PACKAGING AND A METHOD OF MANUFACTURE THEREOF

Abstract

The invention provides a method of manufacturing packaging comprising the steps of: a) providing a packaging material (2) comprising cartonboard, semi-rigid plastics or other semi-rigid packaging material; b) forming fold lines (8) and/or cuts within the packaging material (2) by subjecting the packaging material (2) to laser (12) or mechanical scoring; c) folding the packaging material (2) along the fold lines (8) and/or cuts and securing in position to form a substantially tubular container (200); and d) forming at least one seal (302, 304) by sealing together at least two opposing regions (122, 124, 126, 128) of a blank (4) to form an at least partially sealed package (300); e) performing at least one of steps b), c) and d) on a horizontal or vertical fill, form and seal apparatus (400).

Claims

1. A method of manufacturing packaging comprising the steps of: a) providing a packaging material comprising cartonboard, semi-rigid plastics or other semi-rigid packaging material; b) forming fold lines and/or cuts within the packaging material by subjecting the packaging material to laser or mechanical scoring; c) folding the packaging material along the fold lines and/or cuts and securing in position to form a substantially tubular container; and d) forming at least one seal by sealing together at least two opposing regions of the blank to form an at least partially sealed package; e) performing at least one of steps b), c) and d) on a horizontal or vertical fill, form and seal apparatus.

2. The method as claimed in claim 1, wherein the at least one seal comprises a fin seal formed by sealing together the at least two opposing surfaces of the packaging material.

3. The method as claimed in claim 1, further comprising crimping or embossing the at least one seal along at least a portion thereof to form patterned sealed regions of the packaging.

4. The method as claimed in claim 1, wherein the at least one seal is formed by providing an adhesive on at least a portion of at least one of the regions of the packaging material.

5. The method as claimed in claim 4, wherein the adhesive comprises a peelable or reclosable adhesive.

6. The method as claimed in claim 1, wherein at least one item is placed on an inside surface of the packaging material after step b) or is placed in the container after step c).

7. The method as claimed in claim 1, wherein after performing step d) the formed package is only partially sealed and at least one item is placed into the partially sealed package.

8. The method as claimed in claim 7, wherein at least one further seal is formed after placing at least one item into the partially sealed package such that a fully sealed packaging is formed housing at least one item therein.

9. The method as claimed in claim 6, wherein the at least one item is a food item selected from a confectionery item, bakery item, fruit, vegetable, meat, cheese, powdered food, powdered beverage and snack item.

10. The method as claimed in claim 1, wherein the fold lines and/or cuts are formed within the packaging material separately before loading the packaging material onto apparatus used in conventional horizontal or vertical fill, form and seal processes.

11. The method as claimed in claim 1, wherein the fold lines and/or cuts are formed within the packaging material during a horizontal or vertical fill, form and seal process.

12. The method as claimed in claim 11, wherein the fold lines and/or cuts are formed within the packaging material before an item is located on the packaging material.

13. The method as claimed in claim 11, wherein at least one fold line and/or at least one cut is formed within the packaging material before an item is located on the packaging, and at least one fold line and/or at least one cut is formed within the packaging material after an item is located on the packaging material.

14. The method as claimed in claim 1, wherein the packaging material comprises cartonboard.

15. The method as claimed in claim 1, wherein the packaging material has a thickness of at least 125 microns.

16. Packaging manufactured using the method as claimed in claim 1, comprising at least one set of opposing and spaced apart first and second surfaces, wherein a region of each end the first and second surfaces is sealed together.

17. A method or packaging substantially as described herein with reference to the accompanying drawings.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0049] In order that the invention may be more clearly understood an embodiment thereof will now be described, by way of example only, with reference to the accompanying drawings, in which;

[0050] FIG. 1 is a perspective view of the scoring stage of a method in accordance with the present invention.

[0051] FIG. 2 illustrates an embodiment of a blank produced by a method in accordance with the present invention.

[0052] FIG. 3 is a perspective view of the folding stage of a method in accordance with the present invention.

[0053] FIG. 4 is a perspective view of an embodiment of the packaging of the present invention.

[0054] FIG. 5 is a schematic diagram of a horizontal fill, form and seal apparatus which may be used to perform the method in accordance with the present invention.

