PLASTIC CONTAINER HAVING A WIDE OPENING SEALED BY A FLEXIBLE TOP LID, AND PRODUCTION METHOD

Abstract

The container has a blow molded piece forming a hollow plastic body. The body has a bottom and an annular side wall longitudinally extending from an annular base to a top. A thin flexible lid of foil material covers and seals a wide top opening of the container. The top is connected to the outer rim of an annular top flange. The top flange protrudes radially inward and delimit the opening at an inner rim. The lid is axially adhered to the flange upper face and can be peeled away, optionally using a pull tab that extends beyond the outer rim. Except at region of the pull tab, the annular outer edge of the lid extends parallel to the outer rim, not beyond 1.0 or 2.0 mm from the outer rim.

Claims

1. A container comprising: a hollow body made of plastic material and having only one opening, and a flexible top lid, wherein the hollow body comprises: a top flange, of annular shape, surrounding a top opening, that is said only one opening, the top flange having an outer rim; a bottom at the opposite from the top opening; and a side wall of annular shape, extending around a longitudinal axis, from the bottom to an annular top of the side wall directly connected to the outer rim of the top flange; wherein the flexible top lid comprises: an annular sealing contact area in axial contact with an annular upper face of the top flange so as to close the top opening; wherein the top flange is an internal flange protruding radially inward from the annular top of the side wall, and wherein the flexible top lid is a piece of foil material having an annular outer edge that: does not extend radially beyond the outer rim of the top flange, or extends radially at most 2.0 mm beyond the outer rim of the top flange.

2. The container according to claim 1, wherein the hollow body is a one-piece body made of thermoplastic material.

3. The container according to claim 2, wherein the hollow body is made of PET.

4. The container according to claim 1, wherein the flexible top lid is deprived from any metal foil.

5. The container according to claim 1, wherein the side wall has a flat longitudinal profile, at least in an upper portion of the side wall, the upper portion extending at least 10.0 mm downwardly from the outer rim of the top flange.

6. The container according to claim 1, wherein the side wall comprises an upper portion adjacent to the top and a lower portion adjacent to the base, and wherein the side wall comprises a peripheral bulge at a junction between the upper portion and the lower portion.

7. The container according to claim 1, wherein the side wall is provided with a decorative sleeve covering at least an upper portion of the side wall.

8. The container according to claim 1, wherein the flexible top lid forms an uppermost face of the container.

9. The container according to claim 1, further comprising a pull tab that extends beyond the outer rim of the top flange, wherein the flexible top lid is in an unfolded state when sealing the top opening, so that the pull tab forms an extension in a plane perpendicular to the longitudinal axis, and is laterally shifted with respect to the outer rim of the top flange.

10. The container according to claim 1, further comprising a pull tab that extends beyond the outer rim of the top flange, wherein the following relation is satisfied:
S1/S20< where S1 is the upper surface formed by the pull tab and S20 is the entire upper surface formed by the flexible top lid.

11. The container according to claim 1, further comprising a pull tab that extends beyond the outer rim of the top flange, wherein the pull tab is the only gripping part for separating the flexible top lid from the top flange.

12. The container according to claim 11, wherein the top opening is circular opening, and wherein the outer rim of the top flange is circular, following relation being satisfied:
L1/P5< where P5 is outer perimeter of the outer rim of the top flange and L1 is length of a curved junction separating the pull tab from complementary part of the flexible top lid that covers the body.

13. The container according to claim 3, wherein the hollow body is at least partly transparent or translucent.

14. The container according to claim 1, wherein the flexible top lid is thermosealed to an upper face of the top flange, with a vacuum leak resistance of at least 0.2 mbar/mm.sup.2.

15. A product, comprising the container according to claim 1, wherein at least a part of an interior volume annularly delimited by the hollow body is filled with a content.

16. A method to produce the product according to claim 15, comprising: providing the hollow body having a bottom and a side wall to delimit an interior volume, the side wall extending around a longitudinal axis; filling the interior volume with a content, through the top opening delimited by a top flange that protrudes radially inward from an annular top of the side wall; thermosealing the flexible top lid onto the upper face of the top flange in an annular contact area continuously surrounding the opening, the flexible top lid being sized and shaped so that position of the flexible top lid is adjusted with respect to an outer rim of the top flange during the sealing, so that an annular outer edge of the flexible lid: does not extend radially beyond the outer rim of the top flange, or extends radially at most 2.0 mm, beyond the outer rim of the top flange.

17. The method of claim 16, wherein a decorative sleeve is positioned to the side wall after being transported longitudinally from the bottom side, the decorative sleeve being positioned to the side wall at an axial distance from an annular bearing surface of the bottom.

18. The container of claim 1, further comprising a pull tab that extends beyond the outer rim of the top flange.

19. The container according to claim 2, wherein the flexible top lid is deprived from any metal foil.

20. The container according to claim 3, wherein the flexible top lid is deprived from any metal foil.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0134] FIG. 1 shows a container according to a first embodiment of the invention;

[0135] FIGS. 2A and 2B illustrate same longitudinal section view to show a detail in the upper part of a container before sealing the opening;

[0136] FIG. 2C is a longitudinal section view showing a detail in the upper part of a container in a closed state;

[0137] FIG. 3 is a perspective view showing a cut of a pre-container, in order to obtain the hollow body of the container;

[0138] FIG. 4 illustrates a detail of the view of FIG. 3, showing the top flange that projects radially inward from the top of the side wall;

[0139] FIG. 5 is a top view of a container in accordance with the invention;

[0140] FIG. 6 schematically illustrates filling and sealing steps in a method of producing containers filled with a food composition and such as illustrated in FIG. 1;

[0141] FIG. 7A is a longitudinal section view showing a step of fixing the flexible top lid on an upper face of the top flange;

[0142] FIG. 7B is a bottom view of a sealing head used to perform the kind of fixation shown in FIG. 7A;

[0143] FIG. 8 is a longitudinal section view of a detail in the side wall of a pre-container, before a trimming operation through a circumferential groove.

