Container

A sealing element (2) for a container (1), the container including a sealing element and to a method of forming a container including a sealing element. A container comprises a main body and a lid, the main body of the container including a side wall having a top edge defining an opening of the container 81), and a sealing element for the container comprises a mounting portion (40) comprising an annular member for engaging with the top edge of the side wall; engagement means configured for repeated sealing engagement with said lid of the container; and a securing portion (42) configured to secure the sealing element to the side wall, the securing portion being hingedly connected to the mounting portion and moveable between a first position in which the mounting portion (40) can be engaged and disengaged from said top edge, and a second position in which the securing portion (42) prevents the mounting portion from being disengaged from said top edge.

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Description
BACKGROUND

a. Field of the Invention

This invention relates to a sealing element for a container, to a container including a sealing element and to a method of forming a container including a sealing element.

b. Related Art

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 much attention is packaging.

Containers for hazardous liquids, such as paints, are difficult to dispose of in an environmentally safe manner and very few containers are recycled due to contamination by the paint, oil or other similar substance.

Known paint pots and similar containers filled with environmentally hazardous liquids are typically made from a semi-rigid plastics material or from metal. After use, the pot remains contaminated with paint residue or similar and the entire container must be disposed of in a suitable manner depending on the type of hazardous liquid. Often the containers end up in a specialist landfill. However, the cost associated with dealing with these containers means that it is becoming increasingly difficult to dispose of them in a convenient and cost effective way.

It is known to provide containers for liquids such as paint comprising a main body formed of paperboard and having an inner plastics lining, such as that described in UK patent application GB 2492887. These containers have the advantage that the contaminated plastics lining can be separated from the paperboard shell for disposal once the contents of the container have been used.

Typically, the contents of the container are not used all at one time and it is necessary, therefore, to be able to repeatedly reseal the container and prevent the liquid contents evaporating or drying between uses. It is often difficult, however, to form a good seal, i.e. a liquid-proof seal, between a container formed of paperboard or laminated paperboard and a lid if it is necessary to be able to repeatedly remove the lid from the container.

For example, it is known to seal a paper cup or container with a foil lid that is heat sealed to the rim of the container. These lids can provide a good seal; however, they are designed for single use and once they have been removed, the container cannot be resealed. It is also known to provide plastic lids that snap fit over the rolled rim of a typical paper cup or container, such as those lids that are provided with a drinking hole for disposable coffee cups. These lids can be repeatedly used to close the container; however, they do not provide a good seal. As such, any liquid contents of the container may leak out through small gaps between the rim of the container and the lid. This is especially problematic near any overlapping seams in the container due to the change in thickness of the side wall and rim in this region.

It is, therefore, an object of the present invention to provide a sealing element for a container that enables reliable and repeated sealing of the container.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention, there is provided a sealing element for a container, the container comprising a main body and a lid, the main body of the container including a side wall having a top edge defining an opening of the container, and the sealing element comprising:

    • a mounting portion comprising an annular member for engaging with the top edge of the side wall;
    • engagement means configured for repeated sealing engagement with said lid of the container; and
    • a securing portion configured to secure the sealing element to the side wall, the securing portion being hingedly connected to the mounting portion and moveable between a first position in which the mounting portion can be engaged and disengaged from said top edge, and a second position in which the securing portion prevents the mounting portion from being disengaged from said top edge.

In preferred embodiments the sealing element further comprises retaining means configured to retain the securing portion in the second position. These retaining means may be integrally formed with the securing portion and/or the mounting portion or, alternatively, the retaining means may be separate from the rest of the sealing element. In some preferred embodiments, the retaining means comprises a strap. The retaining means may comprise a band or tape.

In order that the sealing element is securely engaged with the top edge of the container, the annular member preferably comprises a wall portion that, in use, extends down over an interior surface of the side wall of the container. Furthermore it is preferable if, in use, when the securing portion is in the second position, the securing portion extends down over an exterior surface of the side wall of the container.

In some embodiments the container may include a downwardly facing abutment shoulder or edge on an external side of the side wall proximate the top edge. This may be provided, for example, by a rolled rim of the container or a downwardly extending skirt portion at the top of the side wall of the container. In these embodiments the securing portion of the sealing element preferably comprises a detent configured to engage with said shoulder or edge when the securing portion is in the second position, thereby preventing the mounting portion from being disengaged from said top edge.

In preferred embodiments the securing portion comprises a plurality of tabs, each tab being hingedly connected to the annular member. Typically the tabs are spaced around and extend from a periphery of the annular member. Each of the tabs may include a channel or recess for receiving a part of a retaining means in embodiments in which this is provided.

To simplify manufacture of the sealing element, the mounting portion, engagement portion and securing portion are preferably integrally formed and are parts of a unitary piece.

The mounting portion may comprise attachment means for attaching a handle to the sealing element. In particular, the attachment means may allow a handle to be pivotally attached to the sealing element.

According to a second aspect of the present invention there is provided a container comprising:

    • a shell comprising a base and a side wall, the side wall having a top edge defining an opening of the container;
    • a lid for covering and sealing the opening of the shell; and
    • a sealing element secured around the top edge of the side wall of the shell, the sealing element comprising:
    • a mounting portion comprising an annular member for engaging with the top edge of the side wall;
    • engagement means configured for repeated sealing engagement with said lid of the container; and
    • a securing portion configured to secure the sealing element to the side wall, the securing portion being hingedly connected to the mounting portion and moveable between a first position in which the mounting portion can be engaged and disengaged from said top edge, and a second position in which the securing portion prevents the mounting portion from being disengaged from said top edge.

