Multi component pulp molded bottle

Abstract

The present technology generally relates to a pulp molded bottle that comprises components such as the outer body, the shoulder, the neck, the collar ring, the base, and the closure. The outer body, the shoulder and the base may be formed from more than one piece and are manufactured by the molding of wet pulp slurry. The outer body is constructed by joining two diametrically opposed longitudinal halves by bonding the narrow tabs located on their respective vertical edges. The multi-component bottle may incorporate barrier methods on its inner surface, which can be achieved by methods including a liner lamination, coating, or an inner flexible bag. The bottle design enables cost-effective and efficient manufacturing.

Description

MULTI COMPONENT PULP MOLDED BOTTLECROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. provisional patent application No. 63 / 551 ,683, filed on February 9, 2024; the content of which is herein incorporated in entirety by reference.FIELD OF TECHNOLOGY

[0002] The present technology relates to a pulp bottle made up of multiple components with separate body and base parts which are formed by a wet molding process.BACKGROUND

[0003] Pulp bottles are well-known in the art, an attractive alternative to plastic bottles, as plastic bottle waste poses a major environmental problem. Pulp bottles require barrier properties to make them suitable for holding liquids or semi-liquids and to prevent the pulp wall from coming into direct contact with the liquid or semi-liquid inside. Barrier properties for the pulp wall can be achieved by various methods, including spray coating, blending barrier materials with the pulp or and impregnation, co-extrusion with a barrier lining as the inner layer, lamination and a flexible inner bag inside the bottle.

[0004] Pulp bottles can be manufactured as a single piece or as multiple pieces which are then assembled to form a bottle. Production of single-piece pulp bottles necessitates the use of more complex and sophisticated equipment. This requirement poses a significant limitation on the scalability of the production process. Additionally, the application of barrier materials to these pulp bottles presents its own set of challenges. Appropriate methodologies are largely confined to either blending the barrier material directly with the pulp or applying it as a spray coating on the interior or exterior surfaces of the bottle. These methods, while feasible, do not offer the same level of effectiveness in terms of shelf-life extension and recyclability as using film liners. Consequently, this limitation in barrier application technology may impact the overall functionality of the pulp bottles produced using these methods.

[0005] The concept of a modular bottle, made up of multiple components, presents a range of advantages. On contrary to single piece production, a modular bottle provides the advantage of ease of molding and offers feasibility for all the different methods of application of barrier materials. It also provides design versatility by offering the ability to employ diverse materials for distinct parts, depending on their specific functions. Modular bottles have the potential to contribute significantly to sustainable practices by minimizing material consumption. Modular bottles enhance the user experience by offering usability and convenience. They are easy to clean and provide options for various types of closures and fixtures like infusion systems.

[0006] In the manufacture of pulp bottles, the prevalent methods are the wet and dry processes. The wet process involves mixing pulp fibers with water to create a slurry mixture, which is then molded into a bottle shape. Excess water is extracted using vacuum and / or pressure systems, leaving behind a damp fiber structure that is subsequently dried to solidify the fibers and form a rigid bottle. In contrast, the dry process combines dry pulp fibers with a binding agent. This mixture is placed into molds and subjected to heat and pressure, which activates the binding agent and fuses the fibers into a solid bottle shape. An alternative approach involves forming sheets or blanks from the fibers and then shaping them into the desired 3D structures through molding or thermoforming.

[0007] The wet process is particularly advantageous for complex designs and achieving greater depth in design due to the moldability of the slurry pulp mixture, allowing for intricate shapes and textures like curved surfaces, and raised or recessed patterns. This method allows for varied thickness across different parts of the container, enhancing both strength and functionality. Conversely, the dry process, while quicker due to the elimination of a drying phase, tends to thin out the material, leading to less uniform thickness compared to the wet process. Molding containers instead of using flat sheets enables a thicker construction, which is advantageous for firmly securing internal components like liners.

[0008] U.S. Patent No. 10,717,578, incorporated herein by reference, describes a container design that consists of three main components: two side wall elements and a base element. These elements are produced from flat sheets using a hot-pressing technique. The design features overlapping sections at the joints, which are prominentlyvisible on the container's exterior. However, this sheet-based molding approach restricts the range of possible shapes, particularly in terms of draft angles and depth of features. The process of stretching the material to achieve the final bottle shape can result in inconsistent material thickness, potentially impacting the bottle's strength, crucial for supply chain and consumer handling. This method also generates a considerable amount of scrap during the trimming operations needed to detach the finished part from the sheet. This issue is compounded if a barrier material is applied to the sheet prior to forming, as it gets mixed with the scrap, potentially degrading the quality of any recycled material. Moreover, there are no specific structural features on the base piece or the wall element for stronger bonding. The base piece is merely inserted from the bottom opening of the outer body and it is bonded to the inner surface of the outer body. In another embodiment a circular disc of paperboard is placed at the bottom and the bottom edge of the outer shell is folded and bonded to the circular disc base.

