Molded pulp container

Abstract

Aspects of the present disclosure relate to a molded pulp container comprising: a tray comprising a bottom wall and a peripheral side wall extending upwardly from the bottom wall and terminating in a flange, the flange at least partially defining an open top, the flange has a channel defined by spaced apart inner and outer channel walls connected by a bottom channel wall; and a cover closing the open top in the closed configuration, the cover including a protrusion biased against the inner channel wall and the outer channel wall.

Description

Technical Field

[0001] The present disclosure relates to containers, such as pulp molded containers, that can be used, for example, with food products. Background Art

[0002] Consumers generally recognize and believe that molded pulp containers used in the food service industry are more biodegradable or compostable than plastic containers. Molded pulp containers can be manufactured by either a wet or dry process, both of which have their advantages and disadvantages.

[0003] In the wet process, the mold parts or intermediate structure are immersed in a slurry of liquid and pulp fibers to form a fibrous layer impregnated with liquid, which is placed in a mold and subjected to pressure and heat to squeeze out the free liquid and dry the absorbed liquid to the desired extent. The mold is then opened and the container removed.

[0004] In the dry process, pulp fibers are blown onto a carrier such as a conveyor belt to form a fiber layer, which is subjected to pressure, such as by calender rolls, to give the layer or mat a degree of rigidity. The compressed dry fiber layer or mat is then inserted into a mold and subjected to pressure and heat as required. The mold is then opened and the container removed. Summary of the invention

[0005] The present disclosure provides a pulp molded container, comprising: a tray, including a bottom wall and a peripheral side wall, the peripheral side wall extending upward from the bottom wall and terminating in a flange, the flange at least partially defining an open top, the flange having a channel defined by an inner channel wall and an outer channel wall spaced apart and connected by a bottom channel wall; and a lid, which closes the open top in a closed configuration, the lid including a protrusion, the protrusion being biased against at least one of the inner channel wall and the outer channel wall, and forming a sealed joint between at least one of the inner channel wall and the outer channel wall and the protrusion. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] In the attached picture:

[0007] Figure 1 is a perspective view of a container with a lid mounted to a tray in a closed position according to one aspect of the present disclosure.

[0008] Figure 2 is a perspective view of a container with a lid mounted to a tray in an open position according to one aspect of the present disclosure.

[0009] Figure 3 yes Figure 2 A partial cross-section of the container taken along line III-III.

[0010] Figure 4 yes Figure 2A partial cross-section of the container taken along line IV-IV.

[0011] Figure 5 yes Figure 1 A partial cross section of the container taken along line VV.

[0012] Figure 6 yes Figure 1 A partial cross-section of the container taken along line VI-VI.

[0013] Figure 7 A consumer is shown opening a container having a lid mounted to a tray according to one aspect of the present disclosure.

[0014] Figure 8 According to one aspect of the present disclosure Figure 7 The state of the container in after it has been opened and the lid has been separated from the tray. DETAILED DESCRIPTION

[0015] Disposable containers for packaging and storing edible items are often provided with tamper-evident and tamper-evident (TETR) features to prevent unauthorized access to the container and to indicate to consumers whether the container has been opened. Disposable containers are also provided with a fluid seal that prevents liquid or steam or both from flowing out of the container. The combination of the TETR feature and the fluid seal increases the complexity of the container structure and manufacturing. For plastic containers, a common solution is to provide complementary shoulders and undercuts for the container lid / cover and base / tray, and the shoulders are received under the undercut to form a fluid seal, while using a tearable portion or a frangible hinge to achieve TETR. The shoulders and undercuts can be manufactured using conventional injection molding or thermoforming processes because the flexibility and elasticity of the plastic prevent the container from being molded and locked to the mold structure that forms the shoulders and undercuts. Sufficient force can be applied to the container to remove it from the mold, and the plastic will flex or stretch without tearing to be able to remove the container from the mold structure that forms the shoulders and undercuts. During the operation of the plastic container, the opening / closing of the lid / cover on the base / tray causes the shoulder / undercut to deform and return to its original position, usually with a "click" sound, which has led to the fluid seal being called a snap seal or similar name. When the snap seal is a peripheral seal, it is usually necessary to apply pressure on all sides of the container to ensure that the shoulder / undercut is fully engaged at the periphery.

