Scent permeation container seal, container including said seal and methods of making said seal and said container

A seal for containers is provided that allows the scent or aroma from the substance within the container to come through, while preventing leakage of the substance from within the container and/or physical contact of the substance by the consumer. More particularly, a seal is provided having at least one slit scoring fewer than all of the layers of the seal. The slit(s) will allow a consumer to sniff the scent or aroma released through the slit, while the seal remains secured to the container, extending shelf life of the substance, and preventing leakage, as well as, contamination, damage and/or reduced volume caused by consumers sampling the products.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a seal for a container and, more particularly, to a seal for a container holding a cream, gel, powder, liquid, solid or other substance that allows the aroma or scent of the substance in the container to permeate the seal while maintaining the barrier properties of the seal and preventing leakage of the substance within the container.

Description of the Related Art

Seals have been commonly used on containers for many years, to prevent leakage or contamination of the substance within the container and to increase the shelf life of the product. For example, seals are used on containers containing cosmetics, foods, drinks, medicines and other items in the form of creams, gels, powders, liquids and other substances. Seals used for this purpose are typically placed over the opening on the container or, in some instances, within the cap on the container.

However, consumers often want to smell items having a fragrance or aroma, such as lotions, creams, body washes, shampoos, deodorants, perfumes, laundry detergents, air fresheners, coffee and spices, before purchasing the items. As a result, many products are sold today without seals because there is no commercially viable seal on the market today that allows consumers to smell the scent of the product within the container. Specifically, prior art seals are essentially hermetic seals intended to prevent leakage of the product from the container and to limit air flow into and out of the container to preserve the product and maximize the product's shelf life. In so doing, they trap the scent or aroma of the product within the container.

By limiting air flow into and out of the container, these prior art hermetic seals also often result in pressure build-up within the container that may cause the container to expand and collapse based on changes in the surrounding environmental conditions. Although venting seals have been developed to address the pressure build-up problem, these venting seals were not designed for scent permeation purposes and, therefore do not provide the ability to smell the scent of the product in a cost effective manner. As a result, scented products are often sold in containers without seals, so that consumers can remove the cap and smell the scent prior to purchase. The fact that many scented products are still sold in containers without seals today is evidence that the prior art seals do not allow adequate scent permeation in a cost effective manner.

The absence of a seal increases the possibility of spillage during transportation and the chances that a product may be tampered with or tainted prior to sale to the consumer. It is not uncommon for consumers to go beyond simply removing the cap and smelling the item, by actually applying some of the product onto their body to sample the product and its fragrance. In so doing, the consumer may stick their fingers into the substance or on the opening where the substance comes out. Oftentimes, after sampling the product, the consumer closes the cap and returns the container to the shelf in the store.

This sampling of the product causes several problems. From the consumer's perspective, by placing their fingers into the substance and/or coming in contact with the opening where the substance comes out, the sampler may be contaminating the substance and spreading germs/bacteria. Additionally, each time a consumer samples the product and then returns it to the shelf, the volume of the substance within the container decreases. As a result, the consumer that eventually purchases the product is unknowingly purchasing less than a full container of a product that may have been contaminated and/or contain germs/bacteria.

From the retailer's perspective, consumers that sample products and then return them to the shelf sometimes do not place the cap on tightly, which may result in spillage if the container is tilted or falls on its side. Additionally, the shelf life of the substance within the container may be reduced or altered by the absence of a seal on the container or having been opened and exposed to the surrounding environmental conditions by a sampling consumer prior to sale. Also, the absence of a seal on a container may result in the substance contacting and/or accumulating within the cap on the container, which may cause spillage when the cap is removed and a less appealing presentation to the consumer. These situations may result in the retailer being unable to sell the product or generating product returns or charge-backs, which may have an adverse effect on the retailer's, product manufacturer's or distributor's reputation and financial performance. Additionally, the retailer, manufacturer and/or distributor may incur liability if a consumer is harmed by the contaminated product.

