Ergonomic extrudable fiber-based bottle

Abstract

The present disclosure provides an extrudable fiber-based bottle (10) for storing and dispensing a viscous liquid. The bottle (10) comprises a molded base (20) comprising a liquid containing surface having an aperture (30) for dispensing the viscous liquid. The molded base (20) includes a base perimeter having a perimeter surface (22) with an upper edge (24) and a lower edge (16). The extrudable fiber-based bottle (10) includes a fiber-based sidewall (12) having an upper edge (14), a lower edge (16), an inner surface, and an outer surface. The side wall (12) comprises a front panel (4), a rear panel (5) and two opposite side panels (2, 3). At least one of the opposing side panels comprises a crease line (65) forming a flat portion (7, 9). The fiber-based sidewall (12) is attached to the molded base (20) forming an impermeable seal such that the lower edge (16) of the fiber-based sidewall (12) is disposed proximate the peripheral surface upper edge (24) but not proximate the peripheral surface lower edge (26). The impermeable seal is formed around the entire peripheral surface of the molded base (20).

Description

Technical Field

[0001] An ergonomically extrudeable fiber-based bottle for storing and dispensing viscous liquid products on demand in humid environments. Preferably, the extrusive fiber-based bottle is recyclable in beverage carton feed streams. 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. Fiber-based 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 fibers offer excellent structural support and a pleasant decorative surface, their poor oxygen and moisture barrier properties, along with their limited 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 heat-sealable polymer (such as PE) 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.

[0005] High-speed manufacturing processes can be used to form sheets for packaging, such as cartons, cans, or paper tubes. Cartons or cans are suitable for dispensing pourable liquids, but have significant limitations for dispensing viscous formulations, such as those used in cosmetics and personal care. Current paper tubes have folded liquid packaging boards (LPBs) that include fibers for the sidewalls, but still require a significant amount of plastic due to the inclusion of plastic components needed to provide reclosability and dispensing control. Current paper tubes also have suboptimal ergonomics due to a less-than-optimal grip, especially for larger sizes. Paper tubes using commercially available folded fiber-based packaging boards have walls that are generally stiffer than PBLs (plastic barrier laminates) or extruded plastic tubes. This characteristic, combined with the use of plastic closures mounted on the shoulder, limits the tube's compressibility and collapseability, thus limiting the resilience of the final product. Using thinner LPB gauges in current cosmetic tubes can improve compressibility / collapseability, but also results in suboptimal dispensing because the paper laminate lacks the desired "shape" memory / springiness required to provide dispensing control.

[0006] Gripping and dispensing bottles or tubes in damp environments is particularly challenging for disabled or elderly consumers (e.g., those affected by arthritis), especially since packaging surfaces can be slippery. Furthermore, the hygroscopic nature of fibers presents additional challenges for fiber-based packaging applications in humid or damp environments, such as shower or bathroom applications.

[0007] 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.

[0008] It is desirable to maximize the bio-based fiber content in the packaging to improve the bio-based renewable content and recycling rate in fiber reprocessing. It is also desirable to maximize the bio-based fiber content in the packaging to maximize ergonomics during dispensing, especially in humid environments. It is also desirable to increase fiber inclusion to achieve product recovery of over 90% (or even over 95%) and to flatten the bottle upon disposal, which facilitates sorting and the circular economy. It is desirable that fiber-based bottles minimize plastic inclusions and offer unique design shapes, providing a reasonable shelf life of at least 6 months to 2 years, survival in the shower, inclusive use, and recyclability. Preferably, squeezable fiber-based bottles are desired for use in humid environments, capable of maintaining integrity while containing liquid formulations, capable of on-demand dispensing, have excellent ergonomics in use, exhibit a reasonable shelf life, and optimize recycling and disposal. Summary of the Invention

[0009] This disclosure provides a squeezable fiber-based bottle for storing and dispensing viscous liquids. The bottle includes a molded base with a liquid-receiving surface having orifices for dispensing the viscous liquid. The molded base includes a base periphery having peripheral surfaces with upper and lower edges. The squeezable fiber-based bottle includes fiber-based sidewalls having an upper edge, a lower edge, an inner surface, and an outer surface. The fiber-based sidewalls include a front panel, a rear panel, and two opposing side panels. At least one of the two opposing side panels includes a crease line forming a flat portion. The inner surface of the fiber-based sidewall includes a fiber-based sidewall barrier layer having a water vapor transmission rate of less than 20 g / sqm / day at 25°C and 60% relative humidity. The lower edge of the fiber-based sidewall is attached to the molded base to form an impermeable seal. The impermeable seal is formed around the entire peripheral surface of the molded base, wherein the lower edge of the fiber-based sidewall is near the upper edge of the peripheral surface but not near the lower edge of the peripheral surface. The peripheral surface of the molded base may include a lip or flange to receive the lower edge of the fiber-based sidewall. Alternatively, the fiber-based sidewall may be wound around the lower edge of the molded base such that the lower edge of the fiber-based sidewall is located near the inner peripheral surface of the upper edge of the peripheral surface but not near the lower edge of the peripheral surface. The lower edge of the peripheral surface of the molded base is below the liquid-receiving surface, thereby allowing the compressible fiber-based bottle to stand upright. The orifice for dispensing viscous fluid includes a narrow-mouth valve formed of plastic or other resin material. Attached Figure Description

[0010] 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 1 This is a perspective view of the extrudable fiber-based bottle according to this disclosure.

[0011] Figure 2 yes Figure 1 The image shown is a bottom view of the bottle, illustrating its use.

[0012] Figure 3a This is a perspective view of the extrudable fiber-based bottle according to this disclosure.

[0013] Figure 3b yes Figure 3a The side view of the extrudable fiber-based bottle is shown.

[0014] Figure 3c yes Figure 3a The front view of the extrudable fiber-based bottle is shown.

[0015] Figure 4 This is a cross-sectional view of the lower portion of the extrudable fiber-based bottle according to the present disclosure.

[0016] Figure 5a This is a perspective view of an extrudable fiber-based bottle, showing a bottom view of a molded base according to the present disclosure.

[0017] Figure 5b yes Figure 5a The diagram shows a perspective view of a squeezable fiber-based bottle, with the bottle standing upright.

[0018] Figure 5c yes Figure 5b The bottle shown is a side view.

[0019] Figure 5d yes Figure 5b The front view of the bottle shown.

