed container (see, for example, FIG. 3). As a result, gusset panels 44a, 44b, 44c, and 44d must be carefully considered when designing the opening. In this embodiment, opening 140 is positioned so that gusset panels 44a, 44b, 44c, and 44d do not interfere with drinking or dispensing from the container.

[0126] Figure 15 shows another embodiment of a blank 10' according to the present invention. Figures 16 and 17 show a sleeve 96' produced from the blank 10', and Figures 18-21 illustrate a container 100' produced from the sleeve 96'.

[0127] Blank 10' differs from blank 10 disclosed above in that blank 10' has two straight or nearly straight fold line segments 30c'-I and 30c'-II instead of the curved fold line 30c of blank 10.

[0128] Additionally, blank 10' includes semicircular lines of weakness 74' in place of loops of weakness 74 of blank 10, which define panel sections 72' that are arranged to be folded out of the plane of panel 50' during the first opening step. Also, lines of weakness 74' are positioned farther from fold line section 58c' than loops of weakness 74 from fold line section 58c. Like loops of weakness 74 of blank 10, semicircular lines of weakness 74' may be so-called "half-notches," i.e., notches made partially through the blank's laminate substrate from its outer surface, leaving one or more inner layers of the laminate substrate intact to provide an uninterrupted barrier to contained food products.

[0129] Blank 10' also differs from blank 10 in that the intermediate region of blank 10' includes angled fold lines 82a'-82g' instead of fold lines 82a-82d extending generally longitudinally of blank 10. Angled fold lines 82a'-82h' partition angled panels 76a'-76i'.

[0130] Blank 10' is otherwise identical to blank 10, and sleeve 96' (see FIGS. 16 and 17) is produced in substantially the same manner as sleeve 96. Container 100' is produced from sleeve 96' in substantially the same manner as container 100 from sleeve 96. However, when sleeve 96' is erected and folded, angled panels 76a'-76i' will be angled into wall portion 106' of container 100', forming a pattern of slightly distorted wall sections 108a'-108h'. Wall sections 108a', 108g', 108e', and 108c' extend diagonally across the front wall, first side wall, back wall, and second side wall of container 100', respectively. When box 100' is produced, seal area 126' is folded downward onto and attached to wall sections 108d' and 108e' (i.e., the wall sections containing longitudinal seal strip 14'). As a result, like container 100 discussed above, container 100' includes top panel 124' that is devoid of a seal structure.

[0131] Also, instead of including a tear flap, the box 100' includes an opening device or closure 136' comprising a cap 142' and a spout having a flange 144' attached to the top panel 124' above the line of weakness 74'. The opening device or closure 136' is configured to break the line of weakness 74' during a first opening step of the container 100', thus breaking the line of weakness 74' in a manner known in the art. For example, the opening device or closure 136' may include a seal-breaking member (not shown) arranged inside the spout that is activated during the first opening step and pushes downwardly onto the panel section 72', forcing the panel section 72' into the container, so that an opening is created in the top panel substrate. However, the section 72' will not separate from the remainder of the top panel substrate but will remain attached thereto via the uncut substrate area located between the endpoints of the line of weakness 74'.

[0132] FIG. 22 shows a blank 10″ that is substantially similar to the blank 10 shown in FIG. 1 , except that upper boundary edge sections 22a″, 22e″, and 22i″ are curved and top panel 50″ includes a circular pre-cut opening 140″ in the paper- or paperboard-based laminate sheet material of blank 10″. Opening 140″ is positioned adjacent fold line section 58c″ and may be arranged at an orthogonal distance D of 1 mm to 10 mm from fold line section 58c″, similar to removable section 72 of FIG. 1 . Also, compared to blank 10 shown in FIG. 1 , panel 76a″ is slightly wider than panel 76e″, allowing boundary edge 14″ to be positioned substantially equidistant from edges 120″ and 122″ in a container 100″ produced from blank 10″ (see FIGS. 23-27 ).