[0009] JP2022148425A and JP2009196644A, both incorporated herein by reference, describe a container design comprising two longitudinal halves of the body integrated with the base, formed by the wet process. JP2009196644A, incorporated herein by reference, mentions when molding a horizontal base together with the curved vertical parts, the base often ends up with a convex shape, which requires an additional flattening step. It also presents an alternative solution that involves using horizontal sections for the container, including a fully flat base. However, this horizontal molding cylindrical parts approach presents difficulties in achieving the same smooth surface finish as seen in vertically molded parts. A significant challenge in this method is the application of sufficient pressure during both the wet molding and thermal compression stages. Additionally, molding cylindrical shapes typically requires some vertical draft, leading to a slightly conical geometry in the bottles. This document also mentions a joining piece which is a thin flat piece from the boundary that can be bent inside to provide additional boding area as the edges are narrow. It is also provided with perforations for facilitating bending inside. But there are no details on the thickness of the joining piece, as this piece is not supported on the extended side there is a question on the strength and stability of this joining piece which eventually affects the bonding strength.

[0010] With a multitude of benefits of modular bottles and pulp bottles, there is a need for a bottle design that is simple and effective and a simpler manufacturing and assembly process.SUMMARY OF TECHNOLOGY

[0011] In one aspect, the present technology relates to a bottle comprising several components, the bottle having a simple design that facilitates cost-effective and efficient manufacturing and assembly. The bottle comprises an outer body, a shoulder, a neck, a collar ring, a base, and a closure.

[0012] In one aspect, the present technology relates to a bottle comprising multiple components including an outer body, a neck, a collar ring, a base, a closure, and a barrier on an interior surface of the bottle. The outer body is molded as two diametrically opposed longitudinal halves that are attached together to form a complete outer body. The base is molded as multiple pieces comprising an inner base piece and an outer base piece. Both the outer body and the base are provided with one or more structural features on the bottom and the upper edges respectively. These structural features act as means for larger surface area of contact between parts to increase the bonding strength. In some embodiments, the outer body and the base are formed by a wet processing pulp molding method.

[0013] In one embodiment, the outer body is molded as two identical, diametrically opposed longitudinal halves. Each longitudinal half piece includes the vertical trunk body and the curved shoulder parts molded as a single part. The vertical edges of the outer body parts are provided with narrow tabs. When the two longitudinal halves are attached together, it forms an upper opening and lower opening in the bonded outer body. In some embodiments, the outer body is formed by wet pulp molding process.

[0014] The inner surface of the bottom edge of the outer body parts is provided with structural features, such as protrusions and / or cavities which form a lap joint with the complement structures of the joining parts. These structural features provide a larger surface area of contact between parts to be attached together which in turn increases the bonding strength.

[0015] The two longitudinal halves are bonded together by means of adhesive or by thermal sealing at the narrow tabs to securely join them. When the outer body and baseare bonded together, their structural features form an extended lap joint with increased bonding surface area and strength between them.

[0016] The bottle base is made of a supporting inner base piece and an outer base piece. The upper edge of the inner base piece is provided with structural features such as protrusions and cavities that complement the structural features on the inner surface of the outer body parts to form a lap joint between them. The outer body and the inner base piece are bonded together by means of adhesive or by thermal sealing at the lap joints, securely attaching the base to the body. The inner diameter of the outer body matches with outer diameter of the inner base piece for securely bonding with surface features. The outer diameter of the outer base piece and the outer body match one another. The outer base piece is then bonded on the outer side of the inner base piece, forming a seamless outer surface between the base and outer body. The bottle base is formed by wet pulp molding process.

[0017] Both outer body parts and the base pieces are formed by wet pulp molding process. They can be manufactured by any industrially well-known wet pulp molding process. The wet process of pulp molding involves key steps starting with mixing the raw materials like softwood, hardwood, sugarcane bagasse and / or bamboo with water in a pulp pool, where a pulping machine process them into a uniform pulp. The pH value and concentration of this mixture are carefully controlled and any dyeing is also performed at this stage. Next, this pulp is flowed through porous forming molds using a pulp suction system. The fibers collect on the inside surface of the mold building up to the desired part thickness. At this point, the product lacks hardness and contains significant moisture. The subsequent heat setting stage involves electric heating and optional pressure to evaporate about 98% of the water, endowing the product with improved toughness and strength. After heat setting, the product undergoes trimming to refine its edges for a more precise finish. The process's advantages include the versatility of the molding process allowing for a wide range of packaging shapes and textures like curved surfaces, and raised or recessed patterns, facilitating automation in production and providing products with a distinctive, high-end appeal. This method allows for molding varied thickness across different parts of the container, enhancing both strength and functionality.

