The present invention relates generally to a hybrid material package and particularly, although not exclusively, to the connection (directly or indirectly) of a plastics lid to a paper cup.

Hybrid material packaging (packaging in which different parts are formed from different material types) allow for the functionality of different parts to be optimised. However, they can create problems in the recycling stream because often the different parts are not recycled together (e.g. paper and plastics). Accordingly, being able easily to separate different parts of a hybrid container is advantageous.

An aspect of the present invention provides a package comprising a container formed from paper or paper-based material, a lid formed from a plastics material, and a retaining portion which engages the container and retains the lid, the retaining portion can be released from the container to separate the lid therefrom. Such separation of the various parts may be by the end consumer of the package once a product contained therein has been consumed or by a recycling plant/facility that may receive the empty package as disposed of by the consumer.

A further aspect provides a package comprising a container formed from a plastics material and a lid formed from a paper or paper-based material, and a retaining portion which engages the container and retains the lid, the retaining portion can be released from the container to separate the lid therefrom.

A further aspect provides a hybrid material package comprising a container and a lid, and a retaining portion which engages the container and retains the lid, the retaining portion can be released from the container to separate the lid therefrom, the container and the lid and/or the retaining portion are formed from different materials which are incompatible in recycling streams. For example the container may be formed from paper and the lid may be formed from plastics material, or vice versa. The container may be formed from a flexible or semi-flexible material.

The lid and/or retaining ring may be made from a rigid or semi-rigid material.

In some embodiments the retention portion is formed from material which is more rigid than the container.

The container may, for example be formed from paper or a paper-based material such as paperboard or cardboard.

In some aspects and embodiments the term “paper” is intended to be interpreted broadly to refer to material manufactured from the pulp of wood or other fibrous substances, including paper, paperboard and cardboard.

A further aspect provides a package comprising a container, a lid, and a retaining portion which engages the container and retains the lid, the portion can be released from the container to allow separation of the lid therefrom.

A further aspect provides a package comprising a container, a lid, and a retaining portion which engages the container and retains the lid, the retaining portion can be released from the container to allow separation of the lid therefrom.

The lid may be of the type not intended to be removed during normal use of the package by the consumer. In other words the lid is securely fixed to the cup using the retaining member, and once the package is no longer required it can be removed for recycling purposes. That is, the lid is not as such intended to be removed while the consumer is consuming the contents of the package, but is intended to be removed after all of the contents have been consumed or at least when the package is no longer required. In some embodiments the retaining portion forms part of the lid. This could therefore be a two part package i.e. the container and the lid. Alternatively the retaining portion may be a retaining member that is formed separately of the lid.

Some aspects and embodiments provide or relate to connecting a plastic lid to a paper or paper-based cup, for example a lid on paper cup without gluing.

In some embodiments the retaining portion/member engages the container substantially (or only/solely) by geometric interaction, for example by providing cooperating features or formations that snap or clip together or are otherwise fitted/secured/jointed together without the need for additional means such as glue, shrink sleeve or tape.

In some embodiments the retaining portion/member is formed as a retaining ring. The retaining ring may, for example, be generally circular where the container has a circular cross section as regards its opening from which the contents are obtained by the consumer or may be another shape depending on the corresponding shape of the opening of the container.

The lid may be formed from a plastics material, such as polypropylene or polyethylene. In some embodiments the lid and the retaining member are formed from polypropylene.

The lid may comprise one or more access flaps. This is useful, for example, in embodiments in which the lid is not detachable in normal use, but access to the contents of the container is periodically required.

The container may include a folded and/or rolled rim and the retaining member may engage the rim.

The container may be a cup, pot or the like.

The container may, for example be formed from paper, paperboard, cardboard. Some embodiments make use of recycled materials.

In some embodiments the lid is snap-fitted to the container and/or the retaining portion/member, for example one of the lid and the member may have a snap bead and the other may have a cooperating snap bead or groove/recess.

In some embodiments the retaining portion/member cannot be released from the container without altering it.