[0133] In the region of opening 140″, the inner surface of blank 10′ provides a pre-laminated hole (PLH) configuration with a sheet membrane (not shown) covering opening 140″, thus forming a barrier separating opening 140″ from the food product prior to the first opening step of the container. However, it should be understood that instead of being formed by a pre-laminated hole (PLH) configuration, the barrier may comprise a half-cutout, i.e., a removable section bounded by a cutout made from the outer surface of the top panel partially through the top panel, leaving one or more inner layers of the laminated substrate or sheet material intact to provide the barrier, as in the embodiment disclosed in FIGS. 1-13 .

[0134] 23-27 show a container 100'' produced from blank 10''. Container 100'' is produced in substantially the same manner as described above with reference to FIGS. 2-8. Due to the curved nature of upper boundary edge sections 22a'', 22e'', and 22i'', seal area 126'' presents a curved edge 127'' of the container in this embodiment.

[0135] The container 100'' includes an opening device or closure 136'' arranged across the opening 140'' that allows a consumer to break the PLH barrier, open the container, and dispense or access the food product.

[0136] The opening device or closure 136'' comprises a first sheet 150 and a second sheet 160. The first sheet 150 is attached to an outer surface of the paper- or paperboard-based laminate sheet material of the container 100''. The second sheet 160 is releasably attached to the outer surface of the first sheet 150 such that the second sheet 160 is brought from a first position (see Figures 23-25) in which the opening device or closure 136'' is closed to a second position (see Figures 26 and 27) in which the opening device or closure 136'' is open.

[0137] First sheet 150 is generally rectangular and extends between longitudinal edges 151, 152 and lateral edges 153, 154 (see FIG. 28, which shows first sheet 150 prior to being mounted to a laminated sheet material). First sheet 150 exhibits a through opening 155 having substantially the same size and shape as opening 140″ (see FIG. 22). In other words, opening 140″ and through opening 152 are congruent. First sheet 150 is attached to the outer surface of the laminated sheet material of container 100″ such that through opening 155 is aligned with opening 140″. As a result, in the present embodiment, where opening 140″ and through opening 155 are circular, opening 140″ and through opening 155 are coaxially aligned.

[0138] The first sheet 150 comprises a first sheet section 150a extending across the top panel 124'' between the upper edge 134'' of the container 100'' and an area adjacent to the edge 132'' (see FIG. 26). In the disclosed embodiment, the first sheet 150 also comprises a second sheet section 150b extending from the upper edge 134'' over the seal area 126'' to an area adjacent to the edge 127'' (see FIG. 27). As a result, due to the lateral edges 153 and 154 of the first sheet 150 being aligned adjacent to the edge 132'' and the edge 127'', respectively, the first sheet 150 extends across the top edge 134'' of the container 100'' and over substantially the entire length of the top panel 124'' and the seal area 126''.

[0139] In this embodiment, the width of the first sheet 150 is slightly narrower than the width of the top panel 124''. In other words, the sheet 150 does not extend all the way to the edges 128'' and 130'' (see FIG. 26). In an alternative embodiment, the first sheet 150 may have a width substantially equal to the width of the top panel 124''. However, the extent of the first sheet 150 should be sufficient to encompass the opening 140''.

[0140] The second sheet 160 is also generally rectangular, extending between longitudinal edges 161, 162 and lateral edges 163, 164 (see FIG. 29, which shows the second sheet 160 prior to being loaded from the opening device or closure 136''). The second sheet 160 has substantially the same width as the first sheet 150. However, the length of the second sheet 160 is substantially twice the length of the first sheet 150.

[0141] The second sheet 160 comprises a first sheet section 160a extending across the first sheet 150 between the upper edge 134" and the area adjacent the edge 132" of the container 100" prior to the first opening step of the container 100" (see Figures 24 and 29). The lateral edges 163 of the second sheet 160 are substantially aligned with the lateral edges 153 of the first sheet 150. The second sheet 160 also comprises a second sheet section 160b extending from the upper edge 134" over the second sheet section 150b of the first sheet 150, across the edge 127" of the sealing area 126" and over the wall section 108c" of the container 100" prior to the first opening step of the container 100" (see Figure 25).

