Tubular container, assembly with tubular container, and method for manufacturing tubular container

Abstract

The present invention provides a container made of a card-based or paper-based material. The container includes an inner tube, an outer tube, a membrane, and a distal member. The inner tube has a distal end and a closed proximal end. The outer tube is sized to fit snugly over the inner tube. The membrane seals the distal end of the inner tube, forming a sealed interior space. The distal member is fixed relative to the outer tube and forms a backing surface adjacent the distal side of the membrane. Also provided are assemblies including the container and a product contained therein. Also provided are methods of manufacturing the container.

Description

[Technical Field]

[0001] The present invention relates to sealed tubular containers for products made from card-based or paper-based materials, such as cardboard or paperboard, and using a film-based membrane to seal the container.

[0002] The product is a powder or granular product commonly used in the food and cosmetic fields. Furthermore, the container can also be used for granular products such as gel products, pellets, tablets, etc. Other products can also be used in the container of the present invention.

[0003] The present invention also relates to a method for manufacturing such a container. [Background technology]

[0004] Until now, tubular (cylindrical) containers for various products, such as cosmetics, have typically been made from plastic materials, but their manufacturing methods, raw materials, and disposal methods after use can have a negative impact on the environment. For example, many plastic containers are not recycled, leading not only to increased landfill demand but also to pollution caused by materials that do not decompose in the natural environment or decompose very slowly. Even if plastic materials do decompose, they often produce "microplastics," which can have a negative impact on wildlife and other organisms.

[0005] In recent years, there has been a shift to containers made of card- or paper-based materials to avoid the harmful effects associated with the use of plastic materials. However, paperboard and cardboard materials may be weaker in strength or have a shorter lifespan than the plastic materials previously used. Therefore, careful design of containers made of paper- or card-based materials is required to ensure the strength and lifespan required for the container and packaging.

[0006] Certain components of a container must be durable not only during use but also during manufacture and assembly. For example, maintaining the integrity of the container is important during the step of filling the product into the container.

[0007] There is also a need for a repeatable, accurate and simple process for producing such card-based or paper-based materials. Summary of the Invention

[0008] In a first aspect, a container is provided that is manufactured from a card-based or paper-based material and includes an inner tube, an outer tube, a membrane, and a distal member. The inner tube has a distal end and a closed proximal end. The outer tube is sized to fit snugly over the inner tube. The membrane seals the distal end of the inner tube, forming a sealed interior space. The distal member is fixed relative to the outer tube and forms a backing surface adjacent the distal side of the membrane.

[0009] The backing reinforces the membrane, which is thinner and weaker than the card- or paper-based materials that make up the rest of the container, reducing the risk of the membrane breaking or accidentally peeling away from the inner tube due to impact from the product (e.g., during filling).

[0010] The inner and outer tubes may be cylindrical or may have other shapes such as oval or rectangular. They have corresponding shapes.

[0011] The inner and outer tubes are sealed together by friction fitting, adhesives, heat sealing, ultrasonic sealing, etc. Heat or ultrasonic sealing is used when the tubes have a polymer-based coating that can be heated to fuse the tubes together.

[0012] The outer tube may include a proximal portion and a distal portion having a closed distal end. The distal portion may be connected to the proximal portion along a frangible line extending around the circumference of the outer tube.

[0013] Such a line of weakness allows the distal portion of the outer tube, together with the distal member, to function as a cap for the container, which can be removed from the container and reattached once the line of weakness is broken. The line of weakness also provides evidence of product tampering, as a user can determine if the line of weakness has been broken.

[0014] As one example, the line of weakness may be created by perforating the periphery of the outer tube and forming a bridge of cardboard or paperboard between the proximal and distal portions of the outer tube, although other lines of weakness made of weaker materials are also envisioned.

[0015] The container is configured such that when the line of weakness is broken, the proximal portion of the outer tube presents a shoulder at its distal end, the distal portion of the outer tube presents a foot at its proximal end configured to abut the shoulder, and the distal portion of the inner tube is provided with a neck configured to be exposed when the distal portion of the outer tube is removed, and to identify the location of the distal portion of the outer tube when it is reinstalled on the container. When the distal portion is replaced, the shoulder and foot may extend along the same line as the broken line of weakness.

[0016] The shoulder and foot are edges of the distal and proximal portions of the outer tube, respectively, and have shapes corresponding to the lines of weakness. The distal portion of the inner tube forms a tubular neck around which the distal portion of the outer tube is disposed.

[0017] The foot, shoulder and neck have locating features that allow the user to position the distal portion neatly over the remainder of the container so that a replaceable cap can be provided.

[0018] The line of weakness can have a variety of shapes, including a straight line that extends circumferentially around the outer tube (i.e., a straight line on the flat material before it is rolled to form the tube), or it can have any type of wave shape, such as a sinusoidal wave, triangular wave, square wave, or other repeating pattern. The line of weakness can also have an irregular shape. If the line of weakness is not straight, it ensures that any printing or design on the outside of the container will align properly when the distal portion of the outer tube (i.e., the cap) is placed back onto the container.

[0019] In some configurations, the line of weakness may extend through a portion of the outer tube, such as approximately 80% or 90% of the circumference of the outer tube (e.g., approximately 300°-350°, or approximately 315°), thereby leaving an attachment portion that forms a hinge between the distal and proximal portions of the outer tube, such that the distal portion remains hingedly connected to the remainder of the container.

[0020] The inner tube may include an embossed circumferential ridge located distal to the line of weakness and configured to resiliently engage the inner surface of the distal portion of the outer tube, the embossed circumferential ridge being provided on the outer surface of the inner tube.

[0021] The embossed circumferential ridges may provide resilient projections extending outward from the inner tube that press against the distal portion of the outer tube when it rests on the remainder of the container. The ridges provide a degree of frictional resistance to movement of the distal portion relative to the inner tube, whether proximally or distally. This action prevents the distal portion of the outer tube from inadvertently falling off the container and provides a comfortable movement for the user when removing or replacing the distal portion.

[0022] It is also envisioned that the distal outer portion may have embossed ridges on the inside for engaging the outside of the inner tube.

[0023] Alternative features, such as raised dots, dots, or dashes, that function similarly to the circumferential embossed ridges may be provided to engage with the other tube to which they are not attached. Interengaging features may be achieved by providing a first feature on the inner tube and a corresponding second feature on the outer tube.

[0024] The closed proximal end of the inner tube is provided by a proximal cup including a disc and an integral rim, the rim being bonded to the inner surface of the inner tube adjacent the proximal end of the inner tube.

[0025] It is envisioned that the proximal end of the inner tube may be closed using alternative configurations.

[0026] The membrane may comprise layered materials including combinations of layers formed from one or more of paper, paperboard, PE, metallized PET, LDPE plastomer, HDPE, mLDPE, metal foil (e.g., aluminum foil), EVOH, and other polymers or ionomers.

[0027] Alternative suitable materials may be used for the membrane.

[0028] The inner surface of the inner tube may be coated with PE.

[0029] This coating can be particularly useful for products where it is important that the product not come into contact with uncoated card-based or paper-based materials, or where direct contact of the product with such materials would adversely affect its properties.

[0030] Alternative coatings may be used in place of the PE coating.

[0031] A similar coating may be applied to the outer surface of the inner tube and / or to one or both of the inner and outer surfaces of the outer tube. Coatings may also be applied to the distal member and / or proximal cup.

