Composite fiber beverage container and methods for manufacturing the same

Abstract

A composite fiber beverage container includes a partially spherical fiber pressure vessel capable of holding beverages at pressure. The composite fiber beverage container is made from a plurality of components made from plant-based fiber materials such as bagasse, bamboo, coconut husk, cotton, flax, hemp, jute, kenaf, paper, seaweed, straw, other fiber materials, or combinations thereof. The fiber materials are selected from recycled materials, newly made (e.g., nonrecycled) materials, or from a combination of recycled materials and nonrecycled materials.

Description

COMPOSITE FIBER BEVERAGE CONTAINER AND METHODS FORMANUFACTURING THE SAMECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of and priority, under 35 U.S.C. § 119(e), to U.S. Provisional Application Serial No. 63 / 547,109, filed on November 2, 2023, entitled “COMPOSITE FIBER BEVERAGE CONTAINER AND METHODS FOR MANUFACTURING THE SAME,” the entire disclosure of which is hereby incorporated herein by reference, in its entirety, for all that it teaches and for all purposes.BACKGROUND

[0002] The present disclosure is generally directed to liquid containers, in particular, toward composite fiber beverage bottles.

[0003] In general, beverage containers are designed to provide an economical balance between the amounts of material used and the mechanical demands associated with specific beverage packaging requirements. More specifically, to optimize costs, beverage containers are typically engineered to minimize the amount of material required while still maintaining a sufficient structure to effectively hold a beverage during transport, storage, and use. This optimization can result in a beverage container package design that is functionally adequate under normal use conditions but becomes weak and inadequate when subjected to specific forms of damage.

[0004] Most beverage containers today are made from plastic, glass, or metal and, although these materials offer certain mechanical benefits, there are several issues with using these conventional materials. For instance, plastic containers can require a greater amount of carbon emissions to produce when compared to other materials, glass containers can be costly to manufacture and / or transport, and aluminum is mostly non- biodegradable.BRIEF SUMMARY

[0005] The present disclosure describes a composite fiber beverage container comprising at least a partially spherical form that is capable of holding beverages at pressure (e.g., carbonated beverages, beer, etc.) while offering high recyclability, low weight, high biodegradability, low cost, and a range of renewable resource materials that are capable of being sustainably sourced. The composite fiber beverage container may bemade from one or more plant-based fiber materials. These plant-based fiber materials may include, but are in no way limited to, bagasse, bamboo, coconut husk, cotton, flax, hemp, jute, kenaf, paper (e.g., wood pulp paper, office paper, cardboard, card-paper, newspaper, corrugated paper, etc.), seaweed, straw, other fiber materials, and / or combinations thereof. The fiber materials may be selected from recycled materials, newly made (e.g., nonrecycled) materials, or from a combination of recycled materials and nonrecycled materials.

[0006] The fiber materials may be subjected to a pulping process (e.g., bio extraction, chemical pulping, mechanical pulping, etc.) to produce a base fiber pulp. The base fiber pulp may include long fibers, short fibers, and / or a combination of fiber lengths (e.g., a ratio of long fibers and short fibers, etc.). The base fiber pulp may be used to manufacture one or more molded portions and / or components of the composite fiber beverage container. In some embodiments, the base fiber pulp may be configured (e.g., having specific weights, fiber lengths, etc.) for use in molding and forming processes, such as injection molding, blow molding, rotational molding, thermoforming, compression molding, and / or the like.

[0007] As described herein, the length of the fibers (fiber length) making up the fiber material may be measured by an arithmetic average, a weighted average, etc., and / or combinations thereof. The strength of the components of the composite fiber beverage containers, and / or the finished composite fiber beverage containers, may depend on the fiber length used in the fiber pulp. In general, longer fiber lengths may provide greater strength in a fiber material than shorter fiber lengths. However, the fiber material may include a combination of long fibers and short fibers. Among other things, a balanced mix of long fibers and short fibers may provide a controllable formation and quality of fiber material for use in making the components of the composite fiber beverage container while maintaining consistent and repeatable strength properties.

[0008] As used herein, the term “long fibers” may refer to fibers of a material having a length selected from an upper portion of an overall fiber length range (e.g., greater than, or equal to, 50% of the overall fiber length range, etc.) used in the fiber pulp.

[0009] As used herein, the term “short fibers” may refer to fibers of a material having a length selected from a lower portion of an overall fiber length range (e.g., less than 50% of the overall fiber length range, etc.) used in the fiber pulp.

[0010] As used herein the “overall fiber length range” may correspond to an overall range for a particular fiber material or a combination of fiber materials used to make thefiber pulp. For instance, softwoods “needlewoods” can typically have an overall fiber length range measured between and including 2.7 mm to 5.6 mm, plus or minus 1.0 mm, and hardwoods “broadleaf trees” can typically have an overall fiber length range measured between and including 0.7 mm to 1.7 mm, plus or minus 0.5 mm.

[0011] By way of example, the overall fiber length range for bamboo fibers may measure between and including 1.2 mm to 4.0 mm in length. In this example, long fibers may correspond to fibers having lengths from 2.6 mm to 4.0 mm (e.g., greater than, or equal to, 50% of the overall fiber length range of 2.8 mm), plus or minus 0.1 mm, and short fibers may correspond to fibers having lengths from 1.2 mm to 2.5 mm (e.g., less than, or equal to, 50% of the overall fiber length range of 2.8 mm), plus or minus 0.1 mm. As another example, the overall fiber length range for kenaf fibers may measure between and including 0.6 mm to 2.6 mm in length. In this example, long fibers may correspond to fibers having lengths from 1.6 mm to 2.6 mm (e.g., greater than, or equal to, 50% of the overall fiber length range of 2.0 mm), plus or minus 0.1 mm, and short fibers may correspond to fibers having lengths from 0.6 mm to 1.5 mm (e.g., less than, or equal to, 50% of the overall fiber length range of 2.8 mm), plus or minus 0.1 mm. As yet another example, where a combination of materials are used to form the fiber pulp, such as a mix of bamboo fibers (measuring between and including 1.2 mm to 4.0 mm in length) and cotton stalk fibers (measuring between and including 0.6 mm to 0.8 mm in length), may produce an overall fiber length range of 0.6 to 4.0 mm, plus or minus 0.5 mm. Continuing this example, long fibers may correspond to fibers having lengths from 2.3 mm to 4.0 mm (e.g., greater than, or equal to, 50% of the overall fiber length range of 3.4 mm), plus or minus 0.1 mm, and short fibers may correspond to fibers having lengths from 0.6 mm to 2.2 mm (e.g., less than, or equal to, 50% of the overall fiber length range of 3.4 mm), plus or minus 0.1 mm.

[0012] The composite fiber beverage container may be made from a plurality of individual components that are formed, attached, or otherwise joined together to form a vessel configured to hold a fluid (e.g., beverage) inside an internal volume thereof. The composite fiber beverage container may include an opening disposed at an end of the vessel that is configured to receive a closure seal (e.g., lid, cap, closure top, or bottle top). When sealed with the closure seal, the internal volume of the vessel is closed to an outside, or exterior, of the composite fiber beverage container, and the composite fiber beverage container is capable of holding and maintaining a carbonated beverage (e.g., beer, etc.) at pressure. Employing an at least partially spherical shape, or form, the vesselmay be configured to maintain internal pressures up to 90 pounds per square inch (“PSI”), plus or minus 15 PSI, providing a comparable performance and factor of safety to that of glass beer bottles and / or sparkling wine bottles. For example, most carbonated beer beverages generate an internal pressure between approximately 29 PSI and 51 PSI, plus or minus 10 PSI, in a sealed beverage container. Utilizing a composite fiber beverage container, including the at least partially spherical shaped vessel, allows the composite fiber beverage container to safely hold and contain carbonated beer products at pressure indefinitely with a factor of safety of at least 2.0.

