PACKAGING SYSTEM

Abstract

A thermoformed packaging system includes a lid comprising a lid screw thread; and a container comprising a container screw thread. The container also includes a chamber for receiving a product, an opening configured to be closed and sealed by the lid. The lid screw thread and the container screw thread are complementary such that the lid can be screwed to the container, thereby closing and sealing the opening.

Claims

1. A thermoformed packaging system comprising: a lid comprising a lid screw thread; and a container comprising: a container screw thread, a chamber for receiving a product, an opening configured to be closed and sealed by the lid; wherein the lid screw thread and the container screw thread are complementary such that the lid can be screwed to the container, thereby closing and sealing the opening.

2. The thermoformed packaging system according to claim 1, wherein a surface of the container comprises the container screw thread.

3. The thermoformed packaging system according to claim 1, wherein an inner surface of the container comprises the container screw thread.

4. The thermoformed packaging system according to claim 1, wherein an outer surface of the container comprises the container screw thread.

5. The thermoformed packaging system according to claim 1, wherein the lid comprises a central closure formation and an outer rim the outer rim including the lid screw thread.

6. The thermoformed packaging system according to claim 5, wherein the outer rim includes an inner wall and an outer wall defining a generally annular space therebetween, wherein the inner wall comprises the lid screw thread.

7. The thermoformed packaging system according to claim 5, wherein the outer rim includes an inner wall and an outer wall defining a generally annular space therebetween, wherein the outer wall comprises the lid screw thread.

8. The thermoformed packaging system according to claim 6, wherein the container comprises a flange configured to cooperate with the annular space of the lid.

9. The thermoformed packaging system according to claim 1, wherein the lid screw thread and/or the container screw thread includes 1.25 to 2 revolutions.

10. The A thermoformed packaging system according to claim 1, wherein the lid screw thread and/or the container screw thread includes: A pitch between about 3 mm and about 4 mm; A width between about 2.85 mm and about 3.85 mm; and A depth between about 0.5 mm and about 1.0 mm.

11. The A thermoformed packaging system according to claim 1, wherein the lid includes a surface formation configured to assist the user in securing or removing the lid from the container.

12. The thermoformed packaging system according to claim 11, wherein the surface formation comprises a textured surface of the outer rim.

13. The thermoformed packaging system according to claim 11, wherein the surface formation comprises one or more finger recesses in the central portion of the lid.

14. The thermoformed packaging system according to claim 1, wherein the lid comprises an inner protruding portion formed in the closure formation and including a retaining mechanism for securing a secondary container.

15. The thermoformed packaging system according to claim 14, further comprising a secondary container with a secondary retaining mechanism; wherein the retaining mechanism of the closure formation is complementary to the secondary retaining mechanism.

16. The thermoformed packaging system according to claim 1, wherein the lid and the container independently comprise rPET, PET, or PP.

17. The A method of thermoforming a packaging system according to claim 1, the method comprising the steps of: providing a sheet material; heating the sheet material and applying the sheet material into one or more moulds; cooling the sheet material in the one or more moulds to provide one or more moulded articles within the sheet material; and separating the one or more moulded articles from the sheet material to provide one or more packaging systems and skeletal waste.

18. The method according to claim 17, wherein the step of applying the sheet material into one or more moulds comprises forming at least one lid comprising a lid screw thread and at least one container comprising a container screw thread, a chamber for receiving a product, and an opening configured to be closed and sealed by the lid, wherein the lid screw thread and the container screw thread are complementary.

19. The method according to claim 17, wherein the step of heating the sheet material includes one or more of: applying vacuum, applying pressure, and applying plugging.

20. The method according to claim 17, wherein the step of cooling the sheet material includes one or more of: applying a water bath, applying a water jacket, applying a condenser, and applying a jet of cool air.

21. The method according to claim 17, wherein the step of separating the one or more moulded articles from the sheet material includes the step of cutting, perforating, scoring or weakening the sheet material; and subsequently pushing the moulded articles out of the cut, perforated, scored or weakened sheet material.

22. The method according to claim 17, further comprising the step of stacking the one or more packaging systems.

23. The method according to claim 17, further comprising recycling or reusing the skeletal waste.

24. The method according to claim 17, wherein the sheet material comprises rPET, PET or PP.

25. A thermoforming apparatus for implementing the method of claim 17.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0114] The accompanying drawings illustrate presently exemplary embodiments of the disclosure, and together with the general description given above and the detailed description of the embodiments given below, serve to explain, by way of example only, the principles of the disclosure. In the accompanying drawings:

[0115] FIG. 1 is a perspective view of a packaging system according to one embodiment of the invention;

[0116] FIG. 2 is an exploded perspective view of the packaging system of FIG. 1;

[0117] FIG. 3 is an exploded side view of the packaging system of FIG. 1;

[0118] FIG. 4 is a perspective view of a lid of the packaging system of FIG. 1;

[0119] FIG. 5 is a top view of the lid of FIG. 4;

[0120] FIG. 6 is a perspective view of a container of the packaging system of FIG. 1;

[0121] FIG. 7 is a top view of the container of FIG. 6;

[0122] FIG. 8 is a cross-sectional side view of the packaging system of FIG. 1;

[0123] FIG. 9 is an enlarged view of the cross-section side view of FIG. 8;

[0124] FIG. 10 is a cross-sectional side view of the lid of FIG. 4;

[0125] FIG. 11 is a cross-sectional side view of the container of FIG. 6;

[0126] FIG. 12 is an enlarged cross-sectional perspective view of the container of FIG. 6;

[0127] FIG. 13 is a perspective view of a user removing the lid of the packaging system depicted in FIG. 1;

[0128] FIG. 14 is a perspective view of a packaging system according to another embodiment of the invention;

[0129] FIG. 15 is a top view of the packaging system of FIG. 14;

[0130] FIG. 16 is a perspective view of a user removing the lid of the packaging system depicted in FIG. 14;

[0131] FIG. 17 is an exploded perspective view of a packing system according to another embodiment of the invention;

[0132] FIG. 18 is a cross-sectional side view of the packaging system of FIG. 17 in the assembled condition;

[0133] FIG. 19 is a basic thermoforming diagram illustrating an apparatus for thermoforming the packaging systems described herein in accordance with one embodiment; and

[0134] FIG. 20 is a block diagram illustrating a method of thermoforming the packaging systems described herein in accordance with one embodiment.

DETAILED DESCRIPTION

[0135] Referring to FIGS. 1 to 4, 8, 9 and 13, a packaging system 100 according to one embodiment includes a lid 102 and a container 104. The lid 102 and the container 104 are each generally circular in this example.

[0136] With particular reference to FIGS. 4, 5 and 9, the lid 102 includes a central portion 106, which is domed in the depicted example, and an outer rim 108. The central portion 106 and the outer rim 108 are separated by a generally annular shaped space 110. The outer rim 108 is generally formed by an inner wall having a screw thread 112 formed therein, and an outer wall 114. The outer wall 114 is shown as having a plurality of ribs 116 for improving the gripping interaction between the lid 102 and the user's hand during use. A circumferential flange 118 is also provided at the outer wall 116.

[0137] With reference to FIGS. 6, 7, 9 and 12, the container 104 includes a generally cylindrical base 120 and a generally cylindrical side wall 122. The container 104 is provided with an upper rim 124 and an opening 126 for the ingress or egress of products. The uppermost region of the upper rim 124 is generally flat, and the upper rim 124 includes a flange 128.

[0138] Referring particularly to FIGS. 9 and 12, the container 104 is also provided with a screw thread 130, which is formed as part of the generally cylindrical side wall 122 at a point in which it meets the upper rim 124. The container 104 also contains a groove 126 at the stop of the screw thread 130 that aids stacking and closure lead in.

[0139] The packaging system 100, as shown in FIG. 13, can be assembled by screwing the lid 102 to the container 104 in a clockwise direction, such that the respective screw threads 112, 130 engage to secure the lid 102 to the container 104. The screw threads 112, 130 generally correspond to one another in shape, i.e. they are complementary, to ensure a liquid resistant seal. The packaging system 100 can be dissembled by screwing the lid 102 from the container 104 in an opposite, i.e. anticlockwise, direction, such that the respective screw threads 112, 130 disengage to release the lid 102 from the container 104.

[0140] In the described example, each screw thread 112, 130 includes 1.5 revolutions such that the user screws the lid 102 approximately 90 degrees to approximately 120 degrees to secure it to the container 104 and close the opening 126 (see FIG. 6).

[0141] Each screw thread 112, 130 includes a pitch, a width and a depth. The pitch of each screw thread 112, 130 is defined as the distance between each thread of the screw threads 112, 130. For example, as shown in FIG. 10, the pitch of the screw thread 112 of the lid 102 is defined as distance x, defining a distance between a centre of a first thread 112a and a centre of a second thread 112b.

[0142] The width of each screw thread 112, 130 is defined as the thickness of the thread itself. For example, as shown in FIG. 11, the width of the screw thread 130 of the container 104 is defined as distance y.

[0143] Finally, the depth of each screw thread 112, 130 is defined as the distance between the innermost point of the screw thread 112, 130 and the outermost point of the screw thread 112, 130. For example, as shown in FIG. 11, the depth of the screw thread 130 of the container 104 is defined as distance z.

[0144] As will be appreciated by those skilled in the art, the screw threads 112, 130 of the lid 102 and the container 104 respectively are complementary to one another. That is, given the dimensions of one of the screw threads, the skilled person can readily calculate and construct the corresponding screw thread.

[0145] The inventors have found that it is important to construct a screw thread 112, 130 with the correct pitch, width and depth to achieve a liquid seal when the lid 102 is secured to the container 104, and to achieve a successful manufacture of the product by a thermoforming process. As will be appreciated by those skilled in the art, there are three variables that can all be varied with respect to one another, and with respect to the gauge (i.e. the thickness) of the starting sheet material. The gauge of the material is indicated by dimension g in FIG. 10.

[0146] The inventors have found that, surprisingly, the required pitch depends on the width of the screw thread, and that the width, in turn, depends on the gauge of the material used. That is, the pitch of the screw thread has been found to be dependent upon the gauge of the material used. Therefore, it has become clear that the control of the thermoforming process is vital in order to ensure a constant gauge, and thus achieving the desired pitch of the screw thread.

[0147] Table 1 shows a possible example of the dimensions of a screw thread used in the packaging system 100 of FIGS. 1 to 13. The dimensions below are described in relation to the container 104 having a height of 50 mm and a diameter of 89.06 mm. It will be appreciated that the lid 102, having a height of 6.38 mm, a diameter of 94.25 mm and a gauge of 0.50 mm, will have corresponding dimensions to fit accordingly.

TABLE-US-00001 TABLE 1 An example of the dimensions of a container screw thread 130 of container 104. Pitch 3.25 mm Width 3.00 mm Depth 0.70 mm Gauge 0.5 mm Revolutions of thread 1.5

[0148] Referring now to FIGS. 14 and 15, another embodiment of a packaging system 200 is depicted including a lid 202 and a container 204. The lid 202 and the container 204 are substantially the same as that described in relation to FIGS. 1 to 10 and 13.

[0149] The lid 202 is shown as including a central portion 206 and an outer rim 208 separated by a generally annular shaped space 210. The outer rim 208 is provided with a plurality of ribs 216 on the outer wall of the outer rim 208. The lid 202 is provided with a screw thread 212 as described above.

[0150] The container 204 includes a substantially circular base 220 and a substantially circular side wall 222. The container 204 also includes an upper rim (not shown) having a screw thread (not shown) that corresponds to the screw thread 212 of the lid 202, as described above.

[0151] In the packaging system 200 of FIGS. 14 and 15, the central portion 206 is provided with a plurality of finger recesses 232 for improving grip. In use, the user can either use the ribbed surface 216 (refer to FIG. 13) or the finger recesses 232 (see FIG. 16) for screwing or unscrewing the lid 202 to the container 204. This is particularly convenient for use on larger diameter lids, to aid opening and closing.

