Interconnection means for multi parts container

Abstract

To provide interconnection means for a multi-parts container.SOLUTION: Provided is an interconnection structure for connecting a number of parts of a container. The interconnection structure comprises first parts comprising a plurality of interconnection tabs and slits on edges thereof and second parts comprising a plurality of interconnection tabs and slits which are patched to the first parts on edges thereof. The interconnection tabs and the slits have overlapped portions in common. Once the two parts are connected to each other, engaged interconnection tabs are arranged in an inner area of the container. The first edges and the second edges comprise curved sections.SELECTED DRAWING: Figure 1

Description

[Background technology]

[0001] (cross reference) This application claims priority to Provisional Patent Application No. 62 / 323,388, filed April 15, 2016, which is incorporated herein by reference in its entirety.

[0002] BACKGROUND OF THE INVENTION Paper bottles, such as molded fiber, fiber, or pulp bottles, are degradable and widely recyclable, benefiting the environment. However, current paper bottle manufacturing as a container requires multiple parts that must be glued together, which is complex and costly, and involves the use of significant adhesives (e.g., glue) and time. The use of adhesives during the assembly process presents several challenges. In particular, in the case of pulp bottles, the adhesive must be applied in a detailed path, which can be slow, resulting in low production output and high costs. In addition, the properties of the adhesive are easily affected by factors that can be difficult to control, including moisture, temperature, compression, and settling time. These factors can significantly affect the strength of the container. Some types of glue may require a catalyst, such as UV light. Sometimes, the glue can force the peeling of the pulp surface layer, thereby rendering it nonfunctional. Although the majority of the pulp remains intact, it is mechanically inoperable due to the peeling of the adhesive.

[0003] Corrugated cardboard is known to have techniques that use slots and tabs for closure or connection. However, in most cases, these assembly features are located on the exterior portion of the container, affecting the smoothness of the surface. Also, these assembly features are typically used to connect structures on corners or generally flat surfaces (e.g., paperboard panels) that do not contain complex three-dimensional shapes. Furthermore, when the tabs are inserted into the openings upon engagement, they are difficult to manipulate without folding or crimping, which can lead to a source of weakness when a load force is applied.

[0004] Therefore, there is a need for an improved means for connecting container parts together that reduces the use of adhesives while improving the overall strength, performance, and recyclability of the container. Summary of the Invention [Problem to be solved by the invention]

[0005] (summary) The embodiments described herein can address the aforementioned needs by providing an interconnection method and apparatus that can mechanically connect multiple parts of a container together. The container may be formed by multiple parts. The interconnection method can be used for containers made from different recyclable and compostable materials. [Means for solving the problem]

[0006] In one aspect, the present invention provides an improved interconnection method and apparatus for a multi-part container. The interconnection may utilize a plurality of locking features formed along an edge of one part of the container for mechanically securing into a plurality of complementary locking features formed within a portion of another part of the container. When the multiple parts are in an assembled configuration, the locking features are disposed within the container enclosure to form a smooth seam on the outer surface of the container.

[0007] In some embodiments, the first edge or the second edge comprises a curved section. In some embodiments, one or more of the plurality of interconnecting tabs and slits are formed within a shoulder area of ​​the container. In some embodiments, the plurality of interconnecting tabs and slits have shapes, sizes, or spacing that vary along the first edge. Alternatively, the interconnecting feature comprises a plurality of tabs and slits having the same size and shape as the interconnecting tabs and slits on the first edge. In some cases, the interconnecting feature comprises a plurality of slots. In some examples, the plurality of slots have a D-shape.

[0008] In some embodiments, the engaged interconnection tabs are aligned with an inner surface of the container, which in some cases is a curved surface.

[0009] In some embodiments, the first and second shell parts are formed from recycled or biodegradable pulp material. For example, the pulp material is selected from the group consisting of wood pulp and paper pulp. In some cases, the first and second shell parts form a skeleton shell of the container, and the skeleton shell is 100% recyclable. In some cases, the first and second shell parts are molded and then cut to form a plurality of interconnecting tabs and slits or interconnecting features. In some embodiments, the multi-part container further comprises a fitment and a neck for supporting the fitment. In some cases, the fitment comprises one or more interlocking features configured to mate with one or more complementary features in the neck.

[0010] In another aspect, a single-piece container is provided. The container may comprise a single pulp molded open shell having two or more sides for joining together, where at least a first side of the two or more sides comprises a plurality of interconnecting tabs and slits, and a second side for joining with the first side comprises a plurality of interconnecting features, where the plurality of interconnecting tabs are disposed within an interior region of the container when the first and second sides are joined together. In some cases, the interconnecting features comprise a plurality of D-shaped slots or a plurality of interconnecting tabs and slits.

[0011] In some embodiments, the first side or the second side comprises a curved profile.In some embodiments, the container is formed from a recycled or biodegradable pulp material.

[0012] In another aspect, the present invention provides methods and apparatus for connecting molded pulp, fiber, or paper parts together. This can be a single shell joined together, or a hinged shell connected along a hinge. In some embodiments, the connection may not require glue. This can enable the manufacture of cost-effective mass-produced containers. This approach eliminates or reduces adhesives, thereby improving the strength, performance, and recyclability of the container.

[0013] In another aspect, the present invention provides a method for making a molded pulp, fiber, or paper shell container without a liner. In this case, the container can be a highly recyclable single material, which can be compostable and / or recyclable. In another aspect, a fitment for engaging a cap or cover can be present, but without a liner. In some cases, the container can be used to hold powders, particulates, or other materials.

[0014] In a different, further related aspect, the present invention provides a high-barrier or waterproof container using one of many forms of liners, a fitment-attached liner, a single-part liner with an integral fitment feature, or a coating encapsulated by mechanically interconnecting a pulp shell, so that the outer shell can be separated for recycling and the plastic liner can be discarded or recycled, as applicable. For example, the present application provides the following: (Item 1) A multi-part container, a first shell part having a plurality of interconnecting tabs and slits on a first edge; a second shell part including a plurality of interconnection features on a second edge, the plurality of interconnection features being connected to the first edge when the first shell part and the second shell part are connected to form the container; and Equipped with When the plurality of interconnection tabs and slits on the first edge are engaged with the plurality of interconnection features on the second edge, the engaged interconnection tabs are disposed within an interior region of the container. (Item 2) Item 1, wherein the first edge or the second edge comprises a curved section. (Item 3) Item 1. The multi-part container of item 1, wherein one or more of the plurality of interconnecting tabs and slits are formed within a shoulder area of ​​the container. (Item 4) Item 1. The multi-part container of item 1, wherein the plurality of interconnecting tabs and slits have shapes or sizes that vary along the first edge. (Item 5) Item 1. The multi-part container of item 1, wherein the plurality of interconnecting tabs and slits have varying spacing along the first edge. (Item 6) Item 1. The multi-part container of item 1, wherein the interconnection features comprise a plurality of tabs and slits having the same size and shape as the interconnection tabs and slits on the first edge. (Item 7) Item 1. The multi-part container of item 1, wherein the interconnection feature comprises a plurality of slots. (Item 8) 8. The multi-part container of claim 7, wherein the plurality of slots have a D-shape. (Item 9) Item 1. The multi-part container of item 1, wherein the engaged interconnecting tabs are aligned with an inner surface of the container. (Item 10) 10. The multi-part container according to item 9, wherein the inner surface is a curved surface. (Item 11) Item 1. The multi-part container of item 1, wherein the first shell part and the second shell part are formed from recycled or biodegradable pulp material. (Item 12) 12. The multi-part container according to item 11, wherein the pulp material is selected from the group of wood pulp and paper pulp. (Item 13) Item 1. The multi-part container of item 1, wherein the first shell part and the second shell part form a skeleton shell of the container, and the skeleton shell is 100% recyclable. (Item 14) 2. The multi-part container of claim 1, wherein the first shell part and the second shell part are molded and then cut to form the plurality of interconnecting tabs and slits or interconnecting features. (Item 15) 2. The multi-part container of claim 1, further comprising a fitment and a neck supporting the fitment. (Item 16) Item 16. The multi-part container of item 15, wherein the fitment comprises one or more interlocking features configured to mate with one or more complementary features in the neck. (Item 17) Item 16. The multi-part container of item 15, wherein a liner is connected to the multi-part container by the fitment. (Item 18) A container, a single pulp molded open shell having two or more sides for joining together; At least a first side of the two or more sides comprises a plurality of interconnecting tabs and slits, a second side for connection with the first side comprises a plurality of interconnecting features, and when the first side and the second side are joined together, the plurality of interconnecting tabs are disposed within an interior region of the container. (Item 19) Item 19. The container of item 18, wherein the first side or the second side comprises a curved profile. (Item 20) 20. The container of claim 18, wherein the interconnection features comprise a plurality of D-shaped slots or a plurality of interconnection tabs and slits.

[0015] (Incorporated by reference) All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.

