Interconnection means for multi-part containers

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 ART]]

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

[0002] (Background of the Invention) Paper bottles such as molded fiber bottles, fiber bottles or pulp bottles are degradable and widely recyclable, which brings environmental benefits. However, the current manufacture of paper bottles as containers requires production from a plurality of parts that need to be joined together with glue, which is complex and costly, and involves the use of a significant amount of adhesive (e.g., glue) and time. The use of adhesive during the assembly process presents several challenges. In particular, in the case of pulp bottles, since the adhesive needs to be applied on detailed paths, the process is slow and can result in low production output and high cost. In addition, the properties of adhesives 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 cause delamination of the layer on the pulp surface, thereby rendering it non-functional. Most of the pulp still remains intact, but is mechanically non-functional due to adhesive delamination.

[0003] Corrugated cardboard is known to have techniques using slots and tabs for closing or connecting. However, in most cases these assembly features are arranged on the outer portion of the container and affect the smoothness of the surface. These assembly features are also typically used for connecting structures on corner or substantially planar surfaces (e.g., paperboard panels) that do not contain complex three-dimensional shapes. Furthermore, when a tab is inserted into the opening during engagement, it is difficult to operate the tab without folding or bending the tab, which can lead to a source of weakness when a load force is applied.

[0004] Therefore, there is a need for improved means of joining container parts together that reduce the use of adhesives while improving the overall strength, performance, and recyclability of the container. [Overview of the Initiative] [Problems that the invention aims to solve]

[0005] (summary) Embodiments described herein can address the aforementioned need by providing interconnection methods and apparatus that can mechanically connect multiple parts of a container together. The container may be formed from multiple parts. The interconnection methods 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 means may utilize a plurality of locking features for mechanical fastening within a plurality of complementary locking features formed along the edge of one part of the container and within a portion of the other part of the container. When the plurality of parts are in an assembled configuration, the locking features are located within the enclosure of the container and form a smooth seam on the outer surface of the container.

[0007] In some embodiments, the first or second edge includes a curved section. In some embodiments, one or more of a plurality of interconnecting tabs and slits are formed within the shoulder area of ​​the container. In some embodiments, the plurality of interconnecting tabs and slits have a shape, size, or spacing that varies along the first edge. Alternatively, the interconnecting feature includes 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 includes a plurality of slots. In some embodiments, the plurality of slots have a D shape.

[0008] In some embodiments, the engaged interconnection tabs are aligned with the inner surface of the container. In some cases, the inner surface 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 the framework shell of the container, and the framework 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 interconnecting features configured to interlock 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 to be joined together, where at least the first side of the two or more sides comprises a plurality of interconnecting tabs and slits, and the second side to be joined with the first side comprises a plurality of interconnecting features, and when the first and second sides are joined together, the plurality of interconnecting tabs are located within the internal region of the container. 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 or second side has a curved outer shape. In some embodiments, the container is formed from recycled or biodegradable pulp material.

[0012] In another aspect, the present invention provides a method and apparatus for joining together molded pulp, fibers, or paper parts. This can be a single shell joined together, or a hinged shell joined along a hinge. In some embodiments, the joining does not require glue. This can enable the cost-effective mass production of containers. This approach eliminates or reduces adhesives, thereby improving the strength, performance, and recyclability of the containers.

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

[0014] In a different, further related aspect, the present invention provides high-barrier or waterproof containers using one of many forms of liners, liners fitted with fitments, single-piece liners with integrated fitment features, or coatings encapsulated by mechanically interconnecting pulp shells. Thus, the outer shell can be separated for recycling, and the plastic liner can be discarded or recycled, where applicable. For example, this application provides the following items. (Item 1) It is a multi-part container, A first shell part having multiple interconnection tabs and slits on a first edge, A second shell part having a plurality of interconnection features on a second edge, wherein the plurality of interconnection features are connected to the first edge when the first shell part and the second shell part are connected to form the container, and the second shell part and Equipped with, A multi-part container in which, when the plurality of interconnecting tabs and slits on the first edge engage with the plurality of interconnecting features on the second edge, the engaged interconnecting tabs are located within the internal region of the container. (Item 2) The multi-part container according to item 1, wherein the first or second edge comprises a curved section. (Item 3) The multi-part container according to item 1, wherein one or more of the plurality of interconnection tabs and slits are formed within the shoulder area of ​​the container. (Item 4) The multi-part container according to item 1, wherein the plurality of interconnecting tabs and slits have a shape or size that varies along the first edge. (Item 5) The multi-part container according to item 1, wherein the plurality of interconnecting tabs and slits have intervals that vary along the first edge. (Item 6) The multi-part container according to item 1, wherein the interconnection feature comprises a plurality of tabs and slits having the same size and shape as the interconnection tabs and slits on the first edge. (Item 7) The aforementioned interconnection feature is a multi-part container as described in item 1, comprising multiple slots. (Item 8) The aforementioned multiple slots are D-shaped, as described in item 7, for the multi-part container. (Item 9) The multi-part container according to item 1, wherein the engaged interconnection tabs are aligned with the inner surface of the container. (Item 10) The multi-part container described in item 9, wherein the inner surface is a curved surface. (Item 11) The multi-part container according to item 1, wherein the first shell part and the second shell part are formed from recycled or biodegradable pulp material. (Item 12) The multi-part container according to Item 11, wherein the pulp material is selected from the group consisting of wood pulp and paper pulp. (Item 13) The multi-part container according to Item 1, wherein the first shell part and the second shell part form a framework shell of the container, and the framework shell is 100% recyclable. (Item 14) The multi-part container according to Item 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 the interconnecting features. (Item 15) The multi-part container according to Item 1, further comprising a fitment and a neck portion that supports the fitment. (Item 16) The multi-part container according to Item 15, wherein the fitment comprises one or more interlocking features configured to engage with one or more complementary features on the neck. (Item 17) The multi-part container according to Item 15, wherein a liner is connected to the multi-part container by the fitment. (Item 18) A container, comprising: a single pulp-molded open shell having two or more sides to be joined together; wherein at least a first one of the two or more sides comprises a plurality of interconnecting tabs and slits, a second side configured to be connected to 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) The container according to Item 18, wherein the first side or the second side comprises a curved outer profile. (Item 20) The container according to item 18, wherein the interconnection feature comprises a plurality of D-shaped slots, or a plurality of interconnection tabs and slits.

[0015] (Integrated by reference) All publications, patents, and patent applications described herein are incorporated herein by reference to the same degree as each individual publication, patent, or patent application is specifically and individually indicated to be incorporated by reference.