[0018] The neck is a hollow cylindrical part with a structured rim on its lower edge and threading on its upper edge. The diameter of the structured rim is greater than that of theupper opening of the outer body. Conversely, the threaded upper edge has a smaller diameter, allowing it to pass through the upper opening of the outer body. The structured rim which contacts the outer body has surface features such as rough finish or protrusions to increase the friction between the neck and outer body, thereby reducing relative motion. The neck can be constructed from any material which is rigid and suitable for injection or compression molding, including but not limited to thermoplastic resin, bioplastic, composites including pulp fiber composites, and fiberglass. Biopolymers such as Polyhydroxyalkanoates (PHA) can be used for making an eco-friendly bottle.

[0019] The collar ring has inner threads to screw onto the neck. The collar ring has a skirt at the bottom edge that flares outwards to smoothly transition to the outer surface of the container. The inner surface of this flared skirt section is textured, having a rough finish or protrusions, particularly ramped protrusions, to resist unscrewing of the collar ring. The collar ring has a height adequate to securely engage with the threads on the neck's lower edge. While the threads on the neck's upper edge remain available for attaching a closure or dispenser. This arrangement efficiently utilizes the same threads on the neck for both the collar ring and the closure. The collar ring can be constructed from any material which is rigid and suitable for injection molding, including but not limited to thermoplastic resin, bioplastic, composite materials, and fiberglass. Biopolymers such as Polyhydroxyalkanoates (PHA) can be used for making an eco-friendly bottle.

[0020] In one embodiment, a liner lamination is used as the barrier method, a film is vacuum formed onto the inside surfaces of the pulp molded parts. The lamination film can be composed of materials like polyethylene, polypropylene or other materials known for their barrier properties. The film can also be made from biomaterials such as biopolymers, and specifically, PHAs. The process typically involves heating the film to make it pliable, followed by the application of vacuum through the fiber parts to ensure it conforms seamlessly to the contours of the molded fiber parts. The result is a smooth, continuous layer that adheres to the internal surface, creating an effective barrier.

[0021] In one embodiment, a flexible inner bag is used as its barrier mechanism. The opening or mouth of this flexible inner bag is securely affixed to the structural rim of the neck. Various attachment methods can be employed to achieve this, including but not limited to adhesive bonding or thermal fusing. The flexible bag is formed from materials like polyethylene, polypropylene or other materials known for their barrier properties. Theflexible bag can also be made from biomaterials such as biopolymers, and specifically, PHAs.

[0022] In one aspect, the present technology relates to a bottle comprising multiple components including an outer body, a shoulder, a neck, a collar ring, a base, a closure, and a barrier method on the interior of the bottle. The outer body is molded as two identical, diametrically opposed longitudinal halves that are attached together to form a complete outer body. Each longitudinal half piece includes only the vertical trunk body. There is a separate shoulder piece which can be made as a single piece or multiple pieces designed to be attached to the upper edge of the body. The base is formed from multiple molded pieces comprising an inner base piece and an outer base piece. The outer body, shoulder and the base are provided with one or more structural features on the bottom and the upper edges where it is attached to the other part. These structural features act as means for larger surface area of contact between parts to increase the bonding strength. The outer body, shoulder and the base are formed by a wet processing pulp molding method.BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The following figures are included to illustrate certain aspects of the embodiments and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, as will occur to those skilled in the art and having the benefit of this disclosure.

[0024] FIGs. 1A and 1 B are schematic representations of the multi-component bottle according to one embodiment of the present technology. FIG. 1 A and FIG. 1 B depict an embodiment of the multi-component bottle highlighting its key components with a separate shoulder piece.

[0025] FIGs. 2A and 2B are schematic representations of an assembled outer body for embodiments of the multi-component bottle with the shoulder incorporated into the molded body.

[0026] FIGs. 2C and 2D are schematic representations of the assembled outer body for embodiments of the multi-component bottle with the shoulder as a separate piece.

[0027] FIGs. 3A and 3B are schematic representations of the inner base piece with the structural features and outer base piece respectively.

[0028] FIG. 3C is a schematic representation of the inner base piece featuring the structural features complementing the structural features in the outer body part.

[0029] FIG. 3D is a schematic representation of the assembled base pieces and the outer body.

[0030] FIG. 4A is a schematic representation of the shoulder part with the structural features.

[0031] FIG. 4B is a schematic representation of an embodiment of the shoulder part.

[0032] FIG. 4C is a schematic representation of the shoulder part featuring the structural features complementing the structural features in the outer body part.

[0033] FIG. 4D is a schematic representation of the assembled shoulder portion and the outer body.

[0034] FIGs. 5A and 5B is a schematic representation of a collar ring.

[0035] FIG. 5C is a schematic representation of a neck.

[0036] FIG. 5D is a schematic representation of the assembling process of neck and collar ring to the outer body.

[0037] FIGs. 5E and 5F is a schematic representation of the assembled neck, collar ring and the outer body.

[0038] FIGs. 6A, 6B, 6C, and 6D are schematic representations of an embodiment of the multi-component bottle that utilizes an inner flexible bag as the barrier.DETAILED DESCRIPTION OF TECHNOLOGY

[0039] Other objects and advantages of the present technology will become apparent from the following detailed description of the preferred embodiments thereof in connection with the accompanying drawings in which FIGs. 1 A to FIG. 6D explain the features of the multi-component pulp molded bottle of the present technology.

[0040] While aspects of the described multi-component pulp molded bottle can be implemented with any number of additional components like gaskets and other functional or ornamental fitments, the embodiments are described in the context of the following components.

[0041] FIG. 1A provides an exploded view of the multi-component pulp molded bottle of the present technology. The bottle comprises two longitudinal halves (1 a, 1 b) of an outer body (1 ), the neck (2), the collar ring (3), the inner base piece (4a), the outer base piece (4b), and the closure (5).

[0042] FIG. 1 B provides an exploded view of the multi component pulp molded bottle in another embodiment. The bottle comprises two longitudinal halves (11 a, 11 b) of an outer body (11 ), the shoulder (17), the neck (12), the collar ring (13), the inner base piece (14a) and the outer base piece (4b), and the closure (15).

[0043] FIG. 2A and FIG. 2B provide a schematic representation of the outer body (1 ) in one embodiment. Here, the outer body comprises two longitudinal halves (1 a, 1 b), each of which can be molded as a single piece comprising a shoulder and trunk portion. The vertical edges of the two longitudinal halves (1 a, 1 b) are provided with narrow tabs (1 ae, 1 bf) for bonding the two longitudinal halves together to form the outer body (1 ). The narrow tabs facilitate strong bonding with minimal impact on the aesthetics expected of a bottle. The two longitudinal halves (1 a, 1 b) can be joined by means of adhesive or by thermal sealing at the butt joints. Upon bonding of the two longitudinal halves (1 a, 1 b) of the outer body (1 ), an upper opening (1 c) and a lower opening (1 d) are formed. The inner surface of the lower edge of the two longitudinal halves (1a, 1 b) of the outer body (1 ) is provided with structural features, such as a protrusions and cavities (1 e), that complement corresponding structural features on the base (4b) to form a lap joint.

[0044] FIG. 2C and FIG. 2D provide a schematic representation of the outer body (11 ) in another embodiment. Here, the outer body comprises two longitudinal halves (11a, 11 b), each of which can be molded with only trunk portion without shoulder. The vertical edges of the two longitudinal halves (1 1a, 1 1 b) are provided with narrow tabs (11ae, 11 bf) for bonding the two longitudinal halves together to form the outer body (11 ). The narrow tabs facilitate strong bonding with minimal impact on the aesthetics expected of a bottle. The two longitudinal halves (11 a, 11 b) can be joined by adhesive or thermal sealing at the butt joints. Upon bonding together of the two longitudinal halves (1 1a, 11 b) of the outer body (1 1 ), an upper opening (11 c) and a lower opening (11 d) are formed. The inner surface of the lower edge of the two longitudinal halves (11 a, 11 b) of the outer body (11 ) is provided with structural features, such as a protrusions and cavities (1 e), that complement corresponding structural features on the inner base piece (14b) to form a lap joint. The outer surface of the upper edge of the two longitudinal halves (11 a, 11 b) of the outer body (11 ) is provided with structural features, such as a protrusions and cavities (11 f), that complement corresponding structural features on the shoulder (17c) to form a lap joint.

[0045] FIGs. 3A, 3B, 3C, and 3D depict the design of the base (4, 14) for two embodiments depicted in FIG. 1A and FIG. 1 B. The base comprises a supporting inner base piece (4a, 14a) and an outer base piece (4b, 14b). The upper edge of the inner base piece (4a, 14a) is provided with structural features, such as protrusions and cavities (4c, 14c) that complement corresponding structural features on the two longitudinal halves (1a, 1 b) / (11 a, 11 b) of the outer body (1 , 11 ) to form a lap joint. The diameter of the inner base piece (4a, 14a) is designed to be slightly smaller than the lower opening (1 d, 11 d) of the outer body, ensuring a snug fit with the complementary structural features. When assembled, the outer base piece (4b, 14b) is positioned outside of the inner base piece (4a, 14a). Its outer diameter matches that of the outer body (1 , 11 ) which forms a seamless outer surface with the outer body (1 , 11) when assembled. To secure the base (4, 14) to the outer body (1 , 11 ), various joining methods can be employed, such as adhesive bonding or thermal sealing.

