SE544857C2

SE544857C2 - Sealed package and method of making such a sealed package

Info

Publication number: SE544857C2
Application number: SE1850919A
Authority: SE
Inventors: David A Pierce
Original assignee: Celwise Ab
Priority date: 2018-07-19
Filing date: 2018-07-19
Publication date: 2022-12-13
Also published as: SE1850919A1; JP3233395U; DK202100028U1; DK202100028Y3; WO2020016409A1; DE202019005625U1; CN216509783U

Abstract

The document relates to a method of producing a biodegradable, disposable package (5), the method comprising forming a first container part (51) from a first pulp material, and forming a second container part (52) from a second pulp material, wherein the first container part comprises a wall portion (512) which surrounds a product space presenting a cross sectional area, and wherein said wall portion (512) extends along an axial direction perpendicular to the cross sectional area, between a first and a second axially spaced apart end portion of said first container part (51). The method further comprises joining said second end portion of the first container part (51) to the second container part (52), such that the first and second container parts (51, 52) are permanently attached to one another to form a package.

Description

Technical field The present disclosure relates to a sealed package, which is biodegradable, and to a method of making such a sealed package.

Background There is a general desire to use biodegradable packages to a greater extent in the distribution of various products, such as food products, beverages and other household items.

However, products that are moist and/or that are sensitive to e.g. oxidation, present a particular challenge when using pulp based packages. Moreover, there is a particular challenge in packaging food, or perhaps primarily beverages, that are under pressure, such as carbonized beverages.

Furthermore, it is desirable that the manufacturing cost for producing the package is low. lt is also desirable that the package is easily adapted to the packaging process of the product, which are to be enclosed in the package, in order to get an efficient packaging process.

Summary lt is therefore an object of the present disclosure to provide a package that can be manufactured at a low cost and that overcomes at least some of the present challenges of using pulp based packages.

The invention is defined by the appended independent claims. Embodiments are set forth in the appended dependent claims and in the following description and drawings.

According to a first aspect, there is provided a method of producing a biodegradable, disposable package, wherein the method comprises forming a first container part from a first pulp material, and forming a second container part from a second pulp material, wherein the first container part comprises a wall portion which surrounds a product space presenting a cross sectionalarea, and wherein said wall portion extends along an axial direction perpendicular to the cross sectional area, between a first and a second axially spaced apart end portion of said first container part and wherein said »vatt portion. at the second end portion tnereot. extends; at an anoie reiative to the axiai direction. The second container part is torrned so ae to present a oentrai portion and a rirn portion atirrotindino the eentrai portion, tfvheiteiit the rirn portion oornprieee a rim wait, which extends at an anoie reiative to the axiai direotion iiifnien oorreatxonda to said anoie of the firat container parts ttfaii at the second end portion thereof. The method further comprises joining said second end portion of the first container part to the second container part, such that the first and second container parts are permanently attached to one another to form a package. The ioiifiifo is achieved bettßseen a radiailv outwardii; taoino atirtaoe ot the rirri wait and a radiaiiv inwaroit' faoino surface ot the firat container parti; tfvaii, or betvveen a radiaiiv intvardiv faoino surface of the rirn vtfaii and a radiaiitf ontifirardiv faoino attrfaoe ofthe firat container partïe xfvaii. The wait portion ot the first container part ooinprieee at ieaet one radiai step formation, By “disposabie package” is meant that the cost of manufacturing the package is sufficiently low as for the package to be disposed of after a single use.

The first and second pulp material may be the same or different pulp material. Pulp materials are well known and available. Typically, application is performed from a suspension in water, through immersion or spraying.

By “permanently attaching” is meant that the established attachment between the two parts is permanent, i.e. the two parts cannot be separated unless the package is broken.

When in use, the package is adapted to be filled with a content. The first container part may be filled with a content before attaching the second container part permanently. Alternatively, the second container part may be filled with a content, before attaching the first container part. ln this way, the filling of the package can be achieved faster than when the filling is performed through a top opening of a package. As a result, the possibility to fill thepackage with a content before attaching the two parts together, the user of the package can achieve a more efficient manufacturing process.

As an alternative, when desirable the first and second container parts can also be attached before filling, wherein the content is filled through the top opening of the package.

The first container part can be formed such that, prior to the joining, the first end portion forms a closed end and the second end portion forms an open end.

Alternatively, the first container part can be formed such that, prior to the joining, the first end portion forms an open end and the second end portion forms an open end.

Consequently, the first container part can be formed such that, prior to the joining, the first end portion is closed or open. Depending on filling method, it may be desirable that the first end portion is closed, for example when filling the first container part with a content before attaching the second container part. Alternatively, it may be desirable that the first end portion is open, for example when attaching the first and second container parts prior to filling, wherein the content is filled through the opening at the first end portion.

The closed end may comprise a portion of weakened pulp material, adapted to be opened by a consumer of the product enclosed within the package. Alternatively, the first end portion may be closed with a sealing strip of a film material. The sealing strip is preferably made out of a biodegradable material, preferably cellophane, but can also be made of other bioplastic material. The film function as an extra sealing layer, which is adapted to be pulled off by a consumer of the product that is enclosed within the package.

The joining can comprise adhering a-gigçmrim wall of the second container part to the first container part's wall.

The joining may be achieved between a radially outwardly facing surface of the rim wall and a radially inwardly facing surface of the first container part's wall.Alternatively, the joining may be achieved between a radially inwardly facing surface of the rim wall and a radially outwardly facing surface of the first container part's wall.

The wall portion of the first container part ea-ecompriseg at least one radial step formation.

The step formation of the wall portion forms a recess wherein the second container part can be fitted when attaching the first and second container parts. Further, the step formation provides the package with a strong base which helps preventing deformation of the package when filled with a content. Furthermore, it breaks the hydrostatic pressure on the sea| between the first and second container parts.

The step formation can be located within a portion of the wall portion which is closest to the second end portion, and said portion preferably corresponds to 50 % of an axial extent of the wall portion, preferably 33 %, and more preferably 25 %.

The step formation can be located at a distance from the second end portion corresponding to a total axial length of a joint surface of the second container part.

By “a joint surface of the second container part” is meant the surface of the rim wall of the second container part which is adhered to the wall of the first container part.

The joining of the second end portion of the first container part to the second container part can comprise causing the step formation to act as an axial limitation for the other one of the rim wall and the first container part's wall.

The joining of the second end portion of the first container part to the second container part can be achieved through a relative movement of the first and second parts along the axial direction.

The second container part eaabeís formed so as to present a central portion and a rim portion, surrounding the central portion, wherein the rim portion comprises a rim wall, which extends at an angle relative to the axialdirection which corresponds to that of the first container part's wall at the second end portion thereof.

The central portion may consist essentially of a bottom part, which may be planar or curved, and which, at its circumference transitions into the rim portion. The curved bottom part may be formed such that the inwardly facing surface of the bottom part, as seen when attached to the first container part, is convex or concave.

The second container part can comprise a wall portion which extends axially between a bottom and a transition to the rim wall, preferably by an axial distance which is greater than an axial length of the rim wall.

Hence, the second container part may enclose a space which can form part of the product space. ln one embodiment, the second part may have a greater axial length than the first container part. Alternatively, the first container part may have a greater axial length than the second container part.

The method can further comprise forming a container closure part and forming the first end portion of the first container part in such a way that the container closure part and the first container part can be detachably attached to one another, such that the package is sealed when the parts are attached.

The container closure part may be a lid, cap, plug, tap etc. lt is is preferably formed from pulp material, but can also be of other material such as wood, PLA or bio-plastic material.

By “detachably attached” is meant that the established attachment between the two parts is not permanent, i.e. the two parts can be separated without breaking the package.

The method can further comprise detachably attaching the container closure part to the first end of the first container part.

The forming of the container parts can comprise applying a material to a forming surface of a respective first press mold part of a respective first pressing tool and subsequently pressing the material between the respective first press mold part and a respective second press mold part of the first pressing tool.The forming of the container parts can further comprise transferring the pressed material to a respective forming surface of a respective first press mold part of a respective second pressing tool and subsequently pressing the material between the respective first press mold part and a respective second press mold part of the respective second pressing tool.

The forming of the container parts can further comprise transferring the pressed material to a respective forming surface of a respective first press mold part of a respective third pressing tool and subsequently pressing the material between the respective first press mold part and a respective second press mold part of the respective third pressing tool.

The press mold parts can be brought together through a relative movement of the press mold parts along the axial direction.

The forming of the container parts can comprise at least one of drawing vacuum and applying heat, through at least one of the respective first and second press mold parts.

The forming of the container parts can further comprise depositing the material on the respective forming surface of the respective first pressing tool, or on a respective separate forming tool and subsequently transferring the material to the respective first pressing tool.

The deposition may be achieved through immersion of the forming surface into a slurry, by spraying or rolling a slurry onto the forming surface, or by preforming the material in a pickup tool and transferring it onto the forming surface.

The forming of the container parts from a pulp material can be performed with an initial water content of a pulp slurry about 70-90 % by weight, with an initial water content of the pulp slurry of about 45-65 %, typically about 50-60 % by weight, or with an initial water content of the pulp slurry of about 25-45 % by weight, preferably about 30-40 % by weight.

The final water content can be less than about 5 % by weight, preferably less than about 1 % by weight.The method can further comprise applying a gas and/or liquid impermeable film and/or a coating layer to a product space facing surface of the first and/or second container parts.

The gas and/or liquid impermeable film provides the package with a sealing layer, making it possible to enclose a content, both solid, liquid and/or gaseous content, within the package. The film may be attached by means of PVOH, an adhesive etc. The adhesive is preferably biodegradable. The film may be a cellulose film, such as for example cellophane. The cellophane film is also biodegradable, thus making the whole package biodegradable.

The coating layer may be applied by spraying, dipping or pouring the inner surface with/in a cellulose-based coating material.

The gas and/or liquid impermeable film can be a cellulose film.

The method can further comprise attaching an inner container to the first end portion of the first container part, and/or to the second end portion of the second container part, and/or to an inwardly facing surface of the first and/or second container parts.

When in use, the inner container is enclosed by the package. The inner container provides the package with a sealing layer, making it possible to enclose a content, both solid, liquid and/or gaseous content, within the package.

The inner container may have the form of a bag or pouch. The inner container in form of a bag or pouch is preferably made out of a recyclable or biodegradable material, preferably cellophane, but can also be made of other bioplastic material.

Alternatively, the inner container may be a container formed out of a glass material.

Further, the inner container may be attached before or after attaching the first and second container parts. The inner container may be attached at a top circumference of the first end portion of the first container part. Additionally, or alternatively, it may be attached at a bottom circumference of the second container part. Additionally, or alternatively, it may be attached inspots or ribbons along the inwardly facing surface of the first and/or second container parts.

The inner container can be a flexible pouch formed of a biodegradable material.

Alternatively, the inner container can be a container formed out of a glass material.

An inner container formed out of glass is especially applicable for packages intended for beverages under high pressure.

According to a second aspect, there is provided a kit of parts for forming a biodegradable, disposable package, comprising a first container part formed from a first pulp material and a second container part formed from a second pulp material, wherein the first container part comprises a wall portion which surrounds a product space presenting a cross sectional area, and wherein said wall portion extends along an axial direction perpendicular to the cross sectional area, between a first and a second axially spaced apart end portion of said first container part. and tfvhereiit aaio Wait portion. at the eeoostrçi ene portion tnereof, extends at an anoie reiative to the axiai direction. The second container part presents a eentrai oorttoit anti a rirn oortion, aorrotinoino the eentrai portion. tfirnerein the rirn portion oomtirieee a rirn ttfaii, which extenee at an anoie reiathre to the axiai direction which oorreeoontte to said anoie of the first container parts trtrait at the eeoono end oortion thereot. The second end portion of the first container part and the second container part are adapted to be permanently attached to one another in such way that the two parts form a package arta soon tirat a ioiriirto is achieved between a raciiaiiv otittwardiv taoino atsrtaoe ot the rirn ttraii and a radiaiiv inwardiv taoino surface ot the tiret oontainer oarte wtfaii. or oetttfeeit a rariiaiiv invtfardiv taoino etirtaoe of the rârn wait and a raoiaiiv outwarciitf taoino surface ot the firat oontainer parts ttfaii. The tfvaii portion oi' the tiret container tiart oornprieea at teaat one rattiei step 'formation By “disposable package” is meant that the cost of manufacturing the package is sufficiently low as for the package to be disposed of after a single USS.By “permanently attached” is meant that the established attachment between the two parts is permanent, i.e. the two parts cannot be separated unless the package is broken.

The first and second pulp material may be the same or different pulp material.

The first end portion of the first container part can form a closed end and the second end portion can form an open end.

As an alternative, the first end portion of the first container part can form an open end and the second end portion can form an open end.

The second end portion of the first container part and the second container part can present respective joint surfaces which extend at corresponding angles relative to the axial direction.

The second container paﬁeaaapresentms a central portion and a rim portion, surrounding the central portion, wherein the rim portion comprises a rim wall, which extends at an angle relative to the axial direction which corresponds to that of the first container parts wall at the second end portion thereof.

The wall portion of the first container part eawcompriseg at least one radial step formation.

The step formation of the wall portion forms a recess wherein the second container part can be fitted when attaching the first and second container parts. The step formation provides the package with a strong base which helps preventing deformation of the package when filled with a content. Furthermore, it breaks the hydrostatic pressure on the seal between the first and second container parts.

The step formation can form an axial limitation for the other one of the rim wall and the first container part's wall.

The first and second container parts can be joined in the axial direction.

The first and/or second container parts can have a gas and/or liquid impermeable film and/or a coating layer applied on an inwardly facing surface of the respective container part.

The gas and/or liquid impermeable film provides the package with a sealing layer, making it possible to enclose a content, both solid, liquid and/or gaseous content, within the package. The film may be attached by means of PVOH, an adhesive etc. The adhesive is preferably biodegradable. The film may be a cellulose film, such as for example cellophane. The cellophane film is also biodegradable, thus making the whole package biodegradable.The coating layer may be applied by spraying, dipping or pouring the inner surface with/in a cellulose-based coating material.

The gas and/or liquid impermeable film can be a cellulose film.

The cross sectional area of the first container part can increase as seen in the axial direction from the first end portion towards the second end portion.

The first container part may for example have the shape of a bottle, comprising a bottle neck and a bottle body. Alternatively, the first container part may comprise a bottle neck and a portion of a bottle body, wherein the portion of the bottle body may constitute 10-99,9 % of the full bottle body.

Alternatively, the cross sectional area of the first container part can be constant as seen in the axial direction from the first end portion towards the second end portion.

The first container part may for example have the shape of a cylindrical tin orjar.

The open end formed at the second end portion of the first container part can presents the greatest cross sectional area of the package.

By forming the first container part in such way that the open end, formed at the second end portion of the first container part, presents the greatest cross sectional area of the package, the filling of the package can be significantly improved in terms of efficiency, as a faster filling is made possible, provided that the first and second container parts are attached after the filling.

The wall portion of the first container part extending along the axial direction can be rotational symmetric around the axis.

Alternatively, the wall portion of the first container part extending along the axial direction can be non-rotational symmetric around the axis.

A portion of the first and/or second container parts can be formed as a handle.

The first end portion of the first container part can be adapted to receive a container closure part, wherein the container closure part is adaptedto be detachably attached to the first container part in such a way that it seals the package when attached.

The kit of parts can further comprise an inner container.

The inner container may have the form of a bag or a pouch. The inner container in form of a bag or a pouch is preferably made out of a recyclable or biodegradable material, preferably cellophane, but can also be made of other bioplastic material.

The inner container can be a flexible pouch formed of a biodegradable material.

According to a third aspect, there is provided a kit of parts for a biodegradable, disposable package comprising the kit of parts for a package as described above and a container closure part, wherein the container closure part is adapted to be detachably attached to the package in such a way that it seals the package when attached.

The container closure part may be a lid, cap, plug, tap etc. lt is is preferably formed from pulp material, but can also be of other material such as wood, PLA or bio-plastic material.The container closure part can be formed from a third pulp material.

The third pulp material can be the same as the first and/or second pulp material. Alternatively, it can be a different pulp material.

According to a fourth aspect, there is provided a method of packaging a product, comprising providing a kit of parts as described above in relation to the second or third aspect, introducing the product into the first container part and joining the second container part to the first container part, so as to close the product space.

According to a fifth aspect, there is provided a biodegradable, disposable package, comprising a first container part formed from a first pulp material, a second container part formed from a second pulp material, wherein the first container part comprises a wall portion which surrounds a product space, presenting a cross sectional area, and wherein said wall portion extends along an axial direction perpendicular to the cross sectional area, between a first and a second axially spaced apart end portion of said first container part, and tfvhereiit said wall portion, at the second end portion thereot, extends at an anoie relative to the axial direction, The second container' part presents a central portion and a rim portion, surroundind the central portion. vvherein the rirn portion contttrieee a rirn wall, irvhich extends at an anoie reiative to the axial direction which corresportds to said annie ot the tiret container parts anfall at the eeooiïd and portion thereot. whereinﬁeaid second end portion of the first container part and the second container part are permanently joined to one another in such way that the two parts form a package. wiierein the ioinino ie achieved heltween a radialiv ootwardiar tacino surface of the rirn wall and a radiaiiv inwardiv tacino atsrtace ot the tirst container parts wfall or between a radiallv irivirarcilv taciirio eurtace ot the rirn Wall and a radiaiiv outwardiv tacind surface ot the first container parts wall. The tfvall portion et' the firat container part cornorisee at ieaet one radiai etep torrnation.

Such a package can be formed according to the method described above and from the kit of parts described above.Brief description of the drawinqs Embodiments of the present solution will now be described, by way of example, with reference to the accompanying schematic drawings in which: Figs 1a-1c schematically illustrate a molding device.

Fig. 2 schematically illustrates a production process Figs 3a-3e schematically illustrate a first embodiment of a package in the form of a bottle.

Figs 4a-4e schematically illustrate a second embodiment of a package in the form of a bottle.

Figs 5a-5e schematically illustrate a third embodiment of a package in the form of a bottle.

Figs 6a-6e schematically illustrate a fourth embodiment of a package in the form of a bottle.

Figs. 7a-7e schematically illustrate a fifth embodiment of a package in the form of a bottle.

Figs. 8a-8e schematically illustrate different embodiments of an inner container for different embodiments of a package in the form of a bottle.

Detailed description Fig 1a schematically illustrates a pickup tool 1 which is partially immersed in container 1 holding a pulp slurry 2. The pickup tool is mounted to a tool holder 11, which together with the pickup tool defines a vacuum chamber 12 that is connected to a pressure regulator P1. The pressure regulator may have the capability of selectively generating an at least partial vacuum (i.e. air pressure lower than ambient air pressure) and/or an air pressure greater than ambient air pressure.

While the pickup tool is immersed in the pulp slurry 2, the pressure regulator P1 may generate a vacuum, causing pulp fibers 3 to stick to a product face of the pickup tool Fig. 1b schematically illustrates the pickup tool 10 transferring the pulp fibers 3 to a transfer tool 20. The transfer tool may be connected to a second pressure regulator P2, which is capable of generating a vacuum or an air pressure. The transfer tool may also be mounted on a transfer tool holder 21 so as to define a vacuum chamber 22, which is connected to the second pressure regulator.

During the transfer of the pulp fibers 3 from the pickup tool to the transfer tool, an air pressure greater than ambient pressure may be generated by the first pressure regulator P1 to cause the pulp fibers to release from the pickup tool.

Alternatively, or as a supplement, a vacuum may be generated by the second pressure regulator P2, causing the pulp fibers to be received by the transfer tool Fig. 1c schematically illustrates a pressing arrangement comprising a male pressing tool 30 and a female pressing tool 40. One, or both, of the pressing tools may be mounted on a respective tool holder 31, 41 and be connected to a respective vacuum chamber 32, 42. The vacuum chambers may be connected to a respective pressure regulator P3, P One, or both, of the pressing tools may be provided with a heating element 33, 43, energized by an energy supply E1, E2 and optionally controlled by a controller C. The heating may be achieved by electric heating elements, hot air or liquid or induction.

The pressing tools and their associated tool holders may be movable relative one another between an open position, wherein a partially molded pulp product may be inserted, and a pressing position, wherein the pressing tools are forced towards each other thus pressing the product 3” between product faces of the respective tool 30, When in the pressing position, heat may be supplied by one, or both, of the heaters 33, During the pressing step, one or both pressure regulators P3, P4 may provide a vacuum to assist in the evacuation of water vapor from the product 3”.

As an alternative, one of the pressure regulators may provide a vacuum while the other one provides a pressure greater than the ambient air pressure.Optionally, hot air or steam may be introduced through the molds during the pressing process (Fig. 1c). lt is noted that two or more successive pressing steps may be used, e.g. to gradually form all or parts of the product 3” and/or to apply additional features to the product, such as coatings, decors and the like. ln one embodiment, steps are performed in accordance with what has been described with respect to Figs 1a, 1b and 1c.

Referring to Fig. 2, a production process will now be described. ln a first step 101, a pulp slurry layer is provided, e.g. as described with reference to Fig. 1a, wherein a porous pickup tool may be submerged in a pulp slurry with vacuum being applied to a rear side of the pickup tool.

Alternatively, the pulp slurry may be applied to the pickup tool by a coating operation, such as spray coating.

The porous wall portion of the pickup tool may have a surface porosity of 40-75 % with hole sizes 0.1-0.7 mm in diameter, preferably 0.25-0.6 mm. ln a second step 102, the pulp slurry layer is transferred from the pickup tool to a first press tool. The transfer may be performed by the pickup tool, or by means of a separate transfer tool, which may have a transfer tool wall portion that is porous. During the transfer step, a vacuum may be applied to the rear side of the transferring tool wall, such that the pulp slurry is held to the transferring tool wall. ln order to release the pulp slurry layer from the transferring tool wall, it is possible to instead apply pressurized air to the rear side of the transferring tool wall.

Alternatively, the pulp slurry layer may be applied directly to the first press tool. ln a third step 103, the pulp slurry layer may be pressed in the first press tool, which may comprise a pair of mating tool parts, one of which may have a porous wall portion, which contacts the pulp slurry layer, and through which a vacuum can be drawn. ln this first pressing step 103, a pressure lower than the surrounding ambient pressure is applied at a rear side of the porous wall portion, thusresulting in a vacuum at the rear side of the porous wall portion, causing solvent vapor, such as steam, to be drawn through the tool.

The porous wall portion of the first forming tool may have a surface porosity of 40-75 % with hole sizes 0.1 -0.7 mm, preferably 0.25-0.6 mm.

The pressure applied to the rear side of the porous wall portion may be on the order of low or medium level vacuum. That is, a first pressure may be 200-900 mbar below ambient pressure, preferably 300-800 mbar below ambient pressure.

The forming face of the first mold may be heated to about 150-400 °C, preferably 200-300 °C, and in most cases 240-280 °C. Typically, at least one mold face contacting the pulp slurry may be heated. That is one of the first and second mold parts may be heated.

A pressing pressure between mold faces may be on the order of about 390-1570 kPa, and in most cases 580-1170 kPa.

The pressing pressure may be applied during a first pressing time of 0.1-4.0 second, preferably 0.5-2.0 second. ln most settings, a pressing time on the order of 0.5-1 .5 second is sufficient, and often also 0.5-1 second.

Typically, in this first step, an initial water content of the pulp slurry is 70-90 % by weight and after the pressing step has been performed, a final water content may be 45-65 % by weight, typically about 50-60 % by weight.

After the first pressing step 103, the pulp slurry, now with a substantial amount of its solvent removed, may be transferred 104 to a second press tool. The transfer 104 may be performed in the same manner as the first transfer step 102, and with similar equipment. The second press tool may be designed essentially as the first press tool. ln a second pressing step 105, the pulp slurry layer may be pressed in the second press tool, which may comprise a pair of mating tool parts, one of which may have a porous wall portion, which contacts the pulp slurry layer, and through which a vacuum can be drawn. ln this second pressing step 105, a pressure lower than the surrounding ambient pressure is applied at a rear side of the porous wall portion, thus resulting in a vacuum at the rear side ofthe porous wall portion, causing solvent vapor, such as steam, to be drawn through the tool.

The porous wall portion of the second forming tool may have a surface porosity of 25-50 % with hole sizes 0.1 -1 .2 mm, preferably 0.25-1.0 mm. ln the second pressing step, the absolute pressure applied to the rear side of the porous forming face of the second mold may be 200-900 mbar below ambient pressure, preferably 300-800 mbar below ambient pressure, but always greater than in the first pressing step.

The forming face of the second mold may be heated to about 150-400 °C, preferably 200-300 °C, and in most cases 240-280 °C. Typically, all mold faces making up the second mold and contacting the pulp slurry may be heated.

The pressing pressure may be applied during a second pressing time of 0.1 -4.0 second, preferably 0.5-2.0 second. ln most settings, a pressing time on the order of 0.5-1 .5 second is sufficient, and often also 0.5-1 second.

Typically, in this second pressing step, an initial water content of the pulp slurry may be about 45-65 %, typically about 50-60 % by weight.

After the second pressing step 105, the pulp slurry layer, now with a substantial amount of its solvent removed, may be transferred 106 to a third press tool. The transfer 106 may be performed in the same manner as the first transfer step 102 and/or the second transfer step 104, and with similar equipment. The third press tool may be designed essentially as the first press tool. ln a third pressing step 107, the pulp slurry layer may be pressed in the third press tool, which may comprise a pair of mating tool parts, one of which may have a porous wall portion, which contacts the pulp slurry layer, and through which a vacuum can be drawn. ln this third pressing step 107, a pressure lower than the surrounding ambient pressure is applied at a rear side of the porous wall portion, thus resulting in a vacuum at the rear side ofthe porous wall portion, causing solvent vapor, such as steam, to be drawn through the tool.

The porous wall portion of the third forming tool may have a surface porosity of 25-50 % with hole sizes 0.1 -1 .2 mm, preferably 0.25-1.0 mm. ln the third pressing step, an absolute pressure provided at the rear of the porous wall portion of the third mold may be 200-900 mbar below ambient pressure, preferably 300-800 mbar below ambient pressure, but always greater than in the second pressing step.

The forming face of the third mold may be heated to about 150-400 °C, preferably 200-300 °C, and in most cases 240-280 °C. Typically, all mold faces making up the third mold and contacting the pulp slurry may be heated.

The pressing pressure may be applied during a third pressing time of 0.1-4.0 second, preferably 0.5-2.0 second. ln most settings, a pressing time on the order of 0.5-1 .5 second is sufficient, and often also 0.5-1 second.

Typically, in this third pressing step, an initial water content of the pulp slurry may be about 25-45 % by weight, preferably about 30-40 % by weight, and a final water content may be less than about 5 % by weight, preferably less than about 1 % by weight.

After the third pressing step 107, the pulp slurry layer, now with most of its solvent removed, may be transferred 108 out of the machine.

Optionally, additional steps, such as surface treatment, cutting or printing may be performed on the thus essentially dry product. The product may then be packaged, stored and shipped. lt is noted that the third pressing step 107, and thus also its related transfer step 106, is optional. Hence, the process may be finished after the second pressing step 105 with the output step 108 following immediately.

According to the present invention, a sealed package 5 which is biodegradable is provided, as well as a method of making such a package.

The package 5 according to the present invention may have a form of a bottle, a tin or a jar etc. The package is adapted to contain a solid, liquid and/or gaseous content, and can be used as a package for various products such as for example personal care products, home care products, food or beverages etc.

Fig. 3-7 i||ustrates different embodiments of a package 5 in the form of a bottle. As illustrated in Fig. 3-7, the package 5 can have various shapes, for example a cylindrical and symmetrical shape (see Fig. 3, 4 and 7) or a cylindrical and non-symmetrical shape (see Fig. 5 and 6). lt is however understood that the embodiments set forth in the drawings are only illustrated as a way of example, and that other shapes of the package is possible.

The package comprises a first container part 51, a second container part 52 and a container closure part 53 (see Fig. 3b-7b, 3e-7e), which are adapted to be attached to one another such that they together form the package 5 (see Fig. 3a-7a).

The first and second container parts 51, 52 are formed from a first and second pulp material, preferably by using the method described in relation to Fig. 2. The container closure part 53 is preferably formed from a third pulp material, preferably by using the method described in relation to Fig. 2, but can also be of other material such as for example wood, PLA or bio-plastic material. The first, second and third pulp material may be the same or different pulp material.

The first container part 51 comprises a wall portion 512 which surrounds a product space, presenting a cross sectional area. The wall portion 512 extends along an axial direction perpendicular to the cross sectional area, between a first end portion and a second axially spaced apart end portion of said first container part An open end is formed at the second end portion of the first container part 51 _ A closed end is preferably formed at the first end portion of the first container part 51. The closed end may comprise a portion of weakened pulp material (not shown), adapted to be opened by a consumer of the product enclosed within the package. Alternatively, the first end portion may be closed with a sealing strip (not shown) of a film material. The sealing strip is preferably made out of a biodegradable material, preferably cellophane, butcan also be other bioplastic material. The film function as an extra sealing layer, which is adapted to be pulled off by a consumer of the product enclosed within the package.

Alternatively, an open end is formed at the first end portion, which can be sea|ed with a sealing strip and or the container closure portion Fig. 3a-7a further illustrates that the first container part 51 is formed in a way such that the cross sectional area increases, as seen in the axial direction from the first end portion towards the second end portion. However, although not illustrated, other embodiments are possible. For example, the cross sectional area of the first container part 51 may be constant as seen in the axial direction from the first end portion towards the second end portion.

Further, the first container part 51 may be formed in such a way that the open end at the second end portion of the first container part presents the greatest cross sectional area of the package (see Fig. 3b-7b).

Further, the first end portion of the first container part 51 can be adapted to receive a container closure part 53. This is illustrated in Fig. 3d-7d, which all shows a view of the first end portion of the first container part 51, according to different embodiments of the package, and a corresponding container closure part The container closure part 53 may be a lid, cap, plug, tap etc. and is adapted to be attached detachably to the first container part 51 in such a way that it seals the package 5 when attached.

The second container part 52 presents a central portion 523 and a rim portion surrounding the central portion 523 (see for example, Fig.3c-6c). The central portion 523 may consist essentially of a bottom part, which may be planar or curved. The curved bottom part may be formed such that the inwardly facing surface of the bottom part, as seen when attached to the first container part, is convex (see Fig. 8e) or concave (see Fig. 8a-8d). The central portion 523 transitions into the rim portion at the circumference of the central portion (see for example Fig. 3e-6e). The rim portion comprises a rim wall 522, which extends at an angle relative to the axial direction. Theextension of the rim wall 522 corresponds to that of the first container part's wall 512 at the second end portion thereof (see Fig. 3c-6c).

The second container part 52 may further comprise a wall portion 524, as illustrated in Fig 7b and 7e. The wall portion 524 then extends axially between the bottom part 523 and the rim wall 522 (see Fig. 7b). The wall portion 524 preferably extends by an axial distance which is greater than an axial length of the rim wall Consequently, in one embodiment of the present invention, the first container part 51 can enc|ose a space which forms the total product space (see for example, Fig. 3b-6b), wherein the second container part 52 forms the bottom of the package. Thus, the first container part 51 may have a greater axial length than the second container part 52. Alternatively, the second container part 52 can enc|ose a space which forms a part of the product space (see Fig. 7b). Thus, the second container part 52 may have a greater axial length than the first container part The second end portion of the first container part 51 and the second container part 52 presents respective joint surfaces which extend at corresponding angles relative to the axial direction (see Fig. 3c-7c). Consequently, the first and second container parts 51, 52 are adapted to be attached permanently to one another in such way that the two parts form a package. Fig. 3c-6c illustrates the second container part 52 attached to the open end at the second end portion of the first container part 51 _ The two parts can be attached by means of an adhesive.

The wall portion 512 of the first container part can comprise at least one radial step formation 513 (see Fig. 4c, 6c and 7c). The step formation is located within a portion of the wall portion 512 which is closest to the second end portion. The portion of the wall portion located closest to the second end portion may correspond to 50 % of an axial extent of the wall portion, preferably 33 %, and more preferably 25 %. The step formation 513 forms an axial limitation for the other one of the rim wall 522 and the first container parts wall 512. The step formation thereby forms a recess wherein thesecond container part 52 can be fitted when attaching the first and second container parts 51, Further, the first and/or second container parts 51, 52 may be provided with, or formed as to create, user-friendly characteristics of a package, such as for example a handle. Fig. 5a and 6a i||ustrates a package wherein a portion of the first container part 51 is formed as a handle Further, the first and/or second container parts 51, 52 may have a gas and/or liquid impermeable film (not shown) and/or a coating layer (not shown) applied on an inwardly facing surface of the container parts. The gas and/or liquid impermeable film may be a cellulose film, such as for example cellophane. The coating material is preferably a cellulose-based material.

Alternatively, or additionally, the package can comprise an inner container 6. The inner container 6 may have the form of a flexible pouch or bag, as illustrated in Fig. 8a-8e. The inner pouch or bag is preferably made out of a recyclable or biodegradable material, preferably cellophane, but can also be made of other bioplastic material.

The inner pouch or bag is enclosed by the package. lt may be attached at a top circumference of the first end portion of the first container part 51. Additionally, or alternatively, it may be attached at a bottom circumference of the second end portion of the second container part 52. Additionally, or alternatively, it may be attached in spots or ribbons along the inwardly facing surface of the first and/or second container parts 51, Fig. 8a-8e illustrate a pouch attached at a top circumference of the first end portion of the first container part. However, it is also possible that the pouch extends along the inwardly facing surface of the first end portion of the first container part, and is attached to the inwardly facing surface of the first end portion of the first container part Alternatively, the inner container 6 can be made out of a glass material (not illustrated). The inner glass container is then enclosed and held at place by the package. lt may be attached at a top circumference of the first end portion of the first container part 51 _ Additionally, or alternatively, it may be attached at a bottom circumference of the second end portion of the secondcontainer part 52. Additionally, or alternatively, it may be attached in spots or ribbons along the inwardly facing surface of the first and/or second container parts 51, 52, or attached to the whole inwardly facing surface of the package.

The method of producing the package according to the present invention, comprises forming a first container part 51 from a first pulp material and a second container part 52 from a second pulp material, preferably by using the method described in relation to Fig. 2. The first and second pulp material can be the same or different pulp material.

The method further comprises joining the first container part 51 to the second container part 52, such that the first container part 51 and the second container part 52 are permanently attached to one another. The joining is achieved through a relative movement of the first and second parts along the axial direction.

The two parts can be attached by means of an adhesive. The attachment may be achieved between a radially outwardly facing surface of the rim wall 522 and a radially inwardly facing surface of the first container part's wall 512 (see for example Fig. 3c-7c). Alternatively, the attachment may be achieved between a radially inwardly facing surface of the rim wall 522 and a radially outwardly facing surface of the first container part's wall 512 (not shown). ln the embodiments wherein the wall portion 512 of the first container part 51 comprises a step formation 513, the joining further comprises causing the step formation 513 to act as an axial limitation for the other one of the rim wall 522 and the wall 512 of the first container part.

The method can further comprise forming a container closure part 53. The container closure part 53 is preferably formed from a third pulp material, preferably by using the method described in relation to Fig. 2. The third pulp material can be the same as the first and/or second pulp material. Alternatively, it can be a different pulp material. As an alternative, the container closure part 53 can be formed of other material such as for example wood, PLA or bio-plastic material.

The method may further comprise detachably attaching the container closure part 53 to the first end portion of the first container part When in use, the package is adapted to be filled with a content. Consequently, the attachment of the first and second container parts 51, 52 may vary depending on the desired filling method. Preferably, the open end at the first end portion of the first container part 51 is sealed by a weakened portion of pulp material or by applying a sealing strip of a film material and preferably also by attaching the container closure part 53. Then the first container part 51 can be filled with a content before attaching the second container part 52, i.e. a bottom part of the container, permanently.

Alternatively, the second container part 52, for example the second container part illustrated in Fig. 7b, may be filled with a content, before attaching the first container part 51 permanently.

Alternatively, the first and second container parts 51, 52 can be attached before filling. When in use, the package is then filled with the content through a top opening of the package before attaching a sealing strip and/or the container closure part The method of producing the package may further comprise applying a gas and/or liquid impermeable film to an inwardly facing surface of the first and/or second container parts.

The gas and/or liquid impermeable film may be attached by means of PVOH, an adhesive etc. The adhesive is preferably biodegradable. The film may be a cellulose film, such as for example cellophane.

The film is preferably applied during the first pressing step 103 or the second pressing step 105 according to the method as described above in relation to Fig. 2. Alternatively, the film may be applied during the third pressing step The method can additionally or alternatively comprise applying a coating layer to the inner surface of the container parts, using a cellulose- based coating material. The coating layer can be applied by spraying or pouring the coating material at the inner surface, or by dipping the container parts in the coating material.As an alternative to applying a gas and/or liquid impermeable film and/or a coating layer, the method may comprise attaching an inner container 6 to the package. Consequently, when in use, the inner container is enclosed by the package.

The inner container 6 may be attached before or after attaching the first and second container parts 51, 52. The inner container 6 may be attached at a top circumference of the first end portion of the first container part 51. Additionally, or alternatively, it may be attached at a bottom circumference of the second container part 52. Additionally, or alternatively, it may be attached in spots or ribbons along the inwardly facing surface of the first and/or second container parts 51, 52, or attached to the whole inwardly facing surface of the package.

Claims

1. A method of producing a biodegradable, disposable package (5), the method comprising: forming a first container part (51) from a first pulp material, and forming a second container part (52) from a second pulp material, wherein the first container part comprises a wall portion (512) which surrounds a product space presenting a cross sectional area, wherein said wall portion (512) extends along an axial direction perpendicular to the cross sectional area, between a first and a second axially spaced apart end portion of said first container part (51), and wherein said wall portion (512), at the second end portion thereof, extends at an angle relative to the axial direction, wherein the second container part (52) is formed so as to present a central portion and a rim portion, surrounding the central portion (523), wherein the rim portion comprises a rim wall (522), which extends at an angle relative to the axial direction which corresponds to said angle of the first container part's wall (512) at the second end portion thereof, and wherein the method further comprises joining said second end portion of the first container part (51) to the second container part (52), such that the first and second container parts (51, 52) are permanently attached to one another to form a package, wherein the joining is achieved between a radially outwardly facing surface of the rim wall and a radially inwardly facing surface of the first container part's wall, or between a radially inwardly facing surface of the rim wall and a radially outwardly facing surface of the first container part's wall, and wherein the wall portion (512) of the first container part (51) comprises at least one radial step formation (513).

2. The method as claimed in claim 1, wherein the first container part (51) is formed such that, prior to the joining, the first end portion forms a closed end and the second end portion forms an open end.

3. The method as claimed in claim 1, wherein the first container part (51) is formed such that, prior to the joining, the first end portion forms an open end and the second end portion forms an open end.

4. The method as claimed in claim 1-3, wherein said joining comprises adhering the rim wall (522) of the second container part (52) to the first container part's wall (512).

5. The method as claimed in any one of the preceding claims, wherein the step formation (513) is located within a portion of the wall portion (512) which is c|osest to the second end portion, and said portion preferably corresponds to 50 % of an axial extent of the wall portion, preferably 33 %, and more preferably 25 %.

6. The method as claimed in any one of the preceding claims, wherein the step formation (513) is located at a distance from the second end portion corresponding to a total axial length of a joint surface of the second container part (52).

7. The method as claimed in any one of the preceding claims, wherein said joining comprises causing the step formation (513) to act as an axial limitation for the rim wall (522).

8. The method as claimed in any one of the preceding claims, wherein the joining is achieved through a relative movement of the first and second parts along the axial direction.

9. The method as claimed in any one of the preceding claims, wherein the second container part (52) comprises a wall portion (524) which extends axially between a bottom and a transition to the rim wall (522),preferably by an axial distance which is greater than an axial length of the rim wall (522).

