HYBRID PAPERBOARD CONTAINER/PACKAGING

Description

SUMMARY

In one aspect, disclosed herein is a container including a shell made of a recyclable material, and a container insert, including a chamber configured to hold a formulation, an attachment configured to removably couple the container insert with a cap; and a plurality of teeth configured to form an interference fit with the shell by deforming an inner surface of the shell.

In some embodiments, the recyclable material comprises paper, pulp, bamboo, cardboard, cork, seaweed, cotton, wood, bioplastic, jute, beeswax, mushroom material, or a combination thereof.

In some embodiments, the teeth are disposed radially around the container insert. In some embodiments, each tooth of the plurality of teeth has a first width of about 1 mm to about 3 mm. In some embodiments, each tooth of the plurality of teeth includes a body. In some embodiments, the body of each tooth of the plurality of teeth has a first width and a second width, and where the first width is wider than the second width. In some embodiments, the body of each tooth of the plurality of teeth prevent rotation of the container insert.

In some embodiments, the plurality of teeth forms a plurality of grooves in the shell, and where the plurality of grooves is configured to prevent vertical movement of the container insert.

In some embodiments, the plurality of teeth comprises a first plurality of teeth and a second plurality of teeth, where the first plurality of teeth has a first top edge height, and the second plurality of teeth has a second top edge height, where there is an offset between the first top edge height and the second top edge height. In some embodiments, first plurality of teeth and the second plurality of teeth are alternated about the container insert.

In some embodiments, the container further comprises the cap. In some embodiments, the attachment is a thread. In some embodiments, the plurality of teeth is located below the thread.

In some embodiments, each tooth of the plurality of teeth further includes an elongate portion.

In some embodiments, the plurality of teeth is spaced equidistantly about the container insert. In some embodiments, the container insert further comprises a skirt, where the plurality of teeth is coupled to the skirt. In some embodiments, a top edge of each tooth of the plurality of teeth is disposed at an angle.

In another aspect, disclosed herein is a method of using the container insert described herein, the method including pressing the container insert into the shell, deforming the shell in response to a pressure created by pressing the container insert into the shell, and forming an interference fit between the container insert and the shell.

In some embodiments, deforming the shell comprises forming a plurality of grooves in the shell, where the plurality of grooves is configured to prevent vertical movement of the container insert.

In some embodiments, the method further includes preventing rotational movement of the container insert with a body of each tooth of the plurality of teeth, where the body of each tooth of the plurality of teeth has a first width and a second width, and where the first width is wider than the second width.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

DESCRIPTION OF THE DRAWINGS

FIG. 1A is a cross-section of an example container, in accordance with the present technology;

FIG. 1B is an example tooth of the plurality of teeth forming an interference fit with the shell, in accordance with the present technology;

FIG. 1C is an example insert of a container in accordance with the present technology;

FIGS. 2A-2B are other example containers, in accordance with the present technology;

FIGS. 3A-3B are example teeth, in accordance with the present technology;

FIG. 4A is an example insert, in accordance with the present technology;

FIG. 4B is a close-up of the example insert of FIG. 3A, in accordance with the present technology; and

FIG. 5 is a method of retaining an insert into a shell, in accordance with the present technology.

The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings.

DETAILED DESCRIPTION

Disclosed herein are container inserts configured to retain recyclable containers. While environmentally friendly (or “conscious”) containers are desired by industries and consumers alike, recyclable packaging is notoriously difficult to achieve. Especially in the case of retaining liquid, cream, or semi-solid product (or formula), recyclable containers have a tendency to warp, get soggy, or otherwise fall apart. Recyclable materials tend to be “soft,” that is, easy to deform. This can lead to issues with retaining such formulas. Disclosed herein are novel recyclable containers including a shell and a container insert. The shell may be formed of a recyclable container. The container insert may be formed of a material that is not recyclable but could also be recyclable. Advantageously, the container insert has a plurality of specially designed teeth configured to deform the shell and create an interference fit between the shell and the container insert. This can prevent the recyclable shell from coming into contact with the formula, and prevent vertical and/or rotational movement of the container insert. Thus, disclosed herein are recyclable containers that can retain liquid, cream, semi-solid, wax, or solid formula while still retaining their shape and structure.

