GB2609029A

GB2609029A - Container

Info

Publication number: GB2609029A
Application number: GB2110369.2A
Authority: GB
Inventors: Grogan John-Paul
Original assignee: Frugalpac Ltd
Current assignee: Frugalpac 2 Ltd
Priority date: 2021-07-19
Filing date: 2021-07-19
Publication date: 2023-01-25
Also published as: GB202110369D0

Abstract

A recyclable container 2 for beverages such as wine comprising a paperboard outer shell 4 having a side wall formed from a flat sheet and base tabs 40 (figure 6) at its lower edge with perforations at the tabs’ proximal ends, that can be folded and attached to a base portion 24 formed from a flat sheet. The side wall may have a circular cross-section and form a main body portion 8, neck- and shoulder portion 10 and 14, and may be constructed of two wall elements 20 and 22. The base may be a circular disc blank that may have a skirt 52, a convex first surface 54 and concave second surface 56, wherein the base tabs may be adhered to the second surface. There may be one or more perforations 66 (figure 6) at the proximal end of each base tab that may be between 40-50% of the base tabs’ width. A preferably polymeric or metallic liner 6 may be connected to a fitment 72 that is engaged with the outer shell and can carry the liquid product. The outer shell may further comprise a pair of apertures 84 and lugs 80 (figure 4) that extend through the apertures.

Description

Container

FIELD OF THE INVENTION

This invention relates to containers. In particular this invention relates to containers having an outer cardboard or paperboard shell.

BACKGROUND TO THE INVENTION

There is a general desire and need to reduce the amount of waste that is produced and a drive to recycle as much as possible. One particular area that is receiving a lot of attention is containers for food and drink.

Traditionally wine has been stored and sold in glass bottles. The glass used is relatively heavy and typically makes up about 40% of the weight of the filled bottle of wine. This means that the transportation costs are high.

Furthermore, glass breaks relatively easily when, for example, a bottle is dropped. The bottle will typically break into sharp fragments which may cause injury to a 20 consumer.

It is known to make a bottle having a pulp moulded cardboard outer shell and a blow moulded inner plastics lining. Although these containers have a decreased weight compared to glass bottles, they have a number of disadvantages. The shelf life of the wine within the bottles is decreased compared to glass bottles, it is difficult to apply print to the outer surface of the bottle and the unit cost of manufacture is typically significantly greater than the unit cost of a glass bottle.

It is also known to manufacture bottles having an outer shell made of flat sheets of paperboard or cardboard that are pressed to form the three dimensional shape of the bottle. These have an advantage that an outer surface of the paperboard or cardboard shell may be printed prior to forming and assembly. There does, however, remain a difficulty in assembling these bottles to produce a consistent and strong -2 -container, and one which is suitable for mass production.

Against this background it is desired to provide an improved container having a cardboard shell which is easier to manufacture, results in a consistent and aesthetically pleasing product and which is suitable for mass production.

SUMMARY OF THE INVENTION

An aspect of the invention provides a container comprising a paperboard outer shell, the outer shell comprising: a side wall formed from a flat sheet of paperboard, the side wall comprising a plurality of base tabs at a lower edge; and a base element formed from a flat sheet of paperboard, wherein the base tabs are folded at a proximal end of each of the base tabs 15 to extend over a peripheral edge of the base element, and each of the base tabs includes at least one perforation at its proximal end.

The perforations may be disposed along a fold line about which the base tabs are folded to extend over the peripheral edge of the base element.

Although the perforations may weaken the proximal end of the base tabs, they allow the base tabs to fold without uncontrolled tearing of the base tabs. Furthermore, providing perforations in the base tabs in this way means that it is less likely that the base tabs will return to a non-folded configuration due to residual strain in the paperboard material at the fold line. This means that the bonding, e.g. adherence, of the base tabs to the base element is more robust and the base tabs are less likely to become detached.

The side wall of the outer shell may comprise more than eight base tabs. 30 The side wall of the outer shell may comprise more than twelve base tabs.

Each base tab preferably includes a plurality of perforations extending in a line across a width of the base tab at its proximal end. A total perforated length of the -3 -line of perforations is preferably between 40% and 50% of the width of the base tab at the proximal end.

In other embodiments each base tab may include a single perforation, the perforation being elongate and extending in a direction across a width of the base tab.

In preferred embodiments the side wall has a circular cross-sectional shape and the base element is a circular disc.

Each of the base tabs is preferably adhered to the base element.