Typically the shell of the container is made of a paperboard material. In some embodiments the container further comprises a lining covering internal or interior surfaces of said shell. In particularly preferred embodiments the lining is made of a thin film plastics material, the shell is made of a paperboard material and the sealing element is made of a relatively rigid plastics material.

The annular member of the mounting portion preferably comprises a wall portion that, in use, extends down over an interior surface of the side wall of the shell. In embodiments comprising a lining, the lining is preferably bonded to the wall portion.

The container may be for storing at least one of paint, varnish, woodcare liquid, adhesive, filler and putty.

According to a third aspect of the present invention there is provided a method of constructing a container, the container comprising:

    • a shell comprising a base and a side wall, the side wall having a top edge defining an opening of the container; and
    • a sealing element comprising a mounting portion comprising an annular member for engaging with the top edge of the side wall, engagement means configured for repeated sealing engagement with a lid of the container, and a securing portion configured to secure the sealing element to the side wall, the securing portion being hingedly connected to the mounting portion and moveable between a first position in which the mounting portion can be engaged and disengaged from said top edge, and a second position in which the securing portion prevents the mounting portion from being disengaged from said top edge, and
    • the method comprising the steps of:
    • with the securing portion in the first position, seating the mounting portion of the sealing element on the top edge of the side wall; and
    • moving the securing portion into the second position to secure the sealing element to the side wall.

In preferred embodiments the mounting portion of the sealing element comprises a wall portion and the container further comprises a lining covering interior surfaces of said shell. In these embodiments the method preferably comprises seating the mounting portion such that the wall portion extends down over an interior surface of the side wall and an upper region of said lining is located between the side wall and the wall portion of the sealing element, and bonding the wall portion of the sealing element to said lining.

In some embodiments the securing portion comprises a plurality of tabs hingedly connected to the mounting portion. The method, therefore, preferably comprises moving each of said tabs from the first position to the second position once the mounting portion has been engaged with the top edge of the shell.

In preferred embodiments the container further comprises retaining means. In these embodiments the method preferably comprises affixing the retaining means to the sealing element to retain the securing portion in the second position to prevent the sealing element being disengaged from the top edge of the side wall.

In those embodiments in which the retaining means comprises a strap, the securing portion may comprise a channel for receiving said strap. Accordingly, the method comprises placing the strap in the channel and adjusting the strap such that the strap applies a force to the securing portion to retain the securing portion in the second position.

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:

FIG. 1 is a perspective, exploded view of a container including a sealing element according to a first preferred embodiment of the present invention;

FIG. 2 is a vertical cross-sectional view of a pair of stacked containers according to an embodiment of the present invention, the containers being only partially assembled;

FIG. 3 is a perspective view of an outer shell of a main body of a container according to the present invention;

FIG. 4 is a cross-sectional detail view showing the sealing element of FIG. 1 in a partially assembled state;

FIG. 5 is a cross-sectional detail view showing the sealing element of FIG. 1 in a fully assembled state, with the lid separated from the body of the container;

FIG. 6 is a cross-sectional detail view showing the sealing element of FIG. 1 in a fully assembled state, with the lid connected to the body of the container;

FIG. 7 is a cut away perspective view of the container of FIG. 1 in which the container is fully assembled and the lid has been removed;

FIG. 8 is a perspective view from above of a container including a sealing element according to a second preferred embodiment of the present invention;

FIG. 9 is a perspective view from below of the container of FIG. 8;

FIG. 10 shows the sealing element of FIG. 8 in a first, unsecured configuration;

FIG. 11 is a cross-sectional view of a top region of the container of FIG. 8 showing the sealing element in a second, secured configuration;

FIG. 12 is an enlarged view of a part of FIG. 11 indicated by a dashed circle;

FIG. 13 is a cross-sectional view of a top region of the container of FIG. 8 showing a lining of the container and the sealing element in a second, secured configuration and illustrating, in particular, a handle region of the sealing element;

FIG. 14 is an enlarged view of a part of FIG. 13 indicated by a dashed circle;

FIG. 15 is a perspective view from above of a container including a handle, according to a preferred embodiment of the present invention;

FIGS. 16 and 17 are side views of the container of FIG. 15 with the handle omitted.

 DETAILED DESCRIPTION

FIGS. 1, 2 and 7 illustrate a first preferred embodiment of a container 1 comprising a sealing element 2 according to the present invention. The container 1 includes a main body 4 and a lid 6. The main body 4 comprises an outer shell 8 made from a paperboard material, an inner lining 10 made from a thin film plastics material and the sealing element 2 made from a plastics material. In this embodiment the container 1 also comprises a handle 12 (shown in FIG. 1).

The sealing element 2 is designed to engage with a complementary sealing element 14 on the lid 6 in such a way as to enable repeated engagement and disengagement of the lid 6 with the main body 4 of the container 1. This allows the container 1 to be opened, some of the contents to be removed and the container 1 to be resealed in a reliable manner. Furthermore, the seal that is formed between the sealing element 2 and the lid 4 is such that any liquid contents of the container 1 cannot leak from the container.

