WO2025114435A1

WO2025114435A1 - Paperboard based container

Info

Publication number: WO2025114435A1
Application number: PCT/EP2024/083913
Authority: WO
Inventors: Lars Jonas JØRGENSEN NARVHUS; Anders STRÅLIN
Original assignee: Elopak Asa
Current assignee: Elopak Asa
Priority date: 2023-11-28
Filing date: 2024-11-28
Publication date: 2025-06-05
Anticipated expiration: 2026-05-28
Also published as: NO349058B1; NO20231294A1

Abstract

A blank (100) for making a container (1) for holding a pourable product, the blank comprising a first area (225) and a second area (250), wherein the first area (225) and the second area (250) are complementary; wherein the blank (100) is made from a laminated material (10), the laminated material(10) comprising, from an internal side to an external side of the blank (100) a bulk layer (12); a first polymer layer (13), located at least in the first area (225); and a second polymer layer (14) located exclusively in the second area (250); or a bulk layer (12); a second polymer layer (14) located exclusively in the second area (250); and a first polymer layer (13), located at least in the first area (225); wherein the second polymer layer (14) and optional first polymer layer (13) have an average thickness t250 in the second area (250); wherein the first polymer layer (13) has an average thickness t225 in the first area (225); and wherein t250>t225; a container, a method of manufacture of a blank and a product obtainable by the manufacturing method.

Description

PAPERBOARD BASED CONTAINER

Field of the invention

The present invention relates to a blank and a container for holding a pourable food product. The invention further relates to a method for manufacturing the blank.

Background

Within the art of paperboard-based packaging, it is known to produce a blank which is folded and assembled to produce a container. The container may then be utilised to hold a pourable food product, e.g. a liquid, e.g. dairy products, such as milk or yoghurt, or juices.

The blank is typically produced from a laminated packaging material, which typically comprises a multi -ply paperboard sheet on which is laminated one or a plurality of barrier layers for holding the food product and/or prevent migration of air and flavours through the paperboard.

A method of producing the blank from the laminated packaging material typically comprises the steps of cutting the laminated packaging material to a predefined shape, and a method of producing the container from the blank typically comprises the step of folding the blank along predefined folding lines to produce the container.

The blank may be provided with crease lines in the laminated packaging material to aid folding of the blank along the folding lines. A crease line, or crease, may be defined as an embossed or impressed depression on one side of the laminated packaging material with a corresponding raised ridge or welt, also referred to as the bead, on the other side forming a line along which the laminated packaging material is structurally weakened and along which the laminated packaging material will bend or fold when pressure is applied.

Alternatively, a paperboard-based container may be produced in a roll-fed process in which a continuous web of laminated packaging material is fed to a filling machine, folded and sealed longitudinally to form a tube. The tube is then filled with the pourable food product, sealed and cut transversally to form so called pouches. The pouches are then provided with an opening device and manipulated to obtain its final form. Said manipulation typically involves folding down and securing sections of the container to side panel section of the same.

The container may be provided with an opening arrangement allowing a consumer to open the container to access the food product. In the prior art, it is known to use plastic opening arrangements, such as arrangements comprising plastic pour spouts and lid portions. A particular advantageous opening arrangement for such containers is based on the known half-cut method. Details of the half-cut method are disclosed in EP1786618B1. The major advantage of the half-cut method is that the barrier layer is fully intact until the container is opened by an end user. Another advantage of the half-cut method during production is that the laminated material may initially be produced as a homogenous sheet without any cutouts. In similar methods for obtaining an opening having an intact barrier layer, the paperboard is provided with openings before lamination and at least the barrier layer is subsequently laminated over the paperboard including the openings.

In recent years, society has focused on preventing the generation of waste while encouraging the reuse, recycling, and other means of recovering waste. This is also the case for the packaging industry. In order to improve the sustainability properties of laminated material, blanks and container, a focus of the industry has been to replace aluminium as an oxygen barrier with more environmentally friendly materials.

However, there is still a lot of room for improvement in terms of sustainability for the laminated material, blanks and container as a whole. An object of the present invention is to provide laminated material, blanks and container having improved sustainability properties.

SUMMARY OF THE INVENTION

The present invention is defined by the appended claims and in the following:

In a first aspect, the invention relates to a blank for making a container for holding a pourable product, the blank comprising a first area and a second area, wherein the first area and the second area are complementary; wherein the blank is made from a laminated material, the laminated material comprising, from an internal side to an external side of the blank: a bulk layer; a first polymer layer, located at least in the first area; and a second polymer layer located exclusively in the second area; or a bulk layer; a second polymer layer located exclusively in the second area; and a first polymer layer, located at least in the first area; wherein the second polymer layer and optional first polymer layer have an average thickness t250 in the second area; wherein the first polymer layer has an average thickness t225 in the first area; and wherein t250>t225.

As used herein, the term “complementary” means that the first area and the second area together cover the complete area/surface of the blank. In other words, the first and the second area add up to cover the complete area/surface of the blank.

When describing the laminated material comprising as layers of a layer sequence, in a direction from an external side to an internal side of the laminated material, the internal side is the side refers to the side intended to face the inside of the container formed from the laminated material.

In an embodiment, the blank is oriented so that the internal side of the blank is on the internal side of the container. t250 is the average thickness of the second polymer layer and optional first polymer layer in the second area.

This means that

- when the first polymer layer is not present in the second area, t250 is the average thickness of the second polymer layer in the second area; and

- when the first polymer layer is present in the second area (independent of the order of the first and second polymer layer), t250 is the average thickness of the cumulated first and second polymer layer in the second area.

As used herein, the term “average thickness” refers to the arithmetic mean of the thickness over the designated area.

The average thickness may be measured by taking a sample of the blank or of a container made from the blank and measuring the thickness at least at 3 different points.

The thickness of a laminate sample may be measured by : cutting a sample of laminate using a microtome; and measuring the cross section of the layer(s) of interest in the laminate using an optical light microscope.

Any other method known in the art for measuring thickness or grammage may be used. As examples and depending on the range of the measurement calipers, gauges, micrometers, comparators... may be used. Grammages and thicknesses of layers may also be determined according to the official test method of ISO 536:2019 by the unit g/m², while thickness and density may also be determined according to ISO 534:2011, by the units pm (m) and kg/m³, respectively, within the limits described in these standards.

In an embodiment, t250 may be over 110% of t225, i.e. t250 > 120% t225; t250 > 120% t225; t250 > 130% t225; t250 > 140% t225; t250 > 150% t225; t250 > 200% t225; t250 > 250% t225; or t250 > 300% t225.

In an embodiment, t250 may be between 110% and 1000% of t225, between 150% and 500% of t225, or between 200% and 300% of t225.

The first area may be the area of the blank that correspond to the surface of the container that is exposed to the outside when the blank is folded to produce the container. In other words, the first area may be the area in which no sealing takes place. In an embodiment the first polymer layer may be located exclusively in the first area. In other words, in this embodiment, the blank may be made from a laminated material, the laminated material comprising, from an internal side to an external side of the blank: a bulk layer; a first polymer layer, located exclusively in the first area; and a second polymer layer located exclusively in the second area.

In other words, in this embodiment, the first and second polymer layers may be located side by side, on top of the bulk layer.

In an embodiment the first polymer layer may also be located in the second area.

In an embodiment, the blank may be made from a laminated material, wherein the laminated material may comprise, from an internal side to an external side of the blank: a bulk layer; a first polymer layer, located in the first area and in the second area; and a second polymer layer located exclusively in the second area.