FIG. 1A is a cross-section of an example container 100, in accordance with the present technology. In some embodiments, the container 100 includes a shell 105, a cap 110, and an insert 200 (also referred to herein as a “container insert”).

In some embodiments, the shell 105 is made of a recyclable material. In some embodiments, the shell 105 is compostable. In some embodiments, the shell 105 is recyclable. In some embodiments, the shell 105 includes paper, pulp, bamboo, cardboard, cork, seaweed, cotton, wood, bioplastic, jute, beeswax, mushroom material, or a combination thereof. In some embodiments, the shell 105 is made of a deformable material. In some embodiments, the shell 105 is biodegradable.

In some embodiments, the cap 110 is also made of a recyclable material, but in other embodiments, the cap may be plastic, metal, or the like. In some embodiments, the cap 110 is configured to removably couple to the insert 200, and specifically, an attachment 210 of the insert 200.

In some embodiments, the insert 200 includes a chamber 205, an attachment 210, and a plurality of teeth 215A, 215B, 215C . . . 215N. The insert 200 may be formed of plastic, metal, recyclable material, or the like. In some embodiments, the chamber 205 is configured to hold a formulation, such as shown in FIG. 1C. In some embodiments, the formulation may be a cream, a liquid, a solid, a wax, etc.

While the attachment 210 is illustrated as a thread, it should be understood that the attachment 210 may take any form. One skilled in the art would recognize that the attachment 210 could be, for example, one or more magnets, one or more snaps, an interlocking mechanism, a snap mechanism, a twist mechanism, a pry-off mechanism, or a combination thereof. In some embodiments, the attachment 210 is a continuous thread.

The plurality of teeth 215A, 215B, 215C . . . 215N may take many forms, as shown and described in FIGS. 1B, 2A-2B, and 3A-3B. The plurality of teeth 215A, 215B, 215C . . . 215N may be disposed radially around the insert 200. In some embodiments, the plurality of teeth 215A, 215B, 215C . . . 215N are coupled to a skirt 220 around the insert 200. In other embodiments, the plurality of teeth 215A, 215B, 215C . . . 215N may be coupled directly to the container insert 200. Further, the plurality of teeth 215A, 215B, 215C . . . 215N may be located below the attachment 210 (i.e., the thread) of the container insert, to avoid interfering with coupling the cap 110 to the insert 200. In some embodiments, the plurality of teeth 215A, 215B, 215C . . . 215N are configured to form an interference fit with the shell 105 by deforming an inner surface of the shell 105 (as shown in FIG. 1B). In some embodiments, the plurality of teeth 215A, 215B, 215C . . . 215N are designed to form the interference fit of the shell 105 by permanently deforming the recyclable material of the shell 105. In this manner, a substantially recyclable (and thus, environmentally conscious) container is disclosed herein.

FIG. 1B is an example tooth 215A of the plurality of teeth (such as the plurality of teeth 215A, 215B, 215C . . . 215N) forming an interference fit with the shell 105. In some embodiments, the shell 105 has an outer surface OS and an inner surface IS opposite the outer surface OS. In some embodiments, the outer surface OS is the surface along the outside of the container 100. In some embodiments, the inner surface IS is the surface internal to the container 100. In some embodiments, the plurality of teeth are configured to form an interference fit with the shell 105, and specifically with the inner surface IS of the shell 105. This may be achieved by deforming the inner surface IS of the shell 105. In some embodiments, each tooth 215A has a top edge 305. The top edge 305 may be configured to form a groove G in the shell 105. In some embodiments, each tooth 215A of the plurality of teeth is configured to form a groove G in the shell. In some embodiments, the groove G prevents vertical movement of the container insert (such as container insert 200 in FIG. 1A). In some embodiments, a body of each tooth 215A (as shown and described in FIG. 2A) further prevents rotation of the container insert.

