FIELD OF THE INVENTION

The present invention relates to a container of a fluid substance, as well as a semifinished product of said injection-moulded container.

In particular, reference is made to a container commercially known as “tube”, but having a polygonal cross section.

BACKGROUND ART

The current “tube” present on the market has a cylindrical or elliptical body obtained by extrusion, to which a gate (shoulder of the tube and port) obtained by objection is then welded.

Normally, a screw or snap coupling is arranged around the gate.

Once the tube is obtained, a cap has to be applied thereto, said cap being also obtained by injection.

The cap can be a screw cap or of the type currently known as a ‘flip top’. Basically, the tube currently on the market consists of an extruded (cylindrical-elliptic) body and two elements obtained by injection (shoulder/gate and cap). Welding between the cylinder and the shoulder/gate and coupling with the cap is then necessary.

As the body of the tube and the shoulder/gate can normally be made of different plastics, a problem linked to recyclability could exist. Further, the processing procedure is laborious and requires many steps that thus turn into high production costs and energy expenditure.

Lastly, the shape of the “cylindrical” section body of the tubes currently known on the market does not permit optimation of the transportation. In fact, when the tubes are placed side by side for transportation, many volumes remain empty.

The same occurs at the moment of display of the tubes, for example on the shelf of a supermarket.

United States patent 3,595,441 discloses a disposable dispensing container made of a single piece of plastics. This container is designed to be substantially completely collapsible to simplify dispensing of the contents thereof. Also in a partially or totally collapsed state, the bottom of the container remains flat to support said container in an erect position. The upper part of the container is provided with a spout that is made integrally with a cap.

Although the modified container (98) of the third embodiment of the invention, illustrated in figure 12 is said to be made by injection moulding, the Applicant is of the opinion that the skilled person would not seriously consider the idea of injection moulding such a container owing to the shape thereof. In fact, such a shape would require the prior manufacture of a particularly complex and thus costly mould, which would make the entire production run uneconomical, also on a large scale. In particular, especially the upper part of the container, provided with a spout and cap, would require an extremely complex and expensive mould to be made, in addition to a plurality of movements of the mould to free the different sectors that make up the object to be moulded. Moreover, it is further complex to produce such a mould to produce tubes of moderate dimensions, as for the use in question. Even if it were intended to make tubes of large dimensions, not only very complex specific moulds would have to be used but also very oversized moulding plants and consequently with decidedly greater operating costs. Further, producing a container of such complexity, regardless of the dimensions, requires slow production cycles, in order to be able to control the process and thus low productivity.

These considerations also apply to the first embodiment by analogy. A further problem linked to the shape of the modified container (98) lies in the configuration of the bottom (100). The bottom (100) in fact has to be corner welded to three side walls, which have to be orthogonal, causing two problems. The first problem is linked to the tightness and the second to the collapsibility of the container. A skilled person would never consider welding in such a position for a container of fluids because it would be difficult to ensure the tightness thereof. With regard to the collapsibility of the container obtained by welding the bottom (100) to the side walls as shown in figure 12, the Applicant doubts that the modified container (98) in collapsed state can adopt the configuration shown in figure 3 of the patent owing to the fact that it would be difficult to fold the modified container (98) along the welding lines. SUMMARY OF THE INVENTION

The object of the present invention is to provide a container that overcomes the technical drawbacks of the prior art.

A further object of the invention is to provide a container that is cheaper that those that are currently on the market.

Still another object of the present invention is to provide a container that is easily recyclable. Still another object of the present invention is to provide a container that optimizes the transport costs, and which can be arranged on the shelves of a retail outlet efficiently.

