Bottle, method and kit

Abstract

A bottle 200, 300 comprising: a first half-bottle shell 100, 303 comprising: - a first molded pulp layer defining a first half-bottle body 102, 302 comprising at least a first securing element 104a, 304a; - a first adhesive layer 313 provided over the interior of the first half-bottle body; and - a first metallization layer 312 provided over the interior of the first adhesive layer; and a second half-bottle shell 307 comprising: - a second molded pulp layer defining a second half-bottle body comprising at least a second securing element 304b; - a second adhesive layer provided over the interior of the second half-bottle body; and - a second metallization layer provided over the interior of the first adhesive layer; wherein the first securing element is complementary to the second securing element; and the first half-bottle shell and the second half-bottle shell are secured together by a first joint 308a between the first securing element and the second securing element.

Description

[0001] BOTTLE, METHOD AND KIT

[0002] Field of the invention

[0003] The present invention relates to a bottle, a half-bottle shell, a method of forming a bottle, and a kit.

[0004] Background of the invention

[0005] Bottles for beverages and liquid foods are commonly made from plastics (in particular polyethylene terephthalate PET) or glass. There is a desire for alternatives that minimize material use and are compostable.

[0006] Molded pulp is a material that is used with increasing frequency for packaging, particularly of foodstuffs. A key benefit of these materials is that they are easily recycled and biodegrade, often being home compostable. Existing technologies of molded pulp allow the production of rigid containers such as paper cans, paper bottles or capsules for beverage. Being made of cellulosic fibers, it is usually necessary to coat or laminate the molded pulp in order to add sealing and barrier properties (e.g. to prevent ingress of oxygen).

[0007] Paper-based bottles exist in the form of an inner light weight PET container encased in a paper based shell. The paper-based shell provides mechanical support while the PET container provides barrier properties.

[0008] A paper-based bottle is advantageously formed from two half-bottle shells to facilitate coating of the interior of the product. However, the use of two half-bottle shells has typically resulted in a gap at the joint, which must be sealed, or a flange, which affects the reliability of the coating. Summary of the invention

[0009] The objective of the present invention is to improve the state of the art and, in particular, to provide recyclable and compostable bottle for packaging beverages and liquid food products exhibiting adequate barrier properties.

[0010] The objective of the present invention is achieved with a bottle comprising: a first half-bottle shell comprising:

[0011] - a first molded pulp layer defining a first half-bottle body comprising at least a first securing element;

[0012] - a first adhesive layer provided over the interior of the first half-bottle body; and

[0013] - a first metallization layer provided over the interior of the first adhesive layer; and a second half-bottle shell comprising:

[0014] - a second molded pulp layer defining a second half-bottle body comprising at least a second securing element;

[0015] - a second adhesive layer provided over the interior of the second halfbottle body; and

[0016] - a second metallization layer provided over the interior of the first adhesive layer; wherein the first securing element is complementary to the second securing element; and the first half-bottle shell and the second half-bottle shell are secured together by a first joint between the first securing element and the second securing element. In some embodiments, the first joint does not provide a gap or a flange in a body of the bottle.

[0017] In some embodiments, the first securing element and the second securing element are mutually complementary components of a butt joint, rabbet joint, miter joint, lap joint, dado joint, spline joint, mortise and tenant joint, tongue and groove joint, finger joint, or dovetail joint. In some embodiments, the first securing element and the second element are mutually complementary components of a lap joint. In some embodiments, the first securing element is provided around the rim of half of the first half-bottle shell and the second securing element is provided around the opposite half of the second half-bottle shell. In some embodiments, the first joint is a butt joint, rabbet joint, miter joint, lap joint, dado joint, spline joint, mortise and tenant joint, tongue and groove joint, finger joint, or dovetail joint.

[0018] In some embodiments, the first securing element and the second securing element are secured to together by induction sealing.

[0019] In some embodiments, the first half-bottle body comprises a third securing element, the second half-bottle body comprises a fourth securing element, the third securing element is complementary to the fourth securing element, and first half-bottle shell and the second half-bottle shell are secured together by a second joint between the third securing element and the fourth securing element.

[0020] In some embodiments, the first half-bottle shell and the second half-bottle shell are identical in shape to each other. In other embodiments, the first half-bottle shell and the second half-bottle shell are different in shape from one another. When the first-half bottle shell and the second half-bottle shell are identical in shape to each other, the first securing element is the same shape as the fourth securing element and the second securing element is the same shape as the third securing element.

[0021] In some embodiments, the first adhesive layer is polyethylene terephthalate (PET) or polypropylene (PP). In some embodiments, the second adhesive layer is polyethylene terephthalate (PET) or polypropylene (PP). In some embodiments, the first and / or second adhesive layer is any polymer or wax suitable for adhering the metallization layer to the molded pulp layer. In some embodiments, the first and / or second adhesive layer is an extrusion coating or a dispersion coating.

[0022] In some embodiments, the first metallization layer is aluminium. In some embodiments, the second metallization layer is aluminium. In other embodiments, the first and / or second metallization layer is aluminium oxide, silicon dioxide or tin.

[0023] In some embodiments, the first half-bottle shell comprises a first additional polymer layer over the interior of first metallization layer. In some embodiments, the second halfbottle shell comprises a second additional polymer layer over the interior of second metallization layer.

[0024] In some embodiments, the first additional polymer layer is polyethylene terephthalate (PET) or polypropylene (PP). In some embodiments, the second additional polymer layer is polyethylene terephthalate (PET) or polypropylene (PP).

[0025] In some embodiments, the bottle comprises an octagonal neck.

[0026] Also provided is a half-bottle shell adapted to be secured to a second half-bottle shell to provide a bottle as described above. Also provided is a method for preparing a bottle comprising: a. providing a pulp molding tool defining the shape of a half-bottle body comprising at least a first securing element, b. shaping the pulp by aspiration, pressing and drying to form a first half-bottle shell, c. applying an first adhesive layer and a first metallization layer to the first half-bottle shell; d. securing the first half bottle shell to a complementary second half-bottle shell to provide a first joint between the first securing element and a second securing element of the second half-bottle shell.

[0027] In some embodiments, a method for preparing a bottle comprises: e. securing the first securing element and the second securing element together by induction sealing.

[0028] In some embodiments, pressure is applied to the join during induction sealing. Advantageously, a more secure joint is provided.

[0029] The present invention is further directed to a bottle as described or as obtained before, which is filled with a beverage or liquid food product for human or animal consumption, and then sealed.

[0030] Also provided is a kit for forming a bottle comprising: a first half-bottle shell comprising:

[0031] - a first molded pulp layer defining a first half-bottle body comprising at least a first securing element;

[0032] - a first adhesive layer provided over the interior of the first half-bottle body; and - a first metallization layer provided over the interior of the first adhesive layer; and a second half-bottle shell comprising:

[0033] - a second molded pulp layer defining a second half-bottle body comprising at least a second securing element;

[0034] - a second adhesive layer provided over the interior of the second halfbottle body; and

[0035] - a second metallization layer provided over the interior of the first adhesive layer; wherein the first securing element is complementary to the second securing element; and the first half-bottle shell and the second half-bottle shell are securable together by a first joint between the first securing element and the second securing element.

[0036] Features of the bottle and the half-bottle shell(s) disclosed in connection with the bottle are hereby also expressly disclosed in connection with the half-bottle shell, method of preparing a bottle and kit for forming a bottle, and vice versa.

[0037] Brief description of the drawings

[0038] Fig. 1 is a perspective view of a half-bottle shell provided with a cap.

[0039] Fig. 2 is a perspective view of a bottle provided with a cap and feet.

[0040] Fig 3a shows a sectional view of the metallized film being applied to a molded pulp layer defining a half-bottle body.

[0041] Fig 3b shows a sectional view of two half-bottle shells being connected together. Fig 3c shows a sectional view of the one half-bottle shell being secured to the other by induction sealing.

[0042] Detailed description of the invention

[0043] As used in this specification, the words "comprises", "comprising", and similar words, are not to be interpreted in an exclusive or exhaustive sense. In other words, they are intended to mean "including, but not limited to".

[0044] Generally, in the present specification, "extrusion coating", it is meant a method to provide a layer of polymer by using an extruder which forces melted thermoplastic resin (e.g. polyethylene) through a horizontal slot-die onto a moving web of substrate (e.g. paper). The resulting product is a permanently coated web structure.

[0045] By "extrusion lamination", it is meant a similar process to extrusion coating, whereby a polymer resin is extruded between two substrates (e.g. a layer of paper and another layer of polymeric film), and acts as a bonding agent.

[0046] By "adhesive lamination", it is meant a process whereby one paper material is coated with adhesive and laminated to a second paper or paperboard material. In a lamination process, two thick layers of material are combined, either by extrusive lamination or adhesive lamination, whereby the thickness of each layer is far greater than the thickness obtained by dispersion coating.