[0152] Table 2 shows a possible example of the dimensions of a screw thread used in the packaging system 200 of FIGS. 14 to 16. The dimensions below are described in relation to the container 204 having a height of 50 mm and a diameter of 124 mm. It will be appreciated that the lid 202, having a height of 6 mm, a diameter of 129.19 mm and a gauge of 0.60 mm, will have corresponding dimensions to fit accordingly.

TABLE-US-00002 TABLE 2 An example of the dimensions of a container screw thread of container 204. Pitch 3.85 mm Width 3.60 mm Depth 0.70 mm Gauge 1.0 mm Revolutions of thread 1.5

[0153] Referring now to FIGS. 17 and 18, yet another embodiment of a packaging system 300 is provided. The packaging system 300 includes a lid 302, a primary or first container 304, and a secondary or second container 350.

[0154] The lid 302 includes a central portion 306, an outer rim 308 and an inner protruding portion 340. The central portion 306 is separated from the outer rim 308 by a generally annular shaped first space 310. The central portion 306 is separated from the inner protruding portion 340 by a generally annular shaped second space 334. The outer rim 308 also includes a clip retaining mechanism 312, which could alternatively be a first screw thread as described in relation to FIGS. 1 to 16 above.

[0155] Additionally, the lid 302 includes a second screw thread 332 in a side wall of the central portion 306 adjacent the second space 334. As will become clear from the description below, the second screw thread 332 serves to secure the secondary container 350 to the lid 302.

[0156] The primary container 304 includes a substantially circular base 320 and a substantially circular side wall 322. An upper rim 324 is provided at the uppermost part of the side wall 322, having an opening 326 for the ingress or egress of a product. The primary container 304 is also provided with a clip retaining mechanism 330 in the side wall 322, at a point where the side wall 322 meets the upper rim 324, which is complementary to, and configured to engage with, the clip retaining mechanism 312 of the lid 302. Alternatively, the primary container 304 could include a screw thread mechanism in lieu of the clip retaining mechanism 330, which is complementary to a first screw thread of the lid 302. In this way, as described above, the lid 302 can be secured to the primary container 304 thereby sealing a product within the primary container 304.

[0157] The packaging system 300 also includes a secondary container 350. The secondary container 350 includes a substantially circular base 352 and a substantially circular side wall 354. An upper rim 358 is provided at the uppermost part of the side wall 354, having an opening 356 for the ingress or egress of a product. The secondary container 350 is also provided with a screw thread 358 in the side wall 354 at a point where the side wall 354 meets the upper rim 360. The screw thread 358 is complementary to the second screw thread 332 of the lid 302. In this way, the lid 302 can be secured to the secondary container 350 thereby sealing a product within the secondary container 350.

[0158] In an assembled condition, as shown in FIG. 18, the secondary container 350 is secured to the lid 302 and within the primary container 304.

[0159] The packaging system 300 may include threads having substantially similar dimensions as described in relation to either above described packaging system 100, 200.

[0160] Referring now to FIG. 19, there is provided a basic thermoforming diagram illustrative of a thermoforming apparatus 400 for thermoforming any of the packaging systems 100, 200, 300, more specifically the components thereof, as described above.

[0161] The thermoforming apparatus 400 includes a sheet material 410, for example recycled PET, PET or PP, on a reel 420. The sheet material 410 is the basic starting material for producing a thermoformed packaging system as described herein. The sheet material 410 is fed from the reel 420 into a heating station 430 having a heating element 432. The heating element 432 provides heat, i.e. thermal energy, to the sheet material 410. This allows the sheet material 410 to become pliable and workable.

[0162] The heated sheet material 410 is then provided from the heating station 430 into a forming station 440. The forming station 440 includes one or more moulds 442 for imparting the shape of the packaging system to the sheet material 410. There may also be provided one or more plugging mechanisms 444, a vacuum (not shown) and/or pressure inducing means (not shown). The forming station 440 generally causes the heated and pliable sheet material 410 to take on the shape of the mould 442 as the sheet material 410 cools therein. Additional cooling means, such as a water bath, a water jacket, a condenser or jets of cool air, may be provided to assist the cooling process. The additional cooling means may be provided as part of the one or more moulds 442.

