SUSTAINABLE TUBULAR CONTAINER FOR CONSUMER PRODUCTS

Abstract

A sustainable tubular container that is fully recyclable by curbside recycling, repulpable and home compostable and is easy to use, prevents undesired leakage of the consumer product material, can withstand repetitive usage, and overcomes deficiencies of existing all paper consumer product container systems. The tubular container is primarily paper based that may be recycled easily in the existing paper recycling stream with minimal non-paper parts that also are easily biodegradable, recyclable curbside or home compostable. Such a consumer product container preferably is made of paper-based materials with an inner liner or a coating and otherwise, it is made of PHA, PHB and/or other compostable moldable materials.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. provisional application no. 63/700,273 filed Sep. 27, 2024; and U.S. provisional application No. 63/685,165 filed Aug. 20, 2024, both of which are incorporated herein by reference in their entirety.

BACKGROUND

The present invention relates to a sustainable tubular container for storing various types of contents, including consumer products such as toothpaste, lotions, balms, and sunscreen, and, more specifically, a tubular container for consumer products manufactured from primarily paper fiber material and in part from Polyhydroxyalkanoates (PHA), Polyhydroxybutyrate (PHB), or other similar biocompostable materials that can be injection molded or otherwise moldable and home compostable. The weight of the paper fiber material component is such that it is repulpable and recyclable. The PHA parts are fully compostable and comprise a smaller percentage by weight of the tubular container. This combination of paper parts and smaller percentage by weight of PHA parts gives the container of the present invention a unique sustainability profile. It means that the container can be both recyclable and home compostable, and far simpler to manufacture than existing containers intended to be sustainable. If the entire container was made entirely of PHA then it would be compostable, but it would be too expensive to be commercially practical.

Polyhydroxyalkanoates or PHAs are polyesters produced in nature by numerous microorganisms, including through bacterial fermentation of sugars or lipids. When produced by bacteria they serve as both a source of energy and as a carbon store. More than 150 different monomers can be combined within this family to give materials with extremely different properties. These materials are biodegradable.

Previous designs of all paper tubular containers for consumer products proved to be less than optimally for their intended use, too expensive, and difficult to manufacture. The new design of the tubular container in accordance with an embodiment of the present invention has some parts that are made of PHA, PHB, or other biocompostable material that can be injection molded and some parts that are made of paper. The weight of the paper fiber material is such that it is considered repulpable and recyclable.

It is appreciated that PHA is technically not a plastic or a bioplastic; although some might call it that because of its moldability properties. PHA is created by microbes so it is a moldable bio-based material that can be molded like plastic, but it is microbial in origin. PHA is desirable not only for its sustainability, but also for its durability for repeated use. It is intended to be within the scope of the present invention, that the small parts of the container be made of PHA, PHB, or other similar moldable material that is biocompostable.

The packaging of common consumer products such as toothpaste, lotions, balms, and sunscreen is primarily composed of plastic materials, which are challenging to recycle. Previous attempts at creating tubular containers for consumer products out of recyclable materials have faced issues, including properly avoiding leakage of the product material from the container and being airtight to preserve freshness of contents.

A key aspect of recycling fiber materials is the requirement to pass repulpability standards, such as those set by Western Michigan University (WMU) or the Fibre Box Association. These repulpability standards ensure that paper-based products can be efficiently broken down into their original fibers during the recycling process. The repulpability standards assess whether a material can disintegrate into a pulp without leaving behind any large, unrecyclable fragments or contaminants that could hinder the recycling process. To be recyclable in the paper recycling stream, at least 80% by weight of the entire package must be recoverable fibers through the repulping process. This means that the PHA parts must be less than 20% of the total package weight.

There is a need for a tubular container that is fully recyclable by curbside recycling, repulpable and home compostable. There is also a need for a tubular container that is easy to use, prevents undesired leakage of the consumer product material, can withstand repetitive usage, and overcomes deficiencies of existing all paper consumer product container systems. More specifically, there is a need for a tubular container that is primarily paper based that may be recycled easily in the existing paper recycling stream with minimal non-paper parts that also are easily biodegradable, recyclable curbside or home compostable. Such a consumer product container preferably is made of paper fiber material with an inner liner or a coating. But otherwise, it is made of PHA, PHB and/or other compostable moldable materials.

While the present invention in one embodiment relates to a tubular container for consumer products manufactured from primarily paper fiber material and in part from PHA, PHB, or other compostable moldable materials, it is appreciated that other embodiments of the present invention are being contemplated. For example, in another embodiment of the present invention, a tubular container for consumer products is made entirely of paper fiber material that is fully recyclable, easy to use, prevents leakage of the consumer product material, can withstand repetitive usage, and overcomes deficiencies of existing consumer container systems. More specifically, there is a need for a container that is a paper-based tube that may be recycled easily in the existing paper recycling stream. Such a tubular container preferably is made of paper fiber material with an inner liner or a coating. But otherwise, it is entirely made of paper fiber material including all aspects of the cap assembly.

For each embodiment described herein, the configuration of the tubular container could be scaled to any size suitable for the intended purpose. The cap structure could be of various shapes and sizes such as circular, square or rectangular for example.

SUMMARY

The present invention is directed to a tubular container for consumer products manufactured from sustainable materials that can be both recyclable and home compostable. In one embodiment, the container has a tubular body portion with a dispensing top end and an opposite sealed bottom end. The top end includes an opening and provides access to a hollow interior for storing the consumer product material. The top end can be closed with a removable cap to protect the contents of the hollow interior, prevent content leakage from the container, and preserve freshness of contents. The hollow interior of the container is fillable with the consumer product. The consumer product is dispensed towards the opening at the top end of the container with the cap removed by the application of pressure to the exterior of the container such as would be applied when squeezing a tube of toothpaste or a tube containing a lotion such as sunscreen.

In an embodiment, the materials of the tubular container can be both recyclable and home compostable, and are not required to be separated from one another to be recycled in the mainstream. Materials are manufactured from primarily paper fiber and in part from PHA, PHB, or other similar biocompostable materials that can be injection molded or otherwise moldable. The weight of the paper fiber material component is such that it is repulpable and recyclable. The PHA parts are fully compostable and comprise a smaller percentage by weight of the tubular container. PHA is desirable not only for its sustainability, but also for its durability for repeated use. This combination of paper fiber material parts and smaller percentage by weight of PHA parts gives the tubular container of the present invention a unique sustainability profile. It means that the tubular container can be both recyclable and home compostable, and far simpler to manufacture than existing containers intended to be sustainable. If the entire container was made all out of PHA then it would be compostable but would be too expensive to be commercially practical.

In another embodiment, the materials of the tubular container, including all aspects of the cap assembly, are made entirely from paper fiber material that is recyclable and repulpable. Materials used include, for example wound paper fiber, cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. The paper materials may include a lining or coating to prevent absorption by the components and/or leakage of the consumer product material from the container.

This embodiment of the present invention was specifically designed to ensure the repulpability of the packaging. The weight of the cap assembly and the selection of materials are carefully balanced to ensure that the entire package is repulpable, regardless of the type of liner used. By meeting these stringent standards, the tubular container enhances the efficiency and effectiveness of fiber recycling, supporting a more sustainable and recyclable packaging solution for consumer products.

