Card Based Package for Sensitive Materials

Abstract

A card-based package for sensitive food products, comprises a container portion defining an interior space with a base and a sidewall extending to an upper peripheral edge for receiving a removable seal for hermetically sealing the container portion prior to use. The package further comprises a lid structure, that can open and close to allow selective access to the interior space after removal of the seal. The container portion and the lid structure are both formed of card-based material and at least the container portion has light, oxygen, and water vapour barrier properties sufficient for storage of the product for a period exceeding 24 months.

Claims

1. A card-based package for sensitive food products, comprising: a container portion, the container portion defining an interior space for receiving the product and having a base and a sidewall extending to an upper peripheral edge for receiving a removable seal for hermetically sealing the container portion prior to use; a lid structure, that can open and close to allow selective access to the interior space after removal of the seal, wherein the container portion and the lid structure are formed of card-based material and at least the container portion has light, oxygen, and water vapour barrier properties sufficient for storage of the product for a period exceeding 24 months.

2. The package according to claim 1, wherein the sidewall card-based material comprises at least 90 wt % paper and has at least one polyethylene (PE) layer or polyvinyl alcohol (PVOH) layer, and a metal layer.

3. The package according to claim 1 or claim 2, wherein the sidewall has an oxygen transmission rate (OTR) of less than 0.5 cc/m.sup.2/day, preferably less than 0.3 cc/m.sup.2/day and more preferably less than 0.1 cc/m.sup.2/day (ASTM D3985-17en).

4. The package according to any one of the preceding claims, wherein the sidewall has a water vapour transmission rate (WVTR) of less than 0.5 g/m.sup.2/day, preferably less than 0.3 g/m.sup.2/day and more preferably less than 0.1 g/m.sup.2/day (ASTM F1249-20).

5. The package according to any one of the preceding claims, wherein the sidewall has a light transmission in the 300 nm to 700 nm range of less than 0.5%, preferably less than 0.2% (ISO 2471:2008).

6. The package according to any one of the preceding claims, wherein the sidewall comprises an outer structural layer comprising predominantly cellulose material and an inner hygienic layer of a food quality polymer material.

7. The package of claim 6, wherein the inner hygienic layer has a thickness of less than 20 microns, preferably between 2 microns and 20 microns.

8. The container according to any one of the preceding claims, wherein the sidewall comprises an oxygen barrier layer, preferably laminated between an outer structural layer and an inner hygienic layer.

9. The package according to any one of the preceding claims, wherein the sidewall comprises greater than 90 wt % paper.

10. The package according to any one of the preceding claims, wherein the lid structure comprises greater than 95 wt % paper, preferably greater than 97 wt % paper.

11. The package according to any one of the preceding claims, wherein the lid structure comprises a collar portion connected to the upper peripheral edge and a lid portion, hingedly connected to the collar portion.

12. The package according to claim 11, wherein the collar portion comprises a functional insert, including one or more functionalities selected from the group consisting of: scoop leveler, scoop holder, latch, stiffening flange, insect barrier and sealing surface.

13. The package according to claim 11 or claim 12, wherein the lid portion further comprises a gasket located at an underside of the lid and having a resilient edge.

14. The package of any one of the claims 11 to 13, further comprising a locking arrangement between the lid portion and the collar portion

15. The package of any one of claims 11 to 14, further comprising a paper banderol provided prior to use around at least part of the collar portion and the lid portion.

16. The package of claim 15, wherein a circumferentially extending section of the banderol is removable to form a hinge between the lid portion and the collar portion.

17. The package of any one of claims 11 to 16, further comprising a scoop holder, preferably located on an underside of the lid portion.

18. The package of any one of the preceding claims, further comprising a scoop located within the lid structure.

19. The package of any one of the preceding claims, wherein the base and sidewall are joined together, preferably in a folded seam.

20. The package according to any one of the preceding claims, wherein the upper peripheral edge of the container comprises a circumferential flange extending outwards from the container.

21. The package of any one of the preceding claims, wherein the container portion is a tube of a constant first outer cross-section.

22. The package of any one of the preceding claims, further comprising an outer sleeve, surrounding the container portion.

23. The package of claim 22, wherein the container portion has a first outer dimension, and the lid structure has a second outer dimension that is larger than the first outer dimension and the sleeve tapers from the first to the second outer dimension.

24. The package of any one of the preceding claims, wherein the lid structure can be repeatedly closed, ensuring no gaps of greater than 150 microns, preferably less than 100 microns and more preferably less than 70 microns.

25. The package of any one of the preceding claims, further comprising a removable seal hermetically sealing the container prior to use.