10. further comprising forming a container closure part (53) and forming the first The method as claimed in any one of the preceding ciaims, end portion of the first container part (51) in such a way that the container closure part (53) and the first container part (51) can be detachably attached to one another, such that the package (5) is sealed when the parts are attached. detachably attaching the container closure part (53) to the first end of the first The method as claimed in claim 10 further comprising container part (51). wherein the forming of the container parts (51, 52) comprises applying a The method as claimed in any one of the preceding ciaims, material to a forming surface of a respective first press mold part of a respective first pressing tool and subsequently pressing (103) the material between the respective first press mold part and a respective second press mold part of the first pressing tool. 13. transferring the pressed material to a respective forming surface of a The method as claimed in claim 12, further comprising respective first press mold part of a respective second pressing tool and subsequently pressing (105) the material between the respective first press mold part and a respective second press mold part of the respective second pressing tool. transferring the pressed material to a respective forming surface of a The method as claimed in claim 13, further comprising respective first press mold part of a respective third pressing tool and subsequently pressing (107) the material between the respective first press mold part and a respective second press mold part of the respective third pressing tool. 15. press mold parts are brought together through a relative movement of the The method as c|aimed in any one of c|aims 12-14, wherein the press mold parts along the axial direction. 16. forming comprises at least one of drawing vacuum and applying heat, through The method as c|aimed in any one of c|aims 12-15, wherein the at least one of the respective first and second press mold parts. comprising depositing the material on the respective forming surface of the The method as c|aimed in any one of c|aims 12-16, further respective first pressing tool, or on a respective separate forming tool and subsequently transferring the material to the respective first pressing tool. wherein the forming of the container parts from a pulp material is performed The method as c|aimed in any one of the preceding c|aims, with an initial water content of a pulp slurry about 70-90 % by weight, with an typically about 50-60 % by weight, or with an initial water content of the pulp slurry of about 25-45 % by weight, preferably about 30-40 % by weight. initial water content of the pulp slurry of about 45-19. content is less than about 5 % by weight, preferably less than about 1 % by The method as c|aimed in claim 18, wherien a final water weight. 20. The method as c|aimed in any one of the preceding c|aims, further comprising applying a gas and/or liquid impermeable film and/or a coating layer to a product space facing surface of the first and/or second container parts (51, 52).21. The method as claimed in claim 20, wherein the gas and/or liquid impermeable film is a cellulose film. 22. The method as claimed in any one of the preceding claims, further comprising attaching an inner container (6) to the first end portion of the first container part (51 ), and/or to a bottom circumference of the second container part (52), and/or to an inwardly facing surface of the first and/or second container parts. 23. The method as claimed in claim 22, wherein the inner container (6) is a flexible pouch formed of a biodegradable material. 24. The method as claimed in claim 22, wherein the inner container (6) is a container formed out of a glass material. 25. A kit of parts for forming a biodegradable, disposable package, comprising: a first container part (51) formed from a first pulp material, a second container part (52) formed from a second pulp material, wherein the first container part (51) comprises a wall portion (512) which surrounds a product space presenting a cross sectional area, wherein said wall portion extends along an axial direction perpendicular to the cross sectional area, between a first and a second axially spaced apart end portion of said first container part (51), and wherein said wall portion (512), at the second end portion thereof, extends at an angle relative to the axial direction, wherein the second container part (52) presents a central portion (523) and a rim portion, surrounding the central portion (523), wherein the rim portion comprises a rim wall (522), which extends at an angle relative to the axial direction which corresponds to said angle of the first container part's wall (512) at the second end portion thereof, wherein said second end portion of the first container part (51) and the second container part (52) are adapted to be permanently attached to oneanother in such way that the two parts form a package and such that a joining is achieved between a radially outwardly facing surface of the rim wall and a radially inwardly facing surface of the first container part's wall, or between a radially inwardly facing surface of the rim wall and a radially outwardly facing surface of the first container part's wall, and wherein the wall portion (512) of the first container part (51) comprises at least one radia| step formation (513). 26. The kit of parts as c|aimed in c|aim 25, wherein the first end portion of the first container part (51) forms a closed end and the second end portion forms an open end. 27. The kit of parts as c|aimed in c|aim 25, wherein the first end portion of the first container part (51) forms an open end and the second end portion forms an open end. 28. The kit of parts as c|aimed in any one of c|aims 25-27, wherein the second container part (52) comprises a wall portion (524) which extends axially between a bottom and a transition to the rim wall, preferably by an axial distance which is greater than an axial length of the rim wall (522). 29. The kit of parts as c|aimed in any one of c|aims 25-28, wherein the step formation (513) is located within a portion of the wall portion (512) which is closest to the second end portion, and said portion preferably corresponds to 50 % of an axial extent of the wall portion, preferably 33 %, and more preferably 25 %. 30. The kit of parts as c|aimed in any one of c|aims 25-29, wherein the step formation (513) is located at a distance from the second end portion corresponding to a total axial length of a joint surface of the second container part (52).31. The kit of parts as claimed in any one of claims 25-30, wherein the step formation (513) forms an axial limitation for the rim wall (522). 32. The kit of parts as claimed in any one of claims 25-31, wherein the first and second container parts (51, 52) are joined in the axial direction. 33. The kit of parts as claimed in any one of claims 25-32, wherein the first and/or second container parts have a gas and/or liquid impermeable film and/or a coating layer applied on an inwardly facing surface of the respective container part. 34. The kit of parts as claimed in claim 33, wherein the gas and/or liquid impermeable film is a cellulose film. 35. The kit of parts as claimed in any one of claims 25-34, wherein the cross sectional area of the first container part (51) increases as seen in the axial direction from the first end portion towards the second end portion. 36. The kit of parts as claimed in any one of claims 25-34, wherein the cross sectional area of the first container part (51) are constant as seen in the axial direction from the first end portion towards the second end portion. 37. The kit of parts as claimed in any one of claims 26-36, wherein the open end formed at the second end portion of the first container part (51) presents the greatest cross sectional area of the package. 38. The kit of parts as claimed in any one of claims 25-37, wherein the wall portion (512) of the first container part (51) extending along the axial direction is rotational symmetric around the axis.39. The kit of parts as claimed in any one of claims 25-37, wherein the wall portion (512) of the first container part (51) extending along the axial direction is non-rotational symmetric around the axis. 40. The kit of parts as claimed in any one of claims 25-39, wherein a portion of the first and/or second container parts (51, 52) is formed as a handle (7). 41. The kit of parts as claimed in any one of claims 25-40, wherein the first end portion of the first container part (51) is adapted to receive a container closure part (53), wherein the container closure part (53) is adapted to be detachably attached to the first container part (51) in such a way that it seals the package (5) when attached. 42. The kit of parts as claimed in any of claims 25-41, further comprising an inner container (6). 43. The kit of parts as claimed in claim 42, wherein the inner container (6) is a flexible pouch formed of a biodegradable material. 44. The kit of parts as claimed in claim 42, wherein the inner container (6) is a container formed out of a glass material. 45. A kit of parts for a biodegradable, disposable package comprising: the kit of parts for a package according to any one of claims 41-44, and a container closure part (53), wherein the container closure part (53) is adapted to be detachably attached to the package in such a way that it seals the package when attached. 46. The kit of parts according to claim 45, wherein the container closure part (53) is formed from a third pulp material. 47. A method of packaging a product, comprising: providing a kit of parts as claimed in any one of claims 25-44 or 45-46, introducing the product into the first container part (51 ), joining the second container part (52) to the first container part (51 ), so as to close the product space. 48. A biodegradable, disposable package, comprising: a first container part (51) formed from a first pulp material, a second container part (52) formed from a second pulp material, wherein the first container part (51) comprises a wall portion (512) which surrounds a product space, presenting a cross sectional area, wherein said wall portion extends along an axial direction perpendicular to the cross sectional area, between a first and a second axially spaced apart end portion of said first container part (51), and wherein said wall portion (512), at the second end portion thereof, extends at an angle relative to the axial direction, wherein the second container part (52) presents a central portion (523) and a rim portion, surrounding the central portion (523), wherein the rim portion comprises a rim wall (522), which extends at an angle relative to the axial direction which corresponds to said angle of the first container part's wall (512) at the second end portion thereof, wherein said second end portion of the first container part (51) and the second container part (52) are permanently joined to one another in such way that the two parts form a package, wherein the joining is achieved between a radially outwardly facing surface of the rim wall and a radially inwardly facing surface of the first container part's wall, or between a radially inwardly facing surface of the rim wall and a radially outwardly facing surface of the first container part's wall, and wherein the wall portion (512) of the first container part (51) comprises at least one radial step formation (513).