[0142] The outer surface of first sheet 150 may comprise adhesive (shown by a dot pattern in FIG. 28). The inner surface of second sheet 160, i.e., the surface configured to contact first sheet 150 and the laminated sheet material of container 100'' at sidewall section 108c'' prior to the first opening step, may also comprise adhesive. However, in one embodiment, the inner surface of sheet 160 may comprise area 165, arranged to cover through opening 155 of first sheet 150, in which adhesiveness is reduced compared to surrounding sections 166 and 167 (see FIG. 29).

[0143] Prior to the first opening step of container 100'', second sheet 160 is attached to the outer surface of first sheet 150. Second sheet 160 may also be attached to sidewall section 108c'' to ensure that second sheet 160 remains flush with container 100'' prior to the first opening step. As described above, the inner surface of blank 10' comprises a sheet membrane (not shown) that covers opening 140'' and forms a barrier prior to the first opening step. The outer surface of the sheet membrane exposed through opening 140'' and through opening 155 is attached to the inner surface of second sheet 160. However, if the barrier comprises a removable section bounded by a half-cutout instead of being formed by a PLH configuration, the inner surface of second sheet material 160 would instead be attached to the outer surface of the removable section exposed through through opening 155 in a manner similar to the PLH membrane.

[0144] To perform the first opening step, a consumer manually grasps lateral edges 164 of second sheet 160 and pulls second sheet 160 upward over top edge 134″ and then downward toward edge 132″, thereby bringing second sheet 160 to the position shown in FIG. 26 . The downward pulling action will expose through opening 155 and rupture the sheet membrane covering opening 140″. If the barrier comprises a removable section bounded by a half-cutout as discussed above, the downward pulling action will rupture the half-cutout and lift the removable section, revealing an opening similar to opening 140″. Once second sheet 160 is in the position shown in FIG. 26 , a consumer will be able to dispense or access a food product through opening 140″ and through opening 155.

[0145] Due to the first sheet 150 extending from the through opening 155, over the upper edge 134'', over the seal area 126'', and to the area adjacent the edge 127'' (see FIG. 27), the drinking surface, covered by the second sheet 160 prior to the first opening step, will be available to a consumer should they choose to drink from the container 100'' through the side of the wall section 108c''. To prevent the consumer's mouth from contacting the outer surface of the laminated sheet material of the container during such a drinking action, thereby providing an enjoyable drinking experience, the first sheet 150 should preferably extend from the through opening 155 a distance A of at least 20 mm, more preferably at least 25 mm, and even more preferably at least 30 mm from the through opening 155 (see FIG. 28).

[0146] According to one embodiment, second sheet 160 may be configured to allow a consumer to re-close opening device or closure 136'' after the first opening step. This may be accomplished by the consumer bringing second sheet 160 back to its original first position and allowing second sheet 160 to adhere to first sheet area 150a of first sheet 150 within seal area 126''. This may not necessarily be sufficient to provide a liquid-tight seal, but may be sufficient to prevent foreign objects from entering through opening 155.

[0147] In the region of edges 153 and 163, the first and second sheets 150, 160 may be permanently joined, e.g., heat sealed, to one another, thereby ensuring that the second sheet 160 remains attached to the first sheet 150 after the first opening step.

[0148] The first sheet 150 may be heat-sealed to the outer surface of the container 100''. Alternatively, the first sheet 150 may be permanently attached to the outer surface of the container 100'' by other means, for example, using a suitable adhesive.

[0149] The first and second sheets 150, 160 may comprise polymer sheets, such as sheets including a polyethylene layer or a polypropylene layer or both. At least the second sheet 160 may be a laminate sheet, for example, including multiple polymer layers and / or layers including cellulose fibers, such as paper layers. In one embodiment, the second sheet 160 may include an aluminum layer.