26. The package according to claim 25, further comprising an amount of powdered infant nutrition sealed within the interior space.

27. The package according to claim 26, where the interior space contains an inert gas with less than 2% oxygen, preferably less than 1.5% oxygen and more preferably, less than 1% oxygen.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Embodiments will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts.

[0056] FIG. 1 shows a perspective view of a package according to an embodiment of the present invention.

[0057] FIG. 2 is a partially exploded view of the package of FIG. 1.

[0058] FIG. 3 shows a cross-section through a segment of the sidewall of the container portion of FIG. 1.

[0059] FIG. 4A shows a cross-sectional view through the collar portion of FIG. 2 on the sagittal plane X-Z.

[0060] FIG. 4B shows a top view of the collar portion of FIG. 2.

[0061] FIG. 4C show a top view of the collar portion of FIG. 2 with a functional insert according to an alternative configuration.

[0062] FIG. 5A shows an exploded view of the lid portion of FIG. 2.

[0063] FIG. 5B shows a cross-section through the lid portion on the sagittal plane X-Z.

[0064] FIG. 6A shows a cross-section through the package of FIG. 1 on the sagittal plane X-Z.

[0065] FIG. 6B shows a closeup of part of the closure between the lid portion and collar portion from FIG. 6A.

[0066] FIG. 7 shows a perspective rear view of the package of FIG. 1 with the lid portion partially open.

[0067] FIG. 8 shows a cross-sectional view of the package of FIG. 1 stacked with another package.

[0068] The figures are meant for illustrative purposes only, and do not serve as restriction of the scope or the protection as laid down by the claims.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0069] The following is a description of certain embodiments of the invention, given by way of example only and with reference to the figures.

[0070] FIG. 1 shows a card-based package 10 for powdered infant nutrition according to the present invention, comprising a container portion 20 and a lid structure composed by a collar portion 30 and a lid portion 40. The package 10 further comprises a banderol 50 surrounding the collar portion 30 and part of the lid portion 40, which is present prior to first use to guarantee sealing during storage and transportation.

[0071] FIG. 2 is a partially exploded view of the card-based package 10 of FIG. 1 illustrating the arrangement of the individual portions. The package 10 has a longitudinal axis X-X, by which may be defined a transverse plane X-Y and a sagittal plane X-Z. In the following, reference to upper, lower, top, bottom etc. is given with respect to the package 10 in its upright condition, with the axis X-X arranged vertically.

[0072] The container portion 20 comprises a container 21 with a tubular body, having a base 22 and a sidewall 23 extending upwards to an upper peripheral edge 24 to define an interior space S for receiving the powdered infant nutrition. The upper peripheral edge 24 comprises a circumferential flange 25 extending outwards from the container 21, to connect to the collar portion 30 and to receive a removable seal 26. The removable seal 26 hermetically seals the container prior to use and may be removed partially or completely by the user to have access to the interior space S. An outer sleeve 28 surrounds the container portion.

[0073] The collar portion 30 comprises, at the bottom, a connection segment 31; and at the top, an upper peripheral closure rim 32 defining an access opening O to the interior space S of the package 10. The collar portion 30 has a height of around 35 mm in the illustrated embodiment but it will be understood that this may be adapted according to requirements. The height of the collar portion 30 defines an additional inner space above the container 21 that allows for the presence of additional optional elements inside the package 10, for example, an informational leaflet and/or scoop.

[0074] In the package presented in FIG. 2, the collar portion 30 includes a functional insert 33. Insert 33 comprises scoop levelers 34 and detent 72. FIGS. 3A and 3B, described below, show two examples of the insert 33 configured with different functionalities.

[0075] The banderol 50 is a narrow band of paper material having a height of around 35 mm corresponding to that of the collar portion 30. In this view it can be seen to further comprise two circumferential lines of weakness 52 that define a removable strip 51. When the package is to be used for a first time, the strip 51 can be removed to allow the lid portion 40 to be open. The strip 51 may have a contrasting colour, to that of the underlying collar portion 30, that functions as tamper evidence and includes grasping tabs 54, that facilitate its removal.

[0076] The lid portion 40 provides a closure to the package 10 and includes a locking element 71. Further details on the construction of the lid portion 40 are described below with reference to FIG. 4.

[0077] FIG. 3 shows a cross-section through a segment of the sidewall of the container portion of FIG. 1. The inner hygienic layer 110 is uppermost. This is a thin polymer layer (e.g., PE) having a thickness of 20 microns. It will be understood that these dimensions are exemplary, and FIG. 3 is not to scale.

