Paper-based or paperboard-based container

Abstract

A container (1) made of a paper-based or paperboard-based material comprises a sleeve (3) and a molded pulp end plug (50) closing the top end thereof. The end plug includes resilient locking tabs (70) projecting outwardly, each locking tab being received in a respective recess (140) in the interior of the sleeve to securely retain the molded pulp end plug within the end of the sleeve. The sleeve (3) comprises a housing (31) and an insert (33) having a recess (140). The end plug (50) is formed by first and second mutually engaging portions (60, 62). The first portion includes a resilient locking tab (70), and a second portion (62) fits within the first portion and has a sidewall that engages an interior of the sidewall of the first portion to reinforce the first portion.

Description

Technical Field

[0001] The present invention relates to containers made from cardboard-based or paper-based materials, and particularly, but not exclusively, to containers for bottles. Background Art

[0002] From the perspective of environment and sustainability, it is desirable to reduce the amount of plastic material used in packaging. For this reason, containers made of cardboard or paperboard can be used. However, there is a challenge in providing containers of cardboard or paperboard material that is strong enough to hold fragile items (such as bottles). Previous attempts to solve this problem involve using plastic materials to provide strong end closures for containers, for example, providing end plugs and fixing them to the cardboard body of the container. Using plastic materials in this way makes it more difficult to recycle the container effectively and undesirably increases the plastic content of the container because the user must separate the plastic and cardboard material components of the container from each other so that they can be discarded in a suitable recycling stream specifically for plastic and cardboard / paper-based materials. If the user fails to properly separate the materials and discards the entire container in a waste stream intended for cardboard / paper-based materials, this can lead to contamination of the entire batch of materials. Summary of the Invention

[0003] According to the present invention, there is provided a container made of a paper-based or cardboard-based material, comprising:

[0004] a sleeve having a first end and a second end, a first end closure closing the first end of the sleeve, and a second end closure closing the second end of the sleeve;

[0005] the sleeve including a plurality of side walls extending between a first end and a second end thereof, wherein the first side wall of the sleeve includes an opening therein to provide access to an interior space of the sleeve in which the product is disposed when in use;

[0006] The first end closure comprises a molded pulp end plug including resilient locking tabs projecting outwardly therefrom, each locking tab being received in a corresponding recess in the interior of the sleeve to securely retain the molded pulp end plug within the first end of the sleeve.

[0007] The container is made of a cardboard- or paper-based material and includes a closure at its first end, which includes a molded pulp end plug. The end plug includes a formation in the form of a resilient tab protruding outwardly therefrom, which engages with a corresponding recess formed in the interior of the sleeve. In this way, the end plug is securely held in place within the sleeve. The resilient locking tab is provided by a molded formation of the molded pulp end plug. Thus, the resilient locking tab is integrated with (a portion of) the molded pulp end plug. Thus, a secure fastening of the molded pulp end plug to the sleeve is achieved without the need for any plastic fasteners. This can provide a more sustainable container and promote recycling, as the end plug does not need to be removed from the rest of the container before the container is discarded in a recycling stream for cardboard- or paper-based materials. The molded pulp end plug directly cooperates with the sleeve to provide a secure fastening of the end plug to the sleeve.

[0008] When the end plug is inserted into the sleeve through the first end of the sleeve during use, the locking tabs of the end plug can be deflected inwardly and once the locking tabs are aligned with their corresponding recesses, the locking tabs spring outwardly to securely hold the end plug in place. The locking tabs deflect inwardly when the locking tabs engage the side wall of the sleeve in the area between the recess and the first end of the sleeve.

[0009] Each resilient locking tab associated with the molded pulp end plug may be configured to hook into its corresponding recess. The resilient locking tab may be referred to as a resilient locking "hook."

[0010] Each resilient locking tab associated with a molded pulp end plug may have a first end edge that cooperates with an edge of a recess to retain the tab in its recess. The edge of the recess is the edge at the first end of the recess, i.e., its first end edge. Thus, the tab extends into the recess. The cooperating edges of the locking tab and the recess engage with each other to retain the tab in the recess. In this manner, the resilient locking tab defines a hook that is inserted into the recess. In an embodiment, the first end edge of the locking tab is its free end edge. The second end of the locking tab provides the base of the locking tab and is connected to the body of a portion of the end plug (e.g., the body of the first portion thereof, where the end plug includes a first portion and a second portion as described herein). The second end of the locking tab may be connected to the base of the first portion of the end plug. The second end of the locking tab may extend inwardly from the recess in the sidewall of the sleeve to engage the interior of the sleeve sidewall below the recess. Below the recess refers to a position closer to the second end of the sleeve than the second end edge of the recess. This may assist in obtaining a press fit between the end plug and the sleeve.

[0011] Regardless of its configuration, the first end edge of the resilient locking tab cooperating with the first end edge of the recess can engage the edge of the recess between the inner and outer ends of the first end edge of the recess, such that the resilient locking tab does not extend completely through the recess. Consequently, the tab does not extend beyond the plane in which the outermost portion of the recess lies. This enables an outer layer of the container (e.g., an outer jacket or shell of the sleeve) to be positioned in face-to-face contact with the exterior of the sleeve or a layer of the sleeve having the recess, thereby covering the tab and the recess.

[0012] According to the present invention, in any of its aspects or embodiments, each resilient locking tab of a molded pulp end plug may be curved outwardly in a direction from the second end of the tab toward the first end of the tab. The tab may include an outwardly curved surface on its exterior that extends from the second end of the tab toward its first end. The curved shape extends from the second end of the tab over at least a portion of the tab's height, and optionally only over a portion of its height. The curved shape of the tab facilitates insertion of the end plug into the sleeve and positions the first end edge of the locking tab outside the second end of the tab to facilitate hooking the tab into its corresponding recess. The curved shape can be easily produced using the molded pulp process. The curved shape imparts curved inner and outer surfaces to the tab. The curved outer surface can cooperate with corresponding inner inclined surfaces of the sidewall of the sleeve to guide insertion of the end plug, as described below.

[0013] In an embodiment, each resilient locking tab of the molded end plug is configured to hook into its corresponding recess in the sleeve, the locking tab having a first end edge that cooperates with the first end edge of the recess to retain the tab in its recess, the resilient locking tab being bent outwardly in a direction from the second end of the tab toward the first end of the tab.

[0014] The molded pulp end plug of the first closure member can be secured within the first end of the sleeve without the use of adhesive. In an embodiment, the molded pulp end plug is secured to the sleeve without the aid of any external fixing means. Thus, the molded pulp end plug is secured to the sleeve without the need for a plastic fixing.

[0015] The molded pulp end plug can be secured within the first end of the sleeve by a press fit. The press fit and cooperation of the resilient locking tab with the recess securely holds the end plug in place. The molded pulp end plug can be secured within the first end of the sleeve by a press fit and cooperation of the resilient locking tab with the recess, without the use of adhesive. The resilient locking tab of the end plug clamps into the recess of the sleeve.

[0016] The sleeve may be formed from any suitable card-based or paper-based material, such as cardboard or paperboard. The side walls of the sleeve are hingedly connected to each other. The side walls of the sleeve are connected to each other along a fold line.

[0017] The sleeve has a first end and a second end. The container similarly has a first end and a second end. The first end and the second end can be referred to as a top end and a bottom end (or an upper end and a lower end). The container is typically used with the first end being the uppermost end. The sidewalls of the sleeve have a height extending in a direction between the first end and the second end of the sleeve, and a width in a direction perpendicular to the height. The width can be a direction perpendicular to the direction of the fold lines connecting adjacent sidewalls to each other in the sidewalls. The sidewalls of the sleeve can be square or rectangular in shape, that is, they can be rectilinear.

[0018] The sleeve includes a first sidewall having an opening therein for providing access to the interior space of the sleeve. The opening allows the product contained in the container to be removed through the opening during use. Thus, the container has a form in which the product located therein is removed during use through the opening in the first sidewall of the sleeve, for example, through the front panel of the sleeve. Thus, the product can be removed without removing the first and second end closures from the first and second ends of the sleeve. The opening extends through the entire thickness of the first sidewall to create an aperture through the first sidewall. The first sidewall may be the only sidewall of the sleeve having an opening extending through its entire thickness.

[0019] The opening in the first side wall is preferably configured to allow a product in the form of a bottle, such as a drinks bottle, contained in the container to be removed therethrough in use.The bottle may be a glass bottle.

[0020] However, the opening in the first sidewall of the sleeve may have any suitable configuration, depending on the nature of the product to be placed in the container. The opening may be shaped and sized to expose the product through the opening, facilitate removal of the product through the opening, and allow the user to view the product when the opening is exposed. For example, the opening may extend over at least 50% or at least 75% of the area of ​​the sidewall. This arrangement may be particularly suitable when a bottle is placed in the container. The opening may be linear in shape. The opening may extend over a substantial portion or all of the area of ​​the product facing the first sidewall.

[0021] The sleeve may further include a second sidewall opposite the first sidewall, and a pair of opposing third and fourth sidewalls extending between the first and second sidewalls. The third sidewall is hingedly connected to the first sidewall along a fold line on one side thereof and is hingedly connected to the second sidewall along a fold line on the other side thereof. The fourth sidewall is connected to the first and second sidewalls along a fold line on each side thereof.

[0022] The resilient locking tabs of the moulded pulp end plugs may all have the same construction.

[0023] In an embodiment, the molded pulp end plug of the first end closure includes a plurality of sidewalls, each sidewall extending along a corresponding one of the sidewalls of the sleeve, wherein each of the one or more sidewalls of the end plug includes one or more resilient locking tabs protruding outwardly therefrom. Each such locking tab is then received in a corresponding recess in the corresponding sidewall of the sleeve. In an embodiment, each of the plurality of sidewalls of the end plug includes one or more resilient locking tabs protruding outwardly therefrom. The plurality of sidewalls of the end plug having such resilient locking tabs may include at least one pair of opposing sidewalls of the end plug. By providing one or more resilient locking tabs associated with at least one pair of opposing sidewalls of the molded pulp end plug, the securement of the molded pulp end plug to the sleeve may be enhanced. The plurality of sidewalls of the molded pulp end plug having such resilient locking tabs may also include a sidewall connecting a pair of opposing sidewalls of the sidewalls.

[0024] It will be appreciated that the sleeve and the moulded pulp end plug may each comprise at least one pair of opposing side walls, such as a first pair of opposing side walls and a second pair of opposing side walls.The sleeve and the moulded pulp end plug may each comprise four side walls.

[0025] In any of the embodiments, the sidewall of the molded pulp end plug extending along the first sidewall of the sleeve may be devoid of the resilient locking tabs. This may facilitate insertion of the end plug and may assist with alignment features that control the orientation in which the end plug may be inserted into the sleeve. This may also enable the first sidewall of the sleeve to be formed without recesses therein, for example using a single-layer construction as discussed below. Using a single-layer construction for the first sidewall may avoid the need to align openings in multiple layers to provide an opening in the first sidewall through which the product may be accessed.

[0026] In some embodiments, the plurality of side walls of the molded pulp end plug having the resilient locking tab(s) may include all side walls of the end plug except for the side walls that extend along the first side wall of the sleeve.

[0027] For example, the molded pulp end plug of the first end closure may include first, second, third, and fourth side walls extending along the first, second, third, and fourth side walls of the sleeve, respectively. The side walls of the end plug having the resilient locking tab may include the third and fourth side walls, and optionally, in addition, the second side wall. In an embodiment, the first side wall of the molded pulp end plug is free of the resilient locking tab.

[0028] The sidewalls of the molded pulp end plug engage corresponding sidewalls of the sleeve to help provide a press fit between the end plug and the interior of the sleeve. The sidewalls of the molded pulp end plug having the resilient locking tabs provide the outermost sidewalls of the end plug that engage the sidewalls of the sleeve. In some embodiments, as discussed below, the molded pulp end plug may have a two-piece form having a second interior portion having its own sidewalls that are integrally disposed inboard of such outermost sidewalls of the end plug.

[0029] The height of the resilient locking tab may be the same as the height of the (outermost) side wall of the side wall of the end plug engagement sleeve. The first end edge of the resilient locking tab may provide an outwardly protruding segment that connects the first end edge of the side wall portion on either side thereof. The first end edge of the resilient locking tab may be the same as the height of the first end edge of the side wall portion on either side thereof.

[0030] Each resilient locking tab is connected to a portion of the sidewall of its associated end plug on either side. The locking tabs are configured such that, when a force is applied to the locking tab, pushing the tab inward, the tab deflects from an initial position relative to the sidewall in a direction perpendicular to the sidewall toward the interior of the sleeve, and returns to its initial position due to its inherent elasticity when the force is removed. This enables the tab to deflect inward when its first end engages the interior of the sleeve when the end plug is inserted into the sleeve, allowing the end plug to slide into the sleeve until the tab aligns with its corresponding recess in the sleeve, and then springs outward again to lock into the recess. The first end edge of the tab can engage the first end edge of the recess to lock the tab into the recess. Each resilient locking tab can protrude outward from a portion of the end plug's sidewall on either side. The side edge and second end edge of each tab can each be rounded. The rounded edges of the tabs may facilitate smooth insertion of the end plug into a position where the tabs lock into their corresponding recesses, and may be easily formed using a pulp molding process.

[0031] The one or more resilient locking tabs associated with each of the side walls of the end plug may be a plurality of resilient locking tabs. Thus, each of the side walls of the end plug having a resilient locking tab protruding outwardly therefrom may include a plurality of resilient locking tabs protruding outwardly therefrom. For example, each side wall of the end plug having a resilient locking tab may include a pair of such locking tabs. This may further help enhance the stability of the connection between the end plug and the sleeve. Each side wall having a resilient locking tab may have two such tabs, or may have a plurality of two locking tabs. The most suitable arrangement will depend on factors such as the desired strength of the connection, as well as the configuration of the locking tabs and / or the recesses with which they engage. For example, the most appropriate number of locking tabs may vary depending on the weight and / or shape of the product to be retained in the container.

[0032] The resilient locking tabs associated with the side walls of the molded pulp end plug are discrete locking tabs. Therefore, they are separate from each other.

[0033] A plurality of resilient locking tabs associated with the sidewall of the end plug are spaced apart along the length of the sidewall. This provides a portion of the sidewall between the tabs that can engage the corresponding sidewall of the sleeve. This helps provide a press fit between the end plug and the sleeve. Tabs are similarly spaced apart from each end of the sidewall of the end plug. This again provides a portion of the sidewall adjacent the end of the sidewall that can engage the corresponding sidewall of the sleeve.

[0034] The (multiple) recesses of the sleeve for receiving the elastic locking tabs are on the inside of the side wall of the sleeve. Therefore, they are recesses in the inner surface of the sleeve. The recesses of the sleeve for receiving the elastic locking tabs can be spaced apart from the edge of the sleeve at its first end. Therefore, each recess can include a first end edge closest to the first end of the sleeve and a second end edge closest to the second end of the sleeve. Each recess can also include a pair of side edges connecting the first end edge and the second end edge. When the end plug is inserted into the sleeve through the first end of the sleeve, when the locking tab engages the side wall of the sleeve in the area between the recess and the first end of the sleeve (that is, above the recess), the locking tab deflects inwardly. The recess can have any suitable shape. In some exemplary embodiments, they are square or rectangular.

[0035] The molded pulp end plug may also include an alignment feature so that the end plug can only be inserted into the sleeve in a predetermined orientation relative to the sleeve. It may be important to ensure that the molded pulp end plug at the first end of the sleeve can only be inserted into the sleeve in a particular orientation to ensure that the product support on the second side of the end plug is properly aligned with respect to the first sidewall of the sleeve having an opening therein, to allow access to the product and to allow the product to be removed from the sleeve through the opening in the first sidewall. For example, where the product support of the end plug comprises a molded pulp collar, the open end of the collar is aligned so as to face the first sidewall of the sleeve so that the product can be removed from the interior of the sleeve through the opening in the first sidewall. Otherwise, the product may become stuck in the sleeve. Where provided, such a collar can be sized and configured as needed to accommodate the product to be accommodated, for example, to receive the top of a bottle to be accommodated in a container. In an embodiment, the molded pulp end plug of the first end closure includes a product support having a collar on its second side, and the predetermined orientation is an orientation in which the open end of the collar faces the first sidewall of the sleeve so that the product can be removed from the interior of the sleeve through the opening in the first sidewall. The product support (e.g., collar) is integrally molded with a portion of the end plug. Thus, it is a molded pulp product support, such as a collar. The collar can be configured to receive the top of a bottle when placed in the container during use.

[0036] The use of the alignment feature enables reliable assembly of the container in an automated manner (e.g., using a robot), ensuring that the first end plug fits in an orientation that will subsequently allow the product to be removed through the opening in the first sidewall of the sleeve (i.e., through the front of the sleeve) during use. During assembly, the product (e.g., a bottle) can be inserted into the container (i.e., in the sleeve), and then the first end closure is inserted into the first end of the sleeve to close the first end of the container. The predetermined orientation is a rotational orientation relative to the longitudinal axis of the container. The alignment feature also prevents the first end plug from being inserted in an upside-down condition.

[0037] The alignment feature may be provided in a variety of ways. The alignment feature may include one or more measures that require the molded pulp end plug to be inserted in a specific orientation. In some embodiments, the molded pulp end plug includes one or more resilient alignment tabs protruding outwardly therefrom, each resilient alignment tab being received in a corresponding additional recess in the interior of the sleeve, the one or more resilient alignment tabs providing an alignment feature such that the end plug can only be inserted into the sleeve in a predetermined orientation. The additional recess(es) for receiving the alignment tab(s) may be referred to as alignment recess(es). The resilient alignment tabs are similar to the resilient locking tabs and are provided by a molded formation of the end plug. Thus, the resilient alignment tabs are integrated with (part of) the molded pulp end plug. The resilient alignment tabs are discrete tabs.

[0038] In an embodiment, one of the side walls of the molded pulp end plug of the first end closure having one or more resilient locking tabs further comprises one or more resilient alignment tabs, and the corresponding side wall of the sleeve comprises one or more additional recesses for receiving a corresponding one of the one or more resilient alignment tabs, the one or more resilient alignment tabs providing an alignment feature such that the end plug can be inserted into the sleeve only in a predetermined orientation (relative to the sleeve). Such resilient alignment tab(s) may be associated with only one of the side walls of the end plug (e.g., its second side wall). The one or more resilient alignment tabs may comprise a plurality of such tabs, such as two tabs. Using multiple alignment tabs may enhance the ease with which the end plug can be aligned with respect to the sleeve, but a single alignment tab will provide the desired effect.

[0039] In some embodiments, a pair of resilient alignment tabs are provided associated with the sidewalls of the end plug, the alignment tabs being located outboard of one or more resilient locking tabs associated with the sidewalls. "Outboard" means that the resilient alignment tabs are located closer to the ends of the sidewalls (wherein the resilient alignment tabs abut the adjacent sidewalls). The alignment tabs may be arranged with one at each end of the sidewalls, with the locking tab being between the alignment tabs.

[0040] In one embodiment, each recess for receiving a resilient locking tab is spaced from the edge of the sleeve's first end, and each additional recess for receiving a corresponding resilient alignment tab extends to the edge of the sleeve's first end. This ensures that the end plug can only be slid relative to the sleeve toward its second end to insert the end plug into the sleeve's first end when each resilient alignment tab is aligned with a corresponding alignment recess in the sleeve. Otherwise, the bottom of the alignment tab would abut the edge of the sleeve's first end, preventing the first end plug from being inserted into the sleeve's first end. In one embodiment, the one or more recesses for receiving one or more resilient locking tabs are spaced from the edge of the sleeve's first end, and the one or more recesses for receiving one or more resilient alignment tabs extend to the edge of the sleeve's first end.

[0041] The elastic alignment tab can have a structure different from the elastic locking tab. For example, they can be different in shape and / or size. In an embodiment, the elastic alignment tab is smaller than the elastic locking tab.

[0042] The resilient locking tab(s) (and resilient alignment tab(s), where provided) associated with the side wall of the molded pulp end plug are located along the length of the side wall and form projections on either side of the side wall relative to portions of the side wall. The side wall of the molded pulp end plug is continuous, with the locking tabs (and, where applicable, alignment tabs) being defined by projecting portions of the side wall.

[0043] It will be appreciated that the alignment features may alternatively or additionally comprise(s) measures other than providing one or more resilient alignment tabs as exemplified above. For example, whether or not alignment tabs are provided, the interior of the first end of the sleeve and the exterior of the molded pulp end plug of the first end closure may be provided with corresponding angled surfaces that must be aligned with each other in order to allow the end plug to be inserted into the first end of the sleeve.

[0044] The recess of the sleeve with which the resilient locking tab cooperates can be provided in any suitable manner. The recess is provided in the inner surface of the sleeve. In an embodiment, the recess does not extend to the outer surface of the container. This can provide a more attractive appearance. A continuous outer surface of the container can be provided, for example, it can be printed (or the like) with suitable decoration, such as a brand logo. Although in exemplary embodiments, the recess does not extend through the entire thickness of the sleeve, this is not necessarily the case. For example, in the case where the sleeve is covered by another external member (such as a jacket), this can cover the recess in the sleeve. The recess can then be in the form of a groove extending through the entire thickness of the sleeve.

[0045] In an embodiment, the recesses do not extend through the entire thickness of the sidewall of the sleeve. For example, they may be cut into the sidewall of the sleeve. The recesses may then be provided by notches extending through only a portion of the thickness of the sidewall of the sleeve. The sleeve may then have a single-layer structure. Alternatively, the recesses may be covered on the outside by one or more outer layers of the sleeve. For example, the recesses may be covered by an outer layer of the sleeve, wherein the recesses are provided by grooves in an inner layer of the sleeve. The recesses may also be covered by one or more outer layers of the container (such as the jacket of the container).

[0046] Where the end plug further comprises one or more resilient alignment tabs, and the sleeve further comprises one or more additional recesses for cooperating therewith, such additional recesses may be provided in the same manner as the recesses for cooperating with the resilient locking tabs. Thus, the recesses of the sleeve for cooperating with the resilient locking tabs, and optionally, where the end plug comprises one or more resilient alignment tabs, the recesses for cooperating with the one or more resilient alignment tabs, may be provided in any of the manners discussed with respect to the locking tabs. The difference is that the additional recess(es) may extend beyond the recess for receiving the locking tabs towards the first end edge of the sleeve.

[0047] In embodiments, each sidewall of the sleeve having one or more recesses for receiving the resilient locking tabs of the molded pulp end plug of the first end closure comprises, at least in the region of the first end of the sleeve, an inner layer and an outer layer, wherein each recess is provided by a slot extending through the inner layer of the sidewall, and the outer layer of the sidewall covers the slot. In these embodiments, the slot extends through the entire thickness of the inner layer of the sidewall. This provides an aperture extending through the inner layer of the sidewall from the interior to the exterior of the inner layer of the sidewall. The sidewall of the sleeve having the recesses may be a double-layered sidewall, i.e., consisting of an inner layer and an outer layer.

[0048] In embodiments where one of the side walls of the molded pulp end plug further comprises one or more resilient alignment tabs, each additional recess in the side wall of the sleeve for receiving a respective one of the one or more resilient alignment tabs is provided by a slot extending through the inner layer of the side wall, with the outer layer of the side wall covering the slot. The slot may also be covered by any outer layer of the container, such as its jacket.

[0049] The inner layer of the sleeve having the recess may be provided by any suitable inner layer of the sleeve, such as an inner fitting thereof.

[0050] In an embodiment, the sleeve comprises an insert and a housing, each comprising a plurality of panels hingedly connected to one another, wherein slots are provided in the insert panels and are covered by the housing panels. Each panel of the insert is covered by a corresponding panel of the housing. The insert panels face and are secured to the corresponding panel of the housing panels. The slots for providing recesses for cooperating with the locking tabs are provided in this manner. Where applicable, additional recesses for cooperating with the alignment tab(s) may also be provided in this manner.

[0051] The slots of the recessed portion of the sleeve providing for receiving the resilient locking tabs are spaced from the first end edge of the insert. Thus, each slot includes a first end edge closest to the first end of the insert and a second end edge closest to the second end of the insert. A pair of side edges may connect the first end edge and the second end edge. In embodiments in which one or more additional recesses are provided for receiving resilient alignment tabs, the additional recess(es) for receiving the resilient alignment tab(s) extend to the first end edge of the insert. The additional recess(es) interrupt the first end edge of the insert. Thus, the first end edge of the insert may provide an edge which cooperates with the alignment tab to prevent the molded pulp end plug from being inserted in an orientation other than a predetermined orientation in which the alignment tab is aligned with the first end of the alignment recess.

[0052] The sleeve may consist of an insert and an outer shell. The side walls of the sleeve then comprise no more than two layers provided by the insert and the panels of the outer shell. The first side wall then has a single-layer structure, and the other side walls of the sleeve have a double-layer structure.

[0053] The insert and the shell are both of card-based or paper-based material, such as cardboard or paperboard. Opposing faces of the panels of the insert and the shell may be bonded to each other, such as adhesively.

[0054] The insert and the housing can both be of single-piece construction. They can both be provided from a single blank. This can facilitate assembly.

[0055] The panels of the insert may or may not extend over the entire height of the panels of the shell. The insert may be provided only where it is needed, i.e., in the region of the first end of the sleeve, or may extend over a larger area of ​​the sleeve. The insert may act as a reinforcement shell, and therefore, it may be advantageous for it to extend over a larger area of ​​the shell. The shell defines the shape of the sleeve. The extent of the panels of the insert may be selected based on the degree of stability required for the container. In an embodiment, at least one of the panels of the insert extends substantially over the entire height of the corresponding panel of the shell. This can provide stability and also facilitate the positioning of the insert in the shell, i.e., the insert may be inserted until the panel(s) of its entire height reach the bottom of the shell. The first end edges of the insert and the shell may be aligned with each other.

[0056] In some embodiments, the first side wall of the sleeve is provided by a panel of the housing that defines the opening and is not lined with a panel of the insert. Then, the first side wall of the sleeve has a single layer structure. In some embodiments, the insert comprises only first, second and third panels that are covered by the first, second and third panels of the housing, respectively. The housing also comprises a fourth panel connecting the first and third panels thereof, the fourth panel providing the first side wall of the sleeve and comprising an opening therethrough for providing the opening of the sleeve. Of course, the first side wall of the sleeve may alternatively have a multilayer structure, provided that each layer encloses a corresponding opening to result in an opening through the first side wall of the sleeve. However, the use of a single layer first side wall avoids the need to align multiple components having apertures.

[0057] According to the present invention, in any of its embodiments, the first end edge of the sleeve may be spaced apart from the first end edge of the container. This allows the first end edge of the sleeve to cooperate with a portion of the molded pulp first end plug (e.g., its flange) to provide an end stop when the end plug is inserted through the first end of the sleeve. A portion of the end plug (e.g., its flange) may be located in the space between the first end edge of the sleeve and the first end edge of the container. The space may be such that, when fully inserted into the sleeve, with a portion of the first end closure (e.g., the flange) abutting the first end edge of the sleeve, the first end closure is flush with the first end edge of the container. In these embodiments, the container includes an external member disposed outside the sleeve that defines the first end edge of the container. For example, the external member may be an outer jacket. Using an outer jacket may be preferred to provide the container with a uniform and cleaner exterior appearance. The cover of the first end closure (i.e., the cover of the molded pulp end plug) may be flush with the first end edge of the jacket.

[0058] According to the present invention, in any of its embodiments, the container may further comprise an outer jacket defining a first end edge and a second end edge of the container.The outer jacket is disposed outside the sleeve.

[0059] The interior of the sleeve may be provided with a guide device to guide the molded pulp end plug of the first end closure as it is inserted into the sleeve during assembly of the container. For example, at least some of the side walls of the sleeve may include an inner inclined surface at its first end for guiding the molded pulp end plug as it is inserted into the container. In the case where the sleeve comprises an insert and an outer shell, at least some (and optionally each) of the panels of the insert may include an inner inclined surface at its first end. Each inner inclined surface associated with the side wall of the sleeve extends a distance from the first end of the sleeve in a direction toward the interior of the container. Each inner inclined surface associated with the side wall of the sleeve defines an angle of less than 90 degrees relative to a plane defined by the inner surface of the side wall of the sleeve in a region below the inclined surface. The region below the inclined surface is non-inclined. Each inner inclined surface may be a planar surface.

[0060] In an embodiment, the inclined surfaces are associated with those side walls of the sleeve that have recesses for cooperating with the resilient locking tabs of the first end plug. Thus, one or more of the side walls of the sleeve may include such an inclined surface. The first side wall of the sleeve may be free of such an inclined surface. An inner inclined surface associated with the side wall is located between the first end edge of the side wall and the one or more recesses of the side wall. The inner inclined surface may extend across the entire width of the side wall. The inclined surface provides a ramp along which the resilient locking tabs slide when the molded pulp end plug is inserted into the first end of the sleeve, pushing the resilient locking tabs inward from the first end edge of the sleeve a distance such that they can enter the recesses in the sleeve.

[0061] Each resilient locking tab of the molded end plug may include an outwardly curved surface on its exterior that cooperates with a corresponding one of the inner inclined surfaces of the sleeve to deflect the locking tab inward when the end plug is inserted into the first end of the sleeve. The curved surface of the resilient locking tab extends outward a distance from the second end of the tab toward its first end. The curved surface extends from the second end of the locking tab. The curved surface extends from the second end of the tab over at least a portion of the tab's height, and optionally only a portion of its height. Each of the resilient locking tabs associated with a given sidewall of the end plug will cooperate with the same inclined surface extending along the sidewall of the sleeve, the sidewall of the sleeve having a recess with which the tab cooperates. The curved outer surface of the locking tab may be provided by the outwardly curved shape of the tab, which imparts curved inner and outer surfaces to the tab.

[0062] The molded pulp end plug of the first end closure at the first end of the sleeve preferably comprises first and second mutually engaging portions, wherein the first portion provides side walls and one or more resilient locking tabs of the molded pulp end plug, and wherein the second portion fits within the first portion. The molded pulp end plug comprises side walls, each side wall extending along a corresponding one of the side walls of the sleeve, wherein each of one or more of the side walls of the end plug comprises one or more of said resilient locking tabs projecting outwardly therefrom. The first portion provides the side walls of the end plug and the resilient locking tabs.

[0063] The sidewalls of the second portion engage the interior of the sidewalls of the first portion. The first portion and the second portion are separate parts. Each of the first portion and the second portion comprises a molded pulp structure. The first portion and the second portion are formed, i.e., molded, separately from each other. Thus, the first portion and the second portion are formed separately and attached to each other. The first portion has resilient locking tabs and, where applicable, resilient alignment tabs. The first portion defines a sidewall of the molded pulp end plug, which extends along a corresponding one of the sidewalls of the sleeve. The sidewalls of the first portion engage the interior of the sidewalls of the sleeve. Each portion can be produced using a pulp wet molding process.

[0064] The first portion may define a base plane from which the sidewalls of the first portion rise. The base plane is defined by the base of the first portion. The sidewalls extend from the base plane toward the first end of the container. The resilient locking tabs also rise from the base plane of the first portion. The base or second end of each resilient locking tab is connected to the base of the first portion.

[0065] In some embodiments, the molded pulp end plug is a two-piece end plug, ie, having only the first molded pulp portion and the second molded pulp portion as described herein.

[0066] The moulded pulp end plug may be constructed, ie formed, entirely of moulded pulp material.

[0067] A molded pulp end plug having first and second separately formed portions as described herein can be advantageous in providing a more secure fit to a sleeve without the use of adhesives or other securing devices. The second portion can help reinforce the first portion, ensuring that the resilient locking tab remains engaged in the sleeve's recess during use. The second portion can also help ensure that the sidewalls of the first portion remain engaged with the sidewalls of the sleeve, maintaining the end plug in place via a press-fit connection. The second portion can inhibit flexing and other movement of the first portion, which could otherwise occur during use and risk the first portion becoming disengaged from the sleeve. Due to the molded pulp structure of the container, the first portion can have a tendency to distort under the forces encountered during use (e.g., during shipping or storage of the container). Such materials are inherently resilient. Therefore, providing a second portion is particularly advantageous in the context of providing a reliable end plug for a molded pulp structure. The second portion can also help reinforce the first portion, ensuring that the first portion can reliably support a product, for example, via a product support member on its second side.