DETAILED DESCRIPTION OF EMBODIMENTS

[0144] In the various figures, the same references are used to designate identical or similar elements. Some sizes may be exaggerated (for instance some thicknesses) for the purpose of illustration.

[0145] In the present application, the vacuum leak resistance is an indicator of how hermetically the container body 3 and the container lid 20 are fastened. The higher the vacuum leak resistance is the better hermetically the body 3 and the container lid 20 are fastened. The vacuum leak resistance is measured by immersing a sealed container at atmospheric pressure into water, subjecting to vacuum to create in internal pressure inside the container, and determining the depression under which bubbles or product leak from the sealed container, per surface of sealing area. The absence of leaks indicates air tightness. Vacuum leak resistance can be determined according to the following procedure:

[0146] Material: [0147] Bell Jar with transparent bell, for example Lippke 1350 or 1360; [0148] Vacuum pump, for example double head diaphragm pump; Procedure: [0149] Set test depression and test time to 10 seconds [0150] Provide sample(s) at room temperature, preferably from 20 to 25 C. [0151] Fill the vacuum chamber with tap water at room temperature, preferably from 20 to 25 C., [0152] Plunge sample to be tested in the water, preferably with the lid on the top to facilitate reading [0153] Wait until residual bubble disappear [0154] Close the bell and start the pump [0155] Reach the depression to be tested, wait 10 seconds, and observe if bubbles or product leak from the sample(s) [0156] Optionally repeat with higher depressions, and note the depression at which bubbles or product leak. [0157] Divide depression by the surface of the sealing area, to obtain the vacuum leak resistance.

[0158] The vacuum leak resistance is preferably established as an average 5 samples, preferably 10 samples.

[0159] Referring to FIGS. 1 and 5, the container 1 may be provided with a single piece body, which defines a hollow body 3. The body 3 has a determined outer shape and has a tubular side wall 30. Circular or oval shapes for cross section of the side wall 30 may be cited as non-limitative examples. But any other suitable annular shape may be used, such as square or square with round corners shapes. The side wall 30 of the body 3 extends longitudinally, from a bottom 4 provided with a bearing surface 32 to a top 31 of annular shape. The side wall 30 typically extends around a longitudinal axis X, which may optionally be a central axis or a symmetry axis. The bearing surface 32 may be of annular shape and is part of the bottom 4 that is an integral part of the body 3. The height h of the hollow body 3 is defined between the bearing surface 32 and an uppermost end, here formed by a top flange 5. Such height h may be substantially equal to total height H1 of the container 1 as only a thin flexible lid 20 overlies the top flange 5 (difference H1h being for instance less than 100 m, or less than 1% of height H1, for example from 20 to 40 m, preferably from 25 to 40 m.

[0160] The hollow body 3 is here made of plastic material, typically a single plastic material, for example thermoplastic material, and can be browned. It can be obtained form example blow molding an injected preform, typically an injected preform, or by extrusion blow molding. In these cases, as illustrated in FIG. 3, at least one cutting operation may be performed in a pre-container 40 to define a top opening O1, so that the side wall 30 has a tubular shape of relatively wide section. The top opening O1 is also relatively wide as compared to the maximal radial size, here diameter D1 (see FIG. 5), of the hollow body 3. In the following, the top opening O1 is to be interpreted as wide opening due to a diameter or equivalent characteristic size superior or equal to half (or possibly superior or equal to three quarters) of the diameter D1 or similar radial size measured at a maximum of section of the side wall 30 of the body 3.

[0161] A thermoplastic material for the body 3 may typically be polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PP). Polyethylene terephthalate (PET) can be preferred due to certain very advantageous properties of bodies made from this material (namely their good mechanical resistance, the facility to be filled with a hot liquid or substance, the good transparency of the PET which does not adversely affect the appearance of the content, a relatively good barrier effect to oxygen). Also PET containers can benefit from appropriate recycling streams.

[0162] The top opening O1 of the body 3 is delimited by an inner rim 5b having a circumference lower than circumference of the top 31. Indeed, the body 3 is provided with a top flange 5 that protrudes radially inward from the top 31 of the side wall 3. The top flange 5 and the bottom 4 correspond to opposite ends of the body 3, and extend each transversally with respect to the longitudinal axis X.

[0163] Referring to FIGS. 1 and 2A-2B, the inner rim 5b may extend in a horizontal opening plane, while the upper portion 301 of the side wall 30 is substantially vertical or slightly tapering (for instance with a tapering at about 5-25 from the vertical), in a progressive manner, toward the top flange 5. The interior face of the annular upper portion 301 is smooth, without any relief. Here, the same applies for the outer face of the upper portion 301.

[0164] As shown in FIG. 4, the side wall 30 has a flat longitudinal profile, at least in the upper portion 301 and such flat longitudinal profile may extend at least 10 mm, preferably at least 20 mm downwardly from the outer rim 5a of the top flange 5. The inner rim 5b may extend at slightly lower height level than the outer rim 5a, due to angle a5 formed between the lower face 15a of the top flange 5 and a horizontal plane intersecting the top 31 of the annular side wall 30. Referring to FIGS. 2A and 2C, it can be seen that the angle a5 is formed when the container 1 is in a sealed state, while a bigger angle a5 is formed at same location before the sealing by the top lid 20.

[0165] Here, the side wall 30 is a thread-less and neck-less side wall.

[0166] The top opening O1 defines an opening diameter D in an opening plane which is at least equal to 35 or 40 mm, while maximal radial extension Lt of the top flange 5 is less than 5.0 mm, preferably inferior or equal to 4.0 mm. Such radial extension Lt is measured in the opening plane, between the outer rim 5a and the inner rim 5b. The radial extension Lt is optionally constant.

[0167] The top opening O1 may be intersected by the longitudinal axis X and allows content of the container 1 to be retrieved by the consumer. Referring to FIG. 1 or 6, it can be seen that this top opening O1 is typically a particularly wide opening, having typically a diameter D or similar characteristic radial size superior to 35 or 40 mm. This may be advantageous to allow a spoon to be introduced in an interior volume V through the top opening O1. Such wide top opening O1 is required when using the container 1 for receiving a scoopable solid (as opposed to powder), liquid or viscous fluid, composition, for example food composition, for example wet composition, where use of a spoon is convenient for efficiently retrieving the content. As shown in FIGS. 1 and 3, the base 32 of the bottom 4 is not necessarily as wide as the inner rim 5b of the top flange 5. The annular base 32 shown in FIG. 3 forms a bearing surface of smaller size than the top opening O1.

[0168] A top lid 20, here a flexible top lid made of a foil material, is in annular contact with the top flange 5 to seal the top opening O1. The cutting operation to obtain the opening O1 may be performed by transversally cutting a pre-container 40 or a bottle-like piece, which is blow molded from a preform (not shown). The cutting is preferably performed at at least one groove designed for this, so as to form the top opening O1 of the hollow body 3.

[0169] Due to this specific method, PET may advantageously be used to define the hollow body 3. Indeed, PET is of interest to maximise material performance per gram in the stretched area. PET is of interest due to high scale (preforms), link into PET industry roadmap, recyclability, transparency with high quality (better than polypropylene or polyethylene for instance).

[0170] The container 1 is provided with a flexible top lid 20 of suitable size and shape to close the top opening O1. The flexible top lid 20 is arranged in sealing contact with the upper face 15b of the top flange 5, especially in annular contact in an annular contact formed entirely above the side wall 30. Such top flange 5 may be crown-shaped. When the top opening O1 has a diameter or maximal radial size D, greater than or equal to 30 or 35 mm, it is understood, that a central closing portion 21 of the top lid 20 has same characteristic size. Such size D may be inferior or equal to 100 mm.

[0171] The flexible top lid 20 forms here a single foil sealing system, only comprising a sealing foil that is fixed to the upper face 15b of the top flange 5, in order to seal the top opening O1. An appropriate cut is performed to define an outer shape of the sealing foil. The sealing foil may be a one-piece foil of material suitable for food contact. The material allows the sealing foil to be bendable. The material or foil might be comprised of paper, plastic, aluminium and/or associations thereof. In a preferred embodiment the material and/or of foil is metal-free. Typically, the material and/or foil has low water permeability, is approved for food contact and is not flammable.

[0172] Typically, maximal thickness of the top lid 20 is comprised between 20 and 50 m for instance, and preferably between 25 and 40 m.

[0173] The top lid 20 is optionally provided with a pull tab PT. The pull tab PT is here integrally formed with the flexible top lid 20. Easier removal of the flexible top lid 20 is obtained when pinching the pull tab PT that is entirely offset (radially outward) with respect to the top opening O1. The flexible top lid 20 adheres to the top flange 5, using an adhesion force inferior to a tearing force required to tear the top lid 20. The top lid 20 is thus entirely removable without tearing from the annular top flange 5 or similar top portion when pulling the pull tab PT or similar peripheral portion. In other words, no lid material remains affixed to the hollow body 3 when the top of the container is fully open. Easy separation from the body 3 is of interest for disposal of the body 3, which is typically highly suitable for recycling and economical valorization.

[0174] Except at such optional pull tab PT, the flexible top lid 20 does not significantly protrude radially outwards as compared to the side wall 30, as illustrated in FIG. 1 for instance, and more precisely, it is understood that the annular outer edge 25 of the flexible top lid 20 may remain substantially parallel to the outer rim 5a of the top flange 5, thus not extending radially beyond 2.0 mm, preferably not beyond 1.0 mm from such outer rim 5a (except in region of the optional pull tab PT). In one embodiment, not represented, the annular outer edge 25 of the flexible top lid 20 does not extend beyond the outer rim 5a of the top flange 5 (except in region of the optional pull tab PT). As such the flexible top lid 20 would cover only partially the top flange 5 (for example not covering an external margin area of the top flange 5, except in region of the optional pull tab PT if present).

[0175] FIG. 1 shows the pull tab PT defined as an extension locally protruding beyond an annular outer rim 5a of the top flange 5 defined at the top 31 of the side wall 30. The pull tab PT of course has an outer rim that represents a margin part of the full circumference of the top lid, for example less than a quarter or less than a fifth of the full circumference of the top flange 5. Besides, the following relation may be satisfied:

L1/P5<

where P5 is outer perimeter of the outer rim 5a of the top flange 5, and L1 is length of a curved junction (see FIG. 5) where the pull tab PT joins (intersects) the complementary part of the flexible top lid 20 that covers the body 3. Such complementary part of the top lid 20, which may be symmetrical around the longitudinal axis X, consists of the central closing portion 21 and the adhering ring portion 22 in annular contact with the top flange 5.

[0176] Now referring to FIGS. 2A-2B and 4, it can be seen that the top flange 5, of annular shape, may be an inner flange. Indeed, there is typically no outer relief at the top part of the body. The top flange 5 is provided with an inner edge 5b, proximal to the longitudinal axis X, radially offset inward as compared to the side wall 30. With such kind of top flange 5, without any outer protruding edge as compared to the side wall 30, the bulk of the container 1 is not perceived as thin and trays may be filled with the containers 1 without significant space between the containers, unlike containers having outer flanges or similar collars. The container 1 may be more compact. It is also understood that the bodies 3 are designed to maximize amount of content/product per tray and/or per pallet.

[0177] The top flange inner rim 5b has a cut edge obtained by a cut performed in a transverse direction. Optionally, the inner rim 5b may form a thinned part of the top flange 5, opposite to a thick part closer to the side wall 30.

[0178] As illustrated in FIGS. 2A-2B in particular, the top flange 5 of annular shape may have a radial size or extension Lt, measured between the outer rim 5a and the inner rim 5b along the opening plane. Such radial extension Lt is typically less than 5.0 mm, preferably inferior or equal to 4.0 mm. It is understood that the top lid 20 has an adhering ring portion 22 (in contact with the top flange 5, including the outer edge 25 and surrounding the central portion 21) provided with a radial extension not superior to 5 mm.

[0179] The outer edge 20b of the top lid 20 may be defined in a margin portion that overlies the top flange 5, as illustrated in FIG. 1. In the top lid 20, an adhering ring portion 22 (see FIG. 2) may also be a circumferential margin portion of same extension as compared to extension of the top flange 5, as measured in any longitudinal plane parallel to the longitudinal axis X. The adhering ring portion 22 is fixed on the upper face 15b that extends without any significant relief. As illustrated in FIG. 2, the pull tab PT extends beyond an outer limit of the adhering ring portion 22.

[0180] In preferred embodiments, one of the following relations, is satisfied: 1.0 mmLt5.0 mm, preferably 1.5Lt4.0 mm, preferably 2.0Lt3.0 mm.

[0181] Besides, the ratio Lt/D may be inferior to 1:10.

[0182] In the upper face 15b of the top flange 5, a flat annular surface portion may be formed, and radial extension of such flat annular surface portion (i.e., surface portion without any change of curvature) may be about 2 mm. Corresponding thickness in the top flange 5 may be comprised between 400 and 600 m.

[0183] Referring to FIG. 2B, the top flange 5 is slightly tapering upwardly, so that a shallow angle a5 is defined between a horizontal plane perpendicular to the longitudinal axis X and the upper face 15b of the top flange 5. The angle a5 is typically inferior or equal to 7 or 9, preferably strictly inferior to 6, so that height of the top flange 5 is minimized.

[0184] Now referring to FIGS. 2A-2B, as the hollow body 3 is typically semi-rigid, for example as rigid as plastic bottles containing gaseous water or sodas, the body 3 may be provided with an annular part Z3 that acts as a hinge at a junction between the top flange 5 and the top 31 of the side wall 30, i.e. in a region adjacent to the outer rim 5a. When heat sealing the flexible top lid 20 and possibly after, the top flange 5 may be slightly movable axially inwards. This prevents formation of cracks and provides a damping effect, at least with respect to vertical load, suitable to prevent accidental leaks at or around the top opening O1.

[0185] Of course, the hinge effect is only of low amplitude, as plastic material of the hollow body 3 is significantly more rigid than the foil material used for the flexible top lid 20.

[0186] In the exemplary embodiment of FIG. 1, the side wall 30 has an upper portion 301, directly connected to the top flange 5, and a lower portion 302 tapering from the upper portion 301 toward the bottom 4, in a curved manner as clearly apparent in the FIG. 1.

[0187] The bearing surface 32 formed at the bottom 4 may be circular or may optionally define a non-circular shape for the base opening 32, while defining a substantially planar bearing surface for stability purposes. More generally, the side wall 30 may be provided with any ring-shape, either of circular cross-section, or including one or more portions with non-circular cross-sections or with non-symmetric shape.

[0188] Still referring to FIG. 1, the upper portion 301 of the side wall 30 defines a generally flat surface suitable for receiving a strip or similar decorative sleeve 10 (a strip of paper, a sticker or any convenient wrapping element). The decorative sleeve 10 is covering at least the upper portion 301 of the side wall 30.

[0189] The sleeve 10 may be added by an in-mold labelling method or the like, or added after the molding of the body 3. Here, the outer face of the annular upper portion 301 is smooth, without any relief. With such an arrangement, the upper portion 301 is particularly useful for displaying information and can be typically covered by a rectangular shaped strip or sleeve 10 arranged in a form of a sleeve label. It is also compatible with e.g. inline digital printing.

[0190] In some embodiments, the side wall 30 may define a top opening O1 of higher diameter D than the corresponding size defined at the annular bearing surface 32. Such configuration is obtained in FIGS. 1 and 3 by use of the specific lower portion 302, which tapers downwardly, preferably in a curved manner. With such configuration, the content is easy to retrieve by use of a spoon, especially when a circular cross-section or a continuously rounded cross-section is provided in the bottom 4 and in the lower portion 302.

[0191] Alternatively, the bearing surface 32 may be larger than the top opening O1. Independently or additionally, the side wall 30 may be continuously curved in a convex manner (as perceived from outside the container 1), from the top 31 to the bearing surface 32 forming the outer limit of the bottom 4. This option may be of interest to reduce overall height H1 of the container 1.

[0192] In the embodiment of FIG. 1, the side wall 30 of the hollow body 3 may advantageously be provided with an upper portion 301 of cross sections of an increasing size with increased spacing from the top flange 5. With such configuration, a cylindrical portion or a bulge 30c may optionally be provided at a distance from the top 31. The maximal outer diameter or similar greater dimension D1 of the body section, as measured perpendicularly to the longitudinal axis X, is preferably such that the ratio D/D1 remains superior to 1:2. More generally the following relation may be satisfied:

0.70<D/D1<0.97.

