Patent Description:
Currently, many products including household products such as detergents and personal care products are supplied in disposable plastic containers. It is widely recognised that such use of plastic containers is undesirable not least because of the environmental damage that arises from the disposal of such containers. Metal containers can provide a more environmentally friendly alternative and of course many products are already supplied in metal containers including foodstuffs, aerosols, mousses and the like. Such metal containers are often made using a relatively thick steel or aluminium which, whilst allowing for recycling, can be wasteful in terms of the materials used. They are also relatively expensive to manufacture and have higher manufacturing and transportation costs and therefore larger carbon "footprints", discouraging their use as a replacement for plastic containers.

<CIT> describes a product dispensing system that makes use of what are substantially aluminium beverage cans. The can ends are either openable with tabs, e.g. in the form of a substantially fully open ends, or are provided with circular apertures closed with foil panels. The cans are filled with product and, for use, are loaded into a plastic two-part container comprising a main, generally cylindrical body and an end dispenser. In the case of an end with a tab, the end is opened by pulling the tab, and the can loaded into the body with the end dispenser being screwed over the can and onto the main body. The end dispenser is of a pump type and comprises a tube which is inserted through the opening in the can end. Once the end dispenser is secured to the main body, product can be dispensed. In the case where the can end has a foil panel, securing the end dispenser to the main body may cause the tube to break through the foil panel and pass into the can body.

Conventional beverage can production is highly optimised in terms of material use and manufacturing speed and cost. The use of a tab in the concept described in <CIT> is undesirable as it will increase metal usage, complexity and therefore cost. Whilst the use of a foil panel instead of a tab may address this problem, it will in turn introduce potential problems due to the departure from conventional end manufacturing processes. Furthermore, this approach will likely require the use of an adhesive, e.g. on the underside of the can end, potentially causing product contamination and / or product deterioration, as well as providing a weak point in the can end, e.g. the foil panel may be susceptible to breaking during transport as well as due to internal and external pressures.

<CIT> discloses a self-dispensing container for carbonated product and comprising a hollow body having a filling aperture, a carbonated product inserted into the hollow body via the filling aperture leaving a headspace, and an end adapted to seal the filling aperture after insertion of the carbonated product. After sealing, the headspace fills with CO2 from the carbonated product to equalise the pressure within the container.

<CIT> discloses a can having a tab-less end. A score extends around a region of the end such that a user can press down on the region within the score, fracturing the score and creating an opening in the end.

<CIT> discloses a can lid in which a very small non-breaking part for preventing an opening piece from being opened in a part of a score line for demarcating the opening piece of the can lid, and the remaining thickness of the non-breaking part can be easily controlled.

<CIT> discloses a small capacity, full aperture beverage can and a can end for the same.

<CIT> discloses a resealable container lid assembly, including a cap rotationally assembled to a lid.

A tab-less can end <NUM> will now be described with reference to <FIG> and <FIG>. The can end is similar to standard beverage can ends, and the manufacturing process is also similar. For the purpose of the following discussion, the end <NUM> is assumed to be a "<NUM>" end having a seamed diameter of approximately <NUM>. Of course other end sizes are possible (e.g. "<NUM>", "<NUM>", "<NUM>") and the skilled person will take account of this when determining dimensions of other end features.

The key differences between the end <NUM> described here and standard ends are the absence of a tab and its associated score, and the provision of a discontinuous score <NUM>. The end <NUM> is referred to here as a "tab-less end" due to the absence of the tab which is otherwise commonly used in the opening of a can end by pulling or pressing against its associated score, and is created by cutting out circular disks from metal sheet having a thickness in the range of <NUM> - <NUM>. The disks are then formed to provide a chuck wall <NUM> with a curl <NUM> at the top to allow seaming of the end <NUM> onto a can body <NUM>. The chuck wall <NUM> and curl <NUM> extend around the entire circumference of the end <NUM>, defining a generally U-shaped channel <NUM> between the chuck wall <NUM> and a central panel <NUM>. The score <NUM> is formed on an upper surface of the panel <NUM> (i.e. on a surface that is exterior to the can <NUM> after seaming of the end <NUM> to a can body <NUM>), and follows a circular path <NUM> that is substantially concentric with the chuck wall <NUM>. The diameter of the score <NUM> is approximately <NUM>, and has a depth of between <NUM> and <NUM>, preferably approximately <NUM>. For the metal thickness considered here, this results in a score "residual" of <NUM> ± <NUM>.

As the score <NUM> is discontinuous, a portion of the circular path <NUM> is unscored. The unscored portion of the circular path <NUM> acts as a hinge <NUM> when the can end <NUM> is opened as discussed further below. The linear extent, indicated in <FIG> by distance d, of the hinge <NUM> is preferably between <NUM> and <NUM>, more preferably between <NUM> and <NUM>, and more preferably substantially <NUM>. The score depth (and therefore score residual) may be adjusted to optimise end performance. In particular, the score depth is deep enough that it can be opened with the aid of some device which gives mechanical advantage, but not so deep that it can be opened with a thumb or a finger pressing directly against it.

As best illustrated in <FIG>, the panel <NUM> of the can end <NUM> is formed to provide three terraces <NUM> formed by two circular and concentric steps 12a, 12b. A first step 12a has a radius that is substantially <NUM> greater than the radius of the score <NUM>, whilst the second step 12b has a radius that is substantially <NUM> less than the radius of the score <NUM>. The terraces <NUM> therefore descend in height towards the centre of the end <NUM>, with the first step 12a having a step height of <NUM> and the second step 12b having a step height of <NUM>. As is known in the art, the use of such terraces can "absorb" metal displaced during forming operations and can improve end performance by adding strength to the can end <NUM>, minimising "doming" when the can end <NUM> is seamed onto a can body <NUM> and pressurised.

When the can end <NUM> is seamed onto the can body <NUM> as shown in <FIG> (using a conventional beverage can seaming process), the can end <NUM> closes an upper opening in the can body <NUM> (seaming of the end occurs after filling of the can body with a product). For the purpose of this discussion it is assumed that the can <NUM> is a two-piece can in which a bottom of the can body <NUM> is formed integrally with the can sidewalls (of course, use of a two-part can body is possible). The contents of the can <NUM> may be a beverage, a foodstuff, a household cleaning product, or a condiment; however this list is not exhaustive and other products, such as creams, ointments, healthcare and personal care products, and medical products, may be stored in the can <NUM>. Additionally, dry granular products may also be stored in the can <NUM>. Preferably, the can end <NUM> and the can body <NUM> are formed of steel, aluminium, or an aluminium alloy, and the filled can is pressurised to at least 10psi (<NUM> kPa). Pressurising the can <NUM> is helpful in maintaining structural integrity for thin walled cans.

A dispenser <NUM> for use with the can <NUM> of <FIG> will now be discussed with reference to <FIG>. <FIG> shows an exploded view of the dispenser <NUM> in which the can <NUM> of <FIG> is loaded into a main body or "cup" <NUM>, with a lid <NUM> and a dispensing cap <NUM> positioned for attachment to the cup <NUM>, whilst <FIG> shows a cross-sectional view of the exploded view of <FIG>. Both the lid <NUM> and the cup <NUM> have cooperating features that allow the lid <NUM> to be removably secured to the cup <NUM>. In this particular embodiment, the cooperating features are threads <NUM> that allow the lid <NUM> and the cup <NUM> to be screwed together to completely enclose the can <NUM>. Optionally, a circular band <NUM> of an elastomeric plastic or other suitable material is located around the outside of the cup <NUM> such that it is "sandwiched" between the lid <NUM> and the cup <NUM> following closure, for example, to provide for a leak proof closure whilst preventing or limiting over-tightening. Alternatively, a corresponding circumferential region of the cup may be enlarged to provide a flush outer surface when the lid is attached. The threads <NUM> are formed on regions of the lid <NUM> and the cup <NUM> having reduced thicknesses such that the closed dispenser <NUM> has a substantially flush outer surface. It will be appreciated that the inner diameter of the cup <NUM> (and lid <NUM>) are such as to allow the can to be easily inserted and removed. This may require a small space to be present between the outer surface of the can and the cup <NUM>, e.g. on the order of <NUM>. When the can <NUM> of <FIG> is loaded into the dispenser <NUM>, the cup <NUM> provides additional support to the can <NUM> once it has been opened and potentially depressurised. The cup <NUM> and lid <NUM> may be made of metal, plastic or any other suitable material, as may other components of the dispenser.

