CONTAINER LID AND LINER, AND METHOD OF MANUFACTURING THE SAME

Abstract

This invention provides for a laminated liner (2) for a food or beverage ingredient container lid (416) comprising at least one lower layer (4) comprising one or more perforations (8) and at least one upper layer (6) comprising no perforations, and wherein the non-perforated upper layer or layers is/are releasably attached to the perforated lower layer or layers.

Claims

1: A laminated liner for a food or beverage ingredient container lid comprising at least one perforated lower layer comprising one or more perforations and at least one non-perforated upper layer comprising no perforations, and wherein the non-perforated upper layer or layers is/are releasably attached to the perforated lower layer or layers.

2: A laminated liner as claimed in claim 1 wherein the liner comprises only one non-perforated upper layer.

3: A laminated liner as claimed in claim 1 wherein the liner comprises at least two perforated lower layers and a non-perforated upper layer.

4: A laminated liner as claimed in claim 1 comprising multiple perforations.

5: (canceled)

6: A laminated liner as claimed in claim 1 wherein the total length of the diameter or diameters (or largest dimension) of the perforation or the perforations is in the range of 0.01 to 1 mm.

7: A laminated liner as claimed in claim 1 wherein the non-perforated layer or layers is/are releasably connected to the perforated layer or layers, by way of an adhesive layer.

8: (canceled)

9: A laminated liner as claimed in claim 1 wherein the non-perforated layer or layers has/have the same diameter and/or dimensions as the perforated layer or layers.

10-12: (canceled)

13: A laminated liner as claimed in claim 1 wherein the perforation or perforations of the perforated layer or layers is/are arranged such that in use each perforation is exposed to the atmosphere after detaching the non-perforated upper layer or layers from the lower layer or layers.

14: A laminated liner according to claim 13 wherein the perforation or perforations on the perforated layer or layers is/are arranged in use to open a fluid communication through the lower layer or layers after the upper layer or layers is/are detached.

15: A laminated liner as claimed in claim 1 wherein the perforated layer or an uppermost one of the perforated layers in use becomes an uppermost layer of the liner after detaching the non-perforated layer or layers.

16: A food or beverage ingredient container lid having an inside and an outside surface and comprising a multi-layered laminated liner according to claim 1 wherein an uppermost layer of the liner is connected to the inside surface of the lid.

17: A food or beverage ingredient container lid according to claim 16 wherein the non-perforated layer or layers on the inside surface of the lid is/are fixedly retained on the inside surface of the lid after the layer or layers is/are detached.

18: A food or beverage ingredient container lid as claimed in claim 16 wherein only the uppermost layer of the liner is non-perforated.

19: A method of assembling a liner for a food or beverage ingredient container lid comprising the steps of a) providing a laminated liner comprising at least one lower layer and at least one upper layer, wherein the upper layer or layers is/are releasably connected to the lower layer or layers; and b) making at least one perforation through the lower layer or layers of the laminated liner, whilst leaving at least one upper layer intact with no perforation, in order to obtain a partially perforated laminated liner.

20: A method according to claim 19 further comprising a step of shaping a liner perimeter between step a) and b) or simultaneously with step b).

21: A method according to claim 19 wherein the shaping step comprises cutting the liner to form a perimeter shape corresponding to a food or beverage ingredient container lid interior surface perimeter.

22: A method according to claim 19 wherein the liner comprises at least two lower layers which are perforated in step b).

23: A method according to claim 22, wherein the liner comprises at least two lower layers comprising a lowermost container opening sealing layer and an adhesive layer, and an upper layer comprising an uppermost container lid contact layer.

24: A method according to claim 22 wherein the liner comprises four or more layers and each layer other than an uppermost one of the layers is perforated in step b).

25: A method according to claim 24 wherein the four layers comprise a lowermost container opening sealing layer, a metal layer, an adhesive layer and an uppermost container lid contact layer.

26-29: (canceled)

30: A method of manufacturing a food or beverage ingredient container lid comprising performing the method of claim 19 and further comprising: step c) providing a food or beverage container lid having an inside surface and an outside surface and connecting the uppermost layer of the partially perforated liner to the inside of the food or beverage container lid; and wherein steps b) and c) are performed simultaneously or consecutively.

31: A method of assembling a food or beverage ingredient container comprising the steps of sealing a lowermost layer of the liner produced in claim 19 to an opening of a food or beverage ingredient container before, during or after a step of providing a food or beverage container lid having an inside surface and an outside surface and connecting the uppermost layer of the partially perforated liner to the inside of the food or beverage container lid.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0063] In order that the invention may be more clearly understood, embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings of which:

[0064] FIG. 1a illustrates a top-down view of a first embodiment of a laminated liner for a food or beverage ingredient container lid (or a laminated seal or cover for the opening or rim of a food or beverage container) according to the invention;

[0065] FIG. 1b illustrates a side cross sectional view along line C-C of a laminated liner of the first embodiment of FIG. 1a according to the invention;

[0066] FIG. 2 illustrates a side cross sectional view along line C-C of a second embodiment of a laminated liner for a food or beverage ingredient container lid (or a laminated seal or cover for the opening or rim of a food or beverage container) according to the invention, having three layers;

[0067] FIG. 3 illustrates a side cross sectional view along line C-C of a third embodiment of a laminated liner for a food or beverage ingredient container lid (or a laminated seal or cover for the opening or rim of a food or beverage container) comprising three lower perforated layers and one single non-perforated upper layer, according to the invention;

[0068] FIG. 4 illustrates a side cross sectional view along line C-C of an alternative four-layer laminated liner for a food or beverage ingredient container lid (or a laminated seal or cover for the opening or rim of a food or beverage container) to that shown in FIG. 3, comprising two lower perforated layers and two upper non-perforated layers, according to the invention;

[0069] FIG. 5 illustrates a side cross sectional view along line C-C of an assembly of a two-layer laminated liner of the invention, inserted into a food or beverage ingredient container lid according to the invention;

[0070] FIG. 6a illustrates a side cross sectional view along line C-C of a container of the invention comprising an assembly of a food or beverage ingredient container lid of the invention provided with a two-layers laminated liner of the invention, and a food or beverage ingredient container;

[0071] FIG. 6b illustrates a side cross sectional view along line C-C of the food or beverage ingredient container lid detached from a food or beverage ingredient container of FIG. 6a.

[0072] Referring to the following Figures like numbers represent like components.

[0073] Referring firstly to FIG. 1a and FIG. 1b an embodiment of a two-layer laminated liner (2) for a food or beverage ingredient container lid, according to the invention, is shown. In such embodiment the laminated liner (2) is provided by the combination of a lower, perforated layer (4) and an upper, non-perforated layer (6) in such a way that the lower surface of the non-perforated (6) layer detachably adheres to the upper surface of the perforated layer (4). The lower perforated layer (4) includes a number of perforations (8) extending therethrough. Both layers (4, 6) are aligned with each other so that the lower surface of the non-perforated layer (6), is configured on the upper surface of the perforated layer (4), and covers the perforations (8) of the perforated layer (4) and the external perimeters and shapes of (1) of the two layers (4, 6) match each other.

[0074] The two layers (4, 6) in this embodiment are maintained adjacent by the conformation, shape and/or structure of the abutting surfaces which comprise gripping means which may for example be textured and/or embossed areas of one or both layers (4,6), ensuring a stable engagement of the two layers (4,6) to each other.

[0075] In an alternative arrangement of the first embodiment (not shown), the two layers (4, 6) may be kept adjacent and aligned through an adhesive material (not shown) which may be applied to the abutting surfaces of one or both the adjacent layers (4, 6).

[0076] In a further arrangement, as alternative solution, the layers' (4,6) surfaces to be releasably connected may be made of and/or incorporate an adhesive or tacky material which makes the two surfaces releasably adhere to each other, keeping them connected until further forces are applied to them.

