In the specification which follows problems of packaging milk are specifically addressed. However, it will be appreciated that other pourable fluids such as fruit juices present similar packaging problems. The present invention is, however, only concerned with fluids which are not required to be packed in a gas-tight manner.

Accordingly, the problems of packaging carbonated drinks are not addressed. The present invention is also specifically concerned with types of packaging where the weight of the container is an issue and therefore relates specifically to thin-walled blow moulded bottles.

The Technical Background Conventionally, milk has been packaged in cardboard, gable top packs which are notoriously difficult to open and result in numerous consumer complaints about milk spillage and difficulty in pouring. The fibre carton was <BR> <BR> <BR> <BR> only suitable for packaging liquids up to a capacity or 1.5 litres.

In order to resolve these problems blow moulded plastics polyethylene bottles have been used. These bottles are provided with resealable caps. The resealable caps are normally injection moulded items. Since weight is significant in the packaging of fluids such as milk, these caps must also be light in weight. A weight of 2 to 3 g is usually the maximum that can be tolerated.

There is also a fundamental problem in achieving a good seal between a blow moulded bottle neck and an injection moulded plastics cap. This is because the tolerance of the neck is of the order of 0.3mm whereas the tolerance of an injection moulded item such as the cap is O. lmm.

This means that a proportion of caps will not seal tightly when fitted to their necks. For all designs of caps this results in difficulties of fitting on the production line and, for retailers and distributors, leakage problems. The ultimate consumer may also have difficulty in resealing the bottle or opening it in the first place if the cap is over-tight.

A number of designs of injection moulded caps have been developed in an attempt to address these problems. For example, in a cap design known as a valve seal or pliable seal closure, a plug is provided in the cap which pushes into the neck of the bottle and a multiple start thread is provided on the interior wall of the cap skirt. This type of cap provides a double seal. The plug provides the seal against the inner wall of the neck. The second seal is provided by means of an inwardly projecting ridge above the threads on the inner wall of the cap which seals against the outer wall of the neck. Tamper evidence for this type of cap can be provided by a pliable pull away ring around the lower edge of the cap.

With a cap made of low density polyethylene, it is possible to prise off the cap with the ring attached so that this form of tamper evidence is not very secure.

Another design known as the induction heat seal closure (IHS) provides a foil insert seated into the base of the cap. On the production line the filled bottles with caps fitted are passed through an induction heater which fuses the foil to the neck of the bottle. When the consumer

unscrews the cap the neck of the bottle is still sealed by the foil. This foil seal is pulled off in a separate operation. Severing the seal results in small hairs being raised on the plastics surface of the bottle neck.

The setting of parameters for the bonding process using an induction heat seal closure is critical in order to achieve a bond which is weak enough to allow the consumer to be able to peel away the foil, yet strong enough to maintain a good primary seal with the container neck.

Because the presence of the foil means that no plug can be provided the susceptibility to leakage in the consumer's home is increased as the resealing of the cap is poor. The cap is also relatively expensive as the provision of the foil insert can add as much as 20% to the cost.

Another set of problems arises from the production line process of filling the bottles and sealing them. Since the maximum linear speed of milk is restricted by the speed at which the milk starts to froth, the rate of filling depends upon the size of the nozzle used to pour the milk into the bottles. The nozzle size is constrained by the dimensions of the neck. For a typical milk container this is 38mm. Larger necks allow for quicker filling but present greater sealing problems and require larger caps.

In the present context the term blow moulding refers to extrusion blow moulding rather than injection stretch blow moulding. In many modern production lines, a blow moulding plant is adjacent the dairy. This allows the bottles to be formed, filled and sealed in a single continuous production process. The most complex stage in blow moulding is balancing each parison and controlling the material distribution. The parison is then inflated

against the wall of a temperature regulated mould solidifying to assume the shape of the mould cavity. In one conventional design of blow moulding machine a block of moulds shuttles between an extrusion station and a blowing station. The number of die-heads provided is generally equal to the number of cavities in the block or some fraction thereof. These die-heads are fed by a head manifold which typically results in an imbalance in the delivery of plastics material to each of the resulting parisons. This process results in difficulties in forming consistently the neck-portion of thin walled containers, achieving at best tolerances of +/-0.3 mm with repeatable accuracy. To achieve good performance with valve seal closures, it is imperative to form a perfectly round neck-bore with a minimum amount of ovality in both bore and threaded portion. Two processes are known to achieve the above result in multi-cavity blow moulding. They are namely a"pull-up"process, which is the lifting of a blow pin through a shear-steel assembly to cut a round bore in a bottle neck, or a"ram- down"process, which is the forcing downwards of a blow pin into a shear steel assembly. The drawback with pull- up is that the neck component is physically weak in its construction leading to poor sealing with valve seal closures as the bore relaxes over time causing leakage.