As is perhaps best illustrated in the cross-sectional views of <FIG> (at initiation of closure of the lid <NUM>) and 6B (during closure of the lid <NUM>), the lid <NUM> has a piercing member <NUM> that is configured to fracture the score <NUM> of the can end <NUM> upon closure, and thereby create an opening which brings the interior of the can <NUM> into communication with an interior space of the lid <NUM>. The piercing member <NUM> acts as a device which gives mechanical advantage during closure, enabling the score <NUM> to be fractured during closure. The piercing member <NUM> has the form of a hollow cylindrical member that is concentric with the outer surface of the lid <NUM>. The piercing member <NUM> has an axial length that varies around its circumference providing a tip <NUM>. To allow effective fracturing of the score <NUM> upon closure, the outer diameter of the hollow cylindrical member <NUM> is very slightly less than the inner diameter of the score <NUM>. As will be discussed further below, the lid <NUM> comprises a resilient sealing member <NUM> in the form of an O-ring or the like, and which is located around the outer circumference of the piercing member <NUM>, supported beneath a collar <NUM> extending circumferentially around the outer surface of the piercing member <NUM>.

<FIG> show a pump-style dispensing cap <NUM> comprising a tube <NUM>, a pump head <NUM>, and a pumping mechanism (not shown but including, for example, a spring), located with respect to the cup <NUM> and loaded can <NUM>. The dispensing cap <NUM> can be removably secured to the lid <NUM> (cf. When the dispensing cap <NUM> is secured to the lid <NUM>, e.g. via a snap-fit arrangement, a channel is defined through which a product can flow from the interior space of the can <NUM> to an exterior of the dispenser <NUM>. The dispensing cap <NUM> also comprises a resilient sealing member <NUM> that forms a seal between the dispensing cap <NUM> and the lid <NUM> (see below). The resilient sealing member <NUM> may be in the form of a flattened elastomeric ring, an O-ring, or other suitable resilient member. The dispensing cap <NUM> does not of course need to be a pump-type dispenser and may be some other type of dispenser or valve as discussed below.

The operation of assembling the dispenser <NUM> around a can <NUM> will now be described. Reference to the cross-sectional detail of <FIG> will be helpful in this regard.

A user loads a can (filled with product) into the dispenser cup <NUM>. The lid <NUM> is located on the open end of the cup <NUM>, above the tab-less can end. The user then presses the lid <NUM> onto the cup <NUM>, with the threads <NUM> aligned, and rotates the lid <NUM> relative to the cup <NUM> to screw the lid <NUM> down onto the cup <NUM>. This action provides the mechanical advantage that causes the tip <NUM> of the piercing member (the hollow cylinder) <NUM> to exert a force on a point just inside the score <NUM>, causing the score to fracture at this point. As the user continues to screw the lid <NUM> down, the fracture will propagate around the score <NUM>, whilst pushing the panel region within the score <NUM> into the can body <NUM>. The fracture stops at the hinge <NUM> of course. The hinge <NUM> prevents the portion of the can end <NUM> that is outlined by the score <NUM> from fully separating from the can end <NUM>. Upon completion of this operation, the resilient sealing member <NUM> surrounding the piercing member <NUM> is pressed into the opening, or around the panel region surrounding the formed opening, thereby establishing a seal between the interior of the can <NUM> and an interior space of the lid <NUM>.

It will be appreciated that this construction and method of operation allows the end <NUM> to be opened without the use of a tab. The can end <NUM> can be manufactured with fewer steps and with reduced metal. Furthermore, because the underside of the can end <NUM> does not use or expose an adhesive, undesirable material interactions and product contamination are avoided. A still further advantage is that the cans <NUM> may be more effectively child-proofed, given that the cans <NUM> can only be opened with a suitable dispenser <NUM> which provides the needed mechanical advantage (or lid in the case where a container body is not required). Of course, the absence of a tab or ring pull means that the can <NUM> is not similar in appearance to a standard beverage can, and so is less likely to be mistaken for a can containing a typical single serve consumable product or indeed non-consumable product.

After the lid <NUM> has been secured to the cup <NUM> as described, the dispensing cap <NUM> is secured to the lid <NUM> by inserting the tube <NUM> through the interior space of the lid <NUM> until the resilient sealing member <NUM> is engaged beneath a circular shoulder extending around an upstanding cylindrical collar <NUM> of the lid <NUM>. This is best illustrated by the detail of <FIG>. The formed seal prevents the contents of the can <NUM> from leaking into the lid <NUM>. The seal is also required of course to allow the dispensing cap <NUM> to pressurise the interior of the can <NUM> during operation of the pump, thereby causing the product to be forced up into the tube <NUM> and out through an exit port of the dispensing cap.