[0068] The use of a multi-piece construction for the end plugs is also advantageous in facilitating the molding of features of the end plugs from pulp material and avoiding problems that might otherwise be encountered if attempts were made to mold such features into a one-piece end plug. Certain features can be difficult to mold in pulp material. For example, end plugs can typically be produced using a wet molding process. Certain features can be incompatible with such processes and / or can interfere with the ability to remove the part from the mold, at least without potentially damaging the part. This includes so-called "undercut" features, or indeed, other features having a shape that can tend to get stuck on the mold when attempting to remove the molded part from the mold and / or can be difficult to mold using a pulp molding process. For example, it can be difficult to mold features that result in cavities being present in the formed member. Such problems are exacerbated in the context of molding pulp, as compared to molding plastics, for example, using an injection molding process. For example, when molding plastics, it can be possible to use more complex tools that open to allow the release of the part.

[0069] When molding a one-piece end plug that includes a resilient locking tab, it may be necessary to carefully design the shape of the end plug and the mold to avoid such complications. For example, it may be necessary to compromise the shape of the features of the end plug in the area of ​​the resilient locking tab in order to avoid creating an area that would be difficult to mold if a one-piece end plug were to be used.

[0070] By contrast, by using a two-piece structure, it was found that it was possible to easily mold the desired features without compromising the ability to remove the end plugs from the mold, and to easily mold the desired features in a manner consistent with the process used to mold the pulp material (e.g., a wet molding process). This was achieved by designing the first and second parts in a manner such that, when fitted together, a formation of the desired shape was produced. However, each part can be designed so that it can be molded using an applicable molding process (e.g., a wet molding process) without complexity. The molds for each of the first and second parts can be appropriately designed with respect to the formations they include so that those parts can be easily removed from the mold without risk of damaging any features of the part, and in a manner compatible with the molding process to be used (e.g., wet molding). For example, the parts may be wet moulded using a simple male / female down / up type process in which, for each part, a mould having a moulding surface shaped to provide the part is dipped into a slurry of pulp so that the pulp material is deposited on the moulding surface to provide a three-dimensional preform of pulp material in the desired shape of the part having an end plug.

[0071] When the parts of a molded pulp end plug are subsequently mated together, it is possible to create formations in the combined structure that would not be possible in a single-piece molding process. This can include undercut portions, other features with shapes that can otherwise be snapped onto the mold (such as overhanging features), and / or features that result in cavities within the piece. This has been found to be particularly helpful in providing the end plug with a desired configuration in the area of ​​the resilient locking tab, which can interact with other formations in its vicinity to create such areas that would otherwise be difficult or impossible to mold from pulp in a single piece. The increased ease of molding provided by the multi-piece structure thus offers greater freedom in designing the formations associated with the resulting end plug, allowing features of the combined end plug structure to be optimized for a given application while still being easily formed from features molded into the corresponding separately formed parts of the end plug. For example, this can enable the shape of the overall end plug to be designed in a manner that optimizes desired properties (e.g., strength of connection to the sleeve, ability to support the product (e.g., gripping the top of the bottle)) without compromising such properties due to molding difficulties.

[0072] However, it is not essential that the molded pulp end plug of the first end closure comprises multiple molded pulp parts in this way. Alternatively, a one-piece molded pulp end plug may be used. The resilient tab may still provide a secure connection to the sleeve. The shape of the end plug may be appropriately selected to allow it to be molded using an applicable process (e.g., a wet molding process). The choice of whether to use a one-piece or two-piece structure will depend on the particular requirements of the container, for example based on the intended contents, expected conditions of use, desired closure strength, any applicable regulations, etc., as well as the intended shape of the end plug. A one-piece structure can provide a simpler end closure that facilitates assembly and is advantageous in providing a simple, cost-effective, sustainable container of structure. However, a two-part structure can provide a particularly strong first end closure, where this is important, for example, for the specific intended use of the container and / or where the container is required to pass certain tests to ensure the strength of the end closure. For example, it was found that the two-piece first end plug remained securely in place even when a 10 kg weight was inserted into the container and the container was shaken upside down, as may be required under certain strength testing protocols. Such an arrangement can provide a similar level of strength to closures using interengaging plastic parts. The two-part structure facilitates molding and provides greater freedom in the design of the parts of the end plug, allowing the characteristics of the resulting combined end plug structure to be optimized as discussed above, for example to provide a particular level of strength required for a given context. In either case, the molded pulp structure provides a lightweight, sustainable end closure.

[0073] Where the moulded pulp end plug comprises a single part, that part may have any of the features described herein in relation to the first part of the end plug, such as features for securing the end plug to the sleeve, facilitating insertion of the end plug into the sleeve or attachment to a lid, but those features of the first part which provide for mutual engagement with the second part of the end plug will not be necessary.

[0074] Where the moulded pulp end plug comprises a first portion and a second portion, the first portion is located closest to the second end of the sleeve. Hence, the first portion and the second portion may be referred to as a lower portion and an upper portion respectively.

[0075] The second portion of the end plug may extend on a first side thereof toward the first end of the container beyond the first portion of the end plug (i.e., it may extend in height beyond the first portion of the end plug). This may allow the second portion to provide a spacer function, retaining the first portion and its resilient locking tab at an appropriate depth in the first end of the container to enable the locking tab to be retained in the recess of the sleeve.

[0076] The second portion of the molded pulp end plug includes a sidewall disposed inboard of the sidewalls of the first portion of the end plug, wherein the sidewalls of the second portion engage the sidewalls of the first portion. This helps strengthen the sidewalls of the first portion and helps reduce the risk of the resilient locking tabs flexing once inserted into their recesses during use, thereby reducing the risk of the end plug becoming disengaged from the sleeve. This also enhances the effectiveness of the first portion's ability to provide support for the product. The sidewalls of the second portion engage the sidewalls of the first portion at locations other than the locations of the resilient locking tabs. The sidewalls of the first portion are disposed outboard of the sidewalls of the second portion and provide the sidewalls of the end plug as referred to herein. Thus, the sidewalls of the end plug are its outermost walls.

[0077] Each sidewall of the second portion that engages a sidewall of the first portion and has one or more resilient locking tabs protruding therefrom engages the sidewall of the first portion in an area other than the location of each of the one or more resilient locking tabs associated therewith. Thus, the resilient locking tabs interrupt the engagement between the sidewalls of the first and second portions. Any resilient alignment tabs present may similarly interrupt the engagement between the sidewalls.

[0078] In an embodiment, the sidewall of the second portion includes a recess at a position corresponding to the position of a resilient locking tab associated with the sidewall of the first portion of the molded pulp end plug. A recess located at a position corresponding to the position of the resilient locking tab is a recess located such that it faces the interior of the resilient locking tab. During insertion of the end plug into the first end of the sleeve, the recess facilitates inward deflection of the resilient locking tab. Such a recess can facilitate inward deflection of the resilient locking tab when the end plug is inserted into the sleeve through the first end during assembly. Thus, such a recess can facilitate assembly of the container, for example, enabling assembly using a robot, wherein the end plug is inserted through the first end of the sleeve toward the second end. The recess extends toward the interior of the container.

[0079] Each recess is defined by an applicable sidewall of the second portion. The recess is provided by a recessed portion of the sidewall. Each recess associated with the sidewall of the second portion extends inwardly on either side of the sidewall relative to the area of ​​the sidewall that engages the interior of the sidewall of the first portion of the end plug. The recesses in the sidewall of the second portion do not need to provide for resilient alignment tabs (if provided). The sidewall of the second portion is continuous, with the recesses defined by the recessed areas of the sidewall. The recesses do not create openings in the sidewall. One recess is provided for each resilient locking tab. The recesses may extend over the entire height of the sidewall with which they are associated.

[0080] A recess in the sidewall of the second portion, located at a position corresponding to the position of the resilient locking tab of the first portion, spaces the sidewall of the second portion from the inner surface of the locking tab, resulting in a cavity defined between the outer surface of the sidewall of the second portion and the inner surface of the resilient locking tab. The separate formation of the first and second portions facilitates the provision of such a cavity. The cavity extends inwardly, relative to the non-recessed portion of the sidewall of the second portion, on either side of the recess in the sidewall of the second portion. As mentioned above, the resilient locking tab may have an outwardly curved shape. The outer edge of the cavity may then have a corresponding curved shape that follows the curved inner surface of the locking tab.

[0081] In embodiments, each recess in the sidewall of the second portion at a location corresponding to the location of the resilient locking tab of the first portion spaces the sidewall of the second portion from the inner surface of the locking tab, resulting in a cavity defined between the outer surface of the sidewall of the second portion and the inner surface of the resilient locking tab. The separate formation of the first and second portions facilitates providing such a cavity. This cavity in the end plug may form part of a larger cavity extending in the direction of the first end of the container, as discussed below.

[0082] It is recognized that the presence of such a recess in the sidewall of the second part in the region of the resilient locking tab can create a shape that cannot be easily molded in a single piece when the first and second parts are combined. This is because the recess creates a cavity in the structure between the sidewall of the second part and the interior of the resilient locking tab. Such a cavity can interfere with the ability to remove the molded structure from the mold (if attempting to mold the molded structure in a single piece) and can be difficult or virtually impossible to mold using typical pulp molding processes (e.g., wet molding). This problem is exacerbated where the resilient locking tab has an outwardly curved shape. By providing the recess and locking tab on the separately molded first and second parts of the end plug, such problems are avoided.

[0083] Each side wall of the second portion that engages the side wall of the first portion having one or more resilient locking tabs protruding therefrom may include a plurality of first areas spaced apart along the length of the wall that engage the side wall of the first portion, each pair of adjacent first areas being separated by a second area in which the side wall of the second portion does not engage the side wall of the first portion, the second area being defined by recesses in the side wall of the second portion that correspond to the locations of the resilient locking tabs of the side wall of the first portion.

[0084] Each sidewall of the second portion that engages the sidewall of the first portion having one or more resilient locking tabs protruding therefrom may include alternating first and second regions along its length, each first region engaging the sidewall of the first portion, and each second region defining a recess in the sidewall at a location corresponding to the location of the resilient locking tab of the sidewall of the first portion. The second region is recessed relative to the first region. Each second region is recessed relative to the first region on either side of the first region. If the sidewall of the first portion has multiple resilient locking tabs, multiple first regions and multiple second regions are defined on the sidewall of the second portion. If the sidewall of the first portion has a single resilient locking tab, multiple first regions and a single second region are defined on the sidewall of the second portion.

[0085] In an embodiment, the recess of the sleeve for receiving the resilient locking tab is spaced from the first end edge of the sleeve, and the side wall of the second part of the molded pulp end plug has a height greater than the height of the side wall of the first part of the molded pulp end plug so as to space the resilient locking tab of the first part from the first end edge of the sleeve so that the locking tab can be received in the recess.

[0086] The second part of the molded pulp end plug may include a flange at its first end, with the side wall of the second part upstanding from the flange. The flange may cooperate with the sleeve to position the molded pulp end plug. The side wall of the second part extends relative to the flange in a direction towards the second end of the container. The flange may define a base plane of the second part. The flange may assist in positioning the molded pulp end plug during insertion, as described below, and may also cooperate with the first end of the sleeve to maintain the end plug in place when in use, with the resilient tabs engaging in the recesses of the sleeve. The flange may also provide a suitable planar top surface to which a cap of the end plug may be bonded, for example, to provide a desired decorative appearance to the top of the container, covering the molded pulp end plug.

[0087] In some embodiments in which the second portion comprises a flange, the second side portion of the flange may engage the end edge of the side wall of the sleeve at the first end of the sleeve to position the molded pulp end plug. In this way, the flange and the end edge of the side wall of the sleeve at the first end of the sleeve cooperate to provide an end stop during insertion of the first end plug. The flange of the second portion of the end plug may extend between the first end edge of the container and the first end edge of the sleeve. The first end edge of the container may be defined by the outer jacket of the container and / or by the first end edge of the first end closure (such as its lid). In the case where a lid is provided for the end plug, at least a portion of the lid may be located in such an area between the first end edge of the container and the first end edge of the sleeve. This may enable the first end closure to provide a flush fit with the first end of the container.

[0088] Where the sleeve comprises an insert and an outer shell, the second side of the flange may engage first end edges of the insert and outer shell of the sleeve at the first end of the sleeve.

[0089] When the second part of the end plug is fully inserted into the first part thereof, the second end of the side wall of the second part may engage the first side of the base of the first part. Such a fully inserted position may correspond to a position in which the flange of the second part engages the first end edge of the side wall of the sleeve.

[0090] Regardless of the configuration of the flange and how it relates to the sleeve, in embodiments, the recess of the sleeve for receiving the resilient locking tab is spaced from the first end edge of the sleeve, and the sidewall of the second portion of the molded pulp end plug has a height greater than the height of the sidewall of the first portion of the molded pulp end plug, so that the resilient locking tab of the first portion is spaced from the first end edge of the sleeve to enable the locking tab to be received in the recess, and the flange is spaced from and depends from the first end edge of the resilient locking tab of the first portion. The flange may extend outwardly beyond the resilient locking tab. Such an overhanging structure is again advantageous when molded using the multi-piece construction of the end plug described herein, as it can create a cavity within the structure of the end plug that would be difficult or impossible to mold from pulp material in a single piece.

[0091] A cavity can be defined in the end plug in the region of each resilient locking tab. The cavity is bounded on its inner side by the outer surface of the sidewall of the second portion, on the side closest to the first end of the container by the second side of the flange, and on the outer side by the inner surface of the resilient locking tab at a portion of the cavity's height closer to the second end of the container. Furthermore, on the outer side by the inner surface of the sleeve in the region between the first end edge of the sleeve's recess and the second side of the flange at a portion of the cavity's height closer to the first end of the container. The separate formation of the first and second portions facilitates the provision of the cavity. Thus, the opening into the cavity in the end plug structure is provided by the space defined between the second side of the flange and the first end edge of the resilient locking tab. Consequently, in the end plug structure, the cavity is unrestricted on its outer side in the region between the flange and the first end edge of the resilient locking tab. Within the container, this portion of the cavity is closed by the inner surface of the sleeve in the region between the first end edge of the sleeve's recess and the second side of the flange. The multi-piece formation of the end plug facilitates achieving such a cavity, which is located between the end plug formations and is overhung by the flange. It would be impossible to produce such a shape using a single-piece molded pulp structure. This particular structure has been found to be particularly effective in enabling the tabs to function reliably while securely holding the end plug in place in the first end of the sleeve and facilitating insertion, for example, to implement robotic configurations.

[0092] The cavity may be bounded by the base of the first portion on the side closest to the second end of the container.

[0093] In the case where the side wall of the second part comprises a recess at a position corresponding to the position of the resilient locking tab associated with the side wall of the first part of the molded pulp end plug, the cavity is delimited on its inner side by the outer surface of the recessed portion of the side wall of the second part. The cavity discussed above, defined in the end plug between the side wall of the second part in the region of its recess and the resilient locking tab, forms part of this larger cavity extending up to the flange.

[0094] The first and second parts of the molded pulp end plug are press-fitted together. The first and second parts are matingly engaged. The first and second parts may be attached to each other with or without the use of an adhesive. In some embodiments, the first and second parts may be secured to each other solely by a press fit. Subsequently, the first and second parts may be attached to each other without the use of an adhesive. The first and second parts may be attached to each other without the use of any external adhesive material or other fasteners. In other embodiments, in addition to being press-fitted to each other, the first and second parts are adhesively bonded to each other.

[0095] Both the first and second parts have a molded pulp structure. Each part includes formations defining a pattern of recesses and protrusions on each side thereof, with the formations on one side being inversely proportional to those on the opposite side. The formations are imparted during the molding process. Each of the first and second parts has a single-piece construction. Each part is defined by a single shell of molded pulp material. Each part may have a single-layer structure.

[0096] The corners where the side walls of the first portion join each other may be rounded to facilitate insertion of the end plug into the first end of the sleeve.

[0097] The first portion and the second portion may comprise any suitable complementary formations that cooperate with each other to provide suitable interengagement between the first portion and the second portion.

[0098] The first portion defines a first side and an opposite second side, with the second side of the first portion facing the second end of the sleeve. The second side may include a product support. In an embodiment, the second side includes one or more formations for supporting the top of a product (such as a bottle) when located in the container. The first side and the second side are positioned closer to the first and second ends of the sleeve, respectively. The second side may include one or more protrusions defining a collar for receiving the top of a product in the form of a bottle, wherein the open end of the collar faces the first sidewall of the sleeve. This allows the bottle to be easily removed through the opening in the first sidewall, with the first end closure and the second end closure remaining in place. The collar may be defined by a single protrusion on the second side of the first portion of the end plug. The collar may be C-shaped. Therefore, the collar may be defined by a single C-shaped protrusion.

[0099] The one or more formations for supporting the top of the product may extend in a direction opposite to the direction of the side wall of the first portion relative to the plane of its base.The one or more formations for supporting the top of the product extend towards the second end of the container.

[0100] The second portion defines a first side and an opposing second side, with the second side of the first portion facing the second end of the sleeve. The first and second sides are positioned closer to the first and second ends of the sleeve, respectively. The second side of the second portion may include one or more protrusions for supporting the collar, each of which is received in a corresponding recess on the first side of the first portion defined by the inverted portion of the one or more protrusions defining the collar. If the collar is defined by a single protrusion, the one or more protrusions on the second side of the second portion are each received in a single recess on the first side of the first portion defined by the inverted portion of the protrusion defining the collar. In some embodiments, the second portion includes a pair of such protrusions, which are received in respective arms of a C-shaped recess on the first side of the first portion defined by the inverted portion of the C-shaped protrusion defining the collar. In other embodiments, the second side of the second portion includes a single such protrusion in the form of a C-shaped rib, which is received in the C-shaped recess on the first side of the first portion. In either case, the outer edge of the or each protrusion on the second side of the second portion engages against the interior wall of the recess on the first side of the first portion to support the collar.

[0101] Alternatively or additionally, the first side of the first portion may include a central protrusion, such as a generally cylindrical protrusion, which is received in a complementary recess on the second side of the second portion to assist in positioning the first and second portions relative to each other. The cooperating protrusions and recesses may alternatively be reversed, with such a protrusion on the second side of the second portion being received in a recess on the first side of the first portion.

[0102] The first end closure may further comprise a lid for the moulded pulp end plug at the first end of the container.The lid may be adhesively bonded to the first side of the moulded pulp end plug, for example.

[0103] The lid may be a laminate comprising an outer layer and an inner layer. The inner layer may be selected to promote adhesion to the pulp material of the end plug. The outer layer may be selected to match the exterior appearance of the rest of the container (e.g., its jacket). It is contemplated that, while in embodiments the lid has a two-layer structure (comprising the inner and outer layers mentioned above), one or more intermediate layers may be provided. The lid may comprise a cardboard or paper-based material, such as cardboard or paperboard. The lid may provide a planar surface at the first (top) end of the container.

[0104] The edge of the lid may be flush with the top of the side wall of the container. The top of the side wall of the container may be provided by the top of the edge of the outer jacket of the container (if provided) and / or by the top of the edge of the sleeve (e.g., its outer shell).

[0105] Where the molded pulp end plug comprises a first portion and a second portion, the first side of the second portion may be adhesively bonded to the lid, for example. The flange of the second portion may engage and optionally be bonded to the lid. The edge of the flange may be flush with the edge of the lid.

[0106] Where the molded pulp end plug of the first end closure comprises a first portion and a second portion, the second portion may comprise one or more (e.g., a pair of) protrusions on its first side, each protrusion defining a planar surface for bonding to the lid. This may facilitate bonding of the pulp material of the end plug to the lid. The planar surface is the top surface, i.e., the surface closest to the first end of the container.

[0107] Multiple examples of the second part of the molded pulp end plug can be provided and bonded to a sheet of covering material (such as a laminate), wherein the assembly of the second part of the molded pulp end plug and its cover is then cut from the sheet of covering material. This avoids the need to align the cut piece of covering material with the second part of the molded pulp end plug and facilitates bonding the covering material to the pulp material of the end plug. The subassembly of the cover and the second part can then be assembled with the first part of the first end plug. Of course, other techniques can be used. For example, the first and second parts of the end plug can be assembled before bonding the second part to the cover.

[0108] According to any of the embodiments of the present invention, the container may include an outer jacket. The outer jacket may have any suitable form. The outer jacket defines the outermost surface of the container. The first end and the second end of the outer jacket may define the first end and the second end of the container.

[0109] The second end closure may be of any suitable type, provided it has a cardboard or paper-based structure. The second end closure may comprise a molded pulp end plug, but this is not required. The molded pulp end plug used at the second end of the container may have any structure, as compared to the molded pulp end plug at the first end of the container. The second end closure may be adhesively secured in place. It is contemplated that the second end closure may alternatively be provided, for example, using a set of interengaging flaps associated with the second end of the container. For example, these flaps may be integral with the outer shell of the sleeve.

[0110] In some embodiments, the second end closure comprises a molded pulp end plug having a flange that engages the interior of the sleeve. The end plug may include a central protrusion on its second side. One or more support members with apertures may optionally be positioned above the protrusion to support the flange. Depending on the desired strength of the second end closure, the support member may or may not be used. The support member(s) may comprise cardboard or paperboard.

[0111] Where both the first end closure and the second end closure comprise moulded pulp end plugs, the end plugs may be referred to as a first moulded pulp end plug and a second moulded pulp end plug, respectively.

[0112] The first sidewall of the sleeve includes an opening therein to provide access to the interior space of the sleeve. This allows the product to be removed from the interior of the sleeve through the opening during use. The container may include a door that can be rotated about a fold line between a closed position and an open position. In the closed position, the door covers the opening in the first sidewall, and in the open position, the opening is uncovered to provide access to the interior of the sleeve. This allows the product to be removed from the interior of the sleeve through the opening.

[0113] The door can be provided in any suitable manner. For example, the door can be provided by a flap in the first sidewall of the sleeve. In one embodiment, the container includes an outer jacket secured to the exterior thereof, the outer jacket comprising a set of panels hingedly connected to one another, wherein the door is provided by the jacket panels. The outer jacket can be provided with a suitable surface that presents an attractive appearance to consumers. For example, the exterior of the outer jacket can be printed or otherwise provided with a suitable decoration.

[0114] The outer jacket is of a card-based or paper-based material, such as cardboard or paperboard.

[0115] The outer jacket may further comprise one or more additional panels hingedly connected to the door panel on one side thereof, each additional panel being secured to a corresponding sidewall of the sleeve; and a closure mechanism attached to the door panel on the other side thereof for releasably securing the door in a closed position. The closure mechanism may be in the form of a flap. The closure mechanism may be attached to the door panel via one or more intermediate jacket panels.

[0116] In one exemplary embodiment, a panel of a set of jacketed panels is secured at one end to its respective sidewall of a sleeve with a spacer therebetween, such that a gap is defined between the jacketed panel and the sleeve, and the closure is in the form of a flap that plugs into the gap to releasably secure the door in a closed position. The interior of the spacer is bonded to the exterior of the sidewall of the sleeve, and the exterior of the spacer can be, for example, adhesively bonded to the jacketed panel. The spacer comprises a cardboard or paper-based material, such as cardboard or paperboard. The spacer extends only over a portion of the width of the sidewall of the sleeve to which it is attached. The jacket is then wrapped around the sleeve to close the opening.

[0117] The jacket panel secured to the side wall of the sleeve via the spacer may be a first jacket panel, the jacket further comprising a second panel adjacent thereto and secured to the adjacent side wall of the sleeve, a third panel providing a door and extending over the first side wall of the sleeve when the door is in a closed position, and a closure flap connected to the third panel of the jacket via a fourth jacket panel, the fourth jacket panel extending over the side wall of the sleeve adjacent to the side wall having the spacer when the flap is inserted into the gap. When the door moves between its open and closed positions, the fourth jacket panel and the flap are capable of pivoting together with the door panel about a fold line connecting the door panel to the second jacket panel. Thus, the first and second panels of the jacket are secured (e.g., bonded) to the side walls of the sleeve, while the third and fourth panels of the jacket are not secured to the sleeve so that they can move relative to the sleeve when the door moves between the open and closed positions. The second panel of the jacket may be bonded directly to the exterior of the applicable side wall of the sleeve.

[0118] In one example, the first jacket panel and the second jacket panel may be secured to the second sidewall and one of the third and fourth sidewalls of the sleeve, respectively, wherein the first jacket panel is secured to the second sidewall via a spacer, and the third jacket panel extends over the other of the third and fourth sidewalls of the sleeve and is tucked into a gap between the first jacket panel and the second sidewall of the sleeve.

[0119] Of course, other closure mechanisms can be used. However, using a flap that fits between the panels of the container is advantageous because it provides a secure, releasable, and refastenable closure without the need for materials other than paper or cardboard, facilitating container recycling and reducing environmental impact. By associating the flap with the jacket, such an advantageous closure can be achieved while also providing the container with an attractive exterior appearance by appropriately selecting the jacket's material / any decoration. When in the closed position, the jacket can cover all sidewalls of the sleeve. The jacket's panels can cover the entire area of ​​the sleeve's corresponding sidewalls.

[0120] The container can be used for any suitable product. However, it has been found to be particularly useful where it is desirable to provide a container that is made of cardboard or paper-based materials with high strength. Thus, the container is particularly useful in the context of fragile products such as glass bottles. In an exemplary embodiment, the container is used for bottles, such as beverage bottles.

[0121] The present invention extends to any container of the present invention having a product positioned therein, optionally wherein the product is a bottle. The bottle may be a glass bottle and / or a beverage bottle. The bottle is positioned within the interior of the sleeve. The bottom end of the bottle is supported on the second end closure. The top end of the bottle may be supported by a product support provided on a second side of a pulp molded end plug of the first end closure. The container may contain a single product, such as a bottle.

[0122] The present invention extends to a method of assembling a container, comprising inserting a molded pulp end plug of a first end closure into a sleeve through a first end of the sleeve until a resilient locking tab of the molded pulp end plug of the first end closure engages a recess in the sleeve. This may be performed robotically. The method may include assembling a sleeve and a second end closure; inserting a product through the open first end of the sleeve to support it on the second end closure; and then inserting the molded pulp end plug of the first end closure into the sleeve to close the first end of the sleeve. The molded pulp end plug for the first end closure described herein is advantageous in allowing such assembly of the first end closure with the sleeve through the first end of the sleeve after the product is positioned in the sleeve. The use of the molded pulp end plug advantageously allows the end plug to be assembled with the sleeve in this manner without the use of adhesive. This may facilitate assembly using robotics. The ability to avoid the use of adhesive provides a cleaner process with fewer steps and may therefore be advantageous.

[0123] The step of inserting the molded pulp end plug of the first end closure into the sleeve may involve inserting the assembled first end closure into the sleeve in a specified manner. Thus, the molded pulp end plug may advantageously be assembled with any other components (e.g., a cap) before being inserted into the sleeve.

[0124] It was found that the embodiments of the container described herein can enable the container to pass a strength test that involves placing a 10 kg weight in the container, closing the end closure, inverting the container, and shaking the container for a predetermined time with the weight in the container. During such a test, the first end closure can remain securely fixed to the sleeve by the cooperation of the resilient tab and the recess.

[0125] The present invention may extend to producing any of the first molded end plugs in its embodiments, and in embodiments in which the first molded end plug includes a first portion and a second portion, each of the first portion and the second portion of the first molded pulp end plug is produced using a pulp molding process (e.g., a wet molding process). Each of the first portion and the second portion (where present) is produced using a respective mold that is configured to provide a respective one of the first portion and the second portion. For example, producing the first portion and the second portion of the first molded pulp end plug using a wet molding process may involve individually molding each of the first portion and the second portion using a respective mold having a shaped molding surface configured to provide a formation of the respective one of the first portion and the second portion. The method may include depositing pulp material onto the shaped molding surface of the mold to produce the respective one of the first portion and the second portion. The shaped molding surface provides the respective portion of the first end plug with its intended three-dimensional shape. Each mold may be a male mold, but this is not necessarily the case.

[0126] The method may include molding each of the first portion and the second portion by a method comprising: lowering a mold having a shaped molding surface into a container of pulp slurry, the shaped molding surface being for providing a formation of a molded pulp end plug for a respective one of the first and second portions; accumulating pulp material on the shaped molding surface; and lifting the mold out of the container of pulp slurry, wherein the pulp material is deposited on the molding surface of the mold to provide a preform for the respective one of the first and second portions. The preform has a three-dimensional shape imparted by the molding surface that corresponds to the desired shape of the first portion or the second portion. The method may involve using a vacuum to assist in accumulating the pulp material on the shaped molding surface. The molding surface may be any suitable porous surface. The molding surface may include, for example, a mesh on which the pulp material collects.

[0127] The method may further include drying the preform. The method may further include removing the preform from the forming molding surface. This may occur before or after drying the preform, or between steps involved in the drying process. The step of drying the preform may involve one or more steps that may involve dewatering the deposited pulp material from the forming molding surface, such as by pressing and / or heating the material. The step of drying the preform may or may not involve transferring the preform to another support surface, such as another mold or another support surface of a conveyor belt.

[0128] The method may involve, after the (first) mold is lifted out of the slurry, mating a shaped molding surface having the preform thereon with a cooperating shaped molding surface of a further mold. The preform may be pressed between the molding surfaces, for example, to dewater and further assist in shaping the material. Of course, other techniques may alternatively be used to produce the molded pulp end plug (and portions thereof, where applicable).

[0129] In an embodiment, the first and second portions of the first end plug are each formed by depositing pulp material onto a shaped molding surface of a respective mold (or shaped so that they can be formed by depositing pulp material onto a shaped molding surface of a respective mold), the shaped molding surface being configured to produce a formation of the respective one of the first and second portions. Thus, the shaped molding surface provides the respective one of the first and second portions with its intended three-dimensional shape. A preform having the intended three-dimensional shape of the respective one of the first and second portions can be provided by immersing the shaped molding surface in the pulp slurry. The portion may have a mold-facing side and an opposing side. When the mold is immersed in the pulp slurry, the opposing side does not contact the mold.

[0130] All components of the container may be formed from cardboard-based or paper-based materials.

[0131] The term "molded pulp" is used herein in its commonly understood manner. As is known in the art, molded pulp material comprises cellulose fibers. The fibers may comprise recycled fibers and / or virgin fibers. The molded pulp material may be produced in any suitable molding process. For example, a wet molding process may be used. Each of the first portion and the second portion of the first molded pulp end plug described herein has a molded pulp structure and may have a single-walled molded pulp structure. Each portion, as well as the entire molded pulp end plug, may be composed of molded pulp material.

[0132] Unless the context requires otherwise, any reference herein to bonding may refer to adhesive bonding, or any other type of bonding, such as thermal bonding.

[0133] Unless the context requires otherwise, references herein to inward or inwardly refer to a direction closer to the axial centerline of the container, i.e., in a direction into the interior of the container. Conversely, unless the context requires otherwise, references herein to outward or outwardly refer to a direction away from the axial centerline of the container, i.e., in a direction toward the exterior of the container.

[0134] As referred to herein, a fold line refers to any line about which a member folds. A fold line may include a weakening line, a fold line, and / or a perforation.

[0135] For the sake of brevity herein, the resilient locking tab(s) may be referred to as "locking tab(s).

[0136] Unless the context requires otherwise, any reference to height refers to the dimension as measured along a direction extending between the first end and the second end of the container (or sleeve, jacket, shell, insert, or container, as appropriate). The width of a sidewall or sidewall panel is measured in a direction connecting opposite side edges of the sidewall or sidewall panel. The width dimension may be measured in a direction perpendicular to the direction connecting the first end and the second end of the sidewall or sidewall panel. BRIEF DESCRIPTION OF THE DRAWINGS

[0137] Some preferred embodiments of the present invention will now be described, by way of example only, and with reference to the following drawings, in which:

[0138] Figure 1 is a perspective view of a cardboard- or paper-based material container according to an embodiment of the present invention and showing a bottle positioned within the container. Figure 1 Container 1 is shown, wherein the door of the container is in an open state;

[0139] Figure 2 show Figure 1 The container 1 of the embodiment, wherein the door is in a closed state;

[0140] Figure 3 is yet another view omitting the outer shell of the container jacket and the container sleeve to illustrate in greater detail the interaction between the first end closure and the insert portion of the sleeve, and between the bottle and the first and second end closures;

[0141] Figure 4 showing the jacket and sleeve portions of the container 1 with the bottle and end closure omitted, and with the door in an open position, to illustrate certain features of the container in further detail;

[0142] Figure 5 The sleeve portion of the container is shown with the end closures, jacket, and bottle omitted;

[0143] Figure 6 The insert portion of the sleeve is shown;

[0144] Figure 7 is a perspective view of a first portion of a molded pulp first end plug, with the lowermost side being uppermost in use;

[0145] Figure 8 is a perspective view from a top side of a first portion of a first end plug;

[0146] Figure 9 is a view from above of the first portion of the first end plug, with the uppermost side being uppermost in use;

[0147] Figure 10is a view from the side of a first portion of the first end plug, the side portion extending along the second side wall of the sleeve in use;

[0148] Figure 11 is a perspective view of the second portion of the first end plug, with the lowermost side being uppermost in use;

[0149] Figure 12 is a perspective view from the top side of the second portion of the first end plug;

[0150] Figure 13 is a view from above of the second portion of the first end plug, with the lowermost side being uppermost when in use;

[0151] Figure 14 is a side view of a second portion of the first end plug, the side portion extending along a second side wall of the sleeve in use;

[0152] Figure 15A showing a second molded pulp end plug of the second end closure from a top side of the second end closure, the top side facing the first end of the container;

[0153] Figure 15B showing the combination of the second end plug and the support member of the second end closure;

[0154] Figure 16 is an exploded view of a molded pulp end plug of a first end closure, the exploded view showing the first and second portions thereof separated from one another, as in an intermediate stage in assembly of the first end plug, and with the cap assembled with the second portion;

[0155] Figure 17 is with Figure 16 an exploded view similar to, but taken from above, the exploded view of the molded pulp end plug of the first end closure showing an upper or first side of a first portion of the end plug;

[0156] Figure 18 Is through Figure 3 a section of the container shown in , with the jacket and shell omitted, the section showing in more detail the cooperation of the molded pulp end plug of the first end closure with the top of the bottle;

[0157] Figure 19 is a more detailed view showing the cooperation of the molded pulp end plug of the first end closure with the top of the insert and the engagement of the resilient locking tab with the slot in the insert, with the jacket and housing again omitted;

[0158] Figure 20 showing a first end closure inserted into a top end of an insert, with the jacket and housing omitted for ease of illustration;

[0159] Figure 21 The top end of the insert 33 is shown in more detail;

[0160] Figure 22 showing the cooperation between the inclined surface of the interior of the insert at the top of the wall of the insert and the resilient locking tabs of the first part of the moulded pulp end plug of the first end closure as it is inserted into the top of the insert (with the jacket and housing again omitted);

[0161] Figure 23 A first molded pulp end plug is shown inserted into a first end of an insert in its final position with the locking tab inserted into the slot of the insert and the alignment tab inserted into the alignment slot (with the jacket and housing again omitted);

[0162] Figure 24 The assembly of the collet and the sleeve is shown in the region of a first end portion thereof;

[0163] Figure 25 is with Figure 24 a similar view, but with the jacket omitted so that the spacers can be more clearly seen;

[0164] Figure 26 The insert is shown assembled with the housing to provide the sleeve;

[0165] Figure 27 is a view from a second side of a first portion of an alternative first end plug that can be used in accordance with yet another embodiment of the present invention;

[0166] Figure 28 is a view from a first side of a first portion of an alternative first end plug;

[0167] Figure 29 is a view from a second side of the second portion of the alternative first end plug;

[0168] Figure 30 is a view from a first side of the second portion of the alternative first end plug; and

[0169] Figure 31 yes Figure 19 Details of the arrangement shown in . DETAILED DESCRIPTION

[0170] With particular reference Figure 1 and Figure 2, a container 1 according to an embodiment of the present invention includes a sleeve 3 having a first sidewall 5, a second sidewall 7, a third sidewall 9, and a fourth sidewall 11. The sleeve has a first end 2 and a second end 4. The first end 2 and the second end 4 may be referred to as the upper end and the lower end of the sleeve. The container has corresponding first and second ends. The first sidewall 5 of the sleeve includes an opening 12 that allows access to the interior of the container, i.e., for removing a bottle when it is located therein.

[0171] The first side wall 5 of the sleeve is connected to the third side wall 9 along a fold line 13 along one edge of the first side wall 5, and is connected to the fourth side wall 11 along a fold line 19 along the opposite edge of the first side wall 5. The second side wall 7 is connected to the third side wall 9 along a fold line 15 along one edge of the second side wall 7, and is connected to the fourth side wall 11 along a fold line 17 along the opposite edge of the second side wall 7. The first side wall 5 and the second side wall 7 form a first pair of opposing side walls of the sleeve 3, and the third side wall 9 and the fourth side wall 11 form a second pair of opposing side walls of the sleeve.

[0172] In the illustrated embodiment, the container further comprises an outer jacket 20. For the sake of brevity, the outer jacket may be referred to herein as the "jacket." Figure 1 and Figure 4 In particular, see Figure 1 、 Figure 2 and Figure 4 The jacket 20 includes a first panel 21 and a second panel 22 that are wrapped around and secured to the second and third side walls 7, 9 of the sleeve, respectively. The second panel 22 of the jacket is directly, for example, adhesively bonded to the outer surface of the third side wall 9 of the sleeve, while the first panel 21 is, for example, adhesively bonded to the outer surface of a spacer 26, which is, for example, adhesively bonded to the outer surface of the second side wall 7 of the sleeve. Thus, the spacer 26 is sandwiched between the second side wall 7 of the sleeve and the first panel 21 of the jacket 20. The spacer 26 extends only over a portion of the width of the second side wall 7, leaving a gap 18 of width W between the edge of the spacer farthest from the fold line 15, where the third side wall 9 is connected to the second side wall 7, and the fold line 17, where the edge of the second side wall 7 is connected to the edge of the fourth side wall 11. The gap 18 extends over the entire height of the sleeve between its first and second ends and is located between the outer surface of the second side wall 7 of the sleeve and the inner surface of the first panel 21 of the jacket. The width of the second side wall 7 is the direction extending between the edges of the second side wall 7 that are connected to the third side wall 9 and the fourth side wall 11 respectively, that is, the direction extending between the fold lines 15 and 17.

[0173] In addition to the first panel 21 and the second panel 22, the jacket also includes a third panel 23 and a fourth panel 24. The first panel 21, the second panel 22, the third panel 23 and the fourth panel 24 are hingedly connected to each other along fold lines 25, 27 and 29. Unlike the first panel 21 and the second panel 22 of the jacket, the third panel 23 and the fourth panel 24 are not fixed to the outer surface of the sleeve, but are capable of rotating about the fold line 27 connecting the second panel 22 and the third panel 23 of the jacket (which is located above the fold line 15 of the sleeve) so as to be able to be positioned relative to the sleeve in which the third panel 23 and the fourth panel 24 of the jacket are located above the first side wall 5 and the fourth side wall 11 of the sleeve respectively (as shown in FIG. Figure 2 and wherein the third panel 23 and the fourth panel 24 of the jacket are positioned away from the first side wall 5 and the fourth side wall 11 of the sleeve, respectively. Figure 1 In this manner, the third panel 23 of the jacket 20 provides a door that can be moved in an open position (e.g., about a fold line 27). Figure 1 ) and closed state (as shown in Figure 2 ) between which the hinged movement occurs when the hinge is in the closed position (as shown in Figure 2 ), the third panel 23 closes the opening 12 in the first side wall 5, and when in the open state of the door (as shown in FIG. Figure 1 ), the third panel 23 leaves the opening 12 uncovered to allow access to the bottles within the container through the opening 12.

[0174] The flap 28 is connected to the fourth panel 24 of the jacket along a fold line 31. The flap 28 of the jacket provides a releasable closure for the door. Figure 2 In the closed position shown in FIG, the fourth panel 24 of the jacket extends over the fourth side wall 11 of the sleeve and the flap 28 is inserted into the gap 18 between the first panel 21 of the jacket and the second side wall 7 of the sleeve to retain the third and fourth panels of the jacket in place, with the third panel 23 closing the opening 12. Figure 2 The arrangement of the flap 28, the gap 18 and the jacket panel 21 is shown in the following diagram. Figure 24 and 25 Shown in more detail.

[0175] Certainly, other arrangements can be used for providing the door for covering the opening 12 in the first sidewall 5 of sleeve, rather than using the jacket as shown.For example, door can be provided by the flap cut into the first sidewall 5.Similarly, in the case where door is provided by a separate member (for example, the jacket attached to sleeve 3), the jacket need not have the structure shown.Also can use alternative closure mechanisms, rather than stuffing the flap into the gap as shown.The arrangement shown is advantageous, because it makes firm closure be obtained, and does not use any material (for example, magnet etc.) based on cardboard or based on the structure of paper, is therefore easier to recycle.Jack 20 also provides a surface, and it can be printed or decorated in addition to provide the outward appearance of expectation to container.

[0176] The container 1 also includes a first end closure 150 comprising a first molded pulp end plug 50 ("first end plug") inserted into the first end of the container 1; and a second end closure 154 comprising a second molded pulp end plug 52 ("second end plug") inserted into the second end of the container 1. Figure 1 and Figure 3 More clearly shown in.

[0177] In the illustrated embodiment, the first end closure 150 further includes a lid 51 for the first molded pulp end plug 50. The lid 51 is optional. The lid 51 is in the form of a piece of cardboard- or paper-based material (such as cardboard or paperboard). The lid 51 is adhesively bonded to the upper surface of the first end plug 50, for example. The lid 51 provides an attractive appearance to the top of the container, covering the undulating upper surface of the molded pulp first end plug 50. The lid 51 can be flush with the top of the container (corresponding to the first end edge of the jacket 20 in the illustrated embodiment). Thus, the lid and the first molded pulp end plug form part of a single unit (the first end closure, which is inserted into the first end of the sleeve and closes the first end of the sleeve).

[0178] The sleeve 3 includes a pair of locking recesses 140 within each of its second, third, and fourth sidewalls 7, 9, and 11, which do not extend through the entire thickness of the sidewalls. The locking recesses 140 are located at the top, or first, end of the sleeve and receive the locking tabs 70 of the first end plug 50, as described in greater detail below, to enable the first end plug 50 to be clamped into place. The second sidewall 7 also includes a pair of alignment recesses 142 on its inner surface that extend a short distance from its top, or first edge, toward the second end of the sleeve. These alignment recesses 142 are located on only one of the sleeve's sidewalls and cooperate with the alignment tabs 72 of the first end plug 50, as described below, to ensure that the first end plug 50 can be inserted into the sleeve only in a given orientation. The alignment recesses 142 also do not extend through the entire thickness of the sleeve's sidewalls.

[0179] If you can Figure 1-3 and especially in Figure 3 As seen in FIG. 1 , the bottle is supported on a second end closure 154, i.e., its second end plug 52. The second end closure includes a flange 54 that engages the interior of the sleeve's sidewall. In the illustrated embodiment, a recess 59 is defined in the upper first side of the second end plug 52 for receiving the bottom end of the bottle. A corresponding protrusion is defined on the second (i.e., lower) side of the second end plug 52. In the illustrated embodiment, the second end closure 154 also includes a support member 57. The protrusion of the second end plug 52 is received in a central aperture of the support member 57, which is comprised of a cardboard or paper-based material. In the illustrated embodiment, the support member 57 comprises a corrugated cardboard structure and reinforces the strength of the closure at the second end of the container 1, supporting the flange 54. Such a support member 57 is optional, and if present, its structure and / or characteristics may vary from those shown, depending on the desired strength of the second end closure. The support member 57 may enhance the strength of the second end closure, for example, where it is necessary to pass specific strength tests associated with the intended use scenario. For example, some packages are required to pass a test for evaluating shipping strength that involves repeatedly dropping the container on different sides of the container. The second end closure 154 may have a different configuration than shown and need not include a molded pulp end plug. However, the second end closure may have a cardboard-based or paper-based material.

[0180] The first end plug 50 of the first end closure 150 closes the first upper end of the sleeve 3, with the top of the bottle retained within a C-shaped protrusion on the underside of the first end plug 50. The structure of the first end plug 50 is described in more detail below. The first end plug 50, which provides the first end closure, includes integrally molded features that enable the first end plug 50 to be securely secured to the first end of the sleeve via a press fit, without the need for adhesives. The first end plug 50 is held in place by the press fit and the cooperation of the resilient tab and recess.

[0181] The container is made of a cardboard- or paper-based material. The sleeve (including the insert and the outer shell) and the jacket are both made of such material (e.g., cardboard or paperboard), as are the end closures. In addition to the molded pulp first end plug, the first end closure may include a lid of cardboard or paperboard material. The second end closure may include a combination of a molded pulp end plug and optionally a cardboard or paperboard support, or may have any other suitable form, provided it is of a cardboard- or paper-based material. Therefore, the second end closure does not need to include a molded pulp end plug. This allows all components of the container to be recycled in the same waste stream for cardboard- and paper-based materials, without the user having to separate any components prior to recycling to avoid contaminating the dedicated waste stream.

[0182] Reference will now be made in particular to Figure 5 and Figure 6 The structure of the sleeve 3 is described in more detail. Figure 5 The sleeve portion of the container is shown alone, wherein the other parts of the container, namely the first and second end closures, the spacer and the jacket are omitted, and Figure 6 The insert portion of the sleeve is shown.

[0183] The sleeve 3 is formed by an outer shell 31 and an insert 33. The insert 33 has a first panel 35, a second panel 37, and a third panel 39 hingedly connected to each other along fold lines 36, 38. The outer shell 31 has a first panel 40, a second panel 41, a third panel 43, and a fourth panel 45 hingedly connected to each other along fold lines. The first panel 40 is connected to the third panel 43 along fold line 47 and to the fourth panel 45 along fold line 49. The second panel 41 is connected to the third panel 43 along fold line 55 and to the fourth panel 45 along fold line 53. The outer shell can be built from a single piece of blank. For example, the outer shell can include a structural flap (not shown) attached to one of the longitudinally extending edges of one of its panels along the fold line, the structural flap being bonded to the interior of an adjacent one of the panels to hold the outer shell in an upright configuration.

[0184] like Figure 6 As shown in more detail in FIG. 1 (which is a view showing the first end of the sleeve), each of the first panel 35, the second panel 37, and the third panel 39 of the inner shell 33 of the sleeve 3 includes a pair of locking grooves 120 therein for receiving the locking tabs 70 of the first end plug 50, as will be described in more detail below. The locking grooves 120 are spaced from the edge of the panel at its first end. The second panel 37 additionally includes a pair of alignment grooves 122 extending to the edge of the panel at its first end. The locking grooves 120 form the locking recesses 140, and the alignment grooves 122 form the alignment recesses 142 in the interior of the side wall of the sleeve 3 mentioned above.

[0185] The top or first end of the panels 35, 37, 39 includes an inclined surface on its interior. The inclined surfaces are labeled 131, 133, 135. The inclined surface extends inwardly from the first end edge of the respective panel at its first end, adjacent the first end edge of the panel, toward the interior of the sleeve, and extends in a direction toward the second end of the sleeve. The inclined surface is provided in the area above the locking slot 120 in each panel. This facilitates the insertion of the first end plug 50, as described below. The inclined surface defines an angle α of less than 90 degrees relative to the plane in which the interior (non-inclined) surface of the panel below the inclined surface lies.

[0186] like Figure 5, the insert 33 is adhesively bonded to the interior of the outer shell 31, for example, wherein the first panel 35, the second panel 37, and the third panel 39 of the insert 33 are adhesively bonded to the third panel 43, the second panel 41, and the fourth panel 45 of the outer shell 31. Thus, the second side wall, the third side wall, and the fourth side wall of the sleeve have a multi-layer structure, which includes an inner layer provided by the corresponding panel of the insert and an outer layer provided by the corresponding panel of the outer shell. The first side wall of the sleeve is provided as a single-layer structure by the corresponding first panel 40 of the outer shell. The window in the first panel 40 provides the opening 12 of the container.

[0187] In the illustrated embodiment, insert 33 extends substantially the entire height of housing 31, but it is contemplated that it may extend only above the upper portion of the sidewalls of housing 31. Insert 33 provides the sleeve's sidewalls with recesses in their upper portions that cooperate with the resilient tabs of the first end closure in the manner described below. In the illustrated embodiment, the top end of the insert includes certain additional features that cooperate with the first end closure to provide directional alignment and facilitate insertion of the first end closure into the top end of the sleeve. Therefore, provided the insert includes the necessary features to cooperate with the first end closure, it need not extend the entire height of the sidewalls of the housing. However, extending the entire height can provide greater rigidity to the sleeve and help create a sturdy container ideal for holding fragile bottles. Preferably, at least one panel of the insert extends the entire height of the corresponding sidewall of the housing to facilitate positioning of the insert within the housing and provide stability to the resulting sleeve.