[0055] FIG. 6 illustrates a further embodiment of a blank produced by a method in accordance with the present invention.

[0056] FIG. 7 is a perspective view of an embodiment of the packaging of the present invention formed from the blank illustrated in FIG. 6.

[0057] A method in accordance with the present invention will now be described with reference to FIGS. 1-4.

[0058] Initially, a sheet of packaging material 2 is provided. In the illustrated embodiment the sheet of packaging material 2 comprises cartonboard having a thickness of around 205 microns. However, other forms of semi-rigid material may be used. Blanks 4, 4′ are formed in the sheet of packaging material 2 and are defined by edges 5, 6 as illustrated in FIG. 1. Fold lines (shown as dotted lines 8) are formed within the packaging material 2. The fold lines 8 are formed in the sheet 2 using laser light 10 from a laser cutter 12. Although the illustrated method uses a laser cutter 12, it should be appreciated that other means of forming fold lines 8 in the sheet 2 may be employed including mechanical creasing, such as die-cutting for example.

[0059] In this embodiment, the individual blanks 4, 4′ remain connected along the edges 5, 5′ however, it is envisaged that in some embodiments the blanks 4, 4′ may be separated by forming cuts in the packaging material 2 along the edges 5, 6. The cuts 5, 6 may also be formed in the sheet 2 using laser light 10 from a laser cutter 12.

[0060] FIG. 2 illustrates an embodiment of an individual blank 4 as produced by the scoring stage shown in FIG. 1. The completed blank 4 includes front panel 102 and a back panel 104 each comprising opposite longitudinal edges. Extending between the edges of the front and back panels 102, 104 is a first side panel 105 integrally formed with front and back panels 102, 104 and connected by fold lines 109, 109′. Integrally formed with the opposite edge of the front panel 102 to which the first side panel 105 is connected is a second side panel 110 extending therealong, connected to the front panel 102 by fold line 107. Integrally formed with the opposite edge of the second side panel 110 to which the front panel 102 is connected is a securement tab 120. The securement tab 120 is connected to the edge of the second side panel 110 by fold line 111.

[0061] At the longitudinal ends of the front panel 102 and the back panel 104 are end regions 112, 114 at a first end, and end regions 116, 118 at the opposite end. The end regions 112, 114, 116, 118 are defined on the front 102 and rear 104 panels by respective fold lines 108, 108′, 108″, 108′″. Integrally formed with each end region 112, 114, 116, 118 are respective sealing regions 122, 124, 126, 128 connected to their respective end region 112, 114, 116, 118 by fold lines 107, 107′, 107″, 107′″. The sealing regions 122, 124, 126, 128 extend outwardly from their respective end regions 112, 114, 116, 118.

[0062] The first side panel 105 and second side panel 110 are provided with end regions 130, 132, 134, 136 at the ends thereof. End regions 132, 136 are located adjacent to the end regions 112, 114 and end regions 116, 118 respectively of the front and rear panels 102, 104. End regions 130, 134 are located adjacent end region 112 and end region 116 respectively of the front panel 102. Furthermore, each side panel end region 130, 132, 134, 136 includes a triangular fold-line assembly 140, 140′, 140″, 140′″.

[0063] After forming blanks 4, 4′ etc. within the packaging material 2, the packaging material 2 is subsequently folded to form a tubular container 200 as illustrated in FIG. 3. Container 200 is formed by folding along the fold lines formed in the packaging material 2 which defines the panels 102, 104, 105, 110 of the blanks 4, 4′ etc. The fold lines are folded in a constant direction and the defined securement tab 120 is secured to an inner surface of back panel 104. The folding of the packaging material 2 to form the tubular container 200 results in sealing regions 122, 16 of the front panel 102 of each blank 4, 4′ etc. being positioned opposite to the respective sealing regions 124, 128 of the back panel 104.

[0064] FIG. 3 further illustrates the position of a product 202 within the tubular container 200. The product 202 is located on an inner surface of either the front panel 102 or the back panel 104 of a blank 4 prior to folding the packaging material using the abovementioned method. In doing so, the packaging material 2 may be folded about the product 202 to form a tubular container 200 housing the product 202. In the illustrated embodiment, the tubular container 200 comprises a plurality of connected blanks 4, 4′. In such embodiments, there is provided a product 202 on a panel 102, 104 of each blank 4, 4′ formed in the packaging material 2. In this way, the tubular container 200 encloses a plurality of products 202.

[0065] The method described above mimics conventional flow-wrapping methods. However, it is envisaged that the product 202 may be located within the tubular container 200 subsequent to it being formed by slotting the product 202 into an open end of the container 200.

[0066] To complete the wrapping process, and in doing so forming a packaging 300, adjacent surfaces of sealing regions 122, 124 and sealing regions 126, 128 are sealed together to form sealed end regions.

[0067] To assist in the sealing of sealing regions 122, 124, 126, 128, an adhesive strip is applied to at least one of the sealing regions 122, 124 and to at least one of sealing regions 126, 128. The adhesive strip may be applied to the blank 4 prior to folding the packaging material 2, or applied to the sealing regions 122, 124, 126, 128 of each blank 4, 4′, after forming the tubular container 200 from the packaging material 2. The adhesive strip 200 may comprise a hot melt adhesive or other suitable adhesive. In other embodiments the sealing regions are heat welded without the use of an adhesive.

[0068] This process is repeated for the sealing regions of each blank 4, 4′ which is formed in the packaging material 2. In this way, the tubular container 200 now comprises a series of connected sealed compartments each enclosing a single product 202. To form the packaging 300, as illustrated in FIG. 3, the series of sealed compartments are separated by, forming cuts across adjacent sealed regions of adjacent sealed compartments.

[0069] The formed packaging 300 encloses a single product 202 and comprises sealed end regions in the form of fin seals 302, 304. The formed packaging also includes gabled end regions 306, 308, 310, 312. The gabled end regions 306, 308, 310, 312 are formed during the sealing of the regions 122, 126 and 124, 128 by folding end regions 130, 132, 134, 136 of the first and second side panels 105, 110 about their respective triangular fold-line assemblies 140, 140′, 140″, 140′″. The triangular fold line assemblies 140, 140′, 140″, 140′″ enable the folding of the end regions 130, 132, 134, 136 without affecting the orientation of the first and second side panels 105, 110 which remain substantially perpendicular to the front panel 102 and rear panel 104. In this way, a packaging 300 is formed enclosing a product 202 therein comprising a configuration which mimics conventional flow-wrapped packaging. The packaging 300 maybe decorated in any suitable manner with branding and artwork, which will enable masking the cartonboard appearance, further helping to give the packaging the impression of being produced in a flow-wrap process.

[0070] As the sealing regions 122, 124, 126, 128 are secured together, they may also be embossed using suitable sealing jaw patterns, in order to provide an embossed pattern. In alternative embodiments, an image of an embossing pattern may be printed on the sealing regions 122, 124, 126, 128 in place of actual embossing of the regions.

[0071] In some embodiments, the packaging material 2 may be separated into individual blanks 4, 4′ etc. by forming cuts along edges 5 and 6 before the packaging material 2 is folded about the products 202. It is envisaged that the individual blanks 4, 4′ may be loaded onto a conventional horizontal or vertical fill, form and seal process apparatus after being divided, rather than loading a sheet of packaging material 2 onto the apparatus and subsequently dividing a formed tubular container.

[0072] FIG. 5 illustrates a conventional horizontal fill, form and seal apparatus 400 which may be used to perform the method in accordance with the present invention. The apparatus 400 comprises a loading station 402, wrapping station 404, sealing station 406 and cutting station 408.

[0073] Loading station 402 comprises a conveyor 410 operable in use to transport items 202. Sealing station 406 includes a clamp 409 operable in use to aid in the sealing of surfaces of packaging material 2. Cutting station 408 includes a guillotine 411 operable in use to form cuts within the packaging material 2 to divide the packaging material 2 into individual packages.

[0074] In use, the apparatus 400 is initially loaded with packaging material 2. In the illustrated embodiment, the packaging material 2 has been subjected to laser scoring prior to being loaded onto the apparatus 400. The laser scoring is performed by a laser cutter which forms fold lines and/or cuts within the packaging material 2 (in accordance with the method illustrated by FIG. 1).

[0075] The packaging material is loaded onto the apparatus 400 and wrapped around driving cylinders 414, 415, 416. The driving cylinders 414, 415, 416 are operable in use to move the packaging material 2 through the apparatus 400.

[0076] Initially, the sheet of packaging material 2 is moved through the wrapping station 404 where it is wrapped around products 202 located on the conveyor 402. The packaging material 2 is subsequently sealed along an edge such that it forms a partially sealed tubular container 200 (as illustrated in FIG. 3) enclosing a plurality of products 202. The tubular container 200 is then passed through the sealing station 406 wherein the regions of the tubular container 200 between adjacent products 202 are sealed together. This is achieved using clamp 409 which applies pressure to the outer surfaces of the tubular container 200. Applying pressure to the outer surfaces of tubular container 200 activates pressure sensitive adhesives (not shown) located on at least one inner surface of the tubular container 200. The adhesives may be applied prior to loading the packaging material 2 onto the apparatus 400, such as during the scoring of the packaging material 2, or within the sealing station 406 itself.

[0077] The tubular container 200, having sealed regions between the locations of adjacent products 202 is subsequently passed through the cutting station 408. The cutting station 408 divides the container 200 into formed packages 300 by cutting transversely across the container 200 along adjacent sealed regions. This forms a package 300 enclosing a product 202 having sealed end regions

[0078] The apparatus 400 further comprises a second conveyor 412 operable in use to transport the formed packaging 300 away from the cutting station 408.

[0079] In the embodiment of the apparatus 400 shown in FIG. 4, the packaging material 2 is scored prior to loading the packaging material 2 onto the apparatus 400. However, it is envisaged that other embodiments of the apparatus may be employed to perform the claimed method wherein there is provided a scoring station operable in use to form fold lines and/or cuts within the packaging material 2 and forms part of the apparatus 400. The scoring station may be located after driving cylinders 414, 415, 416, for example.

[0080] A further embodiment of a blank 500 as produced using a method in accordance with the present invention is illustrated in FIG. 6. The blank 500 includes a front panel 502 having opposite longitudinal edges. Extending along a first edge of the front panel 502 is a first side panel 505 integrally formed with front panel 502 and connected by connecting region 540. The connecting region 540 is formed integrally with the front panel 502 and side panel 505 along opposing edges by fold lines 506, 506′. Integrally formed with the opposite edge of the front panel 502 to which the first side panel 505 is connected is a second side panel 510 extending there along, connected to the front panel 502 by a second connecting region 542. The connecting region 542 is formed integrally with the front panel 502 and side panel 510 along opposing edges by fold lines 509, 509′. Integrally formed with the opposite edges of the first and second side panels 505, 510 to which the front panel 502 is connected are sealing tabs 520, 520′. The sealing tabs 520, 520′ are connected to the edges of the first and second side panels 505, 510 by respective fold lines 511, 511′.

[0081] At the longitudinal ends of the front panel are end regions 512, 516. The end regions 512, 516 are connected to the front 502 panel by third and fourth connecting regions 541, 543. The connecting regions 541, 543 are formed integrally with the front panel 502 and respective end regions 512, 516 along opposing edges which are defined by fold lines 507, 507′, 508, 508′.

[0082] The first side panel 505 and second side panel 510 are provided with end regions 530, 532, 534, 536 at the ends thereof. End regions 530, 532 are located adjacent to the end region 512 and end regions 534, 536 are located adjacent end region 516. Furthermore, there is also provided triangular fold line assemblies 550 connecting each of the connecting regions 540, 541, 542, 543.

[0083] The blank 500 illustrated in FIG. 6 may be used in the same way as described above with reference to FIG. 5. The blank 500 is specifically designed to be used to wrap products which have a triangular cross section, rather than those with a rectangular cross section as illustrated in FIG. 5.

[0084] FIG. 7 illustrates an embodiment of a packaging 600 formed using the blank as shown in FIG. 6. The packaging 600 encloses a single product which comprises a triangular cross section and includes sealed end regions in the form of fin seals 602, 604. The embodiment of the packaging 600 illustrated in FIG. 7 also comprises embossing applied to the fin seals 602, 604 for decorative purposes. Furthermore, fin seals 602 further includes cut out regions 608 located along an edge, also for decorative purposes.

[0085] The above embodiments are described by way of example only. Many variations are possible without departing from the scope of the invention as defined in the appended claims.