[0013] In some embodiments, a coating or layer may be applied to at least the inside of the pressure vessel of the composite fiber beverage container. Among other things, the coating or layer may add the requisite barrier properties to the molded fiber pressure vessel ensuring the quality of the beverage held therein is maintained over time. This coating or layer may be deposited via vapor deposition, spray coating, adhesive attachment, and / or the like. In some embodiments, the coating or layer may be provided as a barrier material that is mixed with the fibers and / or other materials prior to forming one or more portions of the composite fiber beverage container. For instance, the barrier materials may be combined with the base fiber pulp or fiber materials used to make one or more components of the composite fiber beverage container. In any event, the barrier materials may protect against leaks from a beverage (e.g., a beer, etc.) contained within the pressure vessel of the composite fiber beverage container such as, but in no way limited to, the leak of acids, compounds, fluids, gases, oils, vapors, etc., and / or combinations thereof. In one embodiment, the barrier materials may form a watertight and / or an airtight package for the composite fiber beverage container. Examples of barrier materials may include, but are in no way limited to, an acrylic copolymer, a latex, an acrylic copolymer latex, a polyolefin, polyvinyl, polyvinyl alcohol, etc., and / or combinations thereof. The barrier materials may be formed as a coating, dispersion, emulsion, and / or other mixture or additive. In some embodiments, the barrier materials may be selected to provide sufficient resistance to chemicals, fluids, gases, compounds, vapors, etc., while being food-safe and / or free of fluorocarbons, etc.

[0014] The composite fiber beverage container may include a multiple-part construction for the vessel, the closure, and / or outer tube. In one embodiment, the composite fiber beverage container may include a molded spherical, or at least partially spherical, pressure vessel, a separate end closure, and an outer fiber reinforcement tube. The end closure may be joined (e.g., via adhesive, interference fits, ultrasonic welding, mechanical joining, etc.,and / or combinations thereof) to an open end of the pressure vessel. The pressure vessel may be inserted at least partially within an opening of the fiber reinforcement tube such that an outer portion of the pressure vessel is surrounded by the fiber reinforcement tube. The fiber reinforcement tube may correspond to a substantially cylindrical tube (e.g., an extruded tube, a uniform cylindrical shaped tube, etc.) that is configured to surround the pressure vessel. The pressure vessel may be inserted into the fiber reinforcement tube before or after joining the end closure to the open end of the pressure vessel. Together, the pressure vessel, end closure, and fiber reinforcement tube may form the composite fiber beverage container described herein.

[0015] In one embodiment, the composite fiber beverage container may include a clamshell pressure vessel construction including a molded frame having an integral end closure attached thereto and two semi-spherical long fiber shell portions that are attached thereto. The molded frame may define a longitudinal center of the composite fiber beverage container, a first side of which a first long fiber shell portion is attached, and a second side of which a second long fiber shell portion is attached. The shell portions may be joined, or attached, to the molded frame via a mechanical joint running along a peripheral edge of the frame and the shell portions. Once joined together, the molded frame and shell portions form the clamshell pressure vessel. The clamshell pressure vessel may be inserted, at least partially, into the opening of a fiber tube. The fiber tube may correspond to a substantially cylindrical tube (e.g., an extruded tube, a uniform cylindrical shaped tube, etc.) that is configured to surround the clamshell pressure vessel. The fiber tube may reinforce the clamshell pressure vessel by maintaining a compressive pressure around a cylindrical outer periphery of the clamshell pressure vessel. Among other things, this fiber tube may prevent the joints between the molded frame and the shell portions from separating. Together, the pressure vessel and fiber tube may form the composite fiber beverage container described herein.

[0016] In some embodiments, the composite fiber beverage container may comprise a pressure vessel having an at least partially spherical lower form that is mechanically joined to an at least partially spherical upper form. The upper form may define a neck and end closure of the composite fiber beverage container. The end closure may correspond to a fiber end closure or a metal roll-on closure. In any event, the upper form may be joined to the lower form along a peripheral lap joint interface, a friction joint, interference fit, or other mechanical interface. In one embodiment, the upper form may be glued, welded, adhered, clipped, and / or otherwise attached to the lower form, or vice versa. A lid or capmay be selectively attached to, or detached from, the end closure of the upper form of the composite fiber beverage container. A base cup may be joined to the lower form (e.g., around the at least partially spherical portion of the lower form) providing a cylindrical shape at the bottom of the composite fiber beverage container where the composite fiber beverage container can stand or rest. In some embodiments, the base cup may include a flat surface that is configured to stably support the composite fiber beverage container when placed on a flat surface. Together, the pressure vessel (including the upper form and lower form) and the base cup may form the composite fiber beverage container described herein.

[0017] The composite fiber beverage container may be conveyed (e.g., along a material handling line, conveyor system, etc.) to one or more fluid fill stations of a beverage line. When the composite fiber beverage container is arranged at a fluid fill station, a beverage (e.g., a carbonated beverage, beer, soft drink, etc.) may be dispensed through an opening in the end closure into the internal volume of the pressure vessel. Once filled to a predetermined volume, the end closure of the composite fiber beverage container may be capped, or closed, with a lid or cap (e.g., sealing the beverage inside the pressure vessel at pressure).

[0018] The preceding is a simplified summary of the disclosure to provide an understanding of some aspects of the disclosure. This summary is neither an extensive nor exhaustive overview of the disclosure and its various aspects, embodiments, and configurations. It is intended neither to identify key or critical elements of the disclosure nor to delineate the scope of the disclosure but to present selected concepts of the disclosure in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other aspects, embodiments, and configurations of the disclosure are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.

[0019] Numerous additional features and advantages are described herein and will be apparent to those skilled in the art upon consideration of the following Detailed Description and in view of the figures.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0020] The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present disclosure. These drawings, together with the description, explain the principles of the disclosure. The drawings simplyillustrate preferred and alternative examples of how the disclosure can be made and used and are not to be construed as limiting the disclosure to only the illustrated and described examples. Further features and advantages will become apparent from the following, more detailed, description of the various aspects, embodiments, and configurations of the disclosure, as illustrated by the drawings referenced below.

[0021] Fig. 1 A shows a schematic view of a composite fiber beverage container including a spherical pressure vessel in accordance with embodiments of the present disclosure;

[0022] Fig. IB shows a schematic view of a composite fiber beverage container including an elongate spherical pressure vessel in accordance with embodiments of the present disclosure;

[0023] Fig. 2A shows an exploded schematic perspective view of a clamshell pressure vessel arrangement of a composite fiber beverage container in accordance with an embodiment of the present disclosure;

[0024] Fig. 2B shows a perspective view of a clamshell pressure vessel arrangement of a composite fiber beverage container prior to insertion into a fiber tube in accordance with an embodiment of the present disclosure;

[0025] Fig. 3 A shows a perspective view of an assembled and capped composite fiber beverage container in accordance with embodiments of the present disclosure;

[0026] Fig. 3B shows a perspective view of the components of the composite fiber beverage container shown in Fig. 3 A prior to assembly in accordance with embodiments of the present disclosure;

[0027] Fig. 4A shows a first assembly step of the composite fiber beverage container shown in Figs. 3 A and 3B in accordance with embodiments of the present disclosure;

[0028] Fig. 4B shows a second assembly step of the composite fiber beverage container shown in Figs. 3 A and 3B in accordance with embodiments of the present disclosure;

[0029] Fig. 4C shows a third assembly step of the composite fiber beverage container shown in Figs. 3 A and 3B in accordance with embodiments of the present disclosure;

[0030] Fig. 4D shows a fourth assembly step of the composite fiber beverage container shown in Figs. 3 A and 3B in accordance with embodiments of the present disclosure;

[0031] Fig. 4E shows a fifth assembly step of the composite fiber beverage container shown in Figs. 3 A and 3B in accordance with embodiments of the present disclosure;

[0032] Fig. 4F shows a sixth assembly step of the composite fiber beverage container shown in Figs. 3 A and 3B in accordance with embodiments of the present disclosure;

[0033] Fig. 5 A shows a perspective view of a composite fiber beverage container in accordance with embodiments of the present disclosure;

[0034] Fig. 5B shows an exploded perspective section view of the composite fiber beverage container taken through line “5B-5B” of Fig. 5 A;

[0035] Fig. 5C shows a section view of the composite fiber beverage container taken through line “5B-5B” of Fig. 5 A;

[0036] Fig. 6A shows a schematic detail view of a mechanical interconnection interface between the upper form and the lower form of the composite fiber beverage container before assembly in accordance with embodiments of the present disclosure;

[0037] Fig. 6B shows a schematic detail view of a mechanical interconnection interface between the upper form and the lower form of the composite fiber beverage container after assembly in accordance with embodiments of the present disclosure;

[0038] Fig. 7 shows a schematic block diagram of a fiber material forming system for forming components of the composite fiber beverage container in accordance with embodiments of the present disclosure;

[0039] Fig. 8 shows a schematic block diagram of a fiber material forming system and method for forming components of the composite fiber beverage container in accordance with embodiments of the present disclosure;

[0040] Fig. 9 shows a schematic block diagram of a recycled fiber material forming system for forming components of the composite fiber beverage container in accordance with embodiments of the present disclosure; and

[0041] Fig. 10 is a flow diagram of a method for forming and filling a composite fiber beverage container in accordance with embodiments of the present disclosure.DETAILED DESCRIPTION

[0042] Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Further, the present disclosure may use examples to illustrate one ormore aspects thereof. Unless explicitly stated otherwise, the use or listing of one or more examples (which may be denoted by “for example,” “by way of example,” “e.g.,” “such as,” or similar language) is not intended to and does not limit the scope of the present disclosure.