FIG. 1 shows a container 1 according to a first preferred embodiment of the present invention. The container 1 is in the form of a paint pot or other similar container that may hold liquid or semi-liquid products, for example paint or varnish. The container may also be used to hold other products such as pastes, e.g. grout, or colloidal suspensions, e.g. hand creams. The container may be designed to contain and store hazardous or non-hazardous products such as paints, cleaning products, cosmetics and foodstuffs.

The outer shell 8 of the container 1 is made from a suitable paperboard or cardboard material with no wax or plastics coating or lamination. The shell 8 comprises a base 16 and a side wall 18, the side wall 18 extending fully around the periphery of the base 16 and extending upwards from the base. The base 16 and side wall 18 thereby define an interior volume of the main body 4 of the container 1, as shown most clearly in FIGS. 2 and 7.

The outer shell 8 is made from sheet paperboard that has been folded and glued to form the final shape of the shell. In particular, a first sheet of paperboard is cut and folded to form the base 16 of the shell 8, and a second sheet of paperboard is cut and folded to form the side wall 18 of the shell 8. The base 16 is adhered to the side wall 18 around a bottom edge 20 of the container 1.

In this example the base 16 has a rounded rectangular shape and the side wall 18 includes curved corner panels 22 and substantially straight side panels 24. As shown in FIG. 3, the shell 8 is manufactured such that, initially, the height of each of the side panels 24 is greater than the height of each of the corner panels 22; the corner panels 22 each being of a first height and the side panels 24 each being of a second height. In this way, tab portions 25 of the side panels 24 extend upwards beyond the height of the corner panels 22.

To finish forming the shell 8 of the container 1 the tab portions 25 are folded outwards as indicated by the arrows in FIG. 3. Once folded, the tab portions 25 form skirt portions 26 that extend downwards on an exterior side of the side panels 24. The folded or curved top edge 28 of each of the skirt portions 26 preferably lies flush with a top edge 30 of each of the corner panels 22, thereby forming a continuous top edge or rim 32 of the shell 8; however, the top edge 28 of each of the side panels 24 may lie above the top edge 30 of the corner panels 22 as shown in FIG. 1.

Although in this embodiment the outer shell 8 is made from a cardboard or paperboard material, in other embodiments the outer shell 8 may be made from a plastics material.

The sealing element or collar 2, shown most clearly in FIGS. 4 to 7, includes an annular member 34 that attaches to and extends around the rim 32 of the shell 8 of the container 1. Accordingly, in this example, the annular member 34 is substantially non-circular, having a rounded rectangular shape comprising corner regions 36 and side regions 38.

The sealing element 2 comprises a mounting portion 40, a securing portion 42 and engagement means 44. The mounting portion 40 includes a first, inner annular wall 46, and a second outer annular wall 48. The inner and outer annular walls 46, 48 are connected at their respective top edges, thereby defining a channel 50 between them that extends fully around the sealing element 2. When the sealing element 2 is secured to the shell 8, the element 2 is seated over the rim 32 of the shell 8 so that inner annular wall 46 extends downwards over an interior surface 47 of the side wall 18 of the shell 8, the second outer annular wall 48 extends downwards around an exterior of the shell 8, and the rim 32 of the shell 8 is positioned within the channel 50.

In this embodiment a first part of the engagement means 44, in the form of a rail member 52, extends upwards from the mounting portion 40. The rail member 52 extends continuously around the sealing element 2. A second part of the engagement means 44, in the form of a rib or barb 54, projects from an outer surface of the outer annular wall 48 of the mounting portion 40. The engagement means 44 is designed to engage with a complementary sealing element 14 on the lid 6 of the container 1, as described further below.

As shown most clearly in FIG. 5, the arrangement of the rail member 52 and the inner and outer annular walls 46, 48 is such that a vertical cross-section through the mounting portion 40 and engagement means 44 is substantially wishbone-shaped.

In this example, the securing portion 42 is connected to the outer annular wall 48 of the mounting portion 40. The securing portion 42 is arranged to engage with the skirt portion 26 of the shell 8 to secure the sealing element 2 to the shell 8. The securing portion 42 comprises a substantially U-shaped channel member 56 having two parallel arm members 58, 60 that extend along the length of the channel member 56 and a base member 62 connecting the two arm members 58, 60, such that an opening 63 is defined between the arm members 58, 60. An edge of a first one of the arm members 58 is hingedly connected to the outer annular wall 48 of the mounting portion 40. An edge 64 of the other one of the arm members 60 is a free edge 64.

In this embodiment the annular member 34 of the sealing element 2 is a unitary member and the arm member 58 is hingedly connected to the outer annular wall 48 by a natural or live hinge 66 formed in the plastics material of the sealing element 2. In other embodiments the hinged connection may be formed in any other suitable way. In still further embodiments the connection between the mounting portion 40 and the securing portion 42 may be made in any suitable way that enables pivoting or rotation of the securing portion 42 with respect to the mounting portion 40.