[0032] If a coating is present, the different components may be joined by heat sealing or ultrasonic sealing, whereby either a heated element or an ultrasonic head, or other suitable device, may be used to fuse the polymers in the coating to each other and / or to the other components, e.g., by melting and then solidifying.

[0033] The inner tube may include an inner tube rolled end edge at its distal end, and the membrane may be secured distal to the inner tube rolled end edge.

[0034] The inner tube rolled end edge is an end edge that is rolled inward and may include a complete roll or only a folded end edge. The distal side of the inner tube rolled end edge is not a raw end edge.

[0035] Where an inner tube rolled end edge is present, the membrane may be bonded thereto and located at the most distal portion of the inner tube, which means that the backing surface can be provided with a simpler arrangement requiring only a flat disk, without the need for a structure that protrudes proximally beyond the distal end of the inner tube.

[0036] The closed distal end of the outer tube includes a rolled end edge of the outer tube and a distal disk seated against the proximal end of the second rolled end edge, the distal disk providing a distal member and a backing surface.

[0037] The second rolled end edge may be an inward rolled edge.

[0038] The distal disc is stronger than the membrane and can be made from a variety of paper- or card-based materials. For example, the distal disc can be a cardboard or cardboard disc with a polymer-based coating. It can also include a grooved or corrugated cardboard or cardboard material to increase compressive stiffness.

[0039] The distal disc is shaped to fit the shape of the tube and sized to fit over the second rolled end edge. For example, if the tube is cylindrical, the distal disc will be circular. On the other hand, if the tube has a rectangular cross section, the distal disc will be rectangular. Therefore, the distal disc may be referred to as the distal piece.

[0040] The membrane may include a circular disc and a tab extending from the circumference of the circular disc.

[0041] The tabs may be small protrusions that protrude from the periphery of the circular disk of the membrane, or from the main shape of the membrane if the tube is not cylindrical and the membrane has a different shape. The tabs protrude beyond the part of the membrane that is attached to the inner tube.

[0042] The tab allows the user to more easily remove the membrane from the inner tube when necessary, or to lift a portion of the membrane to access the product inside the container.

[0043] In alternative configurations, other means may be provided for gripping and removing the membrane from the inner tube.

[0044] In another embodiment, the membrane includes an axially extending rim that extends distally and may be secured to the inner surface of the inner tube, and the rim may be attached to a disk or diaphragm made of the same material as the membrane that extends across the inner tube.

[0045] In this configuration, the inner tube does not have an inwardly rolled edge at its tip, so only one side of the inner tube faces the product contained within the container, allowing only the inner surface of the inner tube to be coated with a polymeric material or other coating suitable for product contact. In this configuration, the outer surface of the inner tube only comes into contact with the outer tube.

[0046] In this configuration, the closed distal end of the outer tube may include a rolled end edge of the outer tube and a distal cup having a base and at least one lip extending distally into the second rolled end edge. The distal cup provides the distal member, and the base of the distal cup may provide the backing surface. The at least one lip allows the base of the distal cup (which provides the backing surface) to be positioned adjacent to and in contact with the membrane, particularly the disk or diaphragm of the membrane, despite the membrane being spaced from the distal end of the inner tube and thus the connection between the at least one lip and the rolled end edge of the outer tube.

[0047] As previously mentioned, maintaining the backing surface and membrane adjacent and / or in contact helps reduce the likelihood of product impact damaging the membrane or damaging the connection between the membrane and the inner tube.

[0048] The container may have an axial length of 30 to 300 mm and a diameter of 5 to 200 mm, or may have an axial length of 150 to 200 mm and a diameter of 100 to 150 mm, or more precisely, an axial length of 167 mm and a diameter of 127 mm.

[0049] In some embodiments, the diameter of the containers described herein can be about 30 mm to 60 mm, more specifically about 40 mm to 50 mm, or about 45 mm. These sizes are suitable for stick-type deodorant products, for example.

[0050] In other embodiments, the diameter of the containers described herein may be about 7 mm to 25 mm, about 12 mm to 20 mm, or about 15 mm. These sizes are suitable for lipstick products, for example.

[0051] Some aspects and embodiments may include a single-layer container with the outer tube removed and an alternative means for providing a lining surface to the membrane, where the container is a single-layer container corresponding to the inner tube of the previously described aspect, with a closed proximal end, a membrane secured to the distal end, and an additional member adjacent the membrane providing the lining surface.

[0052] In another aspect, there is provided an assembly including any of the containers described above and a product contained within the inner tube of the container.

[0053] The products are powdered or granular products commonly found in the food and cosmetic industries, as well as granular products such as gels, pellets, and tablets.

[0054] In another aspect, there is provided a method for manufacturing any of the containers described above, the method including the steps of: providing a first blank made of a card-based or paper-based material, winding the first blank and joining axial edges of the first blank to form an inner tube, providing a membrane having a diameter equal to or greater than that of the inner tube, adhering the membrane to a distal end of the inner tube, providing a second blank made of a card-based or paper-based material, winding the second blank and joining axial edges of the second blank to form an outer tube, providing a distal member made of a card-based or paper-based material, inserting the distal member into the outer tube to form a snug fit, rolling an end edge of the outer tube to form a rounded end edge at the distal end of the outer tube, inserting the inner tube into the outer tube to abut the membrane and the distal member, filling the inner tube with a product, and closing the proximal end of the inner tube.

[0055] The steps of rolling the end edge of the inner tube to form a rounded rolled end edge at the distal end of the inner tube and bonding the membrane to the distal end of the inner tube can include bonding the membrane to the inner tube distal to the rolled end edge, which can be done using ultrasonic sealing, which allows for close control of the temperature used and allows for precise formation of the attachment between the membrane and the inner tube.

[0056] The distal member may be a distal disk, and rolling the end edge of the outer tube may include forming a rounded rolled edge at the distal end of the outer tube, the rounded rolled edge forming a seat that abuts the distal face of the distal disk around the periphery of the distal disk. If desired, further sealing or joining steps may be performed, such as applying and curing an adhesive between the rolled end edge of the outer tube and the distal disk, or using ultrasonic sealing or other heat sealing methods.

[0057] The membrane may have an axially extending rim. In this example, joining the membrane to the distal end of the inner tube includes joining the axially extending rim of the membrane to the inner surface adjacent the distal end of the inner tube. In this example, a disk or diaphragm of the membrane extends across the inner tube. This design provides an extended seal between the membrane and the inner tube.

[0058] In this configuration, the distal member may include a distal cup having a base and at least one lip. The step of rolling the end edge of the outer tube may include forming a rounded rolled edge on the distal end of the outer tube that grips the at least one lip of the distal cup. That is, the at least one lip of the distal cup is positioned in a gap between the raw edge of the outer tube and the inner surface of the outer tube, and the raw edge of the outer tube is rolled round so that it faces outward. Similarly, the raw edge of the outer tube may be folded over, sandwiching the at least one lip between the two surfaces. The at least one lip may be held in place by the elasticity of the rolled outer tube material or secured by adhesive or other methods (e.g., heat sealing).

[0059] The step of joining the axial ends of the first and second blanks can be performed by ultrasonic sealing, which has proven to be an advantageous option because it allows precise control of the temperature and location of heating of the materials to be joined, thereby reducing the possibility of damage or deformation elsewhere in the container and avoiding undesirable consequences.