[0016] The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which: [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 provides a partial view of a portion of two container parts with an exemplary internal interconnect structure. [Figure 2] FIG. 2 shows an example of an interconnect structure with an oversized slit feature, according to some embodiments. [Figure 3] FIG. 3 provides a partial view of another embodiment of an interconnect structure. [Figure 4] FIG. 4 shows an example of a portion of two pulp molded parts connected via an interconnect structure, according to some embodiments. [Figure 5] FIG. 5 illustrates an exemplary process for engaging multiple interconnect structures. [Figure 6] FIG. 6 provides a side view of interconnection features formed along the edges of two pieces of the container shell, including curved edges at the shoulders of the container. [Figure 7] FIG. 7 provides an example of a container comprising two parts connected by an interconnect structure, according to some embodiments. [Figure 8]FIG. 8 provides an example of a pulp molded container shell comprising multiple parts connected by interconnect structures, according to some embodiments. [Figure 9] FIG. 9 illustrates stackable container components or parts with interlocking features, according to some embodiments. [Figure 10] FIG. 10 provides an example of a pulp molded container shell comprising multiple parts connected by interconnect structures, according to some embodiments. [Figure 11A] FIG. 11A shows an example of a pulp molded container shell with interconnecting features at different stages of the manufacturing process. [Figure 11B] FIG. 11B illustrates an embodiment of a container shell with and without interconnecting features formed during the molding process. [Figure 12] FIG. 12 shows examples of tab and slot / slit features that can be formed by the cutting process. [Figure 13] FIG. 13 illustrates an exemplary process for determining a cutting path. [Figure 14A] 14A and 14B show examples of different cutting directions. [Figure 14B] 14A and 14B show examples of different cutting directions. [Figure 15] FIG. 15 shows an example of laser cutting. [Figure 16] FIG. 16 shows an example of using laser cutting to form interconnect features. [Figure 17] FIG. 17 shows an example of a cutting method. [Figure 18] FIG. 18 shows an embodiment in which a mandrel is used to hold the formed container shell. [Figure 19] FIG. 19 shows an embodiment of a load lug formed around the periphery of the container shell. [Figure 20] FIG. 20 shows an embodiment of a loading lug formed in the bottom area of ​​the container shell. [Figure 21]FIG. 21 shows an embodiment of a container having a liner with fitment features. [Figure 22] FIG. 22 shows an embodiment of a container having a cross section to prevent rotation of the liner. DETAILED DESCRIPTION OF THE INVENTION

[0018] (Detailed Description of the Invention) In the following detailed description, numerous specific details are set forth to provide a thorough understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, and structures have not been described in detail so as not to obscure the present invention. Various modifications to the described embodiments will be apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments. It is not intended that the present invention be limited to the specific embodiments shown and described.

[0019] The invention described herein provides an interconnection method and system that allows multiple parts of a container to be mechanically connected together to form a single, uniform structure.

[0020] The containers described herein can be used for the delivery and / or storage of materials for human consumption, or for the delivery of other materials not intended for human consumption. In some cases, the contained materials can be solids, such as powders or granules, tablets, and other particulates. In other cases, the materials can be liquids. In these cases, the container may further comprise a liquid-holding vessel or bag. Examples of materials that can be contained include beverages, syrups, concentrates, soaps, inks, gels, solids, and powders.

[0021] In some embodiments of the present invention, the container may have a fiber or pulp molded body. The fiber and pulp molded body can be a hollow shell with two or more parts connected together. In some embodiments, the two or more parts of the shell may be fixedly connected via internal interconnecting features.

[0022] FIG. 1 provides a partial view of a portion of two container parts with an exemplary internal interconnection structure. As shown in FIG. 1, the internal interconnection structure may include a plurality of internal interconnection tab portions 101 and interconnection slit portions 110 disposed along an edge of a first part of a container shell 100. In some embodiments, the multiple interconnection tab portions 101 may be interposed between multiple interconnection slit portions 110 formed on the same edge, and an overlapping portion 107 may be formed by adjacent tab portions 101 and slit portions 110. In some embodiments, a second part of a containing shell 120 may include the same interconnection features along an edge for mating with an edge of the first part. The multiple internal interconnection tab portions 101 can be designed to be inserted through multiple mating linear slit portions in the second part to form a secure locking configuration.

[0023] The internal interconnection tab portion 101 as depicted in FIG. 1 may also be referred to as a mushroom-shaped interconnection tab feature. In some embodiments, the mushroom-shaped interconnection tab feature 101 may include a tip portion 103, a root portion 105, and an undercut portion 107. The tip portion 103 may be designed to help guide the tab feature into the complementary slit 110 during manual or automated assembly. The undercut portion 107 may be designed to interfere with the undercut portion of a mating tab so that the contact edges of the two parts are prevented from separating once they are in a locked configuration (as shown in FIG. 4). In some cases, the edge within the undercut portion 107 can withstand the pulling force of the connecting edges of the two parts applied by the interference tab. In some cases, after multiple internal interconnection tabs are engaged with the linear slit, the undercut portion 107 can provide a secure lock that prevents relative movement between the tabs and slits in one, two, three, or more directions.

[0024] As depicted in FIG. 1 , an internal interconnection tab feature may have a mushroom shape to overlap another component of the container. In some embodiments, the tip portion 103 of the interconnection tab feature may have a different configuration, such as a semicircular, arrow-type, or T-shaped. The shape of the tab feature need not be symmetrical. For example, one half of the tab feature can have a different shape or size than the other half, such that the tab can have an off-center lead-in feature. Thus, during engagement of the locking feature, the entry angle may alternate based on the molded lead-in feature. In some embodiments, the centering or off-centering tip portion used to guide insertion of the interconnection tab through the complementary slit can affect the range of the entry angle during engagement.

[0025] In another example, the undercut portions from the two sides of one interconnection tab may not be the same. For example, the undercut portion from one side may be shorter in length than the other side. In other cases, the undercut portion may only be present on one side. The internal interconnection tabs for insertion through complementary features can have various shapes as long as there is an interference edge to withstand the non-frictional contact force between a pair of locking features with the bearing. Other shapes, such as hook-shaped, L-shaped, Y-shaped, T-shaped, triangular, and diamond-shaped, can also be used to secure the interconnection tabs and complementary features (see FIG. 2, part B). In some embodiments, the interconnection tab features on the same side of the container part do not need to be the same. For example, the interconnection tab feature 101 may be mushroom-shaped, while the neighboring tab feature 109 may be T-shaped.

[0026] As depicted in FIG. 1 , root portion 105 and undercut portion 107 of adjacent interconnecting tab features define slit portion 110. Slit portions as depicted in FIG. 1 may also be referred to as overlapping linear slit portions. In some embodiments, undercut portion 107 of an interconnecting tab feature may be part of overlapping linear slit portion 110 such that the undercut portion is shared by interconnecting tab portion 101 and adjacent slit portion 110. In some embodiments, undercut portion 107 may be an area where a pair of locking tab features interfere with each other when in a locked configuration. The pitch and shape of the slit portion may be designed to match the location of the mating tab portion.

[0027] In some embodiments, the overlapping linear slit feature may have a curved profile 210, as shown in FIG. 2, part A. The profile of the overlapping linear slit feature may be a convex curve with any suitable curvature. In other embodiments, the profile of the overlapping linear slit feature may have various shapes, such as a straight line, a wavy line, or a concave curve (i.e., a curve in the opposite direction of 210). In other embodiments, the overlapping linear slit feature may be alternating, forcing the mating tab to flex in order to pass therethrough, which may result in different locking performance (as shown in FIG. 2, part B). The overlapping linear slit feature may adopt various shapes and provide contact edges to secure the mating tab feature in place. The overlapping linear slit feature may have a thickness 201. The thickness of the overlapping linear slit feature 201 may be determined by the undercut portion of the neighboring interconnecting tab feature. In some embodiments, the thickness of the overlapping linear slit feature may be substantially equivalent to the thickness of the pulp material in the tab feature, which may further provide a firm feel in the interconnecting feature. The thickness of the pulp material may be, for example, in the range of 0.3 mm to 8 mm. The thickness of the pulp material may be at least 0.1 mm, 0.2 mm, 0.3 mm, 0.5 mm, 0.7 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, and the like. Alternatively, or in addition, the thickness of the pulp material may be only 0.2 mm, 0.3 mm, 0.5 mm, 0.7 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 20 mm, and the like. The thickness of the pulp material may or may not be uniform across the container. For example, a container shell may have a first wall thickness in the upper area of ​​the shell and a second wall thickness in other areas. The thickness may be controlled by the pulp molding process. Controlling the pulp thickness is important from the perspective of integration of two container shells mated together and ease of assembly.

[0028] In some cases, the thickness of the overlapping linear slits may be increased to allow the interconnecting tabs to pass with minimal or less resistance. In some cases, when an interconnecting tab feature enters a mating linear slit feature, the slit feature may open to a certain extent to accept the tab feature with minimal interference. In some cases, a pulp shell with a variable thickness may pass through a given linear slit with reduced interference. For example, a tab feature with a variable thickness may be inserted into a slit or slot with a constant thickness. This reduced interference with larger slits results in larger visible external gaps between the assembled shells in the assembled bottle. This may be undesirable in some cases where aesthetics or container integrity of a linerless container is important. These gaps may become more visible when the assembled shells are forced apart and separate to the point where the trailing edges of the tabs on the opposing shells contact each other and resist separation of the shells. The thickness and other dimensions of the linear slots are important to provide the desired bottle performance.

[0029] In some embodiments, the linear interconnect slit feature need not be formed in conjunction with neighboring interconnect tab features. For example, instead of multiple slit features formed on the edge interposed between the interconnect tab features, only a slit feature may be included within a portion of the container part, such as the interconnect feature in FIG. 6. The linear slit feature may or may not be formed on the edge of the container part. In some embodiments, additional features, such as a slit (e.g., 609 in FIG. 6), may be employed. The slit 609 may allow for a larger opening during the engagement process so that resistance forces may be reduced.