[0047] By "dispersion coating", it is meant a coating technique whereby an aqueous dispersion of fine polymer particles or polymer solution is applied to the surface of paper or board as such, in order to form a solid, non-porous film after drying. Dispersion coating can be performed by gravure, flexo-gravure, rod, blade, slot-die, curtain air knife, roll coating or any other known method of paper coating. Dispersion coating can create a much thinner layer than extrusion lamination and / or adhesive lamination, since the polymer is mixed in an aqueous water solution. This brings advantages in terms of quantity of polymer usage, its barrier performance and recyclability of resulting paper structure. The target of dispersion coating is to achieve a barrier layer against water, water vapour, grease, oil, gas, etc. by environmentally friendly coating. Another target is to prepare surface of paper material for a vacuum deposition process.

[0048] By "fibre", it is meant a cellulosic fibre, which is generally extracted from plants, seeds or trees; such fibres contain not only cellulose molecules, but also hemi-cellulose as well as lignin.

[0049] The multilayer structure according to the invention is preferably designed to qualify for being recyclable in a standard recycled paper stream process, according to most regional or national paper recyclability regulations.

[0050] Recyclability in the paper stream is achieved by a multilayer structure according to the invention wherein:

[0051] - fibre contents is predominant relatively to all the ingredients contained therein (the definition of recyclability in the paper stream depends on national legislations but in average, it is required that the material contains at least 80% fibre to be accepted in a recycling process dedicated to paper), and

[0052] - the metallization layer is ultrathin (i.e. a few nanometres, typically between 1 and 100 nm) and its thickness is constituted of a few atoms.

[0053] A bottle according to the invention has a fiber content of at least 50%, advantageously at least 70%, 80% or 90% by weight. In some embodiments, the first and / or second molded pulp layer has a grammage of from 300 to 600 gsm, preferably of from 350 to 550 gsm, more preferably of from 400 to 500 gsm.

[0054] In some embodiments, the liner, that is, the metallization layer, adhesive layer and any additional polymer layers, has a grammage of from 30 to 200 gsm, preferably from 50 to 150 gm, more preferable of from 75 to 125 gsm.

[0055] Fig. 1 shows a perspective view of a half-bottle shell 100 provided with a cap 108 comprising a screw thread. The half-bottle shell 100 comprises a molded pulp layer defining a half-bottle body 102, a first securing element 104a and a second securing element 104b. The first securing element 104a is provided as a recess in the rim one part of the exterior of the half-bottle body 102 and the second securing element 104b is provided as a recess in the rim of one part of the interior of half-bottle body 102. In this way, one half-bottle shell 100 can be connected to another to provide a joint. Typically, the recessed rim is half the thickness of the remainder of the half-bottle shell 100 so that, when two half-bottle shells 100 are connected, the first joint is flush and there is no gap or flange provided on the interior or exterior of the bottle or any gap or flange is minimal. The half-bottle shell 100 has a halfneck 106 that is the shape of a half-octagon.

[0056] Fig. 2 shows a perspective view of a bottle 200 provided with a cap 208 comprising a screw thread. The bottle 200 comprises a molded pulp layer defining a body 202. The bottle is formed from a first half-bottle shell and a second half-bottle shell secured together at a joint (not shown). The bottle is further provided with feet 210 to support the bottle upright and an octagonal neck 206 to provide mechanical strength for securing the cap 208.

[0057] Figs 3a-3b illustrate a method of preparing the bottle. Fig. 3a shows a metallized film (liner) 315 comprising an additional polymer layer 311, a metallization layer 312 and an adhesive layer 313 being applied to a molded pulp layer defining a half-bottle body 302, a first securing element 304a and a third securing element 304c. First securing element 304a is in the form of a recess in the rim of one side of the exterior of the half-bottle body. Third securing element 304c is in the form of an opposite recess in the rim of the interior of the half-bottle body. The metallized film 315 may be secured to the molded pulp layer by thermolamination or by any other means of adhesive lamination known in the art.

[0058] Fig. 3b shows a first half-bottle shell 303 and a second half-bottle shell 307 being connected. First half-bottle shell 303 comprises first securing element 304a in the form of a recess in the rim of one side of the exterior of the half-bottle body and a third securing element 304c is in the form of an opposite recess in the rim of the interior of the half-bottle body. Second half-bottle shell 307 is identical to first half-bottle shell 303 and comprises a second securing element 304b in the form of a recess in the rim of one side of the interior of the half-bottle body and a fourth securing element 304d in the form of an opposite recess in the rim of the exterior of the half-bottle body. Each securing element 304a, 304b, 304c, 304d is half the thickness of the rest of the half-bottle body so that, when secured, the joint 308a, 308b is flush.

