Removable plastic liner for metallic container systems

Abstract

A container system allowing for metal components and sealed by a removable plastic insert / liner is described. The insert is formed with a peripheral flange that provides a hermetic seal between the container body and the cap without the use of a metallized foil or crimped metal panel. In turn, various features on and in the insert facilitate the attachment and separation processes. The insert also reduces costs and material usage.

Description

TITLEREMOVABLE PLASTIC LINER FOR METALLIC CONTAINER SYSTEMSCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to United States provisional patent application serial number 63 / 707,243 filed on October 15, 2024, which is incorporated by reference.TECHNICAL FIELD

[0002] The present invention relates to closure system capable of hermetically sealing contents from components that can be easily recycled and, more specifically, a closure system using a removable plastic liner to hermetically seal metallic container systems.BACKGROUND

[0003] Closures for container systems often require initial hermetic sealing, as well as easy to use closures (e.g., flip top or screw top caps) for subsequent use, in order to protect their contents from ambient environmental conditions. Aromatic consumables, such as coffee or other foodstuffs where flavor and aroma are a key aspect of the user’s experience, can be particularly demanding because retention of the aroma, along with the ability to repeatedly access the container, requires packaging solutions that are robust.

[0004] To the extent the consumables are associated with high value brands, these container systems often require a specific aesthetic in addition to the aforementioned functionality. For example, sellers may prefer the style and perceived durability of metallic containers. However, sealing a metallic container can be at cross-purposes with ease of opening / use and, separately, with the ability to recycle the container if plastic films or liners are needed for hermetic sealing. As a result, conventional but expensive all-metal containers often employ “beverage can” style seals in which the top edges of the metal can are crimped over a flat, metallic top, which can include an opening mechanism (e.g., a soft drink can with a lever that detaches a portion of the metal along a thinned groove).

[0005] Figure 1 provides an exploded view of an all-metallic container system 10 designed to meet the specific issues noted above. A cup-shaped can or main body 11 defines an interior space that may be packed with a consumable product C (as shown, ground coffee). The top edge18869752of body 11 includes threads 12 within an axially extending region 13. Metallic closure panel 14 is coaxially received and seated on a radial ledge or indent in the extension 13, after which the combination is swaged or crimped so that the panel becomes permanently attached and creates a hermetic seal. A metallic cap 15 with cooperating threads (not shown) on an inner surface of the skirt 17 is then screwed onto the enclosed body. Upon initial use, the consumer must rely on the pull tab 16 formed on the panel, which then detaches or releases from the body (either at its periphery or along a deliberately formed, thinned section in the panel 14). Thereafter, the consumer can rely on the metallic cap 15 to reseal the container system.

[0006] Because of its use of a discarded metallic panel 14, the cost of the container system 10 can be high (at least as compared to systems using lower cost plastic components in place of metal). Some consumers may also struggle to remove the metallic panel 14 using the lever-and- pull mechanism. Therefore, a more cost effective and intuitive, easy-to-use design would be welcomed.

[0007] More simplistic conventional sealing mechanisms employ a plastic sleeve shrink- wrapped around the closure and the container opening. However, the resulting seal may not be sufficiently hermetic to retain aroma / flavor, and the positioning of the wrap on an exterior surface made it susceptible to accidental tearing or removal.

[0008] Alternative seals can position a plastic or composite metallized plastic film on the top edge of the container opening. Typically, this involves adhering or welding (e.g., inductively, via infrared, etc.) the periphery of the liner to a flat portion along the container’s edge. These operations add cost and complexity to closure operations, while the need to punch circular shapes into a roll of film creates significant waste.

[0009] Additional solutions can be found in United States patents 4,340,149; 4,709,825; 5,452,818; 5,663,223; 5,686,040; 6,964,346; 9,943,998; 10,065,233; 10,800,585; 10,954,040; and 11,858,701, as well as in United States patent publications 2002 / 0092852; 2004 / 0252918; 2008 / 0073309; 2016 / 0304264; and 2022 / 0411146. All of these documents are incorporated by reference herein. Additional solutions may be found in European patent publication EP3603925A1, Japanese patent 4540049B2, and Canadian patent publication 2472216A1.