[0060] The step of joining the membrane to the inner tube can be performed by ultrasonic sealing, with similar advantages.

[0061] In certain embodiments, the step of winding a first blank and joining its axial edges to form an inner tube is performed around a first mandrel, the step of winding a second blank and joining its axial edges to form an outer tube is performed around a second mandrel, and the step of rolling the end edges of the outer tubes is performed with each outer tube wrapped around the second mandrel, which may result in more efficient container production.

[0062] In some of the above-described embodiments, the step of rolling the end edge of the inner tube occurs while the inner tube is wrapped around the first mandrel. This applies only to container embodiments that include an inner tube with a rolled end edge.

[0063] In another embodiment, the steps of wrapping a first blank and joining its axial edges to form an inner tube are performed around a first mandrel, and the steps of wrapping a second blank and joining its axial edges to form an outer tube and rolling the end edges of the outer tube are performed around the inner tube while the inner tube remains attached to the first mandrel. This means that only a single mandrel needs to be used, which can be advantageous in terms of container manufacturing efficiency.

[0064] It is also envisioned that each step may be performed on a separate mandrel, which may allow for a continuous assembly line and potentially lead to a more efficient manufacturing process for multiple containers.

[0065] The step of providing a second blank may include punching a line along the blank to provide a circumferential line of weakness between the distal and proximal portions of the outer tube after it has been formed. This line of weakness may take a variety of shapes, as discussed above with respect to the features of the container itself. Providing a line of weakness in the blank for the outer tube may facilitate manufacturing.

[0066] The step of closing the proximal end of the inner tube may include the steps of providing a proximal cup having a disc and a rim, and sealing the proximal cup within the proximal end of the inner tube by adhering the rim to the inner surface of the inner tube, optionally by ultrasonic sealing.

[0067] The membrane and distal member may each be formed by stamping with a die. Alternative methods for providing the membrane and distal member are contemplated, such as being cut from a continuous reel of material, which may or may not be arranged to allow the membrane and distal member to be fed directly to their respective locations for assembly with the rest of the container.

[0068] The step of providing the first and second blanks may include skiving material off one or more of their axial edges, which ensures that the overlapping areas are not too thick, reducing the visual impact of the seam on the container, and also allows for the raw edges of the material to be folded away from areas that may contact or be exposed to the product and weaken the integrity and strength of the container.

[0069] In another aspect, yet another method for manufacturing any of the containers described above is provided. The method includes filling the container from the distal end rather than the proximal end. This container does not realize the benefit of providing a backing surface on the membrane with respect to impacts from filling the container with a product, but still realizes the benefit of impacts on the membrane from product movement within the container after assembly (e.g., during use or transport). The method includes the steps of providing a first blank of card-based or paper-based material; wrapping the first blank and joining axial edges of the first blank to form an inner tube; closing the proximal end of the inner tube (optionally providing a proximal cup having a rim and a base and sealing the rim of the proximal cup to the inner surface of the inner tube); filling the inner tube with the product from the distal end of the inner tube; providing a membrane having a diameter equal to or greater than the diameter of the inner tube; and adhering the membrane to the distal end of the inner tube. providing a second blank of card-based or paper-based material; wrapping the second blank and joining axial edges of the second blank to form an outer tube; providing a distal member of card-based or paper-based material; inserting the distal member into the outer tube to form a snug fit; rolling an end edge of the outer tube to form a rounded rolled end edge at the distal end of the outer tube; inserting an inner tube into the outer tube to position the membrane and distal member adjacent to each other; and adhering the inner tube to the outer tube.

[0070] The features previously described for the first method may also be combined with this method.

[0071] As used herein, card-based or paper-based materials refer to materials that are substantially composed of card or paper, such as cardboard or paperboard. This means that these materials must have a card or paper content that allows them to be used in the recycling stream. Card-based materials may include corrugated cardboard sheets coated with a thin PE film layer, but the PE film layer accounts for a low percentage of the material's overall composition, allowing the material to be recycled. Other polymer film layers or coatings may be used in place of PE. Similarly, pure corrugated cardboard or paperboard that does not contain polymers may also be card-based or paper-based materials. [Brief explanation of the drawings]

[0072] Some embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figures 2A to 2K collectively illustrate a process for manufacturing the container of Figure 1, with each step shown in cross section.

[0073] [Figure 1] 1 shows a cross-sectional view of a container according to an embodiment. [Figure 1A] 2 shows an enlarged view of a portion of the container of FIG. 1. [Figure 1B] 2 shows a close-up view of another portion of the container of FIG. 1. [Figure 2A] 1 shows a step of scraping material off the tube precursor. [Figure 2B] The procedure for winding the inner tube is shown below. [Figure 2C] 4 shows the step of rolling the end edge of the inner tube. [Figure 2D] 1 shows the step of forming a top membrane. [Figure 2E] 10 shows the step of attaching the membrane to the inner tube. [Figure 2F] 10 shows the step of winding the outer tube. [Figure 2G] 10 illustrates the steps of forming a distal disc. [Figure 2H] 13 shows the step of attaching the distal disc to the outer tube. [Figure 2I] 10 illustrates steps for forming a bottom cup. [Figure 2J] 1 illustrates the procedure for assembling the outer and inner tubes in preparation for filling the container with product. [Figure 2K] 1 shows the steps of assembling and sealing the bottom cup to the inner and outer tubes to obtain the finished container. [Figure 3] 1 shows a flow chart of a method for manufacturing a container as described herein. [Figure 3A] 10 shows a flow chart of an alternative method of manufacturing a container, in which the container is filled from the distal end. [Figure 4] 2 shows a perspective view of the container of FIG. 1. [Figure 5] 1 shows a cross-sectional view of a container according to another embodiment. [Figure 5A] 6 shows an enlarged view of a portion of the container of FIG. 5. [Figure 5B] 6 shows a plan view of a blank for forming part of the container of FIG. 5; DETAILED DESCRIPTION OF THE INVENTION

[0074] An exemplary container 2 according to the present invention will be described with reference to Figures 1, 1A, 1B, and 4. Figures 1A and 1B are enlarged views of sections A and B of Figure 1. Figure 4 is a perspective view of the container 2, showing only the exterior components.

[0075] The container 2 includes an inner tube 4, an outer tube 6, a membrane 8, a distal disc 10, and a proximal cup 12. Each of the inner tube 4, outer tube 6, distal disc 10, and proximal cup 12 is made from a card-based or paper-based material.

[0076] The illustrated inner tube 4 is a cylindrical tube having a rolled distal edge 14, also referred to as an inwardly facing rolled edge. The illustrated rolled distal edge 14 is rolled so that the raw edge 16 faces radially outward, and the distal edge faces the inside of the inner tube 4, thereby forming a generally toroidal shape; however, the rolled distal edge 14 may also be bent so that the raw edge 16 faces axially proximally.

[0077] The illustrated outer tube 6 is also a cylindrical tube with a rolled distal edge 18. The illustrated rolled distal edge 18 also has a generally toroidal shape, with its raw edge 20 rolled radially outward, although the rolled distal edge 18 can be rolled or folded into other shapes. The rolled distal edge 18 of the outer tube 6 provides a seat for the distal disk 10. The distal disk 10 can be adhesively secured to the rolled distal edge 18 or sized to be secured by friction, such as a friction or interference fit. The distal disk 10 provides a backing surface adjacent the distal side of the membrane 8, reducing the possibility of damage to the membrane 8 or the attachment between the membrane and the inner tube 4 due to product impacts when the container is filled or due to movement during use or transport. The distal disk 10 can be made of a paper or card-based material, such as paperboard or cardboard. The distal disc 10 may or may not have a barrier coating. For example, it may be made of Kraft board, folding corrugated cardboard, or a polymer-grade material of appropriate thickness. The distal disc 10 may be made of a grooved or corrugated material if more rigidity is required. In the illustrated example, the distal disc 10 is circular and configured to fit snugly within the outer tube 6.

[0078] The outer tube 6 is sized to fit snugly within the inner tube 4, and the two may be joined by an interference fit, adhesive bonding, or ultrasonic sealing (which may be combined with the ultrasonic sealing step of joining the proximal cup 12 to the inner tube 4, as described below).

[0079] The outer tube 6 and the inner tube 4 each share a central axis X in the longitudinal direction.

[0080] The membrane 8 is secured to the distal side of the rolled distal edge 14 of the inner tube 4. This bond is formed to seal the interior chamber 22 of the container 2, but allows a user to remove the membrane 8 and open the container 2 (after breaking the line of weakness 38 and removing the distal portion 36 of the outer tube 6, as described below). For example, the membrane 8 may be secured to the rolled distal edge 14 by ultrasonic sealing. Alternatively, the membrane 8 may be heat sealed to the rolled distal edge 14. However, ultrasonic sealing allows for more precise control of temperature during processing, allowing the membrane 8 to be bonded to the rolled distal edge in a controlled manner. This reduces the risk of damage to the container 2 from the potential for overheating that can occur with other methods of bonding the membrane 8 in certain areas of the inner tube 4. The membrane 8 may be made from a variety of materials or a layered material that combines various materials.

[0081] These materials include paper, PE, metallized PET, LDPE plastomer, HDPE, mLDPE, metal foil (e.g., aluminum foil), EVOH, Surlyn®, other polymers or ionomers, etc. Some exemplary layer configurations are (optionally paper or paperboard) / PE / metallized PET / LDPE-plastomer, (optionally paper or paperboard) / PE / 1.5 mm HDPE-mLDPE, (optionally paper or paperboard) / PE / 7 μm foil / plastomer-LDPE, or multi-layer laminates such as PE / Al / Surlyn® or PE / EVOH / Surlyn®. The choice of material depends on the product to be contained in container 2 and is determined by various factors, such as the required moisture vapor transition rate (MVTR) threshold. In some embodiments, membrane 8 is constructed from either PE (polyethylene)-coated paper, metallized PE-coated paper, heat-sealed membrane, or other suitable polymer-coated material and has a suitably low moisture vapor transmission rate (MVTR). The thickness of the film 8 may be about 0.05 to 0.5 mm, more precisely about 0.1 mm.

[0082] 1A , tab 24 (or lug) is seen folded 90° (i.e., axially) and extending proximally between inner tube 4 and outer tube 6. It will be understood that only tab 24 of membrane 8 extends proximally in this manner; the remainder of membrane 8 does not extend proximally beyond rolled distal edge 14 of inner tube 4. In use (after a portion of outer tube 6 has been removed, as described further below), a user pulls tab 24 substantially distally to release membrane 8 from inner tube 4 and provide access to the contents of container 2 within internal chamber 22.

[0083] The illustrated membrane 8 is positioned adjacent to the distal disc 10 and is in contact with the distal disc 10 as shown.

[0084] The proximal cup 12 (also referred to as a bottom plug, proximal plug, proximal disk, bottom cup, or bottom disk) is positioned at the proximal end of the container 2. The proximal cup 12 comprises a flat disk 26 and an annular rim 28, which are joined at rounded corners 30. The rounded corners 30 may be sharp. In some embodiments, the proximal cup 12 may be replaced by a flat disk joined to the proximal end of the container 2. The illustrated rim 28 of the proximal cup 12 is joined to the inner surface 32 of the inner tube 4, for example, by ultrasonic sealing. This seal along the axial length of the rim 28 ensures a good seal at the proximal end of the container 2, typically at the base of the container 2, during use, reducing the possibility of leakage therefrom. The additional layer of paper- or card-based material provided by the rim 28 at the base of the container 2 also improves the structural rigidity of the container 2.

[0085] The outer tube 6 includes a proximal portion 34 and a distal portion 36, and includes a line of weakness 38 (or frangible bond) extending circumferentially around the outer tube 6. The line of weakness 38 may comprise, for example, a hole punched in the card- or paper-based material comprising the outer tube 6. While the illustrated line of weakness 38 extends only circumferentially and forms a circle with no axial component, in some embodiments, the line of weakness 38 may extend diagonally with an axial component, forming an oval shape with one end closer to the proximal end of the container 2 than the other end. Similarly, in other embodiments, the line of weakness 38 may have a waveform, such as a sinusoidal or triangular wave, extending around the circumference of the outer tube 6. In another configuration, the line of weakness 38 may extend only a portion of the circumference of the outer tube 6 (e.g., a majority of the circumference, e.g., about 300°-350°, e.g., about 315°). In this case, when the user breaks the line of weakness 38, the remaining portion forms a connection portion that acts as a hinge, maintaining the distal portion 36 of the outer tube 6 connected to the proximal portion 34 of the outer tube 6.

[0086] In use, when the line of weakness 38 breaks, for example by a user applying a force (optionally with a torsional component) that pulls the distal portion of the outer tube 6 away from the remainder of the container 2, the distal portion 36 functions as a cap for the container 2 and is replaceably removable from the container 2. The inner tube distal portion 40 (in other words, the distal portion 40 of the inner tube 4) is defined as the portion of the inner tube 4 that extends axially distal to the line of weakness 38 and provides a neck for positioning the outer tube distal portion 36 on the container 2. The proximal portion 34 of the outer tube 6 has a distal edge 42 at its distal end that provides a shoulder against which a foot provided by the proximal edge 44 of the distal portion 36 of the outer tube 6 rests when the proximal portion 34 (cap) is replaced on the container 2.

[0087] If the line of weakness 8 extends only circumferentially, the distal portion 36 may be positioned on the container in any orientation, which may be desirable in some circumstances, for example, to facilitate reassembly. If the shape of the line of weakness is more complex, the distal portion 36 may need to be aligned with the proximal portion 34 of the outer tube 6, which may provide other benefits, such as aligning visual designs or wording printed or otherwise positioned on the exterior of the container 2.

[0088] Distal portion 36 may include circumferential ridges (not shown) extending from the inner surface of distal portion 36 and configured to resiliently engage the outer surface of inner tube 4. This engagement improves the friction fit, providing a user with additional frictional resistance when removing or attaching the distal portion to container 2. The circumferential ridges may be referred to as creases, embossments, or protrusions. Other protrusions extending inward from the inner surface of distal portion 36 may provide a similar effect.

[0089] The container 2 is shown without any product in the chamber 22. When the container 2 contains a product, the arrangement can be referred to as an assembly.

[0090] An exemplary construction method will now be described with reference to Figures 2A-2K and Figure 3. Figure 3 shows a flow chart of each of the steps shown in Figures 2A-2K.