[0016] For molded pulp fiber containers, the use of shoulders and undercuts to form fluid seals is not a viable option because the molded pulp fibers lack the flexibility and elasticity required to prevent mold lock or to be removed from the mold structure without tearing. In other words, in order for the shoulders / undercuts in the molded pulp fibers to be structurally sufficient to function as a fluid seal, the molded pulp fibers will be mold locked to the mold structure that forms the shoulders / undercuts and / or the container will tear when it is removed from the mold. If the shoulders / undercuts are sized to prevent mold lock and / or tearing, the shoulders / undercuts will not be sufficient to function as a fluid seal. In order to address the problem of molded pulp fiber containers tearing when they are removed from the mold structure that forms the shoulders and undercuts, some plastics have been introduced for use with the pulp fibers. While enough plastic can be added to address the problem of tearing when removed from the mold, any addition of plastic will destroy the compostable and biodegradable properties of the molded pulp containers, which are precisely the properties that make molded pulp containers more popular than plastic containers. While compostable or biodegradable plastics exist, they take longer to compost or biodegrade than pulp fibers (less than a year), so it is undesirable to use them with molded pulp fibers because this changes the beneficial compostable / biodegradable time frame of the container.

[0017] The present disclosure is directed to solving the problem of providing a molded pulp container with a suitable fluid seal without mold lock or demoulding tearing, and can be achieved without the use of shoulders / undercuts. The suitable fluid seal can also be achieved without adding plastic to the pulp fibers. The suitable fluid seal is advantageously achieved in combination with a TETR feature. For example, the TETR feature can be used to apply a force to the overlapping portions of the lid and base of the molded pulp container to form a fluid seal at the interface of the overlapping portions. Due to the high surface roughness of the molded pulp material (such as compared to plastic containers), the interface does not separate. The force applied by the TETR structure to the interface increases the separation force required to open the container.

[0018] Figure 1 A container 10 including a tray 12 and a lid 14 is shown, wherein the lid 14 is in a closed configuration. The container 10 may include a first side 20 (e.g., a front side), a second side 22 (e.g., a rear side) opposite the first side 20, a third side 24 (e.g., a first lateral side), and a fourth side 26 (e.g., a second lateral side) opposite the third side 24. In general, the sides 20, 22, 24, 26 form an outer perimeter of the container 10. As shown, the tray 12 may extend beyond the lid 14 at three or more of these sides, such as the second side, the third side, and the fourth side 22-26 in the example including the hinge 40. For example, the lid 14 may not be visible from the bottom of the container 10 except for one or more portions (such as the portion at the first side 20 near the hinge 40).

[0019] Figure 2 Container 10 is shown with lid 14 in an open configuration. Tray 12 may include bottom wall 30, peripheral sidewall 32, and tray flange 34, which defines a first sealing structure 42. Peripheral sidewall 32 may extend generally upward from bottom wall 30 to tray flange 34, and tray flange 34 may define an open top 36. Bottom wall 30 and peripheral sidewall 32 may at least partially define a chamber 38. Chamber 38 may, for example, contain one or more food items. Lid 14 may selectively close open top 36 to close chamber 38. Lid 14 has top wall 54, which is at least partially defined by peripheral lid flange 44, which defines a second sealing structure 46. First sealing structure 42 and second sealing structure 46 cooperate to form a fluid seal 48 around at least a portion of container 10. Hinge 40 couples lid 14 to tray 12. Tray flange 34 may define a channel 50 of first sealing structure 42. Tray flange 34 may be non-detachably connected to tray 12. The lid flange 44 may define a protrusion 52 of the second sealing structure 46. The lid flange 44 and the protrusion 52 may be non-detachably connected to the lid 14. The channel 50 may extend along at least three sides of the tray 12, such as the sides 22-26 of the container 10.

[0020] The tray 12 and the lid 14 are generally shown as having a rounded rectangular configuration, but may have other configurations, such as a circular configuration, an oval configuration, etc. The relative height and width and depth of the container 10 may be different from that shown. Although the tray 12 and the lid 14 are described as containing food, the food may be solid as well as liquid, including soup. In addition, the tray may be in the form of a cup for containing liquid, and the lid may be a lid for the cup. In addition, although the lid 14 is shown as being connected to the tray 12 by a hinge 40, the lid 14 may be completely separated from the tray 12, and the container 10 may not include the hinge 40. In an example without the hinge 40, the tray 12 may extend beyond the lid 14 at all four sides 20-26, so that the lid 14 is not visible from the bottom of the container 10 in the closed configuration.

[0021] Looking at the tray flange 34 in more detail, the tray flange 34 can extend outward from the peripheral sidewall 32 relative to the center of the tray 12 and can define a channel 50 for the first sealing structure 42. The channel 50 can be configured to at least partially receive a protrusion 52 of the cover 14 so as to provide a sealing interface (e.g., a sealing contact) between the first sealing structure 42 and the second sealing structure 46. The protrusion 52 can extend from the cover flange 44 around some or all of the perimeter of the cover 14. The top wall 54 can include an internal recessed portion 56, one or more external recessed portions 58, or a combination thereof. The top wall 54 can include a structural rib 60 that can at least partially define the internal recessed portion 56. The internal recessed portion 56 can be centered on the center of the top wall 54. The one or more external recessed portions 58 can be disposed at or near a corner of the top wall 54. Figure 2 In the open configuration shown in , the protrusion 52 can extend generally upward. Figure 1 In the closed configuration shown in FIG. 5 , the protrusion 52 can be inserted downwardly into the channel 50 .

[0022] Reference Figure 3 , the tray flange 34 may include an inner channel wall 70 and an outer channel wall 72 spaced apart from the inner channel wall 70. The inner channel wall 70 and the outer channel wall 72 may be connected by a bottom channel wall 74, which may be connected to the bottom wall 30 ( Figure 2 ) is parallel to the bottom wall 30 ( Figure 2 ) are parallel, but the bottom channel wall 74 may include other non-parallel configurations. The channel walls 70, 72, 74 can define the channel 50, and can be arranged so that the channel 50 includes a U-shaped configuration that is open upward (e.g., away from the bottom wall 30). The distance between the inner channel wall 70 and the outer channel wall 72 can define a channel width 50w. The inner channel wall 70 may include an inner channel wall length 70L that extends between the bottom channel wall 74 and a top 76 of the inner channel wall 70. The top 76 of the inner channel wall 70 can be disposed at a top 78 of the peripheral sidewall 32. The outer channel wall 72 may include an outer channel wall length 72L that extends from the bottom channel wall 74 to a top 80 of the outer channel wall 72. The outer channel wall length 72L may be shorter than the inner channel wall length 70L. Additionally or alternatively, relative to the bottom wall 30 ( Figure 2 ), the height of the top 80 of the outer channel wall 72 can be lower than the height of the top 76 of the inner channel wall 70.

[0023] The interior channel wall 70 can be vertical or can be angled such that a bottom portion 82 of the interior channel wall 70 is angled away from the peripheral sidewall 32, which can include the bottom portion 82 being disposed farther from the center of the container 10 than the top 76. In some configurations, the interior channel wall 70 can include vertical portions and angled portions.

[0024] The outer channel wall 72 can be vertical or can be angled so that the bottom portion 84 of the outer channel wall 72 is angled toward the peripheral sidewall 32, which can include the bottom portion 84 being disposed closer to the center of the container 10 than the top 80. In some configurations, the outer channel wall 72 can include a vertical portion and an angled portion. The angle of at least some portions of the channel walls 70, 72 can facilitate removal of the tray 12 from the mold during the molding process. The angle of at least some portions of one or both of the channel walls 70, 72 can be such that the width 50w of the channel 50 decreases toward the bottom channel wall 74, such that the width 50w is the smallest at the bottom channel wall 74. The channel walls 70, 72 and the resilient members 110, 112 can be angled at the same angle, respectively.

[0025] The bottom channel wall 74 may include a planar portion 90, a first curved portion 92, and a second curved portion 94 (e.g., a pair of curved portions). The first curved portion 92 may extend from the planar portion 90 and may be connected to the inner channel wall 70, such as to the bottom portion 82. The second curved portion 94 may extend from the side of the planar portion 90 opposite the first curved portion 92 and may be connected to the outer channel wall 72, such as to the bottom portion 84. The planar portion 90 may be parallel to the bottom wall 30 ( Figure 2 ), but may include non-parallel configurations. One or both of the inner channel wall 70 and the outer channel wall 72 may be planar and extend from respective curved portions 92 , 94 .

