Extrusion fiber-based bottle

Abstract

A squeezable fiber-based bottle for storing and dispensing a viscous liquid. The bottle comprises a pulp molded base (20) and a pulp sidewall (12). The pulp molded base comprises: a liquid containing surface (28) having an aperture (30) for dispensing viscous liquid; and a base perimeter having a perimeter surface (22) with an upper edge (24) and a lower edge (26). A susceptor barrier structure (40) is disposed on the liquid containing surface and the upper edge of the susceptor perimeter. The fiber-based sidewall has an upper edge, a lower edge, an inner surface, and an outer surface. The inner surface includes a fiber-based sidewall barrier layer. The lower edge of the fiber-based sidewall is attached to the pulp molded base, thereby forming an impermeable seal (42). The impermeable seal is formed around the entire peripheral surface of the pulp molded base near an upper edge of the peripheral surface but not near a lower edge of the peripheral surface.

Description

Technical Field

[0001] A squeezable fiber-based bottle for storing and dispensing viscous liquid products on demand in humid environments. Preferably, the squeezable fiber-based bottle is recyclable. Background Technology

[0002] Since the industrial age, plastic products have been widely used in daily life. Due to their relatively low production costs and versatility, plastic packaging materials have experienced a higher growth rate in the global market compared to other packaging materials. However, most of the plastics we see on the market are made from non-renewable sources of natural crude oil. Despite continuous improvements in waste management infrastructure, plastic packaging is sometimes not recycled after use, thus leaking into the environment and potentially persisting there. Plastic pollution is prompting increasingly stringent scrutiny of plastic use and the emergence of new environmental regulations that restrict the use of plastics in packaging, especially for short-life applications.

[0003] Packaging made from natural cellulose fibers has become an area of ​​increasing interest, as part of the overall trend towards renewable and less durable raw materials. Pulp packaging also typically boasts very high recyclability. Cellulose products are often formed into films or multilayer boards using papermaking processes, or into 3D shaped objects using pulp molding methods. While pulp provides excellent structural support and a good decorative surface, its poor oxygen and moisture barrier properties, as well as its poor liquid containment characteristics, lead to a loss of integrity, making individual sheets or shaped objects unsuitable for packaging liquid products. Therefore, after manufacturing cellulose products, a protective coating is usually applied to the inside to extend the shelf life of the packaged liquid product.

[0004] Liquid packaging sheets (LPBs) are typically laminated with a polymer (such as PE) with heat-sealing properties in a structure that may include one or more barrier layers (such as EVOH, vacuum metallized alumina, etc.), or alternatively coated with a thin layer applied using dispersion techniques (such as spraying, roller coating, dip coating, blade coating, or curtain coating). However, coatings present a trade-off between barrier performance and packaging recyclability. Packaging, such as cartons, cans, or paper tubes, cans can be manufactured using high-speed manufacturing processes to form sheets. Cartons or cans are suitable for dispensing pourable liquids but not for dispensing viscous formulations, such as those used in cosmetics and personal care. Current paper tubes include liquid sheets and require significant amounts of plastic due to the inclusion of plastic components necessary to provide reclosability and dispensing control. Furthermore, the hygroscopic nature of pulp poses additional challenges for pulp packaging applications used in humid or damp environments (such as in shower rooms or bathrooms). Liquid packaging boards typically contain high levels of adhesives (such as alkyl ketene dimer (AKD)) to increase hygroscopicity, but are susceptible to in-plane edge wicking, which is usually caused by liquid being drawn into the cut edges via capillary action. This liquid wicking leads to delamination and exposure of unbonded fiber-to-fiber bonds and / or weakening of layer-to-layer adhesions, resulting in the separation of multilayer surfaces.

[0005] Packaging made from rigid pulp molding, such as bottles, is less susceptible to edge wicking. Compared to liquid packaging sheets, pulp molding also allows for greater shape and material selection freedom. To achieve desired liquid containment, moisture, and oxygen barrier properties, bottles can be coated with thin plastic liners, for example, produced by blow molding, rotational molding, or spraying. Pulp molding slurries can also contain additives to modify the properties of the cellulose material, such as porosity, sizing properties, or wet strength. As with paper sheets, incorporating such liners, coatings, and additives involves a compromise between recyclability and barrier performance. Furthermore, incorporating large amounts of fiber in functional accessories such as necks and closures presents numerous challenges due to stringent forming tolerance requirements and coating integrity and reliability issues under multiple open / close cycles. Current pulp molding bottle manufacturing processes require plastic pumps to control and carefully dispense the viscous formulation, as bottles are typically produced with large neck openings and rigid side panels.

[0006] It is desirable to maximize the bio-based fiber inclusion in packaging to improve the bio-based renewable content and recycling rates in fiber reprocessing. It is also desirable to maximize the bio-based fiber inclusion in packaging to form articles with regional variations in mechanical properties across the product. For example, bottles made of plastic can be formed to be rigid relative to top loading while also including flexible panels that users can squeeze to dispense the product. It is also desirable to increase fiber inclusion to achieve over 95% product recovery and flatten the bottle upon disposal, which facilitates sorting and the circular economy. Fiber-based bottles are expected to minimize plastic inclusion while offering unique design shapes, providing a reasonable shelf life of at least 6 months to 2 years, and offering shower resistance and recyclability. Preferably, extrudable pulp fiber-based bottles are intended for use in humid environments, capable of maintaining integrity while containing liquid formulations, capable of on-demand dispensing, possessing excellent ergonomics in use, exhibiting a reasonable shelf life, and optimizing recycling and disposal. Summary of the Invention

[0007] This disclosure provides a squeezable fiber-based bottle for storing and dispensing viscous liquids. The bottle includes a pulp-molded base with a liquid-receiving surface having an orifice for dispensing the viscous liquid. The pulp-molded base includes a base periphery having a peripheral surface with an upper edge and a lower edge. A base barrier structure is disposed on the liquid-receiving surface and the upper edge of the base periphery. The base barrier structure has a WVTR of less than 20 g / m² / day at 25°C and 60% relative humidity. The squeezable fiber-based bottle includes a fiber-based sidewall having an upper edge, a lower edge, an inner surface, and an outer surface. The inner surface includes a fiber-based sidewall barrier layer having a WVTR of less than 20 g / m² / day at 25°C and 60% relative humidity. The lower edge of the fiber-based sidewall is attached to the pulp-molded base to form an impermeable seal. The impermeable seal is formed around the entire peripheral surface of the pulp molding base, near the upper edge of the peripheral surface but not near the lower edge. The peripheral surface of the pulp molding base may include a lip or flange to receive the lower edge of the pulp sidewall. The lower edge of the peripheral surface of the pulp molding base is below the liquid-receiving surface, thereby allowing the extrudable fiber-based bottle to stand upright. The orifice for dispensing viscous fluid includes a separable slot valve disposed opposite the liquid-receiving surface. The separable slot valve is formed of plastic or other resin material and includes tabs that facilitate removal. Attached Figure Description

[0008] Although claims that are specifically pointed out and clearly claimed after the specification are provided, the exemplary embodiments of the invention are believed to be better understood from the following description taken in conjunction with the accompanying drawings, wherein: Figure 1a is a perspective view of an extrudable fiber-based bottle according to the present disclosure.

[0009] Figure 1b is a cross-sectional view of the extrudable fiber-based bottle in Figure 1a.

[0010] Figure 1c is a cross-sectional view of the pulp molding base used for the bottle in Figure 1b.

[0011] Figure 2a is an exploded view of the bottom portion of the extrudable fiber-based bottle according to the present disclosure.

[0012] Figure 2b is a perspective view of a separable narrow-mouth valve according to the present disclosure.

[0013] Figure 3a is a cross-sectional view of the pulp molding base before the assembly of the pulp molding base barrier layer.

[0014] Figure 3b is a cross-sectional view of the pulp molding base in Figure 3a after the pulp molding base barrier layer is assembled.

[0015] Figure 3c is a cross-sectional view of the pulp molding base, showing the final assembly of the pulp molding base barrier layer.

[0016] Figure 4a is a perspective view of an extrudable fiber-based bottle with a cylindrical tubular structure according to the present disclosure, the extrudable fiber-based bottle having an open end opposite to a pulp molding base.

[0017] Figure 4b is a perspective view of a squeezable fiber-based bottle according to Figure 4a of this disclosure, the squeezable fiber-based bottle having a closed end opposite to a pulp molding base.

[0018] Figure 4c is a bottom view of the extrudable fiber-based bottle shown in Figures 4a and 4b according to this disclosure.

[0019] Figure 4d is a side view of the extrudable fiber-based bottle shown in Figure 4b according to this disclosure.

[0020] Figure 5a This is a cross-sectional view of the lower portion of the squeezeable bottle according to this disclosure.

[0021] Figure 5b This is a cross-sectional view of the lower portion of a squeezeable bottle according to the present disclosure, showing barrier layers located on the inner and outer surfaces of the sidewalls.

[0022] Figure 5c This is a cross-sectional view of the lower portion of a squeezeable bottle according to the present disclosure, showing a barrier layer on the liquid-containing surface and the bottom surface of the pulp molding base.

[0023] Figure 6a shows a perspective view of the upper edge of the sidewall of the extrudable fiber-based bottle according to the present disclosure, the upper edge having an edge seal formed by a single fold edge protection.

[0024] Figure 6b shows a perspective view of the upper edge of the sidewall of the extrudable fiber-based bottle according to the present disclosure, the upper edge having an edge seal formed by double-folded edge protection.

[0025] Figure 6c shows a perspective view of the upper edge of the sidewall of a squeezable fiber-based bottle according to the present disclosure, the upper edge having an edge seal formed by a saddle-shaped folded edge protection.

[0026] Figure 6d shows a perspective view of the upper edge of the sidewall of the extrudable fiber-based bottle according to the present disclosure, the upper edge having an edge seal formed by a triple-fold edge protection.

[0027] Figure 7a is a perspective view of an extrudable fiber-based bottle according to the present disclosure, the extrudable fiber-based bottle having an open end opposite to a pulp molding base.

[0028] Figure 7b is a cross-sectional view of an extrudable fiber-based bottle with a cylindrical tubular structure according to the present disclosure, the extrudable fiber-based bottle having an open end opposite to a pulp molding base.

[0029] Figure 7c is a perspective view of an extrudable fiber-based bottle shown in Figure 7b according to the present disclosure, the extrudable fiber-based bottle having a closed end opposite to a pulp molding base.

[0030] Figure 7d It is a plan view of the blank used to form the side panel of the extrudable bottle shown in Figures 7a to 7c according to this disclosure.

[0031] Figure 7e This is a cross-sectional view of the side panel of the squeezeable bottle shown in Figures 7a to 7c according to this disclosure.