This and other objects are achieved by a container made according to the appended claims, and by a semifinished product of this container. BRIEF DESCRIPTION OF THE DRAWINGS

Further characteristics and advantages of the innovation will be apparent from the description of a preferred but non-exclusive embodiment of the invention, illustrated by working examples provided for illustrative and non-limiting purposes, as well as the accompanying figures, wherein: figure 1 is a perspective view of the container in a configuration in which it is filled with a fluid substance (it should be noted that a cap is further shown, only for illustrative purposes, in a closed configuration); figure 1A is a side view of a semifinished product of the container obtained directly by injection moulding, i.e. before an end is flattened and fixed to form the container and before a cap is associated; figure 2 is a simplified section of the container of figure 1, taken along line II- II of figure 4 (it should be noted that in the section of figure 2 a cap is further shown, only for illustrative purposes, in a closed configuration); figure 3 is a simplified section of the body of the container of figure 1, taken along line III-III shown in figure 5; figure 4 is a top view of the container of figure 2, (it should be noted that a cap is further shown, only for illustrative purposes, in an open configuration); figure 5 is a simplified top view of the body of figure 1A and of figure 3; figure 6 is a simplified section taken along line VI- VI of figure 2; figure 7 is a simplified section taken along line VII- VII of figure 2; and figure 8 is a simplified section taken along line VIII- VIII of figure 2. DETAILED DESCRIPTION OF THE INVENTION

With reference to figures 1-8, a container is shown that is overall indicated with the reference number 1, whereas in figure 1A a semifinished product is shown, i.e. the container before an end is flattened and fixed.

The container 1 of a fluid substance, as well as the semifinished product thereof, comprises a tubular body 2 with a polygonal section.

The term “polygonal” hereby means that the cross section of the tubular body 2 in the semifinished product, is a convex polygon, which is preferably regular, or is essentially a convex polygon, i.e. the sides can have a curve (see for example figure 6). In the final container 1 on the other hand, the shape of the cross section of the tubular body 2 is not constant, first and foremost because of the folding and flattening of an end (see figures 6-8). Further, also aesthetic choices can have an influence, so that a cross section is pleasant in which the sides have a convex curve (see for example figure 6); in fact, in this manner, the resulting container 1 will have rounded side walls (see for example figure 1). In other cases, the side walls of the container 1 could also be rounded also through the effect of the inner pressure exerted by the fluid substance once it is introduced. The term “fluid substance” may hereby mean a solution, suspension, emulsion, paste, gel, cream, lotion, oil, such as for example in products such as a shampoo, a shower gel, a cream, etc.

In more details, the present invention relates to a container 1 of a fluid substance comprising a tubular body 2 with a polygonal section comprising side walls 3, a first end 4 folded and flattened on itself to form a zone 4 A that is flattened and fixed tightly, and a second end 5 where a shaped portion 8 is provided which defines a neck 80 in which a hole 6 is obtained, the neck 80 being provided with means 8A for fixing to a cap, and the tubular body 2 with a polygonal section, being made as a single injection-moulded piece. Preferably, said first end 4 is folded, being the side of at least one side wall 3, at the first end 4, folded towards the inside of the tubular body 2. In other words, the first end 4 is crushed on itself by one or more forces that are orthogonal to the side walls 3 and directed towards the inside of the tubular body 2 so that two opposite side walls 3 mate, at an end portion thereof, forming a flattened zone 4A. In particular, when the side walls 3 are four in number, as shown in figures, the flattened zone 4A comprises the end portions of two opposite side walls, in the entire length thereof, arranged on each other with the end portions interposed of the two remaining opposite folded side walls. Accordingly, the flattened zone 4A comprises four layers, so that if the thickness of the side walls 3 were constant, the flattened zone 4A would have a thickness that is equal to four times the thickness of the side walls 3. If the polygon constituting the section of the tubular body 2 is a circle or a polygon with an uneven number of sides, the force or the forces applied to crush the tubular body 2 would deform the polygon to create two opposite portions that finish by mating with interposition of further portions of side walls 3, forming the flattened zone 4A. In preferred embodiments, the tubular body 2 with a polygonal section comprises an even number of side walls 3. Optionally, the polygonal section is essentially a polygon in which the sides have a convex curve, so that the side walls 3 are rounded on the outside, as also shown in figures 4-6. In more preferred embodiments, the tubular body 2 with a polygonal section comprises four, six or eight side walls 3, preferably four side walls 3, as also shown in figures 1-8.