[0020] Figure 6a This is a perspective view of an extrudable fiber-based bottle, showing a bottom view of a molded base according to the present disclosure.

[0021] Figure 6b yes Figure 6a The diagram shows a perspective view of a squeezeable bottle, with the bottle standing upright.

[0022] Figure 6c yes Figure 6b The bottle shown is a side view.

[0023] Figure 6d yes Figure 6b The front view of the bottle shown.

[0024] Figures 7a to 7f The steps for forming a compressible fiber-based bottle according to the invention are shown.

[0025] Figure 8a A preform for forming a squeezeable bottle according to the present disclosure is shown.

[0026] Figure 8b It is by Figure 8a The diagram shows a perspective view of the extrudable fiber-based bottle formed from the preform.

[0027] Figure 8c Based on this disclosure Figure 8b The side view of the extrudable fiber-based bottle is shown.

[0028] Figure 9a This is a side view of an apparatus for indenting liquid carton boards that form the fiber-based sidewalls of a squeezeable bottle according to the present disclosure.

[0029] Figure 9b yes Figure 9aThe image shows a side view of the equipment used to indent liquid cardboard.

[0030] Figures 10a to 10f This is a side view of an extrudable fiber-based bottle according to the present disclosure, showing a textured panel in the sidewall.

[0031] Figure 11a This is a perspective view of a squeezeable bottle including crease lines near the upper edge of the sidewall, according to this disclosure.

[0032] Figure 11b yes Figure 11a The figure shows a perspective view of a squeezable fiber-based bottle, illustrating crease lines separated near the upper edge of the side panel according to the present disclosure.

[0033] Figure 12a This is a perspective view of a squeeze bottle, showing the crease in the upper edge.

[0034] Figure 12b yes Figure 12a A perspective view of the bottle, including the crease line below the folded upper edge.

[0035] Figure 12c yes Figure 12b A perspective view of the bottle, showing the crease line separating below the folded upper edge.

[0036] Figure 13 This is a perspective view of the extrudable fiber-based bottle according to this disclosure.

[0037] Figure 14 yes Figure 13 The image shows a cross-sectional view of the lower portion of the extrudable fiber-based bottle.

[0038] Figure 15 yes Figure 13 The figure shows a cross-sectional view of the lower portion of the extrudable fiber-based bottle, illustrating an alternative valve arrangement.

[0039] Figure 16 yes Figure 13 The figure shows a cross-sectional view of the lower portion of the extrudable fiber-based bottle, illustrating an alternative valve arrangement.

[0040] Figure 17 yes Figure 13 The figure shows a cross-sectional view of the lower portion of the extrudable fiber-based bottle, illustrating an alternative valve arrangement. Detailed Implementation

[0041] 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.

[0042] One object of the present invention is to provide a squeezable fiber-based bottle for liquid compositions comprising at least 50% fiber content, which can be repulped in paper / paperboard recycling streams (including used beverage carton recycling streams) to provide excellent ergonomics and dispensing, enabling greater than 90% product emptying, flattening upon disposal, achieving high volumetric packaging efficiency, and withstanding dispensing, storage, and use in humid environments.

[0043] Another objective is to provide a method for forming an extrudable fiber-based container. The method includes the step of cutting a planar, elongated blank from a liquid packaging sheet or web. The blank has a first side edge, a second side edge, a lower edge, and a upper edge. The blank is indented to form a line extending oriented from the lower edge to the upper edge. The blank is secured to a jig corresponding to the shape of a bottle to be manufactured. The blank is folded around the jig such that the first and second side edges overlap, forming an integral bottle shape with two open ends. Heat-sealing energy and pressure are applied to the overlapping side edges to form an airtight seal. The jig is removed from the container interior, and the lower edge of the fiber-based sidewall is attached to a molding base to form an impermeable seal. The molding base has an upper edge and a lower edge of a peripheral surface. The lower edge of the fiber-based sidewall is located near the upper edge of the peripheral surface but not near the lower edge of the peripheral surface. The bottle is filled, and the upper edge is sealed.

[0044] Another object of the present invention is to provide a squeezeable bottle with creases so that the bottle can be torn open before disposal to obtain the remaining contents and clean any residue inside the bottle.

[0045] "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.

[0046] "Fiber" is preferably defined as a natural substance of wood or plant origin that is significantly longer than it is wide.

[0047] "Molded base" is preferably defined as a component made of plastic using injection molding, compression molding, or thermoforming, or a component made of fiber using pulp molding or liquid cardboard molding.

[0048] An "impermeable seal" is preferably defined as a liquid-impermeable area between two or more mating surfaces or objects. This may include each fluid-sealed connection area to prevent leakage of product from the bottle, as well as components to protect paper / cardboard rough edges.

[0049] Figure 1 An exemplary extrudable fiber-based bottle 10 is shown. The extrudable fiber-based bottle 10 includes a fiber-based sidewall 12 and a molded base 20. The fiber-based sidewall 12 includes an upper edge 14, a lower edge 16 attached to the molded base 20, a front panel 4, a rear panel 5, two opposing side panels 2, 3, an outer surface 19, and an inner surface (not shown). The inner surface of the fiber-based sidewall includes a liquid-containing material (not shown). The fiber-based sidewall 12 may include a liquid carton sheet comprising a multilayer sheet having a multilayer substrate and one or more functional layers. The sidewall 12 includes pleats 65 in the two opposing side panels 2, 3 extending from the lower edge 16 at the base 20 to the upper edge 14. The pleats 65 form sustainable flat portions 7 and 9 in the two opposing side panels 2, 3, thereby forming flat portions 7 and 9, respectively. The molded base 20 includes orifices 30 for dispensing a viscous liquid contained in the extrudable fiber-based bottle 10. The two opposing side panels 2 and 3 include a flat side 7 and a flat side 9.

[0050] Existing cosmetic paper tubes include a wrinkle-free liquid packaging plate (LPB) in the sidewalls, which has a higher modulus and flexural stiffness compared to plastic laminates; that is, the LPB is bent into a cylinder and formed as a single curved surface. When an acceptable compressive force is applied, the rigid sidewalls, combined with the rigid tube structure, allow the cylindrical sidewall sections to act as tubular springs to limit the dispensed dose. For example, a 30 N compressive force, compressing a 50 mm diameter filled commercially available paper tube with a 10 mm displacement, produces a dose of approximately 1.6 g. It has been determined that consumers typically apply a compressive force of 20 N to 30 N to the tube, and this compressive force rarely exceeds 50 N. Since the typical desired dose for most personal care applications is 5 g to 10 g, consumers find it inconvenient to repeatedly compress the tube or apply very large compressive pressures, leading to tube denting and undesirable permanent deformation.

