Patent Application
20250122001
An ergonomic squeezable fiber-based bottle for storing and on-demand dispensing viscous liquid product in wet environments. Preferably the squeezable fiber-based bottle is recyclable in the beverage carton stream.
Since the era of industrialization, plastic products have been widely used in daily life. By virtue of quite low production costs and their versatility, plastic packaging materials have a higher rate of increase in the world market compared with other packaging materials. However, most of the plastics that we have on the market are made of virgin crude oil which is not a renewable source. Despite continuous improvement in the waste management infrastructure, plastic packaging sometimes doesn't get recycled after use and as a result, leak into the environment where it can be very persistent. Plastic pollution is causing both increased scrutiny by society in the use of plastics as well as an emergence of new environmental regulations limiting the use of plastics in packaging especially for applications with a short-life span.
Packaging made from natural cellulose fibers has become a point of increasing interest as part of a general movement towards inclusion of renewal and less persistent feedstock. Fiber based packaging generally also has a very high rate of recyclability. Cellulosic articles are generally formed as film or multi-ply boards using paper making processes or as 3D formed objects using pulp molding methods. While fibers can provide excellent structural support and a good decoration surface, paper sheets or formed objects alone cannot be used to pack liquid products due to their poor oxygen and moisture barrier and poor liquid containment properties leading to integrity failures. Thus, a protective coating is generally applied on the inner side after the cellulosic article is manufactured to extend the shelf life of the packaged liquid products.
Liquid packaging boards (LPB) are generally laminated with polymers with heat seal properties such as PE in a structure that can include one or more barrier layers such as EVOH, vacuum metalized aluminum oxide, etc. or alternatively coated with thin layer applied using a dispersion technique such as spray, roll, dip, blade or curtain coating. However, coatings bring trade-offs between barrier performance and package recyclability.
Boards can be formed to make packages such as cartons, cans or paper tubes using high-speed manufacturing processes. Paper cartons or cans can be suitable to dispense liquids that can be poured but have severe limitation to dispense viscous formulas such as those used in beauty and personal care. Current paper tubes have folded liquid packaging boards (LPB) including fiber for the side wall, but still require the use of a large amount of plastic due to the inclusion of plastic components needed to provide re-closability and dispensing control. Current paper tubes have also suboptimal ergonomics especially for large sizes due to a non-optimal grip. Paper tubes using commercially available folded fiber-based packaging boards have a generally stiffer wall than PBL (plastic barrier laminate) or extruded plastic tubes. This characteristic combined with the use of plastic closures mounted on shoulders limits the tube squeezability, collapsibility and thus the final product restitution. The use of thinner LPB gauges in current cosmetic tubes can improve squeezability/collapsibility, but also leads to suboptimal dispensing as the paper laminate lacks the desired “shape” memory/bounce back necessary to provide dispensing control.
The grip and dispensing of bottles or tubes in a wet environment is also particularly challenging for consumers with disabilities or aging consumer e.g., impacted by arthritis especially since the package surface can be slippery. Also, the hygroscopicity nature of fibers presents additional challenges for fiber-based packaging applications used in damp or wet environments such as in-shower or bathroom use.
Liquid packaging boards typically contain relatively high amount of sizing agents such alkyl ketene dimers (AKD) to increase the hygroscopicity but suffers failures from in-plane edge wicking typically induced by liquid sorption into cut raw edges by capillary action. Such liquid sorption results in delamination and exposure of unsized fiber-fiber bonds and/or weakening of bonds between layers resulting in separation of multi-ply surfaces.
Maximizing the inclusion of bio-based fibers in the package is desired to improve the bio-based renewable content and recovery in re-processing the fibers. Maximizing the inclusion of bio-based fibers in the package is also desired to maximize the ergonomics during dispensing especially in a wet environment. Increasing fiber inclusion is also desired to enable a product restitution above 90% (or even above 95%) and flatten the bottle at disposal, which is beneficial for sorting and circular economy. Fiber-based bottles are desired that minimize plastic inclusion as well as provide unique design shapes, deliver a reasonable shelf life of at least 6 months to 2 years, in-shower survival, inclusivity usage and recyclability. Preferably, squeezable fiber-based bottles are desired for use in wet environments, capable of maintaining integrity while containing liquid formulas, enabling on-demand dispensing, superior in-use ergonomics, exhibiting a reasonable shelf-life, and optimized for recycling and disposal.