An embodiment of the sustainable container for a consumer product comprises a body having a tubular configuration surrounding a hollow interior for storing the consumer product, the body having a top end and an opposite bottom end that is sealable, the top end including an opening to provide access to the hollow interior, the body having an inner surface that is impermeable to prevent the consumer product from penetrating the body, the body being repeatedly deformable to compress the consumer product stored within the hollow interior, the body being formed from at least in part of a paper fiber material, the body being repulpable and recyclable; a nozzle coupled to the top end of the body and in communication with the hollow interior, the nozzle forming a compressed interface with the body to form a sealed connection between the nozzle and the body to prevent the consumer product from leaking between the nozzle and the body, the nozzle configured to dispense the consumer product from the hollow interior upon application of pressure on the body, the nozzle being formed at least in part of a polyhydroxyalkanoates (PHA) material that is moldable, the nozzle being biocompostable; and a cap for engaging and removably covering the nozzle, the cap formed at least in part from the paper fiber material and the PHA material, the cap being recyclable and biocompostable, the cap having a first engagement portion molded from the PHA material of the cap for engaging a second engagement portion molded from the PHA material of the nozzle, wherein the sustainable container being composed of the paper fiber material that is at least 80% of the total weight of the sustainable container and the PHA material that is not greater than 20% of the total weight of the sustainable container.

In an embodiment of the sustainable container the paper fiber material is at least one of wound paper fiber, cardboard, corrugated cardboard, and cellulose.

In an embodiment of the sustainable container the inner surface of the body is at least one of coated, laminated, combined, and treated with biodegradable materials to prevent absorption of the consumer product by the body and leakage of the consumer product from the body.

In an embodiment of the sustainable container the inner surface of the body includes a layer of metallized polyethylene terephthalate (PET).

In an embodiment of the sustainable container the inner surface of the body includes a heat sealable liner.

In an embodiment of the sustainable container the body is configured to be filled from the top end.

In an embodiment of the sustainable container the body is configured to be filled from the bottom end.

In an embodiment of the sustainable container the body is sealed to be airtight to preserve freshness of the consumer product.

In an embodiment of the sustainable container the bottom end is sealed using at least one of heat, pressure, thermal bonding, induction sealing, and adhesives.

In an embodiment of the sustainable container the cap includes a shell, an external plate, an internal plate, and an outer ring.

In an embodiment of the sustainable container the external plate is coupled to the shell by at least one of a pressure fitting, mechanical bonding, thermal bonding, and adhesives, the external plate and the shell being formed at least in part of the paper fiber material, the external plate and the shell being repulpable and recyclable.

In an embodiment of the sustainable container the internal plate is coupled to the external plate and the shell, the internal plate being formed with an opening sized and configured to receive a portion of the nozzle when the cap is positioned over the end of the nozzle of the sustainable container, the internal plate being formed at least in part of the paper fiber material, the internal plate being repulpable and recyclable.

In an embodiment of the sustainable container the outer ring is coupled to the internal plate and the shell, at least a portion of the outer ring forming the first engagement portion of the cap, the outer ring being formed at least in part of the PHA material, the outer ring being biocompostable.

In an embodiment of the sustainable the first engagement portion of the cap includes a thread.

In an embodiment of the sustainable container the second engagement portion of the nozzle includes a thread.

In an embodiment of the sustainable container the first engagement portion of the cap is configured to engage the second engagement portion of the nozzle by at least one of a snap-fit, a friction-fit, an interference-fit, a thread, and rotational locks.

In an embodiment of the sustainable container the nozzle is coupled to the body using at least one of pressure, friction, adhesives, thermo-bonding, and induction sealing.

In an embodiment of the sustainable container the nozzle further includes a shoulder for stopping the cap when the cap threadably engages with the nozzle to prevent overtightening of the cap.

In an embodiment of the sustainable container the nozzle further includes at least one rib formed to depress into a portion of the body when coupled to the body to create a compression fit that is anti-rotational as between the nozzle and the body.

An embodiment of the sustainable container further comprises a rim coupled to the body by an interference fit, the rim configured to removably engage with the body and the nozzle, the rim being formed from at least in part of the paper fiber material, the rim being repulpable and recyclable.

In an embodiment of the sustainable container the rim further comprises an aperture, the nozzle includes a knub, and the aperture being configured to engage the knub to mechanically couple the rim to the nozzle.

An embodiment of the sustainable container further comprising a bag having an opening for storing the consumer product and being sized and configured to fit within at least a portion of the hollow interior of the body, the bag being configured between the knub of the nozzle and the aperture of the rim to create a pressure fit, the bag being formed at least in part of the PHA material and being biocompostable.

An embodiment of the sustainable container further comprising a seal removably coupled to an opening in the nozzle for dispensing consumer product using at least one of pressure, friction, adhesives, thermo-bonding, and induction sealing, the seal being formed from at least one of a recyclable and compostable material that prevents leakage of the consumer product from the body.

A novel aspect of the present invention is the combination of the materials in certain weights. For example, by keeping the amount of PHA below 20% of the total weight of the container, then that makes the container recyclable in the paper recycling stream and WMU repulpable. By making it from paper fiber material and PHA this makes it home compostable.

While the container of the present invention is described herein as a tube, other containers for dispensing consumer products such as toothpaste, lotions, balms, and sunscreen are intended to be within the scope of the present invention. Also, while an embodiment of the container is shown as having a tubular cross section, it is appreciated that the container may have any other configuration and cross-sectional shape suitable for the intended purpose.

These as well as still further features, objects and benefits of the invention will now become clear upon a review of the following detailed description of illustrative embodiments, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide further understanding of the present invention disclosed in the present disclosure and are incorporated in and constitute a part of this specification, illustrate aspects of the present invention and together with the description serve to explain the principles of the present invention. In the drawings:

FIG. 1 is a perspective view of a tubular container in accordance with an embodiment of the present invention;

FIG. 2 is a cross-sectional view of the tubular container in accordance with an embodiment of the present invention;

FIG. 3 is an exploded end view of the tubular container in accordance with an embodiment of the present invention;

FIG. 4 is a perspective view of the tubular container in accordance with an embodiment of the present invention;

FIG. 5 is a side elevational view of the tubular container in accordance with an embodiment of the present invention;

FIG. 6 is a front elevational view of the tubular container in accordance with an embodiment of the present invention;

FIG. 7 is a top plan view of the tubular container in accordance with an embodiment of the present invention;

FIG. 8 is an enlarged, partial cross-sectional front view of the tubular container in accordance with an embodiment of the present invention;

FIG. 9 is a bottom elevational view of a nozzle in accordance with an embodiment of the present invention;

FIG. 10 is a top perspective view of an outer cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 11 is a bottom perspective view of the outer cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 12 is an exploded, perspective side view of the outer cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 13 is a bottom elevational view of the outer cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 14 is a side elevational view of the outer cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 15 is a cross-sectional view along lines 15-15 of FIG. 14;

FIG. 16 is a side perspective view of a tubular body and an outer rim in accordance with an embodiment of the present invention;

FIG. 17 is a side perspective view of the tubular body in accordance with an embodiment of the present invention;

FIG. 18 is a side perspective view of the rim in accordance with an embodiment of the present invention;

FIG. 19 is a side cross-sectional view of the tubular body and the rim in accordance with an embodiment of the present invention;

FIG. 20 is a top perspective view of the nozzle in accordance with an embodiment of the present invention;