[0077] Further, in other arrangements, to ensure that the two layers stay in contact, a wax type material may be used as an alternative to or in combination with the adhesive material. In the arrangement of the first embodiment, the connection between the perforated layer (4) and the non-perforated layer is a releasable connection, i.e. the two layers (4,6) can be separated from each other to expose the perforations (8) through an action performed by the user which breaks this connection.

[0078] In the first embodiment, the perforated and non-perforated layers (4,6) have identical shapes and these may include a disc, circle, oval, triangle, trapezium, rectangle, square, rectangle, square, parallelogram, or pentagon shape. When the perforated and non-perforated layers (4,6) have a disc or circular shape, the largest dimension (diameter) may be identical and in the range of 10 mm and 100 mm. In a preferred arrangement of the first embodiment of the invention, the diameter can vary between 20 mm and 70 mm.

[0079] The perforated layer (4) of FIG. 1 may be in the form of an aluminium foil, while the non-perforated layer (6) may be in the form of a cardboard, cartonboard, paperboard, paper and/or a polymeric substrate such as polyethylene, expanded polyethylene foam or the like, and preferably having a thickness of between 0.01 to 2 mm. For manufacturing the non-perforated layer (6) any combination of the abovementioned materials can be taken into consideration.

[0080] In an alternative arrangement of the first embodiment of the invention the lower perforated layer (4) may include one single perforation or hole rather than a plurality of perforations or holes (8). In the embodiment shown for FIG. 1a and 1b, the multiple perforations (8) may be arranged into a pattern or arranged randomly through the entire surface of the perforated layer (4). The single perforation and/or the plurality of perforations (8) is/are adapted to extend the entire depth of the perforated layer in order to create a passageway through the perforated layer (4) itself.

[0081] In a preferred arrangement of the first embodiment of the invention, the total length of the diameter or diameters of the perforation and/or perforations (8) may be in the range between 0.1 and 1 mm, preferably between 0.2 and 0.7 mm and more preferably around 0.5 mm. The connection between the perforated layer (4) and non-perforated layer (6) is a releasable connection which ensures exposure of the perforations (8) to the atmosphere when a force is applied to the liner, such as pulling the upper non-perforated layer.

[0082] In the embodiment of FIG. 2, a three-layer laminated liner (102) according to the invention is represented.

[0083] In the embodiment of FIG. 2, the liner (102) comprises a lowermost lower perforated layer (110) and an uppermost lower perforated layer (104) which are connected to each other in such a way that their perimeters (101) match and are aligned one on top of the other. The lower surface of the uppermost perforated layer (104) is abutting/adjacent to the upper surface of the lowermost perforated layer (110). A plurality of perforations (108) goes all the way through the entire depth of the two perforated layers (104, 110).

[0084] A non-perforated layer (106) is connected to the uppermost perforated layer (104) in such a way that perforations (108) are obstructed and not exposed to the atmosphere. The same types of connections as described in the embodiment of FIG. 1, can be used to connect, attach, the two layers 104 and 106.

[0085] Further, shapes, dimensions and materials of the three layers 106, 104 and 110 correspond respectively to the shapes, dimensions and material described in the arrangements of FIG. 1 in relation to the two layers (6) and (4).

[0086] In a preferred arrangement of the first embodiment of FIG. 2, the lowermost perforated layer (110) is in the form a glassine, i.e. a smooth and thin paper layer highly resistant to the passage of air/moisture and grease. Alternative materials may be used to manufacture the lowermost perforated layer (110) include polyethylene, polyethylene terephthalate and metalised foil and substrates, for example.

[0087] In an alternative arrangement of the embodiment of FIG. 2 (not shown) a single perforation may be provided through the depth of the two lower layers 104 and 110. As per the arrangement shown in FIG. 2 this perforation is obstructed by the uppermost non-perforated layer (106) when the non-perforated layer is connected to the uppermost lower, perforated layer (104).

[0088] FIG. 3 shows a third embodiment of a liner (202) of the invention, comprising a four-layer laminated liner (202) according to the invention.

[0089] In a preferred arrangement, the liner (202) comprises three lower layers (204, 210 and 212) which are in the form respectively of a lowermost glassine layer (212), an aluminium middle layer (210), and an uppermost adhesive layer (204) in the form of a wax layer and/or alternatively a lacquer and/or polyolefins and/or a combination of these materials.

[0090] A plurality of perforations (208) extend though the three lower layers (204, 210, 214) but an alternative arrangement may include a single perforation. The perforations (208) are aligned to each other along the depth of the three layers (204, 210 and 212) in order to create a continuous and uninterrupted passageway through the depth of the three layers (204, 210 and 212) when connected to each other.

[0091] The perforations (208) are closed by an uppermost (upper) non-perforated layer (206) which acts as obstacle to obstruct these passages (208) preventing them to be exposed to the atmosphere while the upper non-perforated layer (206) is connected. Furthermore, the external perimeters (201) of the three perforated layers (204, 210 and 212) and the non-perforated layer (206) match and are aligned one on top to the other. The non-perforated layer (206) is connected to the uppermost perforated layer (204).

[0092] In a preferred arrangement, the uppermost non-perforated layer (206) is releasably connected to the uppermost perforated adhesive layer (204) in such a way that the two layers (204, 206) may be detached by an external action or force which breaks said connection, exposing the perforations (208) to the atmosphere opening the passageway through these perforations (208).

[0093] The intrinsic characteristic of the adhesive material of layer (204) ensures a connection not only between the non-perforated layer (206) and the uppermost perforated adhesive layer (204) but also between the adhesive perforated layer (204) and the aluminium middle perforated layer (210).

[0094] In a further arrangement, the lowermost perforated layer (212) is kept adjacent and aligned to the upper perforated layer (210) through an adhesive material (not shown) which may be applied to the abutting surfaces of one or both the adjacent layers (210, 212), or through heat lamination.

[0095] In some arrangements, the two perforated layers (210, 212) may be maintained adjacent by the conformation (shape and/or structure) of the abutting surfaces which may for example be textured (not shown) and/or embossed (not shown) ensuring a stable engagement of the two layers (210, 212) one to the other.

[0096] Further, in other arrangements, to ensure that the two layers (210, 212) stay in contact, a wax type material may be used as an alternative to, or in combination with, other adhesive materials.

[0097] In some further arrangements, the perforated and non-perforated layers (204, 210, 212, 206) may have identical shapes and these may include a disc, circle, oval, triangle, trapezium, rectangle, square, rectangle, square, parallelogram, or pentagon shape, for example. When the perforated and non-perforated layers (204, 210, 2012, 206) have a disc or circular shape, their diameter of the layers may be in the range of 10 mm and 100 mm.

[0098] In a preferred arrangement of the first embodiment of the invention, the diameter length can vary between 20 mm and 80 mm, such as between 50 mm and 80 mm and especially 53 mm or 70 mm.

[0099] The non-perforated layer (206) may be in the form of a cardboard, cartonboard, paperboard and/or paper having a thickness of at least 0.01 to 2 mm. For manufacturing the non-perforated layer (206) any combination of the abovementioned materials can be taken into consideration.

[0100] Referring to FIG. 4, an embodiment of a four-layer laminated liner (402) for a food or beverage ingredient container lid, according to the invention, is shown.

[0101] The laminated liner (302) presents two lower perforated layers (304, 310) and two upper non-perforated layers (306, 314).

[0102] In a preferred arrangement of the embodiment of FIG. 4, the liner (302) comprises two lower perforated layers (304, 310) and two upper non-perforated layers (306, 314). The uppermost perforated layer (304) and the lowermost non-perforated layer (306) are releasably connected, and attached to each other in such a way that their perimeters (301) match and are aligned one on top to the other. The lower layers (304, 310) include a plurality of perforations (308) extending therethrough. The lower surface (not shown) of the uppermost perforated layer (304) is abutting/adjacent to the upper surface (not shown) of the lowermost non-perforated layer (306) in such a way that the lowermost non-perforated layer (306) obstructs the perforations (308), preventing them to be exposed to the atmosphere.