[0032] Figure 8a This is a perspective view of an extrudable fiber-based bottle having molded side panels according to the present disclosure.

[0033] Figure 8b is based on this disclosure. Figure 8a The cross-sectional view of the extrudable fiber-based bottle is shown.

[0034] Figure 8c is a perspective view of the cross section shown in Figure 8b according to this disclosure.

[0035] Figure 9a is a perspective view of an extrudable fiber-based bottle according to the present disclosure.

[0036] Figure 9b is a cross-sectional view of the pulp molded bottle shown in Figure 9a according to this disclosure.

[0037] Figure 10a is a perspective view of an extrudable fiber-based bottle according to the present disclosure, the extrudable fiber-based bottle having an open end opposite to a pulp molding base.

[0038] Figure 10b is a cross-sectional view of the extrudable fiber-based bottle shown in Figure 10a according to the present disclosure.

[0039] Figure 10c is a perspective view of an extrudable fiber-based bottle shown in Figures 10a and 10b according to the present disclosure, the extrudable fiber-based bottle having a closed, sealed end opposite to a pulp molding base.

[0040] Figure 10d is a cross-sectional view of an extrudable fiber-based bottle according to Figure 10c of the present disclosure, the extrudable fiber-based bottle having a closed, sealed end opposite to a pulp molding base.

[0041] Figure 11a is a cross-sectional view of the pulp molding base according to the present disclosure. Figure 11b is a bottom view of the pulp molding base according to the present disclosure.

[0042] Figure 12 This is an exploded perspective view of the pulp molding base according to this disclosure.

[0043] Figure 13 This is a cross-sectional view of the lower portion of the squeezeable bottle according to this disclosure.

[0044] Figure 14 This is a cross-sectional view of the lower portion of the squeezeable bottle according to this disclosure.

[0045] Figure 15 This is a cross-sectional view of the lower portion of the squeezeable bottle according to this disclosure. Detailed Implementation

[0046] The invention can be more readily understood by referring to the following detailed description of exemplary and preferred embodiments. It should be understood that the scope of the claims is not limited to the specific components, methods, conditions, apparatus, or parameters described herein, and the terminology used herein is not intended to limit the invention protected by the claims. Furthermore, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the,” and “the,” also include the plural, and reference to a particular numerical value includes at least that particular value, unless the context explicitly specifies otherwise. When indicating a range of values, another embodiment includes starting from one particular value and / or ending at another particular value. Similarly, when a value is expressed as an approximation using the antecedent “about,” it should be understood that the particular value forms another embodiment. All ranges are inclusive and composable.

[0047] One object of the present invention is to provide a squeezable fiber-based bottle for liquid compositions comprising equal to or greater than 85% fiber content, resizing, capable of emptying equal to or greater than 95% of the product, capable of flattening upon disposal, dispensing control via a self-sealing valve, and capable of withstanding delivery, storage and use in humid environments.

[0048] Another object of the present invention is to provide a squeezable bottle having collapsible pulp sidewalls, which is molded into a single component.

[0049] Another object of the present invention is to provide a squeezeable bottle having collapsible molded pulp sidewalls that can be filled and sealed from the top, similar to a cosmetic tube.

[0050] Another object of the present invention is to provide an integrally formed extrudable pulp molded bottle.

[0051] Another object of the present invention is to provide a removable valve that can be separated from the bottle by the consumer before disposal.

[0052] "Pulp" is preferably defined as a fibrous material produced by separating fibers from a sustainable source through mechanical or chemical methods and then suspending them in a fluid.

[0053] "Fiber" is preferably defined as a natural substance of wood or plant origin that is significantly longer than it is wide.

[0054] Figures 1a and 1b illustrate an exemplary extrudable fiber-based bottle 10. The extrudable fiber-based bottle 10 includes a fiber-based sidewall 12 having an upper edge 14, a lower edge 16, an inner surface 18, and an outer surface 19. The inner surface 18 of the fiber-based sidewall 12 includes a liquid-containing material. The lower edge 16 is attached to a pulp molding base 20. The pulp molding base 20 shown in Figure 1c includes a liquid-containing surface 28 having a base barrier structure 40 and an orifice 30 disposed at the center of the liquid-containing surface 28 for dispensing a viscous liquid contained in the extrudable fiber-based bottle 10.

[0055] Figure 2a is an unfolded view showing the lower edge 16 of the pulp molding sidewall 12, the base barrier structure 40, and the pulp molding base 20 before assembly. As shown, the pulp molding base 20 includes a base periphery having a peripheral surface 22, which has the same upper edge 24 and lower edge 26 as the upper edge 24 and lower edge 26 of the pulp molding base 20.

[0056] The pulp molding base 20 can be formed using a wet pulp molding process. The wet pulp molding process begins with the preparation of a pulp containing fibers and additives dispersed in water. In this document, the terms “fiber raw material,” “pulp raw material,” and “pulp” are used synonymously and are completely interchangeable. As used herein, “pulp” is a fiber suspension that may consist of 0.5% to 10% cellulose fibers, with the remainder being water and additives. As explained in WO2018 / 020219, a higher fiber content affects the flow characteristics of the suspension, making it difficult to transport the suspension and achieve a uniform coating on the mold. In a preferred embodiment, the concentration of the fiber material in the suspension is about 1%. In the wet molding process, the pulp is deposited onto a screened mold to form a layer by spraying, or more commonly by immersing the mold and subsequently applying a vacuum to the back of the screened mold. In the second step, the pulp layer is pressed onto a tool comprising two mating tool parts, one of which may have a porous wall that contacts the pulp layer and through which a vacuum can be drawn to reduce the water content. Following this pressing step, the molded article is dried in a heated mold or oven. After heating the mold or oven, the water content may still be about 10% to 20%. The article can then be subjected to a subsequent pressing operation to apply heat to reduce surface roughness and porosity, and further reduce the water content, preferably to below 8%, more preferably to below 5%, and even more preferably to below 1%. The wet-molded part has a substantially uniform wall thickness. The average wall thickness of the wet-molded part using this process can vary between 0.6 mm and 1.2 mm, preferably between about 0.8 mm and 1.0 mm. Local variations in thickness and density within the part may be desirable to improve assembly with other components or to securely support the part during assembly. Several established techniques exist for achieving localized variations in thickness and density in wet pulp molding processes. EP1081285 discloses the use of a segmented mold with multiple hollow chambers, where suction pressure can be independently controlled: this allows for variations in the amount of pulp fiber deposited in different parts of the chambers to produce thicker areas. EP1081285 also discloses areas in the mold where pulp slurry can be contained to increase wall thickness. EP0656444 discloses the use of meshes with different aperture sizes to control water flow through different areas of the mold: this flow variation results in variations in pulp deposition thickness. EP0656444 also discloses a method in which the size, spacing, and / or arrangement of discharge orifices are used to vary part thickness. WO2023104711 describes how localized variations in thickness and / or density can be achieved using localized mechanical compression, ultrasonic treatment, and / or heating. Following the pulp molding process, protruding edges can be trimmed as needed.

[0057] Cellulose fibers can be wood-based or non-wood-based. Wood fibers can be long coniferous fibers, such as pine, spruce, fir, and hemlock, or short hardwood fibers, such as birch, eucalyptus, poplar, acacia, and oak. Non-wood plant fibers are typically categorized into coniferous substitutes (such as cotton linters and cottonseed linters; flax, hemp, and kenaf bast fibers; sisal; abaca; bamboo (longer fiber types)) and hardwood substitutes, such as cereal straw, sugarcane, bagasse, bamboo (shorter fiber types), reeds and grasses, Spanish grass, kenaf (whole stalk or core fiber), corn stalks, sorghum stalks, etc. Fiber formulations are typically selected to optimize dehydration and production cycle time, mechanical properties (such as burst strength), and surface finish (roughness and porosity). Depending on the desired properties of the final part, the fiber preferably comprises both short and long fibers. Fibers can be extracted using bleached or unbleached chemical or mechanical processes. Fibers may include recycled fibers.

[0058] The slurry may contain additives for process control or functional enhancement. Typical additives for process control include retention aids, defoamers, pH adjusters, and mud control agents. Additives for functional enhancement include: (1) fillers, such as inorganic mineral fillers; (2) sizing agents, such as alkyl ketone dimers (AKD), alkenyl succinic anhydride (ASA), rosin, or lignin; (3) additives for dry strength enhancement, such as starch, amphoteric, cationic, or anionic polyacrylamide resins, enzymes, and modified polyamines; (4) additives for wet strength enhancement, such as polyamide-amine (PAE) or polyamine-epoxychloropropane, epoxy resins, or cationic glyoxal-oxidized resins, or (5) microfibrillated cellulose (MFC) or cellulose nanocrystal (CNC) additives. In the case of applying the barrier layer by spraying or dip coating, it is preferred that the slurry contains a certain amount of inorganic mineral filler to close the pores in the surface. Preferably, the inorganic mineral filler particles may be selected from calcium carbonate and flaky kaolin or any mixture thereof.

[0059] In a preferred embodiment, the slurry may contain 0.5% to 2% AKD, more preferably about 1% AKD, based on dry fiber, to provide a degree of water resistance. Alternatively, an emulsion of alkenyl succinic anhydride (ASA) or rosin may be used. The slurry may also contain less than 0.5% PAE or glyoxal-treated polyacrylamide (GPAM) to provide wet strength to the final product. In another preferred embodiment, the slurry may contain 2% to 5% MFC, preferably 3% to 4% MFC, based on dry fiber, to improve surface smoothness, stiffness, burst resistance, and wet strength for barrier applications. Examples of commercially available MFCs include Curran or Fiberlean. This addition is particularly beneficial for improving the barrier effectiveness of spray or dip coatings by reducing surface porosity to prevent coating penetration.