[0188] Other arrangements may be used that result in the recess for receiving the resilient locking tab of the first end plug (and any alignment recess present) not extending through the entire thickness of the container wall to the exterior of the container. For example, the groove may extend through the entire thickness of the container's sleeve, covered by an outer layer of the container (e.g., a jacket or other outer member providing the outermost surface of the container). The two-part construction of the sleeve described herein is not essential. Desirably, the recess does not extend to the outer surface of the container in order to conceal the tab and avoid interrupting the outermost surface of the container, which typically is provided with branding or other decorative finishes.

[0189] The present invention is concerned with the structure of the first end closure 50 and its cooperation with the sleeve as will be described in more detail below.

[0190] Figure 3 is a longitudinal section through the container 1 with the bottle 36 in place within the interior space of the container 1 . Figure 3 The outer shell 31 of the sleeve is omitted, as is the jacket 20. Figure 1 and Figure 2The same side of the container is obtained and, except that the jacket 20 and the outer shell 31 of the sleeve 3 are removed, corresponds to Figure 1 and Figure 2 Thus, the open front portion of the insert 33 will be positioned beneath the first panel 40 of the housing 31 , and the first side wall 35 of the insert will be positioned beneath and bonded to the third panel 43 of the housing 31 .

[0191] Figure 3 Certain features of the first end plug 50 of the first end closure 150 are shown which cooperate with the side walls of the sleeve 3 to retain the first end plug 50, and therefore the first end closure 150, in place.

[0192] Figure 3 It also facilitates understanding of the second end plug 52 of the second end closure 154 (which is Figure 15A and Figure 15B (shown in more detail in ). Figure 15A The molded pulp second end plug 52 is shown from its top side, which faces the first end of the container. Figure 15A As seen in FIG, the central portion of the second end plug 52 defines a recess 59 on a first, upper side of the second end plug 52 (in which the bottom of the bottle 36 is received), and a corresponding protrusion on a second (lower) side of the end plug 52. A flange 54 surrounds the central portion of the end plug 52. In contrast to the first end plug, the second end plug 52 is adhesively secured in place to provide a stronger bottom closure. The second end closure 154 may take other forms provided it provides sufficient strength for the intended purpose of the container. Figure 15B As shown in FIG, in the illustrated embodiment, a support member 57 made of cardboard or paper-based material (which does not have a molded pulp structure) receives a protrusion on the second lower side of the end plug 52 to reinforce the end closure. This can enhance the strength of the end closure, for example, where it is desired to meet certain strength standards for the closure for a particular application of the container. In the exemplary arrangement, the support member 57 has a corrugated cardboard structure and has a laminated structure comprising multiple layers of cardboard material. The support member 57 is adhesively attached to the underside of the flange 54. The underside of the support member 57 also provides a flat surface on which the container can stand and reinforces the lower end of the sleeve 3.

[0193] Reference will now be made additionally to Figure 7-14The first end plug 50 of the first end closure 150 is described in more detail. The first end plug 50 is formed of two pieces that are engaged with each other. Each piece is formed from molded pulp. These pieces are a first portion 60 and a second portion 62. It is contemplated that the second portion 62 may be omitted. The first portion 60 and the second portion 62 each include a formation defining a pattern of recesses and protrusions in their upper and lower surfaces, which are imparted by the molding process used to form the respective portions. The pattern of recesses and protrusions of one of the first and second surfaces (i.e., the upper and lower surfaces) of the first or second portion is opposite to the pattern of recesses and protrusions of the opposite one of its first and second surfaces.

[0194] When the first end plug is disposed in the first end of the sleeve, the first portion 60 is the lowermost portion, i.e., located closest to the second end of the sleeve, and is Figure 7-10 Displayed in.

[0195] Figure 7 is a perspective view of the first portion 60 of the first end plug 52, with the lowermost side (the second side) being uppermost in use. Figure 8 is a perspective view from the top (or first) side of the first portion 60 . Figure 9 is a view of the first portion 60 from above, wherein the uppermost side (ie the first side) is uppermost in use, and Figure 10 It is a view of the first portion 60 from the side which, in use, extends along the second side wall 7 of the sleeve 3 .

[0196] Figure 11-14 The second portion 62 of the first end plug 52 is shown in FIG. Figure 11 is a perspective view of the second portion 62 of the first end plug 50, with the lowermost side (the second side) being uppermost in use. Figure 12 It is a perspective view from the top side (first side) of the second portion 62 . Figure 13 is a view of the second portion 62 from above, wherein the lowermost side (the second side) is uppermost when in use, and Figure 14 It is a view of the second portion 62 from the side which, in use, extends along the second side wall 7 of the sleeve 3 .

[0197] For ease of reference, the terms upper and lower will be used to refer to positions toward the first and second ends of the container when in use, but do not imply any particular orientation of the container in use. Typically, the container will be oriented with the first end uppermost. References to upper and lower sides of a member may be replaced by references to the first and second sides, which are, instead, those sides that are closer to the first and second ends of the sleeve or container when in use, and vice versa.

[0198] Now refer to Figure 7-10 The features of the first portion 60 of the first end plug 50 are described in more detail.

[0199] The first portion 60 includes a first side wall 61, a second side wall 63, a third side wall 65, and a fourth side wall 67, which extend along the first side wall 5, the second side wall 7, the third side wall 9, and the fourth side wall 11 of the sleeve, respectively. Each side wall of the first portion 60 contacts a corresponding one of the side walls of the sleeve. The side walls 61, 63, 65, 67 stand upright from a base 66 of the first portion. The base 66 defines a base plane of the first portion 60. Figure 10 As shown in FIG, a rounded edge is defined where the base of the side wall meets the base plane 66 of the first portion 60 to facilitate insertion of the first end portion into the sleeve of the container.

[0200] The second sidewall 63, third sidewall 65, and fourth sidewall 67 of the first portion 50 each include two resilient locking tabs 70 projecting outwardly therefrom. These locking tabs 70 cooperate with the interior of the sleeve in the manner described below to securely secure the first end plug 50 in the first end of the sleeve 3 without the need for adhesive. In the illustrated embodiment, the resilient locking tabs 70 extend the entire height of the sidewalls. The second sidewall 63 of the first portion 60 includes a further pair of resilient tabs 72, which, in the illustrated embodiment, are smaller in width than the locking tabs 70 (it will be appreciated that the configuration of the resilient tabs 70 and 72 may vary depending on the desired characteristics of the container, the degree of security of the locking effect to be achieved, etc.).

[0201] Additional tabs 72 provide alignment features that prevent the first end plug 50 from being positioned in the first end of the sleeve in an orientation other than the intended rotational orientation, i.e., with the first sidewall 61 of the first portion 60 of the end plug 50 extending along the first sidewall 5 of the sleeve, etc. This ensures that the locking tabs 70 can be positioned in corresponding recesses 140 within the interior of the sleeve 3 to secure the end plug 50 in place and allow the bottle to be removed through the open end of the collar 80. If the end plug is inserted in the incorrect orientation, the collar will effectively prevent the bottle from being removed through the opening 16 in the first sidewall 5 of the sleeve 3. The use of alignment tabs 72 is optional. Other alignment features may be used alternatively or additionally, or the alignment features may be omitted. Both the alignment tabs 72 and the locking tabs 70 are integrally molded with the first portion 60 of the first end plug. Thus, they are provided by the molded formation of the molded pulp first portion 60 of the end plug. By virtue of their molded pulp structure, the tabs 70, 72 are inherently resilient.

[0202] It is contemplated that the number of locking tabs 70 used on each sidewall (having locking tabs) of the first portion 60 of the first end plug 50 may vary from that shown. Sidewalls provided with locking tabs may have a single tab, more than two tabs, or a combination thereof, rather than a pair of such locking tabs. Furthermore, while three sidewalls are shown as having such locking tabs, it is contemplated that all sidewalls may have such locking tabs, or that fewer than three sidewalls may have such tabs, such as two or even one. For example, the opposing third and fourth sidewalls 9 and 11 may be the only sidewalls with such locking tabs. If the first sidewall 61 is provided with locking tabs, some cooperating formations would need to be provided inside the sleeve to receive the tabs. Ideally, at least one pair of opposing sidewalls among the sidewalls has tabs to provide improved stability. It has been found that a pair of locking tabs associated with each of at least two (e.g., three) of the sidewalls provides a balance between secure locking of the end plug and easy molding and reliable operation of the end plug's locking tabs. The number of locking tabs present will depend on factors of the intended product, such as shape and weight.

[0203] The underside of the first portion 60 of the first end plug 50 (i.e., the second side closest to the second end of the sleeve / container and, in use, the lowest part) also includes a collar 80 for supporting the top of the bottle when it is in the container. The collar 80 extends upward from the base 66 and, in use, extends toward the second end of the container. Thus, the collar 80 and the sidewalls 61, 63, 65, 67 of the first portion 60 extend in opposite directions from the base 66 of the first portion 60, i.e., upward from the second and first sides of the first end portion 60, respectively. An opening 81 in the collar is located on the side closest to the first portion 60, which extends along the first sidewall 5 of the sleeve 3 when the first end plug 50 is in the first end of the sleeve (i.e., in the container). Thus, it faces the sidewall 61 of the first portion 60. This helps hold the bottle in a desired position within the container while allowing the bottle to be removed through the opening 12 provided in the first sidewall 7 of the sleeve during use (when the container door is open). The collar 80 is shown as being provided by a single C-shaped protrusion on the second side of the first portion 60 of the first end plug 50. The C-shaped protrusion extends around the central recess. However, the shape of the bottle support may vary from that shown and, for example, may be provided using a plurality of discrete protrusions rather than a single C-shaped protrusion.

[0204] The upper (ie, first) side of the first portion 60 also includes a central protrusion 114 to assist in positioning the first portion 60 relative to the second portion 62 , as described below.

[0205] Figure 11-145. The second portion 62 of the first end plug 50 is shown in FIG. The second portion 62 includes a peripheral flange 90 and upstanding first, second, third, 95, and fourth side walls 97 therefrom. The portion of the second portion 62 upstanding from the flange 90 fits within a first side portion of the first portion 60 of the first end plug 50, wherein the first, second, third, 95, and fourth side walls 97 of the second portion 62 engage the corresponding side walls 61, 63, 65, 67 of the first portion 60.

[0206] The flange 90 rests on top of the first end edge of the sleeve (i.e. its insert and shell), wherein the underside of the flange cooperates with the end edge of the sleeve to provide an end stop during insertion of the first end closure through the first end of the sleeve during assembly of the container. Figure 19 and 23 Once the first end closure is fully inserted, the flange can be disposed in the space between the end edge of the sleeve and the first end edge of the container. The lid can be flush with the first end edge of the container at the first end of the container (e.g., as provided by the jacket in the illustrated embodiment).

[0207] Each sidewall of the second portion 62 includes a recess 100 corresponding to the location of the locking tab 70 of the sidewall of the first portion 60 with which it engages. The remaining portion of each sidewall 91, 93, 95, 97 engages the corresponding sidewall 61, 63, 65, 67 of the first portion 60 to reinforce the wall and inhibit wall flexing, which could otherwise allow the locking tab 70 to move out of engagement with its corresponding recess 140 in the interior of the sleeve. The reinforcement also helps ensure that the product support provided by the collar on the second side of the first portion of the end plug remains engaged with the product. Therefore, using a two-piece first end plug 50 is advantageous in helping to ensure that the locking tab 70 can reliably function to secure the first end plug 50 in the first end of the sleeve and enable the end plug to function to provide reliable product support. However, in some cases, the second portion 62 of the first end plug 50 may be omitted. The recesses 100 mean that the sidewalls of the second portion 62 of the first end plug 50 do not contact the sidewalls of the first portion 60 in the area of ​​the resilient locking tabs, so that the locking tabs can retain their natural resiliency to facilitate locking the tabs into the recesses 140 in the interior of the sleeve when the end plug 50 is inserted into the first end of the sleeve. Thus, the sidewalls of the second portion 62 of the end plug 50 have a pattern of alternating recessed and non-recessed areas along their length, wherein the recessed areas align with the locations of the resilient locking tabs of the first portion, while the non-recessed areas are disposed between the resilient locking tabs and engage the sidewalls of the first portion 60.

[0208] The use of a two-piece end plug is also advantageous in facilitating the molding of the end plug. The end plug includes a resilient locking tab protruding from it. By molding the end plug in two pieces, it is possible to design each piece so that it can be easily molded and removed from the mold using the intended pulp molding process. Certain features may be difficult or even impossible to mold from pulp material, for example using a wet molding process (at least when using pulp forming techniques, which are not complicated and do not risk damage when removed from the mold). These features include configurations in which features interact to provide cavities, overhangs, undercuts, etc. in the piece. Alternatively, by using a two-piece structure, the desired formation can be produced from a combination of features of parts molded as a first part and a second part that are molded separately, without attempting to provide such features in a single piece. This provides greater design freedom with respect to the resulting end plug structure, allowing for the provision of beneficial formations without having to compromise on the construction of the end plug due to the constraints of a single-piece molding process, and enabling features to be produced in end plugs that were previously not moldable from pulp material. It will be appreciated that the use of pulp material constrains the shapes that can be produced during the molding process, for example compared to when molding plastic materials, and the two-piece construction described herein opens up possibilities with respect to the shapes that can be produced for end plugs, enabling features that can enable end plugs to function particularly effectively, for example in providing a strong end closure, while still having a sustainable pulp material produced as discussed herein. This is all discussed below with respect to Figure 31 Discussed in more detail.Through appropriate design and molding of the first and second parts, the two-part structure enables the inclusion of desired features without compromising the ability to mold separate first and second parts and remove them from their molds without damage.

[0209] The second portion 62 also includes protrusions 112 on its first side. These protrusions can provide a flat surface to which the lid 51 can be bonded. The second portion includes a central recess in its second lower surface which receives the protrusions 114 in the first upper side of the first portion 60 so as to position the portions relative to each other and assist in providing a press fit between the portions. A protrusion 110 in the form of a C-shaped ridge is also provided on the second lower surface of the first end portion 60 for cooperating with a recess defined by the reverse portion of the collar 80 of the first portion 60 to assist in providing a press fit between the first and second portions of the first end plug and to support the collar and prevent it from deforming during use. This helps ensure the stability of the collar so that it can reliably support the bottle during use. Although the protrusion for supporting the collar is shown as C-shaped, roughly corresponding in shape to the collar, other forms of support may be used. For example, multiple protrusions may be used rather than a single protrusion. Alternative constructions are Figure 27 Displayed in.

[0210] The first portion 60 and the second portion 62 may include various other recesses and protrusions that will not be described here. The exact formations present may vary depending on the desired characteristics of the first end plug, its intended use, etc. For example, the pattern of the formations may help provide the end plug with a desired level of strength and may facilitate the mutual engagement between the first and second portions. Provided that the end plug includes resilient locking tabs that cooperate with the sleeve to retain the end plug in place, the exact configuration of the end plug, and indeed, whether it includes one or two (or even more) molded pulp portions, may vary.

[0211] Figure 16 is an exploded view of the first end plug 50 showing its first portion 60 and second portion 62 separated from one another. This would be seen as an intermediate stage in the assembly of the first end plug 50 and the entire first end closure 150. The cover 51 is shown secured to a first side of the second portion 62 and flush with its flange 90. The first portion 60 and the second portion 62 are pushed together so as to engage with one another by a press fit through cooperation between formations on the second side of the second portion 62 and formations on the first side of the first portion 60. The first portion 60 and the second portion 62 may additionally be adhesively bonded to one another or, in some embodiments, may be held together solely by a press fit and without the use of an adhesive or any other bonding material. For example, an adhesive may be applied to the side of the base of the first portion that faces the second portion of the end plug.

[0212] Figure 16 More clearly shown is the C-shaped projection 110 on the second side of the second portion 62 which fits within a recess corresponding to the reverse portion of the collar 80 on the first side of the first portion 60 to assist in providing a press fit between the first and second portions and to support the collar during use.

[0213] Figure 17 is the first end plug 50 and Figure 16 A similar exploded view of FIG. 5 but taken from above shows the upper or first side of the first portion 60 of the end plug.

