Secondary packaging

Abstract

The present invention relates to a tubular package comprising a tube, the tube comprising a paperboard, the paperboard having a tubular form and a multilayered packaging material at least partially laminated to an internal surface of the paperboard, the multilayered packaging material comprising a paper layer; a barrier layer selected from organic barrier layers, inorganic barrier layers, and combinations thereof; and a seal layer; and a pair of closures, one located at each end of the tube.

Description

[0001] Secondary Packaging

[0002] Gerhard NIEDERREITER

[0003] Nico GALAFFU

[0004] Lucile MONCRIEFF

[0005] Abhijit BHATTACHARYA

[0006] Field of the invention

[0007] The present invention relates to tubular packaging with barrier properties and methods for their production.

[0008] Background of the invention

[0009] Many products are provided in primary and secondary packaging, such as multipacks of food or beverage items. Many such items have primary packaging that is not able to provide sufficient impediment to the movement of gases (such as oxygen and water vapour), for example teabags, and require secondary packaging, often comprising continuous polymer films, to provide the required barrier properties.

[0010] There is a general requirement for packaging products to become more recyclable and / or biodegradable (e.g. compostable). However, the materials used in such packaging tend to have poorer barrier properties than traditional materials. This therefore simultaneously increases the proportion of primary packaging that is insufficient in barrier properties and prompts the need for recyclable and / or compostable secondary packaging.

[0011] One example is in relation to coffee pods or capsules. The capsules themselves are the primary packaging for the ground coffee and have historically been formed of aluminium, which provides a highly effective barrier and can withstand the internal environment of the coffee machine. For ease, the capsules are provided in paperboard secondary packaging. Although recyclable, there are moves to form the capsules of alternative materials that are simpler for consumers to recycle (e.g. through municipal waste and / or composting). However, many of the alternative materials do not offer the required barrier properties.

[0012] It is the object of the present invention to address at least one of the foregoing problems. Summary of the invention

[0013] A first aspect of the present invention relates to a tubular package comprising: a tube comprising: a paperboard, the paperboard having a tubular form; and a multilayered packaging material at least partially laminated to an internal surface of the paperboard, the multilayered packaging material comprising: a paper layer; a barrier layer selected from organic barrier layers, inorganic barrier layers, and combinations thereof; and a seal layer; and a pair of closures, one located at each end of the tube.

[0014] The tube may have a substantially rectangular, optionally square, cross section.

[0015] Either or both of the closures may comprise a terminal portion of the tube configured to provide a seal.

[0016] The terminal portion may be a gusset, the gusset being formed from first and second opposing pairs of sides of the terminal portion, each of the first opposing pair of sides is folded toward the central axis of the tubular package, each of the second opposing pair of sides is brought together, and a seal region is provided where the internal surfaces of the first and second opposing pairs of sides are in contact. In embodiments, one of the second opposing pair of sides is folded perpendicular to the central axis of the tubular package and the other of the second opposing pair of sides is flat and outermost. In some embodiments, the axial length of the terminal portion is equal to the radial distance between the second opposing pair of sides prior to folding. In some embodiments, each of the axial length of the seal region and the axial distance between the seal region and the main portion of the tube is half of the radial distance between the second opposing pair of sides prior to folding. In some embodiments, a fold perpendicular to the central axis of the tubular package is provided in one of the second opposing pair of sides, the fold located halfway along the axial length of the terminal portion.

[0017] The terminal portion may be a fin seal, the fin seal being formed from first and second opposing pairs of sides of the terminal portion, wherein each of the first opposing pair of sides is folded away from the central axis of the tubular package, each of the second opposing pair of sides is brought together, and a seal region is provided where the internal surfaces of the first and second opposition pairs of sides are in contact. In embodiments, the axial distance between the seal region and the main portion of the tube is half of the radial distance between the second opposing pair of sides prior to folding. In some embodiments, the portion of seal region formed from the contact of the second opposing pair of sides lies substantially within the plane perpendicular to the central axis of the tubular package. In some embodiments, the material of each of the first opposing pair of sides is affixed to the material of the second opposing pair of sides. In some embodiments, the material of each of the first opposing pair of sides is affixed to the adjacent surface of the main portion of the tube such that it is substantially coplanar with said adjacent surface.

[0018] Either or both of the closures may comprise a terminal portion of the tube divided into a plurality of flaps and a tubular portion of the multilayered packaging material, the tubular portion affixed to the internal surface of the main portion of the tube, the tubular portion of the multilayered packaging material configured to provide a seal.

[0019] Either or both of the closures comprise a terminal portion of the tube wherein the paperboard and the multilayered packaging material are not laminated together, the paperboard being divided into a plurality of flaps, the multilayered packaging material being configured to provide a seal.

[0020] Either or both of the closures may comprise a terminal portion of the tube divided into a plurality of flaps and a closure portion of the multilayered packaging material affixed to the internal surfaces of each of the flaps so as to provide a seal.

[0021] In embodiments, the flaps may extend towards the central axis of the tubular packaging such that they are overlapping and substantially coplanar. In embodiments, the flaps include at least one flap being substantially equal to the cross-section of the tube in shape and size, said flap being outermost.

[0022] Either or both of the closures may comprise a cap, the cap configured to have an external surface in continuous contact with the internal surface of the tube and sealed thereto.

[0023] The tubular package may further comprise a covering, such as a pressure sensitive label, over at least a portion of the terminal portion.

[0024] A second aspect of the present invention relates to a method of forming a tubular package of the first aspect of the present invention, the method comprising the steps of a) providing a paperboard with a multilayered packaging material at least partially laminated thereto, the multilayered packaging material comprising: a paper layer; a barrier layer selected from organic barrier layers, inorganic barrier layers, and combinations thereof; and a seal layer; b) forming the paperboard into a tube with the multilayered packaging material innermost; and c) providing a pair of closures, one located at each end of the tube.

[0025] The paperboard may be formed into a tube with a substantially rectangular, optionally square, cross-section.

[0026] Either or both of the closures may be provided by forming a terminal portion of the tube into a gusset by: a) folding each of a first pair of opposing sides of the terminal portion towards the central axis of the tubular package; b) bringing each of a second pair of opposing sides of the terminal portion together; and c) forming a seal region where the internal surfaces of the first and second opposing pairs of sides are in contact, optionally by heat sealing.