[0016] Novel features of the present invention are described in detail in the appended claims. A deeper understanding of the features and advantages of the present invention will be obtained by referring to the following embodiments for carrying out the invention, which describe exemplary embodiments in which the principles of the present invention are utilized, and to the appended drawings. [Brief explanation of the drawing]

[0017] [Figure 1] Figure 1 provides a partial view of two container components with an exemplary internal interconnection structure. [Figure 2] Figure 2 shows examples of interconnection structures with excessive slit features according to several embodiments. [Figure 3] Figure 3 provides a partial view of another embodiment of the interconnection structure. [Figure 4] Figure 4 shows some embodiments of two pulp molded parts connected via an interconnection structure, according to several embodiments. [Figure 5] Figure 5 illustrates an exemplary process for engaging multiple interconnection structures. [Figure 6] Figure 6 provides a side view of interconnection features formed along the edges of two parts of a container shell, including a curved edge on the shoulder of the container. [Figure 7] Figure 7 provides an embodiment of a container comprising two parts connected by an interconnection structure, according to several embodiments. [Figure 8]Figure 8 provides an example of a pulp molded container shell comprising a number of parts connected by an interconnection structure, according to several embodiments. [Figure 9] Figure 9 shows loadable container components or parts with interlocking features according to several embodiments. [Figure 10] Figure 10 provides an example of a pulp molded container shell comprising a number of parts connected by an interconnection structure, according to several embodiments. [Figure 11A] Figure 11A shows an example of a pulp-molded container shell with interconnection features at different stages of the manufacturing process. [Figure 11B] Figure 11B illustrates examples of container shells with and without interconnection features formed during the molding process. [Figure 12] Figure 12 shows examples of tab and slot / slit features that can be formed by the cutting process. [Figure 13] Figure 13 illustrates an exemplary process for determining the cutting path. [Figure 14A] Figures 14A and 14B show examples of different cutting directions. [Figure 14B] Figures 14A and 14B show examples of different cutting directions. [Figure 15] Figure 15 shows an example of laser cutting. [Figure 16] Figure 16 shows an example of forming interconnection features using laser cutting. [Figure 17] Figure 17 shows an example of the cutting method. [Figure 18] Figure 18 shows an example of using a mandrel to secure a molded container shell. [Figure 19] Figure 19 shows an example of a loading handle formed along the periphery of a container shell. [Figure 20] Figure 20 shows an example of a loading handle formed on the bottom surface of a container shell. [Figure 21]Figure 21 shows an example of a container with a liner featuring fitment characteristics. [Figure 22] Figure 22 shows an example of a container having a cross-section to prevent the liner from rotating. [Modes for carrying out the invention]

[0018] (Detailed description of the invention) In the embodiments for carrying out the invention described below, many specific details are provided to give a thorough understanding of the invention. However, it will be understood by those skilled in the art that the invention can be practiced without these specific details. In other cases, well-known methods, procedures, and configurations are not described in detail so as not to obscure the invention. Various modifications of the embodiments described will be obvious to those skilled in the art, and the general principles defined herein may apply to other embodiments. The invention is not intended to be limited to the specific embodiments illustrated and described.

[0019] The present invention, as described herein, provides an interconnection method and system that can mechanically connect multiple parts of a container together to form a uniform, single 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 for human consumption. In some cases, the materials contained may be solid, such as powders or granules, tablets, and other fine particles. In other cases, the materials may be liquid. In these cases, the container may further comprise a liquid-holding container or bag. Examples of materials that may 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 may be a hollow shell comprising two or more parts that are connected together. In some embodiments, the two or more parts of the shell may be fixedly connected via internal interconnection features.

[0022] Figure 1 provides a partial view of two container components having an exemplary internal interconnection structure. As shown in Figure 1, the internal interconnection structure may comprise a plurality of internal interconnection tab portions 101 and interconnection slit portions 110 arranged along the edge of a first component of the container shell 100. In some embodiments, the plurality of interconnection tab portions 101 are interposed between a plurality of interconnection slit portions 110 formed on the same edge, and overlapping portions 107 may be formed by adjacent tab portions 101 and slit portions 110. In some embodiments, a second component of the containing shell 120 may have the same interconnection features along its edge for interlocking with the edge of the first component. The plurality of internal interconnection tab portions 101 can be inserted through a plurality of interlocking linear slit portions within the second component and designed to form a secure locking configuration.

[0023] The internal interconnect tab portion 101, as depicted in Figure 1, may also be referred to as a mushroom-shaped interconnect tab feature. In some embodiments, the mushroom-shaped interconnect tab feature 101 may comprise a tip portion 103, a root portion 105, and a relief groove portion 107. The tip portion 103 may be designed to assist in guiding the tab feature into the complementary slit 110 during manual or automated assembly. The relief groove portion 107 may be designed to interfere with the relief groove portion of the interlocking tab to prevent the contact edges of the two parts from separating once they are in a locked configuration (as shown in Figure 4). In some cases, the edges within the relief groove portion 107 can withstand the pulling force between the two parts of the connecting edge applied by the interfering tab. In some cases, after multiple internal interconnect tabs have engaged with a linear slit, the relief groove portion 107 can provide a secure locking that prevents relative movement between the tabs and slits in one, two, three, or more directions.

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

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

[0026] As depicted in Figure 1, the root portion 105 and the relief groove portion 107 of the neighbor interconnect tab feature define the slit portion 110. The slit portion as depicted in Figure 1 may also be referred to as an overlapping linear slit portion. In some embodiments, the relief groove portion 107 of the interconnect tab feature may be part of the overlapping linear slit portion 110, such that the relief groove portion is shared by the interconnect tab portion 101 and the neighbor slit portion 110. In some embodiments, the relief groove portion 107 may be the region where a pair of locking tab features interfere with each other when in a locking configuration. The pitch and shape of the slit portion may be designed to match the location of the interlocking tab portion.

[0027] In some embodiments, the overlapping linear slit feature may have a curved outer shape 210, as shown in part A of Figure 2. The outer shape of the overlapping linear slit feature may be a convex curve with any preferred curvature. In other embodiments, the outer shape 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 slits may be alternating, forcing the interlocking tab to flex in order to pass through them, which may result in different locking performance (as shown in part B of Figure 2). The overlapping slit feature may employ various shapes and provide a contact edge for fixing the interlocking 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 relief groove portion of the neighboring interconnecting tab feature. In some embodiments, the thickness of the overlapping linear slit feature may be substantially equal 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 equivalents. Alternatively, or in addition, the thickness of the pulp material may be as little as 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 equivalents. 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 in terms of the integration and ease of assembly of two container shells that engage together.

[0028] In some cases, the thickness of the overlapping linear slits may be increased to allow interconnecting tabs to pass through with minimal or no resistance. In some cases, when the interconnecting tab feature enters the interlocking linear slit feature, the slit feature may be opened to some extent to accept the tab feature with minimal interference. In some cases, a pulp shell with variable thickness may pass through a given linear slit with reduced interference. For example, a tab feature with variable thickness may be inserted into the slit or slot with a constant thickness. This reduction in interference with larger slits results in a larger visible external gap between assembled shells in the assembled bottle. This may be undesirable in some cases where appearance is important or the container integrity of the linerless container is important. These gaps may become more visible when the assembled shells are forcibly pulled apart and the shells separate to the point where the trailing edges of the tabs of the opposing shells contact each other and resist separation of the shells. The thickness dimensions of the linear slits and other dimensions are important to provide the desired bottle performance.

[0029] In some embodiments, linear interconnection slit features do not need to be formed in conjunction with neighbor interconnection tab features. For example, instead of multiple slit features formed on the edges interposed between interconnection tab features, only the slit features may be included within a portion of the container component, such as the interconnection feature in Figure 6. The linear slit features may or may not be formed on the edges of the container component. In some embodiments, additional features such as slits (e.g., 609 in Figure 6) may be employed. Slit 609 may allow for a larger opening during the engagement process so that resistance can be reduced.

[0030] Figure 2 shows examples of interconnect structures with oversized slit features according to several embodiments. Designing slit features with a width exceeding the width of tab features (i.e., undersized interconnect tab features) may enable the engagement process with minimal resistance. As depicted in Figure 2, the mushroom-shaped interconnect tab may have a maximum width of 203, which is smaller than the width of the complementary linear slit 205. A 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 interlocking slit feature can be any number, as long as an overlapping portion for engagement (e.g., 107 in Figure 1) is provided and the root portion of the tab feature is not weakened. In some embodiments, the dimensions of the overlapping portion may vary 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. Considering the fixed pitch between features, there is a trade-off between the width of the tab root and the width of the slot. Wider slots are helpful in shell assembly and can accommodate mismatches between shells as they engage with other shells. In some cases, the two sides to be connected together may have identical interconnection features so that the slit on one side may be identical to the slit on the opposite side. In this case, the interconnection tab features may have a width that is the same as or slightly smaller than the width of the slit features formed on the same side. In alternative cases, the two sides to be connected together may have different interconnection features so that the slit on one side does not need to be identical to the slit on the opposite side. In this case, the interconnection tab features may have a width that is smaller than, equivalent to, or greater than the slit formed on the same side.

[0031] Figure 3 provides a partial view of another embodiment of the interconnection structure. As shown in Figure 3, the internal interconnection structure may comprise a plurality of internal interconnection tab features 301 positioned along the edge of one part of the container shell, and a plurality of slot features 303 positioned close to the edge of another part of the container shell. The location of the slot features 303 relative to the edge of the shell part determines the overlapping region where a double-wall feature is formed. If a larger region of double or multiple walls is preferred, the locations of the interconnection slots may be arranged further away from the edge of the shell part.

[0032] In some embodiments, the interconnection slot may have a D-shape with a maximum width 307 that is smaller than the maximum width 305 of the interlocking interconnection tab feature. In this case, the interconnection tab feature may deform slightly when passing through the interconnection slot opening 309, as shown in Figure 3. The width of the interconnection 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 edge of the slot when the interconnection feature is in a locking configuration, and thus preventing the connected shell components from separating. On the other hand, the width difference may be designed to provide desired flexibility so that the tab can deform to some extent when passing through the slot.

[0033] Once the interconnecting tab feature passes through the slot opening, the relief groove portion of the tab feature can rebound and form a locking portion between the two shell parts. In some cases, the gap may be visible 311 within the locked interconnecting feature. The relief groove portions 107 may interfere with the relief groove portion of the meshing tab once they are in a locked configuration and may be designed to prevent the contact edges of the two parts from separating 313, as described in any of the foregoing, and may also interfere with the edge of the D-shaped slot once they are in a locked configuration and may be designed to prevent 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 under-interconnection slots. For example, longitudinal slits within the interconnection tab may be used to allow flexible deformation of the interconnection tab during insertion without forming permanent deformation or folds.

[0035] Figure 4 shows some embodiments of two pulp molded parts connected via an interconnecting structure, according to several embodiments. As shown in Figure 4, a plurality of internal interconnecting tab features and overlapping linear slits are assembled along the edges of the two pulp molded parts. The plurality of interconnecting features may be identical on the connecting edges from separate parts where the two parts abut. Once the interconnecting features are configured to lock together, the plurality of contact edges and surfaces, such as in the overlapping portion 401 and the linear slit portion 403, may be configured to ensure a strong bond between the two parts. The plurality of interconnecting features may help distribute the load force so that the force applied to each pair of interconnecting features is reduced, preventing the two parts from splitting at the joint under load. In some embodiments, the plurality of assembled interconnecting features may be configured to effectively prevent substantial relative motion in any direction, such as translation or rotation. In some embodiments, the two connected parts may be allowed to have relative rotational motion about an axis 405 along the contact edges. The flexibility in adjusting the rotation angle around 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 a locked configuration, movement around axis 405 can be restricted by the engagement on the other side of the container shell.

[0036] Figure 5 illustrates an exemplary process for engaging multiple interconnection features. As shown in Figure 5, an internal interconnection tab from one part of the shell may be inserted into a complementary slit in a direction not aligned with the plane of the meshing part 501. The engagement angle 507 can define the direction of the engaging movement between the two shell parts. In some cases, a tab feature on one shell part may enter a slot feature on the meshing part from the outer surface of the meshing part at the engagement angle. The engaging movement may be performed by moving one or both of the shell parts. Once the interconnection features have passed through each other, the interconnection tabs may flex so as to protrude from the inner surface of the bottle and then return to the inner surface of the shell part 503. Once the interconnection tabs have fully rebounded or been forced back, they may form 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 Figure 5, the engaged interconnect features are formed in close proximity to the inner surface 505 of the container shell. The surfaces of the locked interconnect features can be substantially aligned with each 509. In some embodiments, the interconnect tabs are formed within the curved surface as an extended portion of the shell part so that, when in the locked configuration, the interconnect tabs can be aligned with other shell parts from the inner surface. It should be understood that as the material thickness increases, more surface contact exists between the hook features. This distributes the pulling force over more hook surfaces. Similarly, thicker material can allow the system to function to resist the pulling force despite some misalignment of the hook portion of the tab, and the additional material thickness ensures that the degree of contact between the hooks remains the same. Features formed within the hooks that serve to increase surface contact between the hooks or accommodate some degree of misalignment, but do not increase the wall thickness, are considered. This is advantageous for reducing wall thickness from an environmental point of view, and in such cases, the formation of features to improve resistance to separation from pulling is considered. Achieving increased surface area for resistance may involve the use of folding, the addition of localized materials, or localized offsets of pulp shell materials.

[0037] Figure 6 provides a side view of interconnect features formed along the edges of two parts of a container shell. As shown in Figure 6, interconnect tab features 604 on one part and complementary interconnect slit features 609 on the other part can engage to ensure assembly of the container shell. As depicted in part A of Figure 6, the interconnect tab / slit features do not need to be uniformly spaced. In some embodiments, the spacing or pitch of the interconnect features may be designed for best performance and aesthetic effect. In some embodiments, the pitch or spacing of the interconnect features may vary in response to the curvature of the surface or side of the shell parts. For example, in the shoulder area, where the bottle's shape transitions from the side wall to the neck area or other area with a change in shape, 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 interconnect features do not need to be uniform. The dimensions and / or shape of the interconnect 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, the wide interconnect tab feature 607 may be located along the straight side, while the narrow interconnect tab features 605-1, 605-2 may be located along the curved side, such as the shoulder area or corner of the bottle. Relatively smaller sizes and / or pitches of the interconnect features can provide flexibility to adapt to various curvatures and contours. Modified pitches and sizes of interconnected features can also be applied along the 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 mentioned above, the pitch or spacing of interconnect features on one side of a container component may or may not be uniform. The shape or size of interconnect features on one side of a container component may or may not be constant. The interconnect features on one side of a container component may vary in at least one of the shape, size, spacing, or pitch. Alternatively, the interconnect features on one side of a container component may be constant.

[0039] Part B of Figure 6 shows an assembled container with interconnect features connected. As shown in the figure, interconnect tab / slit features can be formed along a straight edge 611, a curved outline 613 (e.g., shoulder area), and a corner 615. The cross section of an interconnect tab feature may have a curved shape when formed within a region with a curved outline. In some embodiments, interconnect tabs are formed within a curved surface as an extended portion of a shell part, such as an interconnect tab formed within a shoulder region. The formed interconnect features may then have a curved surface according to the curvature of the shell part. The formed interconnect features may have a curved shape in one or more directions. For example, the interconnect features may be curved along the side of the container, perpendicular to the side of the container, or a combination of both. The assembled interconnect features may be flush with a flat planar surface, or may not be. For example, when the container has a rectangular cross section, the interconnect features may be formed and assembled on a substantially planar surface. In another embodiment, when the container has a cylindrical shape, the interconnect features may be formed and assembled on a curved surface. The interconnect features can 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 side walls of a cylindrical container), or a combination of both (e.g., the shoulder area of ​​a cylindrical container).

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

[0041] In some embodiments, multiple fiber or pulp molded parts can be connected via provided interconnecting means to form a container with a hollow body for filling. Figure 7 provides an embodiment of a container comprising two parts connected by multiple interconnecting features, according to some embodiments. As shown in part A of Figure 7, once the two parts of the container are assembled, the interconnecting features are positioned within the enclosure area of ​​the container so as not to be visible from the outside of the container. As previously stated, once the two parts are in a fixed locking configuration, the interconnecting features can be substantially aligned with the inner surface of the container. In some embodiments, if additional robustness of the container is required, 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 outer surface of the container. The seam observed from the outer surface of the container may be formed by multiple interconnecting slits or edges of slots. Thus, adjustment of the shape, spacing, and / or pitch of the slits or slot features can achieve a variety of aesthetic effects.

[0042] In some embodiments, multiple interconnection features may be arranged along the edges of the container components. Multiple interconnection features can be located anywhere on the shell components. Figure 7 provides a side view of internal interconnection features along the side of the container. However, the location should not be limited to the side of the container. In some embodiments, interconnection features may be formed on the bottom, top, or sides of the container. The edges where interconnection features 705 are formed, either there or in close proximity there, do not need to be straight. For example, when the edge is on a side wall, it may have a curved outline 703 (part B of Figure 7), a triangular shape, or not be parallel to the longitudinal axis of the bottle. Thus, interconnection slit / slot features on the same edge do not need to be aligned with each other. The outline of the seams, as visible from the outside of the bottle, can therefore be further adjusted for aesthetic effect and best performance.

[0043] Interconnecting features can be formed along the entire side or a portion of the side of a shell component. For example, interconnecting features can be formed only on the lower half of the edge, while the upper half of the edge can be connected through other connecting means. It should be noted that various combinations of connecting means can be used to connect multiple shell components, even on a single side. For example, a portion of the side can be connected using adhesive force, while another portion can be connected using the interconnecting features described. In other cases, other attachment means such as heat seals, adhesive or non-adhesive tapes, sealing waxes, or snaps can be used to provide additional sealing or connection in addition to the interconnecting methods described. However, when no other materials are included in the container, the interconnecting methods and systems described provide a highly recyclable single-material container, which can be fully compostable and / or recyclable.

[0044] In some embodiments, the two interlocking parts may have the same interconnection features, such as internal interconnection tabs and overlapping linear slits, as described in Figure 1. In other embodiments, the interlocking parts of the container may have different interconnection features for each connecting part, such as in the embodiment in Figure 6. For example, on one interlocking side where two parts of the container are connected, the edge of the container shell part may have multiple interconnection tabs, while the interlocking portion of the other part of the container shell may have multiple complementary interconnection slots (e.g., the interconnection features in Figure 4). With respect to a single part of the container shell 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, interconnection mushroom features may not be required for each tab feature. Some simple tab features that do not need to be interconnected can be more easily followed by the tightly curved shape within the container. These simple tabs may then have interconnecting mushroom tabs before and after them to hold the shell together.

[0045] Figure 8 provides an embodiment of a fiber or pulp molded container shell comprising a number of parts connected by an interconnecting structure. The interconnecting structure described herein may comprise a plurality of internal interconnecting tabs and interconnecting slits / slots, where, once the parts are connected, the engaged interconnecting features / tabs are positioned within the internal region 803 of the container. In some embodiments, a single part of the container may have one, two, three, or more interconnecting features on its edges. These interconnecting features may or may not be uniform on each edge or all of the edges. In some embodiments, a part may have internal interconnecting tabs 801-1 on one side and interconnecting slits or slots 801-2 on the other side. Interconnecting tabs and interconnecting slits or slots formed on the same shell part may or may not be interlocking features. In some cases, as shown in Figure 8, tabs and slots formed on a single shell part may be interlocking features for mutual connection, allowing two identical shell parts to be connected to each other. This may be beneficial for simplifying the manufacturing process.

[0046] As shown in Figure 8, interconnection features may be located anywhere on the container, such as on the shoulders, neck, corners, and bottom of the container. The edges to be connected may have various combinations of attachment means. The numerous parts of the container do not need to be joined together by having internal interconnection features along the entire length of the joint edge. For example, the joint edge may have internal interconnection features on part of it, forming a smooth mechanical connection, while other parts may be joined by other types of connection features such as flanges, knob features, overlapping flaps, hinged overlapping flaps, etc. As shown in Figure 8, other connection means may be used to join the numerous parts together and form an assembled container 805. As depicted in Figure 8, the container may have a flange side 807 on one part and a smooth mechanical interconnection side 809 on the other part.

[0047] In some embodiments, the pulp-molded container shell may have molded features on the neck for directly receiving a lid, membrane, cap, twist cap, snap cap, or even a threaded cap. Locking features such as 813 in Figure 8 may be molded into the pulp. Complementary features within the fitment engage with the locking feature 813 so that the fitment is fixed to the shell body while providing through-hole access to the contents of the container. The fitment may or may not have threaded features for receiving a lid (e.g., 617 in Part B of Figure 6). 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 can provide options for more shape or detail than the shell body. In some embodiments, the fitment may be formed from molded or formed pulp or fibers. The cap may be formed from thermoformed pulp or fibers. The lid or cap may be provided across the fitment. The lid may be removable or replaceable. Its connection to the fitment and shell is physically connected and may reduce the forces of lid removal and installation, including rotational, pulling, and pushing forces. The interlocking tabs 813 may contact the fitment and play a role in reducing the movement of the fitment caused by these forces.

[0048] In alternative embodiments, the fitment may be prevented from having rotational movement relative to the container by the non-circular cross-sectional shape of the container at the neck. In some cases, the interlocking tabs described above may not be required at the neck of the container. Figure 21 shows an embodiment of a container with non-circular cross-sections 2101, 2103 at the neck. Rotational movement between the fitment and the connected container can be prevented by the non-circular cross-section in the engagement region. For example, the cross-sectional shape of the fitment at the neck may be non-circular, and the container shell for engagement with the fitment may have an engagement shape, which is also non-circular so as to prevent the fitment from rotating relative to the container at the neck. The cross-sections of the fitment and the neck of the container can have any non-circular shape, including, but not limited to, elliptical, rectangular, wedge-shaped, irregular, and various others. Note that the fitments described may be independent fitments, fitments connected to a pouch, or fitment features integrated with a liner.

[0049] Figure 22 shows an embodiment of a container comprising a liner 2203 with an integrated fitment 2201. As illustrated in the figure, the blow-molded liner 2203 with the integrated fitment 2201 may be integrated into a pulp-molded container shell 2205. The fitment may have features such as threads 2207 for connection to the container shell. The liner can be formed from a blow-molding process. The blow-molding process may include, but is not limited to, injection blow, stretch blow, parison blow, 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 the container is filled, and the thermal energy generated from the RF interacting with the metal foil is used to seal the fitment to the liner. The heat generated by the RF energy adheres the fitment to the plastic liner through melting or activation of an adhesive. The fitment may be attached to the shell by heat, welding, high-frequency induction welding, glue, flange, mutual locking connection, friction, snap, lock, clip, rail, mechanical deformation, or by the use of any other mechanism known to those skilled in the art.