[0103] The plurality of perforations (308) extend through the entire depth of the two perforated layers (304, 310).

[0104] The same types of connections as described in the embodiment of FIG. 1 and FIG. 3 can be considered to connect the two non-perforated layers 304 and 306 and/or the two perforated layers 306 and 314, i.e. through an adhesive material and/or textured or embossed conformation of the surfaces to be connected.

[0105] Furthermore, the shapes, dimensions and materials of the two layers 304 and 310 respectively correspond to shapes, dimensions and material described in the arrangements of FIG. 2 in relation to the two perforated layers 104 and 110.

[0106] The two upper non-perforated layers (306, 314) are in the form of a cardboard, cartonboard, paperboard and/or paper having a thickness of at least 0.01 to 2 mm or a combination thereof. The two upper layers (306, 314) may be kept adjacent through the abovementioned ways of connection, for example through textured or embossed conformation of the surfaces to be connected or using an adhesive material applied to one or both the two surfaces which need to be attached to each other.

[0107] FIG. 5 shows an embodiment of the two-layer laminated liner (2) as described above in relation to FIGS. 1 and 2, inserted in a food or beverage ingredient container lid (416), to provide a food or beverage ingredient container lid assembly (402) according to the invention. The lid (416) includes an outer surface (419) and an inner surface (418), as well as a screw thread (420) arranged in use to match a corresponding screw thread of a food or beverage ingredient container.

[0108] In a preferred arrangement, the two-layer laminated liner (2) is inserted into the interior surface of the lid which may be in the form a standard closure as a screw cap for sealing the food or beverage ingredient container (for example a coffee powder jar). Further closures can be considered for this purpose, for example friction fit closures and/or snap on caps.

[0109] The liner 2 adheres by friction fit of the upper layer (6) of the liner (2) to the interior surface of the lid (416), fitting firmly into the space within the upper interior surface (418) of the lid (416) and the ridge of its screw thread (420).

[0110] According to this embodiment of the invention, the assembly (402) of the lid (416) and the laminated liner (2) of FIG. 5 may be screwed onto the threaded neck of an ingredient container, as shown in an embodiment of a food or beverage container and lid assembly (502) in FIG. 6a.

[0111] The embodiment of the container and lid assembly (502) of FIG. 6a is the result of the assembly a lid (516), which is identical to the lid (416) of FIG. 5, screwed onto the threaded neck (522) of an ingredient container (524). FIGS. 6a and 6b shows the use of the liner (2) of FIG. 1b and the lid assembly (502) on a beverage or food ingredient container (524). All the liners described in FIGS. 1a, 1b, 2, 3, 4, 5 can be connected the interior surface (518) of the lid (516) to seal the ingredient container (524), which has an opening in the form of a neck (528) having an upper rim (526).

[0112] In use, the lower perforated layer (4) of the liner (2) within the lid (516) is sealed to the upper rim (526) of the ingredient container neck (528) by a wet glue process (not shown), i.e. applying wet glue to the rim (526) and sealing/pressing the lid (516) including the laminated liner (2) onto the glued rim (526). In this way the underside of the lower perforated layer (4) of the liner (2) adheres to the rim (526) to secure the liner (2) across the neck (528). This ensures hygiene and shelf life of the food or beverage ingredient inside the container (524). Thus, the liner (2) can also be considered a seal or cover for the rim (526) or opening of a food or beverage ingredient container (524).

[0113] In another preferred embodiment, the four-layer laminated liner (202) of FIG. 3 can be applied to the interior surface (518) of the lid (524) of FIG. 6a.