[0027] In embodiments, the method further comprises the step of affixing the seal region to one of the second pair of opposing sides such that the gusset lies substantially within the plane perpendicular to the central axis of the tubular package.

[0028] Either or both of the closures may be provided by forming a terminal portion of the tube into a fin seal by: a) folding each of a first pair of opposing sides of the terminal portion away from the central axis of the tubular package; b) bringing each of a second pair of opposing sides of the terminal portion together; and c) forming a seal region where the internal surfaces of the first and second opposing pairs of sides are in contact, optionally by heat sealing. In embodiments, the method further comprises the step of affixing the seal region formed from contact of the second opposing pair of sides to one of the second pair of opposing sides such that the seal region formed from contact of the second opposing pair of sides lies substantially within the plane perpendicular to the central axis of the tubular package. In embodiments, the method further comprises the step of affixing the material of each of the first opposing pair of sides to the material of the second opposing pair of sides. In embodiments, the method further comprises the step of affixing the material of each of the first opposing pair of sides to the adjacent surface of the tube such that it is substantially coplanar with the adjacent surface of the tube.

[0029] Either or both of the closures may be provided by: a) dividing a terminal portion of the tube into a plurality of flaps; b) affixing a tubular portion of the multilayered packaging material to the internal surface of the main portion of the tube; and c) sealing the tubular portion, optionally by heat sealing.

[0030] Either or both of the closures may be provided by: a) ensuring that a portion of the multilayered packaging adjacent to an edge of the paperboard is unlaminated when providing the paperboard with a multilayered packaging material at least partially laminated thereto and ensuring that said portion is a terminal portion of the tube; b) dividing the paperboard of the terminal portion into a plurality of flaps; c) sealing the multilayered packaging material, optionally by heat sealing.

[0031] Either or both of the closures may be provided by: a) dividing a terminal portion of the tube into a plurality of flaps; and b) sealing a closure portion to the internal surfaces of each of the flaps, optionally by heat sealing.

[0032] Either or both of the closures may be provided by: a) inserting a cap into the end of the tubular packaging, the cap configured to have an external surface in continuous contact with the internal surface of the tube; and b) sealing the external surface of the cap to the internal surface of the tubular packaging, optionally by heat sealing. A third aspect of the present invention relates to a kit of parts comprising: a paperboard to which a multilayered packaging material is at least partially laminated to an internal surface thereof, the multilayered packaging material comprising: a paper layer; a barrier layer selected from organic barrier layers, inorganic barrier layers, and combinations thereof; and a heat seal layer; and one or more closures selected from: a) a tubular portion of the multilayered packaging material; b) a closure portion of the multilayered packaging material; and c) a cap.

[0033] A fourth aspect of the present invention relates to the use of the tubular package of the first aspect of the present invention, for packing an edible product for human or animal consumption

[0034] A fifth aspect of the present invention relates to a packaged edible product, comprising the tubular package of the first aspect of the present invention, at least partially filled with an edible product for human or animal consumption.

[0035] Brief description of the drawings

[0036] Fig. 1 shows three stages in the formation of a gusset seal in a profile view.

[0037] Fig. 2 shows four stages in the formation of a gusset seal in a perspective view.

[0038] Fig. 3 shows three stages in the formation of a gusset seal in a profile view.

[0039] Fig. 4 shows five stages in the formation of a gusset seal in a perspective view.

[0040] Fig. 5 shows five stages in the formation of a fin seal in a perspective view.

[0041] Fig. 6 shows five stages in the formation of a fin seal in a perspective view. Fig. 7 shows three stages in the formation of a seal using a tubular portion of the multilayered packaging material in a cut-away profile view.

[0042] Fig. 8 shows four stages in the formation of a seal using a tubular portion of the multilayered packaging material in a perspective view.

[0043] Fig. 9 shows five stages in the formation of a seal using a closure portion of the multilayered packaging material in a perspective view.

[0044] Fig. 10A shows a profile view of a tubular package and end cap.

[0045] Fig. 10B shows a profile view of a tubular package with end cap in place.

[0046] Detailed description of the invention

[0047] Tubular Package

[0048] The present invention relates to a tubular package 1 comprising a tube 2 and a pair of closures 8a, 8b, one located at each end of the tube 2. The tube 2 comprises a paperboard 3, the paperboard having a tubular form, and a multilayered packaging material 4 laminated to the interior of the paperboard 3. The tubular package 1 may be used as primary or secondary packaging.

[0049] The paperboard 3 is relatively rigid and provides structure to the tubular package 1 . The paperboard 3 may have a grammage of from 160 to 500 g / m2. In certain embodiments, the paperboard 3 may be replaced with cardboard, typically with a grammage in excess of 500 g / m2.

[0050] The paperboard 3 may be the outermost layer of the packaging. The paperboard 3 may therefore be provided with additional surface coatings, such as colorants, inks, and / or varnishes, in order to improve its aesthetic and tactile qualities.

[0051] The multilayer packaging material 4 provides barrier properties to the tubular package 1 . The multilayer packaging material 4 comprises a paper layer; a barrier layer; and a seal layer. The paper layer typically has a grammage of from 30 to 120 g / m2, providing sufficient toughness and flexibility for manipulation and processing into the tubular package. For the avoidance of doubt, it is the paper layer that is contact with the paperboard 3 when these materials are laminated to one another.

[0052] The barrier layer provides the barrier properties of the multilayer packaging material and may be selected from organic barrier layers, inorganic barrier layers, or combinations thereof. Suitable organic barrier layers include polyvinylalcohol (PVOH), ethylene vinyl alcohol (EVOH), butenediol vinyl alcohol co-polymer (BVOH), cyclic olefin copolymers, and combinations thereof. These polymers may be present in weights of 0.5 to 40 g / m2, such as 5 to 35 g / m2, or 10 to 30 g / m2. Suitable inorganic barrier layers include metals, metalloids, oxides thereof, or a combination thereof, with preferred barrier layers being selected from aluminium aluminium oxide and silicon oxide. Typical thicknesses for inorganic barrier layers are from 1 to 100 nm.

[0053] In embodiments, the barrier layer comprises at least one organic barrier layer disposed over the paper layer, with an inorganic barrier layer disposed over the organic barrier layer. In a preferred embodiment, the barrier layer comprises an organic barrier layer comprising polyvinylalcohol (PVOH), ethylene vinyl alcohol (EVOH), butenediol vinyl alcohol co-polymer (BVOH), cyclic olefin copolymers, and combinations thereof disposed over the paper layer, with an inorganic barrier layer comprising aluminium, aluminium oxide and / or silicon oxide disposed over the organic barrier layer.