[0026] The tray flange 34 may include an outer flange wall 100 extending (e.g., downwardly) from the top 80 of the outer channel wall 72 such that at least a portion of the outer flange wall 100 is spaced apart from the outer channel wall 72. The outer channel wall 72 and the outer flange wall 100 may be arranged in a downwardly open U-shaped configuration.

[0027] Reference Figure 4, the protrusion 52 of the cover 14 may include an internal elastic member 110 and an external elastic member 112. In some examples, the internal elastic member 110, the external elastic member 112, or both may be configured as elastic walls. The internal elastic member 110 may extend downward from the top wall 54. The external elastic member 112 may extend outward and upward from a bottom portion 114 of the internal elastic member 110, such that at least a portion of the external elastic member 112 is spaced apart from the internal elastic member 110. The internal elastic member 110 and the external elastic member 112 may be arranged in a J-shaped configuration. For example, the length 110L of the internal elastic member 110 may be longer than the length 112L of the external elastic member 112, the bottom portion 114 of the internal elastic member 110 may be bent, and the bottom portion 116 of the external elastic member 112 may be bent. The protrusion 52 may include an unflexed configuration, such as Figure 4 . In the unflexed configuration, the protrusion 52 may include a width 52w that is wider than the channel width 50w. For example, in the unflexed configuration, the maximum value of the width 52w of the protrusion may be greater than the maximum value of the width 50w of the channel, or the minimum value of the width 52w of the protrusion may be greater than the minimum value of the width 50w of the channel; or the maximum value of the width 52w of the protrusion may be greater than the maximum value of the width 50w of the channel, and the minimum value of the width 52w of the protrusion may be greater than the minimum value of the width 50w of the channel.

[0028] The protrusion 52 may include an outer edge 140 disposed at a distal end of the outer elastic member 112. The outer elastic member 112 may define an outer elastic member plane 142. The protrusion 52 may include an angled protrusion 144 located at a distal end of the outer elastic member 112 that defines the outer edge 140. The angled protrusion 144 may extend at an angle relative to the outer elastic member plane 142, such as an oblique or right angle.

[0029] Structural ribs 60 may be disposed around the perimeter of lid 14, such as between lid flange 44 and interior recessed portion 56. Structural ribs 60 may increase the strength of lid 14. Interior recessed portion 56 may be used, for example, to at least temporarily store one or more items, such as napkins, cutlery, etc. Additionally or alternatively, interior recessed portion 56 may receive at least a portion of a second container configured in the same manner as container 10 when container 10 is in the closed configuration. For example, interior recessed portion 56 may receive a portion of the perimeter sidewall and bottom wall of the second container.

[0030] Reference Figure 5 , generally showing a portion of the container 10 in a closed configuration. In the closed configuration, the protrusion 52 of the lid 14 is at least partially disposed in the channel 50 in a flexed configuration. The protrusion 52 can be at least partially inserted into the channel 50 with an interference fit, which can involve the protrusion 52 being moved from an unflexed configuration ( Figure 4 ) to a flexed configuration. In the flexed configuration, at least one of the inner resilient member 110 and the outer resilient member 112 is flexed from its position in the unflexed configuration. For example, the inner resilient member 110 can be flexed outwardly relative to the center of the container 10 at least to a certain extent, the outer resilient member 112 can be flexed inwardly at least to a certain extent, or a combination thereof. In the flexed configuration, the inner resilient member 110 can be in contact with and biased against the inner channel wall 70, the outer resilient member 112 can be in contact with and biased against the outer channel wall 72, and the inner resilient member 110 and the outer resilient member 112 can be spaced apart from and not in contact with the bottom channel wall 74, so that there is a gap 130 between the bottom channel wall 74 and the protrusion 52. For example, the inner resilient member 110 can apply a first biasing force F1 to the inner channel wall 70, and the outer resilient member 112 can apply a second biasing force F2 to the outer channel wall 72. The biasing forces F1, F2 may correspond to the protrusion width 52w being greater than the channel width 50w and a corresponding deflection of at least one of the inner resilient member 110 and the outer resilient member 112 from an undeflected configuration to a deflected configuration due to the insertion of the protrusion 52 into the channel 50. The first biasing force F1 may be directed inwardly relative to the center of the container 10. The second biasing force F2 may be directed outwardly relative to the center of the container 10.

[0031] The contact between the protrusion 52 and the channel 50, such as the contact between the inner channel wall 70, the outer channel wall 72 and the inner resilient member 110, the outer resilient member 112, can provide a sealing joint at least one of (i) between the inner channel wall 70 and the inner resilient member 110 and (ii) between the outer channel wall 72 and the outer resilient member 112. For example, in the flexed configuration, the protrusion 52 and the channel 50 can cooperate to provide a liquid seal between the tray 12 and the lid 14.

[0032] One or more of the inner channel wall 70, the outer channel wall 72, the inner elastic member 110, and the outer elastic member 112 may include an increased surface roughness relative to other designs. For example, one or more of the walls 70, 72 and the elastic members 110, 112 may include pulp, which may have an increased surface roughness relative to other materials such as plastics and metals. In some examples, the surface roughness of one or more of the inner channel wall 70, the outer channel wall 72, the inner elastic member 110, and the outer elastic member 112 may be in the range of 200 Sheffield units to 1020 Sheffield units (i.e., equal to 200 Sheffield units or 1020 Sheffield units, or between 200 Sheffield units and 1020 Sheffield units), such as in the range of 800 Sheffield units to 1020 Sheffield units (i.e., equal to 800 Sheffield units or 1020 Sheffield units, or between 800 Sheffield units and 1020 Sheffield units), but may also have other roughness values.

[0033] The increased surface roughness can increase the force required to remove the protrusion 52 from the channel 50, which can limit accidental opening of the container 10, make the container 10 tamper-resistant, make container tamper-evident (e.g., attempting to remove the protrusion 52 may damage the protrusion 52, the channel 50, or both), or a combination thereof.

[0034] In the closed configuration of the container 10, and the protrusion 52 is in the flexed configuration, the outer edge 140 of the protrusion 52 can be arranged in the channel 50 and below the top 80 of the outer channel wall 72. For example, the length 72L of the outer channel wall 72 can be longer than the length 112L of the outer elastic member 112. In some examples, the outer edge 140 can be aligned between 20% and 80% of the outer channel wall length 72L, wherein 0% is represented at the bottom channel wall 74 and 100% is represented at the top 80 of the outer channel wall 72. Placing the outer edge 140 below the top 80 can make the outer edge 140 more difficult to access, which can make the container 10 tamper-resistant, tamper-evident, or both. For example, it may be challenging for a user to grasp the outer edge 140 in the channel 50, which may make it challenging to remove the protrusion 52 from the channel 50 and improperly open the container 10 without damaging one or both of the protrusion 52 and the channel 50.

[0035] Reference Figure 6, generally showing portions of an example of a container 10 having a hinge 40. The hinge 40 can be located on the first side 20 of the container 10. The hinge 40 can include a weakening line 160 in the form of a score line, a series of perforations, or a combination thereof to weaken the hinge 40 so that the hinge 40 can be torn along the weakening line 160 to separate the lid 14 from the tray 12. The weakening line 160 can form a hinge line or hinge axis about which the tray 12 and the lid 14 can rotate relative to each other to move the container 10 between an open configuration and a closed configuration.

[0036] Reference Figure 7 , the tray 12 may include one or more tray protrusions 170 that may extend outward from the tray flange 34, such as from the corner of the intersection of the first side 20 and the third side 24, from the corner of the intersection of the first side 20 and the fourth side 26, or both. The lid 14 may include one or more lid protrusions 172 that are laterally spaced apart from the tray protrusion 170. As shown, the tray protrusion 170 and the lid protrusion 172 may be labeled with the words "LIFT" and "HOLD", respectively, to guide the consumer to open the container. The lid protrusion 170 and the tray protrusion 172 may be labeled with different words or no words at all.

[0037] The tray 12 and lid 14 may be integrally formed, such as via wet or dry pulp molding. If the container 10 includes a hinge 40, the hinge 40 may be integrally formed with the tray 12, the lid 14, or both. Non-limiting examples of suitable materials for the container 10 include pulp, such as from recycled paper. All or part of the container 10 may be compostable.

[0038] While the lid 14 has a generally rectangular shape and may be considered to include opposing front and rear sides 20, 22 and opposing lateral sides 24, 26, the container 10 including the tray 12 and lid 14 may have a variety of different shapes, including non-linear shapes such as circular, oval, hexagonal, etc.

[0039] Reference Figure 7, to open the container 10, the consumer 180 separates the lid 14 from the tray 12, such as via the hinge 40. The outer edge 140 disposed or recessed in the channel 50 can limit or prevent access to the outer edge. To separate the lid 14 from the tray 12, the consumer 180 grasps the lid tab 172 and the tray tab 170 and pulls the lid tab 172 to separate the lid 14 from the tray 12. When the consumer 180 pulls the lid tab 172, the protrusion disengages from its position within the channel 50 and the hinge 40 tears along the weakened line 160. In this manner, the recessed position of the outer edge 140 relative to the open top of the channel 50 provides a tamper-proof function to the container 10 because the container 10 is not easily opened unless in a manner that provides evidence that the container 10 has been opened (e.g., by tearing the hinge 40).

[0040] In the example with hinge 40, after container 10 is fully opened, tray 12 and lid 14 can be separated along hinge 40, such as Figure 8 As shown. The tearing of the hinge 40 provides evidence to the consumer that the container 10 has been opened or that an attempt has been made to open the container 10. After the lid 14 has been separated from the tray 12 to gain access to the contents of the container 10, the lid 14 can be replaced on the tray 12 and held in place by the engagement between the protrusion 52 and the channel 50. The consumer 180 can apply force to one or more of the recessed portions 56, 58, which can be marked with the word "LOCK", with a different label, or without a label. The torn hinge 40 serves as a visual indicator that the container 10 has been opened and provides a tamper-evident feature to the container 10.

[0041] The hinge 40 may not extend along the entire length of the first side 20 of the container 10, but may extend only along the portion of the first side 20 located between the lid protrusions 172. The tray protrusion 170 may be laterally spaced from both the hinge 40 and the lid protrusion 172. The length of the hinge 40 and the spacing of the tray protrusion 170 from the hinge 40 and the lid protrusion 172 provide space below the lid protrusion 172 for the consumer 180 to grasp the lid protrusion 172, thereby making it easier for the consumer 180 to fully grasp the lid protrusion 172 and provide sufficient force to overcome the peripheral seal between the tray 12 and the lid 14 (e.g., between the protrusion 52 and the channel 50) to separate the tray 12 and the lid 14.

[0042] Although the container 10 is shown as having a pair of tray protrusions 170 and lid protrusions 172 on each side of the hinge 40, the container 10 may have other numbers of protrusions, such as a single tray protrusion 170 and a single tray protrusion 172, more than two tray protrusions 170, or more than two lid protrusions 172.

[0043] The container 10 may contain an amount of plastic to modify certain properties or may be free of plastic.

[0044] Although tray 12 is described as including channel 50 and lid 14 is described as including protrusion 52, the configuration may be reversed such that tray 12 includes protrusion 52 and lid 14 includes channel 50, or a combination thereof (e.g., tray 12 and lid 14 each include a portion of channel 50 and protrusion 52).

[0045] The following clauses define additional aspects of the present disclosure, which are included herein. These aspects can be combined as desired to form combinations included in the present disclosure.

[0046] A pulp molded container comprises: a tray including a bottom wall and a peripheral side wall, the peripheral side wall extending upward from the bottom wall and terminating in a flange, the flange at least partially defining an open top, the flange having a channel defined by spaced inner and outer channel walls connected by a bottom channel wall; and a lid that closes the open top in a closed configuration, the lid including a protrusion that is biased against at least one of the inner and outer channel walls and forms a sealed joint between at least one of the inner and outer channel walls and the protrusion.

[0047] A container according to any preceding clause, wherein the surface roughness of the inner channel wall is in the range of 200 Sheffield Units to 1020 Sheffield Units (ie equal to 200 Sheffield Units or 1020 Sheffield Units or between 200 Sheffield Units and 1020 Sheffield Units).

[0048] A container according to any preceding clause, wherein the surface roughness is in the range of 800 Sheffield Units to 1020 Sheffield Units (ie equal to 800 Sheffield Units or 1020 Sheffield Units or between 800 Sheffield Units and 1020 Sheffield Units).

[0049] A container as claimed in any preceding clause, wherein, in the closed configuration, the protrusion is in contact with the inner channel wall and the outer channel wall and is spaced from the bottom channel wall.

[0050] A container according to any preceding clause, wherein the channel is U-shaped and open upwardly; and wherein the protrusion is J-shaped and open upwardly.

[0051] A container according to any of the preceding clauses, wherein the distance between the inner channel wall and the outer channel wall defines the channel width; in the undeflected configuration of the protrusion, the width of the protrusion is greater than the channel width.

[0052] A container as described in any of the preceding clauses, wherein inserting the protrusion into the channel causes the protrusion to flex from an unflexed configuration to a flexed configuration such that the protrusion applies a biasing force to at least one of the inner channel wall and the outer channel wall.

[0053] A container according to any preceding clause, wherein in the deflected configuration of the protrusion, the protrusion applies an inward force to the inner channel wall and an outward force to the outer channel wall relative to the centre of the tray.

[0054] A container as described in any preceding clause, wherein in the flexed configuration the outer edge of the protrusion is disposed in the channel below the top of the outer channel wall.

[0055] A container according to any of the preceding clauses, wherein the outer channel wall defines an outer channel wall length between the top and bottom channel walls of the outer channel wall; in the flexed configuration, the outer edge of the protrusion is aligned between 65% and 75% of the outer channel wall length.

[0056] A container according to any preceding clause, wherein at least one of the inner channel wall and the outer channel wall is planar.

[0057] A container according to any of the preceding clauses, wherein the inner channel wall and the outer channel wall are planar and the bottom channel wall has a planar portion and a pair of curved portions extending from the planar portion and connected to the inner channel wall and the outer channel wall.

[0058] A container as claimed in any preceding clause, wherein, in the flexed configuration, the protrusion and the channel cooperate to provide a liquid seal between the tray and the lid.

[0059] A container according to any preceding clause, wherein the outer channel wall is shorter than the inner channel wall.

[0060] A container according to any of the preceding clauses, wherein the protrusion comprises an outer resilient member defining an outer resilient member plane; and the protrusion comprises an angled projection defining an outer edge, the angled projection extending at an angle relative to the outer resilient member plane.

[0061] A container as described in any of the preceding clauses, wherein, in the flexed configuration, the protrusion contacts the inner channel wall and the outer channel wall, and the protrusion does not contact the bottom channel wall.

[0062] A container according to any of the preceding clauses, wherein the inner channel wall is vertical or angled so that the bottom portion of the inner channel wall is angled away from the peripheral side wall; and wherein the outer channel wall is vertical or angled so that the bottom portion of the outer channel wall is angled toward the peripheral side wall.

[0063] A container according to any of the preceding clauses, wherein the flange includes an outer flange wall extending downward from the top of the outer channel wall so that at least a portion of the outer flange wall is spaced apart from the outer channel wall; and wherein the outer channel wall and the outer flange wall are arranged in a downwardly open U-shaped structure.

[0064] A container according to any of the preceding clauses, wherein the lid has a rectangular configuration, a circular configuration, or an oval configuration; and the container is free of plastic.

[0065] A container according to any preceding clause, comprising a hinge rotatably connecting the tray and the lid.

[0066] A container as claimed in any preceding clause wherein the tray, lid and hinge are integrally formed from pressed pulp fibres.

[0067] A container as claimed in any preceding clause, wherein the channel extends along at least three sides of the tray.

[0068] A container as claimed in any preceding clause, wherein the tray and lid are compostable.

[0069] A container as claimed in any preceding clause, wherein the flange is non-detachably connected to the tray and the protrusion is non-detachably connected to the lid.

[0070] A pulp molded container comprises: a tray including a bottom wall and a peripheral side wall, the peripheral side wall extending upward from the bottom wall and terminating in a flange, the flange at least partially defining an open top, the flange having a channel defined by spaced inner and outer channel walls connected by the bottom channel wall; a lid that closes the open top in a closed configuration, the lid including a protrusion that is biased against at least one of the inner and outer channel walls and forms a sealing joint between at least one of the inner and outer channel walls and the protrusion; and a hinge that rotatably connects the tray and the lid.

[0071] A container according to any preceding clause, wherein the lid and tray have a rectangular configuration, a circular configuration or an oval configuration.

[0072] In the scope not yet described, different features and structures of various aspects of the present disclosure can be used in combination with each other as needed. For example, one or more features shown and / or described with respect to one aspect of the present disclosure can be used or combined with one or more features shown and / or described with respect to other aspects. A feature may not be shown in all aspects of the present disclosure, which does not mean that it cannot be done, but for the sake of brevity of description. Therefore, various features of different aspects can be mixed and matched as needed to form new aspects, whether or not the new aspects are explicitly described.

[0073] Although aspects of the present disclosure have been specifically described in conjunction with certain specific aspects of the present disclosure, it should be understood that this is illustrative rather than restrictive. Reasonable variations and modifications may be made within the scope of the foregoing disclosure and the accompanying drawings without departing from the spirit of the present disclosure as defined in the appended claims.

Claims

1. A pulp molded container, comprising: Pallet, including: a bottom wall; and a peripheral sidewall extending upwardly from the bottom wall and terminating in a flange at least partially defining an open top, the flange having a channel defined by spaced apart inner and outer channel walls connected by a bottom channel wall; and A cover closes the open top in a closed configuration, the cover including a protrusion biased against at least one of the inner channel wall and the outer channel wall and forming a sealing joint between at least one of the inner channel wall and the outer channel wall and the protrusion.

2. The container according to claim 1, wherein The surface roughness of the inner channel wall is in the range of 200 Sheffield units to 1020 Sheffield units.

3. The container according to claim 2, wherein: The surface roughness is in the range of 800 Sheffield units to 1020 Sheffield units.

4. The container according to claim 3, wherein: In the closed configuration, the protrusion is in contact with the inner channel wall and the outer channel wall and is spaced apart from the bottom channel wall.

5. The container according to claim 1, wherein The channel is U-shaped and open upwards; and Wherein, the protrusion is J-shaped and open upward.

6. The container according to claim 1, wherein The distance between the inner channel wall and the outer channel wall defines a channel width; and In an undeflected configuration of the protrusion, a width of the protrusion is greater than a width of the channel.

7. The container according to claim 6, wherein: Inserting the protrusion into the channel deflects the protrusion from the undeflected configuration to a deflected configuration such that the protrusion applies a biasing force to at least one of the inner channel wall and the outer channel wall.

8. The container according to claim 6, wherein: In the deflected configuration of the protrusion, the protrusion applies an inward force to the inner channel wall and an outward force to the outer channel wall relative to the center of the tray.

9. The container according to claim 8, wherein In the flexed configuration, the outer edge of the protrusion is disposed in the channel below the top of the outer channel wall.

10. The container according to claim 9, wherein the outer channel wall defining an outer channel wall length between a top portion of the outer channel wall and the bottom channel wall; In the flexed configuration, the outer edge of the protrusion is aligned between 65% and 75% of the length of the outer channel wall.

11. The container according to claim 9, wherein At least one of the inner channel wall and the outer channel wall is planar.

12. The container according to claim 11, wherein The inner channel wall and the outer channel wall are planar, and the bottom channel wall has a planar portion and a pair of curved portions extending from the planar portion and connected to the inner channel wall and the outer channel wall.

13. The container according to claim 9, wherein: In the flexed configuration, the protrusion and the channel cooperate to provide a liquid seal between the tray and the cover.

14. The container according to claim 9, wherein The outer channel wall is shorter than the inner channel wall.

15. The container according to claim 9, wherein The protrusion includes an outer resilient member defining an outer resilient member plane; and The protrusion includes an angled projection defining the outer edge, the angled projection extending at an angle relative to the outer resilient member plane.

16. The container according to claim 9, wherein In the flexed configuration, the protrusion is in contact with the inner channel wall and the outer channel wall, and the protrusion is not in contact with the bottom channel wall.

17. The container according to claim 9, wherein: The interior channel wall is vertical or angled such that a bottom portion of the interior channel wall is angled away from the peripheral side wall; and Wherein, the outer channel wall is vertical or angled such that a bottom portion of the outer channel wall is angled toward the peripheral side wall.

18. The container according to claim 1, wherein the flange comprising an outer flange wall extending downwardly from a top of the outer channel wall such that at least a portion of the outer flange wall is spaced apart from the outer channel wall; and Wherein, the outer channel wall and the outer flange wall are arranged to be a U-shaped structure open downwards.

19. The container according to claim 1, wherein The cover has a rectangular configuration, a circular configuration, or an oval configuration; and The container contains no plastic.

20. The container of claim 1, comprising a hinge rotatably connecting the tray to the lid.

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