[0030] FIG. 2 shows an example of an interconnect structure with an oversized slit feature, according to some embodiments. Designing a slit feature with a width greater than the width of a tab feature (i.e., an undersized interconnect tab feature) can enable the engagement process with minimal resistance. As depicted in FIG. 2, the mushroom-shaped interconnect tab may have a maximum width 203, which is smaller than the width of the complementary linear slit 205. The larger width of the linear slit feature may allow the interconnect tab feature to pass through the slit with less interference or resistance. The amount of width difference between the tab feature and the mating slit feature can be any number, as long as an overlap portion (e.g., 107 in FIG. 1) for engagement is provided and the root portion of the tab feature is not weakened. In some embodiments, the overlap portion may be varied in size to improve the strength of the engagement. In some embodiments, the width of the root portion may be increased to ensure the strength or rigidity of the interconnect tab feature. Given the fixed pitch between features, there is a trade-off between the width of the root of the tab and the width of the slot. The wider slots aid in shell assembly and can accommodate misalignments between one shell as it is mated with another. In some cases, two sides to be connected together may include identical interconnect features, such that the slit on one side can be identical to the slit on the opposing side. In this case, the interconnect tab feature may have a width that is the same as or slightly smaller than the width of the slit feature formed on the same side. In alternative cases, two sides to be connected together may include different interconnect features, such that the slit on one side need not be identical to the slit on the opposing side. In this case, the interconnect tab feature may have a width that is smaller than, equivalent to, or greater than the width of the slit formed on the same side.

[0031] 3 provides a partial view of another embodiment of an interconnect structure. As shown in FIG. 3, the internal interconnect structure may include a plurality of internal interconnect tab features 301 disposed along the edge of one part of the container shell and a plurality of slot features 303 disposed proximate the edge of another part of the container shell. The location of the slot features 303 relative to the edge of the shell parts determines the overlap region where the double-wall feature is formed. If a larger area of ​​double or multiple walls is preferred, the location of the interconnect slots can be arranged further away from the edge of the shell parts.

[0032] In some embodiments, the interconnect slot may have a D-shape, with a maximum width 307 that is smaller than the maximum width 305 of the mating interconnect tab feature. In this case, the interconnect tab feature may be slightly deformed when passing through the interconnect slot opening 309, as shown in FIG. 3 . The width of the interconnect tab feature may exceed the maximum width of the slot by a width difference D. The width difference may be designed to prevent the tab feature from interfering with the slot edge and thus separating the connected shell parts when the interconnect feature is in the locking configuration. On the other hand, the width difference may be designed to provide desired flexibility, such that the tab is allowed to deform to some extent when passing through the slot.

[0033] Once the interconnecting tab feature passes through the slot opening, the undercut portion of the tab feature may recoil and form a lock between the two shell parts. In some cases, a gap may be visible 311 within the locked interconnecting feature. The undercut portion 107 may be designed to interfere with the undercut portion of the mating tab once they are in the locked configuration, preventing the contact edges of the two parts from separating 313, as described elsewhere herein, and may also interfere with the edge of the D-shaped slot once they are in the locked configuration, preventing the contact edges of the two parts from separating.

[0034] In some embodiments, additional features may be provided to help compress or flex the tab features when moving through the undersized interconnect slot. For example, a longitudinal slit in the interconnect tab may be used to allow flexible deformation of the interconnect tab during insertion without creating a permanent deformation or bend.

[0035] FIG. 4 shows an example of a portion of two pulp molded parts connected via an interconnect structure, according to some embodiments. As shown in FIG. 4, multiple internal interconnect tab features and overlapping linear slits are assembled along the edges of the two pulp molded parts. The multiple interconnect features may be the same on the connecting edges from separate parts where the two parts abut. Once the interconnect features are in a locked configuration, the multiple contacting edges and surfaces, such as at overlapping portion 401 and linear slit portion 403, may be configured to ensure a strong bond between the two parts. The multiple interconnect features may help distribute load forces so that the force applied to each pair of interconnect features is reduced and the two parts may be prevented from splitting at the seam under load. In some embodiments, the multiple assembled interconnect features may be configured to effectively prevent substantial relative movement in any direction, such as translational or rotational movement. In some embodiments, the two connected parts may be allowed to have relative rotational movement about axis 405 along the contacting edges. The flexibility of the rotational angle adjustment about axis 405 may allow the interconnecting tabs to transition from an engaged configuration to a locked configuration. Once the interconnecting tabs along one side of the container shell are in the locked configuration, movement about axis 405 can be limited by the engagement on the other side of the container shell.

[0036] FIG. 5 illustrates an exemplary process for engaging multiple interconnection features. As shown in FIG. 5, an internal interconnection tab from one shell part may be inserted into a complementary slit in an orientation not aligned with the plane of the mating part 501. An engagement angle 507 may define the direction of engagement movement between the two shell parts. In some cases, a tab feature on one shell part may enter a slot feature on the mating part from the outer surface of the mating part at the engagement angle. The engagement movement may be performed by moving either or both shell parts. Once the interconnection features pass through each other, the interconnection tabs may protrude from the bottle inner surface and then flex back toward the inner surface of the shell part 503. Once the interconnection tabs fully recoil or are forced back, they may assume a locking configuration 505. The hook portion of each interconnection feature withstands the pulling force, resulting in a secure locking engagement between the two parts. As shown in FIG. 5 , the engaged interconnection features are formed proximate the inner surface 505 of the container shell. The surfaces of the locked interconnection features can be substantially aligned with each other 509. In some embodiments, the interconnection tabs are formed within the curved surface as extensions of the shell parts so that, when in the locked configuration, the interconnection tabs can be aligned with other shell parts from the inner surface. It should be understood that as material thickness increases, more surface contact exists between the hook features. This distributes the pulling force over more of the hook surface. Similarly, thicker material can allow the system to function to resist the pulling force even when the hook portions of the tabs are somewhat misaligned, with the additional material thickness ensuring that the degree of contact between the hooks remains intact. Features formed within the hooks that increase the surface contact between the hooks or serve to accommodate some misalignment but do not increase the wall thickness are contemplated. This can be advantageous for reducing wall thickness from an environmental standpoint; in such cases, forming features to improve resistance to separation from pulling is contemplated. Achieving increased surface area for resistance may include the use of folding, localized addition of material, or localized offset of pulp shell material.

[0037] FIG. 6 provides a side view of interconnection features formed along the edges of two parts of a container shell. As shown in FIG. 6, an interconnection tab feature 604 on one part and a complementary interconnection slit feature 609 on the other part can be engaged to secure assembly of the container shells. As depicted in FIG. 6, part A, the interconnection tab / slit features need not be uniformly spaced. In some embodiments, the spacing or pitch of the interconnection features may be designed for best performance and aesthetic effect. In some embodiments, the pitch or spacing of the interconnection features may vary in response to the curvature of the surfaces or sides of the shell parts. For example, in shoulder areas where the bottle contour transitions from the sidewall to the neck area or other areas with contour changes, the pitch or spacing 603-1, 603-2 may be reduced compared to the pitch or spacing 603-3 in areas with less curvature. In some embodiments, the size and / or shape of the interconnection features need not be uniform. The dimensions and / or shape of the interconnection tab / slit features may or may not vary according to the curvature or contour of the container shell. In some cases, the width of the tab or slit / slot feature may vary according to the curvature or contour of the side on which the interconnect feature is formed. For example, a wide interconnect tab feature 607 may be located along a straight side, and narrow interconnect tab features 605-1, 605-2 may be located along a curved side, such as a shoulder area or corner of a bottle. The relatively smaller size and / or pitch of the interconnect features may provide flexibility to accommodate various curvatures and contours. Varying pitch and size of interconnect features may also be applied along a straight side. Thus, one, two, three, or more different shapes and / or sizes of interconnect features may be included on a single side of a container part.

[0038] As previously mentioned, the pitch or spacing of the interconnect features on a single side of a container part may or may not be uniform. The shape or size of the interconnect features on a single side of a container part may or may not be constant. The interconnect features on a single side of a container part may vary in at least one of shape, size, spacing, or pitch. Alternatively, the interconnect features on a single side of a container may be constant.

[0039] FIG. 6, part B, shows an assembled container with interconnect features connected. As shown, the interconnect tab / slit features can be formed along straight edges 611, curved contours 613 (e.g., shoulder areas), and corners 615. The cross section of the interconnect tab feature may have a curved shape when formed in an area with a curved contour. In some embodiments, the interconnect tab is formed in a curved surface as an extension of the shell part, such as an interconnect tab formed in a shoulder area. The formed interconnect feature may then have a curved surface according to the curvature of the shell part. The formed interconnect feature may have a curved shape in one or more directions. For example, the interconnect feature may be curved in a direction along the side of the container, perpendicular to the side of the container, or a combination of both. The assembled interconnect feature may be aligned with a surface that may or may not be a flat, planar surface. For example, when the container has a rectangular cross section, the interconnect feature may be formed and assembled on a generally planar surface. In another example, when the container has a cylindrical shape, the interconnection features may be formed and assembled on a curved surface. The interconnection features may be formed within a surface that is curved in one or more directions. The surface may be curved along the longitudinal axis of the container, perpendicular to the longitudinal axis (e.g., the sidewalls of a cylindrically shaped container), or a combination of both (e.g., the shoulder area of ​​a cylindrically shaped container).