The retaining member/portion may comprise a frangible line.

The retaining member/portion may include a tamper-evident portion.

In some embodiments the retaining member/portion is not removable without destroying the tamper evident portion and/or the retaining member/portion itself.

The retaining portion may comprise a retention hook. In some embodiments a plurality of spaced hooks are provided.

The retention hook/s may be formed on a tear strip. Tearing/removing the strip releases the hooks from the container so that the retaining member/lid can be removed.

The shape of the package (for example in plan/section) may be generally: circular; oval; elliptical; rectangular; rounded square; polygonal; rounded triangle.

The present invention also provides a hybrid material, paper-based package comprising a plastics lid, a plastics retaining member, and a paper cup, in which the retaining member is connected to the cup and in which the plastics lid is attached to the retaining member. The present invention also provides a chewing gum package comprising a plastics lid, a plastics retaining member, and a paper cup, in which the plastics lid is gluelessly attached to the paper cup using the retaining member.

The present invention also provides a method of forming a package comprising the steps of: i) forming a container from a paper or paper-based material, forming a retaining member, and forming a lid; ii) attaching the retaining member to the container; iii) filling the container with product; and iv) fitting the lid onto the retaining member.

Some aspects and embodiments provide one or more of the following benefits: the combination of the lid with the cardboard is without glue or shrink sleeve or tape. the combination is not removable without destroying tamper evidence or the parts (lid and/or retaining member and/or container) themselves. the lid can be removed easily by the consumer by destroying tamper evidence. the packaging can be filled on high speed filling lines.

Easy handling in a filling line may result because of the easiness of the handling during filling. When there is easy handling in the filling without problems of inserting, snapping, etc., the filling line can operate on a higher speed.

Different aspects and embodiments of the invention may be used separately or together.

Further particular and preferred aspects of the present invention are set out in the accompanying independent and dependent claims. Features of the dependent claims may be combined with the features of the independent claims as appropriate, and in combination other than those explicitly set out in the claims.

The present invention is more particularly shown and described, by way of example, in the accompanying drawings, in which:

Figure 1 A is a perspective view of a package shown in a closed position;

Figure 1 B shows the package of Figure 1 A with two access flaps open;

Figure 2 shows a cup forming part of the package;

Figure 3 shows a lid forming part of the package;

Figure 4 shows a retaining ring forming part of the package;

Figure 5 illustrates a frangible line formed in the retaining ring;

Figure 6 is a magnified view of the underneath of the frangible line region;

Figure 7 illustrates retention of the lid on the cup rim;

Figures 8A to 8C show an example of forming a filled package;

Figure 9 illustrates a perspective view of a package formed according to a further embodiment; and

Figure 10 is a section through the package of Figure 9.

The example embodiments are described in sufficient detail to enable those of ordinary skill in the art to embody and implement the systems and processes herein described. It is important to understand that embodiments can be provided in many alternate forms and should not be construed as limited to the examples set forth herein. Accordingly, while an embodiment can be modified in various ways and take on various alternative forms, specific embodiments thereof are shown in the drawings and described in detail below as examples. There is no intent to limit to the particular forms disclosed. On the contrary, all modifications, equivalents, and alternatives falling within the scope of the appended claims should be included. Elements of the example embodiments are consistently denoted by the same reference numerals throughout the drawings and detailed description where appropriate.

Unless otherwise defined, all terms (including technical and scientific terms) used herein are to be interpreted as is customary in the art. It will be further understood that terms in common usage should also be interpreted as is customary in the relevant art and not in an idealized or overly formal sense unless expressly so defined herein.

All orientational terms are used in relation to the drawings and should not be interpreted as limiting on the invention.

Referring first to Figures 1A and 1B there is shown a package generally indicated 10.

The package 10 comprises a cup 20 a lid 30 and a retaining ring 50.

The cup 20, also shown in Figure 2, is formed from a paper material and comprises a frustro-conical sidewall 22 closed at its narrow end by a base and open at its wider end, terminating with a rolled rim 23.