[0043] The ensuing description provides embodiments only, and is not intended to limit the scope, applicability, or configuration of the claims. Rather, the ensuing description will provide those skilled in the art with an enabling description for implementing the described embodiments. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the appended claims.

[0044] In the drawings, the same or equivalent portions / components may be denoted by the same reference signs. In the description of the embodiments described herein, the description regarding any same or equivalent portions / components may be omitted or simplified as appropriate.

[0045] Various aspects of the present disclosure will be described herein with reference to drawings that may be schematic illustrations of idealized configurations.

[0046] As provided above, there are certain shortcomings to manufacturing beverage containers from non-biodegradable, heavy, or plastic materials. Most of the issues surrounding traditional plastic, glass, and / or metal beverage containers are associated with the environmental impacts due to manufacturing, transport, storage, and recycling or disposal. It is with respect to the above issues and other problems that the embodiments presented herein were contemplated.

[0047] Referring now to Figs. 1 A and IB, schematic views of a composite fiber beverage container 100 are shown in accordance with embodiments of the present disclosure. The composite fiber beverage container 100 may include one or more components made from plant-based or natural fibers. Among other things, these fibers can be sustainably sourced and offer an environmentally friendly alternative to traditional packaging solutions. The composite fiber beverage container 100 may include a pressure vessel 104. The pressure vessel 104 is shown as a spherical pressure vessel 104A in Fig.1 A, and shown as an elongated spherical pressure vessel 104B in Fig. IB. Regardless of the shape or configuration of the pressure vessel 104 described herein, the pressure vessel 104 may be arranged at least partially inside a fiber tube 108.

[0048] In one embodiment, by leveraging at least a partially spherical form, the composite fiber beverage container 100 allows for a greater amount of carbonation in apackaged product over traditional bottle-shaped primaries. This benefit is due, in part, to the reduction or elimination of areas in which a structural failure could occur, for example, through controlling, reducing, or eliminating certain points of intersection (e.g., corners, joints, etc.) on the primary beverage container. Additionally or alternatively, a cylindrical fiber secondary structure, or fiber tube 108, may be applied, interconnected, or otherwise attached to the pressure vessel 104 (e.g., the spherical form of the spherical pressure vessel 104A and / or the elongated spherical pressure vessel 104B) to increase the ability of the composite fiber beverage container 100 to hold contents (e.g., a volume of a fluid or beverage, etc.) at pressure when compared to a vessel without the fiber tube 108. In some embodiments, an end closure 112 may be created from a fiber based moldable material (e.g., short fibers) which may be bonded to the fiber body (e.g., long fibers) of the composite fiber beverage container 100 (e.g., the pressure vessel 104) in a two-shot molding process. The composite fiber beverage container 100 comprising the at least partially spherical form may be placed at least partially inside a fiber tube 108. The fiber tube 108 may surround a portion of the at least partially spherical form and / or the cylindrical fiber structure of the composite fiber beverage container 100. This arrangement of the fiber tube 108 may offer additional compressive support to the composite fiber beverage container 100 (e.g., resisting expansion of the composite fiber beverage container 100 due to pressurized contents, etc.) and support material handling and transport functionality (e.g., similar to the shape and size provided by a traditional bottle).

[0049] In one embodiment, the composite fiber beverage container 100 may be manufactured by forming one or more components from moldable plant based natural fibers. For instance, the end closure 112 may be injection molded (e.g., from moldable fibers, etc.) to form a body of the closure and the longer fiber body may be formed around the end closure 112 in a blow molding process. This bonded two-piece structure may then be placed at least partially into a fiber tube 108. The fiber tube 108 may serve as a structural component that offers additional strength and / or handling properties for the composite fiber beverage container 100. For instance, the fiber tube 108 may provide resistance to swelling or expansion of the pressure vessel 104 inserted therein. Stated another way, the fiber tube 108 may apply a ring of compressive force around the periphery of the pressure vessel 104 when assembled as part of the composite fiber beverage container 100. In one embodiment, an adhesive may be applied to the interior of the fiber tube 108 and / or to a portion of the periphery of the pressure vessel 104 prior to assembly. When assembled together, the adhesive may cure (e.g., by time, temperature,pressure, ultraviolet (“UV”) exposure, etc.) and form a secure joint fixing the fiber tube 108 with the pressure vessel 104 (e.g., fixed axially and / or radially, etc.).

[0050] Although shown as a separate component in Figs. 1 A and IB, the end closure 112 may be integrally formed with the pressure vessel 104. The end closure 112 may be formed to include threads that are capable of engaging with a screw-on cap 116. In any event, the combination of the composite components described above support the ability for the composite fiber beverage container 100 to hold a pressurized fluid such as a carbonated beverage (e.g., beer).

[0051] In one example, the end closure 112 described herein may correspond to a metal component. The end closure 112 may be metal injection molded and formed along with one or more portions of the pressure vessel 104. In some examples, the end closure 112 may be insert-molded with, or attached to, one or more portions of the pressure vessel 104. In any event, when the end closure 112 is made from metal, the end closure 112 may be mechanically separated from the pressure vessel 104 prior to recycling the end closure 112 and / or the pressure vessel 104.

[0052] The features of the composite fiber beverage container 100 shown and described in conjunction with Figs. 1 A and IB may apply to one or more other embodiments, arrangements, and / or configurations of the composite fiber beverage containers described herein.

[0053] Referring to Figs. 2A and 2B, perspective views of a “clamshell” or “split-shell” style of pressure vessel 204 and composite fiber beverage container 200 are shown in accordance with embodiments of the present disclosure. The split-shell pressure vessel 204 shown in Figs 2A and 2B may include a molded frame 206 having an integral end closure 112 attached thereto and two semi-spherical, or elongate semi-spherical, fiber shell portions 204A, 204B that are attached thereto. The molded frame 206 may define a longitudinal center of the composite fiber beverage container 200. For example, the molded frame 206 may include a neck and end closure 112 end with an open frame 206 extending therefrom in a loop shape. A first open side of the loop may include one or more receiving features for attaching with a first fiber shell portion 204A. A second open side of the loop may include one or more receiving features for attaching with a second fiber shell portion 204B. The receiving features on the first and / or second open side may include, but are in no way limited to, a lap joint structure, tongue-and-groove interface, flanged joint, and / or the like. The first fiber shell portion 204A and the second fiber shell portion 204Bmay be formed from a fiber pulp including long fibers. These long fibers may provide additional strength to the structure of the first and second fiber shell portions 204 A, 204B.

[0054] Although configured as having multiple shell portions 204A, 204B attached to a molded frame 206, once joined together, the split-shell pressure vessel 204 of the composite fiber beverage container 200 shown in Figs. 2A and 2B may correspond to the pressure vessel 104 described in conjunction with the schematic views of Figs. 1 A and IB.

