Rolled paper cup

Abstract

The present application relates to a rolled paper cup comprising: a body, the body being substantially cylindrical or frustoconical and having a top rim and a bottom rim; and a press-formed base affixed to the bottom rim of the body wherein each of the body and the press formed base are formed from a laminate material comprising, from its outer side to its inner side: a paper layer having a grammage in the range of 100 to 400 g / m2, at least one organic barrier layer comprising a biodegradable polymer, and at least one sealing layer. The present application also relates to a method of forming the rolled paper cup.

Description

[0001] ROLLED PAPER CUP

[0002] The present invention relates to a rolled paper cup formed from a laminate material comprising paperboard, an organic barrier layer, and an organic sealing layer and methods of producing such containers.

[0003] Background

[0004] Containers for products and for use as packaging are increasingly made from biodegradable materials, including compostable materials, such as paper or moulded pulp. However, these materials based on cellulose fibre have poor barrier properties and limited resistance to water, leaving their contents vulnerable to environmental factors and leading to a limited shelf life.

[0005] Some applications are more challenging, requiring the materials of the container to react to particular conditions (e.g. on exposure to water) in predictable and reproducible ways. In addition, certain applications require containers to take a specific form and in order to ensure compatibility with existing systems and apparatus.

[0006] It is the object of the present invention to address at least one of the foregoing problems.

[0007] Summary of the Invention

[0008] A first aspect of the present invention relates to a rolled paper cup comprising: a body, the body being substantially cylindrical or frustoconical and having a top rim and a bottom rim; and a press-formed base affixed to the bottom rim of the body wherein each of the body and the press formed base are formed from a laminate material comprising, from its outer side to its inner side: a paper layer having a grammage in the range of 100 to 400 g / m2, at least one organic barrier layer comprising a biodegradable polymer, and at least one sealing layer.

[0009] The rolled paper cup may further comprise a flange at the top rim of the body. The rolled paper cup may further comprise a filter paper, the filter paper contained within the volume defined by the body. At least a portion of the filter paper may be affixed to the internal surface of the body and / or, if present, to the flange.

[0010] The press-formed base and / or the bottom rim of the body may further comprise reinforcing means, optionally wherein the reinforcing means comprise additional creases.

[0011] The rolled paper cup of may further comprise a lid affixed to the top rim of the body or, if present, the flange.

[0012] The biodegradable polymer may be selected within the list of: polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB) and co-polymers thereof, polybutylenesuccinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS-A / PBSa), polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), cellulose acetate, starch, polyvinylalcohol (PVOH), ethylene vinyl alcohol (EVOH), butenediol vinyl alcohol copolymer (BVOH), or combinations thereof. Preferably, the at least one organic barrier layer comprises a layer of BVOH laminated between layers of biodegradable polyester, such as PHAs, PBSA, or PBHAT. The at least one organic barrier layer may be present in an amount of 20 to 200 g / m2.

[0013] The rolled paper cup may further comprise at least one inorganic barrier layer selected within the list of: metals, metalloids, oxides thereof, or a combination thereof, such as aluminium, AIOx, SiOx, and combinations thereof.

[0014] The sealing layer may comprise a heat sealing layer. The sealing layer may be applied in an amount between 2 and 150 g / m2.

[0015] A second aspect of the present invention relates to a method of forming a rolled paper cup, the method comprising: rolling a body precursor, the body precursor having the shape of a rectangle or an annular sector, around a central axis to form a body that is substantially cylindrical or frustoconical, the first two opposing sides of the body precursor that are substantially perpendicular to the central axis forming a top rim and a bottom rim, the second two opposing sides of the body precursor being brought into mutual contact; mutually affixing the second two sides of the body precursor to form the body; affixing a press-formed base to the bottom rim of the body; wherein the laminate material comprises, from its outer side to its inner side: a paper layer having a grammage in the range of 100 to 400 g / m2, at least one organic barrier layer comprising a biodegradable polymer, and at least one sealing layer.

[0016] The method may further comprise forming a flange from the top rim of the body. The method may further comprise affixing a flange to the top rim of the body.

[0017] The method may further comprise affixing a filter paper, the filter paper contained within the volume defined by the body, optionally the filter paper being affixed to the internal surface of the body and / or, if present, to the flange.