[0060] In some embodiments, the pulp molding base 20 can be functionalized after molding by vapor deposition of an inorganic barrier layer. Functionalization here should be understood as altering the properties of the molded part, such as increasing hygroscopicity or wet strength, through surface, morphological, and chemical modifications of the cellulose fibers. Suitable vapor-deposited inorganic coatings can be formed on the pulp fibers by metals or oxides and related compounds. The inorganic barrier layer can be optically opaque, translucent, or transparent, depending on the specific chemical composition applied. Typically, metal barrier layers (such as aluminum) will produce opaque barrier layers, while metal oxide barrier layers (such as alumina or silicon dioxide) will produce transparent barrier layers. In some embodiments, suitable inorganic coatings can be formed by vapor deposition of metals, including but not limited to aluminum, magnesium, titanium, tin, indium, silicon, carbon, gold, silver, chromium, zinc, copper, cerium, hafnium, tantalum, and diamond-like carbon. In some embodiments, suitable inorganic coatings can be formed by vapor deposition of metal oxides, metal nitrides, and related compounds. As used herein, metal oxides include aluminum oxide (e.g., Al2O3), aluminum carbide, aluminum nitride, magnesium oxide, titanium oxide (such as titanium dioxide, titanium oxide (3), or titanium monoxide), zinc oxide, tin oxide, yttrium oxide, or zirconium oxide (e.g., zirconium monoxide), calcium oxide, boron oxide, or metal-like oxides (such as silicon oxide, silicon carbide, and silicon nitride). Silicon oxide coatings or nitride-based coatings may also be coatings selected from the group consisting of SiOX (where x is an integer from 1 to 4) or SiOXNY (where each of x and y is an integer from 1 to 3). The barrier layer is preferably a single-component vapor-deposited layer comprising at least one of the above groups, or a two-component vapor-deposited layer comprising at least one combination of two components selected from the group consisting of SiOx / Al2O3, SiO / ZnO, SiO / CaO, SiO / B2O3, and CaO / Ca(OH)2. It is understood that various processes can be used to vapor-deposit metals and metal oxides. For example, in various embodiments, chemical vapor deposition (CVD) or physical vapor deposition (PVD) processes can be used to vapor-deposit metal or metal oxide coatings. Generally, most CVD processes are suitable due to the stability of metals, metal oxides, and metal oxide precursors. In some embodiments, plasma-assisted CVD processes can be used to form vapor-deposited inorganic coatings. In other embodiments, atomic layer CVD processes can be used alternatively. Preferably, the thickness of the inorganic barrier coating is from 2 nm to 1,000 nm, more preferably from 10 nm to 200 nm, and more preferably from 20 nm to 100 nm. This functionalization has been found to significantly increase wet strength, improve bulk moisture barrier properties, and increase contact angle, while maintaining recyclability. This effect is further enhanced when these deposition processes are used in high-density pulp matrices, especially in combination with high-refined pulps, MFC, or CNC.

[0061] Alternatively, the pulp molding base 20 can be molded using a wet pulp molding process with rapid dewatering and pulse drying, as disclosed by Celwise in WO2020 / 016409 and US 2021 / 0269983. This process has been found to produce parts with higher strength and hydrophobicity compared to parts formed by conventional wet molding. Without being bound by theory, it is speculated that this is due to the rapid dewatering enabling the cellulose fibers to quickly re-bond each other, and the high-pressure / high-temperature process promoting lignin polymerization.

[0062] Alternatively, the pulp molding base 20 can be molded using a dry molding method. According to this process, air is used as the transport medium (“airflow web”) to transport the cellulose fibers and form them into a preform. The preform is then subsequently formed in a press at a temperature above 100°C and a pressure of at least 1 MPa. According to this process, additives (such as sizing agents) can be sprayed in solid form or added to the cellulose fibers and / or the cellulose preform. Pulpac discloses examples of this process in SE541995, SE1851373, and SE543410. Dry molding is advantageous compared to conventional wet molding because it reduces cycle time and energy consumption by eliminating the need for drying. Parts produced using this process have been found to be robust yet highly flexible. This is presumably due to the low degree of interfiber hydrogen bonding. Preferably, the pulp molding base can be achieved using dry compression molding with an all-metal isostatic die, as demonstrated by SACMI, to allow for a wide variety of shapes, including the ability to mold undercut parts, while achieving a good degree of dimensional control.

[0063] As shown in Figure 1c, the pulp molding base 20 includes a base barrier structure 40 disposed on a liquid-containing surface 28 and on a peripheral surface 22 near the upper edge 24 of the pulp molding base 20. The lower edge 16 of a fiber-based sidewall 12 is attached to the pulp molding base 20, thereby forming an impermeable seal 42. The impermeable seal 42 is formed around the entire peripheral surface 22 of the pulp molding base 20 near the upper edge 24 of the peripheral surface but not near the lower edge 26 of the peripheral surface. Preferably, the impermeable seal 42 is formed by welding, such as by exposing the area to hot air. However, other methods of forming the impermeable seal, such as ultrasonication, are contemplated. Preferably, the lower edge 16 of the fiber-based sidewall 12 is at least 1 mm from the lower edge 26 of the peripheral surface. The peripheral surface 22 of the pulp molding base 20 may include a flange 25 to receive the lower edge 16 of the fiber-based sidewall 12. The flange 25 is preferably at least 1 mm from the lower edge 26 of the peripheral surface.

[0064] As illustrated in Figures 1c and 2a, an orifice 30 for dispensing a viscous fluid extends into a conduit 32 disposed on a bottom surface 27 of a pulp molding base 20, which is the side opposite to a liquid-containing surface 28. The conduit 32 includes a conduit opening 34 and a flexible, resilient, narrow-mouth valve 50 disposed on the conduit opening 34. The narrow-mouth valve 50 is configured to (1) allow fluid flow in response to a predetermined discharge pressure within the bottle when squeezed, and (2) automatically close to cut off the flow when the pressure decreases. Such a valve and designs of fittings using such a valve are shown in U.S. Patent Nos. 5,271,732, 5,927,446, 5,942,712, 6,545,901, and 10,287,066. The narrow-mouth valve can be selected based on the desired dispensing experience and product viscosity to adjust the sealing pressure, rupture pressure, and flow rate versus pressure curve. Preferably, the product viscosity can be between 3,000 cps and 10s. -1 Up to 30,000 cps in 10 seconds -1 Between, more preferably between 5,000 cps and 10s -1 Up to 20,000 cps in 10 seconds -1The narrow-mouth valve 50 is preferably molded from an elastic, flexible material and a material that is inert to the fluid product being packaged and dispensed. In a preferred embodiment, the narrow-mouth valve 50 may be molded from liquid silicone rubber. Examples of commercially available silicone rubber grades include DC-99-525 and RBL-9525-54, sold by Dow Corning Corp. Valve 50 may include other elastomers, such as synthetic, thermosetting, or thermoplastic polymers or thermoplastic elastomers, including those based on materials such as thermoplastic propylene, ethylene, and styrene, including their halogenated counterparts. Valve 50 may also be formed as an integral structure from a flexible, tough, elastic, and resilient material membrane, as disclosed in U.S. Patent No. 10,287,066, and includes linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), LLDPE / LDPE blends, acetates, acetals, ultra-high molecular weight polyethylene (UHMW), polyesters, polyurethanes, ethylene-vinyl acetate (EVA), polypropylene, and high-density polyethylene. The separable slit valve 50 is releasably attached to the orifice 30 by snap-fit ​​or other means, such as gently gluing the slit valve 50 to the conduit 32 so that it can be easily removed by hand. The conduit opening 34 may include a lip 36 to mate with the separable slit valve 50. The separable slit valve 50 is formed of plastic or other resin material. As shown in FIG. 2b, the separable slit valve 50 may include a tab 52 or other features to facilitate removal. The lower edge 26 of the peripheral surface 22 of the pulp molding base lies below the liquid receiving surface 28, the conduit opening 34, and the separable slit valve 50, thereby allowing the extrudable fiber-based bottle 10 to stand upright. The pulp molding base includes a component for preventing distribution via the valve if pressure is accidentally applied through the sidewalls during transport or handling. This component may be a pulp molding closure having a polymer barrier structure (not shown) dip-coated, spray-coated, or vacuum-laminated. Preferably, the valve can be sealed with a removable cap that uses a metallized laminate attached to the pulp molding closure using a pressure-sensitive adhesive (not shown).

[0065] It has been found that the pulp molding base 20 according to the invention is surprisingly capable of providing excellent protection for liquid formulations and maintaining their integrity during use in humid environments such as bathrooms and shower rooms, while still having a fiber content of more than 80% and being recyclable in the paper stream according to PTS-RH 021:2012 Cat 2. The base barrier structure 40 disposed on the liquid-containing surface 28 and on the peripheral surface 22 near the upper edge 24 of the pulp molding base 20 can be applied to the pulp molding base 20 by spraying, dipping, or alternatively by welding or gluing as a laminate.

[0066] In the case of spraying or dipping, the substrate barrier structure may include a primer and one or more topcoats. The primer is preferably applied in the form of a polymer dispersion, more preferably an aqueous polymer dispersion. The primer may be a latex dispersion, a polyvinyl alcohol dispersion, a polyhydroxyalkanoate (PHA) dispersion, or a polyolefin dispersion. An example of a polyolefin dispersion is Rhobarr, sold by DOW Corporation. ® Preferably, the base coating is a styrene acrylate, such as Joncryl sold by BASF. ® 4010. Generally, the barrier layer should be as thin as possible, but thick enough to form a barrier between the pulp molding substrates as a topcoat. The average amount of the primer applied to the surface of the molding substrate should preferably be less than 60 g / m². 2 More preferably less than 40g / m 2 Even more preferably less than 20g / m 2 The base barrier structure 40 may include one or more topcoats, i.e., one or more topcoats applied on top of the base coat. Depending on the chemical composition, the topcoat is applied immediately after the base coat and before drying in the form of an aqueous dispersion. The topcoat composition may contain a polymer dispersion for producing a heat-sealable coating. The polymer dispersion is preferably a hydrocarbon polymer dispersion, more preferably a synthetic hydrocarbon polymer dispersion, such as styrene-acrylate latex. The topcoat may also contain one or more additives (such as wax, MFC, or CNC) to enhance water barrier properties. Preferably, the topcoat is styrene-acrylate based, such as Joncryl sold by BASF. ® 4030. The amount of each topcoat layer can be less than 30g / m². 2 Preferably at 6g / m 2 Up to 26g / m 2 More preferably within the range of 12 g / m 2 Up to 18g / m 2 Within a certain range. Typically, more than one top coat is applied to reduce the incidence of surface defects such as pinholes, spots, or cracks. After applying the primer and top coat, the part can be transferred to a heating unit, such as a hot air drying hood, to remove moisture from the coating and to facilitate film formation by melting or partially melting the polymer in the barrier layers. Preferably, the drying temperature is between 100°C and 150°C, and most preferably between 110°C and 120°C. After spraying and drying, the average thickness of all barrier layers is between 10 micrometers and 100 micrometers.

[0067] Alternatively, the base barrier structure 40 may be formed by a powder polymer coating to reduce emissions of volatile organic compounds (VOCs) and paint waste. Preferably, the powder may comprise a thermoplastic polymer selected from polyolefins, such as polyethylene or polypropylene and their copolymers. The polymer powder may also comprise water-soluble synthetic polymers, such as polyvinyl alcohol, or polysaccharides, such as cellulose. The powder particles typically have an average size in the range of 1 pm to 200 pm (e.g., 5 pm to 100 pm, e.g., 10 pm to 50 pm). For example, according to the process described in WO2022207507, the coating may be applied by a spraying device and then cured / melted to form a continuous film on the surface. The average thickness of the film applied in this system may preferably be from 10 micrometers to 100 micrometers.

[0068] Preferably, the base barrier structure 40 can be a layer applied by thermoforming, as depicted in Figures 3a, 3b, and 3c. The barrier layer is preferably made of a PE laminate with a thickness of 30 to 150 micrometers, preferably 60 to 90 micrometers, depending on the target average final thickness before application. In a preferred embodiment, the laminate comprises a P1B / LLDPE outer sealing layer and a nucleated HDPE 90 / 10 Surpass. ® The 167 / 640i LDPE core layer and the 90% LLDPE / 10% LDPE inner sealing layer are used. The outer P1B / LLDPE sealing layer can have a thickness ranging from 5µm to 15µm, and preferably a mixture ratio of 15% P1B / 85% LLDPE to 25% P1B / 75% LLDPE. The nucleating HDPE 90 / 10 Surpass 167 / 640i LDPE core layer can have a thickness ranging from 30mm to 200mm. The inner LLDPE / LDPE sealing layer can have a thickness ranging from 5µm to 20µm, and preferably a mixture ratio of 95% LLDPE / 5% LDPE to 85% LLDPE / 15% LDPE. In a particularly preferred embodiment, the multilayer barrier structure has a total thickness of 90µm, comprising a 5µm top layer of 15% P1B / 85% LLDPE, a 70mm core layer of nucleated HDPE 90 / 10Surpass 167 / 640i LDPE, and a 15µm inner layer of 90% LLDPE / 10% LDPE. The structure of the film lamination can be optimized and configured based on performance requirements such as barrier properties after application, adhesion to the pulp surface, and the percentage of recyclable pulp.

[0069] Figure 3a shows the pulp molding base 20 before thermoforming and the base barrier layer 40 including the laminate. Before application, the barrier layer 40 is adhered to a heating plate by pressure applied under vacuum, thereby heating the barrier layer to the molding temperature. The pulp molding base 20 is located on a mandrel. Once the target temperature is reached, the vacuum on the top plate is released, and the barrier layer 40 is draped downwards by a vacuum applied to the mandrel side. The bottom mandrel can also be heated to facilitate adhesion of the laminate to the pulp molding base 20. Figure 3b shows the post-laminated state, illustrating the base barrier layer 40 covering the liquid-containing surface 28 including the pipe opening 34 and the peripheral surface 22 of the pulp molding base. Although the base barrier layer 40 shown in Figure 3b has a uniform wall thickness, in practice, a thickness gradient is generated depending on the amount of film stretching during the application process. It has been found that applying localized heating to the film (i.e., by using a system such as WATTTRON) can reduce the film's thickness. ® This helps to achieve a more uniform wall thickness and prevent pinholes. After application, the average thickness of the base barrier layer 40 is preferably less than 90 micrometers, more preferably less than 75 micrometers, even more preferably less than 50 micrometers, and ideally less than 20 micrometers, depending on the desired barrier properties. Figure 3c shows the thermoformed pulp molding base 20, in which pipe openings 34 are cut out in the pipes 32.

[0070] Figures 4a to 4d illustrate the construction of an exemplary extrudable fiber-based bottle 110 with a cylindrical tubular structural component. According to this embodiment, the fiber-based sidewall 112 may comprise paperboard. The paperboard is typically made of a multilayer structure consisting of multiple substrates and one or more functional layers. As shown in Figure 4a, functional layer 113 may be located on inner layer 118 and / or outer layer 119. An example of commercially available paperboard is Natura Barr from Stora Enso. ® Alternatively, Billerud's Liquid LC. The inner coating is preferably an LDPE laminate to ensure good solderability and durability in contact with the product. Alternatively, the inner coating may be Natura from Stora Enso. ® Or CupformaNatura ® A polymer aqueous dispersion on the plate. Dispersions such as BASF Joncryl can be used. ® Or Down Rhobarr ®The aqueous dispersion can be applied using various techniques, such as dip coating, bar coating, doctor blade coating, gravure printing, reverse roll coating, air knife coating, and forward roll coating or spray coating, followed by a drying step. The substrate of the liquid carton board preferably comprises lignocellulose fibers obtained through any conventional pulping process, including bleached or unbleached chemical pulping, mechanical pulping, and chemimechanical pulping. The carton board can be made from more than one sheet (typically three sheets) and is usually in the form of a fiber web. Preferably, the carton board has a basis weight of 170 gsm to 350 gsm, more preferably about 250 gsm to 280 gsm. An example of a carton board using a water-based dispersion coating is Cupforma, sold by Stora Enso. ® Natura Aqua+ and ISLA sold by Kotkamills ® Additional layers may be used, such as aluminum foil, one or more HDPE layers, thin layers produced by vapor deposition of inorganic materials, or water-dispersible nanocomposite layers that form nanosheets during drying. In this preferred embodiment, the cylindrical tubular structural component has a fiber percentage of more than 85%, more preferably more than 90%, and most preferably more than 95% of the total weight.

[0071] The manufacture of extrudable fiber-based bottles 110 comprising cylindrical tubular structures using fiber-based sidewalls 112 is well known in the art and is described in WO2022185176, WO2022229810, EP2007567, EP284389, and EP2630052. Based on the described process, multilayer sheets are assembled end-to-end into a tubular cylindrical structure, preferably with reinforcing strips added at the assembly location, and then cut into discrete lengths. Subsequently, a pulp molding base 120 is placed into the core, and the impermeable seal 142 can be subjected to heat, or alternatively, glue can be applied. In a further subsequent step, the inner surface 118 of the tubular body is pressed against the impermeable seal 142 to perform assembly.

[0072] Figure 5aAn example of a pulp molding base 120 assembled according to this process to a cylindrical tubular structure is shown, wherein the sidewall 112 is a single-sided coated sidewall. In this configuration, a valve 150 can be assembled onto a corresponding seat on the liquid-receiving surface 128 of the pulp molding base 120. The valve 150 can be held in place by thermally stacking a fully padded pulp disc (valve seat) 151 onto the padded base. The padded material coated on the pulp disc can be LDPE applied by vacuum forming, or a heat-sealable polymer aqueous dispersion applied by spraying or dipping. Alternatively, a liquid-compatible adhesive can be used for assembly. This configuration has the advantage of generating a natural resistance to displacement of the valve 150 due to internal liquid pressure during dispensing. The sealing force of the disc on the padded base can still be configured to ensure that the user can easily access and remove the valve 150 by flattening the container before disposal.

[0073] Figure 5b Another embodiment is shown, wherein the sidewall 112 is a double-coated sidewall, wherein the sidewall 112 includes an inner coating and an outer coating 113. And Figure 5c An alternative embodiment is shown having a pulp barrier layer 113, which completely encapsulates the pulp molding base 120, for example, by impregnation with a polymer aqueous dispersion.

[0074] The impermeable seal 142 connecting the fiber-based sidewall 112 of the connecting tubular structure and the pulp molding base 120, as well as the sealing area 129 on the fiber-based sidewall 112 at the upper edge 114, may include components for preventing edge wicking to avoid catastrophic integrity failure or undesirable deformation. Edge wicking is particularly problematic in areas where liquid carton board edges are cut (“rough edges”) and exposed to water, such as when bottles are used in a shower. Edge wicking of cardboard has been extensively studied, for example, in the following literature: Harju, 2018, Master's thesis, “Liquid Penetration in Food Service Boards.” Several methods are known in the art to provide edge protection, such as spraying sizing agents or other hydrophobic agents, scraping, crimping, or covering cut edges with adhesive plastic strips. Edge protection methods for the upper seal 129 may employ spraying, dip coating, adding PE-PET-PE strips, or folding, as discussed in Figures 6a to 6d below.

[0075] Figures 7a and 7b illustrate the construction of an exemplary extrudable fiber-based bottle 210 with a conical tubular structure. In this example, it can be constructed by cutting a roll of liquid carton board into a shape such as... Figure 7d The blank shown is used to form the fiber-based sidewall 212. Then, the fiber-based sidewall 212 is folded and welded along its edges, as shown. Figure 7eAs illustrated. Typical welding techniques may include hot air, ultrasonic, or adhesive bonding. The cone may then include a polymer strip 223 welded to a vertical seal 221 to prevent burrs from wicking. The fiber-based sidewall 212 of the tubular cone may be welded to a pulp molding base 220 to produce a compressible bottle 210 including a tube 213, as illustrated in FIG. 7c. The tube 213 may then be filled and sealed, as illustrated in FIG. 7c. Preferably, an edge protection method is applied for an impermeable seal 242 between the upper edge 224 of the peripheral surface of the pulp molding base 120 and the lower edge 216 of the fiber-based sidewall. An upper seal 129 may also be formed between a first side 115 and a second side 117 of the upper edge 114 of the fiber-based sidewall 112. Figures 6a to 6d illustrate examples of how the first side 115 and the second side 117 of the upper edge 114 of the sealed fiber base sidewall 112 are arranged, with Figure 6a depicting a single fold; Figure 6b depicting a double fold; Figure 6c depicting a saddle fold; and Figure 6d depicting a triple fold.

[0076] Figure 8a Figures 8c illustrate the construction of an exemplary extrudable fiber-based bottle 310 having a pulp-molded sidewall 312. The pulp sidewall 312 may be formed from one or more components molded according to the wet molding process and liquid containment barrier structure application process described herein. Preferably, the pulp sidewall 312 is integrally formed by wet molding. The pulp sidewall 312 may have an average wall thickness between 0.6 mm and 1.2 mm, preferably between 0.8 mm and 1.0 mm. It is also preferred that the wall thickness is locally reduced in the extrusion panel, preferably from 0.6 mm to 0.8 mm. The wet molding of the pulp sidewall 312 may follow the same process as previously described for pulp molding bases. Preferably, the process may include methods for rapid dewatering and induction heating to reduce cycle time. The starting pulp used to manufacture the pulp sidewall 312 may consist of 1% to 10%, preferably about 1%, of cellulose fibers, with the remainder being water and additives. The cellulose fibers may be wood-based or non-wood-based. As previously described for pulp molding bases, the fiber formulation can be optimized for dewatering and production cycle times, mechanical properties (such as burst strength), and surface finish (roughness and porosity). The mechanical properties of the pulp sidewalls are particularly important for optimizing dispensing functionality. The pulp sidewalls 312 can be optimized to bend when a user applies pressure, resulting in a reduction in the volume of the bottle chamber. Preferably, the elastic modulus and geometric stiffness of the pulp sidewalls 312 should be low enough to allow deformation, but high enough to allow some rebound upon first use. When the contents are depleted, such as when less than 50% of the total contents are dispensed, or preferably less than 30% of the total contents, the bottle walls preferably collapse and permanently deform, thereby reducing the dispensing force. Cellulose fibers can be of different types to balance these requirements.