Preferably, at least one side wall 3 has preferential folding lines 11, 12 which guide the folding and flattening of said first end 4. It can be seen from the sections of figures 7 and 8 that the preferential folding lines guide the deformation of the tubular body 2 when the first end 4 thereof is folded and flattened on itself to form a zone 4A that is flattened and fixed tightly.

These preferential folding lines 11, 12 can be obtained by a reduction of the thickness of said at least one side wall 3 or by creasing.

Preferably, when the tubular body 2 comprises an even number of side walls 3, these preferential folding lines 11, 12 are on at least two side walls 3 that are not adjacent to each other. More preferably, the preferential folding lines 11, 12 are on at least two side walls 3 opposite to each other.

In preferred embodiments, first preferential folding lines 12 extend from the corners of the same side wall 3, at the shaped portion 8 of the second end 5, and join together at a point along the greater axis of symmetry of this side wall 3, a second folding line 11 departing from said point which runs at said greater axis of symmetry to the first end 4.

Particularly preferred are embodiments wherein the tubular body 2 with a polygonal section comprises four side walls 3, and wherein two side walls 3 opposite to each other have preferential folding lines 11, 12 which guide the folding and flattening of said first end 4, the side of these two side walls 3, at the first end 4, being folded towards the inside of the tubular body 2, as is for example well visible in figure 1.

As said, at the second end 5 of the tubular body 2, a shaped portion 8 is provided that is obtained in one piece with the side walls 3.

The shaped portion 8 defines a neck 80 in which a dispensing hole 6 is obtained.

The neck 80 is designed to fit a cap 50 tightly.

In order to obtain tight fixing of the cap 50 when it is the moment to close the container, the neck 80 is suitably provided with means 8A for fixing the cap to the neck 80. Advantageously, the fixing means 8A can provide snap means or a thread/counter thread.

In a possible configuration, on the neck 80, a possibly discontinuous annular tooth is provided, that cooperates in a snap manner with an undercut element 90 of the cap 50, as exemplified in figure 2. Advantageously, the sides of the side walls 3, at the end 4, once folded and flattened

4A, are welded or glued, to provide a tight fix.

Welding, in particular, can be performed by hot guns with resistance or by hot air, ultrasound or laser guns.

According to another aspect, and as shown for example in figure 1A, the present invention also relates to a semifinished product comprising a tubular body 2 with a polygonal section comprising side walls 3, a first end 4 that is foldable and flattenable on itself and tightly fixable, and a second end 5 where a shaped portion 8 is provided which defines a neck 80 in which a hole 6 is obtained, the neck 80 being provided with means 8A for fixing to a cap, and the tubular body 2 with a polygonal section, being made as a single injection-moulded piece.

The semifinished product is used for filling the tubular body 2 with the fluid substance through the first end 4, preferably by applying and closing a cap 50 on the neck 80 if the fluid substance has low density, i.e. is liquid or liquid-like.

Alternatively, filling can be made directly into the final container 1, through the hole 6, although this option is operationally less convenient, especially with high density substances.

As can be appreciated precisely from the aforesaid figure 1A, a semifinished product that is so configured does not have undercuts that make moulding thereof impossible.

Further, the semifinished product does not have complex elements, like those presented by the container of the cited prior art, which make the production process costly.

Preferably, at least one side wall 3 has preferential folding lines 11, 12 to guide the folding and flattening of said first end 4. Preferably, when the tubular body 2 comprises an even number of side walls 3, the preferential folding lines 11, 12 are on at least two side walls 3 that are not adjacent to each other.

In preferred embodiments, the folding lines 11, 12 are on at least two side walls 3 opposite to each other. Particularly preferred are embodiments wherein first preferential folding lines 12 extend from the corners of the same side wall 3, at the shaped portion 8 of the second end 5, and join together at a point along the greater axis of symmetry of this side wall 3, from said point a second folding line 11 departing which runs at said greater axis of symmetry to said first end 4, as is for example well visible in figure 1A.

