A CONTAINER AND METHOD OF MANUFACTURING SUCH

The invention relates particularly to a container of a type that is ordinarily used for containing and dispensing particulate substances, such as spices. A known container of this type is formed of three separate parts including a tubular container part defining a dispensing formation, e.g. a perforated top wall, at the operative top end thereof and an open bottom end through which the container is ordinarily filled. A base part fits into the bottom end after filling of the container and a removable lid fits on the top end, for blocking the dispensing formation. The container part, in use of the container, often has a label applied thereto, which takes place as a process separate from the manufacture of the container.

Although the container as above described has fulfilled its purpose satisfactorily, it is an object of this invention to provide an improved container. In order to achieve this it is proposed to at least associate a flip top lid with the container, the flip top lid, in its operative configuration, being effectively integrated with the container with a plastics hinge permitting displacement of the lid with respect to the container between a closed position and an open position and urging of the lid towards these positions from a "neutral' position of the lid between said positions.

In relation to the use of a flip top lid on a container, the flip top lid is connected via a plastics hinge to a separate ring-like formation that is securely located on the container part of a container, in a location in which the lid is displaceable between its required closed position and open position with respect to the container. The hinge configuration of a flip top lid with respect to the part to which it is connected is thus already well known and any reference hereinafter to a plastics hinge whereby a flip top lid is connected to another part must therefore be interpreted as a reference to a plastics hinge defining a hinge configuration as above envisaged.

Insofar as it is proposed to associate a flip top lid with a container as herein envisaged, it is also an object of the invention to achieve this in an improved manner,

particularly by associating this with a manufacturing method whereby the manufacture and labeling of the container can be facilitated and rendered more economical.

According to a first aspect of this invention there is provided a synthetic plastics container, which includes a container part in the form of a tubular body part that defines or has a dispensing formation at its operative top end and an open operative bottom end and that has a flip top lid integrally connected thereto via a plastics hinge for blocking the dispensing formation, the tubular body part of the container part defining or comprising an externally tapering segment that tapers from a location spaced from the operative top end thereof to the operative top end thereof and the lid defining an outer side face that forms a substantially continuous extension of the external face defined by the tapering segment of the tubular body part.

The container includes also a separately formed base wall that fits in and/or on the operative bottom end of the tubular body forming the container part, the base wall ordinarily being fitted after the container part has been filled with its required contents. Clearly, the base wall and the tubular body part may define complementary formations for enhancing the secure location of the base wall with respect to the tubular body part of the container part.

The dispensing formation defined by the tubular body part forming the container part may be or comprises a perforated end wall, dispensing apertures defining the perforations in the end wall being configured to permit sprinkling of particulate contents of the container in a controlled fashion from the container. Clearly, the configuration of the perforated end wall and generally the configuration of the dispensing formation are greatly variable and are configured to accommodate particular applications of the container in terms of the contents to be contained thereby and dispensing of the contents. Still further, the flip top lid may define or comprises on its inner face side projecting blocking formations for individually blocking the dispensing apertures associated with the dispensing formation of the tubular body part forming the container part of the container.

Further according to the invention, the dispensing formation and the top end of the tubular body part forming the container part may define formations for accommodating complementary formations defined on the internal side of the flip top lid for holding the lid in its closed position.

The hinge configuration of the plastics hinge connecting the flip top lid to the tubular body part forming the container part of the container of the invention may be essentially conventional. Also, the flip top lid may define an engagement formation that is engageable by, for example, the thumb nail of a person, for facilitating release of the lid from its closed position and the displacement of the lid from this closed position to its open position. A primary tamper indicator, typically a tamper band, may form a severable part of the tubular body part which covers the engagement formation defined by the flip top lid, severing of the tamper indicator being required to first permit opening of the flip top lid.

The degree of taper of the tapering segment of the tubular body part forming the container part of the container of the invention particularly is such that upon manufacture of the container part including the tubular body part thereof and the flip top lid and with the flip top lid displaced into its closed position from its open position in which it is injection moulded as part of its manufacturing process, with the container part located on a male part of the mould in which it is moulded, the container part can be pulled from the female part of the mould without interference by the plastics hinge connecting the flip top lid to the tubular body part and the primary tamper indicator, which both project marginally from the general outer surface defined by the container part, thus permitting subsequent displacement of the container part from the said male part of the mould. This will become more apparent from a description of the manufacture of the container part in conjunction with the mould in which the container part is injection moulded.

Still further according to the first aspect of this invention, the tubular body part forming the container part of the container of the invention, at its operative bottom end, may

define a secondary tamper indicator, e.g. a tamper tab, that is defined by perforations and that is severable from the tubular body part to permit first removal of the base wall of the container and, as such, refilling of the container.