FIG. 21 is a bottom perspective view of the nozzle in accordance with an embodiment of the present invention;

FIG. 22 is a cross-sectional view of the nozzle in accordance with an embodiment of the present invention;

FIG. 23 is a side elevation view of the nozzle in accordance with an embodiment of the present invention;

FIG. 24 is a top elevation plan of the nozzle in accordance with an embodiment of the present invention;

FIG. 25 is a bottom perspective view of an outer ring in accordance with an embodiment of the present invention;

FIG. 26 is a top perspective view of the outer ring in accordance with an embodiment of the present invention;

FIG. 27 is a cross-sectional view of the outer ring in accordance with an embodiment of the present invention;

FIG. 28 is a side elevation view of the outer ring in accordance with an embodiment of the present invention;

FIG. 29 is a top elevation view of the outer ring in accordance with an embodiment of the present invention;

FIG. 30 is a perspective view of a tubular container in accordance with an embodiment of the present invention;

FIG. 31 is a perspective view of a tubular container body assembly of the tubular container in accordance with an embodiment of the present invention;

FIG. 32 is an exploded, side perspective view of a tubular container body assembly and a nozzle of the tubular container in accordance with an embodiment of the present invention;

FIG. 33 is an exploded, side perspective view of a tubular container body, a bag, and a rim of the tubular container in accordance with an embodiment of the present invention;

FIG. 34 is a cross-sectional view of the tubular container assembly of the tubular container in accordance with an embodiment of the present invention;

FIG. 35 is an enlarged, partial cross-sectional front view of the tubular container in accordance with an embodiment of the present invention;

FIG. 36 is an enlarged, partial cross-sectional front view of the tubular container with a knub in accordance an embodiment of the present invention;

FIG. 37 is an enlarged, partial perspective view of a body assembly of tubular container in accordance with an embodiment of the present invention;

FIG. 38 is an enlarged, partial perspective view of the tubular container with a knub mechanical catch in accordance with an embodiment of the present invention;

FIG. 39 is a perspective view of the tubular container in accordance with an embodiment of the present invention;

FIG. 40 is a front elevational view of the tubular container in accordance with an embodiment of the present invention;

FIG. 41 is a cross-sectional view of the tubular container in accordance with an embodiment of the present invention;

FIG. 42 is an end view of the tubular container in accordance with an embodiment of the present invention;

FIG. 43 is an exploded front end view of the tubular container in accordance with an embodiment of the present invention;

FIG. 44 is an exploded rear end view of the tubular container in accordance with an embodiment of the present invention;

FIG. 45 is an exploded, perspective side view of an outer cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 46 is a front perspective view of the outer cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 47 is a rear perspective view of the outer cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 48 is a rear elevation view of the outer cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 49 is side elevation view of the outer cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 50 is a cross-sectional view along lines 50-50 of FIG. 49;

FIG. 51 is an enlarged isolation view along line 51 of FIG. 50;

FIG. 52 is an exploded, perspective side view of an inner cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 53 is a front perspective view of the inner cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 54 is a rear perspective view of the inner cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 55 is a rear elevation view of the inner cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 56 is side elevation view of the inner cap of the tubular container in accordance with an embodiment of the present invention;

FIG. 57 is a cross-sectional view along lines 57-57 of FIG. 56; FIG. 58 is an enlarged isolation view along line 58 of FIG. 57;

FIG. 59 is a side perspective view of the tubular container in accordance with an embodiment of the present invention;

FIG. 60 is an end view of the tubular container in accordance with an embodiment of the present invention;

FIG. 61 is a front elevational view of the tubular container in accordance with an embodiment of the present invention;

FIG. 62 is a cross-sectional view along lines 62-62 of FIG. 61;

FIG. 63 is a cross-sectional view of an unformed tube of the tubular container in accordance with an embodiment of the present invention;

FIG. 64 is an isolation view along line 64of FIG. 62;

FIG. 65 is an enlarged, partial cross-sectional side view of the tubular container in accordance with an embodiment of the present invention:

FIG. 66 is a front elevational view of the tubular container in accordance with an embodiment of the present invention;

FIG. 67 is a side perspective view of the tubular container in accordance with an embodiment of the present invention;

FIG. 68 is an exploded side perspective view of the tubular container in accordance with an embodiment of the present invention;

FIG. 69 is an enlarged isolated partial front perspective view of the tubular container in accordance with an embodiment of the present invention;

FIG. 70 is a cross-sectional front view of the tubular container in accordance with an embodiment of the present invention; and

FIG. 71 is an enlarged, partial cross-sectional front view of the tubular container in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. The detailed description set forth below is intended as a description of various configurations of the present invention and is not intended to represent the only configurations in which the present invention may be practiced. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention. It will be apparent, however, to those of ordinary skill in the art that the present invention is not limited to the specific details set forth herein and may be practiced without these specific details.

Referring to the Figures, FIG. 1 shows an embodiment of a container 100 manufactured from materials that can be both recyclable and home compostable. Container 100 is suitable for containing consumer products such as, but not limited to, toothpaste, lotions, balms, and sunscreen. In an embodiment, container 100 is composed of a paper fiber material that is at least 80% of the total weight of the container 100 and a polyhydroxyalkanoates (PHA) material that is not greater than 20% of the total weight of container 100. PHA is desirable not only for its sustainability, but also for its durability for repeated use.

In an embodiment shown in FIGS. 2-3, container 100 has a tubular body 110, a nozzle 140, a formed shell 132, an external plate 170, an internal plate 180, outer ring 136, and a rim 190. Formed shell 132, external plate 170, internal plate 180, and outer ring 136 are assembled to form an outer cap 130 shown in FIGS. 1-3. Body 110 has a hollow interior 112, a bottom end 114, and a top end 117. Bottom end 114 is sealable. Top end 117 includes an opening 116 to provide access to hollow interior 112. In an embodiment, container 100 can be airtight to preserve freshness of consumer product contents.

Body 110 has as tubular configuration and is made of a material that is fully biodegradable, such as, for example, a paper fiber material including wound paper fiber, cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. In an embodiment, body 110 is repulpable and recyclable. Body 110 has an inner surface 113 that is impermeable to prevent the consumer product from penetrating the body. Preferably, inner surface 113 surrounding hollow interior 112 is coated, laminated, combined or otherwise treated with biodegradable materials to prevent absorption by the components and/or leakage of the consumer product material stored within hollow interior 112. Body 110 is formed to be repeatedly deformable to compress the consumer product stored within hollow interior 112. In an embodiment, bottom end 114 is preferably tapered and sealed using a heat seal. It is appreciated that other forms of sealing may be used to seal bottom end 114, such as heat, pressure, thermal bonding, induction sealing, adhesives, or other processes or materials. Body 110 is configured to be filled with consumer product from either bottom end 114 or top end 117.

In an embodiment, inner surface 113 of body 110 includes a heat sealable liner to create an impermeable barrier to prevent leakage. One skilled in the art will appreciate that body 110 may be lined with one or more layers or combinations of paper, foil, and/or other materials to create an impermeable barrier to prevent leakage. Alternatively, a minimal layer of metallized polyethylene terephthalate (PET) can be used without significantly impacting the sustainability of a container in accordance with the present invention.

FIGS. 4-6 show a perspective view, multiple elevational views, and a top plan view of an embodiment of container 100, respectively, to highlight a shape of container 100. While an embodiment of the container is shown as having a tubular shape, it is appreciated that the container may have any other configuration and/or shape suitable for the intended purpose.