[0193] Of course, the greater dimension D1 is not necessarily measured in a bulge 30c as in FIG. 1 and may be, for instance, a diameter of a cylindrical portion.

[0194] The upper portion 301 may proportionally taper less, upwardly, than the lower portion 302 is tapering, downwardly. In the illustrated embodiment, the annular side wall 30 optionally comprises a peripheral bulge 30c at a junction between the upper portion 301 and the lower portion 302. Here, the annular side wall 30 comprises a bulge 30c having a circular cross section and maximal width of the upper portion is defined at the bulge 30c. Such bulge 30c may be of interest to prevent any slippage (downwardly or upwardly slippage) of a wrapping element or similar decorative banderol, without the need of forming an axial abutment shoulder or similar reliefs for maintaining such element.

[0195] Regarding the flexible top lid 20, such lid is adapted to prevent use of any rigid cap or other cap means above the body 3. The flexible top lid 20 is thus the outermost upper element of the container 1 and may be directly used to form the primary surface for decoration. Digital inline printing or any kind of marking may be performed to define label information and/or decorative elements on the top surface S20 of the top lid 20.

[0196] In some options, using this arrangement with label information and/or decorative marks on the top surface S20 is of interest to provide a hollow body 3 that remains unwrapped and unmarked with printing material, whereby the body 3 is left pure for a better recyclability. The one piece hollow body 3 thus may entirely define the outer face of the side wall 30, without need for additional layer or marking material. The production method may also be simple as no labelling is required around the body side wall 30.

[0197] Now referring to FIGS. 2A-2C, 3, 6 and 7A-7B and 8, some non-limiting examples of making containers 1 are described.

[0198] Referring to FIG. 3, hollow bodies 3 may be each obtained from a plastic piece defining a pre-container 40, here having a single opening 40a. It is understood that the pre-container 40 may be produced as an optimized intermediary blow-molded piece, ready to be cut, preferably by trimming, thanks to a circumferential groove 47 (shown in FIG. 8 when the open section 41 of the pre-container 40 has not been trimmed yet) or similar relief facilitating the cut. FIG. 3 shows the two complementary parts of the pre-container 40 after such cut.

[0199] At the upper end of the body part used to define the hollow body 3, a circumferential flange extending inwardly from the corresponding annular end (top 31) of the side wall 30 is defined during a cutting step, preferably a trimming step. The top flange 5 in an unsealed state is thus obtained. A cutting element may be inserted through the pre-container sidewall at the bottom line BL of the groove 47, so as to perform the trimming.

[0200] Referring to FIG. 8, it can be seen a longitudinal profile of the circumferential groove 47, suitable to define the top flange 5 after the cutting, preferably trimming.

[0201] In the pre-container 40, the part intended to form the top flange 5 is tapering upwardly, so that a shallow angle a5 is defined between a cut plane CP1 perpendicular to the longitudinal axis X and the upper face 15a of the top flange 5.

[0202] The angle a5 is typically between 5 and 20, preferably between 10 and 20, so that height H5 of the top flange 5 in the unsealed state is minimized. Such height H5 may be inferior to 2.0 or 3.0 mm and the ratio H5/H1 is preferably inferior to 2/100 or 3/100.

[0203] Before the cutting, preferably the trimming, the pre-container 40 is obtained in a mold. Such pre-container 40 may be produced by means of blow molding a preform containing PET or similar polymer plastic material. The method to obtain the pre-container 40 may be an injection blow molding method for example an injection stretch blow molding method (both being referred to as l(S)BM), or an extrusion blow molding method (EBM). Such method is suitable to produce a pre-container 40 having a first end provided with a single opening 40a (optionally a narrow opening of greater size as compared to the top opening O1).

[0204] When ejected from the blow molding machine, the pre-container 40 is provided with a bottom section and a section 41 having an open end. The open section 41 optionally includes a neck 41a and a shoulder 41b. The bottom section forms the hollow body 3 and extends longitudinally around the central axis. The central axis typically defines a longitudinal stretching axis.

[0205] The average thickness of the pre-container sidewall may be typically inferior to 450 m, preferably 400 m, preferably 300 m. Optionally, the preform may also be elongated or provided with a tapering toward the lower end, in order to obtain a pre-container 40 of reduced thickness both in an upper portion and in a lower portion of the side wall.

[0206] Having such kind of preform may be of interest to have a longitudinal stretching ratio inferior to the radial stretching ratio, which is often preferred to optimally reduce amount of plastic material in the pre-container sidewall.

[0207] Regarding the circumferential groove 47, formed in the sidewall to allow the cut, such groove 47 may be at least twice as great in width D45 as compared to height H5 (illustrated in FIG. 2A and 8) initially defined between the outer rim 5a and the inner rim 5b of the top flange. Such circumferential groove 47 may have a V-shape longitudinal profile in the sidewall. The V-shape is defined with a determined apex angle also called the aperture angle b45, which is typically comprised between 10 and 40, as measured in any longitudinal plane parallel to the central axis. Such aperture angle is twice the angle a5 obtained after a trimming when the groove has a symmetrical V-shape profile. The angle a5 shown in FIG. 2A is greater than final angle a5 obtained after the sealing of the flexible top lid 20. For instance, the angle a5 is between 5 and 20, preferably between 10 and 20, preferably between 13 and 17.

[0208] The trimming at the bottom line BL of the groove 47 is performed using suitable trimming equipment. When the bottom line BL is circular, a rotation movement may be used for the cutting edge or for the pre-container 40. The one or more blades used for the trimming are extending transversally relative to the central axis. In such trimming operation, the open section 41 of the pre-container 40 is cut away and the hollow body 3 is retrieved. Typically, the open section 41 is internally recycled (which means zero industrial scrap).

[0209] Rotation of the elongated pre-container 40 along a cutting element, for instance a knife having a slightly curved cutting edge, may optionally be limited to the diameter or circumference required for fully cutting the plastic material at a bottom line of the groove, which prevents the generation of chips or plastic particles.

[0210] The cutting element may be a non-heated cold knife, possibly with a re-sharpenable blade. Of course, the trimming operation may be implemented in various manners. It is understood such trimming operation may be performed at high rate of production.

[0211] Referring to FIG. 6, the trimming step may be followed by a filling step and a sealing step for sealing the flexible top lid 20, which allows the container 1 to be closed in tight manner.

[0212] The wide top opening O1 is advantageous for fast filling of the content. Regarding the filling step, it is understood that a single filling may be performed as the hollow body 3 defines a single compartment.

[0213] Referring to FIGS. 6 and 7A-7B, the flexible top lid 20 can be sealed axially to cover the top opening O1, after the filling. The top opening O1 may be advantageously circular as a better sealing, with great homogeneity, can be obtained.

[0214] The flexible lid, here a top lid 20, essentially consists of paper, plastic, or association of such materials, for example a PET material, preferably metal-free. The flexible lid 20 may be deprived from any metallic foil, the flexible lid 20 being preferably a metal-free film for purpose of recyclability.

[0215] Referring to FIG. 2B, the outer rim 5a of the flange 5 has, at least before the sealing, a determined thickness e5a comprised between 400 m and 600 m. Such determined thickness e5a is sufficient to obtain a hinge effect at annular region Z3 shown in FIGS. 2A and 4. Such hinge effect prevents cracks to be formed, especially when pressure applied onto the flange is subject to repeated variations.

[0216] Such hinge effect is easily obtained when the flange 5 is tapering upwardly (at least before the sealing of the flexible top lid 20), so as to define the angle a5, here a slope angle between 5 and 20, preferably between 10 and 20, to the horizontal at the ring portion 22. Typically, the slope angle a5 (in unsealed state of the flange 5) is between 13 and 17, for example 15.

[0217] Referring to FIGS. 2A-8, it is clear that the horizontal typically coincides with the top opening O1 (in normal upstanding position of the container 1 as illustrated in the drawings). In some variants, the top opening O1 may not extend in a horizontal plane but the longitudinal axis X is vertical or substantially vertical (in normal upstanding position of the container 1).

[0218] The flange 5 of the body 3 is provided with an exterior face, here the upper face 15b, having a flat portion of annular shape. Flat here means that the longitudinal profile (as perceived in any longitudinal plane including the longitudinal axis) is straight in the flat portion. Referring to FIG. 2B, the radial width rw of such flat portion of the upper face 15b is of at least 1.5 mm, preferably at least 2 mm, before the sealing. FIG. 8 shows such straight profile in the upper face 15b of the top flange 5, before the sealing. The radial width rw (shown in FIG. 2C) of the flat portion in the upper face 15b may be also superior or equal to 1.5 mm after the sealing.

[0219] As illustrated in FIG. 2B-2C, the ring portion 22 may be less angled after the sealing. The flat portion may form a first portion FP1 distal from the inner rim 5b, which is formed in a second portion FP2 of the flange 5, which is typically horizontal (perpendicular to the longitudinal axis X). After the sealing, the first portion FP1 may extend parallel or nearly parallel to the second portion FP2 (adjacent to the first portion FP1). The second portion FP2 may be a horizontal edge portion (on the inner side of the top flange 5) that is horizontal before and after attachment of the top lid 20, while the first portion FP1 is sloped (with angle a5) at least before the sealing. Preferably the outer rim 5a is formed where there is a minimum radius of curvature in the longitudinal profile of the hollow body 3, such a radius of curvature RC being here comprised between 1.0 and 2.0 mm (at the outer rim 5a), before the sealing by the top lid 20.

[0220] The flat portion FP1 forms or is part of the ring portion 22 that is heated during the sealing. This is of interest to have efficient sealing, especially when PET material is involved.

[0221] When the hollow body is in PET, the flange 5 may have a radial extension Lt superior or equal to 2.0 mm, preferably 2.5 mm, and inferior or equal to 5.0 mm. The radial extension Lt is typically measured in a plane (for instance the opening plane) perpendicular to the longitudinal axis X.

[0222] A sealing head 50, suitable for the sealing step, may be provided with a front face 51 having a central portion 51a provided with vacuum apertures and an annular portion (heating ring 51b) adapted to transmit heat to the top flange 5 and to the crown-shaped or disc-shaped margin portion 22 of the flexible top lid 20. The sealing head 50 provides a vacuum to pick & release the flexible lid 20, and a heating ring to activate the sealing.

[0223] Referring to FIG. 7A, the heating ring 51b in the sealing head 50 may form a metal part and is here designed to operate at a diameter d that is greater than diameter D of the top opening O1. It is typically done by the sealing head 50 pushing linearly, for instance vertically, onto the upper face 15b. The front face 51 is thus facing the upper face 15b of the top flange 5. During the sealing, the position of the flexible top lid 20 is adjusted in a centered manner to cover the front face 51 and can exactly be pushed, by the heating ring 51b (without offset), onto an annular region between the outer rim 5a and the inner rim 5b of the top flange. The flat portion of the ring portion 22 can be pressed and heat.

[0224] The sealing of the lid 20, here a flexible top lid, is performed by applying the sealing head 50 at a temperature that may be maintained at a temperature level comprised between 140 C. and 200 C. The sealing can be divided into at least two sealing sub-steps, preferably from two to four sealing sub-steps. For instance, in order to seal the top lid 20 onto the upper face 15b of the top flange 5, a pushing action from the sealing head 50 may be repeated, with two, three, four or five repetitions.