[0091] As will be appreciated, some of these steps may be performed sequentially, with time between each step, or in an alternating order with some steps performed simultaneously (e.g., winding the inner and outer tubes simultaneously). Also, while only one example is shown of how each step is performed, other methods may be used. For example, while the membrane is shown as being stamped with a die, it could be cut from a sheet of membrane material using a laser or the like.

[0092] FIG. 2A illustrates the step of skiving material from a blank 4A for an inner tube 4. Material is skived from a corner 46 of an axial edge 48, creating a chamfered portion 50. Skiving material involves cutting, scraping, or grinding away the portion of the blank 4A material that is removed to create the chamfered portion 50. The skiving step can be performed on only one axial edge 48 of the material, as shown, or on both axial edges. The material of the blank 4A adjacent to the chamfer 50 can be folded back on itself to provide a coated edge rather than a raw edge of material. This prevents raw edges from becoming weak points and improves the durability of the container. This also ensures a continuous barrier lining that is fully integrated into the inside of the tube, eliminating raw edges that could lead to moisture ingress and loss. Additionally, depending on the product, it may be beneficial to prevent the product from coming into contact with the raw edges of the inner tube 4 material.

[0093] It will be appreciated that the shape shown in FIG. 2A is exemplary, and the exact shape of the resulting chamfered portion 50 of the blank 4A may be shallower or steeper and may extend further or farther through the thickness of the material of the blank 4A, depending on particular design requirements.

[0094] The same or an alternative skiving step may be used for the blank 6A of the outer tube 6.

[0095] Skiving material from blank 4A or blank 6A creates a thin section of material at axial edge 48 that can be overlapped and joined to the other axial edge when forming tubes 4, 6. This can result in a rounder, smoother shape for the resulting tubes 4, 6.

[0096] FIG. 2B illustrates the step of forming the inner tube 4 from a blank 4A. This step involves winding the blank 4A into a cylindrical shape and then joining its axial edges 48. In the illustrated step, a pair of winding wings 54 (or winding arms) are used to wind the blank 4A around a cylindrical mandrel. The winding wings 54 are hinged to one another and have rounded inner surfaces 56 configured to engage the blank 4A when the winding arms press the blank 4A inward. In an alternative configuration, other means of winding the inner tube 4 from the blank 4A can be used instead of the winding wings 54, such as the use of a belt or a positioning grip and rotating mandrel system. Additionally, in some examples, the inner tube 4 and outer tube 6 are provided by a linear winding process with a continuous reel feed.

[0097] An ultrasonic sealing head 57 is then applied to the area where the axial edges 48 of the blank 4A overlap, sealing the blank 4A to form the inner tube 4, such that a side seam is formed where the axial edges 48 are attached. After the wrapping wings 54 are released, the inner tube 4 may be removed from the mandrel 52. More typically, the inner tube 4 is left attached to the mandrel 52 with the wrapping wings 54 removed, ready for the next step.

[0098] FIG. 2C illustrates the step of forming the rolled distal edge 14 of the inner tube 4. If the inner tube 4 was removed from the mandrel 52 in step 2B, it is returned to the mandrel 52 or attached to another mandrel. Otherwise, the inner tube 4 is retained on the mandrel 52. The internal curling head 58 includes a block having an annular recess 60 configured to wind material from the raw distal edge 16 of the inner tube when the internal curling head 58 is pressed against the inner tube 4 to form the inner tube distal rolled edge 14. The illustrated annular recess 60 has a semicircular cross-section to achieve this curling effect, but other shapes may be used to achieve the same effect. Once the internal curling head 58 is removed, the inner tube 4 may then be removed from the mandrel 52. In some examples, the inner tube 4 is left on the mandrel 52, ready for the step of attaching the membrane 8 to the inner tube 4. In other examples, each step, and optionally portions of each step, may be performed on separate mandrels, for example, to aid in product line manufacturing.

[0099] FIG. 2D illustrates the step of forming membrane 8. This step involves preparing a membrane die 62 with a recess 64 that matches the shape desired for the final membrane 8. A membrane precursor 8A, or membrane blank, is a sheet of membrane material (as described above, note the materials listed for membrane 8) and is placed on membrane die 62. A punching block 66 is then pressed against membrane precursor 8A on membrane die 62 to punch out membrane 8. As can be seen in FIG. 2D, membrane 8 is punched out to include tab 24 protruding from the circle of membrane 8.

[0100] As will be appreciated, alternative methods for forming the membrane 8 other than punching out the membrane 8 using a die 62 and punching block 66 may be provided.

[0101] FIG. 2E illustrates the step of attaching the membrane 8 to the inner tube 4. This step is performed by placing the membrane 8 over the distal rolled edge 14 of the inner tube 4 while the inner tube 4 is positioned on the mandrel 52. A second ultrasonic sealing head 68 is positioned over the membrane 8 and pressed against it, bonding the membrane 8 to the distal rolled edge 14. The second ultrasonic sealing head 68 locally heats the membrane 8 where it contacts the distal rolled edge 14, thereby locally melting the membrane material and fusing the membrane 8 to the distal rolled edge 14. Using ultrasonic sealing in this manner allows for greater control over the temperature and location of the membrane 8 than, for example, using simpler resistive heating elements. For example, temperatures of 150°C to 200°C, or more specifically, approximately 175°C, can be applied. This reduces the risk of damage during the sealing step.

[0102] The second ultrasonic sealing head 68 can then be removed and the inner tube removed from the mandrel 52 to provide the inner tube 4 with the membrane secured thereto.

[0103] The illustrated second ultrasonic sealing head 68 is sized and shaped to fit over the inner tube 4 and simultaneously bond the membrane 8 to the inner tube 4 at all points along the connection. As previously mentioned, instead of ultrasonic sealing, heat sealing, such as induction heating sealing, can be used using an appropriately shaped heating die.

[0104] FIG. 2F illustrates the step of forming the outer tube 6. This step is substantially similar to the step illustrated in FIG. 2B and described above, but is applied to a blank 6B for the outer tube 6. This process uses similar or identical wrapping wings 54, curved surface 56, and ultrasonic sealing head 57. Naturally, the mandrel 52′ used in this step may be slightly larger than the mandrel 52 used in the step of FIG. 2B, since the outer tube 6 is sized to accommodate the inner tube 4. Alternatively, the wrapping step illustrated in FIG. 2F may be performed on the same mandrel 52 used to wrap the inner tube 4, with the inner tube 4 still secured on the mandrel 52. That is, the outer tube blank 6B may be wrapped around the inner tube 4, and its edges may be sealed with the ultrasonic sealing head 57.

[0105] As mentioned above, another difference between the outer tube and the inner tube is that the outer tube 6 includes a line of weakness 38 separating its distal and proximal portions 36, 34. This line of weakness 38 may be formed by perforations in the outer tube blank 6B, as described above, or by cutting blades on the winding wings 54 of this step that form the line of weakness 38 as the outer tube 6 is wound. In such an embodiment, the winding wings 54 are not the same as the winding wings 54 used to form the inner tube 4. To ensure that the line of weakness remains frangible around the entire circumference of the outer tube 4B, the ultrasonic sealing head 57 includes a gap and / or is not applied at the portion of the axial seam of the outer tube where the line of weakness 38 intersects.