[0055] In some embodiments, the first and second shell portions 204A, 204B may be joined, or attached, to the molded frame 206 via a mechanical joint running along a peripheral edge of the frame 206 and the shell portions 204A, 204B. This mechanical joint may include the one or more receiving features and corresponding mating features associated with each of the first and second shell portions 204A, 204B. An adhesive (e.g., a food-safe adhesive, etc.) may be dispensed between the first shell portion 204A and the first open side of the loop of the molded frame 206 and between the second shell portion 204B and the second open side of the loop of the molded frame 206. The adhesive may be time, temperature, pressure, and / or UV cured joining the first and second halves (e.g., the first shell portion 204A and the second shell portion 204B) of the split-shell pressure vessel 204 together with the molded frame 206 (shown in Fig. 2B). In any event, once joined together, the molded frame 206 and shell portions 204 A, 204B form the “clamshell” or split-shell pressure vessel 204 of the composite fiber beverage container 200. As illustrated in Fig. 2A, the first fiber shell portion 204A may be moved in a first shell attachment direction 205 A (e.g., toward a radial center of the split-shell pressure vessel 204) such that the first fiber shell portion 204A contacts the molded frame 206, and the second fiber shell portion 204B may be moved in a second shell attachment direction 205B (e.g., toward the radial center of the split-shell pressure vessel 204) such that the second fiber shell portion 204B contacts the molded frame 206.

[0056] In some embodiments, the joined split-shell pressure vessel 204 may be inserted, at least partially, into the opening of a fiber tube 108, base cup, or reinforcement structure. As shown in Fig. 2B, the split-shell pressure vessel 204 may be axially aligned with an axis of a fiber tube 108 and the fiber tube 108 may be moved axially relative to the splitshell pressure vessel 204, and / or vice versa, in a tube engagement direction 207 such that an internal area of the fiber tube 108 is arranged to contact and / or surround an outer peripheral surface of the split-shell pressure vessel 204. The fiber tube 108 may be positioned or otherwise arranged relative to the split-shell pressure vessel 204 such that the upper edge 208 of the fiber tube 108 aligns with the upper limit line 210 shown around thecircumference of the pressure vessel 104 in Fig. 2B. In one embodiment, the upper edge 208 of the fiber tube 108 may be arranged offset a distance from the top end 110A of the composite fiber beverage container 200 (e.g., at or about the start of the curvature of the uppermost portion of the split-shell pressure vessel 204, etc.). Stated another way, the fiber tube 108 may be positioned relative to the split-shell pressure vessel 204 such that the upper edge 208 does not extend beyond the top end 110A of the composite fiber beverage container 200, and a flat base portion of the fiber tube 108 is provided at the bottom end 110B of the composite fiber beverage container 200 (e.g., as illustrated in the schematic diagrams of the pressure vessel 104 and the fiber tube 108 shown in Figs. 1 A and IB).

[0057] The fiber tube 108 may correspond to a substantially cylindrical tube (e.g., an extruded tube, a uniform cylindrical shaped tube, etc.) that is configured to surround at least a portion of the periphery of the split-shell pressure vessel 204. The fiber tube 108 may reinforce the split-shell pressure vessel 204 by, for example, maintaining a compressive pressure around a cylindrical outer periphery of the split-shell pressure vessel 204. In one embodiment, an adhesive may be applied to the interior of the fiber tube 108 and / or to a portion of the periphery of the split-shell pressure vessel 204 prior to assembly. When assembled together, the adhesive may be time, temperature, pressure, and / or UV cured to form a secure joint fixing the fiber tube 108 with the split-shell pressure vessel 204 (e.g., fixed axially and / or radially, etc.). Among other things, this fiber tube 108 may prevent the joints between the molded frame 206 and the first and second shell portions 204A, 204B from separating when contents under pressure are contained and sealed within the internal volume 230 of the split-shell pressure vessel 204. Further, the clamshell design of the split-shell pressure vessel 204 shown in Figs. 2A and 2B may reduce the number of areas that are susceptible to seam failure. Together, the split-shell pressure vessel 204 and fiber tube 108 may form the composite fiber beverage container 100, 200 described herein. In some embodiments, the fiber tube 108 may provide a cylindrical outer surface and a flat base that can be used in traditional material handling equipment (e.g., conveyor systems, pick-and-place devices, filling, and / or other assembly equipment used in the beverage and / or packaging industry).

[0058] Figs. 3 A and 3B show various perspective views of a composite fiber beverage container 300 in accordance with embodiments of the present disclosure. As shown in Figs. 3 A and 3B, the composite fiber beverage container 300 may be configured to include an upper form (e.g., an upper shell portion 304A) and a lower form (e.g., a lower shell portion 304B) that are joined together around a radial peripheral seam 306 (e.g., via a lapjoint, etc.) forming the pressure vessel 304 of the composite fiber beverage container 300 in accordance with embodiments of the present disclosure. This multi-piece pressure vessel 304 may be inserted into a fiber tube 108, base cup, or other reinforcement structure. The fiber tube 108 may be similar, if not identical, to the fiber tube 108 described above. When the multi-piece pressure vessel 304 is inserted into the fiber tube 108, the joint (e.g., the joint seam 306, etc.) between upper shell portion 304 A and the lower shell portion 304B may be completely surrounded by a wall thickness of the fiber tube 108. The fiber tube 108 may reinforce the multi-piece pressure vessel 304 by, for example, maintaining a compressive pressure around a cylindrical outer periphery of the multi-piece pressure vessel 304. The adhesive may be applied to the interior of the fiber tube 108 and / or to a portion of the periphery of the multi-piece pressure vessel 304 prior to assembly. When assembled together, the adhesive may be time, temperature, pressure, and / or UV cured to form a secure joint fixing the fiber tube 108 with the multi-piece pressure vessel 304 (e.g., fixed axially and / or radially, etc.) As can be appreciated, this arrangement offers a reinforced structure for the composite fiber beverage container 300. The assembled composite fiber beverage container 300, shown in Fig. 3 A, includes a cap 116 fastened to the end closure 112 of the composite fiber beverage container 300. Although shown as a screw-on metal cap 116, it should be appreciated that the cap 116 may correspond to a press-fit lid, compression fit cap, or other clinching type of cap made of any material that is configured to seal the internal volume of the split-shell pressure vessel 204 from the exterior of the split-shell pressure vessel 204.

[0059] Fig. 3B shows a perspective view of the components of the composite fiber beverage container 300 shown in Fig. 3 A prior to assembly, in accordance with embodiments of the present disclosure. As illustrated in Fig. 3B, the upper shell portion 304 A of the multi-piece pressure vessel 304 may include a formed joint band 306 A that inserts into a recess 306B of the lower shell portion 304B. Although not shown, in one embodiment, the joint band 306A may be formed in the lower shell portion 304B and the recess 306B may be formed in the upper shell portion 304A. The joint band 306A may correspond to portion of the upper shell portion 304 A having an outer peripheral surface of the upper shell portion 304A that is less than the outer diameter of the composite fiber beverage container 300 and / or the outermost diameter of the upper shell portion 304A or lower shell portion 304B. In one embodiment, the joint band 306 A may be sized to match or fit (e.g., slip fit, interference fit, press fit, etc.) with the internal diameter of the lower shell portion 304B (e.g., at the open end thereof). An adhesive may be applied to thesurface of the joint band 306 A prior to mating the upper shell portion 304 A and lower shell portion 304B together. When the upper shell portion 304 A and lower shell portion 304B are assembled together, this adhesive may be time, temperature, pressure, and / or UV cured to form a secure lap joint fixing the lower shell portion 304B with the upper shell portion 304A. In some embodiments, the adhesive described herein may correspond to a food-safe gasket material (e.g., liquid, gel, etc.) that can be heated and applied prior to assembly.

[0060] In some embodiments, the upper shell portion 304 A may include an integrally formed end closure 112. The end closure 112 may be formed to include threads that are capable of engaging with, and / or receiving, a screw-on cap 116.

[0061] Figs. 4A-4F show a sequence of assembly steps in forming the composite fiber beverage container 300 including the upper shell portion 304A, lower shell portion 304B, and fiber tube 108 illustrated in Figs. 3 A and 3B, in accordance with embodiments of the present disclosure. Although a particular assembly order or sequence is shown in Figs. 4A- 4F, it should be appreciated that the composite fiber beverage container 300 may be assembled in a different order or sequence than that shown in Figs. 4A-4F and the assembly steps are not limited to the sequence shown in Figs. 4A-4F.