The present disclosure provides a squeezable fiber-based bottle for storing and dispensing a viscous liquid. The bottle comprises a molded base including a liquid containing surface having an aperture for dispensing viscous liquid. The molded base includes a base perimeter having a perimeter surface with an upper edge and a lower edge. The squeezable fiber-based bottle comprises a fiber-based side wall having an upper edge, a lower edge, an inner surface, and an outer surface. The fiber-based side wall includes a front, a back and at two opposing side panels. At least one of the two opposing side panels includes crease lines forming a flat portion. The inner surface of the fiber-based side wall includes a fiber-based side wall barrier layer having a WVTR of less than 20 g/sqm/day at 25° C., 60% relative humidity. The lower edge of the fiber-based side wall is attached to the molded base forming an impermeable seal. The impermeable seal is formed about the entire perimeter surface of the molded base wherein the lower edge of the fiber-based side wall is near the perimeter surface upper edge but not the perimeter surface lower edge, The perimeter surface of the molded base can include a lip or ledge to accommodate the lower edge of the fiber-based side wall. Alternatively, the fiber-based side wall can wrap around the lower edge of the molded base so that the lower edge of the fiber-based sidewall is disposed on an inner perimeter surface near the perimeter surface upper edge but not the perimeter surface lower edge. The molded base perimeter surface lower edge is below the liquid containing surface allowing the squeezable fiber-based bottle to stand vertically. The aperture for dispensing viscous fluid includes a slit valve formed of plastic or other resin material.
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that illustrative embodiments of the present invention may be better understood from the following description taken in conjunction with the accompanying drawings, in which:
c is a side view of the squeezable fiber-based bottle shown in
The present invention may be understood more readily by reference to the following detailed description of illustrative and preferred embodiments. It is to be understood that the scope of the claims is not limited to the specific components, methods, conditions, devices, or parameters described herein, and that the terminology used herein is not intended to be limiting of the claimed invention. Also, as used in the specification, including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. When a range of values is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent basis “about,” it will be understood that the particular values form another embodiment. All ranges are inclusive and combinable.
An objective of this invention is to provide a squeezable fiber-based bottle for a liquid composition including at least more than 50% fiber content, repulpable in the paper/cardboard recycling stream (including the used beverage carton recycling stream), providing both superior ergonomics and dispensing, enabling greater than 90% product evacuation, able to be flattened when disposed, enabling high volume packing efficiency and able to survive distribution, storage and use in a wet environment.
Another objective is to provide a method of forming a squeezable fiber-based container. The method comprises the steps of cutting a piece of planar elongated blank from a liquid packaging board sheet or web. The blank has a first side edge, a second side edge, a lower edge and an upper edge. The blank is creased forming lines directionally extending from the lower edge to the upper edge of the blank. The blank is secured to a fixture corresponding to the shape of the bottle to be manufactured. The blank is folded around the fixture so that the first side edge and the second side edge overlap forming monolithic bottle shape with two open ends. Heat-sealing energy and pressure are applied to the overlapped side edges forming a hermetically sealed seam. The fixture is removed from inside the container, and the lower edge of the fiber-based side wall is attached to a molded base forming an impermeable seal. The molded base has a perimeter surface upper edge and a perimeter surface lower edge. The lower edge of the fiber-based side wall is disposed near the perimeter surface upper edge but not the perimeter surface lower edge. The bottle is filled, and the upper edge is sealed.
Another objective of this invention is to provide a squeezable bottle with scores to tear open the bottle, access the residual content and wash the bottle interior from residuals before disposal.
“Pulp” is preferably defined as a fibrous material produced by mechanically or chemically separating fibers from sustainable sources and then suspended in a fluid.
“Fiber” is preferably defined as a natural substance of wood or vegetable origin that is significantly longer than it is wide.
“Molded base” is preferably defined as a component made either in plastic, using either injection molding or compression molding or thermoforming or in fibers, using either pulp molding or liquid-carton-board forming.
“Impermeable seal” is preferably defined as an area between two or more mating surfaces or objects that is impervious to liquids. This can include every fluid tight connection to prevent leakage of the product inside the bottle as well as means of protecting the paper/cardboard raw edge.