[0010] As a final consideration, legal and regulatory schemes continue to emphasize sustainability. Current recycling regimens tend to require the separation of disparate materials, especially with respect to plastics vs. metal. Therefore, closure systems that rely on permanently28869752adhered, welded combinations of plastics and metals are not favored (even though such composites may over weight, cost, and performance advantages). In the event a combination of metal and plastic is used, the resulting components of the system must be easily separable to allow for recycling.

[0011] In view of the foregoing, a container system that can be hermetically sealed, while retaining “high-end” metallic components or finishes would be welcome. Specifically, the container body and the closure cap should have an exterior metallic finish. This system must still allow for the easy and intuitive separation of any plastic parts or films, so as to eliminate any plastic parts being held or retained within the metal components.SUMMARY OF INVENTION

[0012] A closure system includes a metallic container having a cooperating and removable metallic cap, both of which present an exterior metallic finish. A plastic insert is snap-fitted into an inner surface of the cap so that, when the cap is affixed to the container, the plastic periphery provides a hermetic seal. The insert includes pull handle and various features along its axial skirt and / or within the panel itself to allow for the sufficient axial force to detach the insert from the cap after it is first removed from the container. The resulting container system provides a high- end aesthetic while reducing costs in comparison to existing all-metal beverage can-style closures, such as the system depicted in Fig. 1.

[0013] Specific reference is made to the appended claims, drawings, and description below, all of which disclose elements of the invention. While specific embodiments are identified, it will be understood that elements from one described aspect may be combined with those from a separately identified aspect. In the same manner, a person of ordinary skill will have the requisite understanding of common processes, components, and methods, and this description is intended to encompass and disclose such common aspects even if they are not expressly identified herein.DESCRIPTION OF THE DRAWINGS

[0014] Operation of the invention may be better understood by reference to the detailed description taken in connection with the following illustrations. These appended drawings form part of this specification, and any information on / in the drawings is both literally encompassed (i.e., the actual stated values) and relatively encompassed (e.g., ratios for respective dimensions38869752of parts). In the same manner, the relative positioning and relationship of the components as shown in these drawings, as well as their function, shape, dimensions, and appearance, may all further inform certain aspects of the invention as if fully rewritten herein. Unless otherwise stated, all dimensions in the drawings are with reference to inches, and any printed information on / in the drawings form part of this written disclosure.

[0015] In the drawings and attachments, all of which are incorporated as part of this disclosure:

[0016] Figure 1 is a perspective, exploded view of an all-metal hermetically sealed closure system according to the prior art.

[0017] Figure 2 is a perspective, partially exploded and sectional view of a metal-plastic hermetically sealed closure system according to various disclosed aspects herein, with line A indicating how the plastic insert (shown in an exploded and enlarged view as compared to the metallic container body 11) is nested within an inner surface of the metallic cap 15 so as to form a hermetic seal between the container and the closure cap.

[0018] Figure 3A is a perspective view of the underside of the plastic liner depicted in Fig. 2. Figure 3B is a cross sectional perspective view of the cap of Fig. 3A taken along a diameter that bisects the point at which the handle connects to the main panel. Figure 3C is a cross sectional partial view of one of the thinned grooves in the main panel and, separately, the gap in the axial skirt, both in respect to the callout B indicated in Fig. 3B. Figure 3D is a perspective view of the underside of the cap depicted in Fig. 3 A, so as to highlight the frangible pins connecting sidewall sections in the skirt and flexible teeth positioned along caps open edge (both of which are also visible in Fig. 3C).

[0019] Figure 4 is a perspective view of a first alternative aspect in which additional grooves are added to reduce the force required for removing the insert, in combination with providing larger gaps in the skirt and reducing the number of flexible teeth, with Figure 4A being a partial view highlighting these features.

[0020] Figure 5 is a perspective view of a second alternative aspect in which the handle is positioned flush to the main panel, with an offset gap that allows easier grasp of the handle as well as providing a flexing point to enable removal of the insert with axial force (similar to the actions shown in Fig. 7), with Fig. 5A being a perspective partial view of the bottom of the insert from Fig. 5 so as to highlight both the separation gap between the handle and the panel and to48869752illustrate the interface of the skirt with the panel for all aspects employing the enlarged triangular separators (as seen in Figs. 4 and 5).