[0040] In some cases, the container may be assembled using only interconnection features. In this case, no glue or additional materials are included within the container shell, and the described interconnection methods and systems provide a highly recyclable, single-material container, which may be fully compostable and / or recyclable. In some cases, a portion of the sides to be connected may be connected using interconnection features. For example, at least 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% of the sides are connected using interconnection features.

[0041] In some embodiments, multiple fiber or pulp molded parts can be connected via the provided interconnection means to form a container with a hollow body for filling. Figure 7 provides an example of a container comprising two parts connected by multiple interconnection features, according to some embodiments. As shown in Figure 7, part A, when the two parts of the container are assembled, the interconnection features are positioned within the container's enclosure area so that they are not visible from the outside of the container. As previously mentioned, once the two parts are in a securely locked configuration, the interconnection features can be substantially aligned with the container's inner surface. In some embodiments, if additional container robustness is required, an adhesive can be used to secure the assembled tabs to the inner surface. In some embodiments, a smooth seam 701 can be observed from the container's outer surface. The seam observed from the container's outer surface can be formed by multiple interconnecting slits or edges of slots. Thus, adjusting the profile, spacing, and / or pitch of the slit or slot features can achieve various aesthetic effects.

[0042] In some embodiments, multiple interconnect features may be positioned along the edges of a container part. Multiple interconnect features can be located anywhere on the shell part. Figure 7 provides a side view of an internal interconnect feature along the side of a container. However, the location should not be limited to the side of the container. In some embodiments, the interconnect feature may be formed on the bottom, top, or side of the container. The edge at or adjacent to which the interconnect feature 705 is formed need not be straight. For example, when on a sidewall, the edge can have a curved profile 703 (Figure 7, part B), a triangular shape, or be non-parallel to the longitudinal axis of the bottle. Thus, interconnect slit / slot features on the same edge do not have to be aligned with each other. The seam profile as visualized from the outside of the bottle can therefore be further adjusted for aesthetic effect and optimal performance.

[0043] The interconnection features can be formed along the entire side or a portion of the side of the shell parts. For example, the interconnection features can be formed only on the lower half of the rim, while the upper half of the rim can be connected through other connection means. Note that various combinations of connection means can be used to connect multiple shell parts, even on a single side. For example, one portion of the side can be connected using adhesive forces, and another portion can be connected using the described interconnection features. In other cases, other attachment means, such as heat seals, adhesive or non-adhesive tape, sealing wax, or snaps, can be used to provide additional sealing or connection in addition to the described interconnection methods. However, when no other materials are included in the container, the described interconnection methods and systems provide a highly recyclable single-material container, which can be fully compostable and / or recyclable.

[0044] In some embodiments, two mating parts may have the same interconnection feature, such as internal interconnection tabs and overlapping linear slits, as illustrated in FIG. 1. In other embodiments, mating parts of a container may have different interconnection features for each mating side part, such as the embodiment in FIG. 6. For example, on one mating side where two parts of a container are connected, the edge of the container shell part may have multiple interconnection tabs, while the mating portion of the other container shell part may have multiple complementary interconnection slots (e.g., the interconnection feature in FIG. 4). For a single container shell part having two sides to be connected, the part may have interconnection tabs on one side and interconnection slots on the other side. Alternatively, the container shell part may have either interconnection tabs or interconnection slots on both sides. In some cases, an interconnection mushroom feature may not be required for each tab feature. Some simple tab features that do not need to interlock may more easily follow tightly curved contours within the container. These simple tabs may then have interconnecting mushroom tabs at the front and back to hold the shell together.

[0045] FIG. 8 provides an example of a fiber or pulp molded container shell comprising multiple parts connected by an interconnect structure. The interconnect structure as described herein may comprise multiple internal interconnect tabs and interconnect slits / slots such that once the parts are connected, the engaged interconnect features / tabs are positioned within the interior region 803 of the container. In some embodiments, a single part of the container may have interconnect features on one, two, three, or more edges. These interconnect features may or may not be uniform features on each or all edges. In some embodiments, a part may have an internal interconnect tab 801-1 on one side and an interconnect slit or slot 801-2 on the other side. The interconnect tabs and interconnect slits or slots formed on the same shell part may or may not be interlocking features. In some cases, as shown in FIG. 8, the tabs and slots formed on a single shell part may be interlocking features for each other, which may allow two identical shell parts to be connected to each other. This may be beneficial for simplifying the manufacturing process.

[0046] As shown in FIG. 8 , interconnection features may be located anywhere on a container, such as on the container's shoulders, neck, corners, and bottom. The connected edges may comprise various combinations of attachment means. Multiple parts of a container need not be joined together with internal interconnection features along the entire length of the joining edge. For example, a joining edge may have internal interconnection features on one portion to form a smooth mechanical connection, while other portions may be joined by other types of connecting features, such as flanges, tab features, overlapping flaps, hinged overlapping flaps, etc. As shown in FIG. 8 , other connecting means may be used to join multiple parts together to form an assembled container 805. As depicted in FIG. 8 , a container may have a flange side 807 on one portion and a smooth mechanical interconnection side 809 on the other portion.

[0047] In some embodiments, the pulp-molded container shell may include molded features on the neck to directly receive a lid, membrane, cap, twist cap, snap cap, or even a threaded cap. A locking feature, such as 813 in FIG. 8 , may be molded into the pulp. A complementary feature within the fitment mates with the locking feature 813 so that the fitment can be secured to the shell body while providing through-hole access to the contents of the container. The fitment may or may not have a threaded feature to receive a lid (e.g., 617 in FIG. 6 , part B). The fitment may or may not be formed from the same material as the shell body. The fitment may be formed from a material that offers more options for shape or detail than the shell body. In some embodiments, the fitment may be formed from molded or formed pulp or fiber. The cap may be formed from thermoformed pulp or fiber. A lid or cap may be provided over the fitment. The lid may be removable or replaceable. The fitment and its connection to the shell may be physically connected to reduce lid removal and installation forces, including rotational, pulling, and pushing forces. Interlocking tabs 813 contact the fitment and may serve to reduce fitment movement due to these forces.

[0048] In alternative embodiments, the fitment may be prevented from having rotational movement relative to the container by a non-circular cross-sectional shape of the container at the neck. In some cases, interlocking tabs as described above may not be required on the container neck. FIG. 21 shows an example of a container with a neck having non-circular cross-sections 2101, 2103. Rotational movement between the fitment and the connected container may be prevented by a non-circular cross-section in the mating region. For example, the cross-sectional shape of the fitment at the neck may be non-circular, and the container shell to mate with the fitment may have a mating shape that is also non-circular so that the fitment is prevented from rotating relative to the container at the neck. The cross-sections of the fitment and the container neck can have any non-circular shape, including, but not limited to, oval, rectangular, wedge-shaped, irregular, and various others. Note that the fitment as described may be a free-standing fitment, a fitment connected to a pouch, or a fitment feature integral with a liner.

[0049] FIG. 22 shows an example of a container including a liner 2203 with an integral fitment 2201. As shown in the figure, the blow-molded liner 2203 with the integral fitment 2201 may be integrated into a pulp-molded container shell 2205. The fitment may include features such as threads 2207 for connecting to the container shell. The liner can be formed from a blow molding process. Blow molding processes may include, but are not limited to, injection blowing, stretch blowing, parison blowing, and extrusion blow molding. The liner may be attached to the fitment by various manufacturing methods, such as induction welding. For example, when the fitment contains a metal film or foil, radio frequency (RF) energy is used after filling the container to seal the fitment to the liner using heat energy generated from the RF interacting with the metal foil. The heat generated by the RF energy bonds the fitment to the plastic liner through melting or adhesive activation. The fitment can be attached to the shell through the use of heat, welding, high frequency induction welding, glue, flanges, interlocking connections, friction, snaps, locks, clips, rails, mechanical deformation, or any other mechanism known to those skilled in the art.

[0050] In some embodiments, the container may include a lid. The lid may be formed from a polymer-based material. The cap or lid or fitment can be formed from any material, such as a polymer, such as LDPE, HDPE, PET, PS, PP, or a biopolymer. Polymer types can include polyethylene terephthalate (PET), high-density polyethylene (HDPE), polyvinyl chloride (PVC), low-density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), and other polymers. The polymer can be an FDA-approved plastic. The recycle group can include plastic identification codes 1, 2, 3, 4, 5, 6, and 7. The polymer can be a post-consumer recycled (PCR) version of the described polymer or a hybrid of PCR and raw materials. The recycle group can include a set of plastic or polymer types that can be recycled together using a recycling process that does not require separation of the plastic or polymer types prior to the recycling process.

[0051] The container shell can comprise any structural body that provides an enclosure. FIG. 8 shows the container in a cylindrical shape; however, the shape should not be limited to a cylindrical or symmetrical shape. The structure of the container may or may not be geometrically symmetrical. The container walls may be of any configuration such that the contours of the walls may be straight, curved, or any other shape. In some embodiments, the provided internal interconnection features may be formed along straight edges, curved edges, or a combination thereof.

[0052] In some embodiments, the container shell comprises a fiber or pulp molded body. The fiber and pulp molded body can be a clamshell, a two-piece shell, a multi-piece shell, or a combination thereof. The clamshell can be a fiber or pulp molded body with a hinge that can be located on any side of the clamshell and multiple internal interconnecting features included on the opening side for closure of the body. The two-piece shell can comprise two fiber or pulp molded body parts with internal interconnecting features for securing the parts to each other. The two-piece shell can be a two-part assembly of two halves of the body. However, the two parts do not need to be equal in size. For example, one part can be a larger portion of the body structure than the other part. The two-piece shell can be joined to each other on any surface and along any direction. For example, the two-piece shell can be a top half and a bottom half that are joined to each other but not along a side parallel to the longitudinal axis of the container. Once the two parts are joined, the interconnecting tabs can be positioned within the interior region of the container to create a smooth joint seam on the exterior surface. The multi-part shell can include a two-part fiber or pulp-molded body part or a three-part fiber or pulp-molded body part combined with a cap or bottom to secure the multi-part shell in a closed configuration. The container shell parts can be assembled together via the provided interconnecting features alone, or a combination of the interconnecting features and any other means known to those skilled in the art. Heat shrink film can be used to secure the neck to retain the fitment and stop unwanted rotation of the fitment (e.g., 619 in FIG. 6). Heat shrink material can be used as a band or cup at the bottom of the container to add additional retention and increase the container's tip-resistance. Adhesive can be added to selected areas or tabs to improve structural performance. Tape can also be applied to help improve the shell's resistance to separation provided by the interlocking tabs.

[0053] FIG. 9 illustrates stackable container parts or components with interlocking features, according to some embodiments. A stackable container part or component may be a pulp-molded product for transport to an assembly point or a point for fabricating interconnection features. In some embodiments, container parts or components may be stackable. In some cases, uniform and consistent loading spacing between shells is desirable. A first part of a container may be loaded onto a second part. Any number of container parts or components may be loaded on top of each other. Molded features within the container parts or components may prevent the loaded parts from moving laterally relative to each other. In another embodiment, loading features limit the extent to which loaded shells can nest within each other. Features for this purpose may be referred to as loading tabs 901 and may be molded into the shells. These loading tabs are visible, such as 621 in FIG. 6. In another embodiment, additional pulp may be molded into the shells with features that help control loading or other handling characteristics. In a finishing operation, these additional features, such as the loading tabs, can be removed.

[0054] During assembly, two or more mating edges containing internal interconnect features may or may not be engaged side-by-side. For example, an interconnect tab on an edge of one shell part may be inserted through a complementary interconnect slit on the edge of another shell part, followed by engagement of the interconnect features on the other side. Alternatively, interconnect slits / slots from two or more edges of the parts can be manipulated to have an engagement orientation for receiving mating interconnect tabs side-by-side. After the interconnect tabs enter through the mating interconnect slits / slots from the exterior region of the container, the locked tabs can be positioned within the interior region of the container without creating a permanent bend or deformation.

[0055] The interconnection features can provide a strong fastening means for mechanically joining the container parts together. Once the container is assembled, one or more shell parts are in a fixed configuration and cannot move relative to one another. The assembled interconnection features can be configured to effectively prevent substantial relative movement between adjacent parts in any direction, such as translational or rotational movement. In some embodiments, two connected parts can be allowed to have relative rotational movement about an axis generally parallel to the contact edge. Flexibility in adjusting the rotation angle about the axis can allow the interconnection tabs to transition from an engaging configuration to a locking configuration. Once the interconnection tabs along one side of the container shell are in the locking configuration, movement about the contact edge can be limited by the connection on the other side of the container parts. Thus, once assembly of the containing shell is complete, the interconnection features can ensure a tight locking configuration and provide a firm-to-the-touch interconnection area.

[0056] In some embodiments, interconnection features can be formed along the entire side or a portion of the side of a shell component. For example, interconnection features can be formed only on the lower half of the rim, while the other half of the rim can be connected via other connection means. Note that various combinations of connection means can be used to connect multiple shell components, even on a single side. For example, one portion of the side can be connected using adhesive forces, while another portion can be connected using the provided interconnection structure. In some embodiments, a container shell may use different connection means on different sides, portions, and / or areas of the container. In other cases, other attachment means, such as heat seals, adhesive or non-adhesive tape, sealing wax, or mechanical connections, such as locks, fasteners, and snap locks, can be used in addition to the provided interconnection methods to provide a stronger seal or connection. However, when glue or additional materials are not included within the container shell, the described interconnection methods and systems provide a highly recyclable, single-material container, which can be fully compostable and / or recyclable.

[0057] The container may be suitable for containing various types of materials. For example, the container may be suitable for holding liquids, granules, solids, or semi-solids. The container may hold beverages, food, powders, pellets, pills, detergents, or other materials.

[0058] The materials used to form the container shell do not need to be food-grade. In some embodiments, additional features, such as a liquid-holding container, can be included to hold liquid, or any features made from food-grade materials can be included inside the container shell. Thus, the outer shell can be separated for recycling, and other features made from different materials can be discarded or recycled, if applicable. The container shell can include molded fiber or biodegradable materials such as pulp or paper. For example, the container shell may include 100% post-consumer fiber or pulp stock. In another example, the shell may include 100% recycled corrugated fiberboard and newspaper. The container shell or other materials described herein can include raw fiber or pulp stock. The container shell can include Type 2 molded fiber, Type 2A thermoformed fiber, Type 3 thermoformed fiber, Type 4 thermoformed fiber, molded fiber, X-ray formed fiber, infrared formed fiber, microwave formed fiber, vacuum formed fiber, structural fiber, sheet stock, mandrel stock, recycled plastic, thermoformed plastic, sheet plastic, or any other structural material. Any of the materials that can be used to form a container shell may be used in any of the embodiments described herein. Any discussion of pulp may also apply to any of the materials (e.g., fiber molds, natural fibers, biodegradable materials, or compostable materials) that can be used to form the container shell. The formulation can be adjusted to improve desired performance aspects, including, but not limited to, wet strength, tensile strength, compressive strength, moisture resistance, olfactory control additives, oxygen or CO2 or other gaseous permeability. For example, thermoformed fiber materials may provide strength, durability, and flexibility with reduced buckling, which may allow tab features to deform to some extent during engagement. The connection method as provided may allow the container to be fully recyclable, since no glue or other non-recyclable materials are required to assemble the container.

[0059] As the material thickness can be adjusted for best performance (e.g., required material strength), the design of the interconnecting features (e.g., tab features and slit / slot features) in size, arrangement, pitch, spacing, and shape can also be adjusted accordingly to allow for smooth outer surfaces, force-free insertion during the mating process, tight fit after mating, and the like.

[0060] A container shell may be formed from two, three, or more types of pulp-molded parts. A container shell made from multiple parts may include parts formed from any suitable material described anywhere in this specification. Shell parts may or may not be made from the same material. Materials may be combined for purposes of cost reduction, increased structural performance, increased impact attenuation, and to provide higher tolerance areas as well as lower tolerance areas within the same container, for example, so that high tolerance areas can be located specifically for interconnection features. Container shells may be assembled for desired structural performance and to allow for disassembly and to facilitate recycling or composting of unassembled materials.

[0061] The container shell can be formed in a double- or multiple-wall configuration to enable heavy load containment and / or dispensing. One or more shell parts may be formed from two or more layers, enabling container designs with higher load ratings. Alternatively, the container may be assembled as a single-wall container to reduce material consumption. In some embodiments, interconnecting features may be provided to enable conversion of the container into a container suitable for more robust performance (higher overall rigidity) through the addition of one or more wall parts. For example, interconnecting features may be provided in areas where maximum mechanical stress is applied, so that excess wall can be added by connecting through interconnecting features on the interior or exterior surfaces or container shell. Any description of a double-wall configuration herein may also apply to multiple walls.

[0062] The location of the interconnecting slot / slit feature may also determine the double-wall configuration. As previously mentioned, the distance from the location of the slot / slit feature to the edge determines the overlap area. Thus, increasing the space from the interconnecting slit / slot feature to the edge may increase the double-wall area. One or more double-wall areas may be located anywhere on the container shell, including the bottom, top, and sides of the container. Alternatively, the entire container may comprise a double-wall area. The double-wall areas may or may not be connected, and the connection may be through an interconnect or other connection means described herein.

[0063] Internal interconnect features may allow a smooth outer surface to be formed from two pulp molded parts, pieces, or halves (e.g., assembled container 805 in FIG. 8). In some embodiments, internal interconnect features may also allow a uniform or flat surface to be formed on the exterior of the container. For example, interconnect features may be located at the bottom of the container shell such that the bottom surface may be flat or sit flat in the absence of any protruding features (e.g., 1001 in FIG. 10). The flat bottom may be further reinforced by the overlapping area (e.g., double-layer configuration) induced by the interconnect structure, improving load capacity as well as structural integrity.

[0064] Multiple interconnect features can help distribute the load force so that the force applied to each pair of interconnect features is reduced and the two parts can be prevented from splitting under the load.

[0065] As described above, a pulp-molded container shell may include a plurality of interconnecting features for connecting one or more components of the container shell together. A container shell with interconnecting features can be formed in various ways. The formation of the interconnecting features and the body of the container shell may or may not be simultaneous. In some embodiments, the interconnecting features may be formed after the container shell is molded. For example, the interconnecting features may be formed by removing material from the molded container shell. Alternatively, the interconnecting features may be formed in parallel with the molding of the container shell. For example, the associated interconnecting features are included in a mold used in the molding process. In some cases, some of the interconnecting features or a portion of the interconnecting features may be formed by the pulp molding process, while others are formed after the pulp molding process. For example, low-tolerance edges of some of the interconnecting features may be formed by the molding manufacturing process, and high-tolerance edges of the interconnecting features may be formed by the cutting process, or vice versa.