[0106] Figure 2G illustrates the step of forming the distal disc 10 (or upper disc). The step illustrated in Figure 2G is substantially similar to the step illustrated in Figure 2D, except that the punching die 66' of Figure 2G punches the distal disc 10 from a distal disc precursor 10A made of a card- or paper-based material that is placed on a die 62' having a recess 64'. In contrast to the recess 64 of the die in Figure 2D, the recess 64' in this step does not have space to accommodate the tab 24 of the membrane 8, so the distal disc 10 is made circular, thereby fitting within the outer tube 6.

[0107] FIG. 2H illustrates the step of attaching the distal disk 10 (or upper disk) to the outer tube 6. In this step, the outer tube 6 is placed (or held) on the outer tube mandrel 52′, and the distal disk 10 is placed on top of the mandrel 52′ so that the distal disk 10 is positioned within the outer tube 6. Next, this step involves pressing a second internal curling head 58′ having a formed recess 60′ against the distal end of the outer tube 10 to roll its raw distal edge 20 inward, forming the rounded rolled edge 18 of the outer tube 6. Similar to the formed recess 60 of the step-in in FIG. 2C, the formed recess 60′ of the second internal curling head 58′ is annular with a semicircular cross-section, and the outer radius of the annular portion matches the outer radius of the outer tube 6.

[0108] The second inner curling head 58' may then be removed and the outer tube 6 and distal disc 10 may be removed from the mandrel 52'.

[0109] In some embodiments, a ring of adhesive may be applied around the distal face of the distal disc 10 to ensure adhesion between the distal disc 10 and the rolled edge 18 of the outer tube 6 .

[0110] Of course, alternative means of applying the distal disc 10 to the outer tube 6, with or without a rolled edge 18, may also be used.

[0111] FIG. 2I illustrates the step of forming the proximal cup 12 (or bottom cup). This step is somewhat similar to the steps of FIGS. 2D and 2G, except that a punching block 66' forms the final piece from a flat plate of material rather than cutting it out. A cup die 62" is provided, onto which a proximal cup precursor 12A is placed. The cup die 62" has a recess 64" corresponding to the negative of the final shape desired for the proximal cup 12. A punching block 66" is pressed into the recess 64" of the cup die 62", specifically, a protrusion 70 on the punching block 66" is pressed into the recess 64". This causes the proximal cup precursor 12A to bend into a round shape, forming the shape of the proximal cup 12, which, as previously described, has a flat disk portion 26 and a rim 28 joined by (optionally) rounded corners 30.

[0112] The punching block 66'' may then be removed and the proximal cup 12 may be removed from the cup die 62''.

[0113] In addition to the bending function, the punching block 66" can also perform a cutting function in the event that the proximal cup precursor 12A contains excess material beyond the amount required for the proximal cup 12. The proximal cup precursor 12A can be a single precursor attached to a reel to provide multiple proximal cups 12 for different containers 2.

[0114] As will be appreciated, other methods can be used to form the proximal cup 12. For example, the proximal cup 12 can be formed directly into the inner tube 4 (and optionally the outer tube 6) while the inner tube 4 is held on the mandrel 5'. The proximal cup 12 can then be sealed to the inner tube 4 (and also the outer tube 6, if present) optionally by ultrasonic sealing before the proximal cup 12 and inner tube 4 (and also the outer tube 6, if present) are removed together from the mandrel 52. This method can be used when filling a container with product from the distal end.

[0115] 2J illustrates the step of assembling the outer tube 6 and inner tube 4 in preparation for filling the container 2 with product. In this step, the inner tube 4 is slid into the outer tube 6 to form an interference fit. In some embodiments, if the respective tubes 4, 6 are polymer-coated, a heat-seal attachment can be created between the inner tube 4 and outer tube 6 using an ultrasonic sealing or heating element process. Alternatively, an adhesive can be used proximal to the line of weakness 38 to bond the proximal portion 34 of the outer tube 6 to the inner tube 4.

[0116] Not shown in this figure is the step of filling container 2 with product. In this step, the arrangement of FIG. 2J is turned upside down and gravity is used to fill the product. The method for performing this step will vary depending on the product and the filling line being used. For example, solid, cream, or gel products may be filled using a hot-fill or cold-fill process. Powder, particle, or pellet products are poured or funneled into container 2. In either of these methods, container 2 is filled from the proximal end, to which proximal cup 12 is later attached.

[0117] A particular advantage of filling the container after placing the inner tube 4 within the outer tube 6 is that when the product is inserted, the distal disc 10 provides a backstop that prevents the product from tearing the membrane 8 or breaking the seal between the membrane 8 and the rolled distal edge 14 of the inner tube 4.

[0118] In other embodiments, the product is filled from the distal end of the container 2, which requires joining the proximal cup 12 to the inner tube 4 before attaching the membrane 8 to the inner tube 4, after which the membrane 8 is secured and then the inner tube 4 (including the product, membrane 8 and proximal cup 12) can be inserted into the outer tube 6 prior to the joining step between the outer tube 6 and the inner tube 4. Such a method is shown in Figure 3A.

[0119] FIG. 2K shows the step of assembling the container and sealing the proximal (or bottom) cup 12 to the tubes 4,6.

[0120] First, the proximal cup 12 may be inserted into the inner tube 4 within the outer tube 6, with the proximal end of the product obtained in step 2J, i.e., the membrane 8 and distal disk 10 intact. Specifically, the proximal cup 12 is inserted into the proximal end of the inner tube 4. The proximal cup 12 may be temporarily held within the inner tube 4 by a friction fit or an interference fit. A third ultrasonic sealing head 72, having an annular groove 74 sized to fit around the rim 28 of the proximal cup 12 and the proximal ends of the inner and outer tubes 6, is provided for ultrasonically bonding the proximal cup 12 to the inner tube 4 and, optionally, the inner tube 4 to the outer tube 6. In some instances, a heated mandrel shaped to fit within the proximal cup 12 may be used instead of the ultrasonic sealing head 72. The ultrasonic sealing head 72 is configured to simultaneously bond the proximal cup 12 to the inner tube 4 and the inner and outer tubes. In this way, the container 2 can be sealed at its proximal end by the proximal cup 12 , with the distal end already sealed by the membrane 8 .

[0121] The container 2 can then be removed from the ultrasonic sealing head 72 (or vice versa) and oriented as required.

[0122] As will be appreciated, methods other than ultrasonic sealing may be used to sealingly secure the proximal cup 12 to the inner surface 32 of the inner tube 4 .

[0123] Figure 3 illustrates an exemplary method 300 for forming a container 2 described herein. Steps A-K illustrated in Figure 3 correspond to the steps illustrated in Figures 2A-2K.

[0124] As previously mentioned, FIG. 3A illustrates an example of a method 300A for forming a container in which the product is filled from the distal end rather than the proximal end. Steps corresponding to those in FIG. 3 are indicated by corresponding letters, and the order of the steps has been changed. Step J in FIG. 3 is divided into a product filling step and an inner and outer tube assembly and joining step. In the process of FIG. 3A, product filling must occur before the outer tube and top disk are placed around the inner tube and before the membrane is bonded to the inner tube. This is because the proximal cup must be placed within the inner tube to accommodate the product. It will be appreciated that some steps, such as forming the top disk, may be performed earlier in the sequence.