Further, the side walls 3 have a first thickness SI that is smaller at the first end 4 (corresponding to the zone that will be flattened and fixed tightly after filling), with respect to a second thickness S2 in a zone bordering on the shaped portion 8.

A thickness S3 of the shaped zone 8, which defines the second end 5 and the hole 6, can be greater than that of the side wall 3 at a deformable part 15.

Preferably and advantageously, the thickness SI is about 1/4 of the thickness S2.

The thickness S2 has to be such as to permit good manual deformability of the deformable part 15.

For example, the first thickness SI can be 0.1-0.5 mm, whereas the second thickness S2 can be 0.4-2.0 mm. In this manner, following the welding after flattening, the flattened zone 4A will have a thickness similar to the thickness S2. In fact, the thickness of the flattened zone 4A is equal to about four times SI, as explained previously. In preferred embodiments, the first thickness SI is 0.3-0.4 mm, whereas the second thickness S2 is 1.2- 1.6 mm.

The thickness S3 can be 0.5-2.5 mm, preferably, 1.0- 1.4 mm.

As said also for the container above, both the tubular body 2 and the shaped portion 8 have, in cross section, a polygonal shape, preferably with four possibly rounded sides, as can be noted better in figures 4 or 6. Further, the shaped portion 8 (but also the neck 80 and the zones bordering on the neck

80) can have thicknesses S3 that are increased compared with those of the side walls 3 (SI and S2), configured to give the necessary stiffness to the various parts of the container according to the function thereof.

The preferential folding lines 11, 12, further define a deformable portion 15 of the side walls 3 (appreciable in figure 3) which is suitable for being easily deformed manually to squeeze the fluid substance from the hole 6, the deformable portion 15 extending preferably from said shaped portion 8 to said flattened zone 4A.

This configuration permits total squeezability of the tubular body 2, totally with extreme facility.

The convex polygonal or substantially convex polygonal, preferably quadrilateral shape of the shaped portion 8 (but also of the cap 50 that in fact can have a perimeter shape that in a plan shape can correspond to that of the shaped portion 8), makes conveying a plurality of containers 1 extremely advantageous.

The polygonal shape of the shaped portion 8 (and also of the entire container 1 owing to the preferential folding lines 11 and 12), when the containers 1 are alongside one another, minimizes the gaps in the package and maximizes the number of containers transportable on the same surface (area) occupied by the package.

Optionally, the container 1 of the invention can further comprise a cap 50, made for example with a ‘flip top’ configuration. Alternatively, other caps 50 of conventional type can be considered. In fact, it is also possible to provide a simple screw cap 50, possibly with a perimeter shape corresponding to that of the shaped part 8. In the case of a cap 50 of “flip-top” type, the cap 50 can have a base 59 on which a wing 51 is hinged that is obtained as one piece with the base 59.

The hinging can be defined by a zone with reduced thickness (precisely in order to make the hinging flexible and foldable) of the material of which the container is made. From the wing 51, as one piece, an elongated element 7 A (peg) can protrude that cooperates tightly with a (dispensing) opening 60 of the base 59 for a tight closure thereof.

Between the opening 60 and the elongated element 7A and/or between the wing 51 and the base 59 (for example on the inner perimeter) snap means can be provided.

The elongated element 7 A or the opening 60 can adopt a slightly conical configuration, so as to promote the hermetic tightness of the closure.

In a possible configuration, the opening 60 of the cap 50 is made on a wall that extends outwardly with respect to the surface of the base 59, so as to minimize the inner dimension of the container so as to assist the complete expulsion (by squeezing) of the product from the container itself (precisely via the opening 60). A further aspect of the present invention relates to a process of producing the semifinished product comprising the step of injection moulding of the entire tubular body 2 with a polygonal section.

Advantageously, the single injection-moulded piece of which the tubular body 2 is entirely formed, can be made of a single thermoplastic material or of at least two types of mixed thermoplastic material or thermoplastic material that are moulded together.