The hinged connection enables the securing portion 42 of the sealing element 2 to rotate with respect to the mounting portion 40 between a disengaged position, shown most clearly in FIG. 4, and an engaged position, shown most clearly in FIG. 5. In the disengaged position the securing portion 42 is positioned on an external side of the mounting portion 40, with the channel 50 of the mounting portion 40 and the opening 63 of the securing portion 42 oriented in the same direction. In the engaged position, the securing portion is 42 is positioned below the mounting portion 40 so that the channel 50 of the mounting portion 40 and the opening 63 of the securing portion 42 are oriented in opposite directions. Furthermore, in this engaged position the arm member 58 is substantially continuous with the outer annular wall 48 of the mounting portion 40, and the free edge 64 of the arm member 60 is located between the inner and outer annular walls 46, 48.

To secure the sealing element 2 to the outer shell 8, the mounting portion 40 is pressed over the top edge 28 of each of the skirt portions 26. The securing portion 42 is then moved from the disengaged position to the engaged position such that the channel member 56 locates around and under the skirt portion. In the engaged position, the skirt portion 26 of the shell 8 is located in the opening 63 of the securing portion 42 and the arm member 60 is located between the side panel 24 and the skirt portion 26 of the shell 8.

As shown in FIG. 1, separate skirt portions 26 are formed along each of the side panels 24 of the shell 8 and separate securing portions 42 are formed along each of the side regions 38 of the annular member 34. Once all of the securing portions 42 have been moved into their engaged position and engaged with the respective skirt portion 26, the sealing element 2 is then, preferably, fully secured to the shell 8 using suitable retaining means.

In a preferred embodiment the retaining means is in the form of a length of adhesive tape (not shown) that is placed fully around the sealing element 2 in contact with the outer annular wall 48 and all of the arm members 58. With the tape adhered to the sealing element 2 in this way, the securing portions 42 are then unable to move out of their engaged positions back to the disengaged positions without first removing the retaining means.

In this embodiment, the sealing element 2 further comprises attachment means 68 in the form of a pair of mounting tabs or brackets 68 to which the handle 12 may be attached. As shown in FIG. 1, the mounting tabs 68 are positioned centrally along opposing side regions of the annular member 34. Each of the mounting tabs 68 includes a hole 70 for engagement with a part of the handle 12.

The handle 12 is substantially U-shaped and is formed of a suitable plastics material. In preferred embodiments the handle 12 is made of the same plastics material as the sealing element 2. The handle 12 includes two arm portions 72, one extending from either end of a central gripping portion 74. At a free end of each of the arm portions there is an inwardly projecting pin or trunnion 76.

When the handle 12 is attached to the main body 4 of the container 1, each of the trunnions 76 locates in a respective one of the holes 70 in the mounting tabs 68 of the sealing element 2. In this way, a pivotal connection is made between the handle 12 and the main body 4 of the container 1.

When a user lifts the container 1 by the handle 12, an upward force is exerted on the sealing element 2, which tries to pull the sealing element 2 off the top of the side wall 18 of the shell 8. However, because the securing portion 42 of the sealing element 2 is engaged with the skirt portion 26, and in particular because the arm member 60 is located between the side panel 24 and the skirt portion 26 of the shell 8, the sealing element 2 cannot be pulled upwards relative to the shell 8, and the sealing element remains securely attached to the shell 8.

As shown most clearly in FIGS. 5 and 6, the lid 6 includes a sealing element 14 that engages with the engagement means 44 of the sealing element 2 when the lid 6 is placed onto the main body 4 of the container. In this example, the sealing element 14 of the lid 6 comprises a channel portion 78 that is sized to receive the rail member 52, and an inwardly extending projection or barb 80 on an internal surface of an outer side wall 82.

When the sealing element 14 of the lid 6 is pressed down over the sealing element 2 of the main body 4, there is a push fit of the rail member 52 into the channel portion 78, and the outer side wall 82 extends down over the outer annular wall 48. The outer side wall 82 is able to resiliently flex such that the barb 80 of the sealing element 14 engages with the barb 54 of the sealing element 2 to retain the lid 6 on the main body 4, as shown in FIG. 6.

The lid 6 can be removed from the main body 4 by flexing the outer side wall 82 to disengage the barbs 54, 80 and then pulling the lid 6 in an upwards direction to remove the rail member 52 from the channel portion 78.

Because both the sealing elements 2, 14 are formed from a suitable plastics material, the engagement and seal between the sealing elements 2, 14 can be repeatedly formed during use of the container 1.

In preferred embodiments of the invention, the main body of the container includes an inner lining 10 made from a thin film plastics material, shown in FIG. 1. This lining 10 acts as a barrier layer preventing leaking of the contents of the container 1 through the paperboard shell 8. The barrier properties of the lining 10 may additionally prevent moisture or gasses entering or leaving the container 1 which may spoil or degrade the contents of the container 1.

Considering paints in particular, water-based paints are typically flushed with formaldehyde, or a similar substance, immediately before being sealed within a container to prevent the growth of fungus or bacteria in the paint. Similarly, it is necessary to prevent the evaporation of volatile additives from oil-based paints. In both these example, therefore, the barrier properties of the lining 10 must be tailored to prevent gas permeation through the lining 10.