In an embodiment, an exterior length of container 100 may be approximately 221 mm, FIG. 6, and an external diameter of container 100 may be approximately 50 mm, FIG. 7. It is appreciated that other dimensions are also contemplated to be within the scope of the invention.

FIG. 8 shows an embodiment of an assembly of outer cap 130, nozzle 140, body 110, and rim 190. Outer cap 130, as shown in an embodiment in FIGS. 10-15, includes formed shell 132, external plate 170, internal plate 180, and outer ring 136. In an embodiment, formed shell 132, external plate 170, and internal plate 180 are preferably made at least in part from a paper fiber material including wound paper fiber, cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. Preferably, formed shell 132, external plate 170, and internal plate 180 are repulpable and recyclable. Outer cap 130 includes a first engagement portion molded from the PHA material of outer cap 130 for engaging a second engagement portion molded from the PHA material of nozzle 140. In an embodiment, outer cap 130, nozzle 140, and rim 190 form a reusable cap system where outer cap 130, nozzle 140, and rim 190 may be detached from body 110 and either reattached to body 110 or attached to another body.

Formed shell 132 is formed with a rolled lip 133 to receive external plate 170 and create a sealed unit. External plate 170 is secured to formed shell 132 through pressure fitting, mechanical bonding, thermal bonding, and/or adhesive or other known methods or materials suitable for the intended purpose. External plate 170 is cut or stamped and preferably has a liner or coating to prevent leakage of the consumer product material from the container.

Internal plate 180 is cut or stamped and preferably has a liner. In an embodiment, internal plate 180 is coupled to external plate 170 and formed shell 132. In an embodiment, internal plate 180 is formed with an opening 135 sized and configured to receive a portion 126 of nozzle 140 when outer cap 130 is positioned over the end of nozzle 140 to close container 100. When outer cap 130 is assembled, the external plate 170 and internal plate 180 overlap one another and are coupled using an adhesive. It is appreciated that other known processes and material may be used to secure internal plate 180 to external plate 170 in accordance with the present invention.

In an embodiment shown in FIGS. 25-27, outer ring 136 is formed with a thread 137 and is included in outer cap 130 to threadably engage and secure outer cap 130 to nozzle 140. In an embodiment, thread 137 forms the first engagement portion of outer cap 130. Preferably, outer ring 136 is coupled to internal plate 180 and formed shell 132. Outer ring 136 may be secured to formed shell 132 and internal plate 180 in a manner to prevent unwanted rotation, such as using ribs or other protrusion designs, pressure, friction, adhesives, and/or other known methods or materials suitable for the intended purpose. In addition, one skilled in the art will appreciate that other structures may be used for reciprocal engagement between the outer cap 130 and nozzle 140 and are within the scope of the present invention, including, but not limited to, snap-fit, friction-fit, interference-fit, rotational locks and the like. For example, instead of a threaded cap, outer cap 130 can be a snap-on cap. Preferably, outer ring 136 is formed at least in part of PHA, PHB and/or other moldable biocompostable materials to ensure container 100 can be both recyclable and home compostable.

In an embodiment shown FIGS. 16-19, rim 190 may be positioned on body 110 at opening 116. Rim 190 is coupled to body 110 by an interference fit, rim 190 configured to removably engage with body 110 and nozzle 140. Preferably, rim 190 is made of a material that is fully biodegradable, such as, for example, a paper fiber material including wound paper fiber, cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. Rim 190 is repulpable and recyclable. As shown in FIGS. 17-18, rim 190 is formed with a rolled lip 192 to create an interference fit with rolled edge 118 of body 100 when assembled. In an embodiment, rim 190 is assembled with body 110 by inserting bottom end 114 of body 110 through an opening 194 of rim 190 until rolled lip 192 engages with rolled edge 118 as shown in FIGS. 16 and 19. It is appreciated that rim 190 may be fitted with body 110 through pressure fitting, mechanical bonding, thermal bonding, and/or adhesive or other known methods or materials suitable for the intended purpose.

FIGS. 20-24 show an embodiment of nozzle 140, which is preferably made at least in part of PHA, PHB and/or other moldable biocompostable materials to ensure container 100 can be both recyclable and home compostable. In an embodiment, nozzle 140 includes an opening 145 sized and configured to dispense consumer product, such as toothpaste or sunscreen, from hollow interior 112 of body 110 when outer cap 130 is removed and pressure is applied to the tube. In an embodiment, nozzle 140 further includes a shoulder 149 which acts as a stop for outer cap 130 when threadably engaged with nozzle 140 to prevent overtightening of outer cap 130.

Nozzle 140 preferably includes a thread 147 to threadably engage outer cap 130 to close container 100 and seal the consumer product materials inside, or to open container 100 for dispensing the consumer product materials. In an embodiment, thread 147 forms the second engagement portion of nozzle 140. When outer cap 130 is assembled with nozzle 140, a tapered surface 146 of nozzle 140 presses into opening 135 of internal plate 180 and abuts against external plate 170. One skilled in the art will appreciate that other structures may be used for engagement of the first engagement portion of the cap and the second engagement portion of the nozzle and are within the scope of the present invention, including, but not limited to, a snap-fit, a friction-fit, an interference-fit, rotational locks and the like. For example, instead of a threaded cap the cap can be a snap-on cap.

In an embodiment shown in FIG. 8, nozzle 140 is coupled to top end 117 of body 110 and in communication with hollow interior 112. Preferably, nozzle 140 forms a compressed interface with body 110 to form a sealed connection between nozzle 140 and body 110 to prevent the consumer product from leaking between nozzle 140 and body 110. It is appreciated that other types of bonding may be used to couple nozzle 140 with body 110. When assembled, a portion of nozzle 140 fits within body 110 at opening 116 and rolled edge 118 is compressed within a groove 148 of nozzle 140.

As shown in FIGS. 8 and 9, groove 148 includes at least one of a rib 141 formed with a tapered edge to depress into rolled edge 118 of body 110 when coupled to body 110 to create a compression fit that is anti-rotational as between nozzle 140 and body 110. In an embodiment, rib 141 further functions as a stop for nozzle 140 when coupled to body 110 to prevent further advancement of nozzle 140. Nozzle 140 also creates a compression fit with rim 190. Nozzle 140 secures to body 110 in a manner that prevents leakage of consumer product materials from hollow interior 112 of body 110. One skilled in the art will appreciate that such fitting between body 110, nozzle 140, and/or rim 190 may be made through pressure, friction, adhesives, thermo-bonding, induction sealing, or other processes or materials to create a secure fit that prevents leakage of consumer product materials from hollow interior 112 of body 110. For example, induction sealing may be used to seal in freshness of consumer product materials stored in container 100.

In an embodiment shown in FIG. 8, seal 150 completely covers the top of opening 145 of nozzle 140 and may be made of any recyclable or compostable material that prevents leakage of any consumer product from hollow interior 112 when outer cap 130 is removed. Preferably, seal 150 is removably coupled to opening 145 in nozzle 140 for dispensing consumer product using at least one of pressure, thermal bonding, induction sealing, adhesives, or other processes or materials. In an embodiment, induction sealing may be used to seal in freshness of consumer products stored in container 100. Seal 150 helps keep consumer product contents in place, such as during shipping, but is configured to be removable when outer cap 130 is removed. Compression between the upper surface of nozzle 140 and the underside of external plate 170 forms a tight fit for securing the consumer product within container 100.

In an embodiment, nozzle 140 has an approximate height of 21 mm, FIG. 23, and an approximate exterior diameter of 48 mm, FIG. 24. As shown in the embodiment of FIGS. 25-29, outer ring 136, has an approximate height of 10 mm, FIG. 28, and an approximate exterior diameter of 40 mm, FIG. 29. It is appreciated that other dimensions for nozzle 140 and outer ring 136 are also contemplated to be within the scope of the invention.

FIG. 30 shows an embodiment of a container 200 manufactured from materials that can be both recyclable and home compostable. Container 200 is suitable for containing consumer products such as, but not limited to, toothpaste, lotions, balms, and sunscreen. In an embodiment, container 200 is composed of a paper fiber material that is at least 80% of the total weight of the container 200 and a PHA material that is not greater than 20% of the total weight of container 200.

In an embodiment shown in FIGS. 30-35, container 200 has a tubular body 210, a bag 215, an outer cap 230, a nozzle 240, and a rim 290. Body 210 has a hollow interior 212, a bottom end 214, and a top end 217 providing access to hollow interior 212. Bottom end 214 is sealable. Top end 217 includes an opening 216 to provide access to hollow interior 212. In an embodiment, container 200 can be airtight to preserve freshness of consumer product contents.

Body 210 has as tubular configuration and is made of a material that is fully biodegradable, such as, for example, a paper fiber material including wound paper fiber, cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. In an embodiment, body 210 is repulpable and recyclable. Body 210 has an inner surface 213 that is impermeable to prevent the consumer product from penetrating the body. Preferably, inner surface 213 surrounding hollow interior 212 is coated, laminated, combined or otherwise treated with biodegradable materials to prevent absorption by the components and/or leakage of the consumer product material stored within hollow interior 212. Body 210 is formed to be repeatedly deformable to compress the consumer product stored within hollow interior 212.

In an embodiment, bottom end 214 is preferably tapered and sealed using a heat seal. It is appreciated that other forms of sealing may be used to seal bottom end 214, such as heat, pressure, thermal bonding, induction sealing, adhesives, or other processes or materials. While an embodiment of the container is shown as having a tubular shape, it is appreciated that the container may have any other configuration and/or shape suitable for the intended purpose. Body 210 is configured to be filled with consumer product from either bottom end 214 or top end 217.

In an embodiment, inner surface 213 of body 210 includes a heat sealable liner to create an impermeable barrier to prevent leakage. One skilled in the art will appreciate that body 210 may be lined with one or more layers or combinations of paper, foil, and/or other materials to create an impermeable barrier to prevent leakage. Alternatively, a minimal layer of metallized polyethylene terephthalate (PET) can be used without significantly impacting the sustainability of a container in accordance with the present invention.

In an embodiment shown in FIGS. 33-34, bag 215 has an opening 219 for storing consumer product and is sized and configured to fit within at least a portion of hollow interior 212 of body 210. Preferably, bag 215 is made at least in part of PHA, PHB and/or other moldable biocompostable materials to ensure container 200 can be both recyclable and home compostable.

As shown in FIG. 35, outer cap 230 includes a formed shell 232, an external plate 270, an internal plate 280, and an outer ring 236. In an embodiment, formed shell 232, external plate 270, and internal plate 280 are preferably made at least in part from a paper fiber material including wound paper fiber, cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. Preferably, formed shell 232, external plate 270, and internal plate 280 are repulpable and recyclable. One skilled in the art will appreciate that one or more components of outer cap 230 may be made of PHA, PHB and/or other moldable biocompostable materials to ensure container 200 can be both recyclable and home compostable. For example, outer cap 230 may be made of molded pulp and include a conical plug made of PHA. Outer cap 230 includes a first engagement portion molded from the PHA material of outer cap 230 for engaging a second engagement portion molded from the PHA material of nozzle 240. In an embodiment, outer cap 230, nozzle 240, and rim 290 form a reusable cap system where outer cap 230, nozzle 240, and rim 290 may be detached from body 210 and either reattached to body 210 or attached to another body.

Formed shell 232 is formed with a rolled lip 233 to receive external plate 270 and create a sealed unit. External plate 270 is coupled to formed shell 232 through pressure fitting, mechanical bonding, thermal bonding, and/or adhesive or other known methods or materials suitable for the intended purpose. External plate 270 is cut or stamped and preferably has a liner or coating to prevent leakage of the consumer product material from the container.

In an embodiment, outer cap 230, nozzle, 240, and rim 290 form a reusable cap system where outer cap 230, nozzle, 240, and rim 290 may be detached from body 210 and either reattached to body 210 or attached to another body.

Internal plate 280 is cut or stamped and preferably has a liner. In an embodiment, internal plate 280 is coupled to external plate 270 and formed shell 232. In an embodiment shown in FIG. 35, internal plate 280 includes an opening 235 sized and configured to receive a portion 226 of nozzle 240 when outer cap 230 is positioned over the end of nozzle 240 to close container 200. When outer cap 230 is assembled, the external plate 270 and internal plate 280 overlap one another and are coupled using an adhesive. It is appreciated that other known processes and material may be used to secure internal plate 280 to external plate 270 in accordance with the present invention.

In an embodiment, outer ring 236 is formed with a thread 237 and included in outer cap 230 to threadably engage and secure outer cap 230 to nozzle 240. In an embodiment, thread 237 forms the first engagement portion of outer cap 230. Preferably, outer ring 236 is coupled to internal plate 280 and formed shell 232. Outer ring 236 may be secured to formed shell 232 and internal plate 280 in a manner to prevent unwanted rotation, such as using ribs or other protrusion designs, pressure, friction, adhesives, and/or other known methods or materials suitable for the intended purpose. In addition, one skilled in the art will appreciate that other structures may be used for reciprocal engagement between the outer cap 230 and nozzle 240 and are within the scope of the present invention, including, but not limited to, snap-fit, friction-fit, interference-fit, rotational locks and the like. For example, instead of a threaded cap, outer cap 230 can be a snap-on cap. Preferably, outer ring 236 is made of PHA, PHB and/or other moldable biocompostable materials to ensure container 200 can be both recyclable and home compostable.

FIGS. 31-32 and 34-35 show an embodiment of nozzle 240, which preferably is made of PHA, PHB and/or other moldable biocompostable materials to ensure container 200 can be both recyclable and home compostable. In an embodiment, nozzle 240 includes an opening 225 sized and configured to dispense consumer product, such as toothpaste or sunscreen, from hollow interior 212 of body 210 when outer cap 230 is removed and pressure is applied to the tube.

Nozzle 240 preferably includes a thread 227 to threadably engage outer cap 230 to close container 200 and seal the consumer product materials inside, or to open container 200 for dispensing the consumer product materials. When outer cap 230 is assembled with nozzle 240, a tapered surface 244 of nozzle 240 presses into opening 235 of internal plate 280 and abuts against external plate 270. In an embodiment, nozzle 240 further includes a shoulder 249, which is generally planar and acts as a stop for outer cap 230 when threadably engaged with nozzle 240.