Ram-down however, gives a very rigid neck but this has a weight disadvantage causing ovality of the neck coupled with added cost of material wastage. Ovality causes poor sealing with valve seal closures. Neither of these two processes are suitable for moulding pour-lip features on bottle-necks. With the pull-up finish it is almost impossible to mould and with the ram-down it requires significant amounts of extra materia and is almost

impossible to mould without significant ovality and imperfections in the bore.

The above processes described relate to moulding machinery manufactured by companies such as Uniloy, Techne and Bekum, for example.

An alternative type of machine made by Graham Engineering and Uniloy, which is particularly suitable for on-site blow moulding plants, uses a process which is commonly referred to as wheel blow moulding. Unlike the previous processes described, the wheel produces only one parison at a time extruded from a single die-head. The mould blocks are mounted on a rotary wheel structure and pass over the parison closing as the wheel rotates. A needle assembly pierces the parison and inflates the plastic until it solidifies against the wall of the temperature regulated moulds. Wheel blow moulding gives a high level of control in material distribution in containers produced in this way. The set up time for such a machine is significantly reduced as only one die-head needs to be set up.

Where the inner wall of the neck provides one part of a seal, it may be necessary to provide a separate finishina station where the neck is either reamed or punch finished. The finishing step may produce swarf which results in the risk that the swarf could enter inside the bottles and make them unsuitable for immediate filling.

For products such as milk where large quantities are required to be distributed through the retail chain, it is highly desirable to minimise the weight of the packaging. This has resulted in larger containers and thinner walls. Typical wall thicknesses for blow moulded high density polyethylene (HDPE) are 0.4 tc 0.6mm. This

results in a 4 pint (2.27 litres) bottle having a weight of around 40 grams. Therefore any solution to the technical problems described must not increase the weight of the bottle and preferably would allow weight reduction.

Prior Art For cardboard cartons it has been proposed to provide a separate spout assembly which is secured to the carton.

An example is described in WO-A 96/14249 (Capitol Spouts Inc). This spout includes a cap and an integral inner membrane seal and is assembled to an outer wall of a filled carton. The container may have a scored portion so that when the inner membrane seal is removed it brings with it the scored portion of the container wall creating an opening through which the contents of the container can reach the spout. This assembly is not suitable for use with a plastics container where it would be impractical for the user to tear an opening in a plastics walled container. The cardboard carton will typically have a continuous inner lining. This type of spout must be fitted to the carton prior to filling and is not used for filling the container.

GB-A-2 108 464 (Container Corporation of America) describes an end closure arrangement wherein a membrane <BR> <BR> <BR> is sandwiched between and used to bond rim portions of a container body and end member to each other. The membrane has heat activatable sealing materials on both sides such as polyethylene, polypropylene or other similar types of material. The reader is told to use <BR> <BR> <BR> this type of closure with a container which may be c_ all ! plastic or a combination of paperboard and plastic materials. The exact method of producing of the

container body and end member are not further described.

The specification is also silent as to the method of filling the resulting container. The specification particularly suggests use with a cylindrical cardboard container. Such containers would normally be filled from the base once the openable end had been completed and sealed.

US-A-24,815,618 (Gach) shows a tamper indicating closure <BR> <BR> <BR> <BR> for a bottle designed for dry contents. A base section has a skirt which engages with the neck of the bottle and defines a spout. A foil is interposed between the neck of the bottle and an adjacent surface of an upper part of the base. A pull ring is attached to a disc which is connected to the opening in the upper part of the base by means of breakable webs. The disc is bonded to the foil.

The closure is opened by pulling on the pull ring which tears the foil away from the spout. In an alternative embodiment of the Gach invention the disc is not joined to the base section and the foil is provided with a circumferential score line to facilitate tearing at the edge of the inner surface of the spout. In either embodiment a clean opening is unlikely to be produced.

This would not be a problem when the bottle is used for tablets or the like but a torn foil edge within the spout is unsuitable for the pouring of liquids. The material of the bottle is not disclosed.

Although these documents are referred to as the most relevant prior art they do not represent a natural starting point for those seeking to solve the technical problems described in relation to thin-walled plastics bottles, in which the teaching has hitherto been directed exclusively at integral formation of the bottle body and neck.