[0163] Once the sheet material 410 has taken the shape of the moulds 442, the sheet material 410, having moulded articles 454, enters the cutting station 450. The cutting station 450 may include a series of blades 452 configured to cut, perforate, score or generally weaken the sheet material 410 between adjacent moulded articles 454.

[0164] Following the cutting, perforation, scoring or weakening of the sheet material 410 between adjacent moulded articles 454, the moulded articles 454 enter the stacking station 460. Within the stacking station 460, the moulded articles 454 are pushed out of the sheet material 410 to provide a series of stacked packaging systems 456. The moulded articles 454 may be pushed by any conventional means.

[0165] The stacked packaging systems 456 can be separated into single units or into groups 470 of stacked packaging systems. Thereafter, the packaging systems can be processed and packaged into one or more boxes 480 for transporting.

[0166] The remaining sheet material having cut outs, from which the moulded articles 454 are pushed, is collected as skeletal waste 490 on another reel, or fed through an in-line granulation system. The skeletal waste 490 can be recycled or reused.

[0167] Throughout the apparatus 400, the sheet material 410 may be transferred by means of conveyors, belts or the like. The sheet material 410 may additionally be gripped by a series of chains to aid guidance through the apparatus 400.

[0168] There is also provided a method 500 of thermoforming the packaging system as described above. The method 500 includes a step of providing a sheet material into a thermoforming apparatus 510, the thermoforming apparatus including a heating station, a forming station, a cutting station and a stacking station as described above.

[0169] The sheet material is first provided into the heating station at step 520. The sheet material is subjected to heat, such that the sheet material is made to be pliable. Once the sheet material is heated to the appropriate temperature, the heated sheet material is provided into the forming station at step 530.

[0170] The forming station includes a mould that is suitable for creating the desired shape and features of the packaging system. There may be provided a single mould, or a plurality of moulds, for forming a single or multiple packaging systems. There is provided the step of moulding the heated sheet in a mould 532. Optionally, during this step, there may be provided the steps of applying at least one of vacuum, pressure and plugging 534 such that the heated sheet material is forced into the mould. The heated sheet material is allowed to cool at step 536, either passively or actively, such that the sheet material takes on the shape of the mould to form a moulded article within the sheet material. When using active cooling, a water bath, a water jacket, a condenser, jets of cool air, or the like may be utilised. The vacuum, pressure and/or plugging is removed once the sheet material has taken on the shape of the mould. The active cooling means may be provided as part of the one or more moulds 442 (see FIG. 19).

[0171] The moulded articles, formed as part of the sheet material, are then provided into the cutting station at step 540. The sheet material between adjacent moulded articles is cut, perforated, scored or generally weakened at step 542 using a blade, knife or the like. The cut, perforated, scored or generally weakened sheet material and moulded articles are then provided into the stacking station at step 550

[0172] The stacking station is configured to push the moulded articles out of the sheet material at step 552, thereby providing the final packaging system or components thereof at step 560. Since the moulded articles are cut, perforated, scored or generally weakened and adjacent points of the sheet material between moulded articles, the stacking section can easily push each moulded article out of the sheet material to provide the final packaging system or components thereof. The stacking section may include any known means for pushing such moulded articles out of the sheet material. The stacking station may also be configured to stack the packaging system, or components thereof, together, thereby forming a series of stacking packaging systems, or components thereof at step 570.

[0173] After the final products have been produced from the stacking station, skeletal waste is provided at step 580. Skeletal waste is the remainder of the sheet material after the formed packaging systems, or components thereof, have been produced and removed. The method may further comprise the step of reusing, or recycling, the skeletal waste at step 582.

[0174] The sheet material is generally provided throughout each station on a conveyor. The sheet material may be gripped by chains which guide the sheet material through the apparatus. Moreover, the sheet material may be provided in a roll and unrolled gradually from the roll, onto the conveyor or chains, and through the apparatus. Additionally, or alternatively, the skeletal waste may be caused to form a roll as it is provided at the end of the process, or fed through an in-line granulation system.

[0175] It will be appreciated for persons skilled in the art that the above embodiments have been described by way of example only and not in any limiting sense, and that various alterations and modifications are possible without departing from the scope of the invention as defined by the appended claims.