In some embodiments the base element comprises a generally convex first surface and generally concave second surface, and the base tabs are adhered to the second surface. The base element may comprise a planar central region and a peripheral skirt portion that extends fully around the circumference of the central region, the skirt portion extending at a non-zero angle from the planar central region.

In some embodiments the side wall includes a main body portion having a first diameter and a neck portion having a second diameter smaller than the first diameter, the neck portion providing an opening of the container and the neck portion extending from a first end of the main body portion, and the base tabs being provided at a second end of the main body portion. The neck portion of the side wall may comprise at least two overlapping layers or panels of paperboard material. The overlapping layers or panels of paperboard material are preferably bonded together by an adhesive. The side wall of the container may comprise a shoulder region between the main body portion and the neck portion.

In some embodiments the side wall comprises a first side wall element pressed from 30 a flat sheet of paperboard and a second side wall element pressed from a flat sheet of paperboard, the second side wall element being bonded to the first side wall element. -4 -

In some embodiments the container further comprises an inner liner disposed within the outer shell for holding a liquid. Preferably the inner liner is not adhered to the outer shell. The inner liner may comprise a pouch made of a polymeric or metallic material. The pouch may be connected to a fitment and the fitment may be engaged with the outer shell. Preferably the side wall of the outer shell comprises a pair of apertures and the fitment comprises a pair of lugs, and the lugs extend through the apertures.

Preferred and/or optional features of each aspect and embodiment described above may also be used, alone or in appropriate combination, in the other aspects and embodiments also.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be further described by way of example only and with reference to the accompanying drawings, in which like reference signs are used for like features, and in which: Figure 1 is a plan view from a first side of a container in the form of a bottle according to an embodiment of the invention; Figure 2 is a plan view from a second side, orthogonal to the first side, of the bottle of Figure 1; Figure 3 is a cross-sectional view of the bottle along the line III-Ill of Figure 2, showing an outer shell and an inner liner; Figure 4 is a perspective view of the bottle of Figure 1; Figure 5 is a further perspective view of the bottle of Figure 1; Figure 6 is a perspective view of a base of the bottle of Figure 1; -5 -Figure 7 is a plan view of the base of the bottle of Figure 1; Figure 8 illustrates a first side wall blank used to form a part of the outer shell of the bottle of Figure 1; Figure 9 illustrates a second side wall blank used to form a part of the outer shell of the bottle of Figure 1; and Figure 10 shows the first side wall blank of Figure 11 with adhesive applied and partially formed into a 3D shape of the bottle of Figure 1.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A container 2 according to the present invention comprises a paperboard or cardboard outer shell 4 and an inner liner 6. The container 2 is preferably in the form of a bottle.

In the illustrated embodiment the outer shell 4 of the container or bottle 2 is generally cylindrical and includes an elongate, cylindrical main body portion 8 having a first, larger diameter, and an elongate, cylindrical neck portion 10 having a second, smaller diameter. The neck portion 10 extends from a first end of the main body portion 8 and defines an opening 12 of the shell 4. A tapered or curved shoulder portion 14 of the shell 4 of the bottle 2 extends between the neck portion 10 and the main body portion 8.

The shell 4 is formed from three separate elements that are bonded together. The shell 4 comprises a first side wall element 20, a second side wall element 22 and a base element 24. Each of the first and second side wall elements 20, 22 includes a part of the neck portion 10 of the shell 4, a part of the shoulder portion 14 of the shell 4, and a part of the main body portion 8 of the shell 4. When the first and second side wall elements 20, 22 are joined together, a part of the first side wall element 20 overlaps a part of the second side wall element 22 to form a complete and continuous side wall 26 of the shell 4. -6 -

The first and second side wall elements 20, 22 are all made from flat sheets of paperboard that have been pressed to form the required three-dimensional shapes.

Blanks 30, 32 used to form the first and second side wall elements 20, 22 are shown in Figures Band 9. A first side wall blank 30 is used to form the first side wall element 20, and a second side wall blank 32 is used to form the second side wall element 22. Each of the first and second side wall blanks 30, 32 comprises a main body panel or portion 34, a central neck panel or portion 36, and outer neck panels or portions 38. In each of the side wall blanks 30, 32, the central neck panel 36 and outer neck panels 38 extend from a first end of the main body panel 34. Each of the central neck panel 36 and outer neck panels 38 extends to a respective distal edge or top edge 37 furthest from the main body panel 34. A plurality of base tabs 40 extend from an opposite second end of the main body panel 34. In this embodiment the first side wall blank 30 includes ten base tabs 40 and the second side wall blank 32 includes six base tabs 40.