FIG. 1C is an example insert 200 of a container (such as container 100) in accordance with the present technology. In some embodiments, the insert 200 includes a chamber 205 configured to hold a formula F, an attachment 210, and a skirt 220. A plurality of teeth 215A, 215B, 215C . . . 215N may be coupled to the skirt 220, below the attachment 210.

In some embodiments, the plurality of teeth 215A, 215B, 215C . . . 215N is spaced equidistantly about the container insert. For example, as shown in FIG. 1C, each tooth the plurality of teeth 215A, 215B, 215C . . . 215N is separated by a distance D. In some embodiments, the plurality of teeth 215A, 215B, 215C . . . 215N extend towards a bottom S1 of the container insert 200. In some embodiments, a top edge 305 of each tooth of the plurality of teeth 215A, 215B, 215C . . . 215N is disposed at an angle A. This angle A may further contribute to the retention of the container insert 200 in a shell (such as shell 105). This angle A may also prevent vertical movement of the container insert 200 in the shell.

FIG. 2A-2B are other example containers 100, in accordance with the present technology. In some embodiments, the container 100 may take a “stick” form factor, as shown in FIGS. 2A-2B. In such embodiments, the container 100 may include a shell 105, and a cap 110. In some embodiments, the shell 105 and the cap 110 are made of a recyclable material, as described herein.

In some embodiments, the insert 200 includes a skirt 220 and a plurality of teeth 215A, 215B . . . 215N. Closeups of these features may be shown in FIGS. 3A-3B. In some embodiments, the skirt 220 may be rounded as shown in FIG. 2A, but in other embodiments, the skirt 220 may be square, as shown in FIG. 2B. One skilled in the art will recognize that the skirt 220 may take any number of forms, including ovular, polygonal, or organic shapes.

In some embodiments, the insert further includes a shaft 207. This may be in place of, or in combination with an attachment (such as attachment 210). In some embodiments, the shaft 207 also contains a formula F. Accordingly, the shaft 207 may also be referred to as a chamber (such as chamber 205, shown and described herein).

The embodiments shown and described in FIGS. 2A-2B may be particularly good at containing solid, liquid, or gel formulas such as lipsticks, lip glosses, lip balms, lip liners, and the like.

FIGS. 3A-3B are example teeth, in accordance with the present technology.

FIG. 3A is a close-up of an example tooth 215A of a plurality of teeth (such as the plurality of teeth 215A, 215B, 215C . . . 215N in FIG. 1A or plurality of teeth 215A, 215B . . . 215N of FIGS. 2A-2B) of a container (such as container 100), in accordance with the present technology.

In some embodiments, each tooth 215A of the plurality of teeth (such as the 215A, 215B, 215C . . . 215N) is coupled to the skirt 220 of the container. In some embodiments, each tooth 215A of the plurality of teeth includes a top edge 305, an elongate portion 320, and a body 315 (also referred to herein as a “body portion”).

The elongate portion 320 may have a length L1. In some embodiments, the length L1 is about 1 mm to about 5 mm. In some embodiments, the length L1 is about 2 mm to about 3 mm. In some embodiments, the length L is 2.72 mm. In some embodiments, the elongate portion 320 may couple the tooth 215A to the skirt 220. In some embodiments, each tooth 215A of the plurality of teeth has the same length L of the elongate portion 320. In other embodiments, (such as shown and described in FIGS. 4A-4B), one or more teeth of the plurality of teeth may have different lengths of the elongate portion 320.

The body 315 has a first width W1, a second width W2, and a height H1 (also referred to herein as a “top edge height”). In some embodiments, the first width W1 is wider than the second width W2. In such embodiments, the body 315 narrows as it extends towards a bottom (such as bottom S1) of the container insert. In some embodiments, this narrowing of the body 315 prevents rotational movement of the container insert.

In some embodiments, the first width W1 of the is about 1 mm to about 3 mm. In some embodiments, the second width is about 0.1 mm to about 2 mm. In some embodiments, the height H1 is about 0.5 mm to about 2 mm. In some embodiments, each tooth 215A of the plurality of teeth has the same height H1. In other embodiments, (such as shown and described in FIGS. 4A-4B), one or more teeth of the plurality of teeth may have different heights. In some embodiments, the first width W1 is about 1 to 5 mm wide for a packaging with an outer size of 40 mm of less. The width of the teeth may be adjusted for a packaging of a larger size.