[0214] In the embodiment shown, the lid 51 of the first end closure 150 is in the form of a piece of cardboard or paper-based material, such as cardboard or paperboard. The lid 51 is shaped to correspond to the shape of the sleeve 3 at its first end, in this embodiment having a rectangular shape. The lid 51 provides a uniform appearance to the first end of the container, which is consistent with the material forming the side walls of the sleeve. The lid 51 covers the upper side of the first end plug 50, covering the molded pulp material. In the event that it is not necessary to provide a uniform appearance to the exterior of the first end of the container, the lid 51 can be omitted. In the embodiment shown, as shown Figure 18 and 19As shown in more detail in FIG, the cover 51 has a laminate structure comprising an inner layer 152 and an outer layer 151. The inner (or lower) layer 152 is bonded to the first upper side of the second portion 62. (It will be noted that the details of the laminate structure of the cover are not Figure 16 、 17 , 20 and 22.) The lid may include more or fewer layers. The lid may have a single-layer structure. All layers of the lid have a cardboard or paper-based material, such as cardboard. The inner layer 152 facilitates attachment of the lid 51 to the molded pulp material of the second portion 62. The lid 51 (including any (multiple) layers thereof) has a non-molded pulp material, such as cardboard. The outer layer of the lid 51 forms part of the exterior of the container and can be selected to match the appearance of other outer surfaces of the container (for example, as provided by the jacket in the illustrated embodiment). A single-layer lid can be used. However, using a laminated lid allows the inner and outer layers to be selected specifically with respect to their intended use (i.e., attachment to a molded pulp end plug, or providing a visible outer surface of the container). The lid is attached to the second portion 62 by bonding to the surface defined by the protrusion 112 on its first side.

[0215] The idea is that, if Figure 16 17, a member comprising a cover 51 and a second molded pulp portion 62 can be obtained by bonding a plurality of instances of the molded pulp second portion 62 to a sheet of a covering material and then cutting the member from the sheet. This allows obtaining a member in which, as shown in FIG. Figure 16 and 17 As shown in , the edge of the flange of the second pulp portion and the edge of the lid 51 are flush with each other, avoiding any complexity of having to align the edge of the molded pulp member with the edge of the lid. However, other assembly techniques may be used.

[0216] Figure 18 Is through Figure 3, with the jacket and housing removed, shows in greater detail the cooperation of the first end plug 50 of the first end closure 150 with the top of the bottle 36. It can be seen that the top of the bottle is received within the collar 80 of the first portion 60 of the first end plug 50. It can be seen here how the tab 70 is inserted into one of the grooves 120 in the panel 39 of the insert 33 to resiliently clamp the first end plug to the insert and, therefore, the sleeve. It can also be seen that the locking tab 70 is adjacent to one of the recessed portions 100 of the side wall of the second portion 62 of the first end plug 50, so that when the first end plug 50 is inserted (from above) into the first end of the sleeve 3, the locking tab 70 can exhibit its resilient behavior and flex 30 when introduced into the groove 120. In other areas away from the recess 100 that is aligned with the locking tab 70, the sidewalls of the second portion 62 of the first end plug press against the sidewalls of the first portion 60, inhibiting sidewall flexure to help maintain the locking tab 70 in engagement with the slot 120 once inserted therein in use. Figure 18 In the upper left area of ​​the drawing, the engagement between the side walls of the first portion 60 and the second portion 62 can be seen, wherein the first side wall 91 of the second portion 62 is seen engaging the interior of the first side wall 61 of the first portion 60. The engagement of the side walls of the first and second portions of the first end plug assists in obtaining a press fit therebetween.

[0217] Also available in Figure 18 152 to bond the cap 51 to the second portion 62 of the first end plug 50. It can also be seen how the upper surface of the protrusion 112 of the second portion 62 engages and bonds to the lower surface of the lower layer 152 to bond the cap 51 to the second portion 62 of the first end plug 50. It can also be seen that the cooperation between the protrusion 110 and the interior of the recess defined by the opposing sides of the collar 80 assists in forming a press fit between the first portion 60 and the second portion 62 of the end plug 50 and supports the collar to provide stability thereto when in use. The recess 116 on the lower surface of the second portion 60 receives the protrusion 114 on the upper side of the first portion 62 to further assist in positioning the first portion 60 and the second portion 62 relative to each other and obtaining a press fit therebetween. Figure 18 In FIG. 6 , it is seen that there is a protrusion in the upper surface of the second portion 62 provided by the opposite side of the recess 116 on the second / lower side thereof.

[0218] Figure 19is a more detailed view showing the cooperation of the first end plug 50 of the first end closure 150 with the top of the insert 33 and the engagement of the locking tab 70 with the slot 120. The slot is spaced a distance A from the top of the insert 33. It can be seen here that the locking tab includes a bottom or second end 71 which is connected to the base of the first part of the end plug; and an outwardly curved portion 137 which has a curved outer surface upstanding therefrom. During insertion of the first end plug, this curved portion cooperates with an inclined surface on the interior of the sleeve (here the inclined surface at the top of the insert which is planar) to facilitate insertion of the end plug and to deflect the tab inwardly to the extent necessary to allow the tab to enter the slot 120 once the end plug is fully inserted into the first end of the sleeve. Referring now to Figure 21 The inclined surfaces associated with the insert are described in more detail.

[0219] The locking tab 70 also includes a free first end 73 that is located in the slot 120, wherein the first end 73 of the tab engages an edge 121 at the first end of the slot 120 to retain the tab engaged in the slot 120. Thus, the tab hooks into the slot. The second end of the tab 71 engages the interior of the side wall of the insert below the second or lower end 123 of the slot 120 to facilitate retaining the tab in its slot and to facilitate the press fit between the end plug and the first end of the sleeve. Each resilient locking tab 70 has Figure 19 and engage with their corresponding grooves in the same manner.

[0220] Figure 19 It is also shown that the height H of the sidewalls of the second portion of the end plug (i.e., standing upright from the flange 90) is greater than the height h of the sidewalls of the first portion (i.e., standing upright from its base). This causes the second portion of the end plug to extend beyond the first portion of the end plug toward the first end of the container. This enables the first end plug to be positioned with the flange 90 of its second portion resting on top of the sleeve and with the resilient locking tabs 70 seated in their slots 120. The height difference between the sidewalls of the first and second portions of the end plug can be selected based on the spacing between the top of the slots 120 for receiving the locking tabs 70 and the top of the sleeve. The first end edge 121 of the locking slot 120 is spaced a distance A from the first end edge of the insert 33. It can be seen that the flange 90 depends from the first end edge of the locking tab 70.

[0221] Figure 31 Corresponding to Figure 19, showing certain features in more detail. It can be seen here that a cavity C is defined in the end plug resulting from the combined first and second parts 60, 62. The cavity is limited at its inner side by the side walls of the second part in the region of its recess 100. The cavity is limited on its top or first end by the underside of the flange 90 and at its bottom or second end by the first side of the base of the first part 60 of the end plug. On its outer side, towards its second end, the cavity is limited by the interior of the resilient locking tab 70. Only in the end plug is the cavity open or unrestricted towards its first or upper end, whereas when the cavity is closed with Figure 19 The manner shown in FIG. 1 is constrained by the inner surface of the insert in the area between the first end edge of the slot 120 that receives the locking tab and the first end edge of the locking tab when located in the top of the sleeve.

[0222] The formation of end plugs including such cavities is enabled by the end plug's two-piece construction. This enables the first and second parts to be molded separately, designed to facilitate easy molding, but when combined, achieves the desired configuration of the end plug including a cavity of this shape, which would not be possible in a single piece using a pulp molding process (e.g., wet molding). The shape of the cavity results from the interaction between the resilient tab and the surrounding formations, which are desirable to support the function of the resilient tab and, more generally, the functionality of the end plug as described herein. The multi-piece molding process enables such formations to be designed with greater freedom to provide these advantages, without being constrained by the limitations of a single-piece molding process, as they can be provided by combining separately molded pieces. For example, the shape of the cavity resulting from the spacing between the recess in the sidewall of the second part and the interior of the curved locking tab is an example of a shape that would tend to interfere with the ability to remove a single-piece molded component from its mold and may not be compatible with pulp molding processes (e.g., wet molding). This is exacerbated by the presence of a flange depending from this area. Providing such a feature in a single-piece pulp-formed end plug would be complex, if not impossible. In contrast, a multi-piece construction enables each portion to be molded separately using a simple mold (e.g., an upper and lower male-female arrangement), and enables the molded pieces to be removed without risk of damaging the formation.

[0223] Figure 20The first end closure 150 is shown inserted into the top end of the insert 33. Other components of the sleeve, such as the housing and jacket, are omitted. Here, alignment tabs 72 can be seen sliding into additional (alignment) slots 122 of the second panel 37 of the insert 33. The alignment slots, which extend to the top of the panel, are associated only with the second panel 37 of the insert 33, ensuring that the first end plug 50 (and therefore the first end closure) can only be inserted into the top of the sleeve in the orientation shown, i.e., with the first sidewalls 61, 91 of the first and second portions 60, 62 positioned on the open sides of the insert (so that they will be adjacent to the first sidewall 5 of the sleeve). The locking tabs 70 are able to flex inward (when they contact the material of the corresponding insert panel above the slots 120 in which they will be received), allowing the first end plug 50 to slide into place. The locking tabs 70 will then, due to their inherent elastic recovery, move outward into the recesses 120 to lock the first portion 62, and therefore the first end plug 50, to the sleeve.

[0224] The connection between the first end plug 50 and the sleeve 3 is achieved by the press fit and cooperation of the locking tabs with their corresponding recesses, and does not require the use of adhesives or any other external bonding materials. The first and second parts of the first end plug 50 are connected to each other by a press fit, and optionally do not require any external bonding materials. In some embodiments, they are bonded to each other without adhesive.

[0225] As can be seen in the top end of the insert 33 shown in more detail Figure 21 As seen in more detail in FIG, each panel of the insert 33 includes an inclined surface on its interior adjacent the top edge of the panel. These inclined surfaces 131, 133, 135 guide the insertion of the first end plug 50, as shown in FIG. Figure 22 , cooperates with a corresponding inclined surface 137 at the second end of the resilient locking tab 70 to urge the resilient locking tab inwardly to enable the end plug to be inserted into the first end of the sleeve to the extent necessary for the locking tab to enter the locking groove 120. The shape of the resilient locking tab 70 of the first portion 60 of the first end plug is, for example, Figure 22 and Figure 19 The locking tab 70 has an inclined outer surface 137 adjacent the second (or bottom) end of the locking tab that is configured to cooperate with the inclined surface of the adjacent side wall of the sleeve and deflect the locking tab inwardly when the end plug is inserted into the sleeve.

[0226] Figure 23 The first end plug 50 is shown inserted in its final position into the first end of the insert 33 with the locking tab 70 inserted into the slot 120 of the insert 33 and the alignment tab 72 inserted into the alignment slot 122 .

[0227] As can be seen, for example, in a system comprising a jacket and housing 31 and an insert 33 Figure 1 、 2 , 4 and 5, the slots 120 and 122 in the insert are covered on their outer surfaces by the panel of the housing 31. In this way, the slots provide recesses 140 and 142, respectively, in the inner surface of the side wall of the sleeve 3 that do not extend through the entire thickness of the side wall. The housing covers the recesses to help maintain the locking tab 70 in place during use, provide greater integrity to the sleeve structure, and prevent the recesses from being visible from the outside of the sleeve.

[0228] Figure 24 The assembly of the collet and sleeve is shown in the region of its first end, showing how the outer sleeve panel covers the outside of the slot 120 to provide the recess 140 in the side wall of the sleeve 3 provided by the combination of the outer shell 31 and the insert 33. In this view, the closing flap 28 of the collet is shown tucked into the space provided by the spacer 26 between the panel 21 of the collet and the second panel 7 of the sleeve. Figure 25 is a similar view, but with the jacket omitted so that the spacer 26 can be seen more clearly.

[0229] The assembly of a container according to one exemplary arrangement will now be described. The order of steps and the exact operations performed may vary from this example.

[0230] like Figure 26 As shown in FIG, the insert 33 is inserted into the housing 31 from the top or first end of the housing 31 in the direction of the arrow. The adjacent panels of the housing and the insert are bonded to each other, for example, adhesively. This provides Figure 5 Sleeve 3 shown in FIG.

[0231] Next, the spacer 26 is bonded to the outside of the second side wall 7 of the sleeve 3 (eg Figure 25 ). The spacer extends over only part of the width of the second side wall 7 to define a gap 18.

[0232] Next, the second end closure 154 comprising the second end plug 52 and the support member 57 is inserted into the bottom end of the insert so as to plug its bottom end and adhesively secure it in the second end of the sleeve. The second end plug 52 and the support member 57 can be assembled together as a single component before being inserted into the end of the sleeve, or alternatively, the second end plug 52 and the support member 57 can be inserted into the bottom end of the insert in sequence and then secured to each other and the interior of the sleeve. Any suitable arrangement can be used. As described above, in some cases, the support member can be omitted, and the form of the second end closure and / or the end plug can be different from that shown. In particular, it does not need to have a pulp molded structure. However, the second end closure should have a cardboard or paper-based material to allow the container to be recycled without having to separate it into separate components.

[0233] Next, the jacket 20 is wrapped around the outside of the sleeve with its panels 21 and 22 placed over and, for example, adhesively bonded to the second 7 and third 9 side walls of the sleeve. Figure 4 The arrangement shown in , but in which the second end closure has been inserted in the bottom of the sleeve.

[0234] The bottle 36 now drops down through the open first or top end of the sleeve into the subassembly of the sleeve 3, second end closure 154 and jacket 20. The bottle is supported on the second end closure 154.

[0235] As part of the method, the first end closure 150 is assembled. This can occur separately from or simultaneously with the assembly of the sleeve, collet, and second end closure. Assembly of the first end closure 150 involves adhesively bonding the cap 51 to the second portion 62 of the first end plug 50, for example, and then press-fitting this subassembly of the cap and second portion 62 into the first portion 60 of the first end plug 50, as shown. Figure 17 and 18 to produce the Figure 20 6. A first end closure 150 of the form shown in FIG. In one exemplary arrangement for mass-producing a component comprising the second portion 62, multiple instances of the second portion 62 are bonded to a covering material. Subsequently, the component comprising the second portion and the lid is cut from a sheet of material. This avoids the need to align the second portion with the lid. However, other assembly techniques may be used, and the lid may be bonded to the second portion either before or after the lid is assembled with the first portion of the molded pulp end plug. The first portion 60 and the second portion 62 are press-fit together, optionally without the use of adhesive or any other bonding agent or other external fixing agent.

[0236] Next, the assembled first end closure 150 is pushed into the top or first end of the assembled collet and sleeve. This can be performed by a robot. Figure 20 As shown in FIG, the first end plug 50 is slid into the top end of the insert 33 until it is securely locked in place by engagement between the locking tab 70 and the slot 120, as shown in FIG. Figure 23 1 (but with the housing 31 and jacket 20 already in place). No adhesive is required to secure the first end plug in place within the sleeve. The alignment tabs 72 align with the slots 122 to allow the first end plug 50 to be inserted only in the intended orientation, with the open end of the collar adjacent the first sidewall 5 of the sleeve. The underside of the flange 90 of the second portion 62 engages against the top of the sidewall of the insert to position the first end closure.

[0237] Once the first end closure 150 is inserted in this manner, the top of the bottle is supported within the collar of the first portion 60 of the first end plug, as shown. Figure 1 The jacket is then secured in place by folding it around the sleeve and releasably securing it in place by inserting the closure tab 28 into the space 18 between the second side wall of the sleeve and the jacket to provide a Figure 2 In the structure shown in FIG, the door is closed. When closed around the sleeve, the side edges of the lid 51 are flush with the side edges of the jacket to provide an attractive appearance to the container.

[0238] In use, the user may then unfasten the closure tab 28 , open the door to reveal the opening 12 in the first side wall of the sleeve, and remove the bottle through the opening 12 .

[0239] Figures 27-30 An alternative first end plug 50' is shown in FIG. The end plug is similar to the reference Figures 7 to 14 The end plug of the first embodiment described is similar. The two parts 60' and 62' fit together in the same manner using a press fit. A cap (not shown) may be provided, and the resulting first end closure is inserted into the first end of the sleeve to cooperate with the recess on the interior of the sleeve in the same manner as previously described with respect to the first embodiment. Corresponding parts are identified with the same reference numerals as the previous embodiment, with a "'" notation. This further embodiment will be described with reference only to those features that differ.