[0059] Fig. 3c shows a first half-bottle shell 303 and a second half-bottle shell being sealed and secured together by inductive sealing. In particular, the first joint 308a and the second joint 308b are passed under an induction coil emitting an oscillating electromagnetic field. The conductive metallization layer 312 heats up and causes the adhesive layer and / or the additional polymer layer 311 to melt. When cooled, the first half-bottle shell 303 and the second half-bottle shell 307 are secured and hermetically sealed via a lip, gap and flange free joint 308a, 308b. The structures corresponding to the above-described embodiments fulfil the requirements for recyclability of the material or a packaging made thereof, in standard recycled paper mill conditions. In all of the embodiments of the invention described above, the multilayer structure can comprise other additional and optional layers not described in full details therein. Such layers can comprise for instance a print layer on the outer surface of the paper layer, as well as optionally a protective layer that is deposited on the external side of the print layer, and therefore constitutes the outermost layer of the whole structure. Print and optional protective layers are not described in more detail because they are known technology to the skilled person.

Claims

Claims1. A bottle (200, 300) comprising: a first half-bottle shell (100, 303) comprising:- a first molded pulp layer defining a first half-bottle body (102, 302) comprising at least a first securing element (104a, 304a);- a first adhesive layer (313) provided over the interior of the first halfbottle body; and- a first metallization layer (312) provided over the interior of the first adhesive layer; and a second half-bottle shell (307) comprising:- a second molded pulp layer defining a second half-bottle body comprising at least a second securing element (304b);- a second adhesive layer provided over the interior of the second halfbottle body; and- a second metallization layer provided over the interior of the first adhesive layer; wherein the first securing element is complementary to the second securing element; and the first half-bottle shell and the second half-bottle shell are secured together by a first joint (308a) between the first securing element and the second securing element.

2. A bottle to Claim 1, wherein the first joint is does not provide a gap or a flange in a body of the bottle.

3. A bottle to Claim 1 or Claim 2, wherein the first securing element and the second securing element are mutually complementary components of a butt joint, rabbet joint, miter joint, lap joint, dado joint, spline joint, mortise and tenant joint, tongue and groove joint, finger joint, or dovetail joint.

4. A bottle to any of Claims 1 to 3, wherein the first securing element and the second securing element are secured to together by induction sealing.

5. A bottle according to any of Claims 1 to 5, wherein the first half-bottle body comprises a third securing element (304c), the second half-bottle body comprises a fourth securing element (304d), the third securing element is complementary to the fourth securing element, and first half-bottle shell and the second half-bottle shell are secured together by a second joint between the third securing element and the fourth securing element.

6. A bottle according to any of Claims 1 to 5, wherein the first half-bottle shell and the second half-bottle shell are identical in shape to each other.

7. A bottle according to any of Claims 1 to 5, wherein the adhesive layer is polyethylene terephthalate (PET) or polypropylene (PP).

8. A bottle according to any of Claims 1 to 6, wherein the metallization layer is aluminium.

9. A bottle according to any of Claims 1 to 7, wherein the first half-bottle shell comprises a first additional polymer layer over the interior of first metallization layer.

10. A bottle according to Claim 8, wherein the first additional polymer layer is polyethylene terephthalate (PET) or polypropylene (PP).

11. A bottle according to any of Claims 1 to 9, wherein the bottle comprises an octagonal neck (206).

12. A half-bottle shell (100, 303) adapted to be secured to a second half-bottle shell to provide a bottle according to any of Claims 1 to 10.

13. A method for preparing a bottle comprising: a. providing a pulp molding tool defining the shape of a half-bottle body comprising at least a first securing element, b. shaping the pulp by aspiration, pressing and drying to form a first half-bottle shell, c. applying an first adhesive layer and a first metallization layer to the first half-bottle shell; d. securing the first half bottle shell (100, 303) to a complementary second halfbottle shell (307) to provide a first joint (304a) between the first securing element and a second securing element of the second half-bottle shell.

14. A method for preparing a bottle according to Claim 12, comprising: e. securing the first securing element and the second securing element together by induction sealing.

15. A kit for forming a bottle comprising: a first half-bottle shell (100, 303) comprising:- a first molded pulp layer defining a first half-bottle body (102, 302) comprising at least a first securing element (104a, 304a);- a first adhesive layer (313) provided over the interior of the first halfbottle body; anda first metallization layer (312) provided over the interior of the first adhesive layer; and a second half-bottle shell comprising: - a second molded pulp layer defining a second half-bottle body (307) comprising at least a second securing element (304b);- a second adhesive layer provided over the interior of the second halfbottle body; and- a second metallization layer provided over the interior of the first adhesive layer; wherein the first securing element is complementary to the second securing element; and the first half-bottle shell and the second half-bottle shell are securable together by a first joint (308a) between the first securing element and the second securing element.

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