The lid 30, also shown in Figure 3, is a generally disc-shape, with a base plate 31 formed with two openings 32, 33 (which in this embodiment are different sizes). Two flaps 34, 35 are formed on the base plate and are hinged along one side 36, 37 so as to be movable between a closed position (Figure 1A) and an open position (Figure 1B). Figure 4 shows a retaining ring forming part of the package.

Figure 5 illustrates a frangible line formed in the retaining ring.

Figure 6 is a magnified view of the underneath of the frangible line region.

Also referring to Figure 7, the base plate 31 of the lid 30 includes a top deck 38 from which depends an annular inner skirt 39 and an annular outer skirt 40. The outer skirt 40 terminates with an annular snap bead 41.

Figure 7 also shows the smaller flap 35, which includes a depending wall 42 which fits into the opening 33 and holds the flap closed (the friction can be overcome by lifting the flap).

The retaining ring 50, also shown in Figure 4, is generally annular. The section of the ring 50 generally L-shape and is shown in Figure 7. The ring 50 comprises a shorter leg 52 and a longer leg 54. The longer leg includes an annular groove 56 on its inner face that is configured to cooperate with the annular snap bead 41 of the annular outer skirt 40 of the base plate 31 of the lid 30.

As shown best in Figures 5 and 6, the retaining ring 50 includes an axial frangible line 58 formed by frangible bridges 60.

Figures 8A to 8C illustrate assembly of a package using the cup 20, lid 30 and retaining ring 50.

The cup 20 is inserted into the ring 50 (Figure 8A), then product 70 is placed/filled into the cup (Figure 8B) before the lid 30 snap fits onto the ring (Figure 8C).

The lid 30 is securely held by the ring without the need for glue on the cup rim. More specifically, as shown in Figure 7 in conjunction with Fig 8A, the cup 20 passes through the ring 50 until the cup rim 23 encounters the shorter leg 52. When the lid 30 is fitted the snap bead 41 snap fits into the groove 56 and the inner skirt 39 slides down into the interior of the cup sidewall. The cup rim 23 is therefore held between the ring 50, and the inner skirt 39 and outer skirt 40 of the lid.

The ring 50 can be split by rupturing the bridges 60. The ring 50 can then be removed from the cup and the lid can be lifted off (together with the ring or after the ring is removed).

The individual steps for this embodiment in a filling line may be:

1 ) Insert the ring into a cell plate.

2) Insert the paper cup into the ring.

3) Fill the paper cup.

4) Press the top of the lid in the ring.

Due to the fact that this presses two rigid plastic parts (lid and ring) together, there is a lower risk of incomplete snapping.

Figures 9 and 10 illustrate a package 110 formed according to a further embodiment.

In this embodiment there is no separate retaining ring. Rather the lid 180 itself includes the retention functionality and is fitted directly onto the container 122.

The lid 180 comprises a top plate 182 and a depending sidewall 184. The sidewall 184 includes a plurality of retention hooks 186 formed towards its open end on the interior face thereof. The hooks 186 project radially inwardly and upwardly. To facilitate removal/demoulding of the lid from a moulding machine, the top plate has cut-outs 188 corresponding to the hooks. An annular wall section 190 depends from the top plate, from the inner edge of the cut-outs.

The sidewall 184 includes a weakened line 185 which extends therearound, above the hooks (the hooks are therefore carried on a lower section 184 of the wall). A tab 192 is provided at an end of the line 185. The lid 180 is directly fitted to the container by press/snap fitting, with the hooks passing over and then engaging under the container rim 123. The rim 123 is held between the hooks 186, the sidewall 184 and the wall section 190.

The lid can be removed (e.g. by the consumer) by grasping the tab 192 and tearing the sidewall along the line 185. This pulls the wall section 184a away and removes the hooks 186 from under the rim 123. In this embodiment the container and lid are generally oval.

Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiments shown and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention.