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CA-3170790-C - PULP BOTTLE WITH MOLDED INTERIOR LINING AND METHODS OF MAKING SAME

CA3170790CCA 3170790 CCA3170790 CCA 3170790CCA-3170790-C

Abstract

A container with a shell and lining within its interior is provided. The shell and/or lining can be fabricated from a biodegradable, recyclable, and/or compostable material. The lining can be configured as a parison, a preform, and/or other mass that is capable of being expanded. The lining can be inserted within a cavity of the shell and caused to expand to form an expanded state. The lining, in the expanded state, may be used as a barrier, preventing beverage that is inserted into the container from making contact with the shell. The lining, in the expanded state, may be configured to maintain contact with an inner surface of the shell so as to provide adequate shock absorption. The lining can be a thin film, providing an overall thinner construction and/or an overall lighter construction can be used to fabricate the container.

Inventors

  • Fuad Khan
  • Adam Berk
  • Lee Green

Assignees

  • LGAB LLC

Dates

Publication Date
20260505
Application Date
20210312
Priority Date
20200313

Claims (10)

  1. 19 WHAT IS CLAIMED IS: 1. A method of fabricating a lined molded pulp container, the method comprising: generating a molded pulp shell (104), the shell (104) comprising a top opening (120), a sidewall (108), and/or a bottom (110) to the shell (104) so as to define a cavity (102) within the shell (104); generating a polymer blank, the blank comprising a neck (202) and an expandable portion; at least partially inserting the expandable portion of the blank into the shell (104) via the top opening (120); extending the expandable portion of the blank to make contact of an interior of the cavity (102) of the pulp shell (104); heating at least the expandable portion of the blank; applying positive pressure to at least an interior of the expandable portion of the blank; and concurrently vacuum drawing at least the expandable portion of the blank, wherein the extended expandable portion of the blank forms a lining (200) of the interior of the cavity (102) of the pulp shell (104), and wherein the expanded lining (200) is at least partially fused with the interior of the cavity (102) of the pulp shell (104).
  2. 2. The method recited in claim 1, wherein the molded pulp shell (104) further comprising a shoulder (106), wherein inserting the expandable portion of the blank comprising of securing at least a portion of a rim (206) of the blank to at least a portion of the shoulder (106) of the shell (104).
  3. 3. The method recited in claim 1 or claim 2, wherein extending the expandable portion of the blank is by blow molding.
  4. 4. The method recited in any one of claims 1 to 3, wherein generating the molded pulp shell (104) comprises forming an upper shell (124), forming a lower shell (122), and joining the upper and lower shells. CA 3170790
  5. 5. The method recited in any one of claims 1 to 4, wherein generating the molded pulp shell (104) comprises forming the molded pulp shell (104) as a unitary piece.
  6. 6. The method recited in any one of claims 1 to 5, wherein the expandable portion of the blank comprises at least a tube-like piece, which is then expanded.
  7. 7. The method recited in any one of claims 1 to 6, wherein the polymer blank comprises thermal plastic and/or bioplastic or compostable material.
  8. 8. The method recited in any one of claims 1 to 7, wherein the polymer blank comprises high, medium, and/or low density polyethylene, polyethylene terephthalate, polypropylene, and/or polyvinyl chloride.
  9. 9. The method recited in any one of claims 1 to 8, wherein extending the expandable portion of the blank comprises elongating at least the expandable portion of the blank with a push rod (302) or mandrel.
  10. 10. The method recited in any one of claims 1 to 9, wherein the lining (200) makes contact of substantially the entire interior of the cavity (102) of the pulp shell (104). CA 3170790