[0062] In one example assembly step shown in Fig. 4A, the lower shell portion 304B may be arranged adjacent an open end of the fiber tube 108 such that a longitudinal axis of the lower shell portion 304B aligns with the longitudinal axis of the fiber tube 108. In some embodiments, an adhesive may be applied to the interior of the fiber tube 108 and / or to a portion of the periphery of the lower shell portion 304B prior to the next assembly step. When finally assembled together (e.g., as shown in Fig. 4F), the adhesive may be time, temperature, pressure, and / or UV cured to form a secure joint fixing the fiber tube 108 with the lower shell portion 304B.

[0063] The lower shell portion 304B may be inserted into the opening of the fiber tube 108 as shown in Fig. 4B and then moved (e.g., axially) into a first seated position as shown in Fig. 4C (e.g., in a direction toward the bottom end HOB of the fiber tube 108). The upper shell portion 304 A may be prepared to engage with the lower shell portion 304B, as shown in Fig. 4D, by applying an adhesive to the surface of the joint band 306A prior to mating the upper shell portion 304 A and lower shell portion 304B together. When the upper shell portion 304 A and lower shell portion 304B are assembled together, as shown in Fig. 4E, this adhesive may spread along the periphery of the interface between the lower shell portion 304B and the joint band 306A of the upper shell portion 304A. Theupper shell portion 304 A may be moved axially relative to the lower shell portion 304B, for example, until a shoulder of the joint band 306A contacts an upper edge of the lower shell portion 304B. The upper shell portion 304 A and lower shell portion 304B, corresponding to the multi-piece pressure vessel 304 of the composite fiber beverage container 300 may be further moved into the fiber tube 108, where the fiber tube 108 surrounds the joint seam 306, as shown in Fig. 4F. The adhesive between the upper shell portion 304A and lower shell portion 304B and / or the adhesive between the multi-piece pressure vessel 304 and the fiber tube 108 may then be time, temperature, pressure, and / or UV cured to form secure joints fixing the components of the composite fiber beverage container 300 together, for example, in the assembly arrangement shown in Fig. 4F.

[0064] In one embodiment, the upper shell portion 304 A and lower shell portion 304B may be preassembled, prior to coupling with the fiber tube 108, to form the assembly arrangement shown in Fig. 4F.

[0065] Figs. 5A-5C show various views of a composite fiber beverage container 500 comprising an upper shell portion 504A, a lower shell portion 504B, and a base cup 508 in accordance with embodiments of the present disclosure. The composite fiber beverage container 500 may include an upper shell portion 504A (e.g., upper form) joined with a lower shell portion 504B (e.g., lower form) to form the pressure vessel 504 of the composite fiber beverage container 500. The upper shell portion 504A and lower shell portion 504B of Figs. 5A-5C may be similar, if not identical, to the upper shell portion 304A and lower shell portion 304B described at least in conjunction with Figs. 3A-4F. In some embodiments, the upper shell portion 504A may join with the lower shell portion 504B via a lap joint interface.

[0066] The upper shell portion 504A may include a semi -spherical shape (e.g., including large radiuses) that joins with a neck 510 and end closure 112. The semi -spherical shape of the upper shell portion 504A provides reduced areas of stress concentration and increases the ability of the pressure vessel 504 to hold fluid contents at pressure. For instance, utilizing a semi -spherical shape for the upper shell portion 504A allows for an even distribution of pressurized forces across surface of the internal volume of the composite fiber beverage container 500. One or more cap attachment features may be formed at the end closure 112. These cap attachment features may include, but are in no way limited to, threads, lips, flanges, protrusions, etc., and / or combinations thereof. In one example, the cap attachment features may include a 38 mm roll-on, pilfer-proof (“ROPP”) compatible closure and finish.

[0067] The lower shell portion 504B, as illustrated in Figs. 5B and 5C, may include a semi-spherical shaped end 512 that includes, for example, large radiuses and / or surfaces that are absent sharp corners. This semi -spherical shaped end 512 of the lower shell portion 504B decreases potential areas of stress concentration while increasing the ability of the pressure vessel to hold fluid contents at pressure. For instance, utilizing a semi- spherical shape for the lower shell portion 504B, as well as the upper shell portion 504A, allows for an even distribution of pressurized forces across the surfaces of the internal volume of the composite fiber beverage container 500. In some embodiments, the lower shell portion 504B may include a cup seat 516, or region, that is configured to receive and / or engage with a base cup 508, fiber tube 108, and / or other reinforcement structure. The cup seat 516 may include a shoulder and / or a flange that provides one or more surfaces that fit with an opening, or open end, of a base cup 508 and prevent axial movement of the base cup 508 relative to the pressure vessel 504 of the composite fiber beverage container 500.

[0068] As shown in Figs. 5B and 5C, the upper shell portion 504A of the pressure vessel 504 may include a formed joint band 506A that inserts into a joint recess 506B of the lower shell portion 504B. In some embodiments, however, the joint band 506A may be formed in the lower shell portion 504B (e.g., rather than the upper shell portion 504A, as shown) and the joint recess 506B may be formed in the upper shell portion 504A (e.g., rather than in the lower shell portion 504B, as shown). As illustrated in Figs. 5B and 5C, the joint band 506A corresponds to portion of the upper shell portion 504A having an outer peripheral surface of the upper shell portion 504A that is less than an outermost diameter of the composite fiber beverage container 500 and / or an outermost diameter of the upper shell portion 504A. The joint band 506A may be sized to match or fit (e.g., slip fit, interference fit, press fit, etc.) with the internal diameter of the joint recess 506B disposed in the lower shell portion 504B (e.g., at the open end thereof). An adhesive may be applied to the surface of the joint band 506A and / or the joint recess 506B prior to mating the upper shell portion 504A and the lower shell portion 504B together. When the upper shell portion 504A and the lower shell portion 504B are assembled together, this adhesive may be time, temperature, pressure, and / or UV cured to form a secure lap joint fixing the upper shell portion 504A and the lower shell portion 504B together.

[0069] In one embodiment, the upper shell portion 504A and the lower shell portion 504B may be made from a kraft fiber pulp with added hemp extract (e.g., each having a 50-point (0.050 inch) and / or 28-point (0.028 inch) weights at the joint). Using this fibermaterial, at a 2.5 mm wall thickness for the lap joint, the pressure vessel may contain a pressure of 90 PSI, without failing. Moreover, this structural arrangement of the pressure vessel may allow the contents to be held above 90 PSI for a specific period of time without swelling or expanding. In some embodiments, the lap joint connecting the upper shell portion 504A and the lower shell portion 504B may be configured to resist a shear stress of 3.5 MPa, plus or minus 0.5 MPa, at 90 PSI. For instance, the adhesive used in the lap joint (e.g., between the joint band 506A of the upper shell portion 504A and the joint recess 506B of the lower shell portion 504B) may be selected to possess a shear strength that exceeds 3.57 MPa, or 518 PSI.

[0070] The base cup 508 may include an open end (that receives a spherical end 512 of the lower shell portion 504B) and a support end including a flat surface 518 (e.g., for supporting the composite fiber beverage container 500 when assembled). An adhesive may be applied to the interior of the base cup 508 and / or to a portion of the periphery of the cup seat 516 of the lower shell portion 504B prior to assembly together. In some embodiments, an overlap glue joint may be used to attach the base cup 508 to the lower shell portion 504B of the composite fiber beverage container 500. When the base cup 508 is assembled to the lower shell portion 504B and cup seat 516, the adhesive may be time, temperature, pressure, and / or UV cured to form a secure joint fixing the base cup 508 with the lower shell portion 504B and pressure vessel 504.