In this example the lining 10 is made from thin-film polyethylene; however, the lining 10 may be made from any suitable thin-film plastics material. In particular, it may be preferable if the lining 10 is a laminate formed of a number of plastics materials. These laminates may include a gas barrier material such as EVOH that will, amongst other things, prevent paint odours being released from the container 1. The laminates may additionally or alternatively include a nylon layer which provides tear resistance. Preferably the thickness of the lining 10 is less than 200 μm, and more particularly around 100 μm. The thinner the lining 10 the lower the cost of materials and the less waste that is formed. However, the lining 10 should be thick enough that it does not tear during the manufacturing process or during use of the container 1, e.g. when the contents are being stirred, and in particular during removal of the lining 10 from the shell 8, as described below.

In preferred embodiments, the lining 10 is inserted into and secured to the shell 8 of the container 1 after the sealing element 2 has been secured to the rim 32. In particular, once the mounting portion 40 of the sealing element 2 has been fitted over the rim 32 of the shell 8, a pre-formed lining 10 that at least substantially conforms to the internal shape of the shell 8 is then positioned within the interior of the shell 8, and subsequently the lining 10 is adhered to the internal surfaces 47 of the side wall of the shell 8, an internal surface 84 of the base 16 of the shell 8 and the inner annular wall 46 of the sealing element 2.

Preferably the lining 10 is secured to the shell 8 and the sealing element 2 using a suitable adhesive. The adhesive should have a low peel strength but a moderate shear strength, similar to the adhesive used on Post-It® Notes. The moderate shear strength of the adhesive means that the thin-film lining 10 will remain adhered to the internal surfaces 47, 84 of the outer shell 8 during use of the container 1. Additionally, because the containers 1 may be nested during transportation or storage before filling, it is important that, when the nested containers 1 are separated from each other, the lining 10 does not get pulled away from the outer shell 8. In contrast, the low peel strength means that minimal force is required to peel the lining 10 away from the outer shell 8 after use, in order to dispose of and recycle the lining 10 and the outer shell 8 separately. Preferably the peel strength of the adhesive use to bond the lining 10 to the shell 8 is less than 0.05 N, and more preferably between 0.02 N and 0.04 N.

In a preferred embodiment, the adhesive is heat activated. The use of a heat activated adhesive means that the adhesive is only tacky when heated above a certain temperature. In this way, the lining 10 may be inserted into the shell 8 in a non-activated state in which the adhesive is not tacky. Once the lining 10 is correctly positioned within the shell 8, heat is then applied to increase the temperature and cause activation of the adhesive. The activated adhesive, which is tacky, then adheres the lining 10 to the internal surfaces 47, 84 of the shell 8 and the inner annular wall 46 of the sealing element 2.

In other embodiments the adhesive may be pressure activated. As such, the adhesive only becomes tacky once a sufficient pressure has been applied to it. In yet other embodiments the adhesive may be pressure and heat activated.

The advantage of using an activated adhesive is that neither the internal surfaces 84 of the shell 8 nor external surfaces of the lining 10 are tacky when the lining is inserted into the shell 8. This allows the lining 10 to be positioned, and re-positioned, exactly as desired before the lining 10 is finally adhered to the shell 8. In particular it allows the lining to be positioned against the internal surfaces 84 of the shell 8 so that there are no wrinkles or creases in the lining 10.

In preferred embodiments the lining 10 is more securely adhered or bonded to the sealing element 2 than to the internal surfaces 84 of the shell 8. More securely bonding the lining 10 to the sealing element 2 enables the sealing element 2 and the lining 10 to be separated from the shell 8 without the lining 10 separating from the sealing element 2, as described further below.

Because the lining 10 is secured to the sealing element 2, a complete layer of plastics material is provided covering the internal surfaces 47, 84 of the shell 8 and extending over the rim 32 of the shell 8, thereby protecting the paperboard shell 8 from the contents of the container 1.

Once the lining 10 has been secured in the shell 8, the securing portions 42 of the sealing element 2 are engaged with the skirt portions 26 and the retaining means is placed around the sealing element 2, as described above. In other embodiments, the securing portions 42 of the sealing element 2 may be engaged with the skirt portions 26 before the lining 10 is secured within the shell 8.

When a user wishes to dispose of the container 1, he or she can separate the plastics sealing element 2 and lining 10 from the paperboard shell 8 to enable these to be disposed of or recycled separately. To do this a user firstly removes the retaining means from around the sealing element 2. The securing portions 42 are then unclipped from the skirt portions 26 and the sealing element 2 is pulled upwards to disengage the rim 32 of the shell 8 from the mounting portion 40. The relatively low peel strength of the adhesive used to adhere the lining 10 to the internal surfaces 47, 84 of the shell 8 allows the lining 10 to be separated from the shell 8 as the sealing element 2 is removed, such that the sealing element 2 and lining 10 are removed together as a single piece. This allows the plastics and paperboard parts of the container 1 to be disposed of or recycled separately.

In some embodiments the outer shell is made from a plastics material and an inner lining is provided to prevent the contents of the container 1 from contaminating the shell. In these embodiments the construction of the container according to the present invention enables the sealing element and lining, which have been contaminated, to be easily separated from the uncontaminated shell of the container.

In alternative embodiments the sealing element 2 and the lining 10 may be removed from the shell 8 separately.