Therefore, although it is known to produce a separate component defining a neck as in GB-A-2 108 464, the possibility of using this approach to solve the long present technical problems of effective reclosable sealing of thin-walled blow moulded plastics containers for fluids had not hitherto been appreciated and cannot therefore be regarded as obvious.

Solution of the Invention Relative to the prior art defined in Gach which describes a bottle comprising a body having an open mouth, a neck and cap assembly comprising a skirt adapted to engage over the mouth and defining a pour spout and having a ring pull coupled to a removable part held within a base of the neck which seats against an upper surface of the mouth; and a foil interposed between the surface and the base and fused with both such that removal of the ring pull and removable part removes at least part of the foil and opens the spout; the present invention is characterised in that the removable part is an annular flange separated from a remainder of the base by means of a frangible valley defining a plurality of depending teeth each having a saw tooth profile inclined inwardly to a centre of the base such that on removal of the ring pull the foil is torn by the teeth (32).

The use of an annular flange rather than a disc as in Gach allows the neck assembly to be injection moulded in one piece by means of a two part mould tool which can be separated along an axis passing through a centre of the ring pull and flange. The saw tooth teeth tear the foil cleanly ensuring that it is removed with the ring pull allowing fluid to flow freely out of the spout.

Preferably the bottle is a thin-walled plastics bottle comprising a blow moulded body which is fused together with the neck and cap assembly after the body has been filled with a fluid.

This solution has numerous advantages. The neck and cap will fit together in a reliable sealing manner as both components are formed by the same manufacturing technique, preferably injection moulding. The neck and cap assembly can be supplied from a separate factory which can produce them in hygienic circumstances. Any of the pre-existing cap designs can be employed.

The body to which the neck and cap assembly is fitted can have a relatively wide mouth through which it can be filled, thus increasing the filling speed.

In addition, the foil is used to seal the mouth at the same time as the neck and cap assembly is fused to the mouth in a single heat sealing operation. This results in more reliable sealing of the filled bottles avoiding any leakage during the distribution and retailing cycle.

The term thin-walled as used herein is intended to refer to wall thicknesses of 2mm or less and preferably within the range 0. lmm to 1.0 mm. A container having a wall thickness of less than 0. lmm is unlikely to have the necessary structural integrity to hold its shape when filled with fluid. For a milk container of up to 6 pints (3.41 litres) capacity a thickness of 0.4 to 0.6mm is appropriate.

Description of a Preferred Embodiment In order that the invention may be well understood an embodiment thereof will now be described, by way of

example only, with reference to the accompanying drawings, in which: Figure 1 shows a side view of a mouth of a bottle body; Figure 2 shows a perspective view of a mouth of a bottle body ; Figure 3 shows a top plan view of a mouth of a bottle body Figure 4 shows a section through a side wall at a mouth of a bottle body; Figure 5 shows a section through a neck and cap assembly assembled to a bottle body ; Figure 6 shows a perspective view from below of a neck; Figure 7 shows a plan view from below of the neck; Figure 8 shows a perspective view from above the neck; and Figure 9 shows an underside plan view of a cap.

A bottle body 2 has a mouth 4 which is integrally formed in a single blow moulding operation. The remainder of the body shape has not been shown as it may take any suitable form. For example it may be square, rectangular or round in section and may have an integral handle formed as part of the body shape.

The profile 6 of the mouth is best shown in Figure 4 and comprises a vertical wall 8 adjoining an indented recess 10 which merges into an inwardly directed horizontal seating flange 12. The purpose of the recess 10 is to give the mouth profile more rigidity and resistance to

compression when top loaded during the subsequent operations to attach a neck and cap assembly. It is also used to locate a mouth of the neck assembly when applied in the filling process.

The body 2 with its shaped mouth profile 6 is formed by the mould against which a parison of high density polyethylene or other suitable plastics is inflated in any appropriate conventional blow-moulding operation. If the blow moulding takes place on a rotary machine then nicks 14 in the flange 12 as shown in Figure 3 will be formed. These are usually removed in second stage trimming by either reaming or punching after any dome of the parison guillotined from the container to leave the open mouth 6. This invention removes the necessity for this trimming and finishing. It is not necessary to remove these or any other irregularities in the internal profile of the mouth for use in the fusing of the neck to the container profile 6.