[0071] Referring to Fig. 5B, an exploded perspective section view of the composite fiber beverage container 500, taken through line “5B-5B” of Fig. 5 A, is shown in accordance with embodiments of the present disclosure. In some embodiments, the composite fiber beverage container 500, and / or one or more components thereof, may be centerline symmetrical about the longitudinal axis 502. As illustrated in Fig. 5B, the composite fiber beverage container 500 may be made from a plurality of components. These components may include, but are in no way limited to, the lower shell portion 504B, the upper shell portion 504A, and a base cup 508. In some embodiments, the base cup 508 may be attached to and joined with the lower shell portion 504B prior to attaching the upper shell portion 504A to the lower shell portion 504B. The internal volume 230 of the pressure vessel 504 (e.g., the upper shell portion 504A and the lower shell portion 504B) may be closed to an exterior of the composite fiber beverage container 500 by a cap 116 or lid attached to the opening 520 of the end closure 112.

[0072] Fig. 5C shows a section view of the composite fiber beverage container 500 taken through line “5B-5B” of Fig. 5A. As illustrated in Fig. 5C, a lap joint may be formedbetween the upper shell portion 504A and the lower shell portion 504B of the composite fiber beverage container 500. A detail view of the lap joint is shown including a joint seam 506 that runs from an exterior of the composite fiber beverage container 500 to an internal volume 230 of the composite fiber beverage container 500. The lap joint and joint seam 506 may be formed having an S-shape or Z-shape. The adhesive applied between the upper shell portion 504A and the lower shell portion 504B (e.g., at the lap joint) may be applied to one or more surfaces of the joint seam 506.

[0073] In some embodiments, the composite fiber beverage container 100, 300, 500 may employ a mechanical interconnection between the upper shell portion 304A, 504A (e.g., “Upper Form”) and the lower shell portion 304B, 504B (e.g., “Lower Form”). This mechanical interconnection may be used alone or in conjunction with an adhesive attachment, as previously described. As illustrated in Figs. 6A and 6B, the upper shell portion 304A, 504A (e.g., “Upper Form”) and the lower shell portion 304B, 504B (e.g., “Lower Form”) may include a mechanical clip joint interface. For instance, the upper shell portion 304A, 504A (e.g., “Upper Form”) may include a first tab 604A arranged around an end peripheral edge of the shell that faces inward (e.g., in a direction toward the longitudinal axis 502 or center of the composite fiber beverage container 100, 300, 500). The lower shell portion 304B, 504B (e.g., “Lower Form”) may include a second tab 604B arranged around an end peripheral edge of the shell that faces outward (e.g., in a direction toward the exterior of the composite fiber beverage container 100, 300, 500). Prior to assembly, as shown in Fig. 6A, the first and second tabs 604A, 604B are arranged in a position close to interference contact with one another. As the upper shell portion 304 A, 504A (e.g., “Upper Form”) and the lower shell portion 304B, 504B (e.g., “Lower Form”) are moved axially closer to one another, the first and second tabs 604A, 604B may contact and the form of each tab 604A, 604B may flex until the first and second tabs 604A, 604B pass one another and clip together in an assembled state, as shown in Fig. 6B. A fiber tube 108 that is similar, if not identical, to the fiber tube 108 described in conjunction with the figures above, may then be placed around the outer periphery of the pressure vessel 104, 304, 504 ensuring the upper shell portion 304A, 504A (e.g., “Upper Form”) and the lower shell portion 304B, 504B (e.g., “Lower Form”) remain connected at the mechanical interface. In some embodiments, the fiber tube 108 may be assembled to the lower shell portion 304B, 504B (e.g., “Lower Form”) prior to attaching the upper shell portion 304A, 504A (e.g., “Upper Form”), for example, creating a channel in which the upper shell portion 304A, 504A (e.g., “Upper Form”) can be inserted, as shown in Fig. 6A. Byadjusting the profile of the edge (e.g., the tabs 604A, 604B) of the upper shell portion 304A, 504A (e.g., “Upper Form”) and the lower shell portion 304B, 504B (e.g., “Lower Form”), a friction lock may be provided by the arrangement shown in Figs. 6A and 6B.

[0074] Fig. 7 shows a schematic block diagram of a fiber material forming system 700 for forming one or more components of the composite fiber beverage container 100, 200, 300, 500 in accordance with embodiments of the present disclosure. These components may include, but are in no way limited to, the first fiber shell portion 204A, second fiber shell portion 204B, molded frame 206, upper shell portion 304A, 504A, lower shell portion 304B, 504B, fiber tube 108, base cup 508, and / or other feature or component described herein. The system 700 includes obtaining the raw fiber materials including primary and secondary fibers. These fibers may then be prepared by refining the materials with water. Next, the water is extracted from the fiber mixture by a forming operation and tool. Water is further extracted from the formed material by a pre-pressing operation and tool. The final form of the component is then moved to a trimming station where excess material is removed from the mold and the final component shape is cleaned. The final component is then directed to a quality inspection station where visual and / or measurement checks are made to the components. In some embodiments, the quality inspection station may utilize a helium leak check machine to determine an ability of the final component to hold pressure.

[0075] Fig. 8 shows a schematic block diagram of a fiber material forming system and method 800 for forming components of the composite fiber beverage container 100, 200, 300, 500 in accordance with embodiments of the present disclosure. The binder stabilized fabric may correspond to a fiber-based product for making one or more components of the composite fiber beverage container 100, 200, 300, 500 described herein, including, but in no way limited to, the first fiber shell portion 204A, second fiber shell portion 204B, molded frame 206, upper shell portion 304A, 504A, lower shell portion 304B, 504B, fiber tube 108, base cup 508, and / or other feature or component of the composite fiber beverage container 100, 200, 300, 500. In some embodiments, the fiber-based product may be arranged as a laminate having different, alternating, orientations of fiber placement directions. Such an arrangement may offer increased strength in the material (e.g., by providing resistance to multiple directions of applied force, etc.). The laminate fiber material may be preformed (e.g., by applying heat and pressure to a shape of the product) to form a stabilized preform. This preform may then be transferred to a mold and a food-safe resin or coating may be applied to the component being molded. After the component is cured, the molded shaped component is released from the molding system.

[0076] Fig. 9 shows a schematic block diagram of a recycled fiber material forming system 900 for forming components of the composite fiber beverage container 100, 200, 300, 500 in accordance with embodiments of the present disclosure. These components may include, but are in no way limited to, the first fiber shell portion 204A, second fiber shell portion 204B, molded frame 206, upper shell portion 304A, 504A, lower shell portion 304B, 504B, fiber tube 108, base cup 508, and / or other feature or component described herein. The system 900 may include (a) a recycled material collection process and system, (b) a pulp preparation process, and (c) a dry-press technology system, and / or (d) a wet-press technology system. Once formed, the component parts are trimmed and finished for assembly as (e) the composite fiber beverage container. At least one assembly method for creating the composite fiber beverage container is described in conjunction with Figs. 3 A-5C above.

[0077] Fig. 10 is a flow diagram of a method for forming and filling a composite fiber beverage container in accordance with embodiments of the present disclosure. The method may begin at step 1004 by forming the lower shell (e.g., lower form or lower shell portion 304B, 504B, etc.) of the composite fiber beverage container. The lower shell may include one or more of the features described in conjunction with the lower form (e.g., lower shell portion 304B, 504B, etc.) of Figs. 1 A-6B. The method includes forming the upper shell (e.g., upper form or upper shell portion 304A, 504A, etc.) of the composite fiber beverage container (step 1008). The upper shell may include one or more of the features described in conjunction with the upper form (e.g., upper shell portion 304A, 504A, etc.) of Figs. 1 A-6B. The method includes forming the base cup 508 of the composite fiber beverage container (step 1012). The base cup 508 may include one or more of the features described at least in conjunction with Figs. 5A-5C.

[0078] The upper shell, the lower shell, and the base cup 508 may be manufactured by any forming method or methods described herein.

[0079] One example forming method includes a thick-walled molded fiber packaging method. The thick-walled molded package is crafted from a single mold and may feature a wall thickness ranging from 0.1875 inches to 0.375 inches. One side of the molded component is often smooth, while the other side is rougher. Although this type of method may be used for any component of the composite fiber beverage container, the strength of the components produced by this method may offer benefits for the base cup 508 or thefiber tube 108 components that safeguard portions of the composite fiber beverage container.