In other words, in this embodiment the first polymer layer may be located between the bulk layer and the second polymer layer.

In an embodiment, the blank may be made from a laminated material, the laminated material comprising, from an internal side to an external side of the blank: a bulk layer; a second polymer layer located exclusively in the second area; and a first polymer layer, located in the first area and in the second area.

In other words, in this embodiment the second polymer layer may be located between the bulk layer and the first polymer layer.

In an embodiment, the second area may be the area in which all sealing takes place. In an embodiment, the second area may be the area of the blank that is sealed where the blank is folded to produce the container.

In an embodiment, there may be no overlap between the sealing area and the barrier area.

In an embodiment, there may be overlap between the first and the second area. In an embodiment, the second area may be divided in a plurality of sub area. The second polymer layer in each sub area may be made of a different or identical material. The second polymer layer in each sub area may have a different or identical quantity of material. The second polymer layer in each sub area may have a different or identical average thickness.

The second area has an area A250 and an average thickness t250.

Each of the sub area of the second area has a respective area A251, A252, ... and an average thickness t251, t252, . . .

When the second area is divided in a plurality of sub area, the average thickness t250 may be calculated using the following equation:

In other words t251 t252 t250 =

.71251 71252

In an embodiment, the laminated material may comprise on an internal side of the bulk layer a third polymer layer.

In an embodiment, the third polymer layer may be a water barrier.

In an embodiment, the third polymer layer may comprise a polyolefin, such as polyethylene. In an embodiment, the third polymer layer comprises low density polyethylene (LDPE), linear low density polyethylene (LLDPE), metallocene linear low density polyethylene (mLLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), polypropylene (PP) or any blend thereof.

LDPE is a low density polyethylene with a density between 0.910 and 0.925 g/cm3.

LLDPE is a linear low density polyethylene with a density between 0.915 and 0.925 g/cm3.

MDPE is a medium density polyethylene with a density between 0.926 and 0.935 g/cm3.

HDPE is a high density polyethylene with a density greater or equal to 0.936 g/cm3.

In an embodiment, the laminated material may comprise on an internal side of the bulk layer a gas barrier layer.

In an embodiment, the laminated material may comprise on an internal side of the bulk layer a gas barrier layer and then a third polymer layer.

In an embodiment, the gas barrier layer may comprise aluminium foil or a polymer. In an embodiment, the gas barrier layer may be made from a composition mainly comprising a polymer selected from the group consisting of ethylene vinyl alcohol (EVOH ), polyvinyl alcohol (PVOH), polyvinylidene chloride (PVDC), polyamide (PA), polylactic acid, cellulose derivatives, polysaccharides, polyhydroxyalkanoates (PHA), polysaccharide derivatives, graphene and combinations thereof.

Here the term mainly comprising may be interpreted as comprising at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95% or at least 99% of the material in weight.

In an embodiment, the gas barrier layer may be made from a composition consisting of a polymer selected from the group consisting of ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), polyvinylidene chloride (PVDC), polyamide (PA), polylactic acid, cellulose derivatives, polysaccharides, polyhydroxyalkanoates (PHA), polysaccharide derivatives, graphene and combinations thereof.

In an embodiment, the grammage of the gas barrier layer may be under 16 g/m². In an embodiment, the grammage of the gas barrier layer may be under 14 g/m², under 12 g/m², under 10 g/m², under 8 g/m², under 6 g/m², under 5 g/m², or under 4 g/m².

In an embodiment, the grammage of the gas barrier layer may be comprised between 1 g/m² and 16 g/m². In an embodiment, the grammage of the gas barrier layer may be comprised between 2 g/m2 and 10 g/m², between 2 g/m2 and 7 g/m², or between 3 g/m2 and 5 g/m².

In an embodiment, the laminated material may comprise an intermediate layer, between the bulk layer and the first or second polymer layer; and wherein the intermediate layer comprises a polymer binder material and a filler.

In an embodiment, the intermediate layer may be directly adjacent to the bulk layer

Here the skilled person will understand that when a layer is directly adjacent to another layer means that there is no layer between the two adjacent layers, on other words, they are in direct contact.

In an embodiment, the filler of the intermediate layer may be an inorganic filler.

In an embodiment, the filler of the intermediate layer may be a kaolin clay, a bentonite clay, talcum particles, silicate and/or calcium carbonate.

In an embodiment, the polymer binder material of the intermediate layer may be selected from the group consisting of vinyl acetate, styrene-butadiene copolymer (SB) latex, styrene acrylate copolymer (SA) latex, other latexes of acrylate polymers and copolymers, such as vinyl acrylic copolymer latex and vinyl acetate acrylate copolymer latex, and of bio-based polymer materials.

In an embodiment, the intermediate layer may comprise from 1 wt% to 90 wt% of filler.

In an embodiment, the intermediate layer may comprise from 1 wt% to 80 wt%, 1 wt% to 70 wt%, 1 wt% to 60 wt%, 1 wt% to 50 wt%, 1 wt% to 40 wt%, 1 wt% to 30 wt% or 1 wt% to 20 wt% of filler.

In an embodiment, the intermediate layer may comprise from 10 wt% to 90 wt%, 20 wt% to 80 wt%, 30 wt% to 80 wt%, 40 wt% to 80 wt% or 50 wt% to 80 wt% of filler.

In an embodiment, the intermediate layer may comprise from 10 wt% to 99 wt% of binder.

In an embodiment, the intermediate layer may comprise from 20 wt% to 99 wt%, 30 wt% to 99 wt%, 40 wt% to 99 wt%, 50 wt% to 99 wt%, 60 wt% to 99 wt%, 70 wt% to 99 wt% or 80 wt% to 99 wt% of binder.

In an embodiment, the intermediate layer may comprise from 10 wt% to 90 wt%, 20 wt% to 80 wt%, 20 wt% to 70 wt%, 20 wt% to 60 wt% or 20 wt% to 50 wt% of binder.

In an embodiment, the grammage of the intermediate layer may be comprised between 1 g/m² and 20 g/m². In an embodiment, the grammage of the intermediate layer may be comprised between 2 g/m² and 15 g/m², between 5 g/m² and 15 g/m², between 10 g/m² and 15 g/m².

In an embodiment, the intermediate layer may have a Bendtsen smoothness/roughness of less than 1000 ml/min. In an embodiment, the intermediate layer may have a Bendtsen smoothness/roughness of less than 800 ml/min, of less than 600 ml/min, of less than 500 ml/min, of less than 400 ml/min, or of less than 300 ml/min.

In an embodiment, the intermediate layer may have a Bendtsen smoothness/roughness of between 5 ml/min and 1000 ml/min, between 15 ml/min and 500 ml/min, between 50 ml/min and 300 ml/min.

The Bendtsen smoothness/roughness may be measured according to ISO 8791- 2:2013. In an embodiment, the first polymer layer may be the outermost layer in the first area. In other words, there may be no further layer on an external side of the first polymer layer.

In an embodiment, the first polymer layer may be the outermost layer in the second area. In other words, there may be no further layer on an external side of the first polymer layer.

In an embodiment, the second polymer layer may be the outermost layer in the second area. In other words, there may be no further layer on an external side of the second polymer layer.

In an embodiment, the first polymer layer may comprise a polyolefin, a polyethylene, a polyethylene copolymer, a styrene acrylate, or biobased polymer material.