FIGS. 8 to 14 illustrate a second preferred embodiment of a container 101 comprising a sealing element 102 according to the present invention. This container 101 includes many features that are the same as or comparable to features of the container 1 of the first embodiment described above. Similar features have been indicated by reference numerals incremented by 100. An outer shell 108 of the container 101 is made from a suitable paperboard or cardboard material with no wax or plastics coating or lamination. The shell 108 comprises a substantially circular base 116 and a side wall 118, the side wall 118 extending fully around the periphery of the base 116 and extending upwards from the base.

In this embodiment the shell 108 comprises an inner side wall 118a and an outer side wall 118b in contact with each other, as shown most clearly in FIG. 12. The outer side wall 118b is substantially cylindrical and extends between a top edge 131b and a bottom edge 121b. An upper region 126 of the outer side wall 118b proximate the top edge 131b is positioned radially outwardly in relation to the rest of the outer side wall 118b, thereby forming a downwardly facing abutment shoulder or edge 127. This upper region 126 may be in the formed of a rolled edge or a skirt portion 126 that extends downwards on an exterior side of the outer side wall 118b.

The inner side wall 118a comprises a plurality of tabs 119 extending from a bottom edge. The tabs 119 extend radially inwardly and the base 116 of the shell 108 is bonded to an upper surface of the tabs 119.

Top edges 131a, 131b of the inner and outer side walls 118a, 118b together form a rim 132 of the shell 108 that extends around and defines an opening 105 of the shell 108.

Although in this embodiment the container 101 has inner and outer side walls 118a, 118b, it will be appreciated that in other embodiments the container may include a single side wall 118.

The sealing element 102, shown most clearly in FIGS. 10 and 12, comprises a mounting portion 140 for mounting the sealing element 102 on the rim 132 of the shell 108, a securing portion 142 for securing the sealing element 102 to the side wall 118 of the shell 108, and engagement means 144 configured to releasably engage with a lid (not shown) of the container 101. Typically the sealing element 102 will be made from a suitable plastics material.

The mounting portion 140 includes an annular member 134 that extends around the rim 132 of the shell 108. The annular member 134 includes a wall portion 146 that, when engaged with the shell 108 of the container 101, extends downwards over an interior surface 147 of the inner side wall 118a. As such, the external diameter of the wall portion 146 is substantially the same as the internal diameter of the inner side wall 118a. An upper edge of the wall portion 146 includes a flange or lip 145 that extends radially outwardly. This flange 145 will typically abut or be seated on the rim 132 of the shell 108 when the mounting portion 140 is fully engaged with the shell.

The mounting portion 140 further comprises stacking members 186 connected to a radially outer edge of the flange 145. Each of the stacking members 186 comprises a plate member 188 extending substantially perpendicularly to the flange 145. The plate member 188 has a first portion 189 extending upwards from the flange 145 and a second portion 190 extending downwards from the flange 145. The second portion 190 of the plate member 188 therefore extends substantially parallel to the wall portion 146 of the annular member 134, and a gap is defined between the second portion 190 of the plate member 188 and a part of the wall portion 146. When the mounting portion 140 is engaged with the shell 108, a part of the rim 132 of the shell 108 locates in each of these gaps provided by the stacking members 186. The second portions 190 of the stacking members 186 therefore aid in retaining the mounting portion 140 in engagement with the side wall 118 of the shell 108.

The first portions 189 of the plate members 188 protrude above the rest of the annular member 134 and define a space for receiving a base of another container 101 when the containers are being stacked.

In this embodiment four stacking members 186 are provided at spaced apart locations around the annular member 134; however, in other embodiments different numbers of stacking members may be provided. Generally, at least two stacking members are provided located on diametrically opposite sides of the annular member.

The engagement means 144 extends generally radially inwardly from the mounting portion 140, and includes an upward facing channel 192. The engagement means 144 is configured to engage with a complementary sealing element on the lid of the container 101 such that the lid can be repeated engaged and disengaged from the rest of the container 101.

In this embodiment the securing portion 142 comprises a plurality of securing tabs 194 extending from the flange 145 of the annular member 134. The securing portion 142 is arranged to engage with the abutment shoulder 127 of the shell 108 to secure the sealing element 102 to the shell 108. Each of the tabs 194 is hingedly connected to the annular member 134 at a top edge so that the securing portion 142 is movable between a first, disengaged position, shown most clearly in FIG. 10, and a second, engaged position, shown most clearly in FIG. 12.

In this embodiment the sealing element 102 is a unitary member and each of the tabs 194 is hingedly connected to the flange 145 by a natural or live hinge 166 formed in the plastics material of the sealing element 102. In other embodiments the hinged connection may be formed in any other suitable way. In still further embodiments the connection between the mounting portion 140 and the securing portion 142 may be made in any suitable way that enables pivoting or rotation of the securing portion 142 with respect to the mounting portion 140.

Each of the tabs 194 comprises opposing first and second faces 193, 195. When the tab 194 is in the engaged position the first face 193 faces away from the side wall 118 of the shell 108 and the second face 195 is located radially inwardly of the first face 193 and faces towards the side wall 118 of the shell 108. A detent member 196 protrudes from the second face 195 of each of the tabs 194. The detent member 196 is located such that, when the tab 194 is in the second position, the detent member 196 extends under the abutment shoulder 127 of the shell 108. The location of the detent members 196 is, therefore, such that, when the securing portion 142 is in the second position and an upward force is applied to the sealing element 102, the detent members 196 contact the abutment shoulder 127 and prevent the sealing element 102 being pulled off the shell 108.