[0054] The seal layer provides some additional barrier properties and is able to provide a seal by adhering tightly to surfaces, as well as to itself. Typically, the seal layer is a heat seal layer, such layers being non-adherent under normal conditions, but readily adhering when temperature and, optionally, pressure are applied. The heat seal layer is typically present in a weight between 2 and 20 g / m2, preferably in an amount comprised between 4 and 9 g / m2. For the avoidance of doubt, the heat seal layer is the innermost layer in the tubular package.

[0055] Other layers and materials, such as colorants or inks, may be present within the multilayer packaging material, on the condition that they do not prevent the or hinder the functions described herein. The pair of closures 8a, 8b are operable to provide a seal to the otherwise open ends of the tubular package. It will be understood that the closures may be of the same type as described herein or they may be of different types.

[0056] The tubular package 1 may have a constant cross section along its length. The cross section of the tubular package may be substantially rectangular, optionally the cross section may be square.

[0057] The tubular package 1 may be provided with weakened sections (e.g. arrangements of perforations within the paperboard). These weakened sections facilitate opening of the tubular package by consumers.

[0058] The tubular package further comprises a covering 20, such as a pressure sensitive label, over at least a portion of the terminal portion.

[0059] A terminal portion of the tube may be configured to form a seal, thereby providing the closure. In such embodiments, the remaining portion of the tube is designated the main portion. By being configured, it is meant that the terminal portion is shaped (e.g. by dividing, folding, and affixing) to form a barrier that is continuous with the main portion of the tube.

[0060] Gusset sea /

[0061] In some embodiments, the terminal portion 9 is shaped into a gusset. The gusset is formed from first 10 and second 11 opposing pairs of sides of the terminal portion. It will be understood that the first and second opposing pairs of sides 10, 11 are connected along their edges such that they form a continuous circumference around the central axis of the tubular packaging. Each of the first opposing pair of sides 10 is folded toward the central axis. This is achieved by creasing each of the first opposing pair of sides 10 along their axial midline and moving the crease towards the central axis. Each of the second opposing pair of sides 11 is brought together. This results in each of the first opposing pair of sides 10 being folded and held between second opposing pair of sides 11. The seal region 12 is formed where the internal surfaces of the first and second opposing pairs of sides 10,11 are in contact. The seal layer in these regions is adhered to itself and the adjacent material, preferably by heat sealing. Preferably, one of the second opposing pair of sides 11 is folded perpendicular to the central axis of the tubular package and the other of the second opposing pair of sides 11 is flat and outermost. This results in the side comprising the fold being doubled over and the other side being presented outwardly, such that the end of the tube has a flat appearance. Preferably, the side comprising the fold is affixed to itself in the double over position, for example, using adhesive.

[0062] In embodiments, the axial length of the terminal portion is equal to the radial distance between the second opposing pair of sides prior to folding. In other words, the length of the terminal portion 9 is equal to the depth of the tubular packaging. This results in the outermost side of the terminal portion 9 extending across the tubular packaging and, where the tubular packaging is substantially rectangular (preferably square) in cross section, the outermost side of the terminal portion is coextensive with the cross section of the tubular package.

[0063] In embodiments, each of the axial length of the seal region and the axial distance (of the terminal portion) between the seal region and the main portion of the tube is half of the radial distance between the second opposing pair of sides prior to folding. Once configured, the portions of each of the second pairs of opposing faces 11 that are not the seal region are in the plane perpendicular to the central axis, closing the end of the tubular packaging, while the seal region 12 extends parallel to the central axis. The seal region 12 may be affixed to either of the portions of each of the second pairs of opposing faces 11 that are not the seal region to provide a flat end to the tubular package.

[0064] In embodiments, a fold 13 perpendicular to the central axis of the tubular package is provided in one of the second opposing pair of sides 11 , the fold 13 located halfway along the axial length of the terminal portion 9. The distal portion of the face provided with the fold 13 may be affixed to the proximal portion of the same face, thereby providing a flat end to the tubular package.

[0065] A first illustrated embodiment is shown in Figs. 1 and 2 wherein the terminal portion 9 is a gusset seal. Fig. 1 shows the embodiment in the unconfigured state (left hand image), after folding and provision of the seal region 12 (central image), and after the seal region 12 has been folded to be perpendicular to the central axis of the tubular package (right hand image). Fig. 2 shows the progression from the tube 2 with the unconfigured terminal portion 9 to the packaging with the seal region 12 lying flat. In this embodiment, the first pair of opposing sides 10 is creased along its axial midline and folded inwards while each of the second pair of opposing sides 11 is brought together and the seal region 12 is formed where these sides are in contact with one another. The seal region 12 is then folded flat against the end of the tubular packaging 1 to present a flat face. It will be noted that the length of the seal region and the axial distance between the seal region and the main portion of the tube (each denoted ‘a’ in fig. 1 and combining to give a total length of the terminal portion) is equal to that of the distance between the two of the opposing faces of the tube (denoted ‘2a’ in fig. 1).

[0066] A second illustrated embodiment is shown in Figs. 3 and 4 wherein the terminal portion 9 is a gusset seal. Fig. 3 shows the embodiment in the unconfigured state (left hand image), after folding and provision of the seal region 12 (central image), and after the seal region 12 has been folded to be perpendicular to the central axis of the tubular package (right hand image). Fig. 4 shows the progression from the tube 2 with the unconfigured terminal portion to the packaging with the seal region lying flat. In this embodiment, the first pair of opposing sides 10 is creased along its axial midline and folded inwards while each of the second pair of opposing sides 11 is brought together and the seal region 12 is formed where these sides are in contact with one another. The seal region 12 is then folded flat against the end of the tubular packaging to present a flat face. It will be noted that the length of the terminal portion 9 is equal to the radial distance between the second opposing pair of sides.