In a further embodiment, which is not shown in the figures, the container 1 of the present invention, and the relative semifinished product, can comprise a cap 50 (or lid) hinged on the tubular body 2 by a hinge and relative snap means configured to maintain the cap 50 in a closed position. In such a case, the side walls 3, the shaped portion 8, the hinging, the cap 50 and the snap means are formed into a single injection-moulded piece.

The plastics used for moulding the monobloc piece can be one or more of the following: PP, PE, PEHD, PELD, PELLD.

Further, at least one part of the tubular body 2, which can be a substantially flat or slightly rounded part (see for example the surface 30 in figure 1) can have a heat-embossed decoration through in-mould labelling.

The surface 30 can be substantially parallel to the flattened zone 4A and angled with respect to the walls where the preferential folding lines 11 and 12 are made.

“In-Mould Labelling” is a transformation process that enables the container to be customized by total fusion of the label with the package (and with the side walls 3) during the injection process.

According to this process, the label is inserted into the mould by a manipulator after the manipulator has been given an electrostatic charge that enables it to remain attached to the walls of the mould during the injection step.

This technology enables very high printing quality to be obtained and particular high resolution graphic effects and images to be reproduced on the containers.

The presence of a label that is thus printed does not affect the recyclability of the container inasmuch as the labels are made of plastics like the side walls 3. In this manner, from the mould, a container can be extracted that no longer needs any processing (obviously excluding filling and welding of the flattened zone 4A) before being marketed.

The container 1, in accordance with the aforesaid further embodiment in which it also comprises a cap 50 (or lid) hinged on the shaped portion 8, hinging and snap means for closing, is advantageously made by a method that provides the following steps: a. injection moulding in a single piece a semifinished product of a container 1 of a fluid substance comprising a tubular body 2 formed of side walls 3, which is open at one first end 4 and provided with a second end 5 where there is a shaped portion 8, of the side walls 3, which defines a dispensing hole 6 of the fluid substance, a cap 50 (or lid) provided with hinging on the tubular body 2, configured to close tightly the hole 6 at least when it is in a closed position, between the cap 50 (or lid) and the shaped portion 8 snap means being provided that are configured to maintain the cap 50 (or lid) in a closed position; the side walls 3, the shaped portion 8, the hinging, the cap 50 (or lid) and the snap means being formed as a single piece; b. closing the cap 50 (or lid); c. filling a cavity of the tubular body 2 with a fluid substance; d. flattening the first end 4 of the tubular body 2 on itself and fixing the first end 4 tightly.

Advantageously, injection moulding is performed starting from plastics (in granules) that are melted (plasticized) and injected at high pressure inside a closed mould, which is opened after solidification of the product. Injection can be performed at high pressure and at 220°C for PP and 180°C for PE to enable the “plasticized” material to flow inside the machine and the mould.

The tubular body 2 as disclosed leads to a significant energy saving inasmuch as it uses a single step to produce the same body 2 rather than two distinct steps necessary for producing the tube of the gate (shoulder), in addition to welding the tube with the gate. It is thus financially advantageous in addition to increasing production speed.

The semifinished product is further producible at low cost using standard machinery and procedures, ensuring the tightness and collapsibility of the tubular body 2, thus overcoming the drawbacks of the aforementioned US document. Further, by the bi-injection system, it is possible to make the tubular body 2 in two or more colours, or even in two or more distinct plastics, even though it is a single piece.

As already mentioned, the container 1, at least in the configuration of figure 1, provides significant advantages in logistical terms both in the steps of handling and storage and of display on shelves. In every single package, it is possible to convey more containers than a cylindrical tube, thus minimizing the packs to be transported for example by road, with less environmental impact.

In the above description, it has been demonstrated that providing a shaped portion 8 of substantially polygonal shape is particularly advantageous. Various embodiments of the innovation have been disclosed, but others can be conceived exploiting the same innovative concept. It should be understood that all the aspects identified as preferred and advantageous for the container are to be deemed to be similarly preferred and advantageous for the semifinished product, and vice versa.

Also all the possible combinations of the preferred aspects of the container, of the semifinished product, of the uses thereof and of the productive processes thereof as indicated above are moreover to be deemed to be disclosed and thus similarly preferred.