In this embodiment each tab 194 further comprises a pair of rail members 197 extending from the first face 193. The rail members 197 are spaced apart such that a channel 198 is defined between them. The rail members 197 preferably extend substantially parallel to the top edge of the tab 194. The channel 198 between the rail members 197 is sized to receive a part of a retaining means 199, described further below.

In use, with the tabs 194 of the securing portion 142 in the first position, the annular member 134 is engaged with the rim 132 of the container 101 such that the wall portion 146 extends down over the interior surface 147 of the side wall 118 and the second portions 190 of the stacking members 186 extend down over an exterior surface of the side wall 118. Each of the tabs 194 of the securing portion 142 is then pivoted, by means of the hinge, into the second position so that the detent member 196 is located under the outwardly protruding upper region 126 of the side wall 118.

Once all of the tabs 194 are in the second position, retaining means 199 in the form of an elongate strap or band 199 is secured around the outside of the tabs 194 such that the strap or band 199 locates in the channels 198 provided on the tabs 194. The strap or band 199 is tightened, i.e. a diameter of the strap 199 is decreased, so as to apply a radially inwardly directed force to the tabs 194 to retain the tabs 194 in the second position. Locating the strap 199 in the channels 198 means that once the strap 199 has been tightened and secured, the strap 199 cannot be easily removed from around the securing portion 142 without cutting the strap 199. The retaining strap 199 may be made from a suitable plastics material or a paperboard material having sufficient strength to retain the tabs 194 in the engaged position during storage and use of the container 101.

In preferred embodiments the container 101 further comprises a lining 110 that extends over and covers the interior surfaces 147 of the shell 108. The lining 110 is preferably made from a thin film plastics material and acts as a barrier layer preventing leakage of the contents of the container 101 through the paperboard shell 108. The barrier properties of the lining 110 may additionally prevent moisture or gasses entering or leaving the container which may spoil or degrade the contents of the container 101.

The size and shape of the lining 110 is such that it substantially conforms to the internal shape of the shell 108. An upper edge region of the lining 110 locates between the side wall 118 of the shell 108 and the wall portion 146 of the sealing element 102, as illustrated in FIG. 14. This upper edge region of the lining 110 is bonded or welded to the wall portion 146 so as to form a liquid-tight seal between the lining 110 and the sealing element 102.

Typically the lining 110 will not be adhered to the side wall 118 of the shell 108, but the lining 110 may be adhered to the base 116 of the shell 108 to retain the lining 110 in the correct position with respect to the shell 108.

In these embodiments, once the container 101 has been used, the sealing element 102 and the lining 110 may be separated from the shell 108 of the container 101 for disposal or recycling.

To remove the sealing element 102 from the rim 132 of the shell 108, the retaining strap 199 is cut such that the securing tabs 194 can be moved at least partially back towards the first position. In particular each of the securing tabs 194 is moved such that the detent member 196 is withdrawn from under the protruding upper edge 126 of the shell 108. The sealing element 102 can then be lifted off and away from the side wall 118 of the shell 108.

Because the lining 110 is bonded to the mounting portion 140 of the sealing element 102, the lining 110 is removed together with the sealing element 102. In embodiments in which the lining 110 is adhered to the base 116 of the shell 108, the level of adhesion is such that the lining 110 can be pulled or peeled away from the base 116 without tearing the lining 110.

In this embodiment the sealing element 102 further comprises attachment means 168 for a handle. The attachment means 168 comprises a pair of attachment plates 168 connected to the flange 145 of the mounting portion 140. Each of the attachment plates 168 includes an aperture 170 for receiving a part of an end of a handle. The attachment means 168 are preferably configured such that the handle may be pivotally attached to the sealing element 102.

A further example of a container 201 including a handle 212 is shown in FIG. 15. The ends of the handle 212 are attached to the sealing element 202 by means of attachment plates 268 positioned on diametrically opposite sides of the mounting portion 240. The handle 212 and the means of attachment of the handle 212 to the sealing element 202 are substantially identical to the handle 12 and its means of attachment described above in relation to the first embodiment of a container 1 and will not be described further here.

The embodiment of the container 201 illustrated in FIGS. 15 to 17 is substantially identical to the embodiment illustrated in FIGS. 8 to 14 except that the depth of the container 201, i.e. a height of the side wall 218, is increased to provide a larger volume container 201. The diameter of this container 201 is the same as the diameter of the smaller volume container 101 shown in FIGS. 8 to 14. This means that the same sealing element 102, 202 may be used in both sizes of container. Furthermore, the two different sizes of container 101, 201 can be stacked together.

The present invention, therefore, provides a sealing element for a container, a container including a sealing element and a method of forming a container including a sealing element that enables the container to be repeatedly resealed and further enables plastics and paperboard parts, or contaminated and uncontaminated parts, of the container to be easily separated for disposal or recycling.