[0225] Each time, pressure is released and the top flange 5 may oscillate between a pressed state and a release state (which optionally corresponds to a state with a lower pressure from the sealing head).

[0226] Due to the heat treatment and deformation pressure, the slope formed by the top flange 5 is decreased. For instance the angle a5 of about 15+/5 being converted into a final angle a5 of about 4+/3. In the illustrated embodiment of FIGS. 2A-2C and 8, the top flange 5 is typically made of PET, preferably semi-crystalline PET.

[0227] In preferred embodiments, the sealing is performed by at least two pushing actions from the sealing head 50. When the sealing of the flexible lid 20 involves

[0228] PET material at the ring portion, it is typically performed with a variation of pressure values for the contact. This is due to relative movement between the sealing head 50 and the hollow body 3. Hinge effect at hinge area Z3 is of interest to keep perfect integrity of the body 3, here a PET body.

[0229] The slope angle a5 (formed in unsealed state of the flange 5) is decreased in this manner, progressively, to the lower angle value a5 corresponding to the final angle in sealed state.

[0230] The flange 5 has here a maximum thickness e5, which is typically located in region of the ring portion 22 provided with flat surface portion, for contact with the sealing head 50. The maximum thickness e5 is preferably at least 400 m and may be higher than an average thickness e of the side wall 30, preferably at least 100 m higher.

[0231] In preferred embodiments, the flexible top lid 20 is sized and shaped so that only one pull tab PT of the lid is laterally shifted away from the active face of the sealing head. As a result, the pull tab PT is not adhered to the body 3 and radially protrudes outward to be laterally shifted relative to the annular top 31 of the side wall 30. After the sealing, the annular outer edge 20b of the flexible lid 20 extends not beyond 1 mm (except in region of the pull tab PT) from the outer rim 5a of the top flange 5 having the final slope as illustrated in FIG. 2B (the slope being here provided with an angle a5 defined between the lower face 15a of the top flange 5 and a horizontal plane; the angle a5 is of about 5 in non-limitative example of FIG. 2B but could be lower or slightly higher).

[0232] The top flange 5, as obtained after the sealing, may be provided with a low radius of curvature RC in the region adjacent to the top 31 of the annular side wall 30. The radius of curvature RC may be lower than 2 mm and is here slightly lower than the corresponding radius of curvature RC before sealing. Optionally at the outer rim 5a, the radius of curvature RC of the container outer face may be comprised between 1 and 2 mm, for example about 1.5 mm. Such radius of curvature is measured in a plane parallel to the longitudinal axis X and intersected by the longitudinal axis X.

[0233] While the sealing head 50 illustrated in FIG. 7A may be arranged in the longitudinal direction to seal the flexible top lid 10, other configurations may be used, for instance with small tilting of the sealing head 50. Besides, the top flange 5 can optionally be tilted (at a small angle relative to the horizontal plane) in some variants.

[0234] When a decorative sleeve 10 is applied, the fixing step may be performed by a tool moving the sleeve 10 from a direction opposite to the top of the container 1, or more generally opposite to the flexible lid 20. The decorative sleeve is thus adhered to the side wall 30 after being transported longitudinally from the bottom side, preferably at an axial distance from the annular bearing surface 32 of the bottom 4.

[0235] The container 1 can be used for product comprising the container and a content in the container. Thus at least a part of an interior volume V of the container is filled with a content. The container can be a packaging element of the content, useful to transport, protect, preserve, and/or otherwise procure said content.

[0236] The content can be any kind of content to be procured to a user, for example a consumer, in moderate quantities. The content can for example a food or beverage composition, a drug, a personal-care composition, a home-care composition, a home improvement composition, a toy, a small part good.

[0237] Examples of personal care compositions include hair care compositions such as shampoo compositions, conditioner compositions or hair coloring compositions, skin compositions such soap compositions, body wash compositions, sun protection compositions, hydrating compositions or anti-aging compositions, and make-up compositions.

[0238] Examples of home-care compositions include, fabric care compositions such as laundry compositions or softener compositions, dish-washing compositions such as manual dish washing compositions or automatic dish washing compositions, hard-surface cleaning compositions, such as kitchen cleaning compositions, bathroom cleaning compositions, wood floor cleaning compositions or tiles cleaning compositions.

[0239] Examples of home improvement compositions include paints, glues, plasters or cements compositions.

[0240] Examples of small parts goods include nails, screws and the like.

[0241] Food or beverages are compositions that are to be orally consumed. This can be in various forms including liquid, viscous semi-fluid, or solid, optionally as a powder. The food can be a spoonable viscous semi fluid composition or spoonable solid. It can be for example or scoopable solid, as opposed to a spoonable powder.

[0242] The beverage can be water, carbonated or non-carbonated, non-alcoholic beverages (also referred to as soft drinks), carbonated or non-carbonated, alcoholic beverages, carbonated or non-carbonated, milk or vegetal milk substitutes.

[0243] The food can be cereals, dairy compositions, vegetal dairy substitute compositions, deserts compositions such as creams, mousses, gels, puddings, ice-creams compositions, fruits, vegetables, or fruit or vegetables compositions for example whole fruits or whole fruit parts, fruit purees or jams, meat of meat substitutes, confectionary compositions, sauces compositions, soups compositions, infant nutrition compositions, medical nutrition compositions, coffee creaming or whitening compositions, coffee or chocolate compositions, for example instant coffee or chocolate, or other grocery compositions.

[0244] The food can be a frozen composition, chilled or fresh, typically with a storage at a temperature of from 0 C. to 10 C., or long shelf ambient temperature food, typically with a storage at a temperature of higher than 15 C.