Still further, the container part of the container may have a label applied thereto, which label is applied as part of the forming process of the container part by being located within the mould in which the container part is injection moulded and by being secured to the container part by heat fusion upon the formation of the container part by injection moulding within the mould. The material forming the label and the material forming the container part, therefore, are compatible with one another in order to permit their fusion with one another, it being envisaged that both the container part of the container of the invention and the label, which is a sheet material element,, can be formed of a polypropylene material.

According to a second aspect of this invention there is provided a method of manufacturing the container part of a container in accordance with the first aspect of this invention, which includes or comprises, in conjunction with injection moulding equipment and a mould in which the container part can be injection moulded with its flip top lid in its open position and extending from the tubular body part of the container part transversely to the longitudinal axis of the tubular body part and which mould includes at least three main mould parts that are displaceable with respect to one another along a line parallel to the said longitudinal axis of the container part and of which a first part defines the female part for the operative top end of the tubular body part of the container part including its dispensing formation and the male part for the flip top lid of the container part, a second intermediate part defines the female part for the remainder of the tubular body of the container part and the female part for the flip top lid and a third part defines the male part for the complete tubular body part of the container part, the steps of: injection moulding the container part by injecting a molten synthetic plastics material into the mould with its three mould parts displaced together; following sufficient setting of the container part in the mould (sufficient as will be understood by the person of average skill such that the container material

is rigid enough to allow releasing from the moulds), first displacing the first mould part and the second mould part of the mould away from one another; then displacing the flip top lid into its closed position with respect to the tubular body part of the container part; - then displacing the third mould part away from the second mould part while carrying the container part on the male part defined by the third mould part; and then removing the container part from the said male part defined by the third mould part.

The method of the second aspect of the invention may provide for the displacement of the flip top lid into its closed position by the displacement of a displacement member with respect to the mould which is activated in response to the first and second mould parts having being displaced away from one another.

The mould includes also additional mould parts that provide for the formation of the container part of the container, particularly the formation of the various features of the container part as hereinabove defined. These additional mould parts also will be displaceable with respect to each other and other mould parts, as will be apparent to those skilled in the art.

The method of the invention may include still further the application of a label on the container part of the container, as part of the injection moulding process. As such, the method may include positioning the required label, in the form of a sheet element of a suitably plastics sheet material compatible with and heat sealable to the container material, in the formation forming the female part for the tubular body part of the container part as defined by the second mould part and activating electrostatic forces for holding the label against the walls of the said formation in a configuration in which, following the injection of molten synthetic plastics material into the mould, the label is adhered to the external surface of the container part by being heat fused therewith. Insofar as this process of applying a label is already known to those skilled in the art, the process is not defined further herein.

The mould used for forming the container part of the container, as above envisaged, may include also a release member for releasing the container part formed from the formation forming the male part defined by the third mould part, the release member being a member displaceable with respect to the third mould part in a configuration in which it can act on and push the container part from the formation forming the male part defined by the third mould part. This release of the container part may be associated with the operation of a displacement arrangement whereby a container part released from the said male part is engaged and removed from the mould and, as such, the injection moulding equipment, in a controlled manner.

It will be understood that the mould configuration and the operation of the injection moulding equipment in conjunction therewith is greatly variable, while still incorporating the essential method steps as above defined which enables the manufacture of the container part of the container, in accordance with the first aspect of this invention, and particularly also the application of the label in the manner defined.

The mould also may be provided as a multi-cavity mould for manufacturing a plurality of container parts simultaneously and, as such, the operation of the mould and the injection moulding equipment may be suitably adapted to accommodate this.

Insofar as the general operation of injection moulding equipment in conjunction with a mould is already well known and in relation to the manufacture of the container part of a container, except as otherwise defined, will be conventional, insofar as this does not form a specific part of the present invention, this is not defined in further detail herein.

The invention extends also to a mould for use in the method of manufacturing the container part of a container, in accordance with the method of the second aspect of this invention, and also to a container part for a container in accordance with the first aspect of this invention, when manufactured in accordance with the method of the second aspect of this invention.

The first and second aspects of the invention are described hereafter with reference to an example of a container, in accordance with the first aspect of this invention, and an example of a mould for manufacturing this container, in accordance with the method of the second aspect of this invention, which are illustrated in the accompanying diagrammatic drawings. In the drawings:

Figure 1 shows a three-dimensional view of a synthetic plastics container, in accordance with the invention;

Figure 2 shows a cross-sectional side view of the container of Figure 1 ;

Figure 3 shows a cross-sectional rear view of the container of Figure 1 , without its lid;

Figure 4 shows a front view of the container of Figure 1 , without its lid;

Figure 5 shows a cross-sectional side view of a mould for manufacturing the container of Figure 1 , in its closed position; and

Figures 6 to 8 show a cross-sectional side view of the mould of Figure 5 in three operative configurations thereof, illustrating the method of manufacturing the container.

