Composite container with separable top, a body blank, and a method of separating a top end portion from a main body of the container

Abstract

A composite container comprises a tubular body, the tubular body having an inside surface and an outside surface and a container opening at a top end of the tubular body. The composite container comprises a top rim surrounding the container opening, the top rim being attached to a top end portion of the tubular body at the top end of the tubular body, and a lid for opening and closing the composite container. The composite container comprises a separation arrangement, for separating the top end portion of the tubular body together with the attached top rim from a main part of the tubular body, the separation arrangement comprising a tear strip formed between a pair of inside score lines which are arranged from the inside surface of the tubular body.

Claims

1. A composite container comprising: a tubular body, said tubular body having an inside surface and an outside surface and being closed at a bottom end of said tubular body opposite a container opening at a top end of said tubular body, said tubular body being made from a laminate sheet material comprising a carton layer and an inside polymeric layer, said inside polymeric layer being arranged at an inside surface of said carton layer, said composite container comprising a top rim surrounding said container opening, said top rim being attached to a top end portion of said tubular body at said top end of said tubular body, and a lid for opening and closing said composite container, said composite container comprises a separation arrangement, for separating said top end portion of said tubular body together with said attached top rim from a main part of said tubular body, said separation arrangement comprising a tear strip comprising a portion of said inside polymeric layer, said tear strip being formed between a pair of inside score lines which are arranged in said laminate sheet material from said inside surface of said tubular body through only a part of a thickness of said laminate sheet material, said inside score lines and said tear strip extending in a circumferential direction of said tubular body, adjacent said top rim and wherein said separation arrangement comprises a first pull-tab which is arranged at a first end of said tear strip, said first pull-tab comprising a portion of said carton layer and being formed by a set of first pull-tab outside score lines arranged in said laminate sheet material from said outside surface of said tubular body through only a part of said thickness of said laminate sheet material.

2. A composite container according to claim 1, wherein said tear strip has an extension in said circumferential direction of said tubular body corresponding to at least 45% of a circumference of said tubular body.

3. A composite container according to claim 1, wherein said separation arrangement comprises a first opening part for accessing a first end of said tear strip, said first opening part comprising a portion of said carton layer and being formed by a set of opening part outside score lines arranged in said laminate sheet material from said outside surface of said tubular body through only a part of said thickness of said laminate sheet material adjacent said first end of said tear strip.

4. A composite container according to claim 1, wherein said separation arrangement comprises a second pull-tab which is arranged at a second end of said tear strip, said second pull-tab comprising a portion of said carton layer and being formed by a set of second pull-tab outside score lines arranged in said laminate sheet material from said outside surface of said tubular body through only a part of said thickness of said laminate sheet material.

5. A composite container according to claim 1, wherein said inside score lines are arranged in said laminate sheet material from said inside surface of said tubular body through a full thickness of said inside polymeric layer and through only a part of a thickness of said carton layer.

6. A composite container according to claim 1, wherein said inside polymeric layer has a thickness from 20 micrometers to 100 micrometers.

7. A composite container according to claim 1, wherein said inside score lines of said pair of inside score lines are arranged at a distance from each other from 3 millimeters to 10 millimeters.

8. A composite container according to claim 1, wherein a distance between a lower edge of said top rim and said tear strip is less than 15 millimeters.

9. A composite container according to claim 8, wherein said distance between said lower edge of said top rim and said tear strip varies along a length of said tear strip.

10. A composite container according to claim 1, wherein said composite container comprises a top sealing member which is attached to said inside surface of said tubular body at a distance from said top end of said tubular body, said separation arrangement being arranged between said top sealing member and said top rim.

11. A composite container according to claim 1, wherein said lid is a part of a lid component, said lid component comprising said top rim and a lid part, or a frame structure and a lid part.

12. A rectangular body blank for forming a tubular body in a composite container in accordance with claim 1, said body blank having a top edge and a bottom edge and two side edges, an inside surface and an outside surface, said body blank being made from a laminate sheet material comprising a carton layer and an inside polymeric layer, said inside polymeric layer being arranged at said inside surface of said body blank, said body blank comprises a separation arrangement comprising a tear strip, said tear strip comprising a portion of said inside polymeric layer, said tear strip being formed between two inside score lines which are arranged in said laminate sheet material from said inside surface of said body blank through only a part of a thickness of said laminate sheet material and extending along said top edge of said body blank and wherein said separation arrangement comprises a first pull-tab which is arranged at a first end of said tear strip, said first pull-tab comprising a portion of said carton layer and being formed by a set of first pull-tab outside score lines arranged in said laminate sheet material from said outside surface of said body blank through only a part of said thickness of said laminate sheet material.