A neck 16 is shown in the Figures 5,6,7 and 8. The neck comprises an annular side wall 18 which forms a pour spout for the container and terminates in a projecting pour lip 22 which is slightly tapered towards the pouring edge. In the illustrated embodiment the angle of the outer wall of the pour lip is 45° to the horizontal while the angle of the inner wall is at 40°. This produces exceptionally good control and allows a very thin column of liquid to be poured with control from the spout. Such a precise point cannot be blow moulded without weight or cycle time penalties or both and this therefore represents a significant improvement relative to blow moulded pour lips.

Opposite the pour lip the side wall 18 has a base 24 which comprises an outer annular flange 26 projecting outwardly from the side wall 18 and an inner annular flange 28. The inner and outer annular flanges 26,28 are separated by a valley which constitutes an annular frangible portion 30. A series of spaced pointed teeth 32 depend downwardly from the floor of the valley. Each tooth 32 as shown in Figure 7 is circular in plan and has a saw-tooth profile section as shown in Figure 5. The teeth 32 are inclined inwardly to the centre of the base.

It will be appreciated that the pitch of the teeth may be varied from that shown in the drawings.

An inner edge of the inner flange 28 supports a leg 34 which carries a pull ring 36. The depth of the ring is widest adjacent the support leg 34 and is tapered towards the opposite side. The resulting sloping lower (relative to the opening of the pour spout) edge 38 of the pull ring 36 causes the finger of the user to be directed towards the narrowest part of the wall of the ring when inserted into it. A V-shaped notch 39 is provided in the inner annular flange 28 and defines a break line across the flange 28. The notch starts adjacent the leg 34.

The user's force is applied directly opposite leg 34 due to the shape of the ring. Initially the flange 28 will sever at the break line defined by the notch and then the frangible portion 30 will break in a counter-clockwise direction. The notch means that the frangible portion does not sever in both directions away from the leg 34, and therefore the force needed to open the closure is reduced and thus produces a more efficient tear. This design also reduces the risk of breakage of the pull ring 36. Preferably the inner lower edge of the pull ring 36 has a curved rather than a sharp edge in order to prevent

the ring cutting into the user's finger during the pulling operation.

A skirt 40 extends around the exterior of the side wall 18 and depends from the outer edge of the outer flange 26 of the base 24. The skirt 40 terminates in an inwardly projecting rib 42 in order to engage with a recess 10 of the profile 6 of the mouth of the bottle body 2.

In an alternative embodiment (not shown) the annular side wall 18 could be provided with a shoulder so that the pour spout of the neck which is closed by a cap 50 may be of smaller diameter than the mouth of the bottle body.

The design of the side wall and pour spout of the neck 16 is dependent on the type of cap which will be used to complete the neck and cap assembly. The cap 50 in the illustrated embodiment is of the valve seal type which provides a push fit. It will be appreciated that the neck can be adapted for use with screw on caps and for this purpose may have a thread or multi-start threads formed in an outer surface of the side wall 18 to engage with a screw thread formed in an inner wall of the co- operating cap.

The cap 50 is the subject of a separate UK registered design application No 2076559. Design variations may, of course, be made. The cap as shown in Figure 8 is an injection moulded component comprising a cover plate 52 with a depending inner cylindrical plug 54 which in its relaxed condition has a slight outward flare towards its lower edge so that when inserted into the neck 16 it is forced against an inner surface of the side wall 18.

Outwardly of the plug 54 there is provided a peripheral depending flange 56 which forms a bead for engaging against an underside of the pour lip 22. The bead serves to retain the cap on the neck. An outer wall of the plug

54 merges with the underside of the plate by means of a shoulder 58 of the same slope as an-inner wall of the pour lip with which it co-operates.

The cap 50 can be snap fitted onto a mouth of the pour spout. It is sufficiently flexible not to deform the pour lip during the sealing and resealing operation.

With the design illustrated in Figure 5 there are three sealing points between the cap and the neck, namely between the flange 56 and an underside of the pour lip and extending around the outer point of the lip; between the shoulder 58 and an inner wall of the pour lip; and between an outer wall of the plug 54 and an inner surface of the side wall 18 of the neck. This three point sealing is particularly efficient.

The outer profile of the plate 52 of the cap has three curved lobes 60 as seen in Figure 8 which facilitate gripping of the cap to lever it off in use. At these lobes the seal between the flange 56 and the underside of the pour lip will be less good but the other two sealing points will ensure effective sealing of the cap to the neck to prevent leakage.