The first side wall blank 30 additionally comprises side wall tabs 42, neck tabs 44 and shoulder tabs 46. A side wall tab 42 extends from each side edge of the main body panel 34. In this example each side wall tab 42 extends along the full length of the main body panel 34 between the first and second ends. A neck tab 44 extends from an outer side edge of each of the outer neck panels 38. In this example, each neck tab 44 extends from the respective outer neck panel 38 proximate the distal edge 37. Each shoulder tab 46 extends from the outer side edge of each of the outer neck panels 38. Each shoulder tab 46 extends from the respective outer neck panel 38 proximate the main body panel 34. The shoulder tabs 46 are, therefore, disposed between the neck tabs 44 and the side wall tabs 42. The shoulder tabs 46 preferably have a continuously curved outer edge.

Each of the first and second side wall blanks 30, 32 includes a two-dimensional pattern of adhesive 33 applied to a first surface of the blank 30, 32. The first surface of each of the blanks 30, 32 will become a part of an inner surface 25 of the side wall 26 of the bottle 2 once formed. Adhesive 33 applied to a partially formed first -7 -side wall blank 30 is illustrated in Figure 10. Adhesive 33 is applied, in particular, to areas of the outer neck panels 38, the neck tabs 44, the side wall tabs 42 and the base tabs 40.

Each of the first and second side wall blanks 30, 32 are formed or pressed into the required three-dimensional (3D) shape to form each of the first and second side wall elements 20, 22 respectively. Each of the blanks 30, 32 is formed around a former (not shown) such that the outer neck panels 38 overlap a part of the central neck panel 36. This overlapping of the neck panels 36, 38 creates the neck portion 10 of the shell 4, and also forms the shoulder portion 14. The adhesive 33 applied to the first surface of the outer neck panels 38 adheres the outer neck panels 38 to the central neck panel 36.

The first and second side wall elements 20, 22 are then joined together by overlapping the neck tabs 44 and the side wall tabs 42 of the first side wall element with side edge regions of the second side wall element 22. In particular, the adhesive applied to the neck tabs 44 and the side wall tabs 42 adheres these tabs 44, 42 to a part of a second surface of the second side wall element 22.

During joining of the first and second side wall elements 20, 22, the shoulder tabs 46 of the first side wall element 20 extend over the shoulder portion 14 of the second side wall element 22 and the curvature of the edge of the shoulder tabs 46 allows the edge to follow the contours of the shoulder portion 14.

The base element 24 is formed from a circular disc of cardboard or paperboard and includes a planar central region 50 and a peripheral skirt portion 52 that extends fully around the circumference of the central region 50. The skirt portion 52 comprises an edge region of the disc that has been pressed so as to extend at a non-zero angle to the planar central region 50. In this way, a first surface 54 of the base element 24 has a generally convex shape, and an opposite second surface 56 of the base element 24 has a generally concave shape.

During assembly of the shell 4, the base element 24 is inserted into an internal space -8 -defined and surrounded by a lower end region of the side wall 26 proximate the base tabs 40. The base tabs 40 are then folded over the peripheral edge of the base element 24 and adhered to the base element 24. In particular, each of the base tabs 40 is adhered to the second surface 56 of the skirt portion 52 of the base element 24 To allow the container 2 to be assembled quickly and easily, and in particular to prevent the base element 24 being pushed too far into the internal space defined and surrounded by the side wall 26, the container 2 preferably includes a limit feature 60 in the form of a substantially rigid protrusion extending inwardly from the inner surface 25 of the side wall 26. When the base element 24 is pushed into the internal space defined and surrounded by the side wall 26, a peripheral region of the first surface 54 of the base element 24 abuts or comes into contact with the limit feature 60. This ensures the correct positioning of the base element 24 with respect to the first and second side wall elements 20, 22.

In this example, the limit feature 60 comprises a line of adhesive 62 extending in a circumferential direction around the lower region of the inner surface 25 of the side wall 26 proximate but spaced from the base tabs 40. The line of adhesive is preferably applied to the blanks 30, 32 at an early stage in the manufacturing process and then dries or cures to form a substantially rigid protrusion extending inwardly from the inner surface 25 of the side wall 26. The line of adhesive may not extend fully around the circumference of the side wall 26. It will be appreciated that, because the adhesive is cured or dried, the base element 24 is not adhered to the limit feature 60 when it is inserted and abuts the limit feature 60.