[0080] Another example method may include a transfer molded method. Produced using a single forming and transfer mold, transfer molded fiber packaging may provide a wall thickness of 0.125 inches to 0.1875 inches. Molds produced using this method may include a smooth surface on one side and may provide a cost-effective manufacturing method for exterior components of the composite fiber beverage container.

[0081] Yet another example method of forming the components of the composite fiber beverage container includes a thermoforming method. Thermoformed molded fiber components may be made with heated molds and can include wall thicknesses of 0.09375 inches to 0.15625 inches. These thin-walled products provide uniformly smooth surfaces, intricate details, and minimal draft angles. Although the walls produced using thermoforming are slim, when compared to the other forming methods, the walls are dense, appearing like plastic while maintaining strong properties.

[0082] In some embodiments, processed molded pulp products may undergo additional steps beyond the core manufacturing process. These secondary steps can involve dyeing, coating, printing, die-cutting, and / or chemical enhancements. The secondary steps may include applying specialty coatings to surfaces of the components (e.g., providing barrier properties to the molded fiber components, etc.).

[0083] The method includes joining the upper shell to the lower shell (step 1016). In some embodiments, an adhesive may be applied to a joint band 306A, 506A of the upper shell or the lower shell before assembly, as described in conjunction with Figs. 3 A, 3B, 4D, 4E, 5A-5C, etc.

[0084] The method includes joining the base cup 508 to the lower shell of the composite fiber beverage container (step 1020). In one embodiment, the base cup 508 may be attached to the lower shell prior to attaching the upper shell to the lower shell. In any event, the base cup 508 is attached to the lower shell as described in conjunction with the assembly of the composite fiber beverage container of Figs. 5A-5C. Once the upper shell (upper form) and the lower shell (lower form) are joined to form the pressure vessel 140, 340, 540 and the base cup is attached to the pressure vessel, the composite fiber beverage container is formed.

[0085] The method may include conveying the composite fiber beverage container to a beverage filling station. The beverage filling station may correspond to a carbonatedbeverage (e.g., beer) dispenser. In some embodiments, a conveyor may be used to transport the composite fiber beverage container through the filling station.

[0086] Once at the filling station, the opening 520 of the end closure 112 of the composite fiber beverage container may be aligned with a dispensing nozzle of the filling station and the beverage may be dispensed through the opening into the internal volume 230 of the composite fiber beverage container (step 1028).

[0087] The filled composite fiber beverage container may then be capped by applying a cap 116 or lid to seal the opening 520 of the end closure 112 of the composite fiber beverage container (step 1032). In some embodiments, the cap 116 or lid may be applied by a capping station that places a cap onto the end closure 112 of the composite fiber beverage container and applies a torque to the cap 116 engaging threads in the cap 116 with mating threads of the end closure 112. Once sealed, the capped and filled composite fiber beverage container may hold and maintain pressures up to, and including, 90 PSI, without failing, over time.

[0088] Any of the steps, functions, and operations discussed herein can be performed continuously and automatically.

[0089] While the flowcharts have been discussed and illustrated in relation to a particular sequence of events, it should be appreciated that changes, additions, and omissions to this sequence can occur without materially affecting the operation of the disclosed embodiments, configuration, and aspects.

[0090] The exemplary systems and methods of this disclosure have been described in relation to composite fiber beverage containers and methods of forming, shaping, and filling the same. However, to avoid unnecessarily obscuring the present disclosure, the preceding description omits a number of known structures and devices. This omission is not to be construed as a limitation of the scope of the claimed disclosure. Specific details are set forth to provide an understanding of the present disclosure. It should, however, be appreciated that the present disclosure may be practiced in a variety of ways beyond the specific detail set forth herein.

[0091] A number of variations and modifications of the disclosure can be used. It would be possible to provide for some features of the disclosure without providing others.

[0092] It should be appreciated that inventive concepts cover any embodiment in combination with any one or more other embodiments, any one or more of the features disclosed herein, any one or more of the features as substantially disclosed herein, any one or more of the features as substantially disclosed herein in combination with any one ormore other features as substantially disclosed herein, any one of the aspects / features / embodiments in combination with any one or more other aspects / features / embodiments, use of any one or more of the embodiments or features as disclosed herein. It is to be appreciated that any feature described herein can be claimed in combination with any other feature(s) as described herein, regardless of whether the features come from the same described embodiment.

[0093] References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” “some embodiments,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in conjunction with one embodiment, it is submitted that the description of such feature, structure, or characteristic may apply to any other embodiment unless so stated and / or except as will be readily apparent to one skilled in the art from the description. The present disclosure, in various embodiments, configurations, and aspects, includes components, methods, processes, systems and / or apparatus substantially as depicted and described herein, including various embodiments, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the systems and methods disclosed herein after understanding the present disclosure. The present disclosure, in various embodiments, configurations, and aspects, includes providing devices and processes in the absence of items not depicted and / or described herein or in various embodiments, configurations, or aspects hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease, and / or reducing cost of implementation.

[0094] The foregoing discussion of the disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the disclosure are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the embodiments, configurations, or aspects of the disclosure may be combined in alternate embodiments, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoingdisclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the disclosure.

[0095] Moreover, though the description of the disclosure has included description of one or more embodiments, configurations, or aspects and certain variations and modifications, other variations, combinations, and modifications are within the scope of the disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights, which include alternative embodiments, configurations, or aspects to the extent permitted, including alternate, interchangeable and / or equivalent structures, functions, ranges, or steps to those claimed, whether or not such alternate, interchangeable and / or equivalent structures, functions, ranges, or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.

[0096] Exemplary aspects are directed to composite fiber beverage container, comprising: a first fiber shell portion comprising a first open end and a first elongate cylindrical portion terminating at a closed first semi-spherical end; and a second fiber shell portion comprising a second open end and a second elongate cylindrical portion interconnected with a second semi-spherical end, wherein an opening is disposed adjacent the second semi-spherical end; wherein the first fiber shell portion is joined to the second fiber shell portion along a circumferential lap joint at the first open end of the first fiber shell portion and the second open end of the second fiber shell portion.

[0097] Any one or more of the above aspects include a base cup comprising an open end, a hollow cylindrical portion, and a flat surface disposed at a closed end of the base cup opposite the open end of the base cup, wherein the base cup is attached to the first fiber shell portion such that the closed first semi-spherical end is disposed inside the hollow cylindrical portion and the flat surface is offset a distance from the closed first semi-spherical end of the first fiber shell portion. Any one or more of the above aspects include a joint adhesive disposed between an outer circumferential surface of a joint band of the second fiber shell portion and an inner circumferential surface of a joint recess of the first fiber shell portion, and wherein the inner circumferential surface of the joint recess surrounds the outer circumferential surface of the joint band. Any one or more of the above aspects include a base adhesive disposed between a portion of the first fiber shell portion and an internal surface of the hollow cylindrical portion of the base cup. Any one or more of the above aspects include wherein the joint band of the second fiber shellportion and the joint recess of the first fiber shell portion is made from kraft fiber comprising an amount of hemp extract. Any one or more of the above aspects include wherein the opening disposed adjacent the second semi-spherical end of the second fiber shell portion defines an end closure of the composite fiber beverage container, and wherein the end closure comprises a cap attachment feature. Any one or more of the above aspects include wherein the first fiber shell portion and the second fiber shell portion together define a pressure vessel, and wherein the composite fiber beverage container further comprises: a cap attached to the cap attachment feature of the end closure. Any one or more of the above aspects include wherein an internal volume of the pressure vessel is sealed from an exterior of the composite fiber beverage container when the cap is attached to the cap attachment feature. Any one or more of the above aspects include wherein the pressure vessel maintains 90 PSI inside the internal volume over time. Any one or more of the above aspects include wherein the cap attachment feature is a threaded end of the end closure, and wherein the cap is a screw-on cap. Any one or more of the above aspects include a carbonated beverage contained inside the internal volume of the pressure vessel. Any one or more of the above aspects include wherein the carbonated beverage is a beer. Any one or more of the above aspects include a coating applied to internal surfaces of the first fiber shell portion and the second fiber shell portion, wherein the coating provides a barrier layer for the composite fiber beverage container. Any one or more of the above aspects include a fiber tube comprising a hollow cylindrical shape extending from a first end of the fiber tube to a second end of the fiber tube, wherein at least a portion of the first fiber shell portion and the second fiber shell portion are arranged inside the hollow cylindrical shape, and wherein the circumferential lap joint is completely surrounded by a wall of the fiber tube.