Cosmetic paper tubes in the prior art include uncreased liquid packaging boards (LPB) in the side wall of higher modulus and bending stiffness compared to plastic laminates i.e., wherein the LPB is bent into a cylinder and formed into a single curved surface. The stiffer side wall combined with the stiff tube structure enable the cylindrical side wall section to act as a tubular spring limiting the dose dispensed when an acceptable squeezing force is exerted. For example, squeezing a filled commercially available paper tube of 50 mm in diameter with a 10 mm displacement produces a dose of about 1.6 g for a 30N squeezing force. It has been determined that consumers generally exert a 20-30 N squeezing force on a tube and that such squeezing force rarely exceeds 50N. Since a typical desired dosage for most personal care applications is 5-10 g, consumers resolve to inconveniently squeezing the tube multiple times or exerting a very large squeezing pressure resulting in denting the tube and an undesired permanent deformation.
Creasing according to the present disclosure, enables folding the LPB to form sharp edges. The sharp edges result in a discontinuity in the curvature of the side wall surface creating flat portions that are easier to squeeze when deflected than a round or oval tube having the same inner volume and side wall material. This enables a higher dosage per squeeze than prior art cosmetic paper tubes at similar squeezing force. Further, it was found that flat portions 7, 9 on the opposing side panels 2, 3 promote a “spring back” of the squeezed side panels since the creases 65 act as living hinges preventing denting and permanent deformation when the squeezing pressure is released. In addition, the creases enable the opposing side panels to collapse in a flat configuration providing a product restitution greater than 90% and tube disposal when a force of at least 45N is applied to crush the side panels.
The substrate of the liquid carton board forming the fiber-based side wall 12 preferably contains lignocellulosic fibers obtained by any conventional pulping process, including bleached or unbleached chemical, mechanical, chemi-mechanical pulping processes. The carton board can be made from more than one ply, typically 3 plies, and is usually in the form of a fibrous web.
Preferably the carton board has a grammage from 170-430 gsm and more preferably about 250 to 350 gsm. Preferably the functional layers can be on both the inner surface forming the liquid containment portion and the outer surface 19. The most inner and most outer layers are preferably low-density polyethylene (LDPE) layers to ensure good sealing and liquid tightness. The LDPE in the most outer layer also ensures protection from moisture pick-up from splash or wet handling. The LDPE also ensures that after consumer disposal and household collection the NIR detector in industrial sorting facilities can positively identify the bottle and divert the package to the used beverage carton recycling stream where multi-material packages are effectively recycled and the fiber regained for future use.
For example, the liquid carton board may be a multilayer structure comprising one or more layers made of bleached sulphate pulp. The liquid carton board may comprise a top layer made of bleached sulphate pulp, a middle layer made of chemi-thermomechanical pulp CTMP, a back layer made of bleached sulphate pulp and a polyethylene PE layer on the outer surface of the top layer and/or the back layer. The liquid carton board used can be products of the Finnish company Stora Enso marketed with trademarks Natura™ 2PE Board or Natura™ Barr. Natura™ 2PE Board is a bleached liquid packaging board with a three-layer fiber construction, with two outer layers made of bleached sulphate pulp and a middle layer made of CTMP (chemi-thermo-mechanical pulp). Its top and reverse sides are polyethylene PE coated with no inclusion of any additional high barrier coating. Natura™ Barr is a bleached liquid packaging board with a three-layer fiber construction, with two outer layers made of bleached sulphate pulp and a middle layer made of CTMP (chemi-thermo-mechanical pulp). It has a polyethylene PE coating on the top side and a multilayer high-barrier coating on the reverse side. The functional layer can include barrier layers such as high density polyethylene (HDPE), a foil, or a thin coating from metallization, applications of cellulose fibers or water dispersible nanocomposites including nanoplatelets. Alternatively, both the inner and outer coating can be a polymeric water dispersion, such as BASF Joncryl or Down Rhobarr 1. The water dispersions can be applied by a variety of techniques such as dip, rod, doctor blade, knife, gravure, reverse roll, air knife, and forward roll or spray followed by a drying step. An example of carton boards using water-based dispersion coatings are Cupforma Natura Aqua+ commercialized by Stora Enso and ISLA commercialized by Kotkamills.
As shown in
As illustrated in
An alternate method of forming the exemplary squeezable bottle 10 can comprise the steps of:
This alternative method can be preferred to ship the bottle body in a stacked configuration to optimize space, while still maintaining ergonomic benefits.