[0018] The method may further comprise providing the press-formed base and / or the bottom rim of the body with reinforcing means, optionally wherein providing the reinforcing means comprises creasing the laminate material of the press-formed base and / or the bottom rim.

[0019] The method may further comprise depositing at least one inorganic barrier layer selected within the list of: metals, metalloids, oxides thereof, or a combination thereof, such as aluminium, AIOx, SiOx, and combinations thereof.

[0020] The method may further comprise affixing a lid to the top rim of the body or, if present, the flange.

[0021] A third aspect of the present invention relates to a packaged foodstuff or beverage ingredient comprising the rolled cup of the first aspect of the present invention enclosing a foodstuff or a beverage ingredient.

[0022] A fourth aspect of the present invention relates to the use of the rolled paper cup of the first aspect of the present invention for packaging a foodstuff or a beverage ingredient.

[0023] Brief Description of the Drawings

[0024] Fig. 1 A is a plan view of an annular sector of laminate material. Fig. 1 B is a side on of the piece of laminate material shown in Fig. 1A that has been rolled and affixed to form a body with a frustoconical shape.

[0025] Fig. 1C is a side on view of a rolled paper cup formed from the body with a frustoconical shape shown in Fig. 1 B by affixation of a press-formed base and provision of a flange.

[0026] Detailed Description

[0027] A first aspect of the present invention relates to a rolled paper cup comprising a body and a press-formed base affixed to the body. The body is substantially cylindrical or frustoconical. The body 10 has a top rim 40 and a bottom rim 50. Where the body is frustoconical, it is preferred for the bottom rim 50 to be at the narrower end of the frustoconical shape. The press-formed base 60 is affixed to the bottom rim 50 of the body 10. Each of the body 10 and the press-formed base 60 are comprised of a laminate material comprising, from its outer side to its inner side: a paper layer having a grammage in the range of from 100 to 400 g / m2, preferably from 150 to 300 g / m2; at least one organic barrier layer comprising a biodegradable polymer; and at least one sealing layer. The paper layer may comprise any paper, paperboard, cardboard, or other suitable planar cellulosic material. It will be understood that the material of the paper layer is one that is able to be cut and rolled to form the rolled paper cup without tearing or otherwise being mechanically compromised.

[0028] In embodiments where the body is cylindrical, the body is formed from a portion of the laminate material in the shape of a rectangle (including square). The rectangle is rolled around a central axis to overlap two of the opposing edges of the laminate material overlap and are then mutually affixed to form the body.

[0029] In embodiments where the body 10 is frustoconical, the body 10 is formed from a portion of the laminate material in the shape of an annular sector 20. The annular sector is rolled around a central axis 30 such that the two straight edges of the laminate material overlap and are then mutually affixed to form the body 10.

[0030] The press-formed base 60 is a portion of the laminate material in the shape of a circle with an upstand. The upstand is formed by pressing an outer annulus of larger circle of material to extend substantially perpendicularly from the plane of the circle. Optionally, a crease may be provided at the inner edge of the outer annulus. Further optionally, the outer annulus may be provided with radial cuts or notches. The crease and radial cuts or notches aid deformation of the circle to form the press-formed base.

[0031] The press-formed base 60 affixes to the bottom rim 50 of the body by adhering the upstand to the bottom rim 50 of the body. Affixation may be achieved by the application of adhesives. Alternatively, affixation may be achieved by use of the sealing layer present on the press-formed base 60 or the body 10.

[0032] In embodiments, at least one of the press-formed base 60 and the bottom rim 50 of the body is provided with reinforcing means. For example, the laminate material may be thickened, doubled over, or provided with additional creases so as to increase its mechanical strength.

[0033] The organic barrier layer comprises one or more biodegradable polymers. The biodegradable polymer may be any thermoplastic biodegradable polymer. The one or more biodegradable polymers may be selected from the list of: polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB) and co-polymers thereof, polybutylenesuccinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS-A / PBSa), polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), cellulose acetate, starch, polyvinylalcohol (PVOH), ethylene vinyl alcohol (EVOH), butenediol vinyl alcohol co-polymer (BVOH), and combinations thereof. The organic barrier layer may be present in an amount of from 20 to 150 g / m2. By using biodegradable polymer with the rolled paper cup, the entire container can be composted directly without the need for post-use processing.

[0034] The organic barrier layer may be a multilayer. In one preferred embodiment, the organic barrier layer comprises a layer of BVOH laminated between layers of biodegradable polyester, such as PHAs, PBSA, or PBHAT. The thicknesses of the layers of this laminate may be selected to ensure cohesive layers post rolling of the material into the cup and press-formed base.

[0035] The sealing layer is disposed on the internal surface of the organic barrier layer or, if present, the inorganic barrier layer. For the avoidance of doubt, the sealing layer is the innermost of these layers. The sealing layer may be a heat sealing layer. The sealing layer may be a thermoplastic organic polymer. Substantially any food safe thermoplastic polymer may be used, on condition that it has the requisite material properties of robustness and flexibility in the thickness used. In embodiments, the heat sealing layer comprises an ionomer. The sealing layer may be present in an amount of from 2 to 150 g / m2.

[0036] The rolled paper cup may comprise at least one inorganic barrier layer selected within the list of: metals, metalloids, oxides thereof, or a combination thereof, such as aluminium, AIOx, SiOx, and combinations thereof. These inorganic barrier layers provide further barrier properties to limit the movement of moisture and / or gases through the rolled paper cup. Preferably, the at least one inorganic barrier layer is disposed between the organic barrier layer and the sealing layer. The organic barrier layer provides a particularly suitable surface for deposition of the one or more inorganic barrier layers. Alternatively, the at least one inorganic barrier layer is disposed between the paper layer and organic barrier layer. Further alternatively, in embodiments wherein there is more than one organic barrier layer, the at least one inorganic barrier layer may be disposed between organic barrier layers.

[0037] The rolled paper cup may further comprise a filter paper contained within the volume defined by the rolled paper cup. The filter paper is preferably affixed to the internal surface of the sealing layer and / or, if present, to the flange. By being affixed to the internal surface of the sealing layer and / or the flange, the internal volume defined by the rolled paper cup is divided into two volumes. In one example, the filter paper is affixed around the circumference of the internal surface of the rolled paper cup and / or the flange, dividing the volume into an upper compartment and a lower compartment. Affixing may be achieved by any suitable means, such as ultrasonic welding. The filter paper is useful where the rolled paper cup is to be used for beverage applications. The beverage ingredients are held to one side of the filter paper and water is flowed through the rolled paper cup from this side, removing extracts from the beverage ingredients while leaving the bulk ingredient behind. In one embodiment, the beverage ingredient sits in a top compartment and water flowed through under gravity into the bottom compartment, where it is removed using a perforation through the base of the rolled paper cup.

[0038] The rolled paper cup may further comprise a flange 70 at the top rim 40 of the body. Preferably, the flange 70 lies in the plane perpendicular to the central axis 30. In embodiments, the flange 70 is integral to the body. The integral flange 70 is formed by pressing the top rim of the body, preferably after the body has been rolled. The top rim 40 may be provided with a crease to aid deformation of the top rim 40 to form the integral flange 70. For reinforcement, the integral flange 70 may include a return fold, wherein the outer portion that has been pressed is folded under itself. In alternative embodiments, the flange is at least one additional, annular portion of laminate affixed to the top rim of the body. In such embodiments, the top rim may be provided with radial cuts or notches to form tabs. These tabs may be folded to lie perpendicular to the central axis to provide a larger surface area to which the at least one annular portion of laminate may be affixed. In a first example, a single annular portion of laminate is affixed to one side of the tabs, while in a second example, a first annular portion of laminate is affixed to a first side of the tabs and a second annular portion of laminate is affixed to the second side of the tabs.

[0039] The rolled paper cup may further comprise a lid affixed to the top rim or, if present, the flange. The lid is affixed around the entirety of the opening, thereby sealing the rolled paper cup. This allows for the extended storage of goods within the rolled paper cup, for example, for a period of up to 9 months. The storage period may be extended by the use of secondary packaging. The perimeter of the lid may correspond to the perimeter of the top rim or, if present, the flange. In embodiments, at portion of the lid extends beyond the perimeter of the top rim or, if present, the flange. Such a portion provides a tab for the removal of the lid.

[0040] The lid may comprise a laminate material comprising, from its outer side to its inner side: a paper layer having a grammage in the range of 50 to 150 g / m2, at least one organic barrier layer comprising a biodegradable polymer, optionally, an inorganic barrier layer, and optionally, a sealing layer.

[0041] The organic barrier layer may be any biodegradable polymer as described herein. The inorganic barrier layer may be any inorganic barrier layer as described herein. The sealing layer may be any sealing layer as described herein.

[0042] A second aspect of the present invention relate to a method of forming a rolled paper cup. The method comprises: rolling a body precursor, the body precursor having the shape of a rectangle or an annular sector, around a central axis to form a body that is substantially cylindrical or frustoconical, the first two opposing sides of the body precursor that are substantially perpendicular to the central axis forming a top rim and a bottom rim, the second two opposing sides of the body precursor being brought into mutual contact; mutually affixing the second two sides of the body precursor to form the body; affixing a press-formed base to the bottom rim of the body; wherein the laminate material comprises, from its outer side to its inner side: a paper layer having a grammage in the range of from 100 to 400 g / m2, at least one organic barrier layer comprising a biodegradable polymer, and at least one sealing layer.

[0043] The body precursor may be formed by cutting a laminate material into the shape of the rectangle or the annular sector 20.

[0044] The press-formed base may be formed by pressing by circular portion of laminate material to form an outer annulus thereof into an upstand. Prior to pressing, the circular portion of laminate may be provided a crease defining the outer annulus. Additionally, or alternatively, the outer annulus may be provided with radial cuts or notches.

[0045] Mutually affixing the second two sides of the body precursor may comprise applying adhesive. Preferably, mutual affixation is achieved by the sealing layer, for example, by heat sealing.

[0046] The method may further comprise converting the top rim of the body to an integral flange. For example, the top rim of the body may be pressed to lie in the plane perpendicular to the central axis. In embodiments, the pressed portion of the body is provided with a return (i.e. folded under itself). In some embodiments, the top rim of the body is rolled and pressed to form a flange.

[0047] The method may further comprise affixing a flange to the top rim of the body. The flange is formed from an annular section of the laminate material. Affixation of the flange may be achieved by applying adhesive. Preferably, affixation is achieved by the sealing layer, for example, by heat sealing.

[0048] The process of rolling and affixing the body, as well as affixation of the press-formed base and formation of the flange is shown in Figs. 1A to 1C. In Fig. 1A, a piece of laminate in the form of an annular sector 20 is provided. This annular sector 20 is rolled around central axis 20 to form a body 10 in Fig. 1 B, the overlapping edges of which are affixed to one another. The press-formed base 60 is then affixed to the bottom rim 50 of the body and the top rim 40 is converted to flange 70 in Fig. 1C.

[0049] The method may further comprise depositing at least one inorganic barrier layer selected within the list of: metals, metalloids, oxides thereof, or a combination thereof, such as aluminium, AIOx, SiOx, and combinations thereof. Preferably the at least one barrier layer is provided within the laminate, such as between the organic barrier layer and the sealing layer, between the organic barrier layer and the paper, or, if multiple organic barrier layers are present, between organic barrier layers. Any suitable method may be used, such as chemical vapour deposition techniques (e.g. plasma enhanced CVD), transfer metallization, or direct metallization. In certain embodiments, the inorganic barrier layer is provided during formation of the laminate. For example, the inorganic barrier layer may be deposited onto the organic barrier layer and the two barrier layers are applied to the paper layer as a barrier laminate. Alternatively, the barrier laminate may be affixed to a flexible paper layer (for example, having a grammage of from 30 to 120 g / m2) that is then adhered to the paper layer to form the laminate.

[0050] The method may further comprise affixing a filter paper to the rolled paper cup, the filter paper contained within the volume defined by the rolled paper cup. Preferably, the filter paper is affixed to the internal surface of the sealing layer, for example, to divide the volume defined by the paper container into two, such as a lower volume and an upper volume.

[0051] The method may further comprise affixing a lid to the top rim of the body or, if present, to the flange. The lid may be affixed by any suitable means, such as heat sealing or ultrasonic welding. The method may be a method of providing a packaged foodstuff or beverage ingredient, wherein the foodstuff or beverage ingredient is within the volume defined by the rolled paper cup. The foodstuff or beverage ingredient is placed within the rolled paper cup prior to affixing the lid.

[0052] The third aspect of the present invention relates to a packaged foodstuff or beverage ingredient comprising the rolled paper cup as described herein enclosing a foodstuff or beverage. By being packaging within the rolled paper cup as described herein including a lid, the foodstuff or beverage ingredient has an open shelf life of six months, preferable up to nine months.