[0066] FIG. 11A shows an example of a pulp-molded container shell with interconnection features at different stages of the manufacturing process. In some cases, the interconnection features may be formed after the container shell is pulp-molded. As shown in FIG. 11A, the container shell 1101 may be formed after the pulp-molding process. In some cases, the interconnection features may not be formed during the pulp-molding process. In some cases, features such as long sidewalls and flanges may be formed with the molded container shell during the pulp-molding process. These features may or may not be removed in further manufacturing steps. This may provide flexibility in connecting container shells. For example, the pulp-molded container shell 1101 may include at least two types of connection features, such as flanges and interconnection features (e.g., tabs and slots). When a flange is desired, the flange formed with the pulp-molded container shell may be retained to connect shell parts as described elsewhere herein. However, if an interconnection feature is desired on a side whereby a flange is formed, the flange may be removed and the interconnection feature may be formed in place. The removal of molding material can be deliberate and detailed. Various types of manufacturing processes can accompany the pulp molding process, such as thick-wall processes, transfer molding, thermoformed fiber molding, thermoformed polymer sheet molding, modified pulp processes, injection molding, vacuum forming, stamping, or deep drawing. In some cases, when a high-quality thin-walled container is desired, a thermoformed molding process may be implemented. The pulp molding process may or may not include secondary processes or steps to obtain smooth surfaces on the interior and exterior of the container shell.

[0067] In some cases, interconnect features are not formed during the molding process. In some cases, some interconnect features or portions of interconnect features may be formed during the molding process. FIG. 11B illustrates examples of container shells with and without interconnect features formed during the molding process. As previously described, interconnect features do not have to be formed during the molding process. For example, container shell 1107 having substantially straight edges may be formed by pulp molding. In some cases, some or all of the interconnect features may be formed by the molding process. For example, as shown in container shell 1109, the leading edge of a tab feature may be formed during the molding process. In some cases, some low-tolerance features may be formed by the pulp molding process, and high-tolerance features may be formed later by other manufacturing processes, such as cutting. For example, as shown in container shell 1111, the leading edge and side edges of the tab portion may be formed by the molding process, and the trailing edge or slot / slit feature may be formed by cutting.

[0068] Referring back to FIG. 11A , operations may be applied to the pulp-molded container shell 1101 to further form interconnection features 1103, 1105. As described elsewhere herein, interconnection features may be formed anywhere and along any side of the pulp-molded container shell. The provided manufacturing process may provide flexibility in determining the location of the interconnection features. Container shells with interconnection features formed on different locations can be manufactured from the same molded container shell. For example, shell part 1103 may be cut or trimmed to have interconnection features formed on the sidewalls and shoulders of the shell part, and an overlapping flap arrangement may be formed to remain for the bottom of the shell. A different shell part 1105 may have interconnection features on the bottom in addition to the sidewalls and shoulders through a further cutting or trimming process.

[0069] A plurality of interconnection features may be formed on the pulp molded container shell. The interconnection features may be formed by removing material from the pulp molded container shell using a process such as cutting. Various shapes and sizes of the interconnection features can be formed by the cutting process. The various different shapes and sizes of the interconnection features may be designed to affect the assembly process or the performance of the assembled container. For example, the shape and size of the interconnection feature may be selected so that the direction of engagement movement between two shell parts can be determined or the tightness of the interlocking interconnection feature can be determined.

[0070] FIG. 12 shows examples of tab and slot / slit features that may be formed by a cutting process. As described elsewhere herein, the interconnection feature may comprise at least tab portions 1200-1, 1210-1, 1220-1, 1230-1, and 1240-1 and slot / slit portions 1200-2, 1210-2, 1220-2, and 1230-2. The tab portions and slot / slit portions may include various shapes or configurations. For example, the tab portions may comprise leading edges 1201, 1211, and 1231, side edges 1202, 1212, 1222, and 1232, trailing edges 1203, 1214, 1233, and 1241, and root portions 1206 and 1216. The trailing edges may also define portions of the slot or slit portions. The slot or slit portion may be defined by the trailing edge of the tab portion, the cutting edges 1204, 1215, 1233, 1242, and the return cutting features 1205, 1213, 1221.

[0071] As shown in FIG. 12 , the leading edge of the tab portion may have various curvatures and may comprise various linear shapes. For example, the leading edge may be rounded 1201 or curved 1211. The leading edge may be symmetrical 1201 or asymmetrical 1211, 1231. Similarly, the side edges of the tab portion may comprise any linear shape, such as curved 1202 or straight 1222. The side edges on each side of the tab portion may be symmetrical 1202, 1222 or asymmetrical 1212, 1232. In some cases, the leading edge and side edges may collectively affect the direction of engagement movement between the two shell parts. For example, an asymmetrical side edge may allow the tab to enter the mating slot at an angle.

[0072] In some cases, the trailing edge 1241 may be parallel to the cutting edge of the slot or slit portion 1242. In some cases, the trailing edges 1203, 1233 may be parallel to a portion of the cutting edge 1204. In some cases, the trailing edge 1214 may not be parallel to the cutting edge 1215. For example, a tapered slot shape may be defined by non-parallel edges 1214, 1215. In some cases, the trailing edge on one side of the tab portion is parallel to the cutting edge, while the other side is not. The trailing edge may be on both sides of the tab portion. Alternatively, the trailing edge may be formed on one side of the tab portion 1233. In some cases, the trailing edge and / or the cutting edge may affect the tightness of the interlocking features. For example, as described elsewhere herein, the overlap defined by the trailing edge and the cutting edge may be varied in size to improve the strength of the engagement.

[0073] The slot or slit portion may comprise a return cut-off feature 1205, 1213, 1221. In some cases, the return cut-off feature 1205, 1213 may comprise a slot and separate the trailing edge from the root portion, thus allowing the trailing edge 1203, 1214 to move to some extent relative to the root portion 1206, 1216. This may provide flexibility during the flexible engagement process. Alternatively, the return cut-off feature 1221 may not separate the trailing edge and root portion, thus providing high structural stability.

[0074] As mentioned above, interconnect features can be formed within the curved surface as extensions of the shell part. The interconnect features need not be uniformly spaced. The spacing or pitch of the interconnect features may be defined by the cutting process. Such interconnect features may be formed by various cutting methods, including, but not limited to, knife, die cut, punch, perforation tool, water jet, abrasive cutter, laser cutter, hot wire, abrasive blasting, plasma cutting, stamping, or CNC machining. Similarly, other features, such as holes or windows, can also be formed using such methods. In some cases, the interconnect features may be formed using a single method. In some cases, the interconnect features may be formed using two or more methods. The cutting process may be a single-step process. Alternatively, the cutting process may be a multi-step process.

[0075] In some cases, different cutting methods may be selected based on the amount of material to be removed, the shape of the feature, or the tolerance or precision requirements of the feature. For example, forming a slit feature may not require the removal of material, and a slit-forming knife may be used to cut the slit. In another case, when a slot feature requires more material to be removed, a streaming cutter such as a laser, a thicker knife, a punch (like a knife, but thicker and blunter), or a water jet may be used to form the slot feature.

[0076] In some embodiments, the cutting path may be determined prior to the cutting operation. The cutting path may define the edge or shape of the feature to be formed on the pulp molded container shell. The cutting path may be defined according to the working edge of an interconnecting feature. The working edge may include the leading, side, and trailing edges of a tab portion, the cutting edge, or the edge of a tab and slot feature, such as a return cut feature of a slot or slit portion. In some cases, the cutting path may follow the working edge. Alternatively, the cutting path may not overlap all of the working edges. FIG. 13 illustrates an example process for determining a cutting path 1300. A cutting path 1303 may be determined for a pulp molded container 1301. The cutting path may define the shape or edge of a feature 1305 to be formed on the pulp molded container shell. One or more factors may be considered to determine the cutting path. For example, the cutting path may be determined based on the size and shape of the feature to be formed, the frequency of the feature, the area in which the feature is to be formed, the specific cutting tool, the dimensions (e.g., thickness) of the material to be removed, etc. The cut path may be generated automatically or semi-automatically. In some cases, the cut path may require one or more inputs, such as the desired shape or size of the interconnection features, the frequency of the features, the cut direction, the cut action, and the like. In some cases, one or more of the steps in process 1300 may be generated automatically by a manufacturing machine. One or more of the parameters or inputs may be provided by a user each time the cut path is determined. In some cases, one or more of the parameters or inputs may be selected from multiple parameters pre-stored in memory. In some cases, one or more of the parameters or inputs may be automatically generated by a computer program.

[0077] The flowchart of the process for determining the cutting path 1300 is for illustrative purposes only. Note that any of the steps may be skipped or the order may be changed depending on the specific tool used for cutting. In the illustrated example, the process may begin with establishing performance requirements for the container 1311. The performance requirements may relate to one or more performance criteria such as drop height, top load, shipping vibration, and various others. The performance requirements may be input provided by a user. The performance requirements may be selected by a user from multiple pre-stored performance requirements. Next, the process may proceed to determining the desired interconnection feature 1313. In this step, one or more parameters or requirements related to the interconnection feature may be determined, such as the length and width of the tab or slot, the shape of the tab or slot, the working edge of the tab or slot / slit feature, the symmetry of the tab feature, symmetric or opposing tabs, and the like. In some cases, the desired interconnection feature determined in this step may be associated with a single interconnection feature. The desired interconnection feature may be input provided by a user. The desired interconnect feature may be selected by the user from a plurality of pre-stored interconnect features.