[0021] Figure 6 is a perspective view of a third alternative aspect in which the panel is replace with an X-shaped cross member having raised or offset straps to provide a grasping point for removal of the insert with axial force (as shown in Fig. 8).

[0022] Figure 7 includes time sequenced schematic representations A and B illustrating the actions required to separate the insert from the metallic cap using axial force whenever a handle is provided (as in Figs. 3A, 4, and 5).

[0023] Figure 8 includes time sequenced schematic representations A and B illustrating the actions required to separate the insert from the metallic cap using axial force whenever raised or offset straps are employed (as in Fig. 6).DETAILED DESCRIPTION

[0024] Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the invention. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the invention.

[0025] As used herein, the words “example” and “exemplary” mean an instance, or illustration. The words “example” or “exemplary” do not indicate a key or preferred aspect or embodiment. The word “or” is intended to be inclusive rather an exclusive, unless context suggests otherwise. As an example, the phrase “A employs B or C,” includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C). As another matter, the articles “a” and “an” are generally intended to mean “one or more” unless context suggest otherwise.

[0026] References to horizontal and vertical are relative to the drawings and, more specifically, the expectation that industrial drums and containers typically provide an opening along a top facing. Generally, references to coupling or attachment in this disclosure are to be understood as encompassing any of the conventional means used in this field, such as by way of58869752of snap- or force fitting of components, threaded connections, bead-and-groove, and slot-and- flange assemblies and the like. Similarly, the term engagement may involve coupling or an abutting relationships, depending upon the context. Finally, to the extent the containers used in these systems tend to have cylindrical and / or cup-like shape, the height will align in an axial plane (i.e., the vertical or top-to-bottom direction of the pages in the drawings) whereas the width extends radially and perpendicular to the height (i.e., the horizontal direction in the drawings). All of these terms should be considered in the context in which it is used, and any perceived ambiguity can potentially be resolved by referring to the drawings, the description, and the general understanding and expectations in this field.

[0027] With reference to Figures 2 to 8, the container system of the present invention bears some similarities to the aforementioned conventional systems, including that shown in Fig. 1. For example, the inventive system relies upon the same style of metallic container, with threads 12 near the top opening, whereas the bottom is enclosed. The can body 11 can be stamped, molded, or formed from disparate metal pieces. As above, a metallic cap 15, including a skirt 17 and means of coupling (e.g., threads, snap-fittings, etc.) the cap 15 to the body 11 are needed.

[0028] However, the axial extension region 13 of the body will not be crimped or altered to create a hermetic seal. In all aspects of the invention, the metallic panel 14 shown in Fig. 1 is replaced by a plastic insert 100. This insert 100 is configured to be seated and carried inside of the cap 15. When the cap 15 (carrying the insert 100) is affixed to the body 11, a periphery of the insert 100 is sufficient compressed to create a hermetic seal. In some aspects, the insert 100 may also include a complete panel, conforming to the corresponding the panel in the cap 15, in order to provide an additional barrier seal when the insert 100 is initially captured between the cap 15 and the body 11.

[0029] In all aspects, insert 100 is defined by a planar facing 110, a peripheral skirt 120, pull handle 130 positioned to face the interior of the container (i.e., not visible on the exterior when the cap 15 is affixed to the container 11), and peripheral engagement features 140, such as flexing teeth positioned on the terminal edge of the skirt 120. Facing 110 cooperates with and / or matches the shape of the cap 15 (preferably circular). Facing can include one or more contiguous solid panels 111 (with the periphery thereof serving as a sealing flange 116), or it can include a peripheral sealing flange 116 having a cross member 117 extending across it (e.g., along a diameter or one or more arcuate sections) so as to create gaps G and eliminate the material costs68869752associated with a full, contiguous panel. When used, the cross member 117 can have an X-shape (as shown in Figs. 6 and 8), although it is possible to employ a Y-, I-, C- or other shape. The sealing flange 116 is positioned along the intersection between the skirt 120 and the facing 110, with the flange 116 providing a continuous and contiguous sealing surface that engages an edge of the container 11.