The (1) impermeable longitudinal seal 83 connecting the two side wall edges 62, 64 and extending from the lower edge 16 to the upper edge 14, (2) the impermeable seal 42 connecting the fiber-side wall 12 to the molded base 20 as well as (3) the upper seal 29 of the fiber-based side wall 12 can all include means to protect exposed edges from edge water wicking in order to avoid catastrophic integrity failures or unwanted deformation. Edge wicking is particularly problematic in the areas where a liquid carton board edge is cut (“raw edge”) and exposed to water such as when the bottle is used in shower. Edge wicking of boards has been amply studied e.g., Harju 2018 Liquid penetration in food service boards, Master Science thesis. Several methods are known in the art to provide an edge protection such as spraying of a sizing or other hydrophobic agent, skiving, hemming, or covering the cut edge with an adhesive plastic strip. Edge protection methods for the upper seal 29 could employ spray, dip coating, adding a PE-PET-PE strip or folding. Solutions to apply an edge protection to the longitudinal seal 83 are known in the art as described in WO2022185176 or U.S. Pat. No. 11,691,791.
The squeezable fiber-based bottle of the present disclosure preferably includes creasing or scoring of the liquid carton used to form the side wall. Benefits of creasing and scoring include: (a) minimizing the bending stiffness of the liquid carton board to increase squeezability, (b) increasing grip between the tube and the hand especially in wet conditions, (c) maximizing product restitution by allowing consumers to fold/roll-up the side wall as the squeezable fiber-based bottle is used.
It was found that a deeper creasing depth can increase board 60 panel flexibility when squeezed almost like creating a living hinge. Preferably, the ratio between crease depth and width should be between 2:1 and 1:2 and more preferably 1:1. For this application, it is preferred to use boards including bleached chemical pulp and particularly SBB (Solid Bleached Board) due to their exceptional mechanical properties and delamination/micro-cracks resistance especially for deep and narrow creases.
The substrate of the liquid packaging board forming the fiber-based side wall 212 preferably contains lignocellulosic fibers obtained by any conventional pulping process, including bleached or unbleached chemical, mechanical, chemi-mechanical pulping processes. The carton board can be made from more than one ply, typically 3 plies, and is usually in the form of a fibrous web. Preferably the carton board has a grammage from 170-430 gsm and more preferably about 250 to 350 gsm. Preferably the functional layers can be on both the inner surface forming the liquid containment portion and the outer surface 219. The most inner and most outer layers are preferably low-density polyethylene (LDPE) layers to ensure good sealing and liquid tightness. The LDPE in the most outer layer also ensures protection from moisture pick-up from splash or wet handling. The LDPE also ensures that after consumer disposal and household collection the NIR detector in industrial sorting facilities can positively identify the bottle and divert the package to the used beverage carton recycling stream where multi-material packages are effectively recycled and the fiber regained for future use. For example, the liquid carton board may be a multilayer structure comprising one or more layers made of bleached sulphate pulp. The liquid carton board may comprise a top layer made of bleached sulphate pulp, a middle layer made of chemi-thermomechanical pulp CTMP, a back layer made of bleached sulphate pulp and a polyethylene PE layer on the outer surface of the top layer and the back layer. The liquid carton board used can be products of the Finnish company Stora Enso marketed with trademarks Natura™ 2PE Board or Natura™ Barr. Natura™ 2PE Board is a bleached liquid packaging board with a three-layer fiber construction, with two outer layers made of bleached sulphate pulp and a middle layer made of CTMP (chemi-thermo-mechanical pulp). Its top and reverse sides are polyethylene PE coated with no inclusion of any additional high barrier coating. Natura™ Barr is a bleached liquid packaging board with a three-layer fiber construction, with two outer layers made of bleached sulphate pulp and a middle layer made of CTMP (chemi-thermo-mechanical pulp). It has a polyethylene PE coating on the top side and a multilayer high-barrier coating on the reverse side. The functional layer can include barrier layers such as high density polyethylene (HDPE), a foil, or a thin coating from metallization, applications of cellulose fibers or water dispersible nanocomposites including nanoplatelets. Alternatively, both the inner and outer coating can be a polymeric water dispersion, such as BASF Joncryl or Down RhobarrD. The water dispersions can be applied by a variety of techniques such as dip, rod, doctor blade, knife, gravure, reverse roll, air knife, and forward roll or spray followed by a drying step. An example of carton boards using water-based dispersