Recyclable composite container

A recyclable composite container is provided. The recyclable composite container comprises a cardboard hollow body having an open end defining an opening, the body being formed by a sidewall having inner and outer surfaces, the sidewall being provided with an aperture at a distance from the open end. The recyclable composite container also comprises a framing element removably connectable to the open end having a collar sized and shaped for snugly fitting over said open end; and a resilient arm extending from the collar, the arm extending along the inner surface of the sidewall and having a projection sized and shaped to be removably fitted in the aperture of the sidewall of the hollow body. This construction allows connection of the framing element to the cardboard hollow body by fitting the projection of the resilient arm in the aperture of the hollow body, and disconnection of the framing element from the cardboard hollow body by pressing the projection to disengage the projection from the aperture and by pulling the framing element away from the cardboard hollow body.

FIELD OF THE INVENTION

The present invention generally relates to packaging and more particularly relates to a composite container system which can be disassembled and the components thereof recycled.

BACKGROUND

Packaging, such as box-shaped containers, are normally made entirely from a single material such as metal, plastic, wood or cardboard. Also known are composite containers made from combinations of either metal and plastic or metal and cardboard. When an impervious or leak-proof container is required for substances such as paint, toxic or harmful chemical products and the like, which may include volatile or other chemically active components, the containers are generally made entirely of a single material such as metal or plastic because these materials enable the containers to be made both leak-proof and structurally rigid.

The known composite containers typically comprise cardboard tubes closed at either end with metal end framing structures. The peripheral edges of these end framing structures are typically joined to the cardboard tube by a crimping or seaming process wherein the edge of the end framing structure is bent around one of the cylinder's extremities, thereby permanently deforming and connecting both the end framing structure and the cylinder's extremity. The crimping can also retain a metallised liner which is provided along the interior surface of the cardboard cylinder.

U.S. Pat. No. 4,312,459 describes a paint can rim cover and a lid, the rim cover being used to prevent paint from drying within the groove of the rim of a paint can of well-known construction. A typical paint can is formed of a cardboard cylinder having its upper end, which is outwardly rolled, and a metallic rim rolled and crimped around the outwardly rolled end of the cardboard cylinder. The connection between the cardboard cylinder and the metallic rim is made so as to be permanent. The plastic rim cover of the invention is destined to cooperate with the metallic rim of the paint can and has a lip which cooperates with the bead of the metallic rim.

Also known to the Applicant is document U.S. Pat. No. 3,792,797, describing a cover-closure for containers with a relatively large opening. The annular rim of the container is provided with alternating locking cams and depressions, and the cover is provided with corresponding cut-outs and cover-segments. When the cover is secured to the container, the cover-segments grip the depressions of the container, and the cut-outs are aligned with the locking cams. A band-shaped tensioning ring is used to tension the cover-segments in place, thus securing the cover over the container.

U.S. Pat. No. 3,913,774 describes a container having a tubular central section forming sides and rigid end caps in positive engagement. The sides have perforations near the rims and the rigid end caps have engaging means consisting of a first portion for inserting the perforations and a second portion for preventing the disengagement of the perforations for the first portion.

U.S. Pat. No. 7,581,671 describes a shipping container of the type that is often used to ship large format papers and photos. The shipping container includes a paper tube and an end cap. The paper tube is provided with a mounting opening and the cap with a projection which can extend into the opening when the cap is pressed into the open end of the tube. The cap can be removed from the container by rotating the end cap relative to the tube.

A drawback of some of the prior composite containers is that, once assembled, these containers cannot be easily disassembled, making recycling of their various components very difficult. As for containers which can be easily disassembled, the connection of the cap with the body of the container is in most cases not strong enough to resist shocks and the frequent handling of the container.

It would therefore be desirable to provide a composite container system which can overcome this disadvantage.

It would also be desirable to provide a container system which can be dissembled and then recycled, at least partly, and that would also be versatile, lightweight, inexpensive and/or easily manufactured.

SUMMARY OF THE INVENTION

In accordance with the present invention, a recyclable composite container is provided. The recyclable composite container comprises a cardboard hollow body having an open end defining an opening. The body is formed by a sidewall having inner and outer surfaces, and the sidewall is provided with an aperture at distance from the open end. The container also comprises a framing element removably connectable to the open end. The framing element has a collar sized and shaped for snugly fitting over the open end, and a resilient arm extending from the collar. The arm is for extending along the inner surface of the sidewall and has a projection sized and shaped to be removably fitted in the aperture of the sidewall of the hollow body. The connection of the framing element to the cardboard hollow body is allowed by fitting the projection of the resilient arm into the aperture of the hollow body, and the disconnection of the framing element from the cardboard hollow body is allowed by pressing the projection to disengage the projection from the aperture and by pulling the framing element away from the cardboard hollow body.

By composite container, it is meant the container is made of different parts and/or different materials.

By framing element, it is meant an element substantially rigid to provide rigidity and structure to the cardboard hollow body.

The expression “removably connectable” refers to the framing element rather than to a lid, and is intended to mean that when applying a predetermined amount of pressing force on the projections of the framing element, the framing element can be disengaged from the cardboard body.

DESCRIPTION OF PREFERRED EMBODIMENTS

In the following description, similar features in the drawings have been given similar reference numerals. In order to preserve clarity, certain elements may not be identified in some figures if they are already identified in a previous figure. It will be appreciated that positional descriptions such as “top”, “bottom” and the like should, unless otherwise indicated, be taken in the context of the figures and should not be considered limiting.

With reference toFIGS. 1, 1A and 1B, a recyclable composite container10is shown. The container10includes a framing element14and a cardboard hollow body12. The cardboard hollow body12, which in this case has a cylindrical shape though is not necessarily limited to such a shape, is provided with an open end16, which defines an opening18. The cardboard body12is formed by a sidewall20having inner and outer surfaces22,24. The sidewall20is provided with at least one aperture26at distance from the open end16. In this variant of the container10, the cardboard hollow body12is provided with three apertures26. While the hollow body12is shown here with a tubular shape, the hollow body may have any shape of cross-section such as circular, rectangular, square, triangular, or oval.

The framing element14reinforces the open end16of the cardboard body12, and is removably connectable to it. By “removably connectable”, it is meant that the framing element can be connected and disconnected from the body12. The framing element14has a collar28size and shape for snuggly fitting over the open end16of the body12(best shown inFIG. 1B), and at least one resilient arm30which extends from the collar. The arm30extends downward of the lower periphery of the collar28, providing the arm30with flexibility and resiliency required to be pressed in and out of the aperture26. It also allows the collar28to be kept narrow at the open end16of the body12. In this embodiment, the framing element14is provided with three resilient arms30, only two being visible inFIG. 1. Best shown inFIG. 1B, each of the arms30extends along the inner surface22of the sidewall20of the cardboard hollow body12. The arm30is provided with a projection32which is sized and shaped to be removably fitted in the corresponding aperture26of the sidewall20of the cardboard hollow body12. The projection32extends radially outward from the arm30, that is, it projects on the outer surface24of the cardboard body12when the container10is assembled. As it can be appreciated, the size of the projection32and aperture26closely match, allowing the projection32to be retained by friction into the aperture26, preferably on the entire side edge of the projection32. It is also possible, to form the projection32with a size slightly larger than the size of the aperture26, such that the projection32compresses the portion of the cardboard bounding the aperture26, creating a stronger connection between the framing element14and the body12. When assembled, the outer face of the projection32is preferably flush with the outer surface24of the cardboard cylinder12.

As shown inFIGS. 1 and 1A, a bottom cap or cover15is used to close off the bottom opening of the cardboard hollow body12.

As it can be appreciated, the connection of the framing element14to the cardboard hollow body12is made by fitting the projections32of the resilient arms30in the apertures26of the hollow body12. When the container10is empty, the framing element14is preferably disconnected from the cardboard hollow body12by pressing the projections32so as to disengage the projections32from the corresponding apertures26, and by then pulling the framing element14away from the cardboard hollow body12. The pressing force is applied radially on the projection, inwardly, or in other words, towards the inside of the container10. This pressure can be applied manually, by pressing fingers on the projections. The framing element14, for example being made of plastic or metal, and the hollow body12, made of cardboard, can thus be recycled or re-used. Of course, the bottom cap15would also need to be pulled off the bottom opening. The entire composite container10can thus be completely recycled by disassembling the framing element14and cover15from the cardboard hollow body12. This particular construction of the container10allows a connection of its main components which is sturdy enough for general use and yet simple to disassemble, so as to facilitate the recycling of the materials forming the container10.

Of course, the framing element14could include a different number of resilient arms30extending along the collar28, and the cardboard hollow body12could have an equal number of apertures26. In other words, container can be provided with a plurality of resilient arms and apertures, each of the resilient arms fitting in a corresponding one of the apertures when the framing element is connected to the cardboard hollow body.

Now referring toFIGS. 2A to 2D, the framing element14ofFIG. 1will be described more in detail. As shown inFIG. 2D, the collar28has a U-shaped cross-section comprising parallel inner and outer walls34,36which are for clamping the open end of the cardboard hollow body on both its inner and outer surfaces when the framing element14is connected to the cardboard hollow body. The framing element14is also provided with a cover wall38which is integral to the collar33. The cover wall38is perforated with holes40to allow a substance contained within the container, such as powder for example, to be poured or expelled out of the container. Of course, the cover wall38can also not include these holes40, for example as when the objective is to simply close off the container. The protrusions32have a tapered section at the bottom side, that is, they are narrower in their lower portion, to ease the insertion and removal of the protrusions32from the corresponding apertures.

Now referring toFIGS. 3A and 3B, a second variant of a framing element14is shown. In this variant, a portion of the resilient arm30surrounds the protrusion32, allowing the arm30to provide a more sturdy and robust connection of the framing element14to the body when fitted over the open end. With this particular configuration, the peripheral portion33of the resilient arm30surrounding the protrusion32will conform, or contact the inner surface of the cardboard hollow body when the framing element14is connected to the body, reinforcing the connection of these two elements.

With reference toFIGS. 4A and 4B, a third variant of a framing element14is shown, where in this case, the cover wall38is provided with a recess37, providing the framing element14with improved resistance to shocks which may occur during general use of the container10or handling thereof.

Turning now toFIGS. 5A to 5D, a second preferred embodiment of the recyclable composite container10is shown. The recyclable composite container10includes a cardboard hollow body12and a framing element14, and also includes a bag42, an additional framing element44and a lid46. The bag42may be desirable in order to protect the contents of the container10from humidity and/or to prevent odours from escaping the container10. Moreover, the bag42can advantageously be used to protect the cardboard cylinder12, whose main role is to provide structure to the container10. The presence of the bag42will therefore prevent the cardboard cylinder12from being damaged when the contents of the container10are, for example, liquids. For embodiments where a liquid should be contained within a metallic surface, a metalized bag comprising an interior metallic layer can be used, as is known in the art.

When assembled, such as shown inFIG. 5B, the cover15closes off the bottom opening of the cardboard hollow body12. The framing element14, the additional framing element44and the lid46close off the top opening of the body12. Just as explained for the previous embodiment, during assembly of the container10, the framing element14is first aligned with the top of the cardboard body12. The former is then pushed into the latter until its top end16is received within the collar portion28and each projection32is received in its corresponding aperture26. The arms30are resilient enough to allow the slight deformation needed and deflect so as not to damage the cardboard body12. The arm30extends along the inner surface22of the cardboard body12, resulting in the projection32pointing radially outwards.

Once the framing element14is fitted over the cardboard body12, an impervious bag42is placed in the cardboard tube12for lining its inner surface22. Best shown inFIG. 5C, the bag42has an open end43, which is clampable between the framing element14and the U-shaped snapping collar48of the additional framing element44. Best shown inFIGS. 5C and 5D, the bag42is preferably folded around the framing element14, so as to improve the imperviousness of the container.

The closed end of the bag42can be fixed to a bottom end framing structure or can simply be left loose, extending downwards within the cylinder12. As such, whatever is stored within the container10is sealed within the walls of the bag42, the framing elements14,44, and the lid46. In addition, it will be appreciated that even if the bag42is loose, a desirable vacuum may be created between the bag42and the cylinder12as the container10is assembled and filled. This vacuum will naturally serve to keep the bag42tight against the inside of the cylinder12even as it is emptied.

Alternatively, a longer bag42can be provided which extends not just within the cylinder, but along the outer surface of the cylinder as well. Rather than being clamped between the framing elements14,44at the open end16, the bag42can be clamped at its midpoint. The remainder of the bag, i.e. the portion between its midpoint and open end43, passes back along the outer surface24, preferably fitting tightly therearound. The open end43is then clamped a second time with lower end framing element14or cover15. Such a bag42would therefore be able to both contain a liquid within the container10and provide protection for the exterior of the cardboard cylinder12. The portion of the bag42which extends outside the cylinder12could be heat-shrunk in order to ensure the tightness of the bag42around the outer surface24.

Best shown inFIGS. 5C and 5D, the additional framing element44comprises a U-shaped snapping collar48, which is for snapping over the collar28of the framing element14, when the framing element14is connected to the body12. Of course, the U-shaped snapping collar48is sized and shaped such as to snuggly fit over the framing element44.

Preferably, the additional framing element44is provided with a lid receiving flange52and a lid46, which is connectable to the flange52.

Now referring toFIGS. 6A to 6D, the framing element14ofFIG. 5Awill be described in more detail. The framing element14has a peripheral wall35for resting on the end surface of the sidewall of the cardboard hollow body. The inner wall34extends transversally from the peripheral wall35, and hugs the inner surface of the sidewall of the cardboard body when the framing element14is connected to it. The resilient arms30extend from the inner wall34. Preferably, the peripheral wall35is provided with notches39which are aligned with the resilient arms30, to facilitate the molding of the part. The peripheral wall35and inner wall34are part of the collar28of the framing element14. Best shown inFIG. 6D, the collar28has an L-shaped cross-section, and the dimensions of the inner portion of the peripheral wall35correspond substantially to the width of the sidewall of the cardboard hollow body.

Referring toFIGS. 7A to 7D, the additional framing element44ofFIG. 5Ais shown. The framing element44includes the U-shaped snapping collar48, having parallel inner and outer walls53,54, and locking flanges50, which in this case are provided on the inner wall53of the additional framing element44. As best shown inFIG. 5D, these locking flanges50are interlockable with the collar28of the framing element14. The locking flanges50are outwardly curved, so as to snap or interlock underneath the inner wall34of the framing element14.

With reference toFIG. 5D, and also toFIG. 7D, the outer wall54of the framing element44may also be provided with a locking rim or flange51, which is also for interlocking or snapping to the collar of the framing element28, and more specifically for interlocking with the underside of the peripheral wall35of the framing element14.

Also, the lid receiving flange52extends from the collar48of this additional framing element44, and receives the lid46, which is illustrated inFIGS. 8A to 8D.

Now referring toFIGS. 9A to 9D, a third embodiment of the recyclable composite container10is shown. This embodiment of the container10also comprises a cardboard hollow body12with apertures26, the apertures26in this case having a rectangular shape. A framing element14is provided with resilient arms30, from which rectangular projections32protrude radially outward for fitting into the corresponding apertures26. An impervious bag42is used to line the inner surface22of the cardboard hollow body12, and an additional framing element44snaps to the framing element14, thereby clamping the bag42between the two. The additional framing element44can also include a lid46to close off the container10. In this embodiment of the container10, another framing element14is used to close off the bottom open end16of the cardboard hollow body12. As such, apertures26are provided on both sides of the body12, the lower framing element14removably closing off the container10while the upper framing elements14and44, and lid46removably close the container10.

As shown inFIGS. 9C and 9D, and also inFIGS. 10A to 10D, this variant of the framing element14is provided with locking lips58on the protrusion32, for engaging with the outer surface of the sidewall20bounding the aperture26, when the projection32is fitted in it, allowing to reversibly lock the projection32within the aperture26. Of course, different shapes of locking lips can be considered. The locking lip58advantageously provides a stronger connection of the framing element14with the cardboard body12. While inFIGS. 10A and 10Dthe resilient arms30are shown shorter than in the other variants, they are still flexible enough to allow the projections32to be pressed in or out of their corresponding apertures26. Of course, due to the nature of the cardboard12, the area surrounding the aperture26can be slightly deformed when the protrusions32are pressed in or out, such as to allow engagement or disengagement of the protrusions32manually, that is by pressing with fingers projections32from within their apertures26. This type of container configuration is devised to be assembled in the factory, when a substance is poured in the container, and dissembled when the end user has emptied the container and wants to recycle its components. Of course, in the case of paint containers for example, the containers can be brought in batches to a depot, where workers would disassemble the parts to sort and recycle them. The bags, depending on the type of substance it contained, can also be recycled.

Referring toFIGS. 11A to 11D, and also toFIGS. 9B and 9C, in this second variant of the additional framing element44, the outer wall54of the U-shaped snapping collar48is provided with indentations56, which are complementary to the projections32of the resilient arms30. As shown inFIGS. 9B and 9C, the outer wall54extends at least up to the projection32, the projection32being aligned with the indentation56when the framing element14is connected to the cardboard hollow body12, and when the U-shaped snapping collar48of the additional framing element44is snapped on the framing element14. As it can be appreciated, the U-shaped snapping collar48of this variant of the additional framing element44conceals the projection32within its outer wall54. Of course, while in this variant, where the indentation56is flush with the projection32, it is possible to have the outer wall54extend lower than the indentation56, the indentation56in this case taking the form of a hole for providing access to the protrusion32.

Referring toFIGS. 9C and 11B, the inner wall of the additional framing element53is also provided with notches60provided in the locking flange50so as to allow passage of the resilient arm30when the additional framing element44is snapped over the framing element14. It should also be noted that in the variant of the additional framing element44shown inFIG. 11B, the locking flange50extends continuously along the inner wall53.

Now referring toFIGS. 12A to 12B, the bottom framing element14of the container10ofFIG. 9Ais shown. This variant of the framing element14includes a plurality of resilient arms30which are distributed along the collar28, and is closed by a cover wall38.

Referring toFIGS. 13A to 13D, a fourth preferred embodiment of a recyclable composite container10is shown. In this case, such container10can be used for containing substance such as silicone or acrylic caulking. The open end16of the bag42is placed at the bottom of the cardboard hollow body12such that the closed end is located towards the framing element14and is pierced right before use, as commonly known in the art, so as to allow the substance contained within the bag42to be expelled through the spout64. The bag42is provided with a rim66, and a bottom cover cap15closes off the bag42by clamping the bag42between said cover15and the bottom open end16of the cardboard hollow body12. The upper side of the cardboard hollow body12is provided with two apertures26(only one being shown inFIG. 13A) sized and placed to receive the corresponding projections32of the resilient arms30of the framing element14. A spout64can be screwed on the framing element14.

The framing element14ofFIG. 13Ais shown in greater detail inFIGS. 14A to 14D. The resilient arms30are preferably outwardly curved, allowing, when in use, to bias the projections32within the apertures26of the framing element14when connected to the cardboard hollow body12. It is also possible to have the resilient arms30be straight such as shown inFIGS. 15A and 15B. In either one of the variants shown inFIGS. 14A to 15B, the resilient arms30are longer than in previous variants, and they can extend on a longer portion of the inner surface22of the body12.

Finally, with reference toFIGS. 16A and 16B, the bottom cover or cap15of the container ofFIG. 13Ais shown in greater detail, where it can be seen that the peripheral wall is provided with teeth68and inner flanges70for clamping both the bag42and the bottom portion of the sidewall20of the cardboard hollow body12when in use.

In sharp contrast with existing containers, both composite and not, it will be appreciated that a container system in accordance with the present invention advantageously requires no crimping, seaming, bonding or other permanent joining. The hollow body12can be connected to the framing element14via engagement of the aperture(s)26and the arm(s)30alone. As such, the container system can be easily disassembled after use. It will be appreciated that this ability to be disassembled advantageously enables the individual components (at least the hollow body12and the end framing elements14,44, and the bag42if present) to be separated and reused or recycled as appropriate. If the container system were filled with a non-recyclable substance such as paint, the plastic bag liner can be thrown out. The remainder, including the cardboard hollow body, would nonetheless be recyclable and/or reusable.

It will be appreciated that a container system in accordance with the present invention advantageously enables considerable weight savings compared to equivalently sized all-metal or all-plastic containers—up to 30% for an all-metal container. In addition, the present container system also enables considerable costs savings compared to conventional cardboard composite containers.

Although preferred embodiments of the present invention have been described in detail herein and illustrated in the accompanying drawings, it is to be understood that the invention is not limited to these precise embodiments and that various changes and modifications may be effected therein without departing from the scope of the present invention.