[0051] The creases according to this disclosure enable the LPB to be folded to form a sharp edge. This sharp edge results in a discontinuity in the curvature of the sidewall surface, creating a flat portion that is more easily crushed upon deflection than a circular or elliptical tube with the same internal volume and sidewall material. This allows for a higher dosage per squeeze than prior art cosmetic paper tubes under similar extrusion pressure. Furthermore, it has been found that the flat portions 7 and 9 on the opposing side panels 2, 3 promote the “springback” of the crushed side panels, as the creases 65 act as a movable hinge, preventing denting and permanent deformation when the extrusion pressure is released. Moreover, when a force of at least 45 N is applied to crush the side panels, the creases allow the opposing side panels to collapse into a flat configuration, thereby providing greater than 90% product recovery and tube handling.

[0052] The substrate of the liquid cardboard forming the fiber-based sidewalls 12 preferably comprises lignocellulose fibers obtained through any conventional pulping process, including bleached or unbleached chemical pulping, mechanical pulping, and chemimechanical pulping. The cardboard may be made of more than one layer (usually three layers) and is typically in the form of a fiber web.

[0053] Preferably, the cardboard has a basis weight of 170 gsm to 430 gsm, more preferably about 250 gsm to 350 gsm. Preferably, the functional layers can be on both the inner and outer surfaces 19 forming the liquid-containing portion. The innermost and outermost layers are preferably low-density polyethylene (LDPE) layers to ensure good sealing and liquid tightness. The LDPE in the outermost layer also ensures prevention of moisture absorption due to splashing or wet handling. LDPE also ensures that after consumer disposal and household collection, NIR detectors in industrial sorting facilities can reliably identify the bottles and transfer the packaging to a used beverage carton recycling stream, where multi-material packaging is effectively recycled and fibers are recovered for future use.

[0054] For example, liquid corrugated board can be a multilayer structure comprising one or more layers made of bleached sulfate pulp. Liquid corrugated board may include a top layer made of bleached sulfate pulp, an intermediate layer made of chemithermomechanical pulp (CTMP), a back layer made of bleached sulfate pulp, and a polyethylene (PE) layer on the outer surface of the top layer and / or the back layer. The liquid corrugated board used may be branded under the trademark Natura. ™ 2PE Board or Natura ™ Barr sells products from the Finnish company Stora Enso. Natura ™2PE board is a bleached liquid packaging board with a three-layer fiber construction, consisting of two outer layers made of bleached sulfate pulp and an inner layer made of CTMP (chemithermomechanical pulp). Its top and back sides are made of polyethylene (PE) without any additional high-barrier coating. (Natura) ™ Barr is a bleached liquid packaging board with a three-layer fiber structure, comprising two outer layers made of bleached sulfate pulp and an inner layer made of CTMP (chemithermomechanical pulp). It has a polyethylene (PE) coating on the top side and a multi-layer high-barrier coating on the back side. Functional layers may include barrier layers such as high-density polyethylene (HDPE), foil or thin coatings derived from metallization, cellulose fibers, or applications of water-dispersible nanocomposites including nanosheets. Alternatively, both the inner and outer coatings may 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 Cuforma Natura Aqua+ sold by Stora Enso and ISLA sold by Kotkamills.

[0055] Figure 2 A bottom view of an exemplary squeezable fiber-based bottle 10, gripped by a user during dispensing, is shown. As illustrated, the thumb presses down on the rear panel 5, while the other fingers press down on the front panel 4. The flat sides 7 of the bottle 10 interlock with the metacarpal region of the palm. Surprisingly, this configuration has been found to allow most users (95% of adult men and women) to achieve a good grip and maximize squeezing force without relying on high surface friction. This is preferably desirable when the bottle 10 is used in a wet environment. Figure 2As shown, the molding base 20 has a major axis 96 corresponding to the length of the molding base 20 and a minor axis 98 corresponding to the width of the molding base 20. Preferably, the maximum length of the molding base 20 is greater than the maximum width. In a preferred embodiment, the maximum width of the molding base 20 is 66 mm. The rear panel 5 and front panel 4 of the bottle 10 have curvatures corresponding to the peripheral surfaces of the upper edges of the molding base 20, and the lower edge 16 of the side panel 12 is attached to the molding base. The curvature of the rear surface 84 of the molding base 20 may be greater than the curvature of the front surface 82. Similarly, the flat portions 7 and 9 in the two opposing side panels 2 and 3 correspond to the flat surfaces 87 and 89 on the opposing sides of the molding base 20. The length 81 of the flat surfaces 87 and 89 on the opposing sides of the molding base 20 is less than the maximum width of the molding base 20. Preferably, the maximum width of the molding base 20 exceeds the length 81 of the flat surfaces 87 and 89 on the molding base 20 by less than 10 mm. This design optimizes the bottle's volumetric efficiency while maintaining acceptable compressibility.

[0056] Figure 3a An isometric view of the extrudable fiber-based bottle 10 according to the present disclosure is shown, and Figure 3b A side view of a compressible fiber-based bottle 10 according to the present disclosure is shown, wherein the sidewalls 12 include one or more pleats 65 on two opposing side panels 2, 3. In addition to improving grip as previously described, the pleats 65 are found to contribute to enhancing the compressibility of the bottle 10 when collapsed into a flat configuration, such as... Figure 3c As shown, it illustrates the rear panel 5 of the extrudable fiber-based bottle 10. This particularly helps to maximize product evacuation and enhance the flattening of the extrudable fiber-based bottle 10 before disposal.

[0057] Figure 4 This is a cross-sectional view of an exemplary extrudable fiber-based bottle 10, showing the assembled fiber-based sidewalls 12 attached to a molded base 20. The molded base 20 may be an injection-molded thermoplastic polymer, preferably high-density polyethylene (HDPE) or polylactic acid (PLA). Preferably, the molded base 20 is made of a bio-based or post-consumer recycled grade. The polymer may include fillers to increase the renewable content (such as cellulose fibers or non-fibrillated wood particles) in the polymer matrix, as proposed in U.S. Patent Nos. 8,722,773 and 11,504,878. The base may also be made of fibers and fully encapsulated by application, spraying, or dip coating with a polymer film or aqueous dispersion. The base may also be made by compression molding.