In an embodiment shown in FIG. 36, rim 290 secures to body 210 through an interference fit, wherein a rolled lip 242 of rim 290 engages a rolled edge 218 of body 210 at opening 216. Rim 290 is made of a material that is fully biodegradable, such as, for example, a paper fiber material including wound paper fiber, cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. One skilled in the art will appreciate that such fitting between body 210 and rim 290 may be made through pressure, friction, adhesives, thermo-bonding, induction sealing, or other processes or materials to create a secure fit.

In an embodiment, nozzle 240 is coupled to top end 217 of body 210 and in communication with hollow interior 212. Preferably, nozzle 240 forms a compressed interface with body 210 to form a sealed connection between nozzle 240 and body 210 to prevent the consumer product from leaking between nozzle 240 and body 210. It is appreciated that other types of bonding may be used to couple nozzle 240 with body 210. As shown in FIGS. 31-32 and 34-38, nozzle 240 is formed with a knub 246, which is a protrusion. Rim 290 is formed with an aperture 294, which is configured to engage knub 246 to mechanically couple rim 290 to nozzle 240 to create a snap-fit. In an embodiment, the mechanical coupling of rim 290 to nozzle 240 helps secure nozzle 240 to body 210. It is appreciated that the fit between body 210, nozzle 240, and/or rim 290 may be made through pressure, friction, adhesives, thermo-bonding, induction sealing, or other processes or materials to create a secure fit that prevents leakage of consumer product materials from hollow interior 212 of body 210. For example, induction sealing may be used to seal in freshness of consumer product materials stored in container 200.

In an embodiment, bag 215 may be secured to body 210 and nozzle 240 by being configured between body 210, nozzle 240, and rim 290. In an embodiment, bag 215 is assembled between knub 246 of nozzle 240 and aperture 294 of rim 290 to create a pressure fit. One skilled in the art will appreciate that other materials and methods may be used to secure nozzle 240 and/or bag 215 to body 210, including alternate protrusion designs, pressure, friction, thermal bonding, adhesives, and/or other known methods or materials suitable for the intended purpose.

FIG. 39 shows an embodiment of a container 300 made entirely from paper fiber material that is recyclable and repulpable. In an embodiment shown in FIG. 40, container 300 has a tubular body 310 and an outer cap 330. Body 310 has a hollow interior 312, a bottom end 314, and a top end 317. Top end 317 includes an opening 316 for providing access to hollow interior 312, as shown in FIG. 41. Top end 317 is fitted with an outer cap 330 or lid that may be opened and closed. Bottom end 314 is sealable. In an embodiment, bottom end 314 is preferably tapered and sealed using a heat seal. It is appreciated that other forms of sealing may be used to seal bottom end 314, such as heat, pressure, thermal bonding, induction sealing, adhesives, or other processes or materials.

While an embodiment of the container is shown as having a tubular shape, it is appreciated that the container may have any other configuration and/or shape suitable for the intended purpose. Container 300 is configured for compatibility with various products such as for example toothpaste, lotions, sunscreens, and other consumer products. In an embodiment, container 300 can be airtight to preserve freshness of consumer product contents. Body 310 is configured to be filled with consumer product from either bottom end 314 or top end 317.

Body 310 has a tubular configuration and is made of a material that is fully biodegradable such as for example a paper fiber material including wound paper fiber, cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. In an embodiment, body 310 is repulpable and recyclable. Body 310 has an inner surface 313 that is impermeable to prevent the consumer product from penetrating the body. In an embodiment, inner surface 313 of body 310 preferably includes a heat sealable liner, shown in FIG. 64, to create an impermeable barrier to prevent leakage. One skilled in the art will appreciate that body 310 may be lined with one or more layers or combinations of paper, foil, and/or other materials to create an impermeable barrier to prevent leakage. Alternatively, a minimal layer of metallized polyethylene terephthalate (PET) can be used without significantly impacting the sustainability of a container in accordance with the present invention. Body 310 is formed to be repeatedly deformable to compress the consumer product stored within hollow interior 312.

In an embodiment, the external diameter of outer cap 330 is approximately 35 mm, FIG. 42. It is appreciated that other dimensions for outer cap 330 are also contemplated to be within the scope of the invention.

FIGS. 43-44 illustrate an embodiment of container 300 with body 310, outer cap 330, and an inner cap 320. Outer cap 330, in an embodiment shown in FIGS. 45-49, has a formed shell 332, an external plate 370, and an internal plate 380. External plate 370 is cut or stamped and preferably has a liner. Internal plate 380 is cut or stamped and preferably has a liner. Preferably, internal plate 380 is coupled to external plate 370 and formed shell 332. In an embodiment, outer cap 330 and inner cap 320 form a reusable cap system where outer cap 330 and inner cap 320 may be detached from body 310 and either reattached to body 310 or attached to another body.

Internal plate 380 includes an opening 382 sized and configured to receive a portion of nozzle 340 when outer cap 330 is positioned over the end of inner cap 320 to close container 300. When outer cap 330 is assembled, the external plate 370 and internal plate 380 overlap one another with the liner and adhesive oriented as shown in the detail of FIGS. 50-51. Formed shell 332, external plate 370, and internal plate 380 are preferably made from a paper fiber material including wound paper fiber, cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. Formed shell 332, external plate 370, and internal plate 380 are repulpable and recyclable.

FIGS. 52-57 show an embodiment of inner cap 320, which includes a formed shell 322, a cover 360 with an opening 362, a plate 350, and nozzle 340. Plate 350 is cut or stamped and preferably has a liner. Formed shell 322 includes a liner. Cover 360 is cut or stamped and is adhesive-backed. Plate 350 is cut or stamped includes a liner. Plate 350 further includes an opening 352 sized and configured to receive at least a portion of nozzle 340 when nozzle 340 is seated into plate 350. Nozzle 340 includes a liner as shown in FIG. 58 and is secured to plate 350 through adhesives or a heat seal. When inner cap 320 is assembled, plate 350 with nozzle 340 is secured to the inside of shell 322 with an adhesive or other suitable connection, and cover 360 is secured in place to connect plate 350 and nozzle 340 together with the liner and adhesive oriented as shown in the detail of FIG. 58 and covers and seals the gap as shown. When assembled, opening 362, opening 352 and nozzle 340 are aligned to permit the delivery of a product from within container 300.

FIGS. 59-64 show perspective, elevational, bottom, and cross-sectional views of an embodiment of body 310, including an unformed tube in FIG. 63, to highlight a shape of container 300. While an embodiment of the container is shown as having a tubular shape, it is appreciated that the container may have any other configuration and/or shape suitable for the intended purpose.

As shown in FIG. 65, nozzle 340 in inner cap 320 seals against outer cap 330 in two places. Nozzle 340 abuts against solid external plate 370 and tapered surface of nozzle 340 presses into opening 382 of internal plate 380.

Inner cap 320 secures to body 310 in a manner that prevents leakage of consumer product materials from hollow interior 312 of body 310. One skilled in the art will appreciate that such fitting between body 310 and inner cap 320, and/or one or more components of container 300 may be made through pressure, friction, adhesives, thermo-bonding, induction sealing, or other processes or materials to create a secure fit that prevents leakage of consumer product materials from hollow interior 312 of body 310. For example, induction sealing may be used to seal in freshness of consumer product materials stored in container 300.