[0050] In some embodiments, the container may be provided with 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 polymers, including LDPE, HDPE, PET, PS, PP, or biopolymers. Polymer types may include polyethylene terephthalate (PET), high-density polyethylene (HDPE), polyvinyl chloride (PVC), low-density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), and other polymers. Polymers may be FDA-approved plastics. The recycling group may include plastic identification codes 1, 2, 3, 4, 5, 6, and 7. Polymers may be consumer post-use recycling (PCR) versions of the polymers described or hybrids of PCR and raw materials. The recycling group may include a set of plastic or polymer types that can be recycled together using a recycling process that does not require separation of plastic or polymer species before the recycling process.

[0051] The container shell may comprise any structural body that provides the enclosure. Figure 8 shows a container in a cylindrical shape, however, the shape should not be limited to a cylindrical or symmetrical form. The structure of the container may or may not be geometrically symmetrical. The walls of the container may be in any configuration such that the wall contours may be straight, curved, or any other form. In some embodiments, the internal interconnection features provided 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-part shell, a multi-part shell, or a combination thereof. A clamshell can be a fiber or pulp molded body with hinges that may be located on either side of the clamshell and a number of internal interconnection features included on the opening side for closing the body. A two-part shell can comprise two fiber or pulp molded body parts having internal interconnection features for fastening the parts together. A two-part shell can be a two-part assembly of two halves of a body. However, the two parts do not need to be of equal size. For example, one part may be a larger part of the body structure than the other. A two-part shell can be joined together along any direction on any surface. For example, a two-part shell may be an upper half and a bottom half that are joined together not along the side parallel to the longitude axis of the container. Once the two parts are joined, interconnecting tabs may be positioned within the internal region of the container, resulting in a smooth connecting seam on the outer surface. A multi-part shell may comprise two-part fiber or pulp molded body parts, or three-part fiber or pulp molded body parts, which are combined with a cap or bottom for securing the multi-part shell in a closed form. The parts of the container shell may be assembled together only by the provided interconnecting features, or through a combination of the interconnecting features and any other means known to those skilled in the art. Heat-shrinkable film may be used to secure the neck to retain the fitment and prevent undesirable rotation of the fitment (e.g., 619 in Figure 6). Heat-shrinkable material may be used as a band or cup at the bottom of the container to add additional retention capacity and increase the anti-tipping performance of the container. Adhesives may be added to selected areas or tabs to improve structural performance. Tape may also be applied to help improve the resistance of the shell to separation provided by the interconnecting tabs.

[0053] Figure 9 shows stackable container parts or components with interlocking features according to several embodiments. The stackable container parts or components may be pulp molded products to be moved to an assembly site or a site for manufacturing the interlocking features. In some embodiments, the container parts or components may be stackable. In some cases, a uniform and consistent stacking space between shells is desirable. A first part of a container may be stacked on a second part. Any number of container parts or components may be stacked on top of each other. Molded features within the container parts or components may prevent stacked parts from moving laterally relative to each other. In another embodiment, the stacking features limit the degree to which stacked shells are nested with each other. Features for this purpose may be called stacking knobs 901 and can be molded into the shells. These stacking knobs are visible in Figure 6, for example, 621. In another embodiment, additional pulp may be molded into the shells with features that help control stacking or other handling features. During the finishing process, these additional features, such as loading knobs, can be removed.

[0054] During assembly, two or more joint edges, including internal interconnect features, may or may not engage in parallel. For example, an interconnect tab on the 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 feature on the other side. Alternatively, interconnect slits / slots from two or more edges of parts can be operated to have an engagement orientation for receiving interlocking interconnect tabs in parallel. After the interconnect tab enters through the interlocking interconnect slit / slot from the external region of the container, the locked tab may be positioned within the internal region of the container without creating permanent bending or deformation.

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

[0056] In some embodiments, interconnection features can be formed along the entire side or a portion of the side of the shell component. For example, interconnection features can be formed only on the lower half of the edge, while the other half of the edge may be connected via other connecting means. It should be noted that various combinations of connecting means can be used to connect multiple shell components, even on a single side. For example, a portion of the side may be connected using adhesive force, while another portion may be connected using the provided interconnection structure. In some embodiments, the container shell may use different connecting means on different sides, portions, and / or areas of the container. In another example, other attachment means such as heat seals, adhesive or non-adhesive tapes, sealing waxes, or mechanical connections such as locks, fasteners, and snap locks may be used in addition to the provided interconnection method to provide a stronger seal or connection. However, when no glue or additional material is contained within the container shell, the interconnection methods and systems described provide a highly recyclable single-material container, which can be fully compostable and / or recyclable.

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

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

[0059] Since the thickness of the material can be adjusted for best performance (e.g., required material strength), the design of interconnection features in size, arrangement, pitch, spacing, and shape (e.g., tab features and slit / slot features) can also be adjusted accordingly to enable a smooth outer surface, force-free insertion during the engagement process, tight mating after engagement, and equivalent.

[0060] The 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 herein. The shell parts may or may not be made from the same material. The materials may be combined for the purpose of cost reduction, increased structural performance, increased impact damping, and to provide areas of higher tolerance and areas of lower tolerance within the same container, for example, so that high tolerance areas can be specifically located for interconnection features. The container shell may be assembled for desired structural performance and to allow for disassembly and to facilitate the recycling or composting of unassembled materials.

[0061] Container shells are formed in double or multiple wall configurations to enable heavy load encapsulation and / or dispensing. One or more shell parts may be formed from two or more layers to enable container designs with higher load-bearing ratings. Alternatively, containers may be assembled as single-wall containers to reduce material consumption. In some embodiments, interconnection features may be provided to enable the conversion of the container to a container more suitable for robust performance (higher overall rigidity) through the addition of one or more wall parts. For example, interconnection features may be provided in areas where maximum mechanical stress is applied so that surplus walls can be added by connecting through interconnection features on the inner or outer surface or on the container shell. Any description of double-wall configurations herein may also apply to multiple walls.

[0062] The location of interconnection slot / slit features can also determine a double-wall configuration. As previously mentioned, the distance from the location of the slot / slit feature to the edge determines the overlapping area. Therefore, an increase in the space from the interconnection slot / slot feature to the edge can 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 have double-wall areas. The double-wall areas may or may not be connected, and the connection may be through interconnections or other connecting means as described herein.

[0063] Internal interconnect features may allow a smooth outer surface to be formed from two pulp-molded parts, components, or halves (e.g., assembled container 805 in Figure 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 is flat or can sit flat in the absence of any protruding features (e.g., 1001 in Figure 10). A flat bottom can be further enhanced by overlapping area induced by the interconnect structure (e.g., a double-layer configuration), improving load capacity and structural integrity.

[0064] Multiple interconnection features can help distribute load forces so that the force applied to each pair of interconnection features is reduced, preventing the two parts from splitting under load.

[0065] As described above, a pulp-molded container shell may have multiple interconnection features to connect one or more parts of the container shell together. Container shells with interconnection features can be formed in various ways. The formation of the interconnection features and the body of the container shell may be simultaneous or separate. In some embodiments, the interconnection features may be formed after the container shell has been molded. For example, the interconnection features may be formed by removing material from the molded container shell. Alternatively, the interconnection features may be formed in parallel with the molding of the container shell. For example, the associated interconnection features may be contained within a mold used in the molding process. In some cases, some or part of the interconnection features may be formed by the pulp-molding process, while others are formed after the pulp-molding process. For example, some low-tolerance edges of the interconnection features may be formed by the molding process, and high-tolerance edges of the interconnection features may be formed by a cutting process, or vice versa.

[0066] Figure 11A shows an embodiment of a pulp-molded container shell with interconnecting features at different stages of the manufacturing process. In some cases, the interconnecting features may be formed after the container shell has been pulp-molded. As shown in Figure 11A, the container shell 1101 may be formed after the pulp-molding process. In some cases, the interconnecting features may not be formed during the pulp-molding process. In some cases, features such as long sidewalls and flanges may be formed together with the molded container shell during the pulp-molding process. These features may or may not be removed in a further manufacturing step. This can provide flexibility in connecting the container shells. For example, the pulp-molded container shell 1101 may have at least two types of connecting features, such as flanges and interconnecting features (e.g., tabs and slots). When flanges are desired, flanges formed together with the pulp-molded container shell may be retained to connect shell parts as described in any of the foregoing. However, if interconnecting features are desired on the side and thereby flanges are formed, flanges may be removed and interconnecting features may be formed in place. The removal of the molding material may be intentional and detailed. Various types of manufacturing processes may accompany pulp molding processes such as thick-wall processes, transfer molding, thermoformed fiber molding, thermoformed polymer sheet molding, processed pulp processes, injection molding, vacuum forming, stamping, or deep drawing. In some cases, when high-quality thin-walled containers are desired, a thermoformed molding process may be carried out. The pulp molding process may include secondary processes or steps to obtain smooth internal and external surfaces of the container shell, or it may not.

[0067] In some cases, interconnect features are not formed during the molding process. In other cases, some or some interconnect features may be formed during the molding process. Figure 11B illustrates embodiments of container shells with and without interconnect features formed during the molding process. As mentioned above, interconnect features do not have to be formed during the molding process. For example, container shell 1107, which has a substantially straight edge, may be formed by pulp molding. In some cases, some or some 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 and side edges of a 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 Figure 11A, operations for further forming interconnection features 1103, 1105 may be applied to the pulp-molded container shell 1101. As described in any of the foregoing, interconnection features may be formed at any location, along any side of the pulp-molded container shell. The manufacturing process provided may offer flexibility in determining the location of the interconnection features. Container shells with interconnection features formed at different locations may 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, while the overlapping flap arrangement is left as is for the bottom of the shell. Different shell parts 1105 may have interconnection features on the bottom in addition to the sidewalls and shoulders by a further cutting or trimming process.

[0069] Multiple interconnect features may be formed on the pulp-molded container shell. The interconnect features may be formed by removing material from the pulp-molded container shell using processes such as cutting. Various shapes and dimensions of the interconnect features can be formed by the cutting process. The various different shapes and dimensions of the interconnect features may be designed to result in an assembly process or performance of the assembled container. For example, the shape and dimensions of the interconnect features may be selected so that the direction of engagement movement between two shell parts can be determined, or the tightness of the interlocking interconnect features can be determined.

[0070] Figure 12 shows embodiments of tab and slot / slit features that may be formed by a cutting process. As described in any part of this specification, the interconnected features may comprise at least tab portions 1200-1, 1210-1, 1220-1, 1230-1, 1240-1 and slot / slit portions 1200-2, 1210-2, 1220-2, 1230-2. The tab and slot / slit portions may include various shapes or configurations. For example, the tab portions may comprise front edges 1201, 1211, 1231, side edges 1202, 1212, 1222, 1232, rear edges 1203, 1214, 1233, 1241, and root portions 1206, 1216. The rear edges may also define part of the slot or slit portion. The slot or slit portion can 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 Figure 12, the leading edge of the tab portion may have various curvatures and may have 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 have 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 can collectively influence the direction of engagement movement between the two shell parts. For example, an asymmetrical side edge may allow the tab to enter the meshing slot at an oblique 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. Trailing edges may be present 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 cutting edge may affect the tightness of the interlocking features. For example, as described in any of the foregoing, the overlapping portion defined by the trailing edge and cutting edge may be dimensionally varied to improve the strength of the engagement.

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

[0074] As mentioned above, interconnect features can be formed within the curved surface as an extended portion of the shell part. The interconnect features do not need to 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 a variety of cutting methods, including, but not limited to, knife cutting, die cutting, punching tools, water jet, polishing 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, interconnect features may be formed using a single method. In other cases, 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 slitting knife may be used to cut the slit. In other cases, when a slot feature requires the removal of more material, a streaming cutter such as a laser, a thicker knife, a punch (which is knife-like 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 a feature to be formed on the pulp molded container shell. The cutting path may be defined according to the working edge of the interconnecting feature. The working edge may include the edges of tab and slot features, such as the front, side, and rear edges of a tab portion, the cutting edge, or the return cutting 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 with all of the working edges. Figure 13 illustrates an exemplary process for determining the cutting path 1300. The cutting path 1303 may be determined for the 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 dimensions and shape of the feature to be formed, the frequency of the feature, the area on which the feature is formed, the specific cutting tool, or the dimensions (e.g., thickness) of the material to be removed. The cutting path may be generated automatically or semi-automatically. In some cases, the cutting path may require one or more inputs, such as the desired shape or dimensions of interconnect features, the frequency of features, the cutting direction, the cutting action, and equivalents. In some cases, one or more steps in process 1300 may be generated automatically by the manufacturing machine. One or more of the parameters or inputs may be provided by the user each time the cutting path is determined. In some cases, one or more of the parameters or inputs may be selected from a set of parameters pre-stored in memory. In some cases, one or more of the parameters or inputs may be generated automatically by a computer program.

[0077] The flowchart of the process for determining the cutting path 1300 is for illustrative purposes only. Note that depending on the specific tool used for cutting, any of the steps may be skipped or the order may be changed. In the illustrated embodiment, the process may begin with establishing performance requirements for 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 inputs provided by the user. The performance requirements may be selected by the user from a set of pre-stored performance requirements. Next, the process may proceed to determining the desired interconnection features 1313. In this step, one or more parameters or requirements related to the interconnection features 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, symmetry or opposing tabs, and equivalents. In some cases, the desired interconnection features determined in this step may be associated with a single interconnection feature. The desired interconnection features may be inputs provided by the user. The desired interconnection features may be selected from a set of interconnection features pre-stored by the user.

[0078] Next, a cutting process may be selected.1315 This may include the selection of tools and methods for cutting. The cutting process may be selected from a variety of methods, but is not limited to, knives, die cutters, dies, punching tools, water jets, polishing cutters, laser cutters, hot wires, abrasive blasting, plasma cutting, stamping, punching, die cutting, or CNC machining. The cutting process may be input provided by the user. The cutting process may be selected by the user from a plurality of pre-stored cutting processes. The cutting process may be controlled by following a predetermined guide or template.