[0053] The fourth aspect of the present invention relates to the use of the rolled paper cup as described herein for packaging a foodstuff or beverage ingredient.

Claims

CLAIMS:1 . A rolled paper cup comprising: a body, the body being substantially cylindrical or frustoconical and having a top rim and a bottom rim; and a press-formed base affixed to the bottom rim of the body wherein each of the body and the press formed base are formed from a laminate material comprising, from its outer side to its inner side: a paper layer having a grammage in the range of 100 to 400 g / m2, at least one organic barrier layer comprising a biodegradable polymer, and at least one sealing layer.

2. The rolled paper cup of claim 1 , further comprising a flange at the top rim of the body.

3. The rolled paper cup of claim 1 or claim 2, further comprising a filter paper, the filter paper contained within the volume defined by the body.

4. The rolled paper cup of claim 3, wherein at least a portion of the filter paper is affixed to the internal surface of the body and / or, if present, to the flange.

5. The rolled paper cup of any preceding claim, wherein the press-formed base and / or bottom rim of the body further comprise reinforcing means, optionally wherein the reinforcing means comprise additional creases.

6. The rolled paper cup of any preceding claim, further comprising a lid affixed to the top rim of the body or, if present, the flange.

7. The rolled paper cup of any preceding claim, wherein the biodegradable polymer is selected within the list of: polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB) and co-polymers thereof, polybutylenesuccinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS-A / PBSa), polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), cellulose acetate, starch, polyvinylalcohol (PVOH), ethylene vinyl alcohol (EVOH), butenediol vinyl alcohol co-polymer (BVOH), or combinations thereof.

8. The rolled paper cup of claim 7, wherein the at least one organic barrier layer comprises a layer of BVOH laminated between layers of biodegradable polyester, such as PHAs, PBSA, or PBHAT.

9. The rolled paper cup of any preceding claim, wherein the at least one organic barrier layer is present in an amount of 20 to 200 g / m2.

10. The rolled paper cup of any preceding claim, further comprising at least one inorganic barrier layer selected within the list of: metals, metalloids, oxides thereof, or a combination thereof, such as aluminium, AIOx, SiOx, and combinations thereof.11 . The rolled paper cup of any preceding claim, wherein the sealing layer comprises a heat sealing layer.

12. The rolled paper cup of any preceding claim, wherein said sealing layer is applied in an amount between 2 and 150 g / m2.

13. A method of forming a rolled paper cup, the method comprising: rolling a body precursor, the body precursor having the shape of a rectangle or an annular sector, around a central axis to form a body that is substantially cylindrical or frustoconical, the first two opposing sides of the body precursor that are substantially perpendicular to the central axis forming a top rim and a bottom rim, the second two opposing sides of the body precursor being brought into mutual contact; mutually affixing the second two sides of the body precursor to form the body; affixing a press-formed base to the bottom rim of the body; wherein the laminate material comprises, from its outer side to its inner side: a paper layer having a grammage in the range of 100 to 400 g / m2, at least one organic barrier layer comprising a biodegradable polymer, and at least one sealing layer.

14. The method of claim 13, further comprising:i. forming a flange from the top rim of the body; or ii. affixing a flange to the top rim of the body.

15. The method of claim 13 or claim 14, further comprising affixing a filter paper, the filter paper contained within the volume defined by the body, optionally the filter paper being affixed to the internal surface of the body.

16. The method of any of claims 13 to 15, further comprising providing the press- formed base and / or the bottom rim of the body with reinforcing means, optionally wherein providing the reinforcing means comprises creasing the laminate material of the press-formed base and / or the bottom rim.

17. The method of any of claims 13 to 16, further comprising depositing at least one inorganic barrier layer selected within the list of: metals, metalloids, oxides thereof, or a combination thereof, such as aluminium, AIOx, SiOx, and combinations thereof.

18. The method of any of claims 13 to 17, further comprising affixing a lid to the top rim of the body or, if present, the flange.

19. A packaged foodstuff or beverage ingredient comprising the rolled cup of any of claims 1 to 12 enclosing a foodstuff or a beverage ingredient.

20. The use of the rolled paper cup of any of claims 1 to 12 for packaging a foodstuff or a beverage ingredient.

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