[0125] As will be appreciated, the order of some steps is not important, e.g., step F of wrapping the outer tube can be performed before any of steps B through E. However, the order of some steps is important, e.g., step G of forming the distal disk must be performed before step H of attaching the distal disk to the outer tube. Those skilled in the art will be able to perform these steps in the appropriate order using their general knowledge.

[0126] Another embodiment of a container is described with reference to Figures 5, 5A and 5B. Similar or corresponding elements are numbered with corresponding reference numerals increased by 100. For example, Figure 1 shows container 2, while Figure 5 shows container 102.

[0127] Because the elements of the vessel 102 of FIG. 5 are the same as the elements of the vessel 102 of FIG. 1, a detailed description will be omitted for the sake of brevity, and only the differences will be described in detail.

[0128] The bottom cup 112 of FIG. 5 is the same as the bottom cup 12 of FIG.

[0129] Inner tube 104 of Figure 5 is similar to inner tube 4 of Figure 1, except that inner tube 104 of Figure 5 does not include a rolled distal edge and instead maintains a straight, unrolled distal portion 114 with its unmachined edge 116 (labeled in Figure 5A) facing distally. The overall length of inner tube 104 of Figure 5 is less than or equal to the length of inner tube 4 of Figure 1, despite having a straight distal portion 104. Thus, the blank used to form inner tube 104 is shorter than blank 4A used to form inner tube 4.

[0130] The membrane 108 of FIG. 5 may be made of the same material as the membrane 8 of FIG. 1 but has a different shape due to the way it is attached to the container. In particular, the membrane 108 has a larger diameter and forms a rim 109. After assembly, the rim 109 extends distally from the center of the membrane, forming a disk that traverses the inner tube 104. The rim 109 is secured to the inner surface 132 of the inner tube 104, for example, by ultrasonic bonding. The membrane 108 includes a tab (not shown) that a user can grasp to remove the membrane 108 from the container 102. The tab may be attached around the periphery of the membrane 108, or it may be attached to the middle of the membrane 108 and bendable, extending distally to provide a grip for the user to grasp when removing the membrane 108. The connection between the rim 109 and the middle of the membrane 108 may be curved. The axial length of the rim 109 may be selected depending on the desired bond strength between the membrane 108 and the inner tube 104.

[0131] Thus, without a rolled distal edge, product within interior chamber 122 contacts only one side of inner tube 114, namely, inner surface 132. This contrasts with inner tube 4 of FIG. 1, which has rolled distal edge 14 such that product may contact surface 33 of inner tube 4 opposite inner surface 32 (see FIG. 1A) at rolled distal edge 14. That is, surface 33 would be the outer surface if the distal end of inner tube 4 were not rolled, but with such rolling, it becomes the inner surface facing interior chamber 22 of container 2 of FIG. 1.

[0132] As a result, only one side of the blank for the inner tube 104 of the dispenser 102 of FIG. 5 needs to be coated with an oil-resistant coating such as a PE film or similar coating, which reduces manufacturing costs and complexity and makes the container 102 easier to recycle.

[0133] The container 102 of FIG. 5 has a distal cup 110 instead of the distal disk 10 of FIG. 1 . Importantly, because the distal cup 110 of the container 102 is in substantial contact with the membrane 108, if product from the internal chamber 122 impacts the membrane 108, the distal cup 110, located behind the membrane 108, absorbs most of the force, reducing the likelihood of the membrane 108 being perforated by the product. Product may impact the membrane 108 during the step of filling the container 102 with product (in embodiments where the product is filled from the proximal end of the container 102). Product may also impact the membrane 108 if the filled container is vibrated, whether intentionally or unintentionally, during use, transportation, or other circumstances. However, even if product does impact the membrane 108, the backing provided by the distal cup 110, or the distal disk 10 of FIG. 1 , is beneficial in reducing the likelihood of the membrane 108 being damaged, which is important when the product needs to remain sealed within the container 2, 102 until opened by the user. Distal cup 110 includes one or more lips 111 disposed to extend distally to a distal end rolled edge 118 .

[0134] The lip 111 is held to a rolled edge 118 at the distal end by a friction fit or, optionally, by being adhered, for example, by adhesive.

[0135] The axial length of the lip 111 allows the central portion of the distal cup 110 to be positioned adjacent to the membrane 108 despite the presence of the rim 109 of the membrane 108, and the central portion of the membrane 108 is axially spaced from the distal end of the container 102, and in particular, from the position where the flat tip disk would be located if it axially abutted against the rolled end edge 118 of the outer tube 106.

[0136] 5B shows a blank 110A for a distal cup 110. In particular, the blank 110A shown has a dodecagonal shape formed by combining three squares with rounded vertices. However, the distal cup blank 110A may be shaped as a different star polygon or an entirely different shape, as appropriate. In particular, the distal cup blank 110A has a protrusion 111A forming a lip 111 that extends to a distal end rolled edge 118.

[0137] The outer tube 106 of the container 102 of Figure 5 differs from the outer tube 6 of the container 2 of Figure 1 only in that the rolled end edge 118 of the outer tube 106 of Figure 5 is not rolled as tightly. That is, there is a space between the raw end edge 120 of the outer tube 106 and the inner surface of the distal end of the outer tube 106, into which the lip 111 extends (or slots in) as described above.

[0138] The method for manufacturing the container 102 of FIG. 5 is substantially similar to the method for manufacturing the container 2 of FIG. 1, except for the following steps: The membrane 108 is secured to the inner surface 132 of the inner tube 104 at its rim 109 using an ultrasonic sealing head similar to that used to seal the proximal cup 12 to the inner tube 4 as shown in FIG. 2K, optionally using an ultrasonic sealing head similar to that used to seal the proximal cup 12 to the inner tube 4 as shown in FIG. 2K, rather than placing and sealing the membrane 108 on the distal rolled edge. The method steps shown in FIG. 2H are coordinated so that as the distal end edge of the outer tube 106 is rolled, material from the rolled distal edge 118 is folded around and thereby pinches the lip 111 of the distal cup 110. The step of inserting the distal cup 110 into the outer tube 106 while the outer tube 106 is mounted on a mandrel folds the lip 111 distally. This is because the diameter of the distal cup blank 110A, including the protrusion 111A, is larger than the inner diameter of the outer tube 106.

[0139] The term "proximal" as used herein means away from the end of the container 2 that the user opens. Typically, the proximal direction is downward, or toward the bottom of the container 2, and is defined as the orientation during use.

[0140] The term "distal" refers to the opposite direction to "proximal," i.e., the distal direction refers to the "top" or upward direction of the container 2 when in use.

[0141] The axis X of the container 2 is the axis X of each of the inner tube 4 and the outer tube 6, and is a longitudinal axis X extending along the centerline of the tubes (tubular bodies) 4, 6 from the proximal end to the distal end.

[0142] The radial direction is the direction outward from or inward of the axis X and is perpendicular to the axis X.