Description

WO 2021/183877 PCT /US2021 /022094 PULP BOTTLE WITH MOLDED INTERIOR LINING AND METHODS OF MAKING SAME FIELD OF THE INVENTION 5 [0001] Embodiments disclose molded pulp containers having integral lining within its interior and method of making such container. BACKGROUND OF THE INVENTION [0002] Plastic drink bottles, such as for bottled water, juice or carbonated beverages, are in wide spread use. Conventional drink bottles are made from thermal plastic polymers, 10 and are typically made through a molding process. The drink bottles need to provide sufficient mechanical strength to support the content and their own weight to be free standing, and also protect the content during packaging and transportation. This sets a minimal amount of plastic that is required for each bottle. The wall of the plastic drink bottles tend to rely on thick component parts, which lead to waste and added cost (e.g., 15 transportation and supply chain management costs). Given the tremendous number of drink bottles made every year, and lack of effective recycling, plastic drink bottles are contributing to worldwide plastic pollution. [0003] Paper and pulp containers are naturally biodegradable, and may be attractive materials as alternatives to plastic drink bottles. However, paper and pulp are naturally 20 porous, and typically not suitable for handling liquid unless some type oflining is incorporated. Beverages can be introduced into the lining portion, where a paper or component may provide structural support for the bottle and the beverage. Conventional methods of fabricating such bottles may require constructing the containers in several structural pieces, each is separately lined with a plastic barrier, and then glued or attached 25 together. Such fabrication methods can be inefficient and ineffective. Such methods also add to the complexity of fabrication and overall weight of the finished container. The finished product also departs from the aesthetic look of traditional drink bottles. [0004] Examples of conventional bottles with linings can be found within the disclosures ofUS 9126717, US 8991635, US 20130140325, US 20130140326, US 20130145730, US 30 20130146616, US 20130146617, WO 2007066090, CN 103038140, AU 2012211504, WO 2009/133355. and WO 2009/133359. 1 CA 03170790 2022-9-6 [0005] There exists an unmet need to reduce the amount of plastic used in drink bottles, make it at least partially biodegrable, and still provide the strength suitable for packaging and transportation. SUMMARY OF THE INVENTION 5 [0006] The present disclosure provides a method of fabricating a lined molded pulp container, the method comprising generating a molded pulp shell, the shell comprising a top opening, a shoulder, a sidewall, and/or a bottom to the shell so as to generate a cavity within the shell, generating a polymer blank, the blank comprising a neck and an expandable portion, at least partially inserting the expandable portion of the blank into the 10 shell via the top opening, placing the polymer blank and the molded pulp shell in a mold, and extending the expandable portion of the blank to make contact of an interior of the cavity of the pulp shell. In some embodiments, the inserting the expandable portion of the blank comprises of securing at least a portion of a rim of the blank to at least a portion of a shoulder of the shell. In some embodiments, the extending the expandable portion of the 15 blank is by blow molding. [0007] In some embodiments, the generating the molded pulp shell comprises forming a container upper, forming a container lower, and joining the container upper and container lower. [0008] In some embodiments, the expandable portion of the blank comprises at least a 20 tube-like piece, which is then expanded. In some embodiments, the polymer blank comprises thermal plastic and/or bioplastic, which for example can be high, medium, and/or low density polyethylene, polyethylene terephthalate, polypropylene, and/or polyvinyl chloride. [0009] In some embodiments, extending the expandable portion of the blank comprises 25 heating at least the expandable portion of the blank. In some embodiments, extending the expandable portion of the blank comprising vacuum drawing at least the expandable portion of the blank. In some embodiments, extending the expandable portion of the blank comprises elongating at least the expandable portion of the blank with a push rod or mandrel. In some embodiments, the extended expandable portion of the blank forms a 30 lining of the interior of the cavity of the pulp shell. In some embodiments, the expanded lining makes contact of substantially the entire interior of the cavity of the pulp shell. [0010] The present disclosure also provides a container, comprises a pulp shell having a top opening and an interior cavity, an interior lining comprising an integral neck, wherein 2 CA 03170790 2022-9-6 the lining is expanded and makes contact to substantially an entire interior of the cavity of the shell