[0058] like Figure 4As shown, the molded base 20 includes a base periphery having an outer peripheral surface 22 with an upper edge 24 and a lower edge 26. The lower edge 16 of a fiber-based sidewall 12 is attached to the molded base 20, thereby forming an impermeable seal 42 between the fiber-based sidewall 12 and the outer peripheral surface 22. The lower edge of the fiber-based sidewall is located near the upper edge 24 of the peripheral surface but not near the lower edge 26. 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 of the molded base 20 may include a flange (not shown) to receive the lower edge 16 of the fiber-based sidewall 12. This flange is preferably at least 1 mm from the lower edge 26 of the peripheral surface. The impermeable seal 42 is formed around the entire outer peripheral surface 22 of the molded base 20. 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 42, such as ultrasonication or application of adhesive, are contemplated.

[0059] like Figure 4 As shown, an orifice 30 for dispensing a viscous fluid extends into a conduit 32 disposed on a bottom surface 27 of a molded base 20, which is the side opposite to a liquid-containing surface 28. The conduit 32 may include 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 50 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 -1Between. The narrow-mouth valve 50 is preferably molded from an elastic, flexible 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 film, 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. A slit valve 50 may be mounted on the liquid-receiving surface 28 of the molded base 20 and clamped between the molded base 20 and the plastic disc 51 by snap-fit ​​molding, thermal stacking, or ultrasonic welding. The slit valve 50 may also be clamped between the plastic disc 51 and another small plastic mating part (not shown). The plastic disc 51 may be assembled to the molded base 20 by snap-fit ​​molding, thermal stacking, or ultrasonic sealing. Ultrasonic sealing has been found to produce a strong seal bond. This configuration is particularly advantageous in ensuring that the valve 50 does not accidentally pop out during product dispensing. In some embodiments, the slit valve 50 may also be made of a thermoplastic polymer and integrated with the base (not shown). The lower edge 26 of the peripheral surface of the molded base lies below the liquid-receiving surface 28, the pipe opening 34, and the slit valve 50, thereby allowing the extrudable fiber-based bottle 10 to stand upright. The molded base includes components to prevent dispensing via the valve if pressure is accidentally applied through the sidewall 12 during transport or handling. This may be a molded closure (not shown). The narrow-mouth valve 50 may also include a mechanism to prevent dripping or leakage during transport for use with lower viscosities, such as 300 cps 10s. -1 Up to 3,000 cps in 10 seconds -1 As disclosed in U.S. Patent No. 10,611,531. Preferably, valve 50 can be sealed with a removable cap that is attached to a metallized laminate of a molded closure using a pressure-sensitive adhesive (not shown).

[0060] Figures 5a to 5dA preferred embodiment of an exemplary squeezable fiber-based bottle 10 is shown, wherein the upper edge 14 of the fiber-based sidewall 12 is included within the occupied area of ​​the base 20, such that the length of the upper edge 14 is less than or equal to the length and width of the molded base 20 measured along the major axis 96 and minor axis 98, respectively. This configuration is found to be particularly advantageous for achieving better grip than conventional round or oval cosmetic tubes with comparable fill volumes, especially for larger tubes. In particular, the squeezable fiber-based bottle of this disclosure is found to provide optimal ergonomics for sizes up to 500 mL, while current paper cosmetic tubes are typically limited to a fill volume of 250 mL. Another benefit is better emptying of contents and dispensing control. Another benefit is a smaller occupied area compared to conventional cosmetic tubes with equivalent fill volumes.

[0061] Figures 6a to 6d Another preferred embodiment of the exemplary extrudable fiber-based bottle 10 is shown. In this embodiment, the front panel 4 and the rear panel 5 have the same curvature. Preferably, the maximum length (i.e., measured along the major axis 96) / maximum width (i.e., measured along the minor axis 98) of the molded base is 66 mm and 44 mm, respectively. Preferably, the upper edge 14 of the fiber-based sidewall 12 has a length less than or equal to the length and width of the molded base 20, such that the upper edge 14 is contained within the area occupied by the molded base 20. This configuration is found to be particularly advantageous in minimizing the need for readjustment of gripping force on the extrudable fiber-based bottle 10 during use.

[0062] Figures 7a to 7f A method for forming an exemplary squeezeable bottle 10 according to the present disclosure is shown. The method includes the following steps: a) A flat, elongated blank 60 is cut from a liquid packaging sheet or web, the blank 60 having a first side edge 62, a second side edge 64, an upper edge 114, and a lower edge 116, as shown below. Figure 7a As shown.

[0063] b) Indent the blank 60 so that the crease line 65 extends from the upper edge 114 to the lower edge 116 of the blank 60, as shown. Figure 7b As shown.

[0064] c) Fix the blank 60 onto the fixture 70, which corresponds to the shape of the bottle to be manufactured, such as Figure 7c As shown.

[0065] d) Fold the blank 60 around the clamp 70 so that the first side edge 62 and the second side edge 64 overlap, as shown. Figure 7dAs shown, ultrasonic or heat-sealing energy and pressure are applied to the overlapping first edge 62 and second edge 64 to form an airtight seal 83 and an integral bottle shape with two open ends. Preferably, the seal 83 is a butt joint type or an overlapping side seam type with a smooth outer surface. For example, the seal 83 does not include bulges in the overlapping area.

[0066] e) Seal the molded base 20 to the lower edge 16 of the sidewall 12 to form an impermeable seal 42, and then remove the clamp from inside the bottle 10, as follows. Figure 7e As shown. The molded base has a peripheral surface with an upper edge and a lower edge. The lower edge 16 of the sidewall 12 is located near the upper edge 24 of the peripheral surface of the molded base, but not near the lower edge 26 of the peripheral surface.

[0067] f) The bottle 10 is filled with contents through the opening at the upper edge 14 of the side wall 12, and the upper edge 14 of the side wall 12 is sealed to form an upper seal 29, as shown. Figure 7f As shown.

[0068] This method can preferably fill bottle 10 in a manner similar to that of the current tube.

[0069] An alternative method of forming the exemplary squeezeable bottle 10 may include the following steps: a) to d) as described above; e) Remove the clamp from inside the bottle 10 and seal the upper edge 14 of the side wall 12; f) Fill the contents and seal the molded base 20 to the lower edge 16 of the sidewall 12 to form an impermeable seal 42.

[0070] This alternative method can preferably transport the bottles in a stacked configuration to optimize space while still maintaining ergonomic benefits.

[0071] (1) An impermeable longitudinal seal 83 connecting the two sidewall edges 62, 64 and extending from the lower edge 16 to the upper edge 14, (2) an impermeable seal 42 connecting the fiber sidewall 12 to the molding base 20, and (3) an upper seal 29 for the fiber-based sidewall 12 may all include components that protect the exposed edges from 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 for showering. Edge wicking of cardboard has been extensively studied, for example, in Harju 2018, Master’s Thesis on Liquid Permeation in Food Service Cardboard. Several methods are known in the art to provide edge protection, such as spraying adhesives or other hydrophobic agents, scraping, crimping, or covering cut edges with adhesive plastic strips. Edge protection methods for the upper seal 29 may include spraying, dipping, adding PE-PET-PE strips, or folding. Solutions for applying edge protection to longitudinal seal 83 are known in the art, as described in WO2022185176 or U.S. Patent No. 11,691,791.

[0072] Figure 8a An alternative method of indenting the blank 60 after cutting is shown. According to this method, the crease line 65 extends only partially from the lower edge 116 in the direction of the upper edge 114. This results in the extrudable fiber-based bottle 110 having a flat side 107 that does not extend the entire length of the side panel 102, but only in the lower portion intended for the user to grip, such as... Figure 8b As shown. Figure 8c A side view of an exemplary compressible bottle 110 formed from a blank with partial pleats is shown, wherein pleats 65 extend from the lower edge 116 less than the entire length of the side panel 102. Figure 8c The extrudable fiber-based bottle 110 shown has a higher density than... Figure 6c The extrudable fiber-based bottle 10 shown has better filling volume efficiency. This extrudable fiber-based bottle is formed using the same molding base and preform 60, but with pleats 65 extending the entire length of the side panel 2 from the lower edge 16 to the upper edge 14. Specifically, it has been found that for... Figure 8c In the illustrated embodiment, the front panel 104 and the rear panel 105 are less near the upper edge 114 than Figure 6c The front panel 4 and rear panel 5 of the illustrated embodiment are rigid.

[0073] The extrudable fiber-based bottle disclosed herein preferably includes creases or notches for forming the sidewalls of the liquid carton. The benefits of creases and notches include: (a) minimizing the bending stiffness of the liquid carton board to increase extrudability; (b) increasing grip between the tube and hand, especially under wet conditions; and (c) maximizing product resilience by allowing consumers to fold / roll up the sidewalls when using the extrudable fiber-based bottle.

[0074] Figure 9a and Figure 9b A manufacturing method for indenting liquid carton board webs or sheets 60 is shown. Specifically, Figure 9a The image shows an undeformed liquid cardboard board 60 before indentation. Figure 9b The illustration shows a cardboard sheet 60 being pushed into a precisely cut groove in a prepared (mold or base mold) 131 by an indentation ruler 130, with the cardboard sheet 60 positioned on the groove. This results in a localized variation in the curvature of the sheet 60 while maintaining its overall nominal wall thickness geometry.

[0075] It has been found that deeper indentation depth can increase the flexibility of the board 60 panel when compressed, almost like forming a movable hinge. Preferably, the ratio between indentation depth and width is between 2:1 and 1:2, and more preferably 1:1. For this application, boards comprising bleached chemical pulp, especially SBB (Solid Bleached Board), are preferred because they have excellent mechanical properties and resistance to delamination / microcracks, especially for deep and narrow indentations.

[0076] Figures 10a to 10f It shows the use of Figure 9a and Figure 9b A non-limiting example of the textured pattern 95 on the sidewall 112 obtained by the indentation method described herein, to increase the functionality and usability of the extrudable fiber-based bottle and to provide aesthetic benefits. Specifically, Figure 10a An exemplary squeezeable bottle 110 is shown, which has a pattern that is found to provide a good grip particularly effectively by increasing the contact area between the hand holding the package and the sidewall surface, and ultimately by high friction. Figure 10b An exemplary squeezeable bottle 110 with pattern 95 is shown, which is found to enhance grip in wet conditions particularly effectively by better draining water that accumulates on the surface. Figure 10c An exemplary squeezeable bottle 110 with pattern 95 is shown, which is found to be particularly effective in allowing for more complete extraction of the product from the packaging via folding / rolling up the packaging, resulting in less waste. Figure 10d An exemplary squeezeable bottle 110 with pattern 95 is shown, which has been found to be particularly effective in reducing the local bending stiffness of the walls to reduce the squeezing force required to dispense the product. Figure 10eAn exemplary squeezeable bottle 110 with pattern 95 is shown, which is found to be particularly effective in better indicating the direction of dispensing. Figure 10f An exemplary squeezeable bottle 110 with pattern 95 is shown, and this pattern is found to be particularly effective in better communicating where to squeeze the bottle 110 for optimal performance.

[0077] Figure 11a An exemplary extrudeable fiber-based bottle 110 is shown, which has a crease line 115 on the sidewall 112 in a region just below the upper edge 114 of the seal. Figure 11b As shown, the crease line 115 allows the user to tear open the top of the bottle at the end of its lifespan to access any remaining product and to clean the washing chamber to remove any residue before disposal. The crease line 115 is formed using a process known as grooving, where a knife penetrates 30% of the sheet or blank to create the crease line. The location of the crease line below the upper edge 114 minimizes the chance of accidental tearing during bottle dispensing.

[0078] Figure 12a An exemplary squeezeable bottle 110 is shown, which has a crease line 115 (not shown) on the side wall 112 in an area just below the upper edge 114 of the seal, wherein the crease area is partially or completely covered by a simple crease 117. This configuration is preferred for liquid plates with low rigidity to prevent the crease line from accidentally opening during normal tube operation. According to this configuration, the user first... Figure 12b The crease 117 in the upper edge 114 is unfolded to expose the crease area 115, and then the top of the bottle 110 is torn open as shown in FIG12(c) to access the interior of the bottle 110. This construction can also be achieved with other upper edge folding patterns, such as double folds or saddle folds (not shown).

[0079] Figure 13 This is an isometric view of an exemplary extrudable fiber-based bottle 210, showing assembled fiber-based sidewalls 212 attached to a liquid packaging board molded base 220. The sidewalls have an upper edge 214, a lower edge 216 attached to the base 220, a front panel 204, a rear panel 205, two opposing side panels 202, 203, and a pair of opposing side edges overlapping to form a side seam (not shown). The molded base 220 can be manufactured from a liquid packaging board blanket, heated and thermoformed to achieve a specific shape prior to assembly.

[0080] The substrate of the liquid packaging board forming the fiber-based sidewall 212 preferably comprises lignocellulose fibers obtained through any conventional pulping process, including bleached or unbleached chemical pulping, mechanical pulping, and chemimechanical pulping. The cardboard can be made of more than one layer (typically three layers) and is generally 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. Preferably, functional layers can be on both the inner and outer surfaces 219 forming the liquid-containing portion. The innermost and outermost layers are preferably low-density polyethylene (LDPE) layers to ensure good sealing and liquid tightness. The LDPE in the outermost layer also ensures prevention of moisture absorption due to splashing or wet handling. LDPE also ensures that after consumer disposal and household collection, NIR detectors in industrial sorting facilities can reliably identify the bottle and transfer the packaging to a used beverage carton recycling stream, where multi-material packaging is effectively recycled and the fibers are regained for future use. For example, liquid corrugated board can be a multilayer structure comprising one or more layers made of bleached sulfate pulp. Liquid corrugated board may include a top layer made of bleached sulfate pulp, an intermediate layer made of chemithermomechanical pulp (CTMP), a back layer made of bleached sulfate pulp, and a polyethylene (PE) layer on the outer surfaces of the top and back layers. The liquid corrugated board used may be branded under the trademark Natura. ™ 2PE Board or Natura ™ Barr sells products from the Finnish company Stora Enso. Natura ™ 2PE board is a bleached liquid packaging board with a three-layer fiber construction, consisting of two outer layers made of bleached sulfate pulp and an inner layer made of CTMP (chemithermomechanical pulp). Its top and back sides are made of polyethylene (PE) without any additional high-barrier coating. (Natura) ™ Barr is a bleached liquid packaging board with a three-layer fiber structure, comprising two outer layers made of bleached sulfate pulp and an inner layer made of CTMP (chemithermomechanical pulp). It has a polyethylene (PE) coating on the top side and a multi-layer high-barrier coating on the back side. Functional layers may include barrier layers such as high-density polyethylene (HDPE), foil or thin coatings derived from metallization, cellulose fibers, or applications of water-dispersible nanocomposites including nanosheets. Alternatively, both the inner and outer coatings may be polymeric aqueous dispersions, such as BASF Joncryl. 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 spraying, followed by a drying step. Examples of cardboard using water-based dispersion coatings are Cuforma Natura Aqua+ sold by Stora Enso and ISLA sold by Kotkamills. Preferably, the hole 230 can be sealed with a removable cap that is attached to a metallized laminate of the molded closure using a pressure-sensitive adhesive (not shown).

[0081] Figure 14 yes Figure 13 The figure shows a cross-sectional view of an exemplary compressible fiber-based bottle 210, illustrating an assembled fiber-based sidewall 212 attached to a molded base 220 for a liquid packaging plate. In this embodiment, the inner peripheral surface 223 of the base is recessed within the molded base 220, and a lower portion of the fiber-based sidewall wraps around the lower edge 226 of the molded base 220 such that the lower edge 216 of the fiber-based sidewall is near the upper edge 224 of the peripheral surface but not near the lower edge 226 of the peripheral surface. Preferably, the lower edge 216 of the fiber-based sidewall 212 is at least 1 mm from the lower edge 226 of the peripheral surface. The fiber-based sidewall 212 is attached to the outer peripheral surface 222 of the base, and the lower edge 216 of the fiber-based sidewall 212 is attached to the inner peripheral surface 223 of the base. An impermeable seal 242 is formed between the fiber-based sidewall 212 and the outer peripheral surface 222 of the base. An impermeable seal 243 is also formed between the lower edge 216 of the fiber-based sidewall 212 and the inner peripheral surface 223 of the base, such that the lower edge 216 is located near the upper edge 224 of the peripheral surface but not near the lower edge 226 of the peripheral surface. The seal between the inner peripheral surface 223 of the base and the lower edge 216 can be strengthened by applying an embossed pattern. Preferably, both impermeable seals 242 and 243 are formed by welding, such as exposing the area to hot air. However, other methods of forming impermeable seals 242 and 243 are conceivable, such as ultrasonication or application of glue / adhesive. Figure 14 As shown, an orifice 230 for dispensing a viscous fluid extends into a conduit 232 disposed on the bottom surface of a molding base 220, which is the side opposite to the liquid-receiving surface 228. The conduit may include a conduit opening 234 and a flexible, resilient, narrow-mouth valve 250 disposed within the conduit opening 234. In a preferred embodiment, the exposed edge 235 of the fiber-based molding base 220 facing the conduit opening 234 is scraped to prevent liquid wicking. However, other solutions may be employed to prevent liquid wicking, such as spraying, masking, etc. Figure 14In the illustrated embodiment, valve 250 is mounted on valve seat 252, which is fitted to a recessed area of ​​the liquid packaging plate molding base 220 via an interference fit. Valve seat 252 ensures reliable mounting tolerances and assembly. Valve seat 252 may be made from more than one part to facilitate mounting with valve 250. A lip 236 of the liquid carton plate may be attached to the bottom surface 227 of the molding base 220 to form a temporary seal 244. Lip 236 may include a pull tab to break the temporary seal 244, access and remove valve seat 252 prior to packaging disposal and / or recycling. Preferably, orifice 230 may be sealed with a removable cap that uses a metallized laminate attached to the molded closure with a pressure-sensitive adhesive (not shown).

[0082] Figure 15 An alternative valve assembly embodiment is shown, in which the valve seat 252 includes a flap or disc portion 253 laminated onto a molded base 220 of the liquid packaging plate. The valve seat 252 can be assembled to the molded base 220 before or after assembling the molded base 220 to the sidewall 212 of the fiber-based bottle 210. This design particularly preferably uses ultrasonic welding to assemble the valve seat 252 to the molded base 220 to produce a very strong seal. The disc flange may carry one or more energy-conducting ribs (not shown). In one example, the valve seat 252 is sealed by a 20kHz ultrasonic welding machine (Branson Corporation, Brookfield, Connecticut, USA), model “2000Xd”, which features an unstructured custom ultrasonic generator and anvil. A tear strength exceeding 60N was found at a sealing time of approximately 650ms, an amplitude of 20μm, and a sealing pressure of 60psi. Figure 15 As shown, an exemplary fiber-based bottle may include an additional lip 236 that is also stacked with the flap or disc portion 253 of the valve seat 252 to form a temporary seal 244. The lip 236 may also include a pull tab (such as...). Figure 13 (as shown), to break the temporary seal, access and remove valve seat 252 before packaging disposal and / or recycling. Preferably, hole 230 can be sealed with a removable cap that is attached to a metallized laminate of the molded closure using a pressure-sensitive adhesive (not shown).