FIGS. 66-71 show an embodiment of a container 400 manufactured from materials that can be both recyclable and home compostable. Container 400 is suitable for containing consumer products such as, but not limited to, toothpaste, lotions, balms, and sunscreen. In an embodiment, container 400 is composed of a paper fiber material that is at least 80% of the total weight of the container 400 and a polyhydroxyalkanoates (PHA) material that is not greater than 20% of the total weight of container 400. PHA is desirable not only for its sustainability, but also for its durability for repeated use.

In FIGS. 68-71, container 400 has a tubular body 410, a nozzle 440, and an outer cap 430. Body 410 has a hollow interior 412, a bottom end 414, a side 415a, an opposite side 415b, and a top end 417. Bottom end 414, side 415a, and opposite side 415b of body 410 are sealable. Top end 417 includes an opening 416 to provide access to hollow interior 412. In an embodiment, container 400 can be airtight to preserve freshness of consumer product contents.

Preferably, body 410 has as tubular configuration and is made of a material that is fully biodegradable, such as, for example, a paper fiber material including wound paper fiber, cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. In an embodiment, body 410 is repulpable and recyclable. Body 410 has an inner surface 413 that is impermeable to prevent the consumer product from penetrating the body. Preferably, inner surface 413 has a PHA liner 418 (as shown in FIGS. 70-71) or a PHA coating to prevent absorption by the components and/or leakage of the consumer product material stored within hollow interior 412. In an embodiment, inner surface 413 of body 410 includes a heat sealable liner to create an impermeable barrier to prevent leakage. One skilled in the art will appreciate that body 410 may be lined with one or more layers or combinations of paper, foil, and/or other materials to create an impermeable barrier to prevent leakage. Alternatively, a minimal layer of metallized polyethylene terephthalate (PET) can be used without significantly impacting the sustainability of a container in accordance with the present invention. It is appreciated that, in an embodiment, inner surface 413 surrounding hollow interior 412 may be coated, laminated, combined or otherwise treated with biodegradable materials to prevent absorption by the components and/or leakage of the consumer product material stored within hollow interior 412.

Body 410 is formed to be repeatedly deformable to compress the consumer product stored within hollow interior 412. In an embodiment, bottom end 414, side 415a, and opposite side 415b are preferably tapered and sealed using a heat seal to form a tube. It is appreciated that other forms of sealing may be used to seal bottom end 414, side 415a, and opposite side 415b, such as heat, pressure, thermal bonding, induction sealing, adhesives, or other processes or materials. It is appreciated that, in an embodiment, body 410 is configured to be filled with consumer product from either bottom end 414 or top end 417.

While an embodiment of the container is shown as having a tubular shape, it is appreciated that the container may have any other configuration and/or shape suitable for the intended purpose.

In an embodiment, body 410 further includes a shoulder 449 which acts as a stop for outer cap 430 when threadably engaged with nozzle 440 to prevent overtightening of outer cap 430.

Outer cap 430, as shown in FIGS. 68, 70, and 71, includes a formed shell 432, external plate 470, internal ring 475, and outer ring 436. In an embodiment, formed shell 432, external plate 470, and internal ring 475 are preferably made at least in part from a paper fiber material including wound paper fiber, cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. Formed shell 432, external plate 470, and internal ring 475 are repulpable and recyclable. Outer cap 430 includes a first engagement portion molded from the PHA material of outer cap 430 for engaging a second engagement portion molded from the PHA material of nozzle 440. In an embodiment, outer cap 430 and nozzle 440 form a reusable cap system where outer cap 430 and nozzle 440 may be detached from body 410 and either reattached to body 410 or attached to another body.

Formed shell 432 is formed with a rolled lip 433 to receive external plate 470 and create a sealed unit. External plate 470 is secured to formed shell 432 through pressure fitting, mechanical bonding, thermal bonding, and/or adhesive or other known methods or materials suitable for the intended purpose. External plate 470 is cut or stamped and preferably has a liner or coating to prevent leakage of the consumer product material from the container.

Internal ring 475 has a cylindrical shape and preferably has a liner. In an embodiment, internal ring 475 is coupled to external plate 470. In an embodiment, internal ring 475 is formed with a hollow interior 435 sized and configured to receive nozzle 440 when outer cap 430 is positioned over the end of nozzle 440 to close container 400. When outer cap 430 is assembled, internal ring 475 is coupled to external plate 470 in a configuration where hollow interior 435 of internal ring 475 extends perpendicular to external plate 470. In an embodiment, internal ring 475 and external plate 470 are coupled using an adhesive. It is appreciated that other known processes and material may be used to secure internal ring 475 to external plate 470 in accordance with the present invention.

In an embodiment, outer ring 436 is formed with a thread 437 and is included in outer cap 430 to threadably engage and secure outer cap 430 to nozzle 440. In an embodiment, thread 437 forms the first engagement portion of outer cap 430. Preferably, outer ring 436 is coupled to internal ring 475. Outer ring 436 may be secured to internal ring 475 in a manner to prevent unwanted rotation, such as using ribs or other protrusion designs, pressure, friction, adhesives, and/or other known methods or materials suitable for the intended purpose. In addition, one skilled in the art will appreciate that other structures may be used for reciprocal engagement between the outer cap 430 and nozzle 440 and are within the scope of the present invention, including, but not limited to, snap-fit, friction-fit, interference-fit, rotational locks and the like. For example, instead of a threaded cap, outer cap 430 can be a snap-on cap. Preferably, outer ring 436 is formed at least in part of PHA, PHB and/or other moldable biocompostable materials to ensure container 400 can be both recyclable and home compostable.

FIG. 69 shows an embodiment of nozzle 440, which is preferably made at least in part of PHA, PHB and/or other moldable biocompostable materials to ensure container 400 can be both recyclable and home compostable. In an embodiment, nozzle 440 includes a tip 446 with an opening 445 sized and configured to dispense consumer product, such as toothpaste or sunscreen, from hollow interior 412 of body 410 when outer cap 430 is removed and pressure is applied to the body 410.

Nozzle 440 preferably includes a thread 447 to threadably engage outer cap 430 to close container 400 and seal the consumer product materials inside, or to open container 400 for dispensing the consumer product. In an embodiment, thread 447 forms the second engagement portion of nozzle 440. When outer cap 430 is assembled with nozzle 440, nozzle 440 fits into hollow interior 435 of internal ring 475 and abuts against external plate 470. One skilled in the art will appreciate that other structures may be used for engagement of the first engagement portion of the cap and the second engagement portion of the nozzle and are within the scope of the present invention, including, but not limited to, a snap-fit, a friction-fit, an interference-fit, rotational locks and the like. For example, instead of a threaded cap, the cap can be a snap-on cap.

In an embodiment, nozzle 440 is coupled to top end 417 of body 410 and in communication with hollow interior 412. Preferably, nozzle 440 is coupled to body 410 to form a sealed connection that prevents the consumer product from leaking between nozzle 440 and body 410. In an embodiment, PHA liner 418 and nozzle 440 are molded as one piece. In another embodiment, PHA liner 418 and nozzle 440 are formed as two or more pieces, respectively, to facilitate separation of nozzle 440 from body 410. It is appreciated that other types of bonding may be used to couple nozzle 440 with body 410.

The materials of the tubular container of the present invention are not required to be separated from one another to be recycled in the mainstream. Materials used include, for example, wound paper fiber, cardboard, corrugated cardboard, and cellulose, and in some embodiments, PHA, PHB, or other biodegradable materials to ensure that the tubular container of the present invention can be both recyclable and home compostable. The various components of the tubular container may be coated, laminated, combined or otherwise treated with biodegradable materials to prevent absorption by the components and/or leakage of the consumer product material from the container.