There have been some attempts over the years to address this problem. More particularly, some venting and/or scent emitting seals have been made wherein a one piece, multi-layer induction seal is completely perforated and an additional membrane (not part of an induction seal) is bonded over the perforation. Specifically, one product utilizes a polytetrafluoroethylene (ePTFE) membrane in a section of the liner to allow air to enter and exit the container for venting purposes, while preventing leakage of the substance from within the container. One such induction liner is made by PERFORMANCE SYSTEMATIX INC. However, this product has not proved to be a commercially viable solution because it requires a complex manufacturing process to embed the ePTFE membrane within a cutout section of the liner, the cost of which is significantly greater than the cost to manufacture a conventional seal. It also does not provide the barrier properties provided by conventional seals that are required to restrict air flow into and out of the container, which adversely affects the shelf life of some products. Again, the fact that many scented products are still sold in containers without seals today is evidence that the prior art seals do not provide the combination of scent permeation, leak prevention and barrier property characteristics, in a cost effective manner, desired by product manufacturers today.

Accordingly, there is a need in the art for a seal for containers that allows the scent or aroma from the substance within the container to come through, while preventing leakage of the substance and maintaining the barrier properties necessary to maximize the shelf life of the product. What is further needed is an induction seal that accomplishes the foregoing purpose, without the need for adding additional membranes or materials to the induction seal. Any such seal should be capable of use with any type of container and any type of substance stored within the container. Such a seal should also be capable of being manufactured at a cost comparable to the cost of current conventional seals. The present invention is particularly suited to overcome those problems which remain in the art in a manner not previously known.

SUMMARY OF THE INVENTION

The present invention is directed towards a seal for containers that allows the scent or aroma from the substance within the container to come through, while preventing leakage of the substance within the container and physical contact with the underlying substance by the consumer and maintaining the barrier properties necessary to maximize the shelf life of the product.

In one particular embodiment of the invention, a one piece, multi-layer induction seal having at least one slit extending through at least one layer of the multi-layer induction seal. The at least one slit will allow a consumer to sniff the scent or aroma emitted through the slit(s), while the seal remains secured to the container, thereby providing a tamper evident seal that provides barrier properties and prevents leakage, as well as, contamination, damage and/or reduced volume caused by consumers sampling the products.

Other features, which are considered as characteristic for the invention, are set forth in the drawings and the appended claims.

Although the invention is illustrated and described herein as embodied in a scent permeation container seal, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.

The construction of the invention, together with additional objects and advantages thereof, will be best understood from the following description of the specific embodiments when read in connection with the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now toFIG. 1-5, there will be described a scent or aroma releasing seal10,10′ in accordance with certain particular embodiments of the present invention. The seal10,10′ are structured to be secured to a container20over its mouth or opening22. In accordance with the principles of the present invention, the seal10,10′ may be used on containers20containing foods, beverages, pharmaceuticals, nutraceuticals, cosmetics, confectionery, household products, air care and other items in the form of creams, gels, powders, liquids or solids, and other substances, so as to permit the scent or aroma of the product to be released through the seal, without providing direct access to the product. Note that, for the purposes of the present application, the terms “scent” and “aroma” are used interchangeably.

In one particular embodiment of the invention, the seal10,10′ is generally circular and may include one or more tabs18around the circumferential edge thereof. Note that this is not meant to be limiting, as no tabs18may be included (seeFIGS. 1-3) and/or other shapes of seal10,10′ may be used. For example, an oval or rectangular seal10,10′ may be provided to seal an oblong or rectangular opening or mouth22, without departing from the scope or spirit of the present invention.

The seal10,10′ is affixed to the mouth22of the container20, but can be peeled off to access the contents of the container20. In one particular embodiment, the seal10,10′ is sealed over the mouth22of the container20and can be peeled off using a fingernail or, in embodiments having a tab18, by grasping a tab18between the thumb and forefinger to facilitate removal of the seal10,10′ from the mouth22of the container20.

Additionally, in accordance with the present invention, it is desired that the seal10,10′ include at least one slit12for permitting the scent or aroma of the product contained within the container20to pass through the seal10,10′ without breaking the bond between the seal10,10′ and the circumferential edge of the mouth22.

Through the user of scent permeating seals having at least one slit12, the scent or aroma can exit through the seal, but a consumer's fingers cannot pass through the mouth22to the product below. More particularly, the containers20are filled, either through the mouth22, or through another orifice of the container20(i.e., for bottom or side loaded containers20) and, a seal10,10′, in accordance with the present invention, provides scent or aroma from the product to the consumer without the need for removing the seal10,10′. As can be seen fromFIGS. 1-5, the seal10,10′ of the present invention can be used with different types of containers20and caps40, such as a threaded cap (FIGS. 1, 3 and 4), snap-closed and flip-top caps (FIGS. 2 and 5), or other types of caps know in the industry. As discussed above, the seal10,10′ is bonded to the circumferential edge of the container20over the mouth22, and the cap is closed thereover.

Additionally, as discussed above, the seal10,10′ includes one or more scent permeating slits12. In one particular embodiment of the present invention, the seal10′ includes three slits12, arranged in the seal10′. Note, however, that the seal of the present invention is not meant to be limited to only this number of slits or this configuration of slits, as more or fewer slits may be used in any desired configuration and/or location. Although illustrated in the present particular embodiment as a curved slit or sine wave slit, other shapes of slits can be used without departing from the scope and spirit of the present invention, including, but not limited to, slits of the types described in U.S. patent application Ser. No. 13/922,994, filed on Jun. 20, 2013, incorporated herein by reference. In another particular example, two or more slits could be provided through the seal in matched (FIG. 2) or offset (FIG. 5) pattern.

In connection with the present invention, the slit(s)12extend through fewer than all of the layers if, for example, permeation is possible through one or more of the layers. For example, in one particular embodiment, the bottom-most layer, i.e., the sealing layer, may permit permeation and, thus, would not need to be pierced by the slit(s)12. The length, width, depth and angle of the slit(s)12are structured to allow the scent of the substance within the container20to permeate through the slit(s)12and to substantially prevent leakage out from the slit(s)12by the substance or product within the container20, and still provide barrier properties. The length, width, depth and angle of the slit(s)12may vary depending upon the substance to be placed within the container20and the sniff test requirements and/or leak and barrier properties tests of the product manufacturer. For example, the slit(s)12may be larger for creams and gels than for substances of a lower viscosity or a more liquid nature. In addition, the number and depth of slit(s)12may vary depending upon the strength of the fragrance and aroma within the container20. For example, only one slit12may be used for containers20holding more fragrant/aromatic substances, whereas multiple slits12may be used for containers20holding less fragrant/aromatic substances, so that the less fragrant/aromatic substance has a greater opportunity to permeate the seal10,10′ and be sensed on the outside of the container20.

Additionally, it is a feature of the present invention that the unslitted layer or layers of the seal10, although permitting permeation of the scent, do not permit venting to occur through the seal10. Thus, the seal10is a non-venting seal. More particularly, the intact layer or layers of the seal10do not permit a free flow of air or gas from inside the container20to the outside of the container20.

In an alternate embodiment of the invention (described more particularly in connection withFIG. 10), the slit(s) may be formed through all of the layers of the seal, but at an angle, such that the slit entry point is offset through the body of the seal from its exit point.

The container20may be composed of any materials now known or later developed that are capable of having a tamper evident, removable seal with barrier properties secured to the container20and that are suitable for storage of the substance being sold. In one preferred embodiment, the container20is composed of polyethylene or polypropylene, PET or PVC, and the seal10is secured to the container20by conduction or heat induction. In another embodiment, the container20is glass and the seal is secured to the container20by an adhesive, conduction or heat induction. However, it should be appreciated that the seal10may be secured to the container20by any means now known or later developed, including, but not limited to heat induction sealing, conduction sealing, gluing, contact adhesive, etc. Once the seal10,10′ has been secured over the mouth22of the container20, a cap40is secured to the container20over the seal10,10′. In one particular embodiment of the invention, the cap40is a removable continuous thread closure. However, this is not meant to be limiting, as the seal10,10′ can be used with any type of container20and closure40, and for any type of substance stored within the container20.

A consumer interested in the product stored within the container20may remove the cap40and smell the scent or aroma of the stored product released through the slits12in the seal10,10′, without removing the seal10,10′,10″ and without sampling, tampering with, contaminating and/or spilling the product.

Referring now toFIGS. 6A-7, there is shown one particular embodiment of a seal100or100′, which can be used as the seals10,10′ ofFIGS. 1-5. In the present preferred embodiment, the seals100,100′ have a one piece, multi-layer construction. More particularly, in one particular embodiment of the invention, the seal100,100′ is an induction seal including a polyester film layer110, a layer of EPE foam120, a layer of aluminum foil130and a sealing layer140. It should be noted that more or fewer layers, or layers of other materials than listed herein, may be used without departing from the spirit of the present invention.

The seal100,100′ includes at least one slit112formed in at least one layer thereof. As discussed above, in the most preferred embodiment of the present invention, the slit(s)112are made through fewer than all of the layers of the multi-layer induction seal100,100′. By leaving at least a portion of one of the induction seal layers110,120,130,140, intact, the seal of the present invention eliminates any need for a further layer, membrane or material to be laminated to the seal100,100′ after cutting of the slit(s)112. Thus, in its most preferred embodiment, the present invention takes a standard one piece, multi-layer induction seal100,100′ and scores a slit or slits in one or more layers, but less than all of the layers, from the top face114and/or from the bottom face116, to permit scent to permeate from the product in a container (20ofFIGS. 1-5), through the seal100,100′, while preventing venting through the seal and/or slit(s).

In the present particular embodiment illustrated in the figures, the slit112is shaped like a wave (i.e., in the present particular embodiment, a sine wave). Note that other slit shapes can be used, as desired, including, but not limited to, slits shaped as otherwise described herein and/or slits configured as a line, a circle, an alphanumeric character, a different form of a wave (i.e., cosine; point of inflection; sawtooth; etc) and/or slits of the types described in U.S. patent application Ser. No. 13/922,994. It should be understood that, while still part of the sheet120, each seal100can be made to have more than one slit112, as shown more particularly inFIGS. 5 and 6B, without departing from the scope and spirit of the present invention. In other words, each seal100,100′ includes at least one slit112, but can include two or more slits112.

Although illustrated in the figures as being in the top layer110of the seal100,100′, if desired, the slit(s)112could be formed in the bottom layer or layers of the seal100,100′ and the top layer110can be left unperforated. Whether scoring of the slits is performed from the top layer110down or from the bottom layer140up may have a direct effect on the scent permeation, leakage and barrier properties of the seal100,100′. Consequently, selection of top side scoring or bottom side scoring is made on a case by case basis in order to optimize scent/aroma permeation through a seal100,100′, leakage prevention and shelf life for a particular product and packaging combination. Additionally, the barrier properties of the seal100,100′ (currently measured in terms of oxygen transmission rates (OTR) and moisture vapor transmission rates (MVTR)) can be further controlled by adjusting (reducing or increasing) the size, depth and/or number of slits created in the seal100,100′. In the present invention, the barrier properties of the unperforated layer(s) are maintained so as to permit permeation (near to hermetic levels) through the unscored layers, while preventing venting through the seal100,100′.

Referring now toFIG. 7, there is shown a web sheet of bulk seal material120from which a plurality of individual seals100are cut or punched. Web sheet120is assembled as a one-piece, multi-layer sheet prior to slitting, die cutting and/or punching the seals100from the web sheet. Thus, in the present embodiment, the web sheet120is, first, made from a plurality of individual sheets. Subsequently, the slits112are formed, and finally, the seals100are separated from the composite web sheet120. Alternately, if desired, seals10,10′,100,100′ can be made from strips of composite, multi-layered materials, mounted on reels, that are fed through a lining/punching machine to die cut and punch the seal.

The seal10,10′,100,100′ can be manufactured using rotary die, flat die or a laser method of cutting to control the size and shape of the seal and the length, width, depth and angle of the slit(s)12,112during the manufacturing process. It should be appreciated, however, that other cutting methods now known or later developed may alternatively be used within the spirit and scope of the present invention.

Referring now toFIGS. 6A and 8, there will be described a method for forming slits112in seals100(or, if desired,100′ ofFIG. 6B), in accordance with one particular embodiment of the present invention. More particularly, a sheet120including a plurality of multi-layer induction seals100(not yet provided with a slit or cut from the sheet120) is provided to a station200including a laser210. Sheet120can be an individual sheet120of seals (such as the web sheet120, above), as shown, or can be part of a roll of seals provided to the station200. Additionally, although illustrated as having precut seals100on the sheet120, this is not meant to be limiting. Rather, if desired, the sheet120can have the seals precut thereon, or the sheet120can be a bulk sheet120(not having the seals precut thereon) when provided to the laser210, such that the slits are ablated into the bulk material and, subsequently, the seals100are die cut from the slitted bulk material.

The laser210can be any type of laser desired, such as, but not limited to, a gas laser (e.g., Galvo laser, a CO2laser), a fiber laser, a semiconductor laser, etc. In one particularly preferred embodiment of the invention, the laser210has a power of 6.5 Watts or more. The sheet120is registered under the laser210, and the laser210is operated to form the slit112in at least part of each seal100using ablation performed by a laser beam210a. The sheet120leaves the laser station200with slits112formed in each seal100. The seals100can then be cut from the sheet120to produce individual induction seals100. If desired, more than one laser210can be provided at the station200, to increase speed and/or provide for more paths through the station200.

In one particular embodiment of the system200, the slits112are formed, using the laser210, through one or more layers, but through fewer than all layers, of the multilayer seal material of sheet120. Although illustrated in the figures as being made in the top face, in practice, the laser ablation may be performed from the top (white) side or from the bottom (foil) side, or from both, as desired. In one particularly preferred embodiment of the invention, the laser ablation is performed on the bottom (foil) side of the seal140, so that the slit is not open from the top of the seal100and also does not interrupt, or distract from, any markings printed on the top face of the seal100. The slit(s)112can be made in one or both of the top face114and/or bottom face116of the seal100,100′.

The use of a laser210is particularly desirable and advantage because it can be used to very precisely control the thickness of the resultant slit112. For example, the laser can be accurately controlled to cut through only the thinnest layer of the seal100, which in one particular embodiment is 0.0005 inches (12.7 microns). If desired, the laser210can be used to cut through as little as a partial layer of the seal100or through more than one layer of the seal100, without departing from the scope and spirit of the present invention. In the most preferred embodiment of the present invention, fewer than all of the layers of the multilayer seal100are cut by the laser210. For example, layers110,120and130may be cut by the laser, leaving the sealing layer140, or another scent permeable top layer, intact as a scent permeable layer inhibiting leakage of product through that layer and maintaining the barrier properties of the seal100. Similarly, layers140,130and120can be cut by the laser, leaving the polyester film layer110, or another scent permeable top layer, intact to inhibit leakage of product and maintain the barrier properties of the seal100, while permitting the scent of the product to permeate through the seal100. If desired, as few as one layer and as many as three layers can be cut by the laser210, without departing from the scope and spirit of the present invention.

Additionally, although depicted inFIG. 11as performing the ablation at a normal incidence to the sheet120(i.e., the laser beam210abeing perpendicular to the sheet120), the slits112can be made at this normal incidence, or can be made at an angle relative to the top plane of the sheet120by angling the laser210or using a lens system that causes the laser beam210ato strike the seal100at a non-normal angle. Further, the slit112can be formed in the seal100in a single pass of the laser beam210a, or in two or more passes, as desired.

In one particular example, described for illustrative purposes only, the slit112can be cut through one or more layers of the multilayer seal100, by performing five passes of the laser to form the desired slit pattern (sinusoid, in the present example) in the aluminum (back) side of the seal100, at a depth of 0.0085 inches through the seal. Preferably, the slit112is made by performing from 1 to 8 passes of the laser beam210aover each seal100in the sheet120. The laser210can be stepped in the X axis and Y axis directions, if desired, in order to make the slit in each seal100. Alternately, the sheet120can be stepped in the X and Y axis directions and the laser may remain stationary. In a further alternate embodiment, the laser is stepped along the X-axis, only and the sheet120is part of a roll that is rolled across the laser station200in the direction of the Y-axis.

In one particular example, described for illustrative purposes only, the slits112can be cut through one or more layers of the multilayer seal100(or100′), by performing two or more passes of the laser to form the desired slit pattern (sinusoid, in the present example) in the aluminum (back) side of the seal100, at a depth of 0.0065 inches through the seal.

In one particularly preferred embodiment of the invention, in order to achieve an optimal permeation level for each product, multiple ablation passes are performed by the laser210on each seal100, and a plurality of slits112are made in each or the seals100, as shown, for example, inFIG. 5 or 6B. Each slit112can be formed by one ablation pass of the laser210, or, more preferably in the present embodiment, is formed from multiple ablation passes of the laser210.

Referring now toFIGS. 9-9B, there is shown another embodiment of the present invention for cutting slits into at least one layer of a multilayer seal300. In the present preferred embodiment, a one-piece, multi-layer web sheet320(which can be as described in connection with the web sheet120ofFIG. 7) is fed to a rotary cutting station310having a rotary cutter360with blades360a. Although shown as having the seals300precut on the sheet320, this is not meant to be limiting, as precut sheets320or bulk sheet material320may be provided to the cutting station310, as desired, without departing from the scope or spirit of the present invention. Alternately, the rotary cutter360can be configured to receive bulk sheet material320and cut the seals300and slits312simultaneously (i.e., with the seals being cut all the way through the sheet320, but the slits312being cut through fewer than all layers of the sheet320).

More particularly, in the present preferred embodiment, the blades360aare used to score the seal300, while still on the sheet320, to form the slits312. Note that, in order to score the slits312in all of the seals300of a row on the sheet320, a plurality of blades360aaligned with (and thus hidden behind) the blade360ashown by the enlarged portion340ofFIG. 9illustrated inFIG. 9A. In the present invention, the height of the rotary cutter360relative to the sheet320can be controlled such that the blade360acuts through fewer than all layers of the seal300. Thus, the barrier properties of the seal300can be maintained such that permeation (including scent permeation) can occur through the unscored layer or layers, but venting and leakage cannot.

Referring now toFIGS. 9-10, in one particular embodiment, the blades360aon the rotary cutter360are angled by an angle α relative to the surface of the rotary cutter360(i.e., a non-normal angle), so as to cut into the sheet320at an angle as rolled over the sheet320. Resultantly, the slit312formed in the seals300′ is angled (as illustrated byFIG. 10) through one or more layers of the seal300′, but less than all of the layers, at a non-normal angle, with the perforation312bthrough a distal layer of the seal300′ being linearly displaced from the perforation312athrough the proximal or entry layer of the seal300′. Such a cut permits scent to permeate from the slit312, while the angled cut inhibits leakage of product out from the slit312.

The seals of the present invention provides a simple, cost effective solution that will allow consumers to sample the scent or aroma of a product while the seal remains secured to the container. As a result, manufacturers currently selling products without seals will now be able to include seals on their containers and receive the benefits that seals provide, including maintaining product integrity and barrier properties, extending shelf life and making the seal tamper evident, preventing leakage, preventing products from being contaminated and/or damaged by consumers sampling the products and reducing the volume of unsaleable products resulting from leakage, contamination and damage.

As can be seen from the foregoing, the present invention provides a seal for containers that allows the scent or aroma from the substance within the container to come through, while preventing leakage of the substance within the container and maintaining barrier properties to maximize shelf life. Such a seal can be used with any type of container and with any type of substance or product stored within the container. Additionally, it should be appreciated that the present invention may utilize other seal designs, materials and configurations now known or later developed that are capable of being removably secured to a container, preventing leakage of the substance within the container and maintaining barrier properties, without departing from the spirit of the invention. More particularly, it should be appreciated that the seals of the present invention may be embodied in a wide range of structures and designs, and may be suitable for use with many different types of containers.

Because the seals10,10′,100,100′,300,300′ of the present inventions are capable of use with many different designs, materials and configurations known in the seal industry and may be manufactured and supplied to container manufacturers as precut discs and/or in rolls consistent with current practices, it can be utilized by closure and container manufacturers and end users using existing lining, sealing and capping equipment and current manufacturing processes and technologies. Additionally, because the seal of the present invention may be manufactured using current, commonly used seal designs, materials and constructions and does not require any specialty equipment or manufacturing processes, it is inexpensive to manufacture and can be readily incorporated into the closure and container manufacturing processes. Further, it can be seen that a seal in accordance with the present invention can be manufactured at a cost comparable the cost of current conventional seals.