[0067] Fin seal

[0068] In some embodiments, the terminal portion 9 is a fin seal. The fin seal is formed from first 14 and second 15 opposing pairs of sides of the terminal portion. It will be understood that the first and second opposing pairs of sides 14, 15 are connected along their edges such that they form a continuous circumference around the central axis of the tubular packaging. Each of the first opposing pair of sides is folded away from the central axis of the tubular package. This is achieved by creasing the each of the first opposing pair of sides 14 along their axial midline and moving the crease away from the central axis. Each of the second opposing pair of sides 15 is brought together. This results in the second opposing pair of sides 15 being in mutual contact, while each of the first opposing pair of sides 14 is doubled over and extends away from the central axis. The seal region 16 is formed where the internal surfaces of the first and second opposing pairs of sides 14, 15 are in contact. The seal layer in these regions is adhered to itself and the adjacent material, preferably by heat sealing.

[0069] Preferably, the axial distance between the seal region and the main portion of the tube is half of the radial distance between the second opposing pair of sides prior to folding. Once configured, the portions of each of the second pairs of opposing faces that are not the seal region are in the plane perpendicular to the central axis, closing the end of the tubular packaging, while the seal region extends parallel to the central axis. The portion of the seal region formed from the contact of the second opposing pair of sides may be affixed to the portion of the second opposing pair of sides that does not form the seal region, such that the seal region lies substantially within the plane perpendicular to the central axis of the tubular package.

[0070] The material of each of the first opposing pair of sides may be affixed to the material of the second opposing pair of sides. Where the cross section of the tubular package is substantially rectangular (preferably square), this results in the material of the terminal portion being coextensive with the cross section of the tubular package.

[0071] The material of each of the first opposing pair of sides 14 may affixed to the adjacent surface of the main portion of the tube 2 such that it is substantially coplanar with the adjacent surface of the tube 2.

[0072] A third illustrated embodiment is shown in Fig. 5 wherein the terminal portion 9 is a fin seal. Fig. 5 shows the progression from the tube with the unconfigured terminal portion to the packaging with the seal region 16 lying flat. In this embodiment, the first pair of opposing sides 14 is creased along its axial midline and folded outwards while each of the second pair of opposing sides 15 is brought together and the seal region 16 is formed where these sides are in contact with one another. The seal region 16 is then folded flat against the end of the tubular packaging and the material of the first opposing pair of sides 14 is folded inwards and affixed to the material of the second opposing pair of sides 15 to present a flat face. Preferably, a pressure sensitive label 20 is then applied over the seal. A fourth illustrated embodiment is shown in Fig. 6 wherein the terminal portion 9 is a fin seal. Fig. 6 shows the progression from the tube with the unconfigured terminal portion to the packaging with the seal region lying flat. In this embodiment, the first pair of opposing sides 14 is creased along its axial midline and folded outwards while each of the second pair of opposing sides 15 is brought together and the seal region 16 is formed where these sides are in contact with one another. The seal region 16 is then folded flat against the end of the tubular packaging and the material of the first opposing pair of sides 14 is folded downwards and affixed to the sides of the tubular package to present a flat face. Preferably, a pressure sensitive label 20 is then applied over the seal.

[0073] Tubular Portion

[0074] In some embodiments, either or both of the closures 8a, 8b comprise a terminal portion 9 of the tube 2 divided into a plurality of flaps 17 and a tubular portion 18 of the multilayered packaging material 4. Each of the plurality of flaps 17 is connected to the main portion of the tube 2, but is disconnected from the remaining flaps. The number of flaps 17 generally corresponds with the number of sides of the tube, for example, a tube with a substantially rectangular (preferably square) cross section will have four flaps, the width of each flap being equal to that of the adjoining side of the tube. For the avoidance of doubt, the tubular portion is an additional portion of multilayered packaging material 4 that is not laminated to the cardboard (or “paperboard”) 3, nor is it forming part of the tube 2. The tubular portion is affixed to the internal surface of the main portion of the tube and the tubular portion of the multilayered packaging material is configured to provide a seal. In other words, taken together, the multilayered packaging material and the tubular portion provide a continuous barrier.

[0075] The tubular portion, being separate from the paperboard, retains its flexibility, meaning that it may be sealed in substantially any suitable arrangement. Once the tubular portion is sealed, the flaps are required only to provide physical robustness, not barrier properties, and the flaps may simply be folded so as to extend towards the central axis in the plane perpendicular to the central axis and mutually affixed. Preferably, at least one of the flaps is substantially equal to the cross-section of the tube in shape and size, said flap being outermost.

[0076] A fifth illustrated embodiment is shown in Figs. 7 and 8, wherein the terminal portion 9 is formed by affixing a tubular portion 18 of multilayered packaging material 4 to the interior of the tubular packaging 1 . Fig. 7 shows the embodiment in the after fixing of the tubular portion 18 (left hand image), during folding and provision of the seal region (central image), and after the seal region 16 has been formed (right hand image). Fig. 8 shows the progression from the tubular portion 18 being added to the sealed packaging with the flaps 17 affixed. In this embodiment, the tubular portion 18 is affixed to the interior of the tubular packaging in a contiguous manner and the open end of the tubular portion 18 sealed to itself to seal the tubular packaging 1. The plurality of flaps 17 is then closed over the sealed tubular portion. It will be noted that one of the flaps 17 is substantially coextensive with the cross section of the tubular packaging to present a flat face.

[0077] Partial Lamination

[0078] In some embodiments, either or both of the closures 8a, 8b comprise a terminal portion 9 of the tube 2 wherein the paperboard 3 and the multilayered packaging material 4 are not laminated together. The paperboard 3 is divided into a plurality of flaps 17. Each of the plurality of flaps 17 is connected to the main portion ofthe tube 2, but is disconnected from the remaining flaps. The number of flaps 17 generally corresponds with the number of sides of the tube 2, for example, a tube with a substantially rectangular (preferably square) cross section will have four flaps, the width of each flap being equal to that of the adjoining side of the tube. The multilayered packaging material 4 is configured to provide a seal.

[0079] The multilayered packaging material 4 that is not laminated to the paperboard 3 retains its flexibility, meaning that it may be sealed in substantially any suitable arrangement. Once the multilayered packaging material 4 is sealed, the paperboard flaps 17 may simply be folded so as to extend towards the central axis in the plane perpendicular to the central axis and mutually affixed. Preferably, at least one of the flaps 17 is substantially equal to the cross-section of the tube in shape and size, said flap being outermost.