[0078] Beneath the inner hygienic layer 110 is an oxygen barrier layer 120, which comprises a metalized film 122 and a polymer (e.g., EVOH) barrier film 124. At the outer side of the oxygen barrier layer is an outer structural layer 130. In the illustrated embodiment, the outer structural layer 130 is comprised of an outermost card layer 136, an adhesive layer 134 and a thin paper layer 132.

[0079] In the illustrated exemplary embodiment of FIG. 3, the thin paper layer 132 is delivered from a roll to a deposition station where EVOH is spray coated as an aqueous dispersion and subsequently dried to a thickness of 15 micron. The metalized film 122 is then applied by vapour deposition onto the EVOH layer to a thickness of 5 micron. Finally, the inner hygienic layer 110 is applied by spray coating over the metallized film 122. In a subsequent lamination step, the coated, thin paper layer 132 and the outermost card layer 136 are assembled together with the adhesive layer 134 to form a continuous laminate of sidewall material.

[0080] FIG. 4A shows a cross-sectional view through the collar portion 30 of FIG. 2 on the sagittal plane X-Z. The insert 33 comprises a die-cut plate of card material, with an aperture O corresponding to the package access opening. It is connected to the collar portion 30 by a folded seam that forms the upper peripheral closure rim 32. As can be seen in this view, the upper peripheral closure rim 32 has a slightly smaller outer cross-section that the rest of the collar portion 30. At a lower part of the collar portion 30, groove 35 is formed between two corrugations of the card material. The groove 35 and corrugations extend circumferentially completely around the connection segment 31 of the collar portion 30. The detent 72 is formed by a portion of the insert 33 folded upwards out of the plane of the insert 33 into a triangular or prismatic form. The insert 33 is also folded over at the position of the scoop levelers 34 to give additional strength to the edge that is intended for levelling.

[0081] FIG. 4B and FIG. 4C show top views of the collar portion 30 of FIG. 2 with two possible configurations of insert 33. In the configuration of FIG. 4B, the insert 33 comprises two scoop levelers 34 extending inwards at two corners of the insert 33 at either side of the detent 72. In the case of the configuration shown in FIG. 4C, the insert 33 is provided with scoop levelers 34 and a scoop holder 61 to receive a scoop 60.

[0082] FIG. 5A shows an exploded view of the lid portion 40 according to the package of FIG. 2. The lid portion 40 comprises a frame 42 and a lid 41. The lid 41 is formed as a die-cut plate of card, shaped to be bowed upwards in the central region 47. A supplementary plate 45 is provided at an underside of the lid portion 40 and has the same general shape as the lid 41, also being bowed upwards. The supplementary plate 45 has different functions. In this example, the supplementary plate 45 reinforces the lid 41 providing the lid portion 40 with a more durable and solid construction. Furthermore, the supplementary plate 45 is configured to include scoop holder 61 to have easy access to a scoop after opening the lid portion 40. Finally, in the closed position of the lid 41, a resilient edge 48 of the supplementary plate 45 has the function of a gasket to improve the closure of the lid portion 40. Further details of the gasket function are described below with reference to FIGS. 5B and 6.

[0083] FIG. 5B shows a cross-section through the lid portion on the sagittal plane X-Z. The frame 42 is connected to the lid 41 by a folded seam, which forms an upwardly extending stacking rim 44 at the top of the lid portion. The frame 42 also extends downwards to a closure skirt 43 having a larger cross-section than the stacking rim 44. In this view, it can be seen that the upwardly bowed central region 47 forms a cavity C with a height h corresponding to a height of the frame 42. The cavity C created beneath the lid 41 provides additional space for storing elements such as a scoop or the like.

[0084] The central region 47 of the lid 41 is in direct contact with and adhesively connected to the supplementary plate 45. The resilient edge 48 of the supplementary plate 45 is bowed downwards and floating with respect to the edge of the lid 41. This configuration allows the resilient edge 48 to flex. On a region of the lid portion 40, between the stacking rim 44 and the cavity C, a locking element, in this case a latch 71, is pivotally mounted through the lid 41 and supplementary plate 45. An upper part 73 of the latch 71 extends upwardly from the lid 41, while the lower part 74 has a slit 75 and extends downwards under the supplementary plate 45. A cover 76 is adhesively connected to the upper part 73 to retain it to the lid 41.

[0085] FIGS. 6A and 6B show a partial cross-section through the package of FIG. 1 on the sagittal plane X-Z.