[0046] FIGs. 4A and 4B provide a schematic representation of the shoulder (17) design in one embodiment depicted in FIG. 1 B. In one embodiment, the shoulder (17) is molded as a single piece. In this depiction, the lower edge of the shoulder (17) is provided withstructural features, such as protrusions and cavities (17a), that complement corresponding structural features (11f) on the two longitudinal halves (11 a, 11 b) of the outer body (11 ) to form a lap joint. The upper opening (17c) of the shoulder (17) is connected to the neck (12) and collar ring (13). The shoulder (17) is formed by wet pulp molding process.

[0047] FIG. 4C provides a schematic representation of the assembly of the shoulder (17) assembly. FIG. 4D provides a schematic representation of the assembled shoulder and body parts.

[0048] FIGs. 5A and 5B provide a schematic representation of the collar ring (3, 13) for two embodiments depicted in FIG. 1A and FIG. 1 B. The collar ring (3, 13) is equipped with inner threads (3a, 13a) and a skirt (3b, 13b) on the lower edge. The collar ring (3, 13) has a height adequate to securely engage with the threads on the lower edge (2c, 12c) of the neck (2, 12).

[0049] FIG. 5C provides a schematic representation of the neck (2, 12) for two embodiments depicted in FIG. 1A and FIG. 1 B. The neck (2, 12) is designed with a structured rim (2d, 12d) at its lower edge, threading at its lower edge (2c, 12c) and threading on its upper edge (2b, 12b). The diameter of the structured rim (2d, 12d) is larger than the upper opening (1 c) of the outer body (1 ) in one embodiment and upper opening (17d) of the shoulder (17) in the other embodiment. The threaded upper edge (2b, 12b) has a smaller diameter, allowing it to pass through the said upper openings (1 c, 17d). To assemble, the neck (2, 12) is inserted upwards from the lower opening (1 d) of the outer body (1 , 11 ). As it is inserted, the threaded upper edge (2b, 12b) emerges through the said upper openings (1 c, 17d), protruding outside the outer body (1 , 11 ), with the structured rim (2d, 12d) resting against the interior circumference of the said upper opening (1 c, 17d). While the threads on the neck's upper edge (2a, 12a) remain available for attaching a closure. This arrangement efficiently utilizes the same threads on the neck (2, 12) for both the collar ring (3, 13) and the closure.

[0050] FIGs. 5D, 5D and 5E depict the assembly of the multi component pulp molded bottle’s upper portion. The neck (2, 12) and collar ring (3, 13) are attached to the outer body (1 , 11 ) on the upper part by means of aligning the inner threads (3a, 13a) of the collar ring (3, 13) and the threads on the upper edge of the neck (2b, 12b). A portion ofthe outer body (1 ) near the upper opening (1c) in one embodiment and a portion of the shoulder (17) near the upper opening (17d) in another embodiment are sandwiched between the collar ring’s skirt (3b, 13b) and the neck's structured rim (2d, 12d).

[0051] FIGs. 6A and 6B showcase the schematic depiction of the multi component pulp molded bottle in a specific embodiment that utilizes a flexible inner bag (6, 16), as its barrier mechanism. The opening or mouth of this inner bag is securely affixed to a structured rim (2d, 12d) of the neck (2, 12). Various attachment methods can be employed to achieve this, including but not limited to adhesive bonding or thermal fusing.

[0052] In one embodiment, the multi component pulp molded bottle is constructed starting with assembling the outer body (1 ) by joining the two longitudinal halves (1 a, 1 b). The halves are bonded together using adhesive at the narrow tabs (1 ae, 1 bf). Then the opening or mouth of this flexible inner bag (6) is securely affixed to a structured rim (2d) of the neck (2). Various attachment methods can be employed to achieve this, including but not limited to, adhesive bonding or fusing. The neck (2), along with this flexible inner bag (6), is then introduced through the lower opening (1 d) of the outer body (1 ). The threaded upper portion (2a) of the neck extends through the upper opening (1 c), allowing the structured rim (2d) to rest against the periphery of this opening. The edge of the upper opening (1 c) is positioned on the structured rim (2d), which results in exposure of the threaded upper edge (2b) of the neck. The collar ring (3) is subsequently screwed onto the threaded lower edge (2c) of the neck (2) until the end of its threads, causing the section of the outer body near the upper opening (1 c) to be firmly clamped between the neck's structured rim (2d) and the skirt (3b) of the collar ring. The inner base piece (4a) has an outer diameter matching with the inner diameter of the lower opening (1 d) and it is provided with structural features, such as protrusions and cavities (4c), that complement corresponding structural features on the two longitudinal halves (1 a, 1 b) of the outer body (1 ) to form a lap joint. The outer body (1 ) and the inner base piece (4a) are bonded together using adhesive at the lap joints. The outer base piece (4b) is then bonded to an outer side of the inner base piece (4a), forming a seamless outer surface with the outer body (1 ) and completing the assembly of the multi component pulp molded bottle.