[0030] When used, cross member 117 serves as the handle 130, either directly or by way of one or a plurality of raised, offset loops 131. Loops 131 are affixed to the member 117 and / or the peripheral flange 116 so that, when grasped and pulled, the loops 131 facilitate the separation and removal of the insert 100 from the cap 15 (as will be explained in greater detail below).

[0031] When a solid panel 111 is provided, thinned grooves 112 run across the panel 111, thereby dividing it into fractional segments 113. In one aspect (as seen in Fig. 3 A), two grooves 112 create four equally sized fractional segments 113. In another aspect (as seen in Fig 4), six grooves create twelve segments. Still other arrangements are possible, with an even number of grooves preferred for easily creating twice as many segments. In other aspects, the segments can be deliberately sized differently, and grooves can be provided to align only along a radius or even an arcuate or straight line that connects disparate edges of the peripheral flange 116 without bisecting the center of the facing 110.

[0032] The grooves 112 may carry axially up into the flange 116 (as seen in Fig. 3B), or the flanges can widen as they travel upward (as seen in Figs. 4, 4A, and 5). In some aspects, the gaps 122 can align directly over each axial groove 112 and, as seen in Fig. 5A, a corresponding thinned axial section 112a.

[0033] The skirt 120 is formed from sidewall sections 121, some or all of which may be imparted with threads 122 along an inner facing. Threads 122 will cooperate with threads 12 on the container to allow for rotatable coupling to the can body 11, although other attachment features could be used.

[0034] Sidewall sections 121 are separated by gaps 122 that can be spanned by frangible pins 123. These gaps may be positioned at a constant or slightly tapering spacing (as seen in Fig. 3C) or by way of a polygonal shape that varies so as to reduce material usage and better accommodate flexing (as seen in Fig. 4A). Pins 123 retain the shape and integrity of the insert 100, particularly when it is manufactured and initially disposed inside of the cap. When the insert 100 is removed by pulling on handle 130, the frangible pins 123 may break to allow sidewall78869752sections 121 to compress and flex independently, allowing the insert to be pulled out from the cap 15 as a single unitary and contiguous piece.

[0035] The grooves 121, gaps 122, and other features described herein also impart flexibility for when the insert is initially disposed on the interior of the metallic cap 15. That is, the insert 100 will be resilient and sufficiently pliable to be received and retained in the cap 15, which is then affixed to the body 11 after it has been filled with consumables. The insert will be compressed into a hermetic seal that replaces the previous need for films or crimped metal panels.

[0036] Detents 124 can be formed, as thinned and / or indented sections, along the entire axial length of the sidewall segment 121 with an engagement feature 140 positioned at its edge. In this arrangement, the detents 124 / features 140 are positioned evenly between the gaps 122, again to promote flexing in a predictable and uniform manner. Preferably, the inner facing of the skirt 120 is smooth and circular in shape to allow for rotatable attachment of the insert / cap combination onto the container body 11, while variations in thickness and surface features from the gaps 122, pins 123, detents 124, etc. are only noticeably along the outer surface.

[0037] Handle 130 can include a grasping tab 133, formed as a loop (as shown in Fig. 3b), a T-shaped member, or other suitable shape. In other aspects, the handle 130 is formed integrally as a cross member 117 within the facing 110. Handle 130 can extend away from the planar surface defining the facing 110 (as seen in Figs. 3 A and 4), or it can be positioned within it (as seen in Fig. 5). As seen in Fig. 5, the handle 130 can be separated by a gap from the solid panel 111 so as to attach to the peripheral flange 116.

[0038] In aspects where the handle 130 is centrally located in the insert 100, uniformity may be more advantageous for ease of removal. When the handle 130 is offset or attached along the peripheral flange, different and disparate spacing and sizing of the elements to accommodate the application of axial removal force. When two straps 131 are provided, they may be configured symmetrically so as to impart a centralized effect, although a single strap 131 could have the same basic affect as the inset handle shown in Fig. 5.

[0039] Engagement features 140 are provided around the periphery of the open facing of the insert 100. Features 140 may take the form of polygonal teeth positioned at regular intervals. Teeth 140 may include a terminal ramp and / or thinning taper (as compared to the thickness of the skirt 120) configured to temporarily be captured on a lower edge of the skirt 17, thereby88869752providing sufficient resistance to cause the insert to flex and break as desired (and depicted in Figs. 7 and 8). A lip or radially and inwardly inclined series of features on the skirt 17 may facilitate this capture / resistance.

[0040] With reference to Figs. 7 and 8, the hand of a user is shown grasping the handle 130 and applying a pulling force (as denoted by the arrows F) to release the insert 100 away from and out of the cap 15. In step A of each, the user pulls the loop or grasps the straps and, thereafter in step B, applies force F that is most optimally aligned an axis that is perpendicular / orthogonal to the planar surface of the facing 110. This force causes the insert 100 to flex and buckle in a specifically intended manner, with the grooves 112 and / or gaps 122 flexing or even partially tearing as intended (with the engagement features 140 providing sufficient temporary resistance) so as to cleanly remove the insert 100 as one single and contiguous piece that can be deposited in an appropriate plastic recycling stream. In turn, the metallic body 11 and cap 15 can be separately attended to. In some aspects, the cap 15 may include its own attachment features so as to allow for the cap 15 to continue to be affixed to the body 11 even after the insert 100 is removed.

[0041] Any of the foregoing inserts may be molded from appropriate polymeric materials such as polyethylene, polypropylene, and the like, although other polymeric materials can be selected based upon cost and workability along with various blends of polymers used. In all instances, the polymer selected should be capable of achieving the desired level of sealing (in terms of being air tight and / or water impermeable, as well as with respect to the longevity and compressibility / resilience).

[0042] All components should be made of materials having sufficient flexibility and structural integrity, as well as a chemically inert nature. The materials should also be selected for workability, cost, and weight. In addition to the materials specifically noted above, common polymers amenable to injection molding, extrusion, or other common forming processes should have particular utility, although metals, alloys, and other composites may be used in place of or in addition to more conventional container and closure materials.

[0043] Although the present embodiments have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the invention is not to be limited to just the embodiments disclosed, and numerous rearrangements, modifications and substitutions are also contemplated. The exemplary embodiment has been98869752described with reference to the preferred embodiments, but further modifications and alterations encompass the preceding detailed description. These modifications and alterations also fall within the scope of the appended claims or the equivalents thereof.108869752

Claims

CLAIMSWhat is claimed is:

1. A closure system (100) including metallic components and plastic components that can be separated in order to recycle the closure system, the closure system comprising: a container (11) including an exterior metallic finish and defining an interior volume; a closure cap (15) including an exterior metallic finish; and a insert (100) seated within an inner surface of the closure cap forming a hermetic seal when the closure cap is affixed to the container, wherein the insert consists of a plastic and includes: a planar facing (110), a peripheral skirt (120), a pull handle (130) positioned to face the interior volume, engagement features (140) positioned along a terminal edge of the skirt, a contiguous sealing flange (116) positioned between the peripheral skirt and the planar facing, and wherein the insert: (i) hermetically seals the interior volume, and (ii) is configured to release from the closure cap as a single piece when pulling force (F) is applied to the handle relative to the planar facing.

2. The closure system according to claim 1 wherein the planar facing includes at least one of: a solid panel (111) and a cross member (117).

3. The closure system according to claim 1 or 2 wherein gaps (G) are formed within the planar facing.

4. The closure system according to claim 1, 2, or 3 wherein the skirt includes a plurality of grooves (121) and / or gaps (122).

5. The closure system according to claim 4 wherein the gaps are connected by frangible pins (123).

6. The closure system according to claim 1, 2, 3, ,4, or 5 wherein the pull handle comprises at least two straps (131).

7. The closure system according to claim 1, 2, 3, 4, 5, or 6 wherein the planar facing incudes thinned grooves (112) defining fractional segments (113).1188697528. The closure system according to claim 1, 2, 3, 4, 5, 6, or 7 wherein the pulling force is applied perpendicular to the planar facing.

9. The closure system according to claim 1, 2, 3, 4, 5, 6, 7, or 8 wherein the peripheral skirt includes teeth (150).

10. The closure system according to claim 1, 2, 3, 4, 5, 6, 7, 8, or 9 wherein the pull handle is centrally located on the planar surface.

11. The closure system according to claim 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 wherein the pull handle includes a grasping tab (133).128869752

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