[0078] Next, a cutting process may be selected 1315. This may include selecting a tool and method for cutting. The cutting process may be selected from a variety of methods, including, but not limited to, knife, die cut, punch, perforation tool, water jet, abrasive cutter, laser cutter, hot wire, abrasive blast, plasma cutting, stamping, punch, die cut, or CNC machining. The cutting process may be an input provided by a user. The cutting process may be selected by the user from multiple pre-stored cutting processes. The cutting process may be controlled by following a predetermined guide or template.

[0079] In some cases, a cutting direction may be selected 1317. The cutting direction may determine the direction the cutter approaches the container shell or the direction the container shell begins to cut. FIGS. 14A and 14B show examples of different cutting directions. In some cases, the cutting direction may determine whether the cutter's cutting orientation with respect to the container shell is normal to the surface to be cut. When the cutter's cutting orientation is oblique to surface 1401, the cut may form angled features in the container shell wall. When the cutter's cutting orientation is normal to surface 1403, the cut may form vertical features in the container shell wall. In some cases, the cutting direction may determine the direction the container shell begins to cut. For example, as shown in FIG. 14B, a single container shell may begin to cut from one or more directions, including, but not limited to, the right side 1409, right shoulder 1407, left side 1405, left shoulder 1405, or bottom 1411. In some cases, the cutter may be shaped to accommodate the shape of the container so that a single cutter can be used to trim a side with a curved profile from a single direction. For example, cutter 1405 may be shaped to accommodate the shoulder and sidewall areas so that both the shoulder and sidewall can be cut by a single cutter 1450 through a single translation toward the container. Alternatively, the shoulder and sidewall may be cut from different directions by separate cutters 1407, 1409. In some cases, the cutters may be modular, have various aggregate shapes, and can be arranged to cut different profiles, shells, or shapes. This provides the advantages of cost savings and increased product flexibility. The described methods and cutters may be part of an automated manufacturing system. The container shell to be cut may be mounted on a mandrel. Details regarding the mandrel are described with respect to FIG. 18. The cutter and cutting operation may be automatically controlled by a machine. Material cut during the cutting process may be removed from the cutting area in an automated mechanical manner.For example, material cut from a container shell can be removed through a vacuum, where openings are present proximate the mandrel or cutter that can draw out the cut material during the cutting process. Cut material within an area 1413 of the container shell, such as the periphery of the shell being cut, may be drawn out by the vacuum and associated openings and channels. The vacuum may be applied from various directions, such as from the periphery of the container shell or below the mandrel.

[0080] Referring back to FIG. 13 , a sequence of cutting actions may then be selected 1319. The sequence of cutting actions may include movement of the cutter relative to the container shell. The sequence of cutting actions may compartmentalize the cutting process into multiple actions. Next, the characteristics per area of ​​the container shell may be determined 1321. In some cases, different areas of the container shell may require different interconnect features to be formed. For example, the interconnect features formed on the bottom may not be the same as the interconnect features formed on the sidewalls. In some cases, the number and frequency of interconnect features may be determined 1323. The frequency of interconnect features may include the spacing or pitch of multiple interconnect features of the same or different types. The frequency of interconnect features may or may not be uniform in the same area or along the same side, and the pitch or size of the interconnect features may vary according to the curvature or contour of the container shell. In some cases, the number of interconnect features of the same type may be determined. In some cases, the number of interconnect features within the same area of ​​the container shell may be determined. In some cases, once one of the number and frequency is determined, the other may be automatically determined as appropriate to fit the interconnection features along a given side. In some cases, the cutting path may be adjusted due to compartmentalization of the cutting process 1325.

[0081] Different cutting methods may be used, individually or collectively, to form the various features. In some cases, the various features may be formed by a combination of cutting and non-cutting processes. In some cases, the interconnection features may be formed by a cutting process, a molding process alone, or a combination of both. Figures 15-17 provide examples of different cutting processes that may be used to form the interconnection features. Figure 15 shows an example of laser cutting. As illustrated in Figure 15, a portion of the interconnection feature or working edge 1503 may be formed by a molding process, and the remainder of the working edge 1501 may be formed by laser cutting. In some cases, the portion of the working edge formed by the molding process may be a low-tolerance edge, such as the leading edge and tip edge of the tab portion. In some cases, the low-tolerance portion of the working edge may be formed by a manufacturing process other than a molding process.

[0082] The laser cutter 1505 may move relative to the shaped container shell 1507. In some cases, the laser cutter moves while the container shell is stationary. In some cases, the container shell moves while the laser cutter is fixed. For example, the laser cutter may be fixed in space while the shaped container shell passes through the laser cutter on a conveyor, as illustrated in the figure. In this manner, a straight linear slit or trailing edge of the tab portion may be formed. In other cases, both the container shell and the laser cutter are configured to move. For example, while the container shell moves past the laser cutter, the laser cutter may be configured to move in a vertical direction 1509 so that a curved linear cut may be formed. The relative movement between the laser cutter and the container shell may be a single pass or in one direction. Alternatively, the relative movement between the laser cutter and the container shell may be multiple passes or in two or more directions.

[0083] FIG. 16 shows another example of forming an interconnect feature using laser cutting. In some cases, a working edge or portion of the interconnect feature can be formed by an additional laser cutter. Two or more laser cutters can coordinate with each other and operate on different edges of the interconnect feature. In the illustrated example, the leading edge and leading step 1605 can be formed by a first laser cutter 1605, and the trailing edge or slit 1601 can be formed by a second laser cutter 1607. The first laser cutter 1605 can be configured to move vertically so that the curved profile of the tab portion can be formed. The second laser cutter 1607 can be fixed, and a generally linear and straight cut edge can be formed. The speed and travel path of the first and second laser cutters can be designed so that the interconnect feature can be efficiently formed while the container shell moves through the operating stage.

[0084] FIG. 17 shows another example of a cutting method. In some cases, die cutting may be used to form the interconnecting features. As illustrated in FIG. 17, rotary die cutting may be used. In some cases, the rotary die cutter may correspond to a side of the container shell 1703. If both sides of the container shell are to be cut, each side may be cut by the rotary die cutter 1701. In some cases, the container shell may need to be held in a fixed position 1705 to resist the cutting force imparted by the die cutter.

[0085] The container shell may be held in place to ensure that the relative movement between the cutter and the container shell follows the designed cutting path. The container shell may be aligned or registered with the cutting machine or system so that the relative position between the container shell and the cutter is controlled. Various methods, such as a mandrel or a recessed cavity, may be used to hold the container shell during the cutting process. FIG. 18 shows an example of using mandrels 1803, 1809 to hold the container shell 1801 to be formed. In some cases, the mandrel 1803 may have a shape similar to the container shell to be formed. The mandrel may be substantially identical in size to or slightly offset from the container shell to be formed 1801 so that the container shell can be received on the mandrel. The mandrel may have the same shape and dimensions as the interior surface of the container shell so that the container shell can be supported by the mandrel from the inside.

[0086] The mandrels 1803, 1809 may include features for holding the container shell in place. For example, the mandrels may include one or more vacuum suction cups 1805 or vacuum holes 1807. Any number of vacuum suction cups or holes may be provided. For example, at least 1, 2, 3, 4, 5, 6, 7, 10, or 20 vacuum suction cups or holes may be provided. The vacuum suction cups or holes may be located in variable locations on the mandrel, such as in an area adjacent to or away from the side where the features will be formed. Other features, such as mechanical clamps, solenoids, and magnets, may also be used to hold the container shell in place.

[0087] In some cases, the mandrel 1803 may include features 1811 having a similar shape to the interconnecting features to be formed. Such features may allow a cutter, such as a die cutter, punch, or profile punch, to translate toward the mandrel loaded with the container shell, cut the container shell, and then enter the mandrel through the accommodating features, such as feature 1811. In another case, a knife, traveling cutter, laser, or water jet may move along feature 1811 to form corresponding interconnecting features on the container shell, with feature 1811 allowing the mandrel to resist the cutting action and force. Alternatively, the mandrel 1803 may not have similar forming features, or the like. In this case, the mandrel for holding the container shell in place may be resistant or accommodating to some type of cutter, such as a laser cutter or water jet.

[0088] Other methods can also be used to hold the formed container shell in place during the cutting process. For example, a cavity may be used to receive the container shell. The interior of the cavity may have a similar shape to the container shell. The cavity may be used to support the exterior surface of the container shell, and additional support may or may not be required to support the container shell from the inside. In some cases, the cavity may also be equipped with features such as vacuum holes or suction cups to hold the container shell in place, as described above.

[0089] In some cases, the container shell may include features to facilitate alignment or positioning with the mandrel or cavity. For example, the container shell may include protrusions, holes, or indentations that can align with mating features on the mandrel or cavity. As the relative location between the mandrel / cavity and the cutter becomes known, alignment of the container shell with the mandrel / cavity can provide precise location control between the container and the cutter. In some cases, the mandrel or cavity for aligning the position of the container shell may be part of the cutting system or cutting machine.