<FIG> show details of the various embodiments with different seal arrangements. In the embodiments of <FIG>, the resilient sealing member <NUM> of the lid <NUM> provides a seal around or adjacent to the opening formed in the can end <NUM> by the fracturing of the score <NUM>. In the embodiment of <FIG>, the resilient sealing member <NUM> of the lid <NUM> presses against the portion of the can end <NUM> surrounding the score <NUM> to form the seal. The outer diameter of the sealing member <NUM> is marginally less than the diameter of the outer step 12a such that on closure the resilient sealing member <NUM> presses not only downwards onto the panel <NUM> but also radially against the step.

The embodiment of <FIG> is similar to that of <FIG>, except that in the former the wall of the piercing member above the shoulder supporting the resilient sealing member is circularly cylindrical whilst in the latter that wall has a tapering thickness, increasing as it approaches the shoulder. The embodiment of <FIG> may demonstrate increased strength and rigidity, especially during closure of the lid <NUM> onto the cup <NUM>.

It will be appreciated that by configuring the lid <NUM> to form a suitable seal around the top of the can <NUM> it is possible to do away with the need for the dispenser <NUM> to have a cup <NUM> to support the can <NUM>. Such an arrangement is shown in <FIG> and comprises a lid <NUM> secured directly to the can <NUM>. In order to provide the force necessary for the piercing member <NUM> to fracture the score <NUM> and open the can end <NUM>, a snap-fit mechanism may be provided, whereby the user locates the lid <NUM> around the upper surface of the can <NUM>, and presses down onto the lid <NUM> to cause features of the lid <NUM> to snap over and beneath the rim extending around the can end <NUM>. This action also forces the piercing member <NUM> downwards, fracturing the score <NUM>.

Reference is made to <FIG> which illustrate further configurations and uses of the dispenser <NUM>:.

It will be appreciated by the person of skill in the art that various modifications may be made to the above described embodiments without departing from the scope of the present invention. For example, the size of the can <NUM> may be different from that of a standard (<NUM>) beverage can to allow storage of different amounts of product. For a larger can size, the can body may be "necked" to allow for use with a standard sized can end <NUM>. A larger can <NUM> is advantageous over standard large storage containers such as glass bottles because the weight of the large can <NUM> will be less than the corresponding glass bottle. While terracing has been used in the present description to increase the strength of the can end <NUM>, beading could also be used to increase the strength of the can end <NUM>. For example, radial beads could be used either in addition to the terracing, or instead of the terracing, on the can end <NUM>. Using radial beading in addition to terracing could allow for larger can ends <NUM> to be manufactured that are still strong enough to withstand internal and external pressure.

In understanding the above embodiments, reference should be made to the following table which identifies reference numerals and features of the drawings.

Claim 1:
A system for dispensing a product and comprising a can (<NUM>) having a can body (<NUM>) containing said product and a tab-less metal can end (<NUM>) seamed onto the can body (<NUM>), and a dispenser (<NUM>), wherein the can end (<NUM>) comprises:
a substantially circular and planar panel (<NUM>);
a chuck wall (<NUM>) extending around the periphery of the panel (<NUM>) and defining a curl (<NUM>); and
a discontinuous score (<NUM>) formed in said panel and following a circular path (<NUM>) substantially concentric with said chuck wall (<NUM>), the score (<NUM>) defining a hinge (<NUM>) between first and second ends of the score (<NUM>),
the discontinuous score (<NUM>) being such that it can be fractured by a user only when the user makes use of a mechanical advantage,
the planar panel (<NUM>) defining an outer surface and an inner surface when the end (<NUM>) is seamed to the can body (<NUM>), and the panel (<NUM>) having a thickness in the range <NUM> - <NUM>, said discontinuous score (<NUM>) being formed in the outer surface of the panel (<NUM>) and resulting in a score residual of <NUM> ± <NUM>, and
wherein the dispenser (<NUM>) comprises:
a lid (<NUM>) having features for removably securing the lid (<NUM>) with respect to the can (<NUM>), and the lid (<NUM>) comprising a piercing member (<NUM>) configured to fracture the score (<NUM>) provided in the can end (<NUM>) and create an opening therethrough and thereby bring the interior of the can (<NUM>) into communication with an interior space of the lid (<NUM>).