[0098] Exemplary aspects are directed to a composite fiber beverage container, comprising: a first fiber shell portion comprising a first open end and a first elongate cylindrical portion terminating at a closed first semi -spherical end; a second fiber shell portion comprising a second open end and a second elongate cylindrical portion interconnected with a second semi-spherical end, wherein an opening is disposed adjacent the second semi-spherical end, wherein the first fiber shell portion is joined to the second fiber shell portion along a circumferential lap joint at the first open end of the first fiber shell portion and the second open end of the second fiber shell portion; and a fiber tube comprising a hollow cylindrical shape extending from a first end of the fiber tube to a second end of the fiber tube, wherein at least a portion of the first fiber shell portion andthe second fiber shell portion are arranged inside the hollow cylindrical shape, and wherein the circumferential lap joint is completely surrounded by a wall of the fiber tube.

[0099] Any one or more of the above aspects include wherein the fiber tube comprises a flat surface arranged at the first end of the fiber tube, and wherein the flat surface is offset a distance from the closed first semi-spherical end of the first fiber shell portion such that the flat surface supports the composite fiber beverage container when standing thereon. Any one or more of the above aspects include an adhesive disposed between an inner circumference of the fiber tube and at least one of an outer circumferential surface of the first fiber shell portion and an outer circumferential surface of the second fiber shell portion.

[0100] Any one or more of the above aspects / embodiments as substantially disclosed herein.

[0101] Any one or more of the aspects / embodiments as substantially disclosed herein optionally in combination with any one or more other aspects / embodiments as substantially disclosed herein.

[0102] One or means adapted to perform any one or more of the above aspects / embodiments as substantially disclosed herein.

[0103] Any one or more of the features disclosed herein.

[0104] Any one or more of the features as substantially disclosed herein.

[0105] Any one or more of the features as substantially disclosed herein in combination with any one or more other features as substantially disclosed herein.

[0106] Any one of the aspects / features / embodiments in combination with any one or more other aspects / features / embodiments.

[0107] Use of any one or more of the aspects or features as disclosed herein.

[0108] It is to be appreciated that any feature described herein can be claimed in combination with any other feature(s) as described herein, regardless of whether the features come from the same described embodiment.

[0109] As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “include,” “including,” “includes,” “comprise,” “comprises,” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements,components, and / or groups thereof. The term “and / or” includes any and all combinations of one or more of the associated listed items.

[0110] The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more,” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising,” “including,” and “having” can be used interchangeably.[OHl] The phrases “at least one,” “one or more,” “or,” and “and / or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and / or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together. When each one of A, B, and C in the above expressions refers to an element, such as X, Y, and Z, or a class of elements, such as XI -Xn, Yl-Ym, and Zl-Zo, the phrase is intended to refer to a single element selected from X, Y, and Z, a combination of elements selected from the same class (e.g., XI and X2) as well as a combination of elements selected from two or more classes (e.g., Y1 and Zo).

[0112] The term “automatic” and variations thereof, as used herein, refers to any process or operation, which is typically continuous or semi-continuous, done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material.”

[0113] The terms “determine,” “calculate,” “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation, or technique.

[0114] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and this disclosure.

[0115] It should be understood that every maximum numerical limitation given throughout this disclosure is deemed to include each and every lower numerical limitationas an alternative, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this disclosure is deemed to include each and every higher numerical limitation as an alternative, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this disclosure is deemed to include each and every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.

Claims

CLAIMSWhat is claimed is:

1. A composite fiber beverage container, comprising: a first fiber shell portion comprising a first open end and a first elongate cylindrical portion terminating at a closed first semi -spherical end; and a second fiber shell portion comprising a second open end and a second elongate cylindrical portion interconnected with a second semi -spherical end, wherein an opening is disposed adjacent the second semi -spherical end; wherein the first fiber shell portion is joined to the second fiber shell portion along a circumferential lap joint at the first open end of the first fiber shell portion and the second open end of the second fiber shell portion.

2. The composite fiber beverage container of claim 1, further comprising: a base cup comprising an open end, a hollow cylindrical portion, and a flat surface disposed at a closed end of the base cup opposite the open end of the base cup, wherein the base cup is attached to the first fiber shell portion such that the closed first semi-spherical end is disposed inside the hollow cylindrical portion and the flat surface is offset a distance from the closed first semi -spherical end of the first fiber shell portion.

3. The composite fiber beverage container of claim 2, further comprising: a joint adhesive disposed between an outer circumferential surface of a joint band of the second fiber shell portion and an inner circumferential surface of a joint recess of the first fiber shell portion, and wherein the inner circumferential surface of the joint recess surrounds the outer circumferential surface of the joint band.

4. The composite fiber beverage container of claim 2, further comprising: a base adhesive disposed between a portion of the first fiber shell portion and an internal surface of the hollow cylindrical portion of the base cup.

5. The composite fiber beverage container of claim 3, wherein the joint band of the second fiber shell portion and the joint recess of the first fiber shell portion is made from kraft fiber comprising an amount of hemp extract.

6. The composite fiber beverage container of claim 3, wherein the opening disposed adjacent the second semi -spherical end of the second fiber shell portion defines an end closure of the composite fiber beverage container, and wherein the end closure comprises a cap attachment feature.

7. The composite fiber beverage container of claim 6, wherein the first fiber shell portion and the second fiber shell portion together define a pressure vessel, and wherein the composite fiber beverage container further comprises: a cap attached to the cap attachment feature of the end closure.

8. The composite fiber beverage container of claim 7, wherein an internal volume of the pressure vessel is sealed from an exterior of the composite fiber beverage container when the cap is attached to the cap attachment feature.

9. The composite fiber beverage container of claim 8, wherein the pressure vessel maintains 90 PSI inside the internal volume over time.

10. The composite fiber beverage container of claim 8, wherein the cap attachment feature is a threaded end of the end closure, and wherein the cap is a screw-on cap.

11. The composite fiber beverage container of claim 8, further comprising: a carbonated beverage contained inside the internal volume of the pressure vessel.

12. The composite fiber beverage container of claim 11, wherein the carbonated beverage is a beer.

13. The composite fiber beverage container of claim 1, further comprising: a coating applied to internal surfaces of the first fiber shell portion and the second fiber shell portion, wherein the coating provides a barrier layer for the composite fiber beverage container.

14. The composite fiber beverage container of claim 1, further comprising: a fiber tube comprising a hollow cylindrical shape extending from a first end of the fiber tube to a second end of the fiber tube, wherein at least a portion of the first fiber shell portion and the second fiber shell portion are arranged inside the hollow cylindrical shape, and wherein the circumferential lap joint is completely surrounded by a wall of the fiber tube.

15. A composite fiber beverage container, comprising: a first fiber shell portion comprising a first open end and a first elongate cylindrical portion terminating at a closed first semi -spherical end; a second fiber shell portion comprising a second open end and a second elongate cylindrical portion interconnected with a second semi -spherical end, wherein an opening is disposed adjacent the second semi -spherical end, wherein the first fiber shell portion is joined to the second fiber shell portion along a circumferential lap joint at the first openend of the first fiber shell portion and the second open end of the second fiber shell portion; and a fiber tube comprising a hollow cylindrical shape extending from a first end of the fiber tube to a second end of the fiber tube, wherein at least a portion of the first fiber shell portion and the second fiber shell portion are arranged inside the hollow cylindrical shape, and wherein the circumferential lap joint is completely surrounded by a wall of the fiber tube.

16. The composite fiber beverage container of claim 15, wherein the fiber tube comprises a flat surface arranged at the first end of the fiber tube, and wherein the flat surface is offset a distance from the closed first semi -spherical end of the first fiber shell portion such that the flat surface supports the composite fiber beverage container when standing thereon.

17. The composite fiber beverage container of claim 16, further comprising: an adhesive disposed between an inner circumference of the fiber tube and at least one of an outer circumferential surface of the first fiber shell portion and an outer circumferential surface of the second fiber shell portion.

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