In an embodiment, the first polymer layer may be present at most at a total amount of 10 g/m2 dry weight, at most at a total amount of 9 g/m2 dry weight, at most at a total amount of 8 g/m2 dry weight, at most at a total amount of 7 g/m2 dry weight, at most at a total amount of 6 g/m2 dry weight, at most at a total amount of 5 g/m2 dry weight, at most at a total amount of 4 g/m2 dry weight; or at most at a total amount of 3 g/m2 dry weight.

In an embodiment, the first polymer layer may be present at a total amount of from 0.2 to 10 g/m2 dry weight, from 0.5 to 5 g/m2, dry weight, or from 2 to 5 g/m2, dry weight.

In an embodiment, the second polymer layer may comprise a polyolefin, a polyethylene, or a polyethylene copolymer material.

In an embodiment, the second polymer layer may be present at most at a total amount of 20 g/m2 dry weight, at most at a total amount of 10 g/m2 dry weight, at most at a total amount of 9 g/m2 dry weight, at most at a total amount of 8 g/m2 dry weight, at most at a total amount of 7 g/m2 dry weight, at most at a total amount of 6 g/m2 dry weight, at most at a total amount of 5 g/m2 dry weight, at most at a total amount of 4 g/m2 dry weight; or at most at a total amount of 3 g/m2 dry weight.

In an embodiment, the second polymer layer may be present at a total amount of from 1 to 20 g/m2 dry weight, 1 to 10 g/m2, dry weight or from 6 to 9 g/m2, dry weight.

In an embodiment, the second area may comprise a first sealing sub area and a second sealing sub area. In an embodiment, the second area may consist of the first sealing sub area and the second sealing sub area.

In an embodiment, the first sealing sub area may be the area that is intended to be sealed to the outermost layer of the blank. The first sealing sub area may be made of polyethylene, styrene acrylate, biobased polymer, etc. In an embodiment, the second sealing sub area may be the area that is intended to be sealed to the innermost layer of the blank. In an embodiment, the second sealing sub area may be made of the same type of material as the polymer layer. In an embodiment, the second sealing sub area may comprise a polyolefin. In an embodiment, the second sealing sub area may comprise polyethylene. In an embodiment, the second sealing sub area may comprise HOPE, MDPE, LDPE and/or LLDPE.

In an embodiment, the polymer in the first sealing sub area (i.e. of the second polymer layer and the optional first polymer layer) may be present at a total amount of at most 20 g/m2, at most 10 g/m2, or at most 5 g/m2, dry weight.

In an embodiment, the polymer in the first sealing sub area (i.e. of the second polymer layer and the optional first polymer layer) may be present at a total amount of from 1 to 20 g/m2, 3 to 9 g/m2, dry weight or 4 to 6 g/m2, dry weight.

In an embodiment, the second polymer layer and the optional first polymer layer may have an average total thickness t251 in the first sealing sub area, and wherein the thickness t251 may be at most 20 pm, at most 10 pm, at most 9 pm, at most 8 pm, at most 7 pm, at most 6 pm, or at most 5 pm.

In an embodiment, the thickness t251 may be comprised between 1 and 20 pm, 3 and 9 pm or 4 and 6 pm.

In an embodiment, the polymer in the second sealing sub area (i.e. of the second polymer layer and the optional first polymer layer) may be present at a total amount of at most 20 g/m2, at most 10 g/m2, or at most 5 g/m2, dry weight.

In an embodiment, the polymer in the second sealing sub area (i.e. of the second polymer layer and the optional first polymer layer) may be present at a total amount of from 1 to 20 g/m2, 3 to 10 g/m2, dry weight, 6 to 9 g/m2, dry weight or 7 to 8 g/m2, dry weight.

In an embodiment, the second polymer layer and the optional first polymer layer may have an average total thickness t252 in the second sealing sub area, and wherein the thickness t251 may be at most 20 pm, at most 10 pm, at most 9 pm, at most 8 pm, at most 7 pm, at most 6 pm, or at most 5 pm.

In an embodiment, the thickness t252 may be comprised between 1 and 20 pm, 3 and 10 pm, 6 and 9 pm or 7 and 8 pm.

In a second aspect, the invention relates to a container for holding a pourable food product, made from the blank according to any of the previous claims, wherein the blank is oriented so that the internal side of the blank is on the internal side of the container. In an embodiment, the blank according to the first aspect of the invention or container according to the second aspect of the invention may comprise an opening arrangement, the opening arrangement configured such that a section of the laminated material defined by the cut is pushed or pulled during the first opening of the container, such that the laminated material is ruptured along the cut.

In an embodiment, the cut (or partial depth cut) may extend into the laminated material of the blank or into the container to a depth (De) being within the range of 10% to 95% of the total thickness (D) of the laminated material. In another embodiment, De may be between 20% and 90% of D. In another embodiment, De may be between 20% and 80% of D. In another embodiment, De may be between 30% and 70% of D. In another embodiment, De may be between 70% and 95% of D.

In an embodiment, the cut may extend into the blank or into the container at least partly through the paperboard layer, and at most partly into the intermediate layer. In other words, the cut does not extend through the gas barrier layer.

In an embodiment, the container may further comprise an opening arrangement, the opening arrangement configured such that a section of the laminated material defined by the cut is pushed or pulled during the first opening of the container, such that the laminated material is ruptured along the cut, yielding an opening in the container is obtained. The opening has a periphery corresponding to the cut

In an embodiment, the cut may extend into the laminated material substantially orthogonal to the outside surface of the laminated material.

In a third aspect, the present invention relates to a method of manufacturing a blank suitable for making a container for holding a pourable food product, the blank comprising a first area and a second area, wherein the first area and the second area are complementary; comprising the steps of a) providing a bulk layer; b) applying a first polymer layer on an external side of the bulk layer over the first area and optionally over a second area; c) applying a second polymer layer on an external side of the bulk layer over the second area; wherein steps b) and c) may be achieved in any order; and wherein the second polymer layer and optional first polymer layer have an average thickness t250 in the second area; wherein the first polymer layer has an average thickness t225 in the first area; and wherein t250>t225.

In an embodiment, the first polymer layer and/or the second polymer layer may be provided as a polymer dispersion.

In an embodiment, the first polymer layer and/or the second polymer layer may be applied by printing method such as rotogravure printing, fl exo printing, and/or inkjet printing and/or by a coating method such as reverse gravure roll coating and/or gravure coating.

When a polymer layer is applied covering the whole surface of the blank, any method known in the art may be used. Dispersion coating method may be advantageous to apply thin layers of polymer, especially thinner than by using extrusion coating or film lamination.

Printing methods may be advantageous for applying a layer to a specific area of the blank, i.e. not the total surface. Printing methods may also be used to apply a polymer layer to the whole surface of the blank.

Printing method may be advantageous to apply thin layers of polymer, especially thinner than by using extrusion coating.

In an embodiment, step b) is achieved after step c).

In an embodiment, step c) is achieved after step b).

The method may involve the manufacture of a blank comprising any of the other optional features as set out above in relation to the first aspect and/or the manufacture of a container comprising any of the other optional features as set out above in relation to the second aspect.

In a fourth aspect, the invention relates to a product obtainable by the method according to the third aspect of the invention. Short description of the drawings

In the following description this invention will be further explained by way of exemplary embodiments shown in the drawings:

Fig. l is a top view of a first embodiment of a blank.

Fig. 2 is a top view of a second embodiment of a blank.

Fig. 3 is a top view showing the folding of the blank according to Fig. 1 or 2 to prepare for bottom-sealing.

Fig. 4 is a perspective view of the container made from the blank according to Fig. 1 or 2 after having been bottom-sealed.

Fig. 5 is a perspective view from above of a gable-top container with the pour spout fitment applied thereto.

Fig. 6 is a cross-sectional view of a first example of a laminated material used in a blank.

Fig. 7 is a cross-sectional view of a second example of a laminated material used in a blank.

Fig. 8 is a cross-sectional view of a third example of a laminated material used in a blank.

Fig. 9 is a cross-sectional view of a fourth example of a laminated material used in a blank.

Fig. 10 is a cross-sectional view of a fifth example of a laminated material used in a blank.

Fig. 11 is a cross-sectional view of a sixth example of a laminated material used in a blank.

Fig. 12 is a cross-sectional view of a seventh example of a laminated material used in a blank.

Fig. 13 is a cross-sectional view of a eighth example of a laminated material used in a blank.

Fig. 14 is a cross-sectional view of a ninth example of a laminated material used in a blank.

Fig. 15 is a cross-sectional view of a tenth example of a laminated material used in a blank. Detailed description

In the following embodiments of containers will be described in more detail with reference to the drawings. However, it is specifically intended that the invention as defined in the claims is not limited to the embodiments and illustrations contained herein but includes modified forms of the embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the claims.

A carton blank 100 is disclosed in Fig. 1 and Fig. 2. The blank 100 is disclosed with the surface configured to form the outside surface of the container 1 facing the viewer.

The blank 100 is made from a multi -ply paper or paperboard sheet on which is laminated one or a plurality of barrier layers for holding content, e.g. a liquid, and/or prevent migration of air and flavour degrading substances through the sheet. At least portions of the blank may be coated with a layer of thermoplastic material allowing the container 1 formed from the blank to be sealed by plastic welding.

The blank 100 is generally rectangular and comprises a first, bottom edge 101, a second, top edge 103 and parallel, third and second, side edges 105, 107. The side edges 105 and 107 are linear and parallel, whereas the top and bottom edges 101 and 103 have an irregular shape. The blank 100 also comprises a plurality of crease lines defining folding lines along which the blank 100 is configured to be folded when formed into the carton.

The blank 100 comprises five panels, P1-P5, separated by longitudinal crease lines 102, 104, 106 and 108 defining folding lines extending across the panel 100 from the bottom edge 101 to the top edge 103. In the present embodiment, the longitudinal crease lines 102, 104, 106 and 108 are continuously, i.e. uninterrupted, and, consequently, extend longitudinally, i.e. vertically in Fig. 1, across the blank 100 between the bottom edge 101 and the top edge 103.

Each panel P1-P5 comprises a first sub-panel 110, 112, 114, 116, 118 forming a bottomclosure sub-panel, a second sub-panel 120, 122, 124, 126, 128 forming a wall section subpanel, and a third sub-panel 130, 132, 134, 136, 138 forming a top-closure sub-panel. The bottom closure sub-panels 110, 112, 114, 116 and 118 are configured to form a bottom closure of the carton, and the top-closure sub-panels 130, 132, 134, 136, 138 a top closure of the carton. The wall section sub-panel 120 of the first panel Pl is configured to form a rear wall of the carton and the wall section sub-panel 124 of the third panel P2 a front wall. The wall sections 122 and 126 of the second and third panels P2, P3 are configured to form side walls of the carton. The fifth panel P5 is configured to be attached to an inside surface of the first panel Pl adjacent the side edge 105 when the carton is formed. The blank 100 displays positions TCI, TC2, TC3, TC4, BC1, BC2, BC3 and BC4 defining top and bottom comers of the carton when formed. The top corner positions TCI, TC2, TC3 and TC4 are arranged along a line extending across the panels P1-P5 orthogonal to the side edges 105 and 107. Likewise, the corner positions BC1, BC2, BC3 and BC4 are arranged along a line extending across the panels P1-P5 orthogonal to the side edges 105 and 107 parallel to the line along which the top comer positions TCI, TC2, TC3 and TC4 is arranged.

The first panel Pl comprises a bottom crease line 140 extending from the position BC1 to a position on the side edge 105 level to BC1. In other words, the bottom crease line 140 extends transversely across the panel Pl in a direction which is orthogonal to the side edge 105 and to the longitudinal crease line 102. The bottom crease line 140 forms a border between the bottom-closure sub-panel 110 and the wall section sub-panel 120 of the panel. Further, the first panel Pl comprises a top crease line 150 extending from the position TCI to a position on the side edge 105 level to TCI. Consequently, the top crease line 150 also extends transversely across the panel Pl in a direction which is orthogonal to the side edge 105 and to the longitudinal crease line 102, i.e. parallel to the bottom crease line 140. The top crease line 150 forms a border between the wall section sub-panel 120 and the topclosure sub-panel 130.

The bottom-closure sub-panel 110 comprises a flap 111 which assists in securing a safe closure of the bottom of the carton. Within the art of carton production, the function of such flaps is known as such and the flap 111 will not be discussed further here.

The top-closure sub-panel 130 comprises a top-fin crease line 160 extending transversely across the panel Pl parallel to the top crease line 150, i.e. in a direction which is orthogonal to the side edge 105 and to the longitudinal crease line 102. The top-fin crease line 160 defines a folding line 60 forming a border between a roof panel section 170 and a top-fin panel section 180 of the top-closure panel 130.

The second panel P2 comprises a bottom crease line 142 extending transversely across the panel P2 between positions BC1 and BC2. BC1 and BC2 are level, i.e. arranged along a line which is orthogonal to the longitudinal crease lines 102 and 104. Consequently, the bottom crease line 142 extends transversely across the panel P2 in a direction which is orthogonal to the longitudinal crease lines 102 and 104. The bottom crease line 142 forms a border between the bottom-closure sub-panel 112 and the wall section sub-panel 122. The second panel P2 further comprises a top crease line 152 extending across the panel P2 between positions TCI and TC2 and defining a folding line 52 forming a border between the wall section sub-panel 122 and the top closure sub-section 132. TCI and TC2 are level, i.e. are arranged along a line which is orthogonal to the longitudinal crease lines 102 and 104.

The top-closure sub-panel 132 comprises a top-fin crease line 162 extending transversely across the panel Pl parallel to the top crease line 152, i.e. in a direction which is orthogonal to the longitudinal crease line 102 and to the longitudinal crease line 104. The top-fin crease line 162 defines a folding line 62 forming a border between a gusset panel section 172 and a top-fin panel section 182 of the top-closure panel 132.

The gusset panel section 172 of the top-closure panel 132 comprises diagonal crease lines 173a, 173b and the top-fin panel section 182 comprises a vertical crease line 183, the crease lines 173a, 173b, 183 forming folding lines which are to assist folding of the top-closure sub-panel 132 when the bottom closure of the carton is to be formed.

The bottom-closure sub-panel 112 comprises diagonal crease lines 113a, 113b forming folding lines which are to assist folding of the bottom-closure sub-panel 112 when the bottom closure of the carton is to be formed.

The third panel P3 comprises a bottom crease line 144 extending transversely across the panel P3 between positions BC2 and BC3. BC2 and BC3 are level, i.e. arranged along a line which is orthogonal to the longitudinal crease lines 104 and 106. Consequently, the bottom crease line 144 extends transversely across the panel P4 in a direction which is orthogonal to the longitudinal crease lines 102 and 104. The bottom crease line 144 defines a folding line forming form a border between the bottom-closure sub-panel 114 and the wall section sub-panel 124 of the panel P3. Further, the third panel P3 comprises a top crease line 154 extending across the panel P3 between the top corner positions TC2 and TC3, which top crease line 154 defines a folding line forming a border between the wall section sub-panel 124 and the top-closure sub-panel 134.

