Jar assembly

The present disclosure is related to jars and containers and, more particularly, to the manufacture of readily recyclable jars and containers.An exemplary jar is comprised of an aluminum base and a first aluminum inner cup provided with a first cavity defined with the aluminum base. An outer thread is provided about an exterior surface of the aluminum base, and an aluminum lid with a second aluminum inner cup is provided within a second cavity defined within the aluminum lid. An inner thread mateable with the outer thread is provided about an interior surface of the second aluminum inner cup.A method of manufacturing readily recyclable jars can comprise providing a primary metal material and optionally applying a precoating to the primary metal material. The primary metal material may be formed into a jar with mating threads and a lid with mating threads. The primary metal material may optionally be finished. A liner may optionally be inserted. The lid and jar are then assembled, and a plastic cup may optionally be installed.

BACKGROUND

Jars and related containers are used to provide a practical, convenient and means of containing makeup, creams, powders, emulsions and other products for consumers. Once the contents of the container have been fully utilized or the consumer is otherwise ready to dispose of the container, recycling is the most environmentally friendly and preferred disposable option. However, jars currently in distribution for consumer products are often difficult to recycle, e.g. they may have a PET plastic or glass bottom jar portion, a screw-on lid with plastic components, an inner plastic component with an outer metal shroud, metal vacuumized plastic, two piece construction that is difficult to separate, or otherwise are constructed in a manner that makes recycling the container more arduous, causing consumers to default to disposing of the containers in the trash, with attendant negative environmental impact.

Consequently, there is a need for more easily recyclable containers and methods of making the same.

SUMMARY

The present disclosure relates to jars with improved recyclability.

For example, a jar assembly, comprising an aluminum base and a first aluminum inner cup provided within a first cavity defined within the aluminum base. An outer thread is provided about an exterior surface of the aluminum base. An aluminum lid with a second aluminum inner cup is provided within a second cavity defined within the aluminum lid. An inner thread mateable with the outer thread is provided about an interior surface of the second aluminum inner cup.

A method of manufacturing jars of the present disclosure can comprise providing a primary metal material and optionally applying a precoating to the primary metal material. The primary metal material may be formed into a jar with mating threads and a lid with mating threads. The primary metal material may optionally be finished. A liner may optionally be inserted. The lid and jar are then assembled, and a plastic cup may optionally be installed.

DETAILED DESCRIPTION

The present disclosure is related to jars and containers and, more particularly, to the manufacture of readily recyclable jars and containers.

Currently, standard construction for jars for consumer products for household use, e.g. makeup jars for creams, powders and emulsion-type products, have a PET plastic or a glass bottom jar portion and a screw-on plastic lid, or a plastic lid with metal shroud. In order to recycle these commonly used jars, the consumer must unscrew the jar and can sometimes place the jar in a PET or glass bin in order for the jar to be recycled, but the lid remains difficult to recycle.

FIG.1illustrates a jar100that is easily recyclable, according to one or more embodiments of the present disclosure. In the illustrated example, the illustrated jar100is cylindrically shaped. However, the jar100may have other geometries without departing from the present disclosure.

The jar100includes a lid assembly102and a jar assembly104(or base assembly104). The lid assembly102may be fastened or secured to the jar assembly104. However, the lid assembly102may be detached from the jar assembly104to access an internal cavity500(FIG.5) of the jar100. Thus, as described below, the lid assembly102attaches to the jar assembly104via an attachment means (e.g., mating threads). The attachment means permits a user to selective attach or detach the lid assembly102from the jar assembly104. However, as illustrated, the attachment means are hidden from view when the lid assembly102is assembled on the jar assembly104, which provides the jar100an aesthetically pleasing appearance.

FIG.2illustrates a cross sectional view of the jar100ofFIG.1. In the illustrated example, the lid assembly102and the jar assembly104are each a two-piece design. Thus, the lid assembly102includes an inner cap202aand an outer cap202b, and the jar assembly104includes an inner cup204aand an outer cup204b. Also, as mentioned above, the lid assembly102and the jar assembly104may be attachable via mating threads. Thus, in the illustrated example, the mating threads are provided on an inner diameter of the lid assembly102and on a corresponding outer diameter of the jar assembly104over which the lid assembly102is disposed. In this manner, the threads are hidden from view when lid assembly102and the jar assembly104are assembled together.

FIG.3illustrates a cross sectional view of the jar100ofFIG.1when unassembled. As illustrated, a thread302is provided in the inner diameter of the lid assembly102and a corresponding thread304is provided on the outer diameter of the jar assembly104. Here, the thread302is provided on the inner cap202a, winding around an interior sidewall thereof, and covered by the outer cap202bsuch that the thread302is not visible unless viewing an internal cavity of the lid assembly102when unattached from the jar assembly104. Also, the corresponding thread304of the jar assembly104is provided on the outer cup204b, winding around an outer sidewall thereof, to mesh with the thread302of the lid assembly102. The corresponding thread304of the jar assembly104is thus visible and exposed when the jar100is unassembled, but hidden from view when assembled with the lid assembly102is secured over the jar assembly104. In some embodiments, the jar100may include a secondary closure mechanism in addition to, or instead of, the corresponding threads302,304, for example, a magnetic closure and or interference fit closure for securing the lid assembly102and the jar assembly104together.

The jar100may be made entirely (or predominantly) from a metallic material; however, non-metallic materials may be utilized. In some examples, the lid assembly102and the jar assembly204are made of the same material, whereas in other examples, they are made from one or more dissimilar materials. In one example, the inner cap202aand the outer cap202bof the lid assembly102and the inner cup204aand the outer cup204bof the jar assembly104are all comprised of aluminum. Fabricating the jar100from (predominantly) the same metallic material will improve its recyclability. Also, fabricating the jar100from predominantly a metallic material provides it with a premium metallic appearance, thereby further enhancing its ability to be utilized in applications where aesthetics are desirable.

The jar100may also have some nonmetallic components (e.g., plastic components) and still be recyclable. For example, either or both of the inner cap202aand/or the inner cup204aof the lid assembly102and the jar assembly104, respectively, may be made from a plastic material. In examples where the jar100includes one or more plastic components, such plastic components may be installed in a manner permitting the end user to easily remove it before disposal, to enhance recyclability of the jar100. For example, the inner cup204aof the jar assembly104may be a plastic liner that is press fit within the outer cup204bin a manner permitting the end user to easily remove it from the outer cup204bbefore disposing of the jar assembly104. In some examples, the jar100includes one or more plastic components that need not be removed prior to disposal as such plastic components will be burned up in the metal recycling process. In some examples, the lid assembly102includes a gasket to help form a seal when attached on the jar assembly104. The gasket may be provided on either or both of the lid assembly102and the jar assembly104to form a seal there-between. In some examples, an additional liner is provided within the inner cap202aand/or inner cup204a, such as a polymeric liner or removable and replaceable liner; and in some examples, a series of liners may be so provided such that they are serially removed after each use to provide a clean surface for a subsequent use.

A coating may be applied to the lid assembly102and/or the jar assembly104. Various types of coating may be utilized, for example, a polymeric coating and/or a ceramic spray, and such coatings may be applied after assembly of the jar100or pre-coated materials may be utilized to manufacture the jar100. In some examples, a coating is applied to interior surfaces602,604(FIG.6) of the inner cap202aand/or the inner cup204aof the lid assembly102and the jar assembly104, respectively. For example, the inner cap202aand the inner cup204amay be made from aluminum and a polymeric coating applied to their interior surfaces602,604defining the interior cavity of the jar100. Here, the polymeric coating may be applied after assembly of the jar100or pre-coated components may be utilized to form the inner cap202aand the inner cup204a. The coating may be an FDA-approved polymeric coating, e.g., epoxy powdercoat.

Where metallic materials are utilized to form the jar100, they may be anodized, for example, external surfaces502,504(FIG.5) of the lid assembly102and the jar assembly104. Thus, the external surfaces502,504of the outer cap202band the outer cup204bmay be anodized. This will provide an aesthetically pleasing and premium appearance. Also, the internal surfaces602,604of the jar100defining the internal cavity500may be anodized, or at least some portion of either or both of the internal surfaces502,504of the jar100defining the internal cavity500may be anodized. For example, the internal surfaces602,604of the inner cap202aand the inner cup204amay be anodized regardless of whether the external surfaces502,504are anodized. Also, at least some portion of either or both of the external surfaces502,504of the jar100defining the internal cavity500may be anodized

Various techniques may be utilized to form the inner cap202aand the outer cap202bof the lid assembly102and the inner cup204aand the outer cup204bof the jar assembly104. For example, any or all may be formed via a deep drawing, impact extrusion, roll forming, eyelet stamping etc.

FIGS.4A-4Cillustrate a flowchart of an exemplary process that may be utilized to manufacture the jar100.

As shown inFIG.4A, the manufacturing process begins with providing a primary material, or selecting a primary material. The primary material may be aluminum or aluminum alloys, e.g.,5657,5005,5052,5182,3004,7075,3005,8052, and others known to one skilled in the art; steel, such as pre-coated tin plate, stainless steel or galvanized steel; titanium, or other metal materials adjudged suitable for use by one skilled in the art.

Optionally, the primary metal material may be pre-coated, such a by pre-coating the aluminum alloy, pre-anodizing the metal, or plating. Accordingly, the manufacturing process may include an optional step of precoating the selected material. In some embodiments, the selected material has no precoating. However, Aluminum alloys may be pre-coated with an inorganic barrier-type corrosion inhibitor, e.g., a composition comprising clay particles. In some embodiments, the selected material is pre-anodized. Pre-anodizing the material involves an electrochemical process that converts the metal surface into a decorative, durable, corrosion-resistant, anodic oxide finish. A typical chemical treatment process may involve removing dirt and oils, such as by treatment with an inhibited acid or alkaline cleaner, deoxidizing the material in strong acidic solution to remove natural oxides or heat-treat scale, and chemical etching or brightening. Strong acids or bases may be used to etch the material in order to provide a uniform, matte finish. Brightening, also known as micro-leveling or micro-smoothing, may be achieved by either chemical or electrochemical means, as would be known by one skilled in the art. Alternatively, the selected material may be plated, such as to increase corrosion protection, provide greater wear resistance or to enhance the appearance of a product. Electroplating or an autocatalytic reaction may be used. The plating material may be any commonly known in the art, such as zinc, tin, magnesium, silicon or other metals or metalloids.

Thereafter, the manufacturing process includes a metal forming step. The metal is formed to make the jar assembly and lid assembly, such as by deep draw, impact extrusion, roll forming or eyelet stamping. Deep drawing involves a hydraulic or mechanical press pushing the metal sheet via an appropriately shaped punch into a matching die. Impact extrusion utilizes a punch to press a slug at high velocity and force into the appropriately shaped die or mold. Roll forming passes the metal through a continuous bending operation to bend the metal into the desired shape of a jar assembly or lid.

FIG.4Bis a continuation of an exemplary manufacturing process, and it includes an optional step of metal finishing. The metal may be finished via anodizing, plating, physical vapor deposition (PVD), micro arc oxidation, and/or thermal plasma spray.

The jar assembly and lid assembly may optionally comprise a liner material and/or sealing material, by way of non-limiting examples a gasket, foam liner, or overmolded gasket. According, the manufacturing process may further include an optional step of providing a liner and/or seal.

The manufacturing process then includes the step of assembling the lid assembly. The assembly of the lid assembly, or the combining of the inner cap with the outer cap, may be carried out by means of adhesive bonding, mechanical bonding, welded bonding, or other methods known to one skilled in the art.

FIG.4Cfurther continues the depiction of an exemplary manufacturing process. As shown, the manufacturing process further includes the step of assembling the jar assembly, and this step may be performed before, after, or simultaneously with the step of assembling the lid assembly. The step of assembling the jar assembly be carried out by means of adhesive bonding, mechanical bonding, welded bond, or other methods known to one skilled in the art.

Following the step of assembling the jar assembly, the manufacturing process may include an optional step of installing a cup within the jar assembly. For example, a plastic cup may be installed within the jar assembly. In the illustrated example, the step of installing a cup is provided a final step; however, in other non-illustrated steps, the jar may be further subject to final decorating or design steps, including painting, etching, branding, adding graphics or decals, or providing other indicia as may be desirable for the final end use application.

FIG.5shows the result of the exemplary manufacturing process, namely a perspective view of a jar formed via this process with the lid assembly elevated over the jar assembly.FIG.6is a sectional side view of the jar ofFIG.5.

FIG.7depicts the jar assembly and lid assembly with the inner cup and inner cap separated from the outer cap and base of the jar.FIG.8depicts a sectional side view of the jar ofFIG.5.

FIG.9depicts the jar assembly and lid assembly with the outer cap and base in a cross-section along a midline of the cylindrical jar. The inner cup and inner cap are not sectioned, but are instead complete, thus depicting out the inner portions look absent the outer portions of the lid assembly and jar assembly.

FIG.10is a sectional side view of a jar of the present disclosure with the lid assembly elevated over the jar assembly. Finally,FIG.11depicts an exploded view, with the inner caps202a,204aremoved from the outer portions204a,204bof the jar assembly104and lid assembly102.

This invention has been described with reference to illustrative embodiments, and is not meant to be construed in a limiting sense. It will be apparent to one skilled in the art that elements or process steps from one or more embodiments described herein may be used in combination with elements or process steps from one or more other embodiments described herein, and that the present invention is not limited to the specific embodiments provided herein but only as set forth in the accompanying claims. Various modifications of the illustrative embodiments, as well as additional embodiments to the invention, will be apparent to persons skilled in the art upon reference to this description