[0090] In some embodiments, the transport and handling of container shells at different stages of production may be operated automatically, semi-automatically, or manually. For example, grippers or robotic end effectors may be used to hold container shells on mandrels as they are cut, install or remove container shells from mandrels, and move container shells to assembly points or points for fabricating interconnection features. As mentioned above, container shells may be stackable. Loading features may be used to control the pitch or the degree to which stacked container shells nest within one another. This is useful for an automated robotic end effector to lift a stacked container shell and separate it from another stacked container shell.

[0091] 19 and 20 show examples of loading features. The loading features may be loading tabs. The loading tabs may be formed during the pulp molding process. In some cases, the loading tabs or some of the loading tabs may be removed during the cutting process when the interconnection features are formed. The dimensions of the loading tabs may determine the spacing between adjacent container shells that are loaded together. The loading tabs may vary in shape and size.

[0092] Loading features may be formed in various locations. For example, loading features may be formed along the perimeter of the container shell and / or the bottom of the container shell. As illustrated in FIG. 19, loading lugs 1901, 1903 may be formed along the perimeter of the container shell. The loading lugs can be located just below the rim, such as lugs 1901, 1903, or above the rim, such as the lugs shown in FIG. 6. Any number of lugs can be formed along the perimeter. For example, at least two, three, four, five, six, seven, eight, nine, or ten lug features may be formed along the perimeter. The location of the loading lugs may or may not be the same across loaded container shells. In some cases, loading lugs 1901, 1903 may be located with an offset 1905 between adjacent container shells. The arrangement of the loading lugs on different container shells may or may not be different. For example, the arrangement of load lugs on container shell 1907 may be different from the arrangement of load lugs on container shell 1909. This may be beneficial because, when container shells with different load lug arrangements are stacked on top of each other in an alternating manner, load lugs from one container shell may avoid load lugs from neighboring container shells, allowing the load lugs to rest uninterrupted on the peripheral flanges so as to maintain spacing 1905 between adjacent container shells. A stack of container shells may have any number of different arrangements for the load lugs. The illustrated example shows two different arrangements; however, three, four, or more different arrangements may be employed to control spacing. Alternatively, the locations of the load lugs across the container shells may be aligned or constant without deviation. Different load lugs may be formed within a single container shell. The load lugs formed within a single container shell may vary in shape, size, or location. For example, the shape and size of the loading tabs located on the periphery and bottom of the container shell may vary.

[0093] In some embodiments, different loading lugs may be used to load container shells at different stages of manufacture. The loading lugs for loading container shells after the pulp molding process may or may not be the same loading lugs for loading container shells after the cutting process. For example, loading lugs 1901, 1903 formed along the periphery as shown in FIG. 19 may be used to load pulp-molded container shells, and these loading lugs may be trimmed during the cutting process. Loading lugs 2001, 2003 as shown in FIG. 20 may be used to load container shells after the cutting process. Alternatively, the loading lugs formed within a single container shell may be identical. Loading lugs 2001, 2003 may be located anywhere on the bottom of the container shell, such as centered or offset. Any number of loading lugs may be included on the bottom of the container shell. For example, at least one, two, three, four, five, six, seven, eight, nine, ten, or more loading lugs may be used to maintain spacing and alignment of the loaded container shells.

[0094] With reference to FIG. 20 , loading lugs 2001, 2003 may be formed on the bottom of the container shells. These loading lugs may be formed during the pulp molding process and remain intact after the cutting process. The shape and dimensions of the loading lugs may or may not be identical across the container shells to be stacked together. In some cases, the loading features 2001, 2003 may have mirrored shapes in adjacent container shells stacked together to control the spacing 2005 between the adjacent container shells. The mirrored shapes may allow the loading lugs in adjacent container shells to protrude to different heights from the bottom surface at corresponding locations. For example, as shown by arrows 2007, 2009, loading lug 2001 has a higher surface than loading lug 2003 at the same location on the two container shells. Using different protrusion heights, the distance that a container shell is nested within another container shell is controlled as the lower surface of the loading lug in one container shell contacts and stops against the higher surface of the other container shell. It should be noted, however, that although the illustrated example shows two different loading lugs in a mirrored configuration, any number of different configurations and / or arrangements of loading lugs may be employed.

[0095] From the foregoing, it should be understood that, while particular implementations have been illustrated and described, various modifications can be made thereto and are contemplated herein. It is also not intended that the present invention be limited by the specific examples provided herein. While the present invention has been described with reference to the foregoing specification, the descriptions and illustrations of the preferred embodiments herein are not intended to be construed in a limiting sense. Furthermore, it should be understood that all aspects of the present invention are not limited to the specific depictions, configurations, or relative proportions set forth herein, which depend upon a variety of conditions and variables. Various modifications in form and detail of the embodiments of the present invention will be apparent to those skilled in the art. It is therefore contemplated that the present invention also covers any such modifications, variations, and equivalents.

Claims

1. A multi-part container, the multi-part container comprises a molded hollow body defining an interior hollow region; The hollow body includes: a first molded shell part, the first molded shell part including a plurality of interconnecting tabs and a plurality of slits on a first edge as an extension of the first molded shell part, the plurality of interconnecting tabs including a leading edge having a curved shape; a second molded shell part, the second molded shell part including a plurality of interconnecting features on a second edge as an extension of the second molded shell part, the second edge being connected to the first edge when the first molded shell part and the second molded shell part are connected to form the hollow body; Equipped with when the plurality of interconnection tabs and the plurality of slits on the first edge are engaged with the plurality of interconnection features on the second edge, the engaged plurality of interconnection tabs are disposed within the interior hollow region of the hollow body; each of the first molded shell part and the second molded shell part is molded to form a sidewall portion and a neck portion of the multi-part container, the outer surface of the multi-part container having a shoulder region where an outer curvature of the multi-part container transitions inwardly from the sidewall portion to the neck portion, the pitch or spacing of the plurality of interconnecting tabs and the plurality of slits and the plurality of interconnecting features being smaller in the shoulder region compared to a region away from the shoulder region where the curvature is smaller relative to the curvature in the shoulder region; A multi-part container, wherein at least one of the first edge and the second edge has a curved profile extending from a first end to a second end of the multi-part container.

2. A multi-part container as described in claim 1, wherein the first edge or the second edge has a curved section.

3. A multi-part container as described in claim 1, wherein one or more of the plurality of interconnecting tabs and the plurality of slits are formed within a shoulder region of the multi-part container.

4. A multi-part container as described in claim 1, wherein the plurality of interconnecting tabs and the plurality of slits have shapes or sizes that vary along the first edge.

5. A multi-part container as described in claim 1, wherein the plurality of interconnecting tabs and the plurality of slits have spacing that varies along the first edge.

6. A multi-part container as described in claim 1, wherein the plurality of interconnecting features comprises a plurality of tabs and a plurality of slits having the same size and shape as the plurality of interconnecting tabs and the plurality of slits on the first edge.

7. A multi-part container as described in claim 1, wherein the plurality of interconnecting features comprises a plurality of slots.

8. A multi-part container as described in claim 7, wherein the plurality of slots have a D-shape.

9. A multi-part container as described in claim 1, wherein the engaged interconnecting tabs are aligned with the inner surface of the hollow body.

10. A multi-part container as described in claim 9, wherein the inner surface is a curved surface.

11. A multi-part container as described in claim 1, wherein the first molded shell part and the second molded shell part are formed from recycled or biodegradable pulp material.

12. A multi-part container as described in claim 11, wherein the pulp material is selected from the group consisting of wood pulp and paper pulp.

13. A multi-part container as described in claim 1, wherein the molded hollow body is 100% recyclable.

14. A multi-part container as described in claim 1, wherein the first molded shell part and the second molded shell part are first molded and then cut to form the plurality of interconnecting tabs and the plurality of slits, or the plurality of interconnecting features.

15. A multi-part container as described in claim 1, further comprising a fitment and a neck supporting the fitment.

16. A multi-part container as described in claim 15, wherein the fitment comprises one or more interlocking features configured to mate with one or more complementary features in the neck.

17. A multi-part container as described in claim 15, wherein a liner is connected to the multi-part container by the fitment.

18. A container, the container comprises a unitary pulp molded open hollow shell having two or more sides joined together; At least a first side of the two or more sides comprises a plurality of interconnecting tabs and a plurality of slits as an extension of the first side of the single pulp molded open hollow shell, a second side connected to the first side comprises a plurality of interconnecting features as an extension of the second side of the single pulp molded open hollow shell, and when the first side and the second side are joined together, the plurality of interconnecting tabs are disposed within an interior hollow region of the single pulp molded open hollow shell, and each of the plurality of interconnecting tabs includes a leading edge having a curved shape; each of the first side and the second side being shaped to form a sidewall portion and a neck portion of the container, the outer surface of the container having a shoulder region where an outer curvature of the container transitions inwardly from the sidewall portion to the neck portion, the pitch or spacing of the plurality of interconnecting tabs and the plurality of slits and the plurality of interconnecting features being smaller in the shoulder region compared to a region away from the shoulder region where the curvature is smaller relative to the curvature in the shoulder region; the plurality of interconnection tabs are arranged adjacent a first edge of the first side, the plurality of interconnection features are arranged adjacent a second edge of the second side, and at least one of the first edge and the second edge has a curved profile extending from a first end to a second end of the container.

19. The container of claim 18, wherein the first side or the second side has a curved profile.

20. The container of claim 18, wherein the plurality of interconnecting features comprises a plurality of D-shaped slots, or a plurality of interconnecting tabs and a plurality of slits.

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