The top-closure sub-panel 134 comprises a top-fin crease line 164 extending transversely across the panel P3 in a direction which is orthogonal to the longitudinal crease lines 104 and 106, i.e. parallel to the bottom crease line 144. The top-fin crease line 164 defines a folding line forming a border between a roof panel section 174 and a top-fin panel section 184 of the top-closure panel 134.

The fourth panel P4 comprises a bottom crease line 146 extending transversely across the panel P4 between positions BC3 and BC4. BC3 and BC4 are level, i.e. arranged along a line which is orthogonal to the longitudinal crease lines 106 and 108. Consequently, the bottom crease line 146 extends transversely across the panel P4 in a direction which is orthogonal to the longitudinal crease lines 106 and 108. The bottom crease line 146 defines a folding line forming a border between the bottom-closure sub-panel 116 and the wall section sub-panel 126. The fourth panel P4 further comprises a top crease line 156 extending across the panel P4 between positions TC3 and TC4 defining a folding line 56 forming a border between the wall section sub-panel 126 and the top closure sub-section 136. TC3 and TC4 are level, i.e. are arranged along a line which is orthogonal to the longitudinal crease lines 106 and 108.

The top-closure sub-panel 136 comprises a top-fin crease line 166 extending transversely across the panel Pl parallel to the top crease line 156, i.e. in a direction which is orthogonal to the longitudinal crease line 106 and to the longitudinal crease line 108. The top-fin crease line 166 defines a folding line 66 forming a border between a gusset panel section 176 and a top-fin panel section 186 of the top-closure panel 136.

The gusset panel section 176 of the top-closure panel 136 comprises diagonal crease lines 177a, 177b and the top-fin panel section 186 comprises a vertical crease line 187, the crease lines 177a, 177b, 187 forming folding lines which are to assist folding of the top-closure sub-panel 136 when the bottom closure of the carton is to be formed.

The bottom-closure sub-panel 116 comprises diagonal crease lines 117a, 117b defining folding lines configured to assist folding of the bottom-closure sub-panel 116 when the bottom closure of the carton is to be formed.

In the fifth panel P5, two co-linear bottom crease lines 148a, 148b define a folding line extending across the panel P5, which folding line is co-linear to the bottom crease lines 140, 142, 144, 146 in panels P1-P4 and forms a border between the bottom-closure subpanel 118 and the body sub-panel 128 of panel P5. Also, two co-linear top crease lines 158a, 158b define a folding line which is generally co-linear to the top crease line 150 of the first panel Pl, which folding line forms a border between the body sub-panel 128 and the top-closure sub-panel 138. Furthermore, two co-linear top-fin crease lines 168a, 168b define a folding line 68 which is generally co-linear to the top-fin crease lines 160 and 164 of panels Pl and P3, which folding line 68 forms a border between a roof panel section 178 and a top-fin panel section 188 of the top-closure sub-panel 138.

There are different solutions for opening in the container 1.

A first solution is providing the roof panel section 174 with a circular through-going opening 200 for receiving a pour spout fitment, as illustrated in fig. 2.

A second solution is providing the roof panel sections 170 and 174 with a circular diagonal crease lines 171 and 175, respectively, as illustrated in fig. l. These crease lines 171, 175 defining folding lines configured to assist the consumer when opening the container 1.

Fig. 3 and 4 illustrate how the blank is folded together to form the container 1, and

- the part 110a of the first, bottom-closure sub-panel 110 of panel Pl that is exposed to the outside when the blank 100 is folded to produce the container 1; and

- the part 110b of the first, bottom-closure sub-panel 110 of panel Pl that is intended to be sealed to the first, bottom-closure sub-panel (of panel P3) during folding and sealing of the blank into the container.

There is no crease line between the parts 110a and 110b of the first, bottom-closure subpanel 110. In order to produce containers 1 for holding a pourable product more environmentally friendly and sustainable, the total amount of polymer has been reduced in the laminate and blank used to make the container 1.

Fig. 5 illustrates the container 1, formed following folding, bottom- and side-sealing, filling and top-sealing of the laminate 100, there is then applied to the top surface of the third, top-closure sub-panel 134 (of panel P3) a pour spout fitment 3 consisting of a flanged pour spout 5, a screw cap 7 on the pour spout.

The container 1 of fig. 5 may for example be made from the blank 100 illustrated in fig. 2 or from a blank containing an opening made of the half-cut method (for example disclosed in EP1786618B1).

The inventive solution provides a blank 100 for making a container 1 for holding a pourable product, the blank comprising a first area 225 and a second area 250, wherein the blank 100 is made from a laminated material 10, the laminated material 10 comprising, from an internal side to an external side: a bulk layer 12; and a first polymer layer 13, located in the first area 225; the blank 100 further comprising, on an external side of the laminated material 10, a second polymer layer 14 located exclusively in the second area 250.

The person skilled in the art will understand that the solution is independent from a specific blank or container design and may be applied to any kind of blank or container for holding a pourable food product. The inventive solution may also be applied to modify any kind of laminate structure already in use for making containers for holding a pourable food product.

Here it is a goal of the invention to reduce the amount of polymer used in the first polymer layer 13 located in the first area.

However, there are challenges when reducing the amount of polymer in the laminate, such as loss of water tightness, sealing failures, cracks, pinholes. . .

The innovative solution proposes to distinguish at least a first and a second area on the outer surface of the container that are intended to be provided with different amounts of polymers. In the following examples, the first area 225 is defined as the area of the blank that correspond to the surface of the container that is exposed to the outside when the blank is folded to produce the container. In other words, the first area comprises

- the second, wall section sub-panels 120, 122, 124, 126, of panels Pl, P2, P3 and P4, respectively;

- the roof and gusset panel section sections 170, 172, 174, 176, of sub-panel 130, 132, 134, 136, of panels Pl, P2, P3 and P4, respectively;

- the top-fin panel section 180, 184 of sub-panels 130, 134, of panels Pl and P3, respectively;

- the part 110a of the first, bottom-closure sub-panel 110 of panel Pl that remains exposed to the outside after folding and sealing of the blank into the container; and

- the first, bottom-closure sub-panel 114 of panel P3.

The second area is defined as the area in which all sealing takes place. In other words, the second area is the area of the external surface of the blank that is sealed when the blank is folded to produce the container.

In other words, the second area comprises

- the part 110b of the first, bottom-closure sub-panel 110 of panel Pl that is intended to be sealed to the first, bottom-closure sub-panel (of panel P3) during folding and sealing of the blank into the container;

- the first, bottom-closure sub-panel 112, 116 of panels P2 and P4, respectively;

- the top-fin panel section 182, 186 of panels P2 and P4, respectively; and

- the panel P5; comprising the first, bottom-closure sub-panel 118, the second, wall section sub-panel 128 and third, top-closure sub-panel 138.

Here the first and second area are complementary, i.e. they cover the complete area of the blank.

The following examples are illustrated by fig.6 to fig. 15, the figures are cross sectional representations of the laminate 10, but are not intended to represent the actual thickness of the layers relative to each other.

First example In a first example, the laminate structure, illustrated in fig. 6, comprises from an external side to an internal side, a first polymer layer 13 made of a polyolefin material, located exclusively in the first area 225 and a second polymer layer 14 made of a polyolefin material located exclusively in the second area 250; wherein the first polymer layer has an average thickness t225 in the first area 225; and wherein the second polymer layer has an average thickness t250 in the second area 250; a bulk layer 12 made of paperboard; a third polymer layer 40, made of polyethylene; and wherein t250>t225.