[0080] Pressed Paper Top

[0081] In some embodiments, either or both of the closures 8a, 8b comprise a terminal portion 9 of the tube 2 divided into a plurality of flaps 17 and a closure portion of the multilayered packaging material 4. Each of the plurality of flaps 17 is connected to the main portion of the tube 2, but is disconnected from the remaining flaps. An additional portion of multilayered packaging material 4 may be provided in the regions between adjacent flaps. The number of flaps 17 generally corresponds with the number of sides of the tube 2, for example, a tube with a substantially rectangular (preferably square) cross section will have four flaps, the width of each flap being equal to that of the adjoining side of the tube. For the avoidance of doubt, the closure portion is an additional portion of multilayered packaging material 4 that is not laminated to the cardboard 3, nor is it forming part of the tube. The closure portion is affixed to the internal surface of the flaps and, by being so affixed, provides a seal. In other words, taken together, the multilayered packaging material and the closure portion provide a continuous barrier.

[0082] Once the closure portion is affixed, the flaps are required only to provide physical robustness, not barrier properties, and the flaps may simply be folded so as to extend towards the central axis in the plane perpendicular to the central axis and mutually affixed. Preferably, at least one of the flaps is substantially equal to the cross-section of the tube in shape and size, said flap being outermost.

[0083] A sixth illustrated embodiment is shown in Fig. 9 wherein the terminal portion 9 is a pressed paper top. Fig. 9 shows the progression from the tube 2 prior to application of the pressed paper top to the sealed packaging with the flaps 17 affixed. In this embodiment, the closure portion is sealed to the interior surfaces of each of the plurality of flaps 17 and each of the additional portions of multilayered packaging material 4 that is provided in the regions between adjacent flaps. The flaps 17 are then closed over the sealed tubular portion. It will be noted that one of the flaps is substantially coextensive with the cross section of the tubular packaging to present a flat face.

[0084] Hermetic Tube

[0085] In some embodiments, either or both of the closures 8a, 8b comprise a cap 19, the cap configured to have an external surface in continuous contact with the internal surface of the tube 2 and sealed thereto. The cap 19 may have an inner portion and an outer portion, the inner portion. The inner portion comprises the external surface that is to be in continuous contact with the internal surface of the tube. The outer portion comprises a portion that is to remain external once the cap 19 is fitted to the tube 2 and may have an outer surface that lies flush with the outer surface of the tube. The cap 19 may be formed of any suitable material having the required barrier properties and physical robustness, so as to prevent distortion of the tubular package 1 .

[0086] In embodiments, the cap 19 is formed of moulded pulp, paperboard, or cardboard provided with one or more barrier layers as described herein. The cap 19 is also preferably provided with a seal layer 7 as described herein, such as a heat seal layer. In some embodiments, the barrier layer 6 and sealant layers 7 are provided by lamination with the multilayered packaging material 4 described herein.

[0087] A seventh illustrated embodiment is shown in Figs. 10A and 10B wherein the terminal portion 9 is a cap 19. Fig. 10A shows the tube 2 and cap 19 in the unassembled state. Fig. 10B shows the tube 2 and cap 19 in the assembled state (the inner portion of the cap provided in dashed lines to indicate that it is within the tube).

[0088] Methods of Forming the Tubular Packaging

[0089] The tubular package 1 of the present invention may be formed by the following steps: a) providing a paperboard 3 with a multilayered packaging material 4 at least partially laminated thereto, the multilayered packaging material 4 comprising: a paper layer; a barrier layer selected from organic barrier layers, inorganic barrier layers, and combinations thereof; and a seal layer; b) forming the paperboard 3 into a tube 2 with the multilayered packaging material 4 innermost; and c) providing a pair of closures 8a, 8b, one located at each end of the tube 2.

[0090] Each of the paperboard 3 and multilayered packaging material 4 may be as described herein for the tubular package 1 .

[0091] In embodiments, the laminated paperboard 3 and multilayered packaging material 4 is provided in the correct dimensions for forming into the tube 2. In such embodiments, each of the paperboard 3 and the multilayered packaging material 4 may be cut to the appropriate dimensions and then at least partially laminated together. Preferably, the paperboard 3 and the multilayered packaging material 4 are at least partially laminated together prior to cutting into the correct dimensions. Cutting may be achieved by any suitable means, such as die cutting.

[0092] Forming the paperboard 3 into a tube 2 may be done by bending or folding the paperboard to the appropriate cross-section using any suitable means. Where folding is used, creases may be provided to the paperboard along where the folds 13 are to be provided. The long edges perpendicular to the central axis of the tubular packaging 1 , where the paperboard 3 overlaps, is mutually affixed, forming a seal. Preferably, the seal is formed by heat sealing. The overlap is preferably a lap seal, so that the overlapping material is flush to the surface of the tube.

[0093] Preferably, the cross-section of the tube 2 is substantially rectangular, optionally square. In embodiments, the at least partially laminated paperboard 3 and multilayered packaging material 4 is cut and folded so as to provide two pairs of opposing sides 10, 11 , 14, 15 and an axial flap. Each side in each pair of opposing sides has substantially the same dimensions as the other side within that pair of opposing sides. It will be understood that the first 10, 14 and second 11 , 15 pairs of opposing sides may be different to provide a substantially rectangular (but not square) cross section, or that the first and second pairs of opposing sides may be the same to provide a substantially square cross-section. The axial flap runs along one edge of the at least partially laminated paperboard 3 and multilayered packaging material 4, parallel to the central axis of the tubular package 1 , and is operable for affixing to the opposing edge when folded. The axial flap extends along the full extent of the main portion of the tube 2, so as to provide a complete seal. Preferably, the axial flap does not extend into the terminal portion, if present, so as to avoid interference with the closure means.

[0094] In particular embodiments, each of the paperboard 3 and multilayered packaging material 4, or the laminated paperboard 3 and multilayered packaging material 4 as may be the case, is provided as a roll. Said roll may be unwound, cut to the appropriate dimensions, and then folded and sealed in a continuous process.

[0095] Gusset

[0096] In embodiments, either or both of the closures 8a, 8b may be provided by forming a terminal portion of the tube 2 into a gusset 9. The gusset 9 may be formed by: a) folding each of a first pair of opposing sides 10 of the terminal portion 9 towards the central axis of the tubular package 1 ; b) bringing each of a second pair of opposing sides 11 of the terminal portion 9 together; and c) forming a seal region 12 where the internal surfaces of the first and second opposing pairs of sides 10, 11 are in contact, optionally by heat sealing.