[0077] Preferably, the cellulose fibers forming the molded pulp sidewalls 312 may include coniferous wood, bamboo, and bagasse. The length-weighted average fiber length, arithmetic mean fiber length (ISO 0.2 mm to 7.0 mm), and arithmetic mean fiber width can be determined using a fiber image analyzer such as the Valmet FS5, according to TAPPI T271. Coniferous wood fibers may have a length-weighted average fiber length of about 2.25 mm, an arithmetic mean fiber length of about 1.4 mm (ISO 0.2 mm to 7.0 mm), and an arithmetic mean fiber width of about 30 µm. Bamboo fibers may have a length-weighted average fiber length of about 15 mm, an arithmetic mean fiber length of about 1.0 mm (ISO 0.2 mm to 7.0 mm), and an arithmetic mean fiber width of about 15 µm. The bagasse fiber may have a length-weighted average fiber length of about 1.0 mm, an arithmetic mean fiber length of about 0.6 mm (ISO 0.2 mm to 7.0 mm), and an arithmetic mean fiber width of about 22 µm. Preferably, the fiber count may include between 50% and 60% bamboo, between 40% and 50% bagasse, and between 0% and 10% coniferous wood.

[0078] Cellulose fiber slurries may also contain additives for process control and / or functional enhancement. Typical additives for process control include retention aids, defoamers, pH adjusters, and mud control agents. Additives for functional enhancement include (1) fillers, such as inorganic mineral fillers, such as calcium carbonate and flaky kaolin; (2) sizing agents, such as alkyl ketone dimers (AKD), alkenyl succinic anhydride (ASA), rosin, or lignin; (3) additives for dry strength enhancement, such as starch, amphoteric, cationic, or anionic polyacrylamide resins, enzymes, and modified polyamines; (4) additives for wet strength enhancement, such as polyamide-amine (PAE) or polyamine-epoxychloropropane, epoxy resins, or cationic glyoxal-oxidized resins, or (5) microfibrillated cellulose (MFC) or cellulose nanocrystal (CNC) additives. Fiber chemical treatments, such as the use of low eutectic solvents (DES), can enhance fiber swelling and bonding potential.

[0079] In a preferred embodiment, the slurry may contain 0.5% to 2% AKD, more preferably about 1% AKD, based on dry fiber weight, to provide excellent water resistance. The slurry may also contain between 0.1% and 0.5% PAE to provide excellent wet strength in the final product. In another preferred embodiment, the slurry may contain 2% to 5% MFC, preferably 3% to 4% MFC, based on dry fiber weight, to improve surface smoothness, stiffness, burst resistance, and wet strength for barrier applications. Examples of commercially available MFCs include Curran. ® or Fiberlean ®This addition is particularly beneficial for improving the barrier effectiveness of spray or dip coatings by reducing surface porosity to prevent coating penetration. It is also particularly beneficial for increasing the part's resistance to mechanical stresses caused by bottle extrusion pressure. In some embodiments, the pulp part can be functionalized after molding by vapor deposition of an inorganic barrier layer, as previously described.

[0080] A pulp sidewall barrier layer 313 is disposed on the liquid-receiving surface of the inner surface 318 of the pulp sidewall. The pulp barrier structure can be applied to the molded pulp sidewall 312 by spraying or dipping. The pulp sidewall barrier structure 313 may include a base coat and one or more top coats. The base coat is preferably applied in the form of a polymer dispersion, more preferably an aqueous polymer dispersion. The base coat may be a latex dispersion, a polyvinyl alcohol dispersion, or a polyolefin dispersion. An example of a polyolefin dispersion is Rhobarr, sold by DOW Corporation. ® Preferably, the base coating is a styrene acrylate, such as Joncryl sold by BASF. ® 4010. Generally, the barrier layer should be as thin as possible, but thick enough to form a barrier on the inner surface of the pulp sidewall as a topcoat. The average amount of the base coat applied to the inner surface should preferably be less than 20 g / m². 2 More preferably 3g / m 2 Up to 10g / m 2 Even more preferably 4g / m 2 Up to 9g / m 2 The pulp sidewall barrier structure may include one or more topcoats, i.e., one or more topcoats applied on top of a base coat. Depending on the chemical composition, the topcoat is applied immediately after the base coat and before drying in the form of an aqueous dispersion. The topcoat composition may contain a polymer dispersion for producing a heat-sealable coating. The polymer dispersion is preferably a hydrocarbon polymer dispersion, more preferably a synthetic hydrocarbon polymer dispersion, such as styrene-acrylate latex. The topcoat may also contain one or more additives (such as wax, MFC, or CNC) to enhance water barrier properties. Preferably, the topcoat is styrene-acrylate based, such as Joncryl 4030 sold by BASF. The amount of each topcoat may be less than 30 g / m³. 2 Preferably at 5g / m 2 Up to 12g / m 2 More preferably within the range of 6 g / m 2 Up to 9g / m 2Within a certain range. Typically, more than one top layer is applied to reduce the incidence of surface defects such as pinholes, spots, or cracks. After applying the base coat and top coat, the extrudable fiber-based bottle can be transferred to a heating unit, such as a hot air drying hood, to both remove moisture from the coating and facilitate film formation by melting or partially melting the polymer in the barrier layers. Preferably, the drying temperature can be between 100°C and 150°C, and even more preferably between 110°C and 120°C. After spraying and drying, the average thickness of all barrier layers can be between 10 micrometers and 100 micrometers.

[0081] Alternatively, the pulp sidewall 312 barrier layer 313 may be formed by a powder polymer coating to reduce volatile organic compound (VOC) emissions and coating waste. Preferably, the powder may comprise a thermoplastic polymer selected from polyolefins (such as polyethylene or polypropylene and their copolymers). The polymer powder may also comprise water-soluble synthetic polymers, such as polyvinyl alcohol, or polysaccharides, such as cellulose. The powder particles typically have an average size in the range of 1 pm to 200 pm (e.g., 5 pm to 100 pm, e.g., 10 pm to 50 pm). For example, according to the process described in WO2022207507, the coating may be applied by a spraying device and then cured / melted to form a continuous film on the surface. The average thickness of the barrier layer applied in this system may preferably be from 10 micrometers to 100 micrometers.

[0082] Figure 8a The pulp-molded sidewall 312 assembled to the pulp molding base 320 is shown. This assembly can be performed by hot air welding, ultrasonic welding, or gluing and / or a combination thereof. Figures 8b and 8c show cross-sectional views of the assembled extrudable fiber-based bottle 310 with the pulp-molded sidewall 312. The bottle has been found to be surprisingly resistant to water splashes, while being recyclable and providing good liquid barrier properties. The bottle 310 can also be squeezed with good resilience from first use. During shower use, the bottle 310 can soften, making it easier to squeeze while maintaining its integrity. At the end of use, the bottle can be easily flattened. Flattening allows the pulp molding base 320 to be removed from the sidewall 312, facilitating the separation of the valve 350 from the pulp molding base 320. Consumers can also easily flatten the components for disposal.

[0083] Figure 9 illustrates another exemplary configuration of an extrudable fiber-based bottle 410 with pulp-molded sidewalls 412. In this embodiment, the sidewall barrier layer 413 can be a layer applied by hot vacuum thermoforming, as previously described and depicted for the pulp-molded base 20 in Figures 3a, 3b, and 3c. The barrier layer 413 is preferably made of a PE laminate with a thickness of 30 to 150 micrometers, preferably 60 to 90 micrometers, depending on the target average final thickness before application. In a preferred embodiment, the laminate comprises a P1B / LLDPE outer sealing layer, a nucleated HDPE 90 / 10 Surpass 167 / 640i LDPE core layer, and a 90% LLDPE / 10% LDPE inner sealing layer. The outer P1B / LLDPE sealing layer may have a thickness range of 5µm to 15µm and a preferred mixing ratio of 15% P1B / 85% LLDPE to 25% P1B / 75% LLDPE. The nucleated HDPE 90 / 10 Surpass 167 / 640i LDPE core layer can have a thickness ranging from 30 mm to 200 mm. The inner LLDPE / LDPE sealing layer can have a thickness ranging from 5 µm to 20 µm, and preferably a mixing ratio of 95% LLDPE / 5% LDPE to 85% LLDPE / 15% LDPE. In a preferred embodiment, the multilayer barrier structure has a total thickness of 90 µm, comprising a 5 µm top layer of 15% P1B / 85% LLDPE, a 70 mm nucleated HDPE 90 / 10 Surpass 167 / 640i LDPE core layer, and a 15 µm inner layer of 90% LLDPE / 10% LDPE. The structure of the film lamination can be optimized and configured based on performance requirements such as barrier properties after application, adhesion to the pulp surface, and the percentage of recyclable pulp.

[0084] Prior to application, the barrier layer 413 is adhered to a heating plate by pressure applied under vacuum, thereby heating the barrier layer to the molding temperature. The pulp molding sidewall 412 is located on the core. Once the target temperature is reached, the vacuum on the top plate is released, and the barrier layer is laid down by applying vacuum to the core side. The bottom core can also be heated to facilitate adhesion of the laminate to the pulp molding base 420. Figure 9b shows the laminated state, illustrating the sidewall 412 completely covered by the barrier layer 413. The film also covers the lower edge 416 of the pulp sidewall 412 and a portion of the outer surface 419 to facilitate sealing with the pulp molding base 420. Although the pulp molding base barrier structure 440 shown in Figure 9b has a uniform wall thickness, in practice, a thickness gradient is created depending on the amount of film stretching during the application process. It has been found that applying localized heating to the membrane (i.e., via a system such as WATTTRON) can help achieve a more uniform wall thickness and prevent pinholes. After application, the average thickness of the sidewall barrier structure 413 can preferably be less than 90 micrometers, more preferably less than 75 micrometers, even more preferably less than 50 micrometers, and ideally less than 20 micrometers, depending on the desired barrier properties.

[0085] The pulp molding base 420 can be manufactured by pulp molding. The inner surface is coated using spraying, dip coating, or by applying layers through vacuum thermoforming. Figure 9a shows a pulp molding sidewall 412 assembled to the pulp molding base 420 to form a liquid-tight seal. This assembly can be performed by hot air welding, ultrasonic bonding, or gluing and / or a combination thereof.

[0086] Figures 10a and 10b illustrate another exemplary configuration of an extrudable fiber-based bottle 510 with pulp-molded sidewalls 512. In this embodiment, the sidewalls 512 may be molded with two open surfaces at the upper edge 514 and the lower edge 516. A sidewall barrier layer 513 on the inner surface 518 may be coated or laminated. Preferably, the barrier layer 513 coating is heat-sealable. The pulp-molded base 520 may be manufactured by pulp molding. The base barrier layer 540 may be applied by spraying, dipping, or by applying the layer through vacuum thermoforming. The pulp-molded sidewalls 512 are assembled to the pulp-molded base 520 to form a liquid-tight seal. This assembly may be performed by hot air welding, ultrasonic welding, or gluing and / or combinations thereof. Figures 10a and 10b show the bottle 510 in its configuration for delivery to a bottling plant after assembly with the pulp-molded base 520. In this configuration, the desired amount of product can be filled into the bottle 510 through an opening in the upper edge 514 of the pulp sidewall 512. After filling, the first side 515 of the upper edge of the pulp sidewall can be sealed to the second side 517 of the upper edge of the pulp sidewall, thereby forming an upper seal 529, such as a tube or bag, as shown in Figures 10c and 10d. The upper seal 529 can be formed by hot air welding, hot clamping, or ultrasonic welding.

[0087] Figure 11a shows an exemplary configuration of the lower portion of an extrudable fiber-based bottle 610, which has a mechanism to facilitate consumer separation of the valve 650 from the pulp molding base 620. Facilitating consumer separation of the valve 650 from the pulp molding base 620 may be desirable to reduce the non-fiber portion in the paper recycling stream. According to this configuration, the valve 650 may be sandwiched between the pulp molding base 620 and an additional molded cover 653 attached to the bottom surface 627 of the pulp molding base 620. As shown in Figure 11b, the molded cover 653 may have wing-like features 655 that can be easily gripped by the consumer. Assembly of the molded cover 653 to the pulp molding base 620 may be performed using adhesive to form a light bond, strong enough to prevent premature separation during bottle distribution and use, but low enough to allow the consumer to separate the molded cover 653 before disposal. Before disposal, the consumer grasps the wing 655 and applies a twist to remove the cover 653 from the pulp molding base 620, thereby removing the valve 650.

[0088] Figure 12 An alternative embodiment is shown in which the cover 753 is removed from the pulp molding base 720 and the valve 750 by means of tabs 752.

[0089] Figure 13 An exemplary construction of a compressible fiber-based bottle is shown, wherein the pulp molding base 120 may comprise fiber-based paperboard or cardboard. The paperboard may be made of more than one layer (typically three layers) and is typically in the form of a fiber web. Preferably, the cardboard has a basis weight of 170 gsm to 430 gsm, more preferably about 250 gsm to 350 gsm. Functional layers may be located on both the inner and outer surfaces 127 forming the liquid-containing portion 128. The innermost and outermost layers are preferably low-density polyethylene (LDPE) layers to ensure good sealing and liquid tightness. The liquid cardboard used may be branded under the Natura trademark. ™ 2PEBoard or Natura ™ Barr sells products from Stora Enso, a Finnish company. Alternatively, both the inner and outer coatings can be polymeric aqueous dispersions, such as BASF Joncryl. ® Or Down Rhobarr ® Aqueous dispersions can be applied using a variety of techniques, such as dip coating, bar coating, doctor blade coating, gravure printing, reverse roll coating, air knife coating, and forward roll coating or spray coating, followed by a drying step. Examples of cardboard using water-based dispersion coatings are CupformaNatura Aqua+ sold by Stora Enso and ISLA sold by Kotcamier.

[0090] The pulp molding base 120 can be manufactured from a wet blank, which is heated and thermoformed to achieve a specific shape. The wet blank can be folded and the edges pressed against each other to form an impermeable seal 243. This seal can be reinforced by mechanically applying a knurling pattern. The edges 216 of the molding base 120 can also be scraped or any other solution known in the art to prevent moisture absorption. This construction is particularly advantageous for using commercially available cardboard while reinforcing the base with additional thickness to achieve a reliable impermeable seal 142 with the sidewalls 112 and base stability. The pulp molding base 120 preferably has a flat portion near the opening 30 to ensure reliable assembly of the pulp disc (seat) 151 via ultrasonic or heat sealing. Preferably, the opening 30 can be sealed with a removable cap using a metallized laminate attached to the molded closure using a pressure-sensitive adhesive (not shown).

[0091] Figure 14 An exemplary configuration of an extrudable fiber-based bottle is shown, wherein a membrane is applied to the outer surface 127 of a pulp molding base 120, and another membrane is applied to the inner surface 128. This embodiment is particularly advantageous in minimizing the risk of leakage and pinholes, while ensuring strong adhesion to the pulp disc (seat) 151 via ultrasonic or heat sealing. The membrane applied to the outer surface 127 ensures the possibility of achieving a strong seal 142 with the sidewall 112 via hot air, heat sealing, or ultrasonic waves. The membrane also ensures that the pulp molding base 120 does not absorb moisture, thereby maintaining the stability and integrity of the pulp molding base during bottle use in humid environments.

[0092] Preferably, the first film can be applied to the outer surface 127 by thermoforming. Subsequently, the second film can be applied to the inner surface 128 by vacuum lamination. Then, the two films can be welded in regions 801 and 803 to completely encapsulate the pulp molding base 120, and excess film can be removed in regions 802 and 804 by using a knife tool.

[0093] Figure 15 An exemplary configuration of an extrudable fiber-based bottle is shown, wherein a film is applied to an outer surface 127 and a coating is applied to an inner surface 128 to completely encapsulate the pulp molding base 120. This configuration preferably maximizes the total fiber content. In this specific embodiment, the film is applied to the outer surface by thermal vacuum thermoforming. Excess film is then trimmed in regions 805 and 806 using a knife tool. An undercoating (such as Joncryl) can then be applied to the inner surface 128. ® 4010) and one or more topcoats (such as Joncryl sold by BASF). ® 4030). Then, the pulp disc (valve seat) 151 can be glued to the pulp molding base 120.

[0094] method

[0095] 1) Individual layer thickness

[0096] The thickness of the overall film / individual layer was measured by cutting a 20µm thick cross section of the film sample via a sliding slicer (e.g., Leica SM2010 R), placing it under an optical microscope in transmission light mode (e.g., Leica Diaplan), and applying imaging analysis software.

[0097] 2) Thickness

[0098] The thickness (caliper / thickness) of a monolayer test sample was measured under static load using a micrometer according to pharmacopoeia method ISO 534, with modifications mentioned herein. All measurements were performed in a laboratory maintained at 23°C ± 2°C and 50% ± 2% relative humidity, with the test sample conditioned in this environment for at least 2 hours prior to testing. Thickness was measured using a micrometer equipped with a pressure foot capable of applying a stable pressure of 70 kPa ± 0.05 kPa to the test sample. The micrometer was a statically heavy instrument with readings accurate to 0.1 micrometers. A suitable instrument was the TMI digital micrometer model 49-56, or equivalent, purchased from TestingMachines Inc., New Castle, DE. The pressure foot was a flat, circular, movable surface with a diameter smaller than the test sample, capable of applying the required pressure. A suitable pressure foot diameter was 16.0 mm. The test sample was supported by a horizontal, flat reference platform, which was larger than and parallel to the surface of the pressure foot. The system was calibrated and operated according to the manufacturer's instructions. Measurements are performed on single-layer test samples taken from raw material rolls or sheets, or from finished packaging. When removing test samples from finished packaging, care is taken to avoid contaminating or deforming the sample during the process. The removed sample should be free of residual adhesive and taken from an area of ​​the packaging free of any seams or creases. Ideally, the test sample should be 200 mm in diameter. 2 And it must be greater than the pressure foot. To measure thickness, first zero the micrometer relative to a horizontal, flat reference platform. Place the test sample on the platform, with the test position centered below the pressure foot. Gently lower the pressure foot at a rate of 3.0 mm per second until full pressure is applied to the test sample. Wait 5 seconds, then record the thickness of the test sample, accurate to 0.1 micrometers. Repeat this process for a total of ten replicate test samples. Calculate the arithmetic mean of all thickness measurements and report the value as "Thickness," accurate to 0.1 micrometers.

[0099] 3) Basis weight

[0100] The basis weight of the test sample is the mass (in grams) per unit area (in square meters) of a single material layer, and is measured according to the pharmacopoeia method ISO 536. The test sample is cut into blocks of known area, and the mass of the test sample is determined using an analytical balance accurate to 0.0001 g. All measurements are performed in a laboratory maintained at 23°C ± 2°C and 50% ± 2% relative humidity, and the test samples are conditioned in this environment for at least 2 hours prior to testing. Measurements are performed on test samples taken from raw material rolls or sheets, or from finished packaging. When cutting the test sample from the finished packaging, care is taken to avoid any contamination or deformation of the sample during the process. The cut sample should be free of residual adhesive and taken from an area of ​​the packaging free of any seams or creases. The test sample must be as large as possible to account for any inherent material variability. For flat samples, the dimensions of a single-layer test sample are measured using a calibrated steel ruler or equivalent from NIST. For non-flat samples, the area can be calculated using 3D data. Calculate and record the area of ​​the test sample, accurate to 0.0001 square meters. Use an analytical balance to obtain and record the mass of the test sample, accurate to 0.0001 grams. The weight of the coating can be obtained by subtracting the weight of the coated sample from the uncoated sample. Calculate and record the basis weight by dividing the mass (in grams) by the area (in square meters), accurate to 0.01 grams per square meter (gsm). Repeat this process for a total of ten replicate test samples. Calculate and report the arithmetic mean of the basis weights, accurate to 0.01 grams per square meter.

[0101] 4) Pinhole test method

[0102] This is a test method for detecting and locating any pinholes equal to or greater than 10 μm on a coated surface. Place the part to be tested on the absorbent surface with the coated side facing up. Then spread a dye penetrant solution according to ASTM F3039-23 onto the test surface, preferably using an eyedropper or pipette and a small roller to apply pressure to the surface to ensure adequate contact. The dye penetrant solution should contact all areas exhibiting suspected surface abnormalities, taking care not to allow the dye penetrant solution to flow over the edges of the sample. Wipe away excess dye from the sample using a clean absorbent pad and carefully lift the sample. If there is no evidence of dye penetration or staining to the opposite side of the coated surface, the test passes.

[0103] 5) Bottle Leakage Test Method

[0104] This is a test method for measuring the ability of containers and closed systems to prevent leakage during storage or transportation.