In other words, there is more polymer material in the second area 250 than in the first area 225.

Second example

In a second example, the laminate structure, illustrated in fig. 7, comprises from an external side to an internal side, a first polymer layer 13 made of a polyolefin material, located exclusively in the first area 225 and a second polymer layer 14 made of a polyolefin material located exclusively in the second area 250; wherein the first polymer layer has an average thickness t225 in the first area 225; and wherein the second polymer layer has an average thickness t250 in the second area 250; a bulk layer 12 made of paperboard; a gas barrier layer 30 comprising ethylene vinyl alcohol EVOH; a third polymer layer 40, made of polyethylene; and wherein t250>t225.

In the first and second examples:

The first polymer layer 13 is a water barrier and protects the container from outside humidity, condensation, splashing, etc. The first polymer layer 13 may also protects an optional print layer (not shown) located between the bulk layer 12 and the first polymer layer 13.

The first polymer layer 13 is made of a polyolefin.

The first polymer layer in the first area is present at a total amount of 5 g/m², dry weight.

In other words, the first polymer layer 13 has a thickness of about 5 pm, i.e. t225 = 5pm.

The second polymer layer 14 is made of polyolefin.

The second polymer layer 14 is present at a total amount of 10 g/m², dry weight.

In other words, the second polymer layer 14 has a thickness of about 10 pm, i.e. t250 = 10pm.

In the first and second examples, the total amount of polymer on the laminate, and the blank made from the laminate is reduced compared to known laminates and blanks.

At the same time, the container formed from the laminate or blank will have a sufficient sealing, which means that the container will not leak.

In addition, the container will retain sufficient water barrier properties.

The second example has an additional layer of EVOH as a gas barrier layer compared to the first example. This additional gas barrier layer is optional, but further optimizes the Oxygen Transmission Rate (OTR) of the laminate/blank/container.

Third example

In a third example, the laminate structure, illustrated in fig. 8, comprises from an external side to an internal side, a first polymer layer 13 made of a polyolefin material, located in both the first area 225 and second area 250; exclusively in the second area 250: a second polymer layer 14 made of a polyolefin; wherein the first polymer layer has an average thickness t225 in the first area 225; and wherein the first polymer layer and second polymer layer have a cumulated average thickness t250 in the second area 250; a bulk layer 12 made of paperboard; a third polymer layer 40, made of polyethylene; and wherein t250>t225.

Fourth example

In a fourth example, the laminate structure, illustrated in fig. 9, comprises from an external side to an internal side, a first polymer layer 13 made of a polyolefin material, located in both the first area 225 and second area 250; exclusively in the second area 250: a second polymer layer 14 made of a polyolefin; wherein the first polymer layer has an average thickness t225 in the first area 225; and wherein the first polymer layer and second polymer layer have a cumulated average thickness t250 in the second area 250; a bulk layer 12 made of paperboard; a gas barrier layer 30 made of an aluminium foil; a third polymer layer 40, made of polyethylene; and wherein t250>t225.

Fifth example

In a fifth example, the laminate structure, illustrated in fig. 10, comprises from an external side to an internal side, a first polymer layer 13 made of a polyolefin material, located in both the first area 225 and second area 250; exclusively in the second area 250: a second polymer layer 14 made of a polyolefin; wherein the first polymer layer has an average thickness t225 in the first area 225; and wherein the first polymer layer and second polymer layer have a cumulated average thickness t250 in the second area 250; an intermediate layer 15 made of a clay coating. a bulk layer 12 made of paperboard; a third polymer layer 40, made of polyethylene; and wherein t250>t225.

In the third, fourth and fifth examples:

The first polymer layer 13 is a water barrier and protects the container from outside humidity, condensation, splashing. . . The first polymer layer 13 may also protects an optional print layer (not shown) located between the bulk layer 12 and the first polymer layer 13.

The first polymer layer 13 is made of a polyolefin.

The first polymer layer in the first area 225 and in the second area 250 is present at a total amount of 5 g/m², dry weight in the third and fourth examples and of 3 g/m², dry weight in the fifth example.

In other words, the first polymer layer 13 has a thickness of about 5 pm, i.e. t225 = 5 pm in the third and fourth examples and a thickness of about 3 pm, i.e. t225 = 3 pm in the fifth example.

The second polymer layer 14 is made of a polyolefin.

The second polymer layer 14 is present at a total amount of 5 g/m², dry weight, in the third and fourth examples and of 7 g/m², dry weight in the fifth example.

In other words, the second polymer layer 14 has a thickness of about 5 pm in the third and fourth examples and a thickness of about 7 pm in the fifth example.

The first and second polymer layer therefore have, in the second area 250, a total thickness t250 = 10 pm, in the third, fourth and fifth examples.

In the third, fourth and fifth examples, the total amount of polymer on the laminate, and the blank made from the laminate is reduced compared to known laminates and blanks.

In addition, the container will retain sufficient splash/humidity resistance properties.

The fourth example has an additional layer 30 of aluminium as a gas barrier layer compared to the third example. This additional gas barrier layer is optional but further optimizes the Oxygen Transmission Rate (OTR) of the laminate/blank/container.

The fifth example has an additional intermediate layer 15 made of clay. The external surface of the paperboard layer 12 is uneven (high Bendtsen smoothness/roughness usually over 1000 ml/min). The unevenness of this external surface may limit the reduction of the amount of polymer on an external side of the bulk layer 12. In other words the first polymer layer 13 needs to be sufficiently thick in order to ensure good splash/humidity resistance when placed directly on the paperboard layer 12.

By adding the optional intermediate layer 15, between the paperboard layer 12 and the first or second polymer layer 13,14, the unevenness of the paperboard layer is reduced. In other words, the Bendtsen smoothness/roughness of the intermediate layer 15 (on its external side) is lower than the Bendtsen smoothness/roughness of the paperboard layer 12 (on its external side). Therefore, the first and or second polymer layer 13,14 may have a reduced thickness/density/grammage while presenting similar or even superior barrier properties, i.e. that at least satisfy the requirements to be used in container for holding a pourable food product.

Suitable filler for the intermediate layer of clay 15 are kaolin clay, talcum particles, silicate calcium carbonate, bentonite clay, ball clay, fire clay, red clay, earthenware clay or any blend thereof. These fillers are especially relevant as they are environmental friendly.

The intermediate layer 15 also comprises a binder. Typical binders are cellulose, Polyvinyl Acetate (PVA), starch, gum Arabic, latex, vinyl acetate, styrene-butadiene copolymer (SB) latex, styrene acrylate copolymer (SA) latex, other latexes of acrylate polymers and copolymers, such as vinyl acrylic copolymer latex and vinyl acetate acrylate copolymer latex, and of bio-based polymer materials. These binders are especially relevant as they are environmental friendly.

Suitable examples of kaolin clay are hydrous kaolin, calcined kaolin, ultrafine kaolin, and kaolin blends.

Sixth example

In a sixth example, the laminate structure, illustrated in fig. 11, comprises from an external side to an internal side, exclusively in the second area 250: a second polymer layer 14 made of a polyolefin; a first polymer layer 13 made of a polyolefin material, located in both the first area 225 and second area 250; wherein the first polymer layer has an average thickness t225 in the first area 225; and wherein the first polymer layer and second polymer layer have a cumulated average thickness t250 in the second area 250; a bulk layer 12 made of paperboard; a third polymer layer 40, made of polyethylene; and wherein t250>t225.