Claims

1. A sealing element for a container, the container comprising a main body and a lid, the main body of the container including a side wall having a top edge defining an opening of the container, and the sealing element comprising:

a mounting portion comprising an annular member for engaging with the top edge of the side wall;
engagement means configured for repeated sealing engagement with said lid of the container; and
a securing portion configured to secure the sealing element to the side wall, the securing portion being hingedly connected to the mounting portion and moveable between a first position in which the mounting portion can be engaged and disengaged from said top edge, and a second position in which the securing portion prevents the mounting portion from being disengaged from said top edge.

2. A sealing element as claimed in claim 1, further comprising retaining means configured to retain the securing portion in the second position.

3. A sealing element as claimed in claim 2, wherein the retaining means comprises a strap.

4. A sealing element as claimed in claim 1, wherein the annular member comprises a wall portion that, in use, extends down over an interior surface of the side wall of the container.

5. A sealing element as claimed in claim 1, wherein, in use, when the securing portion is in the second position, the securing portion extends down over an exterior surface of the side wall of the container.

6. A sealing element as claimed in claim 1, wherein the container includes a downwardly facing abutment shoulder or edge on an external side of the side wall proximate the top edge, and the securing portion of the sealing element comprises a detent configured to engage with said shoulder or edge when the securing portion is in the second position, thereby preventing the mounting portion from being disengaged from said top edge.

7. A sealing element as claimed in claim 1, wherein the securing portion comprises a plurality of tabs, each tab being hingedly connected to the annular member.

8. A sealing element as claimed in claim 7, wherein the sealing element comprises means configured to retain the securing portion in the second position and each of the tabs includes a channel for receiving a part of said retaining means.

9. A sealing element as claimed in claim 7, wherein the tabs are spaced around and extend from a periphery of the annular member.

10. A sealing element as claimed in claim 1, wherein the mounting portion, engagement portion and securing portion are parts of a unitary piece.

11. A sealing element as claimed in claim 1, wherein the mounting portion comprises attachment means for attaching a handle to the sealing element.

12. A container comprising:

a shell comprising a base and a side wall, the side wall having a top edge defining an opening of the container;
a lid for covering and sealing the opening of the shell; and
a sealing element secured around the top edge of the side wall of the shell, the sealing element comprising: a mounting portion comprising an annular member for engaging with the top edge of the side wall; engagement means configured for repeated sealing engagement with said lid of the container; and a securing portion configured to secure the sealing element to the side wall, the securing portion being hingedly connected to the mounting portion and moveable between a first position in which the mounting portion can be engaged and disengaged from said top edge, and a second position in which the securing portion prevents the mounting portion from being disengaged from said top edge.

13. A container as claimed in claim 12, wherein the shell of the container is made of a paperboard material.

14. A container as claimed in claim 12, wherein the container further comprises a lining covering internal surfaces of said shell.

15. A container as claimed in claim 14, wherein the lining is made of a thin film plastics material, the shell is made of a paperboard material and the sealing element is made of a relatively rigid plastics material.

16. A container as claimed in claim 14, wherein the annular member comprises a wall portion that, in use, extends down over an interior surface of the side wall of the shell and the lining is bonded to the wall portion.

17. A method of constructing a container, the container comprising:

a shell comprising a base and a side wall, the side wall having a top edge defining an opening of the container; and
a sealing element comprising a mounting portion comprising an annular member for engaging with the top edge of the side wall, engagement means configured for repeated sealing engagement with a lid of the container, and a securing portion configured to secure the sealing element to the side wall, the securing portion being hingedly connected to the mounting portion and moveable between a first position in which the mounting portion can be engaged and disengaged from said top edge, and a second position in which the securing portion prevents the mounting portion from being disengaged from said top edge, and
the method comprising the steps of:
with the securing portion in the first position, seating the mounting portion of the sealing element on the top edge of the side wall; and
moving the securing portion into the second position to secure the sealing element to the side wall.

18. A method of constructing a container as claimed in claim 17, in which the mounting portion of the sealing element comprises a wall portion and the container further comprises a lining covering interior surfaces of said shell, and wherein the method comprises:

seating the mounting portion such that the wall portion extends down over an interior surface of the side wall and an upper region of said lining is located between the side wall and the wall portion of the sealing element; and
bonding the wall portion of the sealing element to said lining.

19. A method of constructing a container as claimed in claim 17, in which the securing portion comprises a plurality of tabs hingedly connected to the mounting portion, and wherein the method comprises moving each of said tabs from the first position to the second position once the mounting portion has been engaged with the top edge of the shell.

20. A method of constructing a container as claimed in claim 17, in which the container further comprises retaining means, and wherein the method comprises affixing the retaining means to the sealing element to retain the securing portion in the second position to prevent the sealing element being disengaged from the top edge of the side wall.

21. A method of constructing a container as claimed in claim 20, wherein the retaining means comprises a strap and the securing portion comprises a channel for receiving said strap, and wherein the method comprises placing the strap in the channel and adjusting the strap such that the strap applies a force to the securing portion to retain the securing portion in the second position.

Patent History
Publication number: 20160272388
Type: Application
Filed: Nov 13, 2014
Publication Date: Sep 22, 2016
Inventor: Henry William Slack (Greater London)
Application Number: 15/034,941
Classifications
International Classification: B65D 53/00 (20060101); B65D 21/02 (20060101); B65D 43/02 (20060101); B65D 25/14 (20060101); B65D 25/32 (20060101);