[0083] Figure 16An alternative valve assembly embodiment is shown, in which an elastomeric valve 250, such as silicone, is sandwiched between two laminate surfaces 271 and 272. This arrangement is particularly advantageous for easy valve removal because, once the lip 236 is removed, the silicone valve can be easily removed due to its low adhesion to the plate surface via a temporary seal 244. In a preferred embodiment, the exposed edge 235 of the fiber-based molded base 220 facing the pipe opening 234 is scraped to prevent liquid wicking. However, other solutions can also be used to prevent liquid wicking, such as spraying, masking, etc. Preferably, the opening 230 can be sealed with a removable cap that uses a metallized laminate attached to the molded closure with a pressure-sensitive adhesive (not shown).

[0084] Figure 17 An alternative valve assembly embodiment is shown, wherein the vane or disc portion 253 of the valve seat 252 is laminated onto the liquid-receiving surface 228 of the liquid packaging plate molding base 220. Similar to... Figure 15 In an exemplary configuration, a strong bond between the valve seat and the molded base 220 can be achieved via ultrasonic welding: in this case, the disc flange can carry one or more energy-conducting ribs 254. This configuration is also particularly advantageous in promoting the sealing integrity of the valve seat and the molded base 220, as the flange 253 acts as a component resisting internal pressure. This embodiment is also particularly advantageous in protecting exposed burrs 255 from product exposure. Preferably, the hole 230 can be sealed with a removable cap that uses a metallized laminate attached to the molded closure with a pressure-sensitive adhesive (not shown).

[0085] method

[0086] 1) Individual layer thickness

[0087] 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.

[0088] 2) thickness

[0089] 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.

[0090] 3) Basis weight

[0091] 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 weight of 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.

[0092] 4) Pinhole test method

[0093] 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.

[0094] 5) Bottle Leakage Test Method

[0095] This is a test method for measuring the ability of bottles and closure systems to prevent leakage during storage or transportation.

[0096] 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.

[0097] 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.

[0098] 6) Water vapor transmission rate (WVTR) test method

[0099] 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.

[0100] 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%.

[0101] 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.

[0102] 7) Weight reduction test method

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] 8) Water resistance test method

[0108] 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.

[0109] Then dispense 5g ± 1g of the contents from the container; 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.

[0110] 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.

[0111] 9) Bottle squeeze test method

[0112] 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.

[0113] Each bottle is then placed in a compression tester using clamps 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 bottom) 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 the 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.

[0114] 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.

[0115] 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).

[0116] 10) Cyclic sorting test

[0117] The tests were conducted using the TOMRA Autosort NIR device (TOMRA ACT operating system). The entire package was placed in the NIR test bench, and the test results were a record of the main classifier in the field of view. These classifiers are specific to each sorting plant installation, and we recorded the main classifier for a key sorting plant in Europe here. If the classifier is "Tetrapak," it indicates that the package was transferred to the old beverage carton bundles at the sorting center.

[0118] 11) Recyclability in Pulp Stream Based on PTS-RH 021 CAT 2

[0119] 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. Approximately 50 ± 1 g of the test material was then 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 dissociator 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.

[0120] 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."

[0121] 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.

[0122] 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."

[0123] 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".

[0124] 12) Flat pressure test

[0125] 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.

[0126] 13) Bursting strength test

[0127] In the burst strength test, screw the empty bottle or tube into the neck fitting and place it between two pressure blocks mounted on a vise. Apply pressure slowly and evenly through the valve or tube opening until 20 psi (137.89 kPa) is reached and held for 15 seconds. During the test, the valve area should be properly sealed to ensure that the applied pressure is directed only through the valve to prevent any leakage or pressure bypass. Repeat for 3 samples. If the empty bottle or tube withstands the specified pressure range without breaking, the test passes.

[0128] 14) Adhesion strength test

[0129] The adhesive strength test is used to determine the adhesive strength between the bottle's sidewall and the base. First, a point must be marked on the sidewall where the impermeable seal intersects the minor and major axes of the base. Then, four perpendicular lines orthogonal to the impermeable seal need to be drawn. Centered on these lines, a 12.7 mm wide strip must be cut as close to the base as possible without damaging the impermeable seal. Place two opposing strips in the instrument's chuck. Set the chuck speed to 12.7 cm / min. Record the maximum force and whether failure occurs through shoulder peeling or material tearing. Repeat the test on the remaining two strips of the sample. Repeat for three samples. For a 12.7 mm (1 / 2 inch) strip, no peel failure is indicated if the force is <45 N.

[0130] Example Table

[0131] Example

[0132] Table 1 includes examples of squeezable bottles that can be used for storing and dispensing consumer products. All bottles in these examples have comparable dimensions and fill weight. 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, squeezability, flattening crushability, sorting using NIR, and resizing properties. The moisture barrier properties of the sidewalls and bases of the bottles in these examples were also evaluated.

[0133] Example 1 discloses a commercially available paper tube that uses liquid cardboard as sidewalls and has an integrated cap on a welded polyethylene shoulder. An extrusion test was performed using a filling made from Garnier... Sold in the German market Wahre SchätzeHonig SchätzeThe tube for the no-rinse conditioner was tested. While the tube could be considered compressible by the published testing methods, the dispensing experience was suboptimal. Applying a 10mm deflection, an average squeezing force of 38N was found for dispensing an average of 1.6g of product when the tube was full. Using a pressure sensor, it was found that consumers typically apply a squeezing force of approximately 20N to 30N, rarely exceeding 50N. A squeezing force greater than 35N with a 10mm deflection is undesirable. It was also found that by squeezing the tube with a 20mm deflection, an average tube dispensed at least 5g of product. However, this required a squeezing force exceeding 50N and resulted in permanent dents / deformation of the tube.