Seventh example

In a seventh example, the laminate structure, illustrated in fig. 12, comprises from an external side to an internal side, exclusively in the second area 250: a second polymer layer 14 made of a polyolefin; a first polymer layer 13 made of a polyolefin material, located in both the first area 225 and second area 250; wherein the first polymer layer has an average thickness t225 in the first area 225; and wherein the first polymer layer and second polymer layer have a cumulated average thickness t250 in the second area 250; a bulk layer 12 made of paperboard; a gas barrier layer 30 comprising polyvinyl alcohol PVOH; a third polymer layer 40, made of polyethylene; and wherein t250>t225.

Eighth example

In an eighth example, the laminate structure, illustrated in fig. 13, comprises from an external side to an internal side, exclusively in the second area 250: a second polymer layer 14 made of a polyolefin; a first polymer layer 13 made of a polyolefin material, located in both the first area 225 and second area 250; wherein the first polymer layer has an average thickness t225 in the first area 225; and wherein the first polymer layer and second polymer layer have a cumulated average thickness t250 in the second area 250; an intermediate layer 15 made of clay. a bulk layer 12 made of paperboard; a third polymer layer 40, made of polyethylene; and wherein t250>t225.

In the sixth, seventh and eighth examples:

The first polymer layer 13 is made of a polyolefin.

The first polymer layer in the first area 225 and in the second area 250 is present at a total amount of 5 g/m², dry weight in the sixth and seventh examples and of 3 g/m², dry weight in the eighth example.

In other words, the first polymer layer 13 has a thickness of about 5 pm, i.e. t225 = 5 pm in the sixth and seventh examples and a thickness of about 3 pm, i.e. t225 = 3 pm in the eighth example.

The second polymer layer 14 is made of a polyolefin.

The second polymer layer 14 is present at a total amount of 5 g/m², dry weight in the sixth and seventh examples and of 7 g/m², dry weight in the eighth example.

In other words, the second polymer layer 14 has a thickness of about 5 pm in the sixth and seventh examples and a thickness of about 7 pm in the eighth example.

The first and second polymer layer therefore have, in the second area 250, a total thickness t250 = 10 pm, in the sixth, seventh and eighth examples.

In the sixth, seventh and eighth examples, the total amount of polymer on the laminate, and the blank made from the laminate is reduced compared to known laminates and blanks.

The seventh example has an additional layer 30 comprising PVOH as a gas barrier layer compared to the third example. This additional gas barrier layer is optional but further optimizes the Oxygen Transmission Rate (OTR) of the laminate/blank/container. The eighth example has an additional intermediate layer 15 made of clay.

Ninth example

In a ninth example, the laminate structure, illustrated in fig. 14, comprises from an external side to an internal side, a second polymer layer 14a, 14b located exclusively in the second area 250, made of a polyolefin material; a first polymer layer 13, made of a polyolefin material, located in the first area 225 and in the second area 250; an intermediate layer 15 made of clay; a bulk layer 12 made of paperboard; and a second polymer layer 40, made of polyethylene.

In this example, the first area comprises the complete blank.

The first polymer layer 13 is made of a polyolefin.

The first polymer layer 13 in the first and second area 225,250 is present at a total amount of 5 g/m², dry weight.

In other words, the first polymer layer 13 has a thickness of about 5 pm, i.e. t225 = 5 pm in the ninth example.

In this example, the second area 250 is the area in which all sealing takes place. In other words, the second area is the area of the external surface of the blank that is sealed when the blank is folded to produce the container. The second area 250 is here divided in a first sealing sub area 251 and a second sealing sub area 252.

The first sealing sub area 251 is the area that is intended to be sealed to the outermost layer of the blank, in other words:

- the first, bottom-closure sub-panel 112, 116 of panels P2 and P4, respectively; and - the top-fin panel section 182, 186 of panels P2 and P4, respectively.

The second sealing sub area 252 is the area that is intended to be sealed to the innermost layer of the blank, in other words:

- the part 110b of the first, bottom-closure sub-panel 110 of panel Pl that is intended to be sealed to the first, bottom-closure sub-panel (of panel P3) during folding and sealing of the blank into the container; and

Here the first and second area are overlapping, and together they still cover the complete area of the blank.

The second polymer layer 14a, 14b in the first and second sealing sub area 251, 252 is made of a polyolefin.

The second polymer layer 14a is present at a total amount of 2 g/m², dry weight in the first sealing area 251, this corresponds to a layer of about 2 pm.

The second polymer layer 14b is present at a total amount of 5 g/m², dry weight in the second sealing area 252, this corresponds to a layer of about 5 pm.

The first and second polymer layer 13,14 therefore have, in the second area 250, a total average thickness t250 > 5 pm, in the ninth example.

In the ninth example, the total amount of polymer on the laminate, and the blank made from the laminate is reduced compared to known laminates and blanks.

In addition, the container will retain sufficient splash/humidity resistance properties. The ninth example does not comprise a barrier layer. An optional layer 30 comprising for example EVOH could be added as a gas barrier layer. This additional gas barrier layer would further optimizes the Oxygen Transmission Rate (OTR) of the laminate/blank/container.

In the ninth example, the amount is of polymer in the second area 250 is further reduced compared to the sixth/seventh/eighth examples.

Tenth example

In a tenth example, the laminate structure, illustrated in fig. 15, comprises from an external side to an internal side, a second polymer layer 14a, 14b located exclusively in the second area 250, made of a polyolefin material; a first polymer layer 13, made of a polyolefin material, located in the first area 225; a bulk layer 12 made of paperboard; a gas barrier layer 30 comprising ethylene vinyl alcohol EVOH; a second polymer layer 40, made of polyethylene.

In this example, the first area comprises the complete blank.

The first polymer layer 13 is made of a polyolefin.

The first polymer layer 13 in the first area 225 is present at a total amount of 5 g/m², dry weight.

In other words, the first polymer layer 13 has a thickness of about 5 pm, i.e. t225 = 5 pm.

- the first, bottom-closure sub-panel 112, 116 of panels P2 and P4, respectively; and the top-fin panel section 182, 186 of panels P2 and P4, respectively. The second sealing sub area 252 is the area that is intended to be sealed to the innermost layer of the blank, in other words:

The second polymer layer 14a, 14b in the first and second sealing sub area 251, 252 is made of polyethylene.

The second polymer layer 14a is present at a total amount of 6 g/m², dry weight in the first sealing area 251, this corresponds to a layer of about 6 pm.

The second polymer layer 14b is present at a total amount of 8 g/m², dry weight in the second sealing area 252, this corresponds to a layer of about 8 pm.

The second polymer layer 14a, 14b therefore has, in the second area 250, a total average thickness t250 > 5 pm, in the tenth example.

In the tenth example, the total amount of polymer on the laminate, and the blank made from the laminate is reduced compared to known laminates and blanks.

The tenth example has an optional layer 30 comprising EVOH as a gas barrier layer. This additional gas barrier layer is optional but further optimizes the Oxygen Transmission Rate (OTR) of the laminate/blank/container.

In the tenth example, the amount is of polymer in the second area 250 is further reduced compared to the first and second examples.

Although not illustrated here, it is fully possible to combine the intermediate layer 15 with a gas barrier layer 30 in any embodiment of the laminate/blank/container. Method of manufacture of the blank 100:

A method for manufacturing the blank 100 illustrated in fig. 1 and 2 the blank comprising a first area 225 and a second area 250, wherein the first area 225 and the second area 250 are complementary; the method comprising the steps of a) providing a bulk layer 12; b) applying a first polymer layer 13 on an external side of the bulk layer 12 over the first area 225 and optionally over a second area 250; c) applying a second polymer layer 14 on an external side of the bulk layer 12 over the second area 250;

In this method, steps b) and c) may be achieved in any order.