[0097] By folding the first pair of opposing sides 10 inward and bringing the second pair of opposing sides 11 together, the terminal portion 9 is concertinaed such that the internal surfaces of the first and second sides 10, 11 are in contact. By way of explanation, viewed from the end of the tube 2, the terminal portion is formed into two mirrored “M” shapes that are then compressed. The folding and compression may be facilitated by the provision of creases along which the first and second sides are to fold.

[0098] Once in contact, the internal surfaces of the first and second sides may be affixed to one another and sealed. Preferably, the sealing is heat-sealing. Heat sealing may be achieved through applying heat and, optionally, pressure as is known in the art, for example by opposing planar heating elements.

[0099] Once the seal region 12 is provided, it may be further folded so that it lies flat to the end of the tube 2 and affixed in place. To facilitate this folding, a crease line may be provided along the one of the second pair of sides that is to be hidden.

[0100] Fin Seal

[0101] In embodiments, either or both of the closures 8a, 8b may be provided by forming a terminal portion 9 of the tube into a fin seal. The fin seal 9 may be formed by: a) folding each of a first pair of opposing sides 14 of the terminal portion 9 away from the central axis of the tubular package 1 ; b) bringing each of a second pair of opposing sides 15 of the terminal portion 9 together; and c) forming a seal region 16 where the internal surfaces of the first and second opposing pairs of sides 14, 15 are in contact, optionally by heat sealing.

[0102] By folding the first pair of opposing sides outward and bringing the second pair of opposing sides together, the two of the second pair of opposing sides is brought into mutual contact and each side of the first pair of opposing sides 14 is doubled back on itself. By way of explanation, viewed from the end the terminal portion is compressed to form a linear seal region 16.

[0103] The folding and compression may be facilitated by the provision of creases along which the first and second pair of sides 14, 15 are to fold.

[0104] Once in contact, the internal surfaces of the first and second pair of sides 14, 15 may be affixed to one another and sealed. Preferably, the sealing is heat-sealing. Heat sealing may be achieved through applying heat and, optionally, pressure as is known in the art, for example by opposing planar heating elements.

[0105] Once the seal region 16 is provided, it may be further folded so that the seal region 16 that is formed from the seal region 16 formed from contact of the second opposing pair of sides 15 is affixed to the first pair of opposing sides 14. By doing so, this portion of the seal region 16 is made to lie substantially within the plane perpendicular to the central axis of the tubular package. In other words, the seal region 16 is made to lie flat against the end of the tubular package 1 .

[0106] Following formation of the seal region 16, the material of the first opposing pair of sides 14 extends radially from the central axis, overhanging the cross section of the tube 2. This overhanging material may be affixed to the main portion of the tube, thereby lying flat to the surface of the tube. Alternatively, this overhanding material may be affixed to the material of the first opposing pair of sides, thereby lying flat to the end of the tube.

[0107] Tubular Portion

[0108] In embodiments, either or both of the closures 8a, 8b may be provided by: a) dividing a terminal portion 9 of the tube 2 into a plurality of flaps 17; b) affixing a tubular portion 18 of the multilayered packaging material 4 to the internal surface of the main portion of the tube 2; and c) sealing the tubular portion 18, optionally by heat sealing.

[0109] Dividing the terminal portion 9 of the tube 2 may be achieved by cutting the paperboard 3 and the multilayered packaging material 4 laminated thereto. Such cutting is preferably undertaken at the same time as cutting the paperboard 3 and the multilayered packaging material 4 laminated thereto to the dimensions required for the tube 2.

[0110] The tubular portion 18 of the multilayered packing material 4 is a loop of multilayered packaging material, the circumference of which is substantially equal to that of the internal surface of the main portion of the tube 2. Affixing the tubular portion of the multilayered packaging material 4 to the internal surface of the main portion of the tube 2 provides a continuous seal around the circumference of the tube. Such affixing may be achieved by any suitable means, preferably by heat sealing. Heat sealing may be achieved through applying heat and, optionally, pressure as is known in the art, for example by opposing planar heating elements.

[0111] The distal end of the tubular portion 18 (i.e. the end not affixed to the main portion), is then formed into a seal. Due to the flexible nature of the multilayered packaging material, it may be formed into substantially any geometry suitable for sealing, for example, a lap seal, a fin seal, a gusset seal, and so on. The seal may be provided by any suitable means, but is preferably a heat seal.

[0112] Partial Lamination

[0113] In embodiments, either or both of the closures 8a, 8b may be provided by: a) ensuring that a portion of the multilayered packaging material 4 adjacent to an edge of the paperboard 3 is unlaminated when providing the paperboard 3 with a multilayered packaging material 4 at least partially laminated thereto and ensuring that said portion is a terminal portion 9 of the tube 2; b) dividing the paperboard 3 of the terminal portion 9 into a plurality of flaps 17; c) sealing the multilayered packaging material 4, optionally by heat sealing.

[0114] The portion of the multilayered packaging material 4 that is not laminated to the paperboard 3 retains its flexibility and may be formed into substantially any geometry suitable for sealing, for example, a lap seal, a fin seal, a gusset seal, and so on. The seal may be provided by any suitable means, but is preferably a heat seal. Heat sealing may be achieved through applying heat and, optionally, pressure as is known in the art, for example by opposing planar heating elements. In preferred embodiments, the unlaminated portion runs parallel to the machine direction as the paperboard is unrolled.

[0115] Pressed Paper Top

[0116] In embodiments, either or both of the closures 8a, 8b may be provided by: a) dividing a terminal portion 9 of the tube 2 into a plurality of flaps 17; and b) sealing a closure portion to the internal surfaces of each of the flaps, optionally by heat sealing.

[0117] The method may additional comprise the step of affixing additional portions of the multilayered packaging material 4 to the regions between adjacent flaps and the further step of sealing the closure portion to the internal surfaces of each of the additional portions, for example, by heat sealing. Heat sealing may be achieved through applying heat and, optionally, pressure as is known in the art, for example by opposing planar heating elements.

[0118] Dividing the terminal portion 9 of the tube 2 may be achieved by cutting the paperboard 3 and the multilayered packaging material 4 laminated thereto. Such cutting is preferably undertaken at the same time as cutting the paperboard 3 and the multilayered packaging material 4 laminated thereto to the dimensions required for the tube.