FIG. 3B is a top down view of a tooth 215A of the plurality of teeth (such as the plurality of teeth 215A, 215B, 215C . . . 215N in FIG. 1A). In some embodiments, each tooth 215A includes a first side edge 325 and a second side edge 330 of the top edge 305. In some embodiments, the top edge, may be sharp (i.e., the two sides of the tooth may meet at angle A to form a sharp edge). Further, the first side edge 325 and the second side edge 330 may also be sharp so as to form a “barb.” This barb may further contribute to preventing vertical and/or rotational movement of the container insert.

FIG. 4A is an example insert 200, in accordance with the present technology. In some embodiments, the container insert 200 includes a chamber 205, an attachment 210, a skirt 220, and a bottom S1. In some embodiments, the plurality of teeth is a first plurality of teeth 215A-i, 215B-i and a second plurality of teeth 215A-ii, 215B-ii. In some embodiments, the first plurality of teeth 215A-i, 215B-i and the second plurality of teeth 215A-ii, 215B-ii are alternated along the container insert 200. In some embodiments, the first plurality of teeth 215A-i, 215B-i, the second plurality of teeth 215A-ii, 215B-ii, or both may have an angled edge as shown in FIG. 1C. In some embodiments, the first plurality of teeth 215A-i, 215B-i and the second plurality of teeth 215A-ii, 215B-ii have characteristics that are distinct from one another (as shown in FIG. 4B). The close-up 4B is shown in detail in FIG. 4B. It should be understood that while insert 200 is shown as circular, in some embodiments, the insert 200 is ovular, square, rectangular, organically shaped, or the like. One skilled in the art will recognize the insert 200 may take any number of forms.

FIG. 4B is a close-up 4B of the example insert 200 of FIG. 4A, in accordance with the present technology. In some embodiments, each tooth 215A-i of the first plurality of teeth (such as first plurality of teeth 215A-i, 215B-i) has an elongate portion 320A and a body 315A. Each tooth 215A-i of the first plurality of teeth may further include a first length L1 and a first height (or “first top edge height”) H1. Further, each tooth 215A-ii of the second plurality of teeth (such as second plurality of teeth 215A-ii, 215B-ii) may have an elongate portion 320B and a body 315B. Each tooth 215A-ii of the second plurality of teeth may have a second length L2 and a second height (or “second top edge height”) H2.

In some embodiments, there is an offset O between the first top edge height H1 of the first plurality of teeth and the second top edge height H2 of the second plurality of teeth. In some embodiments, this is because the first height H1 is larger than the second height H2. In some embodiments, this is because the first length L1 is shorter than the second length L2. In some embodiments, the first plurality of teeth and the second plurality of teeth are alternated about the container insert.

In such embodiments, by alternating the heights (H1, H2) of the first plurality of teeth and the second plurality of teeth, rotational movement of the container insert 200, when retained in a shell (such as shell 105) is further prevented.

FIG. 5 is a method 500 of retaining an insert into a shell, in accordance with the present technology. In some embodiments, the method 500 is carried out with a container (such as container 100) having a shell (such as shell 105) and a container insert (such as insert 200). In some embodiments, the container may further include a cap (such as cap 110). In some embodiments, the container insert may include a chamber (such as chamber 205) configured to hold a formula (such a formula F), an attachment (such as attachment 210), and a plurality of teeth (such as plurality of teeth 215A, 215B, 215C . . . 215N). In some embodiments, the plurality of teeth may include a first plurality of teeth (such as first plurality of teeth 215A-i, 215B-i) and a second plurality of teeth (such as second plurality of teeth 215A-ii, 215B-ii).