[0134] Example 2 discloses a squeezable fiber-based bottle as shown in Figure 6, which has an injection-molded HDPE base and sidewalls including double-sided cardboard. In this example, the upper edge is 65mm. The upper edge matches the width of the base to allow consumers to comfortably hold / squeeze the bottle from both sides and from front to back. The base depth is 42mm to fit firmly in the hand when held / squeezed from front to back, providing a good grip without being too bulky. The liquid cardboard is 295gsm New Natura. 2PE, meaning it contains no aluminum foil sold by Stora Enso, has a fiber content of approximately 87%. The sheet is heat-welded to a base and includes scraping. The upper edge is protected with a thin polymer strip. The sheet web is texturized before die-cutting. After die-cutting, the sheet is also indented, as shown in the image. Figure 7b As shown. The molded base is made of HDPE and includes a small silicone valve 50 to facilitate dispensing. Figure 4 As shown, valve 50 is sandwiched between molded base 20 and plastic disc 51. Valve 50 is externally sealed by a removable membrane patch (not shown) to prevent accidental dispensing during dispensing and storage. The bottle has a total fiber content of over 70%. No leaks or pinholes were found in the bottle. The bottle was also found to be waterproof according to the test methods disclosed herein. At 25°C and 60% RH, the sidewall vapor permeability was measured to be less than 20 g / sqm / day. For a 10 mm deflection in the squeeze test, the same product of Example 1 was found to deliver an average dispensing dose of 9 g for a force of 31 N. Furthermore, the bottle did not permanently dent or deform when squeezed with a 10 mm deflection. While the narrow-neck valve 50 was expected to increase the squeezing force required during dispensing, the bottle of Example 2 was found to be easier to squeeze than the bottle of Example 1, allowing consumers to obtain the expected dose of 5 g to 10 g without requiring multiple squeezes. Based on NIR testing, the bottle can also be classified as a liquid carton and meets the minimum level of PTS-RH 021 / 97 catalog number 2 test, with a fiber recovery rate of at least 50%.

Claims

1. A squeezable fiber-based bottle for storing and dispensing viscous liquids, the bottle comprising: A molded base including a liquid-receiving surface with orifices for dispensing a viscous liquid, the molded base having a base periphery having peripheral surfaces including an upper edge and a lower edge, and A fiber-based sidewall having an upper edge, a lower edge, an outer surface, an inner surface, a front panel, a rear panel, and two opposing side panels, the inner surface including a fiber-based sidewall barrier layer, one of the two opposing side panels including a crease line forming a flat portion, and wherein the lower edge of the fiber-based sidewall is attached around the entire peripheral surface of the molded base to form an impermeable seal, wherein the lower edge of the fiber-based sidewall is located near the upper edge of the peripheral surface but not near the lower edge of the peripheral surface, the lower edge of the peripheral surface of the molded base being below the liquid-containing surface, thereby allowing the compressible fiber-based bottle to stand upright.

2. The extrudable fiber-based bottle of claim 1, wherein the two opposing side panels include crease lines forming flat portions in the opposing side panels, preferably, the opposing side panels have a length extending from the lower edge to the upper edge, and wherein the crease lines extend from the lower edge toward the upper edge less than the length of the opposing side panels.

3. The extrudable fiber-based bottle of claim 1, wherein the molding base has a long axis and a short axis, and wherein the upper edge of the fiber-based sidewall has a length less than or equal to the length of the long axis, preferably, the fiber-based sidewall includes a texture formed by indenting the sidewall.

4. The extrudable fiber-based bottle according to claim 1, wherein the fiber-based sidewall has a WVTR of less than 20 g / sqm / day at 25°C and 60% relative humidity.

5. The extrudable fiber-based bottle according to claim 1, wherein the fiber-based sidewall is a liquid packaging plate formed from a preform, preferably, the preform includes non-parallel side edges, more preferably, the preform includes creases forming flat portions in the side panel.

6. The extrudable fiber-based bottle according to claim 1, wherein the extrudable fiber-based bottle comprises at least 50% fiber content.

7. The extrudable fiber-based bottle according to claim 1, wherein the extrudable fiber-based bottle is sortable and recyclable in the liquid carton board stream.

8. The extrudable fiber-based bottle of claim 1, wherein the orifice for dispensing the viscous fluid comprises a narrow-mouth valve.

9. The extrudable fiber-based bottle of claim 1, wherein the lower edge of the fiber-based sidewall is attached to the entire peripheral surface of the molded base near the upper edge of the peripheral surface and is separated from the lower edge of the peripheral surface by at least 1 mm.

10. The extrudable fiber-based bottle of claim 1, wherein the molded base has a front panel curvature and a rear panel curvature, wherein the front panel curvature is different from the rear panel curvature.

11. The extrudable fiber-based bottle of claim 2, wherein the molded base has a front surface, a rear surface, a major axis, a minor axis, and a width along the minor axis, wherein the flat portions on the two opposing side panels have a length, and wherein the width of the molded base along the minor axis exceeds the length of the flat portions by at least 10 mm.

12. The extrudable fiber-based bottle of claim 1, wherein the sidewall includes a perforation that can be torn to access the interior of the container, preferably, the perforation being located below the upper edge, and more preferably, the upper edge being folded to cover the perforation.

13. The extrudable fiber-based bottle of claim 1, wherein the extrudable fiber-based bottle is capable of being crushed into a flat configuration, thereby providing at least 90% product evacuation.

14. The extrudable fiber-based bottle of claim 1, wherein the extrudable fiber-based bottle maintains structural integrity and performance when used in a humid environment.

15. A method for forming a squeezeable bottle, the method comprising the steps of: a. Cut a flat, elongated blank from a liquid packaging plate, the blank having a first side edge, a second side edge, a lower edge, and a top edge; b. Indenting the blank to form crease lines extending from the lower edge toward the upper edge near the first side edge and the second side edge; c. Fold the blank around the clamp to form the sidewall of a compressible bottle having an integral bottle shape, wherein the upper edge and the lower edge form an open end, a front panel, a rear panel and opposing side panels, wherein the opposing side panels include the crease lines that form flat portions in the opposing side panels; d. Overlap the two side edges of the blank and apply heat sealing energy and pressure to the side edges to form a longitudinally airtight joint; e. Provide a molded base having a base perimeter having a peripheral surface including an upper edge and a lower edge; f. Remove the sidewall from the fixture and seal the lower edge of the sidewall to the molded base near the upper edge of the peripheral surface but not near the lower edge of the peripheral surface, thereby forming an impermeable seal; And fill the bottle with its contents and seal the upper edge.

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