[0143] A circumferential direction is defined as extending around the tubes 4, 6 with respect to the axis X. [Explanation of symbols]

[0144] 2, 102 Container 4, 104, 114 Inner pipe, tube (tube body) 4A Blank 5 mandrels 6, 106 Outer tube, tube (body) 6A, 6B blank 8, 108 membrane 8A Membrane precursor 10 Distal disc 10A Distal disc precursor 11 Free end 12, 112 Proximal cup, bottom cup 12A Proximal cup precursor 14, 114 distal edge, rolled distal edge 16, 116 Unprocessed distal edge 18, 118 distal edge, rolled distal edge 20, 120 distal edge, terminal edge 22, 122 inner chamber 24 tabs 26 discs 28 rims Corners 30 and 46 32, 132 inner surface 33 Surface 34 Proximal part 36, 40 Distal part 38 Weakened Lines 42 Distal Edge 44 proximal edge 48 axial edge, internal curling head 50 Chamfered part 52 Mandrel 54 Wing 56 Curved surfaces, interior surfaces 57, 68, 72 Ultrasonic sealing head 58 Internal Curling Head 60, 64 recess 62 Die 66 Punching Block 70 protrusions 74 Annular groove 109 Rim 110 Distal Cup 110A Distal Cup Blank 111 Lip 111A Protrusion, protrusion

Claims

1. A container made of card-based or paper-based material, an inner tube including a distal end and a closed proximal end; an outer tube sized to fit snugly around the inner tube; a membrane sealingly closing a distal end of the inner tube to provide a sealed interior chamber; a distal member fixed relative to the outer tube and providing a backing surface adjacent a distal side of the membrane; A container comprising:

2. the outer tube having a proximal portion and a distal portion having a closed distal end; The container of claim 1 , wherein the distal portion is connected to the proximal portion along a line of weakness that extends around the circumference of the outer tube.

3. 3. The container of claim 2, wherein when the line of weakness breaks, the proximal portion of the outer tube comprises a shoulder at its distal end, the distal portion of the outer tube comprises a foot at its proximal end configured to abut the shoulder, and the distal portion of the inner tube comprises a neck configured to appear when the distal portion of the outer tube is removed and to allow the distal portion of the outer tube to be located when the distal portion of the outer tube is replaced in the container, and wherein when the distal portion returns to its original position, the shoulder and the foot are configured to extend along the same line as the broken line of weakness.

4. 4. The container of claim 2 or 3, wherein the inner tube includes an embossed circumferential ridge located distal to the line of weakness and configured to resiliently engage the inner surface of the distal portion of the outer tube.

5. 5. The container of claim 1, wherein the closed proximal end of the inner tube is provided by a proximal cup including a disc and an integral rim, the rim being bonded to the inner surface of the inner tube adjacent the proximal end of the inner tube.

6. 6. The container of any one of claims 1 to 5, wherein the membrane comprises a layered material including a combination of layers formed from one or more of paper, paperboard, PE, metallized PET, LDPE plastomer, HDPE, mLDPE, metal foil (e.g., aluminum foil), EVOH, and other polymers or ionomers.

7. The container according to any one of claims 1 to 6, wherein the inner surface of the inner tube is coated with PE.

8. 8. The container of claim 1, wherein the inner tube includes an inner tube rolled end edge at a distal end thereof, and the membrane is secured distally to the inner tube rolled end edge.

9. 9. The container of claim 8, wherein the closed distal end of the outer tube includes an outer tube rolled end edge and a distal disk seated against a proximal end of a second rolled end edge, the distal disk providing a distal member and the backing surface.

10. A container according to any preceding claim, wherein the membrane comprises a circular disc and a tab extending from the circumference of the circular disc.

11. 8. The container of claim 1, wherein the membrane includes an axially extending rim, the axially extending rim extending distally and secured to an inner surface of the inner tube.

12. 12. The container of claim 11, wherein the closed distal end of the outer tube includes a rolled end edge of the outer tube and a distal cup having a base and at least one lip extending distally into the second rolled end edge, the distal cup providing the distal member and the base of the distal cup providing the backing surface.

13. An assembly comprising a container according to any one of claims 1 to 12 and a product contained within the inner tube of the container.

14. A method for producing a container according to any one of claims 1 to 13, comprising the steps of: Providing a first blank made of a card-based or paper-based material; winding the first blank and joining axial edges of the first blank to form an inner tube; providing a membrane having a diameter equal to or greater than the diameter of the inner tube; adhering the membrane to the distal end of the inner tube; providing a second blank made of a card-based or paper-based material; winding the second blank and joining axial edges of the second blank to form an outer tube; providing a distal member constructed from a card-based or paper-based material, and inserting said distal member into said outer tube to form a snug fit; rolling an end edge of the outer tube to form a rounded end edge at the distal end of the outer tube; inserting the inner tube into the outer tube so that the membrane and the distal member are adjacent to each other; filling the inner tube with product; closing the proximal end of the inner tube; The method comprising:

15. 15. The method of claim 14, further comprising rolling an end edge of the inner tube to form a rounded rolled end edge at the distal end of the inner tube, and wherein bonding the film to the distal end of the inner tube comprises bonding the film to a distal side of the rolled end edge of the inner tube.

16. 16. The method of claim 15, wherein the distal member is a distal disk, and rolling the end edge of the outer tube comprises forming a rounded rolled edge on the distal end of the outer tube that provides a seat around the periphery of the distal disk that abuts against a distal face of the distal disk.

17. 15. The method of claim 14, wherein the membrane includes an axially extending rim, and wherein joining the membrane to the distal end of the inner tube includes bonding the axially extending rim of the membrane to an interior surface adjacent the distal end of the inner tube.

18. 20. The method of claim 18, wherein the distal member includes a distal cup having a base and at least one lip, and wherein rolling the end edge of the outer tube includes forming a rounded rolled edge on the distal end of the outer tube that grips the at least one lip of the distal cup.

19. The method according to any one of claims 14 to 18, wherein the step of joining the axial edges of the first blank and the second blank is performed by ultrasonic sealing.

20. The method according to any one of claims 14 to 19, wherein the step of joining the membrane to the inner tube is performed by ultrasonic sealing.

21. 21. The method of any one of claims 14 to 20, wherein the step of winding the first blank and joining the axial edges of the first blank to form the inner tube is performed around a first mandrel, the step of winding the second blank and joining the axial edges of the second blank to form the outer tube is performed around a second mandrel, and the step of rolling the end edges of the outer tubes is performed with each outer tube wrapped around the second mandrel.

22. 22. The method of claim 21, wherein the step of rolling the end edge of the inner tube is performed while the inner tube is wrapped around a first mandrel.

23. 21. The method of any one of claims 14 to 20, wherein the steps of winding the first blank and joining the axial edges of the first blank to form an inner tube are carried out around a first mandrel, and the steps of winding the second blank, joining the axial edges of the second blank to form an outer tube, and rolling the end edges of the outer tube are carried out around the inner tube while the inner tube remains attached around the first mandrel.

24. 24. The method of any one of claims 14 to 23, wherein the step of providing the second blank includes the step of punching a line along the blank to provide a circumferential line of weakness between the distal and proximal portions of the outer tube after forming.

25. 25. The method of any one of claims 14 to 24, wherein closing the proximal end of the inner tube comprises providing a proximal cup having a disc and a rim, and sealing the proximal cup within the proximal end of the inner tube by adhering the rim to the inner surface of the inner tube, optionally by ultrasonic sealing.

26. The method of any one of claims 14 to 25, wherein each of the membrane and distal member is formed by stamping with a die.

27. 27. The method of any one of claims 14 to 26, wherein the steps of providing the first blank and the second blank comprise skiving material from one or more of their axial edges.

Images