[0150] During production of container 100'', first and second sheets 150 and 160 may be attached to one another to form a sheet assembly. The sheet assembly may then be attached to the outer surface of the container's laminated sheet material. Alternatively, first sheet 150 may be attached to the outer surface of the container's laminated sheet material in a first step, and second sheet 160 may be attached to the first sheet 150 in a second subsequent step. The sheet assembly, i.e., first sheet 150 followed by second sheet 160, may be attached to the container's laminated sheet material after the container has been folded, filled, and top-sealed. In an alternative embodiment of producing container 100'', first sheet 150 may be attached to blank 10'' prior to blank 10'' being folded to form a sleeve.

[0151] As described above, blanks are produced in a converting process in which the blanks are cut from a web of laminate material having generally parallel and straight lateral boundary edges. The converting process typically includes feeding the web of laminate material through one or more nips formed between a pair of cutting and / or creasing rollers to produce blanks that are cut from the web and formed with creases, notches, and / or holes for subsequent folding, e.g., to fit a closure into the blank material when a container is produced therefrom.

[0152] Figure 30 shows one embodiment of a nesting pattern of blanks deployed on a web 204 of laminate material. Such patterns are sometimes referred to as nesting patterns. The blanks are the same as those discussed above with reference to Figure 1, and Figure 31 is a detailed view of the nesting pattern of Figure 30, showing some of the fold lines and weakened loops discussed above with reference to Figure 1.

[0153] As is known in the art, a nesting pattern is not a physical pattern visible on the web, but a pattern that illustrates how blanks are going to be cut from the web and / or how the blanks are going to be stamped. In other words, the nesting pattern illustrates the layout of blanks on the web and, as a result, how the available web material is utilized.

[0154] The nesting pattern 200 shown in Figure 30 comprises two rows 202a, 202b of congruent blanks 10a, 10b, each row comprising blanks arranged side by side with a first lateral boundary edge 12 adjacent to a second lateral boundary edge 14 of an adjacent blank (and vice versa). As a result, in the nip of the cutting rollers (not shown), the adjacent lateral boundary edges 12 and 14 in each row can be produced simultaneously using the same cutting tool, utilizing a single cutting edge.

[0155] The blanks 10a of the first row 202a are arranged facing the blanks 10b of the second row 202b such that the upper boundary edges 22 of the blanks of the first row 202a are adjacent to the upper boundary edges 22 of the blanks of the second row 202b. W In the example shown, rows 202a, 202b are offset such that upper boundary edge section 22e of a blank in the first row 202a is adjacent to upper boundary edge sections 22a and 22i of a blank in the second row 202b, and vice versa (see FIG. 31). As a result, adjacent upper boundary edges 22 of oppositely arranged blanks in the nip of the cutting rollers (not shown) can also be produced simultaneously using the same cutting tool, utilizing a single cutting edge.

[0156] Within each row 202a, 202b, the bottom border edge 16 is aligned generally parallel to the side border edges 204a, 204b of the web 204, either generally collinear with the side border edges of the web 204 or within a short distance of the side border edges, e.g., within 1 mm to 5 mm of the side border edges 204a, 204b. This would provide a nesting pattern that would allow substantially the entire area of ​​the web 204 to be covered without any or with very little wasted web material. As a result, the disclosed nesting pattern is highly effective in that substantially all available web material is utilized to form the blanks.

[0157] In the nested pattern 200, the fourth boundary edge 22 is aligned in the longitudinal direction L of the web 204. W 202 a and 202 b form a non-linear line 222 extending approximately centrally at 202 a. Line 22 exhibits two-fold rotational symmetry with respect to a plurality of centers 220 located on line 222. In other words, if line 222 is rotated 180 degrees about any one of centers 220, it will assume the same orientation as before the rotation. This symmetry allows rows 202 a and 202 b to be arranged adjacent to one another without any intervening gaps, thus providing efficient nesting.

[0158] Efficient nesting can also be achieved by arranging multiple such row pairs adjacent to each other, as disclosed, for example, in FIG. 32, which shows two row pairs in such a configuration.

[0159] Figure 33 illustrates the geometry of the blank that allows for the efficient nesting pattern discussed above. Blank 10 is the same blank as previously shown in Figure 1. Upper boundary edge 22 is aligned with central axis C. a In other words, it is reflectively symmetric about the central axis C a as the axis of symmetry, and the central axis C aThe upper boundary edge 22 on one side of the axis Ca is mirrored by the upper boundary edge 22 on the other side of the axis Ca.