In other embodiments the limit feature 60 may be of any suitable form that provides a substantially rigid protrusion extending inwardly from the inner surface 25 of the side wall 26. For example, in some embodiments, a line of a curable composition other than an adhesive may be applied to the inner surface 25 of the side wall 26.

The composition may be a suitable polymeric composition. In other embodiments the adhesive or other composition may be applied as a series or line of discrete beads extending circumferentially around the inner surface 25 of the side wall 26. -9 -

In yet further embodiments the limit feature 60 may be provided by embossing or indenting a region of the side wall 26, or the limit feature 60 may be provided by folding a portion of the side wall 26. Importantly the limit feature 60 provides a substantially rigid protrusion extending inwardly from the inner surface 25 of the side wall 26 that limits the insertion of the base element 40 into the lower end of the side wall 26.

It will be appreciated that when the base tabs 40 are folded over the peripheral edge of the base element 24, each of the base tabs 40 is generally folded through an angle of at least 80°, and more preferably at least 90°. As the first and second side wall blanks 30, 32 are made from a paperboard or cardboard material there is a tendency for the paperboard to tear or delaminate at the fold line due to the tensile stresses applied to the outer surface of the blanks 30, 32 in this region. To reduce or prevent this tearing and possible resultant structural failure of the base tabs 40, a line of perforations or slits 66 is disposed in each of the base tabs 40 proximate or at the fold line. The line of perforations or slits 66 is therefore disposed in a proximal region of each of the base tabs 40 adjacent the second end of the main body panel 34 of the blank 30, 32.

In preferred embodiments a plurality of perforations or slits 66 is provided at a proximal end of each base tab 40, i.e. in a location where the base tab 40 joins the main body panel 34. In a particularly preferred embodiment each base tab 40 includes a line of perforations 66 including five perforations or slits 66. The perforations 66 may be equidistantly spaced apart across the width of the base tab 40. Each perforation 66 may be approximately 1 mm long, with a gap of approximately 1 mm between each perforation 66. Each perforation 66 may extend for approximately 5-10% of the width of the base tab 40 at its proximal end. The total perforated length may be between 40% and 50% of the width of the base tab 40. at its proximal end. In other embodiments each base tab 40 may include a single perforation or slit at its proximal end. The perforation 66 may be preferably centrally disposed across a width of the base tab 40, and a length or long axis of the perforation 66 preferably extends transversely across the base tab 40. The length of the perforation 66 is preferably between one quarter and one half of the width of -10 -the base tab 40 at its proximal end.

In this embodiment the perforations 66 extend through the full thickness of the blanks 30, 32. In other embodiments the perforations or slits 66 may be disposed in an outer surface of the blanks 30, 32 and may not extend fully through the thickness of the paperboard or cardboard of the blank 30, 32.

The inner liner 6 is disposed within the outer shell 4 and is preferably configured to hold a liquid or powder. In this embodiment the inner liner 6 comprises a pouch 70 and a fitment 72. The fitment 72 is secured to the pouch 70 and is engaged with the neck portion 10 of the shell 4 such that the pouch 70 is partially suspended from or supported by the fitment 72 and extends into the main body portion 8 of the shell 4. A lower end of the pouch 70 is preferably supported by or seated on a base 16 of the shell 4. The pouch 70 may be made from a polymeric or metal material.

The fitment 72 is preferably made of a polymeric material. The fitment 72 comprises a trunk portion 76 having a central bore 78 extending therethrough and a pair of lugs 80 extending radially outwardly from the trunk 76. The bore 78 provides a fluid flow path between an internal volume of the pouch 70 and the opening 12 of the shell 4.

The lugs 80 are sized and positioned to engage with and protrude through apertures 84 in the shell 4. In this example the apertures 84 are provided in the central neck panel 36 of each of the first and second side wall elements 20, 22. The lugs 80 are positioned on opposite sides of the trunk portion 76, and a lower edge of each of the lugs 80 is seated on an end surface of a respective aperture 84 to support the weight of the pouch 70 and any liquid held therein.

An upper end 88 of the fitment 72 protrudes from the opening 12 of the shell 4. A portion of the outer surface of the upper end 88 of the fitment 72 includes screw threads. The screw threads are configured to receive and engage with threads of a screw cap 90 for sealing the container or bottle 2.

The inner liner 6 is preferably not adhered to the shell 4. This allows the paperboard shell 4 and the inner liner 6 to be easily separated after use.

In the above example each of the first and second side wall elements 20, 22 included a plurality of base tabs 40. In other embodiments each side wall element may include only one base tab. In this example the inclusion of a plurality of base tabs 40 allowed the blanks 30, 32 to be curved to form the cylindrical side wall 26 of the bottle 2 and allowed the base element 24 to be secured to the side wall 26. The side wall 26 of the outer shell 4 may include two base tabs 40, or more than two base tabs 40. Preferably the side wall 26 comprises more than six base tabs 40, and more preferably more than twelve base tabs 40.

Furthermore, although the example above described a container in the form of a generally cylindrical bottle, in other embodiments the container may have cross-sectional shapes other than circular. Additionally, the side wall of the shell may be formed from more than two side wall elements. For example a container may have a hexagonal cross-sectional shape and be formed from six side wall elements. In yet further embodiments the side wall of the shell may be formed from a single side wall element pressed to form the required cross-sectional shape of the shell. In these embodiments opposite side edges or side edge regions of the single side wall element may be joined together, for example by adhesive, to form the complete side wall.

Other modifications and variations not explicitly disclosed above may also be contemplated without departing from the scope of the invention as defined in the appended claims.

Claims

-12 -CLAIMS1. A container comprising a paperboard outer shell, the outer shell comprising: a side wall formed from a flat sheet of paperboard, the side wall comprising a plurality of base tabs at a lower edge; and a base element formed from a flat sheet of paperboard, wherein the base tabs are folded at a proximal end of each of the base tabs to extend over a peripheral edge of the base element, and each of the base tabs includes at least one perforation at its proximal end.
2. A container as claimed in Claim 1, comprising more than eight base tabs.
A container as claimed in Claim 1, comprising more than twelve base tabs.
4. A container as claimed in any preceding claim, wherein each base tab includes a plurality of perforations extending in a line across a width of the base tab at its proximal end.
5. A container as claimed in Claim 4, wherein a total perforated length of the line of perforations is between 40% and 50% of the width of the base tab at the proximal end.
6. A container as claimed in any one of claims 1 to 3, wherein each base tab includes a single perforation, the perforation being elongate and extending in a direction across a width of the base tab.
7. A container as claimed in any preceding claim, wherein the side wall has a circular cross-sectional shape and the base element is a circular disc.
8. A container as claimed in any preceding claim, wherein each of the base tabs is adhered to the base element.
9. A container as claimed in any preceding claim, wherein the base element -13 -comprises a generally convex first surface and generally concave second surface, and the base tabs are adhered to the second surface.
10. A container as claimed in Claim 9, wherein the base element comprises a planar central region and a peripheral skirt portion that extends fully around the circumference of the central region, the skirt portion extending at a non-zero angle from the planar central region.
11. A container as claimed in any preceding claim, wherein the side wall includes a main body portion having a first diameter and a neck portion having a second diameter smaller than the first diameter, the neck portion providing an opening of the container and the neck portion extending from a first end of the main body portion, and the base tabs being provided at a second end of the main body portion.
12. A container as claimed in Claim 11, wherein the neck portion of the side wall comprises at least two overlapping layers or panels of paperboard material.
13. A container as claimed in Claim 12, wherein the overlapping layers or panels of paperboard material are bonded together by an adhesive.
14. A container as claimed in any one of Claims 11 to 13, wherein the side wall comprises a shoulder region between the main body portion and the neck portion.
15. A container as claimed in any preceding claim, wherein the side wall comprises a first side wall element pressed from a flat sheet of paperboard and a second side wall element pressed from a flat sheet of paperboard, the second side wall element being bonded to the first side wall element.
16. A container as claimed in any preceding claim, further comprising an inner liner disposed within the outer shell for holding a liquid.
17. A container as claimed in Claim 16, wherein the inner liner is not adhered to the outer shell.
18. A container as claimed in Claim 16 or Claim 17, wherein the inner liner comprises a pouch made of a polymeric or metallic material.
19. A container as claimed in Claim 18, wherein the pouch is connected to a fitment and the fitment is engaged with the outer shell.
20. A container as claimed in Claim 19, wherein the side wall of the outer shell comprises a pair of apertures and the fitment comprises a pair of lugs, the lugs extending through the apertures.