13. A method of separating a top end portion of a composite container from a main body portion of said composite container, said composite container comprising a tubular body, said tubular body having an inside surface and an outside surface and being closed at a bottom end of said tubular body opposite a container opening at a top end of said tubular body, said tubular body being made from a laminate sheet material comprising a carton layer and an inside polymeric layer, said inside polymeric layer being arranged at an inside surface of said carton layer, said composite container comprising a top rim surrounding said container opening, said top rim being attached to a top end portion of said tubular body at said top end of said tubular body, and a lid for opening and closing said composite container, said composite container further comprises a separation arrangement, for separating said top end portion of said composite container from said main body portion of said composite container, said separation arrangement comprising a tear strip comprising a portion of said inside polymeric layer, said tear strip being formed between a pair of inside score lines which are arranged in said laminate sheet material from said inside surface of said tubular body through only a part of a thickness of said laminate sheet material, said inside score lines and said tear strip extending in a circumferential direction of said tubular body, adjacent said top rim, and an opening part for accessing an end of said tear strip, said opening part comprising a portion of said carton layer and being formed by outside score lines arranged in said laminate sheet material from said outside surface of said tubular body through only a part of said thickness of said laminate sheet material adjacent said end of said tear strip, and a pull-tab which is arranged at said end of said tear strip, said pull-tab comprising a portion of said carton layer and being formed by outside score lines arranged in said laminate sheet material from said outside surface of said tubular body through only a part of said thickness of said laminate sheet material, wherein said method comprises the steps of: forming an access opening in said tubular body by pushing said opening part in a direction towards an interior of said tubular body; inserting a finger into said access opening in said tubular body and gripping said pull-tab; tearing said tubular body along said tear strip by pulling at said pull-tab; and removing said top end portion of said composite container from a main part of said composite container.

14. A composite container according to claim 1, wherein said separation arrangement comprises an opening part for accessing a first end of said tear strip, said opening part comprising a portion of said carton layer and being formed by a set of opening part outside score lines arranged in said laminate sheet material from said outside surface of said tubular body through only a part of said thickness of said laminate sheet material adjacent said first end of said tear strip, wherein the opening part and the set of opening part outside score lines are configured for forming an access opening in the tubular body for facilitating gripping of the first pull-tab via the access opening.

15. A composite container according to claim 14, wherein the opening part is configured to be pushed in a direction towards an interior of the tubular body to form the access opening.

16. A composite container according to claim 14, wherein the opening part is configured to be folded back on the first pull-tab when the access opening is formed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will be further explained hereinafter by means of non-limiting examples and with reference to the appended drawings wherein:

(2) FIG. 1a shows a rectangular body blank as disclosed herein, from the inside surface;

(3) FIG. 1b shows a rectangular body blank as disclosed herein, from the outside surface;

(4) FIG. 1c shows a rectangular body blank as disclosed herein, with both inside and outside score lines visible;

(5) FIG. 2 shows a cross-section through a sheet material for a body blank;

(6) FIG. 3 shows a composite container with a separation arrangement as disclosed herein;

(7) FIG. 4a shows a detailed view of the separation arrangement in a side wall of the composite container in FIG. 2 before opening;

(8) FIG. 4b shows the separation arrangement in FIG. 3a in the process of being opened; and

(9) FIG. 5 shows the composite container in FIG. 2 with the top part torn off.

DETAILED DESCRIPTION

(10) The invention will, in the following, be exemplified by embodiments. The embodiments are included in order to explain principles of the invention and not to limit the scope of the invention, as defined by the appended claims. It is to be understood that the drawings are schematic and that individual components, such as layers of material are not necessarily drawn to scale. The packaging container and body blank shown in the figures are provided only as examples and should not be considered limiting to the invention. Accordingly, the scope of the invention is determined solely by the appended claims.