[0105] Pre-treat at least three representative empty bottles of the test type at 22±3°C and 60%±10 RH for at least 24 hours. Prepare tap water solutions at room temperature, adding dyes such as rhodamine or toluidine to provide a permanent indication of leakage. Fill the sample with the water / dye solution to the intended filling capacity, e.g., 150±1 ml, at laboratory ambient temperature, equipped with their respective closures (if applicable), and hermetically sealed in the storage configuration. Dry the bottle neck and shoulder area (if necessary) with a (paper) towel to ensure no product residue remains. Place the sample on a flat tray capable of holding the liquid if leakage occurs. Place some absorbent paper under the sample to facilitate leakage detection. Then store the sample at 25±3°C and 60%±10 RH. It is not necessary to place weights or other bottles on top of the tested sample. Alternative sample orientations during testing can be considered so that the suspected leakage area is covered by the liquid in the container. Check for liquid leakage after 24 hours, 1 week, and 2 weeks. Note the location of any eventual leakage.

[0106] If leakage occurs to the outside of the sample, the packaging fails the test. If no leakage occurs to the outside of the sample, the packaging passes the test.

[0107] 6) Water vapor transmission rate (WVTR) test method

[0108] Water vapor transmission rate (WVTR) is defined as the mass of water vapor that permeates through a membrane per unit time per unit area, and it is used as a parameter to measure water barrier properties. Measurements are performed according to the ASTM E96 inverted cup method. For this test, an impermeable cup (such as the “vapometer” E96 cup from Thwing-Albert Instruments) is filled with 50 g of water. The cup opening has an area of ​​3,070 mm². The cup is made of a non-corrosive material and is impermeable to water or water vapor. The flat portion of the specimen to be measured is cut into a circle slightly larger than the opening of the cup. At least three representative specimens of the material and conditions being tested should be tested. The test specimen is clamped between two gaskets and placed on the flange of the cup opening to ensure proper orientation. The specimen is then secured to the cup by tightening the open screw cap to create an impermeable seal. The cup is then weighed using a balance with a resolution of at least 0.01 g. The cup is placed on a flat tray to ensure direct water contact covering the tested specimen. The cup is then stored at 25 ± 3 °C and 60% ± 10 RH. Note that the cup should be placed in a manner that allows airflow to be unrestricted by exposed surfaces. Weigh the cup daily for at least 7 days. A steady-state condition is established when the rate of weight change of the sample remains substantially constant over at least six consecutive weight measurements. A steady-state condition is assumed when a straight line adequately fits a graph of at least six appropriately spaced points (matching periodic weight changes or exceeding 20% ​​of the 100-fold scaling sensitivity). If the weight rate is not in a steady-state condition, the storage period should be extended.

[0109] If the target part to be characterized is not flat and / or the coating is not uniform, for example, made by spray or dip coating application, the water permeability is measured on a representative flat specimen made of the same material according to the same process, and characterized as the average substrate and coating thickness matching the thickness of the target part within a tolerance of + / -20%.

[0110] The water vapor transmission rate (WVTR) of the barrier layer after thermoforming can be calculated based on water vapor permeability theory, requiring two key pieces of information. The first is the inherent barrier material characteristic of water vapor permeability coefficient varying with thickness; the second is the change in barrier thickness after thermoforming. In this study, the relationship between water vapor permeability coefficient and thickness was established using a data regression process for WVTR values, employing ASTM F1249 (AMETEK, MOCON) for different membrane sample thicknesses. The thickness distribution after thermoforming can be obtained through physical measurements from thermoformed membrane samples or prediction using a virtual thermoforming model. Once this key information is obtained, the WVTR after thermoforming can be predicted based on permeability theory. These WVTR predictions were confirmed using a modified ASTM E96 desiccant method with a custom-designed metal sample holder. The sample holder was designed to create an airtight seal between the cavity containing bentonite desiccant, the thermoformed barrier membrane, and the surrounding controlled atmosphere. Following ASTM E96, the sample was weighed repeatedly over a specified duration; the resulting graph of time (days) versus weight increase (grams) was fitted with a linear regression. The slope of the line was recorded and normalized by the area of ​​the thermoformed gasket, and recorded as WVTR.

[0111] 7) Weight Reduction Test Method

[0112] This method is used to determine the weight loss of water through a container or individual component such as a vessel and lid. At least three representative empty samples of the test type are pretreated at 23±2 °C and 60%±10 RH for at least 24 hours.

[0113] Then, at laboratory ambient temperature, fill the sample to its fill volume with the specified amount of tap water or another specified personal care composition, equipped with their respective closures / caps (if applicable), and hermetically seal in the storage configuration. Care should be taken with any different types of closures, such as aluminum foil with paraffin. Dry any outer surfaces (if necessary) with a (paper) towel so that no product residue remains.

[0114] For flat components, such as capping membranes, measurements are performed according to a variant of the ASTM E96 inverted cup method. For this test, an impermeable cup (such as the “vapometer” E96 cup from Thwing-Albert Instruments) is filled with 50g of water or a specified personal care composition. The cup opening has an area of ​​3,070 square millimeters. The cup is made of a non-corrosive material and is impermeable to water or water vapor. The flat portion of the specimen being measured is cut into a circle slightly larger than the cup opening. At least three representative specimens of the material and conditions being tested should be tested. The test specimen is clamped between two gaskets and placed on the cup opening flange to ensure proper orientation. The specimen is then secured to the cup by tightening the open screw cap to create an impermeable seal.

[0115] Record the weight of the filled covered container or cup using a balance with a resolution of at least 0.01 g. Then store the sample under 25 ± 3 °C, 60% ± 10 RH, or another relevant test condition. The sample should be positioned such that water or the test product is in direct contact with the sample being tested. If using an ASTM E96 cup, the cup should be positioned such that airflow is not restricted by the exposed surface. Record the weight daily for two weeks. Once the gradient stabilizes at a “steady state,” calculate the daily weight loss. Calculate the surface area of ​​the container. Calculate the weight loss and record the average daily weight loss per square meter under 25 °C, 60% RH, or a relevant test condition. This test is not applicable if the weight loss does not reach a steady state, such as in cases of packaging failure with leakage.

[0116] 8) Water resistance test method

[0117] This method simulates high-volume use in a humid environment. Bottles are filled with Pantene PRO-V Repair & Protect Shampoo or another specified personal care composition to a specified fill volume (e.g., 150 ± 1 g) and then pretreated at 22 ± 3 °C and 60% ± 10 RH for at least 24 hours.

[0118] Then dispense 5g ± 1g of the contents from the bottle; immerse the package in water for 8 minutes, followed by drying for 10 minutes. This sequence of operations represents a reuse cycle. This test cycle was repeated 19 times. A minimum of 3 bottles were tested.

[0119] If no integrity or performance failure is observed in any bottle, rendering the packaging unusable after all 20 reuse cycles, then the test requirements are met.

[0120] 9) Bottle squeeze test method

[0121] This method is used to measure the force required to dispense a given amount of product from a bottle. Bottles are filled with Pantene PRO-V Repair & Protect Shampoo or another specified personal care composition to a specified fill capacity (e.g., 150 ± 1 g) and then pretreated at 22 ± 3 °C and 60% ± 10 RH for at least 24 hours. The bottles are equipped with their respective closures to ensure no leakage.

[0122] Each bottle is then placed in a compression tester using a clamp to simulate a crushing event. An example of a compression tester is the Z010TN All-round from ZwickRoell GmbH & Co. KG. The load probe has a 3 / 4-inch stainless steel ball attached to simulate a thumb pressing against the bottle panel. The bottle is placed horizontally relative to the load post with its front panel facing upwards, with the two curved aluminum supports positioned in opposite directions of the applied load, by securing one end of the bottle to one end resting on two bent aluminum supports (simulating fingers). The bottle is adjusted to ensure the load is applied at the center of the panel and midway between the neck (or bottle base) and the other end of the bottle. The probe is then lowered to contact the bottle, reaching the maximum preload of 0.5 N. A balance with an accuracy of ±0.01 g and a collection plate is placed under the package to collect the product dispensed from the orifice during crushing. The closure is opened to ensure no product leaks from the orifice before the crush test. Sometimes it is necessary to reorient the bottle.

[0123] The load is then applied to the filled bottle at a speed of 20 mm / s until a displacement of 10 mm is achieved. The probe then returns to the starting position and performs two more load cycles. The total amount of product allocated is weighed. A minimum of three bottles are tested in total.

[0124] The test is considered successful if the average product collected from each dispensing event of all test bottles is at least 1g, and all bottles survive the test without any catastrophic failures that impair bottle function (such as leakage).

[0125] 10) Recyclability in pulp stream based on PTS-RH 021 CAT 2

[0126] The test was conducted using at least 250 g of a representative amount of dried material from the type of packaging to be tested, intended for consumer disposal. The first step involved separating, drying to remove, and weighing easily separable non-paper components, such as closures. The test material was reduced to a sample size of approximately 2 cm × 2 cm, and the moisture content was determined according to DIN EN ISO 287:2009-09. Then, approximately 50 ± 1 g of the test material was dissociated according to DIN EN ISO 5263-1:2004-12. For this purpose, a sample with a total volume of 2,000 ml was dissociated in a standard dissociation machine at a consistency of 2.5% without pre-swelling. The dissociation time was 20 minutes, the speed was 3,000 rpm, and the tap water temperature was 40°C. The resulting fiber suspension was then homogenized according to ZM V / 6 / 61. For this purpose, the sample was transferred to a dispenser, diluted with tap water to a consistency of 0.5%, and homogenized for approximately 5 minutes.

[0127] Then, dissociability was tested according to Zellcheming method ZM V / 18 / 62. For this purpose, the total feedstock was sieved for 5 minutes without any other chemical additives using a Brecht-Holl fractionator with a perforated plate of 0.7 mm pore size. The residue was washed into a 2-liter tank and dehydrated through a filter inserted into a Buchner funnel. The filter was folded once and placed in an oven to dry at 105°C until constant weight. The waste was then visually inspected and weighed. The proportion of dried non-pulp components removed was also included in the calculation of the total waste content. Fiber yield was derived from the difference between the initial material (dried, 100%) and the total waste. If the total waste content did not exceed 20%, the product was rated "recyclable"; if the total waste content was between 20% and 50%, it was "recyclable, but product design improvements are warranted"; and if the total waste content exceeded 50% of the initial material input, it was "not reasonably suitable for paper recycling."