[0053] In another embodiment, the multi-component pulp molded bottle is constructed starting with laminating the pulp molded parts of the bottle, the two longitudinal halves(1a, 1 b) and the base pieces (4a, 4b), by vacuum film forming as barrier methods. The halves are bonded together either by using adhesive or by thermal sealing by melting the lamination material at the narrow tabs (1ae, 1 bf) to form the outer body (1). The neck (2) is then introduced through the lower opening (1 d) of the outer body (1 ). The threaded upper portion (2a) of the neck extends through the upper opening (1 c), allowing the structured rim (2d) to rest against the periphery of this opening. The edge of the upper opening (1 c) is positioned on the structured rim (2d), which results in exposure of the threaded upper edge (2b) of the neck. The collar ring (3) is subsequently screwed onto the threaded lower edge (2c) of the neck (2) until the end of its threads, causing the section of the outer body near the upper opening (1 c) to be firmly clamped between the neck's structured rim (2d) and the skirt (3b) of the collar ring. The inner base piece (4a) has an outer diameter matching with the inner diameter of the lower opening (1 d) and it is provided with structural features, such as protrusions and cavities (4c), that complement corresponding structural features on the two longitudinal halves (1 a, 1 b) of the outer body (1 ) to form a lap joint. The outer body (1 ) and the inner base piece (4a) are bonded together using adhesive or by thermal sealing by melting the lamination material at the lap joints. The outer base piece (4b) is then bonded to an outer side of the inner base piece (4a), forming a seamless outer surface with the outer body (1) and completing the assembly of the multi-component pulp molded bottle.

[0054] In yet another embodiment, the multi-component pulp molded bottle is constructed starting with assembling the outer body (11 ) by joining the two longitudinal halves (11 a, 11 b). The halves are bonded together using adhesive at the narrow tabs (11 ae, 11 bf). The outer surface of the upper edge of the two longitudinal halves (11 a, 11 b) of the outer body (11) is provided with structural features, such as protrusions and cavities (11 f). The lower edge of the pulp molded shoulder (17) is provided with structural features, such as protrusions and cavities (17a), that complement corresponding structural features (11f) on the two longitudinal halves (11 a, 11 b) of the outer body (11 ) to form a lap joint. The outer body (11 ) and the shoulder (17) are then bonded together using adhesive on the lap joints. Then, the opening or mouth of this flexible inner bag (16) is securely affixed to a structured rim (12d) of the neck (12). Various attachment methods can be employed to achieve this, including but not limited to adhesive bonding or fusing. The neck (12), along with this flexible inner bag (16), is then introduced through the lower opening (11 d) of the outer body (11 ). The threaded upper portion (12a) of the neck extends through the upper opening of the shoulder (17d), allowing the structured rim (12d) to rest against theperiphery of this opening. The edge of the upper opening of the shoulder (17d) is positioned on the structured rim (12d), which results in exposure of the threaded upper edge (12b) of the neck (12). The collar ring (13) is subsequently screwed onto the threaded lower edge (12c) of the neck (12) until the end of its threads, causing the section of the outer body near the upper opening of the shoulder (17d) to be firmly clamped between the neck's structured rim (12d) and the skirt (13b) of the collar ring. The inner base piece (14a) has an outer diameter matching with the inner diameter of the lower opening (11 d) and it is provided with structural features, such as protrusions and cavities (14c), that complement corresponding structural features on the two longitudinal halves (11 a, 11 b) of the outer body (11 ) to form a lap joint. The outer body (11 ) and the inner base piece (14a) are bonded together using adhesive at the lap joints. The outer base piece (14b) is then bonded to an outer side of the inner base piece (14a), forming a seamless outer surface with the outer body (11 ) and completing the assembly of the multicomponent pulp molded bottle.