[0119] The closure portion of the multilayered packing material is a sheet of multilayered packaging material. The size and shape of the closure portion is such that contact between the closure portion and the internal surfaces of the flaps (and, if present, the additional portions) is continuous. Preferably this contact is achieved when the flaps are extending away from the central axis of the tubular packaging (e.g. perpendicularly to the central axis of the tubular packaging). Preferably, the closure portion does not extend beyond the outer edges of the flaps.

[0120] Affixing the closure portion of the multilayered packaging to the internal surface of each of the flaps (and, if present, each of the additional portions) provides a continuous seal. Such affixing may be achieved by any suitable means, preferably by heat sealing. Heat sealing may be achieved through applying heat and, optionally, pressure as is known in the art, for example by opposing heating elements. Hermetic Tube

[0121] In embodiments, either or both of the closures 8a, 8b may be provided by: a) inserting a cap 19 into the end of the tubular packaging 1 , the cap 19 configured to have an external surface in continuous contact with the internal surface of the tube 2; and b) sealing the external surface of the cap 19 to the internal surface of the tubular packaging 1 , optionally by heat sealing.

[0122] The cap 19 may have an inner portion comprising the external surface and an outer portion configured to remain external to the tube. Inserting the cap may be achieved by holding the cap (e.g. by the outer portion) and then placing the inner portion within the tube. The external surface of the cap and the internal surface of the tubular packaging may be sealed by any appropriate means. Preferably these surfaces are sealed by heat sealing. Heat sealing may be achieved through applying heat and, optionally, pressure as is known in the art, for example by opposing heating elements.

[0123] Kit of Parts

[0124] The present invention also provides a kit of parts for forming the tubular packaging described herein. The kit of parts comprises: a paperboard 3 to which a multilayered packaging material 4 is at least partially laminated to an internal surface thereof, the multilayered packaging material 4 comprising: a paper layer; a barrier layer selected from organic barrier layers, inorganic barrier layers, and combinations thereof; and a heat seal layer; and one or more closures 8a, 8b selected from: a) a tubular portion 18 of the multilayered packaging material; b) a closure portion of the multilayered packaging material; and c) a cap 19.

[0125] The paperboard 3 to which the multilayered packaging material 4 is at least partially laminated may be in the form of a roll. Alternatively, the paperboard 3 to which the multilayered packaging material 4 is at least partially laminated is in the form of a cut-out suitable for folding into a tube 2 as described herein. Further alternatively, paperboard 3 to which the multilayered packaging material 4 is at least partially laminated is in the form of a tube 2.

[0126] The multilayered packaging material 4 may be as described herein for the tubular packaging material.

[0127] Uses of the Tubular Packaaina

[0128] The present invention also relates to the use of the tubular packaging 1 described herein for packing an edible product for human or animal consumption.

[0129] Preferably, said edible product is a powder, a gel, or kibbles and is selected within the list of: ground coffee, soluble coffee, nutrition compositions for infant, adult, or elderly consumption, soup, confectionery or candies, chocolate-based products, dry animal food, dairy products.

[0130] A Packaged Edible Product

[0131] The present invention also relates to a packaged edible product, comprising the tubular packaging 1 as described herein, at least partially filled with an edible product for human or animal consumption.

[0132] Preferably, said edible product is a powder, a gel, or kibbles and is selected within the list of: ground coffee, soluble coffee, nutrition compositions for infant, adult, or elderly consumption, soup, confectionery or candies, chocolate-based products, dry animal food, dairy products.

Claims

CLAIMS:

1. A tubular package (1) comprising: a tube (2) comprising: a paperboard (3), the paperboard having a tubular form; and a multilayered packaging material (4) at least partially laminated to an internal surface of the paperboard, the multilayered packaging material comprising: a paper layer; a barrier layer selected from organic barrier layers, inorganic barrier layers, and combinations thereof; and a seal layer; and a pair of closures (8a, 8b), one located at each end of the tube.

2. The tubular package (1) of claim 1 , wherein the tube (2) has a substantially rectangular, optionally square, cross section.

3. The tubular package (1) of claim 1 or claim 2, wherein either or both of the closures (8a, 8b) comprise a terminal portion (9) of the tube configured to provide a seal.

4. The tubular package (1) of claim 3, wherein the terminal portion (9) is a gusset, the gusset being formed from first (10) and second (11) opposing pairs of sides of the terminal portion (9), each of the first opposing pair of sides (10) is folded toward the central axis of the tubular package, each of the second opposing pair of sides (11) is brought together, and a seal region (12) is provided where the internal surfaces of the first and second opposing pairs of sides (10, 11) are in contact.

5. The tubular package (1) of claim 4, wherein one of the second opposing pair of sides is folded perpendicular to the central axis of the tubular package (1) and the other of the second opposing pair of sides is flat and outermost.

6. The tubular package (1) of claim 4 or claim 5, wherein the axial length of the terminal portion (9) is equal to the radial distance between the second opposing pair of sides (11) prior to folding.

7. The tubular package (1) of any one of claims 4 to 6, wherein each of the axial length of the seal region (9) and the axial distance between the seal region (9) and the main portion of the tube is half of the radial distance between the second opposing pair of sides (11) prior to folding.

8. The tubular package (1) of any one of claims 4 to 7, wherein a fold (13) perpendicular to the central axis of the tubular package is provided in one of the second opposing pair of sides (11), the fold (13) located halfway along the axial length of the terminal portion (9).

9. The tubular package (1) of claim 3, wherein the terminal portion (9) is a fin seal, the fin seal being formed from first (14) and second (15) opposing pairs of sides of the terminal portion, wherein each of the first opposing pair of sides (14) is folded away from the central axis of the tubular package, each of the second opposing pair of sides (15) is brought together, and a seal region (16) is provided where the internal surfaces of the first and second opposition pairs of sides (15) are in contact.

10. The tubular package (1) of claim 9, wherein the axial distance between the seal region (16) and the main portion of the tube (2) is half of the radial distance between the second opposing pair of sides (15) prior to folding.

11. The tubular package (1) of claim 9 or claim 10, wherein the portion of seal region (16) formed from the contact of the second opposing pair of sides (15) lies substantially within the plane perpendicular to the central axis of the tubular package.

12. The tubular package (1) of any one of claims 9 to 11 , wherein the material of each of the first opposing pair of sides (14) is affixed to the material of the second opposing pair of sides (15).

13. The tubular package (1) of any one of claims 9 to 11 , wherein the material of each of the first opposing pair of sides (14) is affixed to the adjacent surface of the main portion of the tube (2) such that it is substantially coplanar with said adjacent surface.