[0079] In some cases, the cutting direction may be selected.1317 The cutting direction may determine the direction in which the cutter approaches the container shell or the direction in which the container shell begins to be cut. Figures 14A and 14B illustrate embodiments of different cutting directions. In some cases, the cutting direction may determine whether the cutting orientation of the cutter relative to the container shell is normal to the surface to be cut. When the cutting orientation of the cutter is oblique to surface 1401, the cut may form angled features on the wall of the container shell. When the cutting orientation of the cutter is normal to surface 1403, the cut may form perpendicular features on the wall of the container shell. In some cases, the cutting direction may determine the direction in which the container shell begins to be cut. For example, as shown in Figure 14B, a single container shell may begin to be cut from one or more directions, including, but not limited to, the right side 1409, the right shoulder 1407, the left side 1405, the left shoulder 1405, or the bottom 1411. In some cases, the cutters may have a shape to adapt to the shape of the container so that a single cutter can be used to perform trimming on the side with a curved outer shape from a single direction. For example, cutter 1405 may have a shape to adapt to the shoulder and side wall area so that both the shoulder and side wall can be cut by a single cutter 1450 via a single parallel movement toward the container. Alternatively, the shoulder and side wall may be cut from different directions by separate cutters 1407, 1409. In some cases, the cutters may be modular and have various set shapes, which can be arranged to cut different outer shapes, different shells, or different shapes. This offers the advantages of cost savings and increased product flexibility. The methods and cutters described may be part of an automated manufacturing system. The container shell to be cut may be mounted on a mandrel. Details centered on the mandrel are described with reference to Figure 18. The cutters and cutting operations may be automatically controlled by a machine. The material to be cut during the cutting process may be removed from the cutting area in an automated mechanical manner.For example, material cut from the container shell can be removed through a vacuum, where there is an opening adjacent to the mandrel or cutter, allowing the cut material to be drawn out during the cutting process. Cut material within the 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 the periphery of the container shell or below the mandrel.

[0080] Referring back to Figure 13, next, a sequence of cutting operations may be selected 1319. The sequence of cutting operations may include the movement of the cutter relative to the container shell. The sequence of cutting operations may partition the cutting process into multiple operations. Next, the features of each area of ​​the container shell may be determined 1321. In some cases, different areas of the container shell may be required to form different interconnection features. For example, interconnection features formed on the bottom may not be identical to interconnection features formed on the side walls. In some cases, the number and frequency of interconnection features may be determined 1323. The frequency of interconnection features may include the spacing or pitch of multiple interconnection features of the same or different types. The frequency of interconnection features may or may not be uniform in the same area or along the same side, and the pitch or size of the interconnection features may vary according to the curvature or contour of the container shell. In some cases, the number of interconnection features of the same type may be determined. In some cases, the number of interconnection 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 into interconnection features along a predetermined side. In some cases, the cutting path may be adjusted for the partitioning of the cutting process 1325.

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

[0082] The laser cutter 1505 may move relative to the formed container shell 1507. In some cases, the laser cutter moves while the container shell is static. In other cases, the container shell moves while the laser cutter is fixed. For example, the laser cutter may be fixed in space, while the formed container shell passes through the laser cutter on a conveyor, as shown in the figure. Thus, 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, the laser cutter may be configured to move vertically 1509 so that a curved linear cut can be formed while the container shell moves through the laser cutter. 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] Figure 16 shows another embodiment of forming interconnect features 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 may work in coordination with each other on different edges of the interconnect feature. In the illustrated embodiment, the leading edge and tip side step 1605 may be formed by a first laser cutter 1605, and the trailing edge or slit 1601 may be formed by a second laser cutter 1607. The first laser cutter 1605 may be configured to move vertically so that the curved outline of the tab portion can be formed. The second laser cutter 1607 may be fixed and may form substantially linear and straight cutting edges. The speeds and travel paths of the first and second laser cutters may be designed so that the interconnect feature can be efficiently formed while the container shell moves through the operating phase.

[0084] Figure 17 shows another embodiment of the cutting method. In some cases, die cutting may be used to form interconnection features. Rotary die cutting may be used, as shown in Figure 17. In some cases, the rotary die cutter may correspond to one 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 place 1705 to resist the cutting force applied 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 aligned with the cutting machine or cutting system so that the relative position between the container shell and the cutter is controlled. Various methods, such as mandrels or recessed cavities, may be used to hold the container shell during the cutting process. Figure 18 shows an embodiment in which mandrels 1803 and 1809 are used to hold the container shell 1801 being formed. In some cases, mandrel 1803 may have a shape similar to the container shell being formed. The mandrel may be substantially identical in dimensions to or slightly offset from the container 1801 shell being formed so that the container shell can be received on the mandrel. The mandrel may have the same shape and dimensions as the inner surface of the container shell so that the container shell can be supported by the mandrel from the inside.

[0086] Mandrels 1803 and 1809 may have features for holding the container shell in place. For example, a mandrel may have one or more vacuum suction cups 1805 or vacuum holes 1807. Any number of vacuum suction cups or vacuum holes may be provided. For example, at least one, two, three, four, five, six, seven, ten, or twenty vacuum suction cups or vacuum holes may be provided. The vacuum suction cups or vacuum holes may be located at variable locations on the mandrel, such as in an area adjacent to or away from the side where the features are formed. Other features such as mechanical clamps, solenoids, and magnets can also be used to hold the container shell in place.

[0087] In some cases, the mandrel 1811 may have a feature 1811 that has a similar shape to the interconnection feature to be formed. Such a feature may allow a cutter, such as a die cutter, punch, or profile punch, to move parallel to the mandrel loaded with the container shell, cut the container shell, and then enter the mandrel through the adaptive feature such as feature 1811. In another case, a knife, progressive cutter, laser, or water jet may move along feature 1811 to form a corresponding interconnection feature on the container shell, and feature 1811 may allow the mandrel to resist the cutting action and force. Alternatively, the mandrel 1803 may not have a similar forming feature, etc. In this case, the mandrel for holding the container shell in place may be resistant to or adaptable to certain types of cutters, such as a laser cutter or water jet.

[0088] Other methods may also be used to hold the 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 also be used to support the outer 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 have features such as a vacuum hole or suction cup to hold the container shell in place, as described above.

[0089] In some cases, the container shell may have features to facilitate alignment or positioning with the mandrel or cavity. For example, the container shell may have protrusions, holes, or recesses that can be aligned with interlocking features on the mandrel or cavity. As the relative locations between the mandrel / cavity and the cutter become known, the alignment of the container shell with the mandrel / cavity can provide precise positional control between the container and the cutter. In some cases, the mandrel or cavity for positioning the container shell may be part of the cutting system or cutting machine.

[0090] In some embodiments, the transfer and handling of container shells at different manufacturing stages may be operated automatically, semi-automatically, or manually. For example, a gripper or robotic end effector may be used to hold the container shell on a mandrel as it is cut, to position the container shell, or to remove the container shell from the mandrel and move it to a point for manufacturing an assembly point or interconnection feature. As described above, the container shells may be stackable. Stacking features may be used to control the pitch or the degree to which stacked container shells are nested with each other. This is useful for an automated robotic end effector to lift a stacked container shell and separate it from another stacked container shell.

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

[0092] Loading features may be formed in various locations. For example, loading features may be formed along the periphery and / or bottom of the container shell. As shown in Figure 19, loading knobs 1901 and 1903 may be formed along the periphery of the container shell. Loading knobs may be located directly below the rim, such as knobs 1901 and 1903, or above the rim, such as the knobs shown in Figure 6. Any number of knobs may be formed along the periphery. For example, at least two, three, four, five, six, seven, eight, nine, or ten knob features may be formed along the periphery. The locations of the loading knobs may or may not be the same across the loaded container shell. In some cases, loading knobs 1901 and 1903 may be located with an offset 1905 between adjacent container shells. The arrangement of loading knobs on different container shells may or may not be different. For example, the arrangement of loading knobs on container shell 1907 may differ from the arrangement of loading knobs on container shell 1909. This may be beneficial because, when container shells with different loading knob arrangements are stacked on each other in an alternating manner, loading knobs from one container shell may avoid loading knobs from neighboring container shells, allowing the loading knobs to rest on the circumferential flanges without interruption, thus maintaining a spacing 1905 between adjacent container shells. The stacking of container shells may have any number of different arrangements for loading knobs. The illustrated embodiment shows two different arrangements, however, three, four, or more different arrangements may be employed to control the spacing. Alternatively, the location of loading knobs across container shells may be constant without alignment or displacement. Different loading knobs may be formed within a single container shell. Loading knobs formed within a single container shell may differ in shape, dimensions, or location. For example, the shape and dimensions of the loading tabs located around and at the bottom of the container shell may vary.

[0093] In some embodiments, different loading knobs may be used to load container shells at different manufacturing stages. Loading knobs for loading container shells after the pulp molding process may be the same as, or different from, those for loading container shells after the cutting process. For example, loading knobs 1901 and 1903 formed along the periphery as shown in Figure 19 may be used to load pulp-molded container shells, and these loading knobs may be trimmed during the cutting process. Loading knobs 2001 and 2003, as shown in Figure 20, may be used to load container shells after the cutting process. Alternatively, loading knobs formed within a single container shell may be identical. Loading knobs 2001 and 2003 can be located at any location on the bottom of the container shell, such as centered or off-center. Any number of loading knobs 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 knobs may be used to maintain the spacing and alignment of the loaded container shells.

[0094] With respect to Figure 20, the loading knobs 2001 and 2003 may be formed on the bottom of the container shell. These loading knobs may be formed during the pulp molding process and may remain as they are after the cutting process. The shape and dimensions of the loading knobs may or may not be identical across the container shells to be loaded together. In some cases, the loading features 2001 and 2003 may have a mirror shape within adjacent container shells to control the spacing 2005 between adjacent container shells. The mirror shape may allow the loading knobs within adjacent container shells to protrude to different heights from the bottom surface at their corresponding locations. For example, as indicated by arrows 2007 and 2009, at the same location with respect to two container shells, loading knob 2001 has a higher surface than loading knob 2003. By using different projection heights, the distance at which one container shell is nested within another is controlled as the lower surface of the loading knob in one container shell contacts and stops on the higher surface of the other container shell. The illustrated embodiment shows two different loading knobs in a mirrored configuration, however, it should be noted that any number of different configurations and / or arrangements of loading knobs may be employed.

[0095] As stated above, while specific implementations are illustrated and described, it should be understood that various modifications can be made to them and are discussed herein. Furthermore, the present invention is not intended to be limited by the specific embodiments provided herein. Although the present invention is described with reference to the preceding specification, the descriptions and illustrations of preferred embodiments herein are not intended to be constrained. Moreover, it should be understood that all aspects of the present invention are not limited to the specific descriptions, configurations, or relative proportions described herein, which depend on various conditions and variables. Various modifications to the forms and details of embodiments of the present invention will be obvious to those skilled in the art. Therefore, it is also considered that the present invention covers any such modifications, variations, and equivalents.

Claims

1. A multi-part container, The multi-part container comprises a molded hollow body that forms an internal hollow region, The aforementioned hollow body is A first molded shell part, wherein the first molded shell part comprises a plurality of interconnecting tabs and a plurality of slits on a first edge as an extended portion of the first molded shell part, the plurality of interconnecting tabs including a curved leading edge, A second molded shell part, wherein the second molded shell part has a plurality of interconnection features on a second edge as an extended portion of the second molded shell part, and when the first molded shell part and the second molded shell part are connected to form the hollow body, the second edge is connected to the first edge of the second molded shell part and Equipped with, When the plurality of interconnection tabs and the plurality of slits on the first edge engage with the plurality of interconnection features on the second edge, the engaged plurality of interconnection tabs are located within the internal hollow region of the hollow body. Each of the first and second molded shell parts is molded to form the sidewall and neck portions of the multi-part container, the outer surface of the multi-part container having a shoulder region where the curvature of the multi-part container transitions inward from the sidewall portion to the neck portion, and the pitch or spacing of the plurality of interconnecting tabs, the plurality of slits, and the plurality of interconnecting features is smaller in the shoulder region compared to regions further away from the shoulder region where the curvature is smaller in the shoulder region. A multi-part container wherein at least one of the first edge and the second edge has a curved outer shape that extends from the first end to the second end of the multi-part container.

2. The multi-part container according to claim 1, wherein the first edge or the second edge is provided with a curved section.

3. The multi-part container according to claim 1, wherein one or more of the plurality of interconnection tabs and the plurality of slits are formed within the shoulder region of the multi-part container.

4. The multi-part container according to claim 1, wherein the plurality of interconnecting tabs and the plurality of slits have a shape or size that varies along the first edge.

5. The multi-part container according to claim 1, wherein the plurality of interconnecting tabs and the plurality of slits have intervals that vary along the first edge.

6. The multi-part container according to claim 1, wherein the plurality of interconnection features comprises a plurality of tabs and a plurality of slits having the same size and shape as the plurality of interconnection tabs and a plurality of slits on the first edge.

7. The multi-part container according to claim 1, wherein the plurality of interconnection features comprises a plurality of slots.

8. The multi-part container according to claim 7, wherein the plurality of slots have a D shape.

9. The multi-part container according to claim 1, wherein the multiple engaged interconnecting tabs are aligned with the inner surface of the hollow body.

10. The multi-part container according to claim 9, wherein the inner surface is a curved surface.

11. The multi-part container according to claim 1, wherein the first molded shell part and the second molded shell part are formed from recycled or biodegradable pulp material.

12. The multi-part container according to claim 11, wherein the pulp material is selected from the group consisting of wood pulp and paper pulp.

13. The multi-part container according to claim 1, wherein the molded hollow body is 100% recyclable.

14. The multi-part container according to 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 interconnection tabs and the plurality of slits, or the plurality of interconnection features.

15. The multi-part container according to claim 1, further comprising a fitment and a neck portion supporting the fitment.

16. The multi-part container according to claim 15, wherein the fitment comprises one or more interlocking features configured to engage with one or more complementary features in the neck portion.

17. The multi-part container according to claim 15, wherein the liner is connected to the multi-part container by the fitment.

18. A container, The container comprises a single pulp-molded open hollow shell having two or more sides that are joined together, At least one of the two or more sides comprises a plurality of interconnection tabs and a plurality of slits as an extended portion of the first side of the single-pulp molded open hollow shell, and the second side connected to the first side comprises a plurality of interconnection features as an extended portion 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 interconnection tabs are located within the internal hollow region of the single-pulp molded open hollow shell, and each of the plurality of interconnection tabs includes a curved leading edge. Each of the first and second sides is molded to form the sidewall portion and neck portion of the container, the outer surface of the container has a shoulder region where the curvature of the container transitions inward from the sidewall portion to the neck portion, and the pitch or spacing of the plurality of interconnecting tabs, the plurality of slits, and the plurality of interconnecting features is smaller in the shoulder region compared to regions further away from the shoulder region where the curvature is smaller in the shoulder region. A container wherein the plurality of interconnecting tabs are arranged adjacent to a first edge on the first side, and the plurality of interconnecting features are arranged adjacent to a second edge on the second side, and at least one of the first edge and the second edge has a curved outer shape extending from the first end to the second end of the container.

19. The container according to claim 18, wherein the first side or the second side has a curved outer shape.

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

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