[0055] In a further embodiment, the multi-component pulp molded bottle is constructed starting with laminating the pulp molded parts of the bottle, the two longitudinal halves (11 a, 11 b), the shoulder (17) and the base pieces (14a, 14b), by vacuum film forming as barrier methods. The laminated two longitudinal halves (11a, 11 b) are bonded together either by using adhesive or by thermal sealing by melting the lamination material at the narrow tabs (1 ae,1 bf) to form the outer body (1 1 ). The outer surface of the upper edge of the two longitudinal halves (11 a, 11 b) of the outer body (11 ) is provided with structural features, such as protrusions and cavities (1 1f). The lower edge of the pulp molded shoulder (17) is provided with structural features, such as protrusions and cavities (17a), that complement corresponding structural features (11f) on the two longitudinal halves (11 a, 11 b) of the outer body (11 ) to form a lap joint. The outer body (11) and the shoulder (17) are then bonded together either by using adhesive or by thermal sealing by melting the lamination material on the lap joints. The neck (12) is then introduced through the lower opening (11 d) of the outer body (11 ). The threaded upper portion (12a) of the neck extends through the upper opening of the shoulder (17d), allowing the structured rim (12d) to rest against the periphery of this opening. The edge of the upper opening of the shoulder (17d) is positioned on the structured rim (12d), which results in exposure of the threaded upper edge (12b) of the neck (12). The collar ring (13) is subsequently screwed onto the threaded lower edge (12c) of the neck (12) until the end of its threads, causing the section of the outer body near the upper opening of the shoulder (17d) to be firmlyclamped between the neck's structured rim (12d) and the skirt (13b) of the collar ring. The inner base piece (14a) has an outer diameter matching with the inner diameter of the lower opening (11 d) and it is provided with structural features, such as protrusions and cavities (14c), that complement corresponding structural features on the two longitudinal halves (11a, 11 b) of the outer body (11 ) to form a lap joint. The outer body (11 ) and the inner base piece (14a) are bonded together using adhesive at the lap joints. The outer base piece (14b) is then bonded to an outer side of the inner base piece (14a), forming a seamless outer surface with the outer body (11 ) and completing the assembly of the multi- component pulp molded bottle.

Claims

CLAIMS1 . A multi-component bottle, comprising: an outer body molded as two diametrically opposed longitudinal halves that are attached together to form a complete body; a neck; a collar ring; a base molded as multiple pieces with an inner base piece and an outer base piece; a closure; and barrier method on the interior of the bottle, wherein the outer body and the base are provided with one or more structural features on the bottom and the upper edges, respectively, as means to increase the surface area for contact between parts to be attached together, thereby increasing bond strength, and wherein the outer body and the base are formed by wet pulp molding process.

2. The multi-component bottle according to claim 1 , wherein the two longitudinal halves include the trunk part and the curved shoulder portion, molded as a single piece.

3. The multi-component bottle according to claim 1 , wherein the vertical edges of the two longitudinal halves are provided with the narrow tabs for bonding the two longitudinal halves to form the outer body.

4. The multi-component bottle according to claim 1 , wherein the two longitudinal halves are bonded together by adhesive or thermal sealing methods at the narrow tabs.

5. The multi-component bottle as described in claim 1 , wherein bonding together of the two longitudinal halves of the outer body forms an upper opening and a lower opening.

6. The multi-component bottle according to claim 1 , wherein the inner surface of the lower edge of the two longitudinal halves of the outer body is provided with structural features, such as protrusions and cavities, that complement corresponding structural features on the base to form a lap joint.

7. The multi-component bottle according to claim 1 , wherein the base comprises a supporting inner base piece and an outer base piece.

8. The multi-component bottle according to claim 1 , wherein an upper edge of the inner base piece is provided with structural features, such as protrusions and cavities, that complement corresponding structural features on the two longitudinal halves of the outer body to form a lap joint.

9. The multi-component bottle according to claim 1 , wherein the outer body and the inner base piece are bonded together by adhesive or thermal sealing methods at the lap joints.

10. The multi-component bottle according to claim 1 , wherein the outer base piece is bonded to an outer side of the inner base piece, forming a seamless outer surface with the outer body.

11. The multi-component bottle according to claim 1 , wherein the neck is a hollow cylindrical component, comprising: a mouth; an upper edge with design features suitable to engage with the closure; threaded lower edge exposed externally adjacent to an outer side of the upper opening in the outer body; and a structured rim around its circumference at the lower end that abuts the inner side of the upper opening in the outer body.

12. The multi-component bottle according to claim 11 , wherein the structured rim which contacts the outer body has surface features such as rough finish or protrusions to increase the friction between the neck and outer body, thereby reducing relative motion.

13. The multi-component bottle according to claim 11 , wherein the neck has similar threading on the upper edge and the lower edge so that both screw cap and the collar ring can share the same threads on the upper edge and lower edge of the neck respectively.

14. The multi-component bottle according to claim 1 , wherein the collar ring comprises: an inner threading designed to mate with the threading on the lower edge of the neck, allowing the collar ring to sit above the outer body and secure the neck to the outer body; anda skirt at the bottom edge that flares outwards to smoothly transition to the outer surface of the container.