The second polymer layer 14 and optional first polymer layer 13 have an average thickness t250 in the second area 250.

The first polymer layer 13 has an average thickness t225 in the first area 225.

The polymers are applied so that t250 > t225.

Applying in step b) and c) may be achieved by a printing method such as rotogravure printing and/or flexo printing.

The rollers used for rotogravure printing each have a printing area that correspond to the area where the first polymer layer 13 and the second polymer layer 14 will be printed.

These printing areas may be divided in sub printing area having different depths, in order to print polymer layer having varying thickness, such as the second polymer layer 14a, 14b exemplified in the ninth and tenth examples.

In an example, a blank is manufactured by applying a first polymer layer 13 of polyolefin, here polyethylene, in an amount 3 g/m², dry weight of on an external side of a laminated material comprising from an external side to an internal side, an intermediate layer 15 made of clay. a bulk layer 12 made of paperboard; a third polymer layer 40, made of polyethylene. The first polymer layer 13 is applied by rotogravure over the whole area of the blank, in other word on the first and the second area 225, 250 of the blank.

Then a second polymer layer 14 made of polyethylene is applied in an amount 5 g/m², dry weight on the second area 250 of the blank.

This results in a blank illustrated in the sixth example having the structure illustrated in fig. H.

In the inventive method, applying the first polymer layer 13 on the first area 225 and at least part (or over the full) second area 250 reduces the risk of water ingress at the interface between the first and second area 225,250.

In the inventive method, applying the first polymer layer 13 on the first area 225 and over the full second area 250 not only reduces the risk of water ingress at the interface between the first and second area 225,250, but also produces a more even surface for applying the second polymer layer 14.

Applying the first polymer layer 13 first and then the second polymer layer 14, i.e. step b) and then step c), ensures a better contact between the different layers 12,13,14 (15 as well when present).

It is appreciated that certain features of the invention, which, for clarity, have been described above in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which, for brevity, have been described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

In the preceding description, various aspects of a blank, of a container and of a method for manufacture of the blank have been described with reference to the illustrative embodiments. For purposes of explanation, specific numbers, systems and configurations were set forth in order to provide a thorough understanding of the blanks and container and its workings. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiment, as well as other embodiments of the blank and container, which are apparent to person skilled in the art to which the disclosed subject-matter pertains, may lie within the scope of the present invention as defined by the following claims.

Claims

1. A blank (100) for making a container (1) for holding a pourable product, the blank comprising a first area (225) and a second area (250), wherein the first area (225) and the second area (250) are complementary; wherein the blank (100) is made from a laminated material (10), the laminated material (10) comprising, from an internal side to an external side of the blank (100): a bulk layer (12); a first polymer layer (13), located at least in the first area (225); and a second polymer layer (14) located exclusively in the second area (250); or a bulk layer (12); a second polymer layer (14) located exclusively in the second area (250); and a first polymer layer (13), located at least in the first area (225); wherein the second polymer layer (14) and optional first polymer layer (13) have an average thickness t250 in the second area (250); wherein the first polymer layer (13) has an average thickness t225 in the first area (225); and wherein t250>t225.

2. The blank (100) according to claim 1, wherein the laminated material (10) further comprises on an internal side of the bulk layer (12) a third polymer layer (40).

3. The blank (100) according to claim 1 or 2, wherein the laminated material (10) further comprises an intermediate layer (15), between the bulk layer (12) and the first or second polymer layer (13, 14); and wherein the intermediate layer (15) comprises a polymer binder material and a filler.

4. The blank (100) according to any of the previous claims, wherein the filler of the intermediate layer (15) is an inorganic filler.

5. The blank (100) according to any of the previous claims, wherein the filler of the intermediate layer (15) is a kaolin clay, a bentonite clay, talcum particles, silicate and/or calcium carbonate.

6. The blank (100) according to any of the previous claims, wherein the polymer binder material of the intermediate layer (15) is selected from the group consisting of vinyl acetate, styrene-butadiene copolymer (SB) latex, styrene acrylate copolymer (SA) latex, other latexes of acrylate polymers and copolymers, such as vinyl acrylic copolymer latex and vinyl acetate acrylate copolymer latex, and of bio-based polymer materials.

7. The blank (100) according to any of the previous claims, wherein the intermediate layer (15) comprises from 10 to 90 wt% of filler.

8. The blank (100) according to any of the previous claims, wherein the grammage of the intermediate layer (15) is comprised between 1 and 20 g/m².

9. The blank (100) according to any of the previous claims, wherein the first polymer layer (13) is the outermost layer in the first area (225).

10. The blank (100) according to any of the previous claims, wherein the first polymer layer (13) comprises a polyolefin, a polyethylene, a polyethylene copolymer, a styrene acrylate, or biobased polymer material.

11. The blank (100) according to any of the previous claims, wherein the first polymer layer (13) is present at most at a total amount of 10 g/m2 dry weight, at most at a total amount of 9 g/m2 dry weight, at most at a total amount of 8 g/m2 dry weight, at most at a total amount of 7 g/m2 dry weight, at most at a total amount of 6 g/m2 dry weight, at most at a total amount of 5 g/m2 dry weight, at most at a total amount of 4 g/m2 dry weight; or at most at a total amount of 3 g/m2 dry weight.

12. The blank (100) according to any of the previous claims, wherein the second polymer layer (14) comprises a polyolefin, a polyethylene, or a polyethylene copolymer material.

13. The blank (100) according to any of the previous claims, wherein the second polymer layer (14) is present at a total amount of from 1 to 20 g/m2 dry weight, 1 to 10 g/m2, dry weight or from 6 to 9 g/m2, dry weight.

14. A container (1) for holding a pourable food product, made from the blank (100) according to any of the previous claims, wherein the blank is oriented so that the internal side of the blank (100) is on the internal side of the container (1).

15. The container (1) according to claim 14, comprising an opening arrangement, the opening arrangement configured such that a section of the laminated material defined by the cut is pushed or pulled during the first opening of the container, such that the laminated material is ruptured along the cut.

16. The container (1) according to any one of claims 14 or 15, wherein the cut (4) extending into the laminated material substantially orthogonal to the outside surface of the laminated material.

17. A method of manufacturing a blank (100) suitable for making a container (1) for holding a pourable food product, the blank comprising a first area (225) and a second area (250), wherein the first area (225) and the second area (250) are complementary; comprising the steps of a) providing a bulk layer (12); b) applying a first polymer layer (13) on an external side of the bulk layer (12) over the first area (225) and optionally over a second area (250); c) applying a second polymer layer (14) on an external side of the bulk layer (12) over the second area (250); wherein steps b) and c) may be achieved in any order; and wherein the second polymer layer (14) and optional first polymer layer (13) have an average thickness t250 in the second area (250); wherein the first polymer layer (13) has an average thickness t225 in the first area (225); and wherein t250>t225.

18. A method according to claim 17, wherein the first polymer layer (13) and/or the second polymer layer (14) are provided as a polymer dispersion.

19. A method according to claim 17 or 18, wherein the first polymer layer (13) and/or the second polymer layer (14) is/are applied by printing method such as rotogravure printing and/or flexo printing.

20. A method according to claim 17, 18 or 19, wherein step b) is achieved after step c).

21. A method according to claim 17, 18 or 19, wherein step c) is achieved after step b).

22. A product obtainable by the method according to any one of claims 17 to 21.