[0114] FIG. 6b represents the configuration of the liner after removal of the lid (516) from the container (524) shown in FIG. 6a.

[0115] As the lid is unscrewed, the join between the uppermost non-perforated layer (6) and non-perforated layer (6) is ruptured and the non-perforated layer (6) is retained in the lid (516) while and the perforated layer (4) remains sealed on the upper rim (526) of the ingredient container neck (528). Once the releasable connection between the non-perforated layer (6) and the perforated layer (4) is broken, the perforations (8) are exposed to the atmosphere, allowing fluid communication between the inside of the container (518) and the atmosphere surrounding the container (518) itself. In this way, the perforations allow a fluid communication between the inside of the container to the external environment which in turn allows the any pressure build-up within the container (524) to release, together with any ingredient aroma, whilst the ingredient is fully retained by the remaining parts of the liner (2) sealed to the neck (528). In this way, the ingredient cannot burst out of the container (524) upon the release of pressure through the perforations, as the perforations are not large enough for the ingredient to fit through. In this preferred embodiment, the perforated layer (4) of the original two-layer laminated liner remains sealed onto the upper rim (526) of the container's neck (528) after the lid (516) is removed, bringing the upper non-perforated layer (6) with it.

[0116] In an alternative embodiment, the liner into the lid can be replaced with liner of FIGS. 2 to 4.

[0117] Manufacture of the Liners, Lids and Containers of the Invention

Example 1

[0118] An embodiment of a method of production of a multi-layer laminated liner (2, 102, 202, 302) described for FIGS. 1-6 is described hereafter. The method includes seven stages, as follows:

[0119] Stage 1the upper and lower layer or layers of the liner are laminated together;

[0120] Stage 2the laminated layers are rolled into a reel and sent to a drive roller station;

[0121] Stage 3at the drive roller station the laminated liner is flattened and centred in order to be ready for a pre-cutting and perforation station;

[0122] Stage 4liner is pre-cut in discs (or other relevant shapes) which are retained on the reel sheet and simultaneously perforated leaving the at least one upper layer and/or layers intact then the liner is sent to a liner insertion station;

[0123] Stage 5at the liner insertion station a pre-cut disc (or other relevant shape) is punched away from the reel sheet to be immediately inserted into the interior surface of a food or beverage container lid in one single step then the lids are sent to the control station while the reel sheet skeleton resulting from taking off the discs is disposed of;

[0124] Stage 6each lid is checked through a control means (visual for example i.e. a camera, but any suitable control means may be used) to detect the presence of the liner in the lids. The lids which pass the control are then sent to the packaging station;

[0125] Stage 7those lids are applied to containers filled with food ingredient in order to be sealed. The rim of the opening of the container is provided with an adhesive, which permanently seals the lower most layer of the liner to the rim, as the lids are attached to the container.

Example 2

[0126] An alternative embodiment of a method of the production of a multi-layer laminated liner (2, 102, 202, 302) described for FIGS. 1-6. The method includes seven stages as follows:

[0127] Stage 1upper and lower layer or layers of the liner are laminated;

[0128] Stage 2the laminated layers are rolled into a reel and sent to a drive roller station;

[0129] Stage 3at the drive roller station the laminated liner is flattened and centred in order to be ready for a cutting station;

[0130] Stage 4the liner is cut in discs (or other relevant shapes) which separated from the reel sheet skeleton which is disposed then the discs are sent to a liner insertion station;

[0131] Stage 5at the liner insertion station the discs are punched into the interior surface of a food and beverage ingredient container and perforated simultaneously, in one single step. The lids are sent to a control station;

[0132] Stage 6each lid is checked through a control means (visual for example i.e. a camera, but any suitable control means may be used) to detect the presence of the liner into the lids. The lids which pass the control are then sent to the packaging station;

[0133] Stage 7those lids are applied to containers filled with food and/or beverage ingredient in order to be sealed.

[0134] The above embodiments are described by way of example only. Many variations are possible without departing from the scope of the invention as defined in the appended claims.