(11) FIGS. 1a, 1b and 1c show a rectangular body blank 1 for forming a tubular body in a composite container as disclosed herein. As the score lines which are arranged in the body blank 1 overlay each other and cooperate in forming the separation arrangement as disclosed herein, for the sake of facilitating understanding of the invention, FIG. 1a shows a mirror image of the inside surface of the body blank 1 as shown from the outside surface in FIG. 1b.

(12) The body blank 1 has a top edge 2, a bottom edge 3, two side edges 4, 5, an inside surface 6 and an outside surface 7.

(13) The body blank 1 is made from a laminate sheet material 8 comprising a carton layer 10 and an inside polymeric layer 11. As is shown in FIGS. 1a and 2, the inside polymeric layer 11 is arranged at the inside surface 6 of the body blank. The body blank comprises a separation arrangement 12 comprising a tear strip 13. The tear strip 13 is formed between two inside score lines 14,15 which are arranged in the laminate sheet material 8 from the inside surface 6 of the body blank through only a part of a thickness, t, of the laminate sheet material 8 and extending along the top edge 2 of the body blank 1 at a distance from the top edge 2 of the body blank 1.

(14) The distance between the top edge 2 of the body blank and the separation arrangement 12 is selected to be sufficient for accommodating a top rim being attached above the separation arrangement 12. The distance between the top edge 2 of the body blank and the closest part of the separation arrangement 12 in the body blanks as disclosed herein may be in the order of 10 millimeter, such as from 7 to 9 millimeter.

(15) The inside score lines 14, 15 may be arranged at a distance from each other of from 3 millimeter to 10 millimeter. The distance between the score lines 14,15 may vary along the tear line 13, as set out herein.

(16) With reference to FIG. 2, there is shown a cross-section through a sheet material 8 which may be used for forming a body blank and a tubular body made from the body blank as disclosed herein.

(17) As set out herein, the laminate sheet material 8 comprises a carton layer 10 which forms a base layer constituting a major part of the thickness, t, of the sheet material. An inside polymeric layer 11 is applied on the side of the carton layer 10 which is intended to be facing towards an inner compartment in a composite container as disclosed therein. The inside polymeric layer 11 is an outer layer of the laminate sheet material 8 and forms the inside surface 6 of the laminate sheet material 8, corresponding to the inside surface 6 of the body blank 1 and the inside surface 306 of the tubular body 301 as disclosed with reference to FIG. 3, below. In FIG. 2, the outside surface 7 of the laminate sheet material 8 is constituted by an outer surface of the carton layer 10. However, the outside surface of the laminate sheet material 8 may alternatively be constituted by a printed layer, and/or by a polymeric coating or layer applied on the carton layer 10.

(18) The laminate sheet material 8 shown in FIG. 2 further comprises a polymeric bonding layer 18 applied to the inner side of the carton layer and a metal foil layer 19 applied on the polymeric bonding layer 18, between the metal foil layer 19 and the carton layer 10. The polymeric bonding layer 18 and the metal foil layer 19 are optional parts of the laminate sheet material 8 as disclosed herein.

(19) A laminate sheet material which may be used in a composite container as disclosed herein may comprise one or more layers in addition to the mandatory base layer/carton layer 10 and the inside polymeric layer 11. As seen in order from the outside to the inside the laminate material may comprise: a) an optional polymeric coating, such as a laquer, b) an optional printed and/or coloured layer c) a carton layer d) an optional polymeric bonding layer, e.g. a polyethylene (PE) layer e) an optional barrier layer, e.g. an aluminum (Al) foil barrier layer f) an inside polymeric layer, such as a polyethylene (PE) layer. The inside polymeric layer may comprise two or more sub-layers, such as a polyethylene (PE) layer and) a low density polyethylene (LDPE) layer. The sublayers may be coextruded to form the inside polymeric layer, or may be formed as separate films which are laminated together.

(20) The tubular body may also comprise additional layers such as a barrier layer in the form of a metal foil, e.g. aluminium foil layer and one or more polymeric film layers. A polymeric film layer is commonly applied over a metal foil layer to protect the foil layer. The polymeric film layer is commonly a thermoplastic film layer which may contribute to forming a good seal when attaching components such as a top sealing member, a rim, etc. to the tubular container body by heat sealing techniques such as welding. A further plastic layer may be arranged on the outside of the carton layer to protect the carton layer from ambient moisture and to enhance the appearance of the container.

(21) The inside score lines 14, 15 are arranged in said laminate sheet material 8 from said inside surface 6 of the body blank 1 through a full thickness of the inside polymeric layer 11, through a full thickness of an optional metal foil layer 19 and through only a part of the thickness of the carton layer 10.

(22) The inside polymeric layer 11 may have a thickness of from 20 micrometer to 100 micrometer, such as from 30 micrometer to 75 micrometer or from 30 micrometer to 50 micrometer.

(23) The inside score lines 14, 15 are made by partially cutting or punching through the thickness of the body blank 1, as set out herein, thereby creating the tear strip 13 including a band-shaped portion of the inside polymeric layer 11 of the body blank which is defined between the inside score lines 14, 15.

(24) The separation arrangement 12 comprises an opening part 21 for accessing a first and a second pull-tab 22, 23 comprising a first and a second end 22, 23 of the tear strip 13. In the embodiment shown in FIGS. 1a to 1c, the opening part 21 comprises a portion of the carton layer 10 and is formed by cutting or punching a set of opening part outside score lines 16 in the laminate sheet material 8 from the outside surface of the body blank 1 through only a part of the thickness, t, of the laminate sheet material 8 at the first and second ends 22, 23 of the tear strip 13.

(25) The first and second pull-tabs 22,23 are formed by first and second sets of first pull-tab outside score lines 24, 25 which are arranged in the laminate sheet material 8 from the outside surface 7 of the body blank 1 through only a part of the thickness, t, of the laminate sheet material 8.

(26) As can be seen in FIGS. 1a to 1c, the tear strip 13 is a two-part tear strip 13 with one part of the tear strip arranged at each side of the opening part 21 and the pull-tabs 22, 23. In an assembled composite container, the two parts of the tear strip 13 will be separated by a seal in the tubular body of the composite container which is formed between two side edges 4,5 of the body blank forming the tubular body of the composite container. In the embodiment illustrated in FIGS. 1a to 1c, the inside score lines 14, 15 terminate a short distance from the side edges 4, 5 corresponding to the area occupied by a sealing strip when the side edges 4,5 are joined in a body seal in a composite container as disclosed herein. Alternatively, the inside score lines 14, may extend all the way to the side edges 4,5.

(27) The composite container 300 which is shown in FIG. 3 comprises a tubular body 301. In analogy with the body blank 1 shown in FIGS. 1a to 1c, the tubular body 301 has an inside surface 306 and an outside surface 307.

(28) The tubular body 301 of the composite container 300 which is shown in FIG. 3 has a modified square cross-sectional shape including a front wall portion 331, a rear wall portion 332 and two side wall portions 333,334 being connected by curved corner portions 335. The cross-sectional shape of the composite container 300 which is shown in FIG. 3 should not be considered to be limiting to the invention. Accordingly, any suitable cross-sectional shape may be used, as known in the art.

(29) As set out herein, the tubular body 301 may be formed by bringing together the side edges of a body blank, such as the side edges 4, 5 of the body blank 1 shown in FIGS. 1a to 1c, causing the material to assume a tubular shape and sealing the side edges together. Sealing of the side edges may be made by any suitable method as known in the art, such as by welding or gluing, with high frequency induction welding being preferred, as set out herein. Sealing of the side edges of the body blank may involve using a sealing strip, as known in the art. In the composite container 300 which is shown in FIG. 5 with the top end portion 304 torn off from the main portion 351 of the tubular body 301, a sealing strip 355 is visible on the inside 306 of the tubular body 301 at the side wall 334 which is opposite the side wall 333 in which the separation arrangement 312 is arranged.

(30) The tubular body 301 is closed at a bottom end 336 of the tubular body 301 by means of a bottom sealing member. Alternative bottom sealing arrangements may be used, as set out herein. The closure at the bottom end is opposite a container opening 337 arranged at a top end 338 of the tubular body 301.

(31) The tubular body 301 is made from a laminate sheet material 8, as set out herein and comprises a carton layer 310 and an inside polymeric layer 311, the inside polymeric layer 311 being arranged on the inside surface 306 of the tubular body 301, the inside surface 306 facing towards an inner compartment 350 in the composite container 300.

(32) The composite container 300 comprises a top rim 339 which is a loop-shaped component surrounding the container opening 337. The top rim 339 is firmly attached to a top end portion 340 of the tubular body 301 at the top end 338 of the tubular body 301 by adhesive or welding.

(33) The top rim 339 is preferably a molded thermoplastic component. In the composite container shown in FIG. 3, the top rim 339 is part of a lid component 341, the lid component 341 further comprising a lid 342 for opening and closing the composite container 300. The lid 342 is attached to the top rim 339 by means of a hinge 343, illustrated in FIG. 3 by a live hinge, formed integrally with the top rim 339 and the lid 342, as set out herein. Furthermore, a locking arrangement 344 is arranged at the front wall portion 331 of the tubular body 301 for locking the lid 342 in a closed position over the container opening 337.

(34) The inner compartment 350 is sealed by a fully or partly removable top sealing member 352 which is applied over the contents in the composite container and which is sealed with an edge flange to the inside surface 306 of the tubular body 301, as set out herein. The top sealing member 352 is an optional feature of the disclosed composite container 300 and may be omitted.

(35) The composite container 300 is provided with a separation arrangement 312, for separating the top end portion 340 of the tubular body 301 together with the attached top rim 339 from a main part 351 of the tubular body 301. The separation arrangement 312 comprises a tear strip 313.

(36) The separation arrangement 312 is shown in greater detail in FIGS. 4a and 4b which show an upper part of the composite container 300 as seen from the side wall 333 of the tubular body 301 in which the separation arrangement 312 is located. With reference to FIGS. 4a and 4b, the tear strip 313 is formed between two inside score lines 314,315 which are arranged in the tubular body 301 through only a part of the thickness, t, of the laminate sheet material 8 forming the tubular body.

(37) The tear strip 313 extends in a circumferential direction of the tubular body 301, adjacent the top rim 339, as shown in FIG. 3.

(38) The separation arrangement 312 further comprises an opening part 321 for accessing a first and a second pull-tab 322, 323. The opening part 321 comprises a portion of the carton layer 310 and is formed by cutting or punching a set of opening part outside score lines 316 in the laminate sheet material 8 from the outside surface 307 of the tubular body 301 through only a part of the thickness, t, of the laminate sheet material 8.

(39) The first and second pull-tabs 322, 323 are formed by first and second sets of pull-tab outside score lines 324, 325 which are arranged in the laminate sheet material 8 from the outside surface 307 of the tubular body 301 through only a part of the thickness, t, of the laminate sheet material 8.

(40) As in the body blank 1 in FIGS. 1a to 1c, the tear strip 313 is a two-part tear strip 313 with one part of the tear strip arranged at each side of the opening part 321 and the pull-tabs 322, 323. The two parts of the tear strip 313 are separated by a seal in the tubular body 301 of the composite container 300 which is formed in the side wall 334 of the tubular body 301 which is opposite the side wall 333 in which the separation arrangement 312 is located. The seal is covered by a sealing strip 355 as illustrated in FIG. 5.

(41) When the composite container 300 has been emptied of its contents, it may be prepared for recycling by a user forming an access opening 360 in the tubular body 301 by pushing the opening part 321 in a direction towards the inner compartment 350 of the tubular body 301 and inserting a finger into the access opening 360 in the tubular body 301 and gripping a pull-tab 322 or 323. In FIG. 4b, the separation arrangement 312 is shown with the opening part 321 pushed away and folded back on the pull-tab 322 which is shown on the left in FIGS. 4a and 4b. Accordingly, the opening part stays connected to the left-hand pull-tab 322 and forms part of the pull-tab 322. As disclosed herein, the opening part may alternatively be completely pushed through the wall of the tubular body 301 and fall down into the inner compartment 350 or may stay attached to the side wall material at the upper or lower part of the access opening 360, or may stay attached to the pull-tab which is shown on the right in FIGS. 4a and 4b.

(42) After having exposed and gripped the pull-tab 322 or 323, the user may tear open the sheet material 8 in the tubular body 301 by pulling along tear strip 313 to the sealing strip 355 opposite the separation arrangement 312. In a two-part tear strip arrangement as shown in FIG. 3 and FIGS. 4a and 4b, the tearing is repeated from the other side of the opening 360 which has been created in the tubular body 301.

(43) After completing tearing of both parts of the tear strip 313, the user may separate the top end portion 340 of the composite container 300 from the main part 351 of the tubular body 301, constituted by a narrow strip of the tubular body 301 and the attached lid component 341, as shown in FIG. 5.