[0245] In some embodiments the food is a wet food compositions, comprising substantial amounts of moisture or water, as opposed to dehydrated food compositions, for example at least 20% by weight, or at least 30% by weight, or at least 40% by weight, or at least 50% by weight, or at least 60% by weight, at least 80% by weight. Such compositions can be more sensitive to contaminations and a high resistance sealing, for example with a high vacuum leak resistance can be appropriate.

[0246] Dairy compositions or vegetal dairy substitute compositions typically comprise of dairy material or a dairy substitute material. Herein, unless otherwise provided dairy or milk can encompass vegetal substitutes, for example based on soy, oats, almond, rice, coconut and mixture thereof.

[0247] The dairy composition can be for example a dessert, a fermented dairy composition such as yogurt or kefir, a cheese, butter.

[0248] The dairy material is typically comprised of milk and/or ingredients obtained from milk. It is also referred to as a milk-based composition. Herein milk encompasses animal milk, such as cow's milk, and also substitutes to animal milk, such as vegetal milk, such as soy milk, rice milk, coconut milk, almond milk, oats milk etc.

[0249] Dairy compositions are known by the one skilled in the art of dairy products, preferably of fermented dairy products. Herein a milk-based composition encompasses a composition with milk or milk fractions, and compositions obtained by mixing several previously separated milk fractions. Some water or some additives can be added to said milk, milk fractions and mixtures. Preferably the milk is animal milk, for example cow's milk. Some alternative animal milks can be used, such as sheep milk or goat milk.

[0250] The milk-based composition can typically comprise ingredients selected from the group consisting of milk, half skimmed milk, skimmed milk, milk powder, skimmed milk powder, milk concentrate, skim milk concentrate, milk proteins, cream, buttermilk and mixtures thereof. Some water or additives can be mixed therewith. Examples of additives that can be added include sugar, sweeteners, fibers, and texture modifiers.

[0251] Fermented dairy compositions typically comprise bacteria, preferably lactic acid bacteria, preferably alive. Appropriate bacteria for fermentation are known by the one skilled in the art. It is mentioned that lactic acid bacteria are often referred to as ferments or cultures or starters. The lactic acid bacteria preferably comprise, preferably essentially consist of, preferably consist of, Lactobacillus delbrueckii ssp. bulgaricus (i.e. Lactobacillus bulgaricus) and Streptococcus salivarius ssp. thermophilus i.e. (Streptococcus thermophilus) bacteria. The lactic acid bacteria used in the invention typically comprise an association of Streptococcus thermophilus and Lactobacillus bulgaricus bacteria. This association is known and often referred to as a yogurt symbiosis.

[0252] Fermented dairy compositions are typically obtained by a process involving a fermentation step with at least one lactic acid bacteria. In this step the dairy material is inoculated with the lactic acid bacteria, and the mixture is then allowed to ferment at a fermentation temperature. Such inoculation and fermentation operations are known by the one skilled in the art. During fermentation, the lactic acid bacteria produce lactic acid and thus cause a pH decrease. With the pH decreasing proteins coagulate to form a curd, typically at a breaking pH. The fermentation temperature can be of from 30 C. to 45 C., preferably from 35 C. to 40 C., with a pH decrease to a breaking pH at which proteins coagulate to form a curd. The breaking pH is preferably of from 3.50 to 5.50, preferably of from 4.0 to 5.0, preferably from higher than 4.5 to 5.0.

[0253] The containers 1 may be grouped in a food pack. For example, a wrapping element made of cardboard or plastic may be used for packing the containers 1 in two rows. The wrapping element, such as disclosed in document EP 0461947, may define a top panel, a bottom panel and at least two side panels. Spacing elements, for example a beam member or folded members, may be optionally provided to maintain the containers in parallel rows.

[0254] More generally, such food pack may be provided with at least one row of containers. The covering element may be used to group at least two containers, for example by defining respective cavities for receiving with a small play the lower parts of the containers 1.

[0255] The container 1 can be for example a container having a capacity of, or containing a content of a volume of (or mass of) of 50 ml (or 50 g), to 1 L (or 1 kg), for example a container of 50 ml (or 50 g) to 80 ml (or 80 g), or 80 ml (or 80 g) to 100 ml (or 100 g), or 100 ml (or 100 g) to 125 ml (or 125 g), or 125 ml (or 125 g) to 150 ml (or 150 g), or 150 ml (or 150 g) to 200 ml (or 200 g), or 200 ml (or 200 g) to 250 ml (or 250 g) or 250 ml (or 250 g) to 300 ml (or 300 g), or 300 ml (or 300 g) to 500 ml (or 500 g), or 500 ml (or 500 g) to 750 ml (or 750 g), or 750 ml (or 750 g) to 1 L (or 1 kg).

[0256] The present invention has been described in connection with the preferred embodiments. These embodiments, however, are merely for example and the invention is not restricted thereto. For instance, the top flange 5 used for the containers 1 shown in FIGS. 1 and 3 is not necessarily provided with a circular edge. Other shapes, including straight edge portions may be used. Besides, the side wall 30 does not necessarily always extend regularly around a longitudinal axis X, here illustrated as a symmetry axis. Of course, the side wall 30 may be provided with a longitudinal irregular profile and/or significant curves, possibly with at least one oblique gripping part or oblique shoulder.

[0257] It will be understood by those skilled in the art that other variations and modifications can easily be made within the scope of the invention as defined by the appended claims, thus it is only intended that the present invention be limited by the following claims.

[0258] Any reference sign in the following claims should not be construed as limiting the claim. It will be obvious that the use of the verb to comprise and its conjugations does not exclude the presence of any other elements besides those defined in any claim. The word a or an preceding an element does not exclude the presence of a plurality of such elements.