The foregoing outlines features of several examples or embodiments so that those of ordinary skill in the art may better understand various aspects of the present disclosure. Those of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of various examples or embodiments introduced herein. Those of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.

Although the subject matter has been described in language specific to structural features or methodological acts, it is to be understood that the subject matter of the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing at least some of the claims.

Various operations of examples or embodiments are provided herein. The order in which some or all the operations are described should not be construed to imply that these operations are necessarily order dependent. Alternative ordering will be appreciated having the benefit of this description. Further, it will be understood that not all operations are necessarily present in each embodiment provided herein. Also, it will be understood that not all operations are necessary in some examples or embodiments.

Moreover, “exemplary” is used herein to mean serving as an example, instance, illustration, etc., and not necessarily as advantageous. As used in this application, “or” is intended to mean an inclusive “or” rather than an exclusive “or”. In addition, “a” and “an” as used in this application and the appended claims are generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form. Also, at least one of A and B and/or the like generally means A or B or both A and B. Furthermore, to the extent that “includes”, “having”, “has”, “with”, or variants thereof are used, such terms are intended to be inclusive in a manner similar to the term “comprising”. Also, unless specified otherwise, “first,” “second,” or the like are not intended to imply a temporal aspect, a spatial aspect, an ordering, etc. Rather, such terms are merely used as identifiers, names, etc. for features, elements, items, etc. For example, a first element and a second element generally correspond to element A and element B or two different or two identical elements or the same element.

Also, although the disclosure has been shown and described with respect to one or more implementations, equivalent alterations and modifications will occur to others of ordinary skill in the art based upon a reading and understanding of this specification and the annexed drawings. The disclosure comprises all such modifications and alterations and is limited only by the scope of the following claims. In particular regard to the various functions performed by the above-described features (e.g., elements, resources, etc.), the terms used to describe such features are intended to correspond, unless otherwise indicated, to any features which performs the specified function of the described features (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure. In addition, while a particular feature of the disclosure may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or application.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub combination.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the broad scope of the disclosure.

Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein.

Claims

1. A sustainable container for a consumer product, the container comprising:

a body having a tubular configuration surrounding a hollow interior for storing the consumer product, the body having a top end and an opposite bottom end that is sealable, the top end including an opening to provide access to the hollow interior, the body having an inner surface that is impermeable to prevent the consumer product from penetrating the body, the body being repeatedly deformable to compress the consumer product stored within the hollow interior, the body being formed from at least in part of a paper fiber material, the body being repulpable and recyclable;

a nozzle coupled to the top end of the body and in communication with the hollow interior, the nozzle forming a compressed interface with the body to form a sealed connection between the nozzle and the body to prevent the consumer product from leaking between the nozzle and the body, the nozzle configured to dispense the consumer product from the hollow interior upon application of pressure on the body, the nozzle being formed at least in part of a polyhydroxyalkanoates (PHA) material that is moldable, the nozzle being biocompostable; and

a cap for engaging and removably covering the nozzle, the cap formed at least in part from the paper fiber material and the PHA material, the cap being recyclable and biocompostable, the cap having a first engagement portion molded from the PHA material of the cap for engaging a second engagement portion molded from the PHA material of the nozzle,

wherein the sustainable container being composed of the paper fiber material that is at least 80% of the total weight of the sustainable container and the PHA material that is not greater than 20% of the total weight of the sustainable container.

2. The sustainable container of claim 1, wherein the paper fiber material is at least one of wound paper fiber, cardboard, corrugated cardboard, and cellulose.

3. The sustainable container of claim 1, wherein the inner surface of the body is at least one of coated, laminated, combined, and treated with biodegradable materials to prevent absorption of the consumer product by the body and leakage of the consumer product from the body.

4. The sustainable container of claim 1, wherein the inner surface of the body includes a layer of metallized polyethylene terephthalate (PET).

5. The sustainable container of claim 1, wherein the inner surface of the body includes a heat sealable liner.

6. The sustainable container of claim 1, wherein the body is configured to be filled from the top end.

7. The sustainable container of claim 1, wherein the body is configured to be filled from the bottom end.

8. The sustainable container of claim 1, wherein the body is sealed to be airtight to preserve freshness of the consumer product.

9. The sustainable container of claim 1, wherein the bottom end is sealed using at least one of heat, pressure, thermal bonding, induction sealing, and adhesives.

10. The sustainable container of claim 1, wherein the cap includes a shell, an external plate, an internal plate, and an outer ring.

11. The sustainable container of claim 10, wherein the external plate is coupled to the shell by at least one of a pressure fitting, mechanical bonding, thermal bonding, and adhesives, the external plate and the shell being formed at least in part of the paper fiber material, the external plate and the shell being repulpable and recyclable.

12. The sustainable container of claim 10, wherein the internal plate is coupled to the external plate and the shell, the internal plate being formed with an opening sized and configured to receive a portion of the nozzle when the cap is positioned over the end of the nozzle of the sustainable container, the internal plate being formed at least in part of the paper fiber material, the internal plate being repulpable and recyclable.

13. The sustainable container of claim 10, wherein the outer ring is coupled to the internal plate and the shell, at least a portion of the outer ring forming the first engagement portion of the cap, the outer ring being formed at least in part of the PHA material, the outer ring being biocompostable.

14. The sustainable container of claim 13, wherein the first engagement portion of the cap includes a thread.

15. The sustainable container of claim 1, wherein the second engagement portion of the nozzle includes a thread.

16. The sustainable container of claim 1, wherein the first engagement portion of the cap is configured to engage the second engagement portion of the nozzle by at least one of a snap-fit, a friction-fit, an interference-fit, a thread, and rotational locks.

17. The sustainable container of claim 1, wherein the nozzle is coupled to the body using at least one of pressure, friction, adhesives, thermo-bonding, and induction sealing.

18. The sustainable container of claim 1, wherein the nozzle further includes a shoulder for stopping the cap when the cap threadably engages with the nozzle to prevent overtightening of the cap.

19. The sustainable container of claim 1, wherein the nozzle further includes at least one rib formed to depress into a portion of the body when coupled to the body to create a compression fit that is anti-rotational as between the nozzle and the body.

20. The sustainable container of claim 1, further comprising a rim coupled to the body by an interference fit, the rim configured to removably engage with the body and the nozzle, the rim being formed from at least in part of the paper fiber material, the rim being repulpable and recyclable.

21. The sustainable container of claim 20, wherein the rim further comprises an aperture, the nozzle includes a knub, and the aperture being configured to engage the knub to mechanically couple the rim to the nozzle.

22. The sustainable container of claim 21, further comprising a bag having an opening for storing the consumer product and being sized and configured to fit within at least a portion of the hollow interior of the body, the bag being configured between the knub of the nozzle and the aperture of the rim to create a pressure fit, the bag being formed at least in part of the PHA material and being biocompostable.

23. The sustainable container of claim 1, further comprising a seal removably coupled to an opening in the nozzle for dispensing consumer product using at least one of pressure, friction, adhesives, thermo-bonding, and induction sealing, the seal being formed from at least one of a recyclable and compostable material that prevents leakage of the consumer product from the body.