14. The tubular package (1) of any one of the preceding claims, wherein either or both of the closures (8a, 8b) comprise a terminal portion of the tube divided into a plurality of flaps (17) and a tubular portion (18) of the multilayered packaging material, the tubular portion affixed to the internal surface of the main portion of the tube, the tubular portion of the multilayered packaging material configured to provide a seal.

15. The tubular package (1) of any one of the preceding claims, wherein either or both of the closures (8a, 8b) comprise a terminal portion of the tube (2) wherein the paperboard (3) and the multilayered packaging material (4) are not laminated together, the paperboard (3) being divided into a plurality of flaps (17), the multilayered packaging material (4) being configured to provide a seal.

16. The tubular package (1) of any one of the preceding claims, wherein either or both of the closures (8a, 8b) comprise a terminal portion of the tube (2) divided into a plurality of flaps (17) and a closure portion of the multilayered packaging material (4) affixed to the internal surfaces of each of the flaps so as to provide a seal.

17. The tubular package (1) of any one of claims 14 to 16, wherein the flaps (17) extend towards the central axis of the tubular packaging such that they are overlapping and substantially coplanar.

18. The tubular package (1) of any one of claims 14 to 17, wherein the flaps (17) include at least one flap being substantially equal to the cross-section of the tube in shape and size, said flap being outermost.

19. The tubular package (1) of any one of the preceding claims, wherein either or both of the closures (8a, 8b) comprise a cap (19), the cap configured to have an external surface in continuous contact with the internal surface of the tube (2) and sealed thereto.

20. The tubular package (1) of any preceding claim, wherein the tubular package further comprises a covering (20), such as a pressure sensitive label, over at least a portion of the terminal portion.21 . A method of forming a tubular package (1) as described in any one of claims 1 to 20, the method comprising the steps of a) providing a paperboard (3) with a multilayered packaging material (4) at least partially laminated thereto, the multilayered packaging material (4 Comprising: a paper layer; a barrier layer selected from organic barrier layers, inorganic barrier layers, and combinations thereof; and a seal layer; b) forming the paperboard (3) into a tube (2) with the multilayered packaging material (4) innermost; and c) providing a pair of closures (8a, 8b), one located at each end of the tube (2).

22. The method of claim 21 , wherein the paperboard (3) is formed into a tube (2) with a substantially rectangular, optionally square, cross-section.

23. The method of claim 21 or claim 22, where either or both of the closures (8a, 8b) are provided by forming a terminal portion of the tube (2) into a gusset by: a) folding each of a first pair of opposing sides (10) of the terminal portion towards the central axis of the tubular package; b) bringing each of a second pair of opposing sides (11) of the terminal portion together; and c) forming a seal region (12) where the internal surfaces of the first and second opposing pairs of sides (10, 11) are in contact, optionally by heat sealing.

24. The method of claim 23, further comprising the step of affixing the seal region (12) to one of the second pair of opposing sides (11) such that the gusset lies substantially within the plane perpendicular to the central axis of the tubular package.

25. The method of any one of claims 21 to 24, where either or both of the closures (8a, 8b) are provided by forming a terminal portion of the tube into a fin seal by:a) folding each of a first pair of opposing sides (14) of the terminal portion away from the central axis of the tubular package; b) bringing each of a second pair of opposing sides (15) of the terminal portion together; and c) forming a seal region (16) where the internal surfaces of the first and second opposing pairs of sides (14, 15) are in contact, optionally by heat sealing.

26. The method of claim 25, further comprising the step of affixing the seal region (16) formed from contact of the first opposing pair of sides (14) to one of the second pair of opposing sides (15) such that the seal region (16) formed from contact of the second opposing pair of sides lies substantially within the plane perpendicular to the central axis of the tubular package.

27. The method of claim 25 or claim 26, further comprising the step of affixing the material of each of the first opposing pair of sides (14) to the material of the second opposing pair of sides (15).

28. The method of claim 25 or claim 26, further comprising the step of affixing the material of each of the first opposing pair of sides (14) to the adjacent surface of the tube such that it is substantially coplanar with the adjacent surface of the tube (2).

29. The method of any one of claims 21 to 28, wherein either or both of the closures (8a, 8b) are provided by: a) dividing a terminal portion of the tube (2) into a plurality of flaps (17); b) affixing a tubular portion (18) of the multilayered packaging material (4) to the internal surface of the main portion of the tube (2); and c) sealing the tubular portion (18), optionally by heat sealing.

30. The method of any one of claims 21 to 29, wherein either or both of the closures (8a, 8b) are provided by: a) ensuring that a portion of the multilayered packaging material (4) adjacent to an edge of the paperboard (3) is unlaminated when providing the paperboard (3) with a multilayered packaging material (4) at least partially laminated thereto and ensuring that said portion is a terminal portion of the tube; b) dividing the paperboard (3) of the terminal portion into a plurality of flaps (17);c) sealing the multilayered packaging material (4), optionally by heat sealing.31 . The method of any one of claims 21 to 30, wherein either or both of the closures (8a, 8b) are provided by: a) dividing a terminal portion of the tube (2) into a plurality of flaps (17); and b) sealing a closure portion to the internal surfaces of each of the flaps (17), optionally by heat sealing.

32. The method of any one of claims 21 to 31 , wherein either or both of the closures (8a, 8b) are provided by: a) inserting a cap (19) into the end of the tubular packaging, the cap (19) configured to have an external surface in continuous contact with the internal surface of the tube (2); and b) sealing the external surface of the cap (19) to the internal surface of the tubular packaging, optionally by heat sealing.

33. A kit of parts comprising: a paperboard (3) to which a multilayered packaging material (4) is at least partially laminated to an internal surface thereof, the multilayered packaging material (4) comprising: a paper layer; a barrier layer selected from organic barrier layers, inorganic barrier layers, and combinations thereof; and a heat seal layer; and one or more closures (8a, 8b) selected from: a) a tubular portion of the multilayered packaging material (4); b) a closure portion of the multilayered packaging material (4); and c) a cap (19).

34. Use of the tubular package (1) of any one of claims 1 to 20, for packing an edible product for human or animal consumption35. A packaged edible product, comprising the tubular package (1) of any one of claims 1 to 20, at least partially filled with an edible product for human or animal consumption.

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