[0160] The upper boundary edge 22 is inscribed within the right rectangle 206. In other words, the upper boundary edge 22 is enclosed by a "close fit" inside the rectangle 206. The rectangle 206 has a first pair of sides 208, 210 that are parallel to the longitudinal direction L of the blank, and a second pair of sides 212, 214 that are parallel to the transverse direction T. The central axis C a divides rectangle 206 into two congruent right sub-rectangles 216 and 218. In other words, sub-rectangles 216 and 218 are the same size and shape.

[0161] Sub-rectangle 216 has a center 220, i.e., the location where the diagonals of sub-rectangle 216 intersect. Within sub-rectangle 216, upper boundary edge 22 exhibits two-fold rotational symmetry about an axis extending through center 220 and perpendicular to the plane of blank 10. In other words, the portion of upper boundary edge 22 inscribed within sub-rectangle 216 has the same orientation after a 180° (360 / 2°) rotation about center 220.

[0162] The above applies equally to the portion of the upper bounding edge 22 inscribed within the sub-rectangle 218, where the upper bounding edge 22 exhibits two-fold rotational symmetry about an orthogonal axis extending through the center 222 of the sub-rectangle 218. This is because the upper bounding edge 22 is inscribed within the central axis C a , which implies equal rotational symmetry about the respective centers within the sub-rectangles 216 and 218. In other words, the upper bounding edge 22 is axially symmetrical about the central axis C. a and if the portion of the upper bounding edge 22 inscribed in one of the sub-rectangles exhibits two-fold rotational symmetry about the center of that sub-rectangle, then the portion of the upper bounding edge 22 inscribed in the other sub-rectangle will also exhibit two-fold rotational symmetry about the center of the other sub-rectangle.

[0163] Arranging the upper boundary edges 22 of the blanks 10 with reflection symmetry about the central axis Ca, and the portions of the upper boundary edges 22 inscribed within the individual sub-rectangles with two-fold rotational symmetry about the centers of the sub-rectangles, as explained above, would enable the effective nesting pattern disclosed in Figure 30. In particular, this would allow the pattern of blanks to be developed on the web 204 such that the upper boundary edges 22 of the row of blanks 202a coincide with the upper boundary edges 22 of the row of blanks 202b, and therefore would result in there being no unused web material between rows 202a and 202b.

[0164] In FIG. 31 , upper boundary edge sections 22 a and 22 i are equally long, and upper boundary edge section 22 e is twice as long as either one of edge sections 22 a and 22 i. However, it should be understood that an efficient nesting pattern can also be achieved with other geometric shapes. FIG. 34 further illustrates a further embodiment of a nesting pattern of blanks developed on a web of laminate material, and FIG. 35 illustrates a blank 10 ″ cut and embossed according to the nesting pattern shown in FIG. 34 . In this embodiment, upper boundary edge 22 ″ includes curved edge sections 22 a ″, 22 e ″, and 22 i ″ having extensions and curvatures that allow the nesting pattern to be developed with the upper boundary edges of adjacent blanks without an intervening gap as illustrated in FIG. 34 . Once cut from the web of laminate material, blank 10 ″ can be folded, filled, and sealed in a manner similar to blank 10 disclosed in FIG. 1 . FIG. 36 shows a container 100'' produced from the blank 10'' according to FIG.

[0165] It will be appreciated that certain features of the invention which are, for clarity, described above in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination.

[0166] In the foregoing description, various aspects of the blanks and containers according to the present invention have been described with reference to illustrative embodiments. For purposes of explanation, specific values, systems, and configurations have been set forth to provide a thorough understanding of the apparatus and its operation. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiments of the apparatus, as well as other embodiments, that are obvious to those skilled in the art to which the disclosed subject matter pertains may lie within the scope of the invention, as defined by the following claims.

Claims

[Claim 1] The invention described in this specification.

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