15. The bottle according to claim 14, wherein the inner surface of this flared skirt is textured, having a rough finish or protrusions including, but is not limited to, ramped protrusions, to resist unscrewing of the collar ring.

16. The multi-component bottle according to claim 1 , wherein the barrier method includes, but is not limited to, a film liner lamination, a coating, or an inner flexible bag.

17. The bottle according to claim 1 , wherein the barrier is formed by a vacuum formed film laminated onto interior surfaces of the pulp molded outer body and the base components.

18. The multi-component bottle according to claim 1 , wherein the barrier is provided by an inner flexible bag attached to the structured rim of the neck.

19. A multi-component bottle, comprising: an outer body molded as two diametrically opposed longitudinal halves that are attached together to form a complete body; a shoulder; a neck; a collar ring; a base molded as multiple pieces with an inner base piece and an outer base piece; a closure; and a barrier method on the interior of the bottle, wherein the outer body, shoulder and the base are provided with one or more structural features on the upper and the lower edges as means to increase the surface area for contact between parts to be attached together, thereby increasing bond strength, and wherein the outer body, shoulder and the base are formed by wet pulp molding process.

20. The multi-component bottle according to claim 19, wherein the vertical edges of the two longitudinal halves are provided with the narrow tabs for bonding the two longitudinal halves to form the outer body.21 .The multi-component bottle according to claim 19, wherein the two longitudinal halves are bonded together by adhesive or thermal sealing methods at the narrow tabs.

22. The multi-component bottle according to claim 19, wherein bonding together of the two longitudinal halves of the outer body forms an upper opening and a lower opening.

23. The multi-component bottle according to claim 19, wherein the inner surface of the lower edge of the two longitudinal halves of the outer body is provided with structural features, such as protrusions and cavities, that complement corresponding structural features on the inner base piece to form a lap joint.

24. The multi-component bottle according to claim 19, wherein the base comprises a supporting inner base piece and an outer base piece.

25. The multi-component bottle according to claim 19, wherein an upper edge of the inner base piece is provided with structural features, such as protrusions and cavities, that complement corresponding structural features on the two longitudinal halves of the outer body to form a lap joint.

26. The multi-component bottle according to claim 19, wherein the outer body and the inner base piece are bonded together by adhesive or thermal sealing methods at the lap joints.

27. The multi-component bottle according to claim 19, wherein the outer base piece is bonded to an outer side of the inner base piece, forming a seamless outer surface with the outer body.

28. The multi-component bottle according to claim 19, wherein the outer surface of the upper edge of the two longitudinal halves of the outer body is provided with structural features, such as protrusions and cavities, that complement corresponding structural features on the shoulder to form a lap joint.

29. The multi-component bottle according to claim 19, wherein the lower edge of the shoulder is provided with the structural features, such as protrusions and cavities, that complement corresponding structural features on the two longitudinal halves of the outer body to form a lap joint.

30. The multi-component bottle according to claim 19, wherein the outer body and the shoulder are bonded together by adhesive or thermal sealing at the lap joints.

31. The multi-component bottle according to claim 19, wherein the neck is a hollow cylindrical component, comprising: a mouth; an upper edge with design features suitable to engage with the closure; threaded lower edge exposed externally adjacent to an outer side of the upper opening in the shoulder; and a structured rim around its circumference at the lower end that abuts the inner side of the upper opening in the shoulder.

32. The multi-component bottle according to claim 31 , wherein the structured rim which contacts the outer body has surface features such as rough finish or protrusions to increase the friction between the neck and outer body, thereby reducing relative motion.

33. The multi-component bottle according to claim 31 , wherein the neck has similar threading on the upper edge and the lower edge so that both screw cap and the collar ring can share the same threads on the upper edge and lower edge of the neck respectively.

34. The multi-component bottle according to claim 19, wherein the collar ring comprises: an inner threading designed to mate with the threading on the lower edge of the neck, allowing the collar ring to sit above the outer body and secure the neck to the outer body; and a skirt at the bottom edge that flares outwards to smoothly transition to the outer surface of the container.

35. The bottle according to claim 34, wherein the inner surface of this flared skirt is textured, having a rough finish or protrusions including, but is not limited to, ramped protrusions, to resist unscrewing of the collar ring.

36. The multi-component bottle according to claim 19, wherein the barrier method includes, but is not limited to, a film liner lamination, a coating, or an inner flexible bag.

37. The multi-component bottle according to claim 19, wherein the barrier is formed by a vacuum formed film laminated onto interior surfaces of the pulp molded outer body, the shoulder and the base components.

38. The multi-component bottle according to claim 19, wherein the barrier is provided by an inner flexible bag attached to structured rim of the neck.

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