[0240] The first portion 60' of the first end plug 50' is Figure 27 and 28 , and has the same construction as the first portion 60 of the first end plug 50 of the first embodiment described earlier. Figure 27 This is a view from the second side of the first portion 60' which is located lowermost in use, or closest to the second end of the container. As in the earlier embodiments, a collar 80' is provided for supporting the top of the bottle. Figure 28 It is a view from a first side of the first portion 60', which is uppermost in use.

[0241] The first end plug 50' is different from the first end plug 50 of the first embodiment in the structure of the second portion 62'. Figure 29 and Figure 30 In the display, Figure 29 and Figure 30 The second portion 62' is shown from its second or lower side and from its first or upper side, respectively. Instead of having a single C-shaped protrusion defining a ridge on its second side that is inserted into a recess on the first side of the first portion of the first end plug (corresponding to the reverse of the collar 80') to support the collar and assist in providing a press fit between the parts, the second portion 62' has a pair of protrusions 210, 212 on its second side that are inserted into recesses corresponding to the reverse of the collar 80'. These protrusions 210 and 212 are located in the recess at the base of the arms of the recess, on either side of the recess, closest to the corners where the side walls 63' and 65', and 63' and 67', respectively, join one another. Similar to the first embodiment, a projection 112' comprising a planar surface for bonding to a cap of the end plug 50' is provided on a first or upper side of the portion 62', but the projection extends only over a portion of the length of the respective side walls 95' and 97' of the second portion 62' to accommodate a pair of projections 210 and 212.

[0242] This alternative arrangement of the collar for supporting the first part can provide greater stability in certain contexts. The most appropriate configuration of the protrusion(s) on the second side of the second part of the first end plug for supporting the collar of the first part can be selected as desired, for example, depending on the type of product or indeed bottle to be supported by the collar, and the possible forces to be withstood when in use. The shape of the collar and / or its support may be different from that shown. Thus, where the first part comprises a product support in the form of a collar, the second part may comprise a collar support in the form of one or more protrusions that are inserted into a recess provided in the first side of the first part corresponding to the reverse portion of the collar.

[0243] Of course, depending on the intended contents of the container, alternative forms of product supports may be used that do not necessarily include a collar. It will also be understood that the configuration of the molded formations of the first and second portions of the first end plug may vary from those shown and may be selected to provide the desired functionality of the first end plug or either portion thereof, for example, to assist in supporting the product and / or provide for mutual engagement between the first and second portions and / or to provide for attachment to other portions of the container (such as a lid of the first end closure) or to the sleeve. The shape and / or size of the alignment and / or locking tabs may vary from those shown.

[0244] It has been discovered that the container of the present invention, in any of its embodiments, can provide a sustainable container based on paper or cardboard materials that is easily recyclable, allowing all components to be discarded through the same recycling waste stream used for such materials, and can be easily manufactured (e.g., using robotic assembly techniques). The container enables bottles to be loaded from the top end, wherein a first end plug of molded paper pulp is then pressed into the top of the sleeve. The resilient tab of the first end plug enables the plug to be secured in place by a simple press-fit operation that can be performed robotically. Advantageously, the need for gluing after the bottle is inserted can be avoided at this stage in the assembly. This can provide a simpler and cleaner process with fewer steps.

[0245] The container is suitable for fragile products, such as glass bottles. It was found that the structure could withstand the test required for such bottles, which involves inserting a 10 kg weight into the container and shaking the container while inverting it. It was found that the first end plug secured to the sleeve in the manner described provided a sufficiently secure fit to pass such a test.

[0246] The first end plug of the first end closure described herein may provide a closure having a strength that allows it to provide a sustainable alternative to conventional closures using plastic materials (eg involving interlocking plastic parts).

[0247] While the container is described in the context of bottles, it is contemplated that other types of products may be housed in the container. The container may be advantageous in any context where a sturdy container is desired, such as in the context of any fragile items. However, the container of the present invention is particularly useful in housing fragile items such as bottles, for example, beverage bottles. The container may house a single beverage bottle.

[0248] As used herein, molded pulp refers to a material comprising cellulose fibers. The material can be molded using any suitable process. The material is sustainable in that it can be recycled along with other cardboard and / or paper-based materials. The molded pulp material can be formed at least in part from recycled material (i.e., recycled fibers obtained from recycling cardboard or paper-based materials).

[0249] The present invention may extend to producing a first portion and a second portion of a first molded pulp end plug using a pulp molding process (e.g., a wet molding process). Each portion is produced using a respective mold that is configured to provide a respective one of the first portion and the second portion. For example, producing the first portion and the second portion of the first molded pulp end plug using a wet molding process may involve individually molding each of the first portion and the second portion using a respective mold that has a shaped molding surface configured to provide the formation of the respective one of the first portion and the second portion. For example, the molding surface may be a male molding surface.

[0250] The method may include molding each of the first portion and the second portion by a method comprising: lowering a mold having a shaped molding surface into a container of pulp slurry, the shaped molding surface for forming a respective one of the first portion and the second portion of molded pulp providing a molded pulp end plug; accumulating pulp material on the shaped molding surface; and lifting the mold out of the container of pulp slurry, wherein pulp material is deposited on its molding surface to provide a preform of the respective one of the first portion and the second portion of molded pulp. The method may involve using a vacuum to assist in accumulating the pulp material on the shaped molding surface. The molding surface may be any suitable porous surface. The molding surface may include, for example, a mesh on which the pulp material collects.

[0251] The method may further include drying the preform. The method may further include removing the preform from the forming molding surface. This may occur before or after drying the preform, or between steps involved in the drying process. The step of drying the preform may involve one or more steps that may involve dewatering the pulp material, such as by pressing and / or heating the material. The step of drying the deposited material may or may not involve transferring the preform to another support surface, such as another mold or another support surface of a conveyor belt.

[0252] The method may involve, after lifting the (first) mold out of the slurry, mating a shaped molding surface having deposited pulp material thereon (which provides the preform) with a cooperating shaped molding surface of a further mold. The deposited material may be pressed between the molding surfaces, for example to dehydrate the material and assist in shaping it. The further mold may be a female mold, with a male mold immersed in the pulp slurry, although the reverse arrangement is also contemplated.

[0253] While various pulp moulding techniques may be used to produce the moulded pulp end plug, and where applicable, the first and second parts thereof (not limited to the above examples), in an embodiment, the first and second parts of the first end plug are both formed by depositing pulp material onto a shaped moulding surface of a mould (or may be formed by depositing pulp material onto a shaped moulding surface of a mould), the shaped moulding surface being configured to produce a formation of a respective one of the first and second parts.

Claims

1. A container made of a paper-based or cardboard-based material, comprising: a sleeve having a first end and a second end, a first end closure closing the first end of the sleeve, and a second end closure closing the second end of the sleeve; the sleeve including a plurality of side walls extending between the first end and the second end thereof, wherein the first side wall of the sleeve includes an opening therein to provide access to an interior space of the sleeve, the product being disposed in the interior space when in use; wherein the first end closure comprises a molded pulp end plug including resilient locking tabs projecting outwardly therefrom, each locking tab being received in a corresponding recess in the interior of the sleeve to securely retain the molded pulp end plug within the first end of the sleeve.

2. The container according to claim 1, wherein The molded pulp end plug of the first end closure comprises side walls, each side wall extending along a corresponding one of the side walls of the sleeve, wherein each of the plurality of side walls of the end plug comprises one or more of the resilient locking tabs projecting outwardly therefrom and received in corresponding recesses in the corresponding side wall of the sleeve.

3. The container according to claim 2, wherein The multiple side walls of the end plug having the elastic protrusion include at least one pair of opposite side walls of the end plug; optionally, the multiple side walls of the molded pulp end plug having the one or more elastic locking protrusions also include a side wall connecting the pair of opposite side walls among the side walls.

4. The container according to claim 2 or 3, wherein The side wall of the molded pulp end plug extending along the first side wall of the sleeve is free of the resilient locking tab.

5. The container according to any one of claims 2 to 4, wherein Each of the side walls of the end plug having resilient locking tabs protruding outwardly therefrom includes a plurality of the resilient locking tabs, such as a pair of the resilient locking tabs, protruding outwardly therefrom.

6. A container according to any preceding claim, wherein The molded pulp end plug further comprises an alignment feature such that the end plug can only be inserted into the sleeve in a predetermined orientation relative to the sleeve.

7. The container according to claim 6, wherein The molded pulp end plug comprises a product support comprising a molded pulp collar on a second side of the end plug, and the predetermined orientation is an orientation in which the open end of the collar faces the first side wall of the sleeve to enable product to be removed from the interior of the sleeve through the opening in the first side wall.

8. A container according to claim 6 or 7 as appended to any one of claims 2 to 5, wherein One of the side walls of the molded pulp end plug of the first end closure having one or more resilient locking tabs further comprises one or more resilient alignment tabs projecting outwardly therefrom, and the corresponding side wall of the sleeve comprises one or more additional recesses for receiving corresponding ones of the one or more resilient alignment tabs.

9. The container according to claim 8, wherein The one or more recesses for receiving the one or more resilient locking tabs are spaced from the first end edge of the sleeve, and the one or more recesses for receiving the one or more resilient alignment tabs extend to the first end edge of the sleeve.

10. A container according to any preceding claim, wherein Each resilient locking tab of the molded end plug is configured to hook into its corresponding recess in the sleeve, the locking tab having a first end edge that cooperates with the first end edge of the recess to retain the tab in its recess, the resilient locking tab being bent outwardly in a direction from the second end of the tab toward the first end of the tab.

11. A container according to any preceding claim, wherein Each side wall of the sleeve having one or more recesses for cooperating with one or more corresponding resilient locking tabs of the molded pulp end plug includes an inner inclined surface at the first end of the side wall and located between the first end edge of the side wall and the one or more recesses of the side wall for guiding the molded pulp end plug when the molded pulp end plug is inserted into the container.

12. The container according to claim 11, wherein Each resilient locking tab of the molded end plug includes an outwardly curved surface on its exterior that cooperates with a corresponding one of the inner inclined surfaces of the sleeve to cause the locking tab to deflect inwardly when the end plug is inserted into the first end of the sleeve.

13. A container according to any preceding claim, wherein The molded pulp end plug of the first end closure comprises first and second separately formed and mutually engaged molded pulp portions, the first portion being positioned proximate the second end of the sleeve, wherein the molded pulp end plug comprises side walls, each side wall extending along a corresponding one of the side walls of the sleeve, wherein each of one or more of the side walls of the end plug comprises one or more of the resilient locking tabs projecting outwardly therefrom, wherein the first portion provides the side walls of the molded pulp end plug and the one or more resilient locking tabs of the end plug, and wherein the second portion fits within the first portion.

14. The container according to claim 13, wherein The sidewalls of the second portion engage the inner portions of the sidewalls of the first portion to reinforce the first portion.

15. The container according to claim 13 or 14, wherein The side wall of the second portion comprises a recess at a position corresponding to the position of the resilient locking tab associated with the side wall of the first portion of the moulded pulp end plug.

16. The container according to claim 15, wherein Each side wall of the second portion that engages a side wall of the first portion having one or more resilient locking tabs protruding therefrom includes first and second regions alternating along its length, each first region engaging the side wall of the first portion, and each second region defining a recess in the side wall at a location corresponding to the location of the resilient locking tab of the side wall of the first portion.

17. The container according to claim 15 or 16, wherein Each recess in the side wall of the second part at a position corresponding to the position of the resilient locking tab of the first part spaces the side wall of the second part from the inner surface of the locking tab to cause a cavity to be defined between the outer surface of the side wall of the second part and the inner surface of the resilient locking tab, and the separate formation of the first and second parts of the end plug facilitates the provision of such a cavity.

18. A container according to any one of claims 13 to 17, wherein The second portion of the molded pulp end plug comprises a flange at a first end thereof, the side wall of the second portion upstanding from the flange, wherein the flange cooperates with the first end of the sleeve to position the molded pulp end plug.

19. The container according to any one of claims 13 to 18, wherein The recess of the sleeve for receiving the resilient locking tab is spaced from the edge of the sleeve at the first end thereof, and the side wall of the second part of the molded pulp end plug has a height greater than the height of the side wall of the first part of the molded pulp end plug so that the resilient locking tab of the first part is spaced from the first end of the sleeve so that the locking tab can be received in the recess.

20. A container according to claim 19 when appended to claim 18, wherein The flange is spaced from and depends from the first end edge of the resilient locking tab of the first portion.

21. The container according to any one of claims 18 to 20, wherein A cavity is defined in the molded pulp end plug in the region of each resilient locking tab, the cavity being limited on its inner side by the outer surface of the side wall of the second part, on the side closest to the first end of the container by the second side of the flange, and on the outer side by the inner surface of the resilient locking tab on a portion of the height of the cavity closer to the second end of the container, and by the inner surface of the sleeve on a portion of the height of the cavity closer to the first end of the container in the region between the first end edge of the recess of the sleeve and the second side of the flange, the separate formation of the first part and the second part facilitating the provision of such a cavity.

22. A container according to any one of claims 13 to 21, wherein The first and second parts of the molded pulp end plug are secured to each other by a press fit; and are optionally adhesively bonded to each other.

23. A container according to any one of claims 13 to 22, wherein The first portion defines a first side and an opposing second side, the second side facing the second end of the sleeve, wherein the second side includes one or more protrusions defining a collar for receiving a top of a product in the form of a bottle, wherein the open end of the collar faces the first sidewall of the sleeve.

24. The container according to claim 23, wherein The second portion defines a first side and an opposing second side, the second side of the first portion facing the second end of the sleeve, wherein the second side of the second portion includes one or more protrusions for supporting the collar, each protrusion being received in a corresponding recess defined on the first side of the first portion by an inverted portion of the one or more protrusions defining the collar; optionally, wherein the collar is defined by a single C-shaped protrusion on the second side of the first portion, and wherein the second side of the second portion includes a pair of protrusions received in respective arms of a C-shaped recess defined on the second side of the first portion by an inverted portion of the C-shaped protrusion defining the collar; or wherein the second side of the second portion includes a single protrusion in the form of a C-shaped rib, the single protrusion being received in a C-shaped recess defined on the second side of the first portion by an inverted portion of the C-shaped protrusion defining the collar.

25. A container according to any preceding claim, wherein The recess of the sleeve for receiving the resilient locking tab does not extend through the entire thickness of the sleeve.

26. A container according to any preceding claim, wherein Each side wall of the sleeve having one or more recesses for receiving corresponding resilient locking tabs of the molded pulp end plug of the first end closure comprises an inner layer and an outer layer, at least in the region of the first end of the sleeve, wherein each recess is provided by a groove extending through the inner layer of the side wall and the outer layer of the side wall covers the groove.

27. The container according to claim 26, wherein The sleeve comprises an insert and an outer shell, each comprising a plurality of panels hingedly connected to each other, wherein the slots are provided in the panels of the insert, the slots being covered by the panels of the outer shell.

28. The container according to claim 27, wherein The first side wall of the sleeve is provided by a panel of the housing defining an opening providing access to the interior of the sleeve and is not lined by a panel of the insert.

29. The container according to any one of claims 27 or 28, wherein The panel of the insert comprises an inclined surface at the first end thereof to guide the molded pulp end plug of the first end closure when inserted into the sleeve during assembly of the container.

30. A container according to any preceding claim, comprising a door rotatable about a fold line between a closed position and an open position, wherein in the closed position the door covers the opening in the first side wall of the sleeve, and in the open position the opening is uncovered for providing access to the product through the opening when located in the interior space of the sleeve in use.

31. A container according to any preceding claim, wherein The container also includes an outer jacket.

32. A container according to claim 31 when appended to claim 30, wherein The jacket comprises a set of panels hingedly connected to each other, wherein the door is provided by the panels of the jacket, the jacket further comprising: one or more additional panels hingedly connected to the door panel on one side of the door panel, each additional panel being secured to a respective side wall of the sleeve; and a closure mechanism attached to the door panel on the other side of the door panel for releasably securing the door in the closed condition.

33. The container of claim 32, wherein A panel of the set of jacketed panels is secured at one end to its respective side wall of the sleeve via a spacer so that a gap is defined between the jacketed panel and the sleeve, and the closure mechanism is in the form of a flap which is inserted into the gap to releasably secure the door in the closed state.

34. A container according to any preceding claim, wherein The molded pulp end plug is secured within the sleeve by press-fit and cooperation of the resilient locking tabs with the recessed portion of the sleeve, without the need for adhesive.

35. A container according to any preceding claim, further comprising a product in the form of the bottle located therein.

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