[0086] In FIG. 6A is shown the container 21 of the container portion 20. The container 21 is made from a card blank, joined to itself in a longitudinal seam (not shown) to form a tube with constant outer cross-section. At its bottom, the base 22 and the sidewall 23 of the container 21 are joined together by a folded seam which closes the lowest part of the container 21 and forms a base rim 27 extending downwardly and having the same outer cross-section as the container 21. At the top of the container portion 20, the sidewall 23 is rolled over outwardly from the upper peripheral edge 24 of the container 21 to form the circumferential flange 25. In this embodiment, the seal 26 is placed on almost the entire surface defined by the circumferential flange 25, which forms an uppermost edge of the sidewall 23. The seal 26 ensures appropriate hermetic sealing of the container 21 prior to use. FIG. 6A also shows an alternative position for a seal 26 that may be located lower down the sidewall 23 at the upper peripheral edge 24. This alternative position may allow slightly greater headspace below the lid 41 and permits alternative joining techniques between the sidewall 23 and the seal 26. The collar portion 30 is connected to the container portion 20 by a snap-fit joint formed between the circumferential flange 25 and the circumferentially extending groove 35. Additionally, the joint between the collar portion 30 and the container portion 20 may be glued together to ensure proper permanent sealing.

[0087] An outer sleeve 28 made or card-based material 28 surrounds the container portion 20. The sleeve 28 is made from a card blank, similar to the sidewall 23 of the container 21, joined to itself in a longitudinal seam (not shown) to form a tube. The outer sleeve 28 is connected to the bottom part of the collar portion 30 and to the upper peripheral edge 24 by an inwards double bent of its sidewall and forming a squared edge that covers the bottom inner side of the collar portion 30 and the flange 25 of the container portion 20, as shown in FIG. 6A.

[0088] At the top of the container 21, the outer sleeve 28 provides the package with a larger outer dimension at the container portion 20, approximately the same to the outer dimension of the collar portion 30. In the exemplary embodiment of FIG. 6A, the outer sleeve extends downwardly with a decreasing outer dimension and towards the bottom of the container portion 20 stopping just before the base rim 27 and approaching to its outer dimension.

[0089] FIG. 5A also shows a scoop 60 stored in the space formed above the seal 26 by the collar portion 30 and the lid portion 40 and held by the scoop holder 61 in supplementary plate 45. The banderol 50 extends circumferentially around the outer surface of the collar portion 30 and the closure skirt 43 of the lid portion 40.

[0090] In the closed position of the lid portion 40, as shown in FIG. 5B, the closure skirt 43 covers the outer circumferential surface of the upper peripheral closure rim 32, forming a joint between the lid portion 40 and the collar portion 30. The folded seams of the closure skirt 43 and the upper peripheral closure rim 32 ensure that these elements are relatively rigid and can form a tight interference fit. Importantly, high manufacturing tolerances can be achieved ensuring that any gaps are smaller than 70 microns, ensuring adequate insect-tightness. The closure is further improved by the supplementary plate 45. The resilient edge 48 acts as a gasket, flexing into engagement with the upper peripheral closure rim 32. The resilient edge 48 also extends to meet the closure skirt 43, providing additional support for the resilient edge 48 and further enhancing the gasket function.

[0091] In the locked position of the lid portion 40, as shown in FIG. 5B, the detent 72 resides in the slit 75 of the latch 71, effectively retaining the lid portion 40. To unlock the lid portion 40, the upper part 73 of the latch 71 is pushed radially outwards, acting as a lever arm such that the slit 75 releases the detent 72. A pulling movement upwards on the lid portion 40 allows a user to open the package 10.

[0092] FIG. 6 shows a perspective rear view of the package of FIG. 1 with the lid portion 40 partially open after the removal of strip 51. Removing the strip 51 from the banderol 50 releases the joint between the lid portion 30 and the lid portion 40 and forms a hinge 53. The hinge 53 secures the lid portion 40 to the collar portion 30 after the seal 26 has been removed from the container portion 20.

[0093] FIG. 7 shows a cross-sectional view of the package of FIG. 1 stacked with another package. The stacking rim 44 of the first package 10 fits radially outside the base rim 27 of the second package 10, while the base 22 of the second package 10 rests on the top the lid portion 40 of the first package. It can also be seen that there is adequate space for the latch 71 to fit radially inwards of the base rim 27, while the upwardly bowed central region 47 of the lid 41 fits beneath the base 22. This requires that the base rim 27 also extends downwards a distance greater than h below the base 22.

[0094] The invention has been described by reference to certain embodiments discussed above. It will be recognized that these embodiments are susceptible to various modifications and alternative forms well known to those of skill in the art. In particular, both the locking arrangement and the scoop holder may be distinct from the schematically illustrated design. Accordingly, although specific embodiments have been described, these are examples only and are not limiting upon the scope of the invention.