Referring initially to Figures 1 to 4 of the drawings, a synthetic plastics container, particularly suitable for containing particulate substances, such as spices, in accordance with the first aspect of this invention, is designated generally by the reference numeral 10. The container 10 includes a container part 12 comprising a tubular body part 14, that defines a dispensing formation 16 at its operative top end and an open operative bottom end, and a flip top lid 18 integrally formed with the body part 14, being connected thereto via a conventional plastics hinge 20. The lid 18 is displaceable between its open position as shown in Figures 1 and 2 and a closed position in which it covers the dispensing formation 16 of the tubular body part 14.

The container 10 includes also a base wall 22 that fits into the open bottom end of the tubular body part 14, the base wall 22 and the operative bottom end of the tubular body part 14 defining complementary engagement formations for enhancing the secure location of the base wall with respect to the tubular body part. Insofar as the container 10 is a bottom filling container, the base wall 22 ordinarily will be located into its position as shown after filling of the container part 12.

The dispensing formation 16 comprises a perforated wall as shown, perforations being defined by dispensing apertures 24 that are configured to accommodate dispensing of the particulate substance contained in the container 10 by sprinkling the substance from the container. The operative inner face of the lid 18 defines projecting formations 26 that are formed to seat in the apertures 24, the apertures 24 thus being individually blocked by these formations 26 when the lid 18 is displaced into its closed position. The lid 18 and the tubular body part 14 further define complementary formations that provide for the lid to seat in its closed position and be effectively held in this position. The plastics hinge 20 particularly provides for the lid 18 to be urged towards either one of its open position and its closed position, from an intermediate neutral position, which is well known in relation to plastics hinges commonly associated with flip top lids.

As is illustrated in Figure 4 of the drawings, the tubular body part 14 defines a shallow recess formation 28 immediately beneath the location where the lid is located when in its closed position, while the lid defines a projecting tab 30, the recess formation 28 and tab 30 cooperating with one another to facilitate displacement of the lid from its closed position, particularly through engagement of the lid with, for example, a person's thumb nail. Still further, and as shown in Figures 1 and 2 of the drawings, the tubular body part 14 has a tamper indicator arrangement 32 (not clearly shown), typically in the form of a severable tamper band, associated therewith which, before its removal covers the recess formation 28 and tab 30, requiring the tamper band to be severed from the container part 14 to permit first opening of the flip top lid 18.

The container part 12 and particularly the tubular body part 14 further defines a

secondary tamper indicating tab 34 that is defined by perforations within the wall of the tubular body part 14 and that is severable from the tubular body part 14 to permit the base wall 22 to be levered from the tubular body part 14, thereby permitting refilling of the container part 12. While the tab is in position, it will be apparent that the container has not been tampered with and that the container still contains its original contents.

As is clearly apparent from Figures 1 to 4 of the drawings, it is preferred that the operative lower segment 36 of the tubular body part 14 is substantially cylindrical, only being tapered to the extent that is required for separation from the mould in which it is formed, e.g. tapered preferably such that the wall is tapered (inwards towards the top) at an angle of 1-10°, more preferably 1-5° when compared to the vertical axis of the container body. The segment 38, which constitutes a segment from a location spaced from the operative top end of the tubular body part 14 to the top end of the tubular body part 14, preferably defines a substantial taper (e.g. preferably tapered such that the wall is tapered at an angle of 3-40°, more preferably 5-30°, even more preferably 9-20°, when compared to the vertical axis of the container body), this taper being configured to permit the manufacture of the container 10 in the mould as hereinafter described and in accordance with the method of manufacturing a container, in accordance with the second aspect of this invention, also hereinafter described.

As is clearly apparent from the drawings, with the flip top lid 18 disposed in its closed position, the outer side surface of the flip top lid forms a substantially continuous extension of the outer surface of the wall of the tubular body part 14 defining the segment 38, only the plastics hinge 20 and the tamper arrangement 32 projecting marginally from this surface as will be apparent to those skilled in the art.

The substantially cylindrical segment 36 of the tubular body part 14 which is referred to above, can have a label applied thereto that surrounds this segment, it being particularly envisaged that this label is applied to the tubular body part as part of the manufacturing method of the container 10, as hereinafter described and particularly by being heat fused with the tubular body part upon the manufacture thereof. As will

become apparent from what follows, the label also is of a synthetic plastics sheet material, particularly a material that is compatible with the material forming the container 10, to permit effective heat fusion therewith. It is envisaged that the container 10 and/or a label applied thereto both can be formed of a polypropylene 5 material.