[0128] To evaluate the undisturbed paper-forming standard, the total raw material was first sieved following the Zellcheming method ZM V / 1.4 / 86. For this purpose, the total raw material was fractionated for 2 minutes using a Haindl fractionator with a 0.15 mm narrow-mouth plate. The passing fraction was then collected, referred to below as the "qualified material". Paper was then formed on a Rapid Köthen paper forming machine using the qualified material, according to DIN EN ISO 5269-2:2005-03. Two 1.8 g handmade sheets yielded approximately 60 gsm. The drying temperature was approximately 96 °C. For the paper bonding test, the dried handmade paper, along with the roll carrier and cover sheet, was sandwiched between two brass plates and placed in a drying oven where a full-surface pressure of 1.18 kPa was applied for 2 minutes. The sample was then cooled in a shaker for 10 minutes, followed by a paper bonding test and visual inspection for any optical inhomogeneities.

[0129] For the paper adhesion test, the carrier and cover sheet are slowly peeled off the handmade paper one by one. While doing so, the test operator examines for potential adhesion effects. Additionally, the surfaces of the handmade paper, cover sheet, and carrier are inspected for any damage or adhesion to the handmade paper. If no adhesion effect is observed, the product is considered "recyclable"; if some slight adhesion effect is observed with minor damage, it is "limitedly recyclable due to the stickiness of the prepared fiber material"; if adhesion effect is observed with damage, it is "non-recyclable due to the stickiness of the prepared fiber material."

[0130] Then, examine the handmade paper under transmitted light for any defects, transparent and white spots, or dirt spots from ink, coatings, paints, laminating, and adhesive particles. Additionally, evaluate whether the paper is contaminated with any dark colorants. If no or non-interfering optical inhomogeneities are observed, the product is considered "recyclable"; if interfering optical inhomogeneities are observed, the product is considered "limitedly recyclable due to the optical inhomogeneities of the fiber raw material used in its preparation"; and if unacceptable optical inhomogeneities are observed, the product is considered "non-recyclable due to the optical inhomogeneities of the fiber raw material used in its preparation".

[0131] 11) Flat pressure test

[0132] In the flat pressure test, an empty bottle is placed sideways on a plate. A vertical load of 45 N is applied to the bottle, where the diameter of the cylinder is 6 cm. The test passes if the bottle permanently deforms into a substantially flat configuration.

[0133] Example Table

[0134] Example

[0135] Table 1 includes examples of squeezeable bottles that can be used for storing and dispensing consumer products. All bottles in these examples have a net capacity of at least 150 ml. All evaluated bottles were found to be leak-free and free of pinholes larger than 10 micrometers. The bottles were tested for fiber content, spray integrity according to a water resistance method, squeezeability according to the PTS-RH 021 / 97 cat 2 method, and resizing properties. The moisture barrier properties of the sidewalls and bases of the bottles in these examples were also evaluated.

[0136] Example 1 discloses a commercially available paper tube that uses liquid cardboard as sidewalls, has welded polyethylene shoulders, and a polypropylene cap with a movable hinge. It was found that this embodiment has a low fiber content and a low fiber recovery rate (less than 50%) during the repulping process.

[0137] Examples 2 through 6 cover different embodiments of the invention, all of which (1) have a fiber content greater than 85%, (2) pass the compression test, (3) have a sidewall and base vapor transmission rate of less than 20 g / m² / day at 25°C and 60% RH, (4) pass the water resistance test, and (5) fully pass the PTS-RH021 / 97 cat 2 test with a fiber recovery rate of 80% or higher. Additionally, all bottles can be flattened and compressed to near-empty conditions to allow access to all contents, minimize product waste and residue, and ensure optimal disposal.

[0138] Example 2 discloses an extrudable fiber-based bottle having a padded wet-molded base and sidewalls, the sidewalls comprising a single-sided liquid-coated cardboard sheet. The liquid cardboard sheet is a 270 gsm pulp raw material with a 30 gsm LDPE coating. In this example, the pulp molding base 120 is molded from a pulp comprising 50% bamboo, 40% bagasse, and 10% softwood fiber portions. The pulp also includes 1% AKD added as a 10% emulsion. The pulp molding base 120 includes a base barrier structure 140 composed of a laminate from NOVA comprising nucleated HDPE. The average thickness of the laminate before and after molding is 90 micrometers and 60 micrometers, respectively. According to the construction shown in FIG. 1, the pulp molding base 120 includes a small silicone valve 150 to facilitate dispensing. Valve 150 is externally sealed by a removable membrane patch (not shown) to prevent accidental dispensing during delivery and storage.

[0139] Example 3 discloses an alternative embodiment of the extrudable fiber-based bottle, which has a sprayed wet-molded base 120 and a sidewall 112, the sidewall comprising a liquid-coated cardboard sheet on one side. The liquid cardboard sheet sidewall 112 and the pulp molding base 120 are identical to those in Example 2. A pulp molding base barrier structure 140 is applied to the liquid-receiving surface 128 of the pulp molding base 120 and includes a base coat and a top coat applied by spraying. The valve 150 is identical to the valve in Example 2.

[0140] Example 4 discloses as follows Figure 5b The extrudable fiber-based bottle shown has a wet-molded gasketed base 120 and a sidewall 112 comprising a double-sided liquid-coated cardboard. The liquid cardboard is a high-barrier double-sided liquid-coated cardboard from Stora Enso, marketed as Natura Barr. The gasketed base, valve, and valve assembly are identical to those in Example 2.

[0141] Example 5 discloses an extrudable fiber-based bottle having a lined wet-molded base and coated wet-molded sidewalls. The sidewalls are integrally manufactured using the same slurry as disclosed in Example 2, employing a wet molding process. The sidewalls were found to be highly flexible and deformable. A barrier system is applied to the inner surface of the sidewalls and includes a base coat and a top coat applied by spraying. The lined base, valve, and valve assembly are identical to those in Example 2.

[0142] Example 6 discloses an extrudable fiber-based bottle having a wet-molded gasketed base and wet-molded coated sidewalls. Except for the base assembly, the bottle's construction is the same as in Example 5. According to this embodiment, a valve is sandwiched between the pulp-molded base and an additional molded cover, as shown in Figures 11a and 11b.

[0143] The dimensions and values ​​disclosed herein should not be construed as strictly limited to the precise numerical values ​​cited. Rather, unless otherwise specified, each such dimension is intended to represent the stated value and the range surrounding its functional equivalent. For example, a dimension disclosed as “40 mm” is intended to represent “approximately 40 mm”.

[0144] Unless expressly excluded or otherwise limited, every reference cited herein, including any cross-references or related patents or patent applications, and any patent application or patent claiming priority to or benefiting from it, is incorporated herein by reference in its entirety. Reference to any reference is not an endorsement of it as prior art to any disclosed or protected art herein, nor is it an endorsement of any such invention, either on its own or in combination with any one or more references. Furthermore, where any meaning or definition of a term in this invention conflicts with any meaning or definition of the same term in referenced documents, the meaning or definition given to that term in this invention shall prevail.

[0145] While specific embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, it is intended that all such changes and modifications falling within the scope of the invention be covered by the appended claims.

Claims

1. A squeezable fiber-based bottle for storing and dispensing viscous liquids, the bottle comprising: a pulp-molded base including a liquid-receiving surface having an orifice for dispensing viscous liquids, the pulp-molded base having a base perimeter with a perimeter surface including an upper edge and a lower edge, a base barrier structure disposed on the liquid-receiving surface and the upper edge of the base perimeter, and a fiber-based sidewall having an upper edge, a lower edge, an outer surface, and an inner surface, the inner surface including a fiber-based sidewall barrier layer, wherein the lower edge of the fiber-based sidewall is attached around the entire perimeter surface of the pulp-molded base near the perimeter surface upper edge and not near the perimeter surface lower edge, thereby forming an impermeable seal, the pulp-molded base perimeter surface lower edge being below the liquid-receiving surface, thereby allowing the squeezable fiber-based bottle to stand upright.

2. The squeezable fiber-based bottle of claim 1, wherein the base barrier structure includes a WVTR of less than 20 g / m2 / day at 25°C, 60% relative humidity.

3. The squeezable fiber-based bottle of claim 2, wherein the fiber-based sidewall barrier layer includes a WVTR of less than 20 g / m2 / day at 25°C, 60% relative humidity.

4. The squeezable fiber-based bottle of claim 1, wherein the base barrier structure includes a polymeric gasket.

5. The squeezable fiber-based bottle of claim 1, wherein the base barrier structure is a water-based dispersion and includes a microfibrillated cellulose (MFC) or cellulose nanocrystal (CNC) additive.

6. The squeezable fiber-based bottle of claim 1, wherein the squeezable fiber-based bottle includes at least 85% fiber content fiber.

7. The squeezable fiber-based bottle of claim 1, wherein the fiber-based sidewall is a pulp-molded piece including a squeezable side panel.

8. The squeezable fiber-based bottle of claim 1, wherein the orifice for dispensing viscous fluids includes a separable spout valve.

9. The squeezable fiber-based bottle of claim 8, wherein the separable spout valve is attached to a cover, wherein the cover is lightly attached to a bottom surface of the pulp-molded base, wherein the cover can be twisted to release the spout valve from the orifice.

10. The squeezable fiber-based bottle of claim 1, wherein the lower edge of the fiber-based sidewall is attached around the entire perimeter surface of the pulp-molded base near the perimeter surface upper edge and is separated from the perimeter surface lower edge by at least 1 mm.

11. The squeezable fiber-based bottle of claim 1, wherein the pulp-molded sidewall is a monolithic, one-piece sidewall.

12. The squeezable fiber-based bottle of claim 11, wherein the one-piece sidewall upper edge includes a first upper edge and a second upper edge, wherein the first upper edge is attached to the second upper edge, thereby forming a seal.

13. The squeezable fiber-based bottle of claim 1, wherein the outer surface of the pulp molded side wall includes score lines to facilitate bi-directional folding to dispense all viscous liquids.

14. The squeezable fiber-based bottle of claim 1, wherein the fiber-based side wall barrier layer includes a liner on the inner surface.

15. The squeezable fiber-based bottle of claim 1, wherein the squeezable fiber-based bottle can be collapsed into a flat configuration to provide at least 95% product evacuation.

16. The squeezable fiber-based bottle of claim 1, wherein the squeezable fiber-based bottle maintains structural integrity and performance when used in a wet environment.

17. The squeezable fiber-based bottle of claim 6, wherein the fiber count can include between 50% to 60% bamboo, between 40% to 50% bagasse, and 0% to 10% softwood.

18. The squeezable fiber-based bottle of claim 6, wherein the fiber count can include between 50% to 60% bamboo, between 35% to 50% bagasse, and up to 5% microfibrillated or nanofibrillated cellulose fibers.

19. The squeezable fiber-based bottle of claim 7, wherein the inorganic barrier layer is applied by vapor deposition after pulp molding.

20. The squeezable fiber-based bottle of claim 1, wherein the viscous fluid has a viscosity of 5,000 cps 10s -1 to 20,000 cps 10s -1 .

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