In order to minimise the weight of the cap, the plastic of which it is moulded may be foamed. This would allow it to be substantial enough for ease of handling yet lightweight to minimise overall weight and accordingly transport costs.

The neck is assembled to the body with an intermediate sealing foil 70. The foil 70 may be a polymer foil or a polymer foil laminated to an aluminium foil or aluminium.

The foil is selected so that it is capable of being bonded on both sides and torn with minimal user force.

Any of the materials traditionally used for providing a heat-seal foil in existing plastics milk bottles may be

employed. A thinner foil may be necessary than has been used in prior art pealable seals in order to facilitate tearing. Any layer of polymer must also be sufficiently thin so as not to inhibit the tearability of the foil. A foil of aluminium of thickness between 12 and 25 microns with polymer layers on both sides of between 15 and 30 microns or less will tear easily in use but maintain the necessary seal within the cap. Where an aluminium laminate is used small perforations may be provided in the aluminium layer to allow the polymer to pass through during the heat sealing process and thereby form a bond between the flange 12 of the bottle body and the adjacent surface of the base 24 of the neck. The foil 70 is preferably supplied already bonded to the base of the neck and cap assembly.

Both the neck and cap are preferably injection moulded plastics components. Since they are both manufactured by the same method to the same tolerances the seal between neck and cap will be good. The neck and cap assemblies may by supplied to a bottling plant ready assembled, tested and sterilised.

The details of the injection moulding process and the detailed design of the tool will not be described herein as they will be readily apparent to those skilled in the art.

Filling Process The described bottle and neck and cap assembly may be used in various ways in bottling plants. The bottle bodies may be supplied to the plant ready formed bu this results in the need to transport large volumes and it is preferable to form the bodies in a blow moulding plant <BR> <BR> <BR> adjacent the dairy so that they can be formed and filled

in one continuous production line. The absence of any requirement for further trimming and finishing the interior of the mouth of the body makes this design of bottle particularly suitable for such a process.

In a preferred embodiment of the process the bottle bodies are blow moulded using a rotary machine having a series of moulds adapted to pass beneath a single die- head for the supply of a predetermined amount of plastics material to form a parison which is subsequently inflated to form the bodies. Such rotary machines are commercially available and require only the modification of the mould to define the required mouth profile 6 instead of a more conventional neck.

The bodies are filled through the mouth with the fluid such as milk.

In aseptic packaging the foil 70 will be sprayed with a sterilising solution such as a water/paracetic acid mixture in order to sterilise the face of the foil which will be adjacent the milk in the finished container. Such a sterilising solution is marketed under the trademark OXONIA. Alternative sterilising methods such as irradiation may be employed but are at this time more expensive.

The sterilised and foiled neck and cap assemblies are supplied through a chute to a pick and place mechanism, which orients each neck and cap assembly and places it on a filled bottle body. The skirt 40 clips over the profile 6 sandwiching the foil 70 between the two components. In the next step, the neck assembly 16 is bonded to the body 12. Preferably a chute of the pick and place mechanism contains an induction coil so that as each assembly is pressed onto the body induction heating

is applied to bond the foil to the body. To form an effective bond some pressure may be required to hold the body and neck firmly together during this step. The induction heating and bonding may alternatively be carried out at a separate station downstream of the pick and place mechanism. Suitable induction heating machines are supplied by ENERCON AHLBRANDT.

Rotation generated friction heating could also be used to fuse the body and neck and cap assembly without the presence of an intervening foil.

Opening Process When the user receives the filled bottle, the first step is to remove the cap 50 by lifting it at one of the lobes 60 to break the seal around the pour lip and to lever the cap open. This exposes the pull ring 36. The user inserts a finger into the centre of the ring and pulls the ring upwards about an axis defined in the plane of the base 24 perpendicular to the leg 34. This rotational movement stretches the foil 70 against the longer outer face of the saw tooth profiled teeth 32. The points of the teeth tear the foil 70 as the pull ring is lifted.

The tear in the foil is directed in only a counter- clockwise direction by the notch 39 in the inner annular flange 28. The lifting of the ring also causes the base 24 to break at the annular frangible portion 30. That part of the foil 70 which is fused to the flange 28 is pulled away in a spiral with the pull ring 32 attached and is discarded with it.

The fluid may then be poured out of the exposed opening over the pour lip 22. When the user wishes to re-seal the bottle the cap 50 is replaced by simply pushing the plug 54 into the mouth of the neck and pressing down the edge over the pour lip to completely seal the bottle.