In block 505, the container insert is pressed into the shell. In some embodiments, the container insert may be pressed into a shell manually, such as by a person, or in an automated fashion, such as by a production machine. In some embodiments, the shell is made of a recyclable material, while the container insert is made of plastic. In other embodiments, both the shell and the container insert may be made of a recyclable material, including from different recyclable materials. For example, in some embodiments, the shell may be made of paper and the container insert may be made of bioplastic.

In block 510, the shell is deformed by the container insert in response to pressure generated by pressing the container into the shell. In some embodiments, the plurality of teeth deform the shell. In some embodiments, the barbs of each tooth of the plurality of teeth (as shown in FIG. 3B) deform the shell. In some embodiments, deforming the shell includes forming a plurality of grooves (such as groove G) in an inner surface (such as inner surface IS) of the shell. In some embodiments, the grooves are configured to prevent vertical movement of the container insert. In some embodiments, deforming the shell further comprises preventing rotational movement of the container insert with a body (such as body 315) of each tooth of the plurality of teeth. In some embodiments, a first width of the body (such as first width W1) is larger than a second with of the body (such as second width W2), such that the body of the tooth narrows as it extends towards a bottom (such as bottom S1) of the container insert.

In block 515, an interference fit is formed between the container insert and the shell. In some embodiments, the interference fit is formed with the grooves. In some embodiments, the interference fit is further formed with the plurality of teeth. In other embodiments, the interference fit is formed with the first plurality of teeth and the second plurality of teeth. In some embodiments, the interference fit prevents vertical and/or rotational movement of the container insert,

It should be understood that method 500 should be interpreted as merely representative. In some embodiments, process blocks of method 500 may be performed simultaneously, sequentially, in a different order, or even omitted, without departing from the scope of this disclosure.

While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.

The present application may reference quantities and numbers. Unless specifically stated, such quantities and numbers are not to be considered restrictive, but representative of the possible quantities or numbers associated with the present application. Also, in this regard, the present application may use the term “plurality” to reference a quantity or number. In this regard, the term “plurality” is meant to be any number that is more than one, for example, two, three, four, five, etc. The terms “about,” “approximately,” “near,” etc., mean plus or minus 5% of the stated value. For the purposes of the present disclosure, the phrase “at least one of A, B, and C,” for example, means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B, and C), including all further possible permutations when greater than three elements are listed.

The detailed description set forth above in connection with the appended drawings, where like numerals reference like elements, are intended as a description of various embodiments of the present disclosure and are not intended to represent the only embodiments. Each embodiment described in this disclosure is provided merely as an example or illustration and should not be construed as preferred or advantageous over other embodiments. The illustrative examples provided herein are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Similarly, any steps described herein may be interchangeable with other steps, or combinations of steps, in order to achieve the same or substantially similar result. Generally, the embodiments disclosed herein are non-limiting, and the inventors contemplate that other embodiments within the scope of this disclosure may include structures and functionalities from more than one specific embodiment shown in the figures and described in the specification.

In the foregoing description, specific details are set forth to provide a thorough understanding of exemplary embodiments of the present disclosure. It will be apparent to one skilled in the art, however, that the embodiments disclosed herein may be practiced without embodying all the specific details. In some instances, well-known process steps have not been described in detail in order not to unnecessarily obscure various aspects of the present disclosure. Further, it will be appreciated that embodiments of the present disclosure may employ any combination of features described herein.

The present application may include references to directions, such as “vertical,” “horizontal,” “front,” “rear,” “left,” “right,” “top,” and “bottom,” etc. These references, and other similar references in the present application, are intended to assist in helping describe and understand the particular embodiment (such as when the embodiment is positioned for use) and are not intended to limit the present disclosure to these directions or locations.

The present application may also reference quantities and numbers. Unless specifically stated, such quantities and numbers are not to be considered restrictive, but exemplary of the possible quantities or numbers associated with the present application. Also, in this regard, the present application may use the term “plurality” to reference a quantity or number. In this regard, the term “plurality” is meant to be any number that is more than one, for example, two, three, four, five, etc. The term “about,” “approximately,” etc., means plus or minus 5% of the stated value. The term “based upon” means “based at least partially upon.”

The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure, which are intended to be protected, are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the present disclosure as claimed.