Referring now also to Figures 5 to 8 of the drawings, a mould for manufacturing the container part 12 of a container 10 in conjunction with conventional plastics injection moulding equipment is designated generally by the reference numeral 50. Figure 5

10 indicates the mould 50 in its fully closed position in which plastics material for forming the container part can be injected into the mould. The mould 50 essentially includes three main mould parts that are separated by split lines, 54 and 56 respectively, the mould parts including a first mould part 58 that defines a female part 60 for forming the operative top end of the tubular body part 14 of the container part 12, including its

15 dispensing formation, and a male part 62 for the flip top lid 18 of the container part. The intermediate mould part 63 of the mould 50 defines a female part 64 for the remainder of the tubular body 14 of the container part 12 and the female part 66 for the flip top lid, whereas the third mould part 70 defines a male part 72 for the complete tubular body part of the container part. Insofar as the particular configuration

20 of the mould and the formations defined thereby for forming the container of the invention will be clearly apparent to those skilled in the art of plastics injection moulding, the mould 50 is not described in further detail herein.

In its configuration as shown, plastics material is injected into the mould 50 via an

25 injection aperture 74 where indicated, synthetic plastics material entering the spaces within the mould defined between the male and female parts referred to, for forming both the tubular body part and the flip top lid of the container part 12 of the container 10. It will be appreciated in this regard that additional mould parts will provide for the auxiliary formations of the container part including the plastics hinge 20, tamper band

30 32 and perforations associated with the tab 34. The configuration of these mould parts again are essentially conventional, as will be apparent to those skilled in the art of the invention.

Referring now to Figure 6 of the drawings, the method of manufacturing the container of the invention in conjunction with the mould 50 and synthetic plastics injection moulding equipment, following the injection of the synthetic plastics material into the mould 50, includes the displacement of the mould parts 58 and 63 away from one another, which permits displacement of the lid formed from its open position, in which it is formed, into its closed position. The mould 50 includes a displacement member that is displaceable transversely with respect to the axis of displacement of the mould parts of the mould with respect to one another, to provide for this required displacement of the lid.

With the lid in its closed position, the mould parts 63 and 70 are displaced away from one another, as shown in Figure 7 of the drawings, the container part 12 of the container 10 being retained on the male part 72 defined by the mould part 70, the container part 12 and the mould part 72 being engaged with one another via suitable complementary formations that are formed by the moulding process, particularly formations that project internally from the walls of the tubular body part 14 that engage complementary formations defined externally by the male part 72. With the parts 63 and 70 separated and as shown in Figure 8 of the drawings, a release member 80, forming part of the mould part 70, is then displaced as shown, acting against the operative rear end of the container part 12 of the container 10 for forcing it from the male part 72, as is clearly illustrated. This essentially completes the manufacture of the container part 12 of the container 10, it being particularly envisaged that the method as above described can also be associated with the manufacture of container parts 12 in a multi-cavity mould. A displacement arrangement may be associated with the mould used, that can "pick-up" container parts 12 once released, and displace these parts to a spaced location from the injection moulding equipment, for onward displacement to another work station.

As above referred to, as part of the manufacturing method as described, by the reverse displacement of the mould parts the mould can again be closed and the manufacturing method can be repeated. As part of this manufacturing method, it is

envisaged that with the mould parts in their configuration as shown in Figure 7 of the drawings, a label of a synthetic plastic sheet material can be located within the female part 64 defined by the intermediate mould part 62, being held within the cavity defining this female part by electrostatic forces in a manner that is already well known in association with the application of labels on containers. Clearly, the injection moulding equipment will be associated with an arrangement that can provide for the displacement of a label and its location within the intermediate mould part 62 as required, this label being heat fused with the tubular body part 14 upon its formation within the mould 50, as will again be apparent to those skilled in the art of the invention. It is submitted in this regard that this application of the label, in accordance with the method described, is made possible by the method step of closing the flip top lid after the separation of the mould parts 58 and 63, which permits the retraction of the container part formed as described. The use of a mould that would ordinarily be used clearly will not permit the application of the label as described. It will be appreciated also from the above that the taper associated with the segment 38 of the tubular body part 14 is essential to the manufacturing method, insofar as this taper is required to permit the retraction of the container part from the intermediate mould part 63 while held on the male part 72 of the mould part 70, the container part not being so retractable if not associated with the taper as described.

The method of the invention as described thus particularly permits the manufacture of the container part in the manner described and also the application of a label thereon as part of the manufacturing method. It is submitted that the manufacturing method, for the remainder and in association with the mould 50 and injection moulding equipment, is essentially conventional.

The method of manufacturing the container part 32 as described is considered a time efficient and economical method of manufacture, it being clearly apparent that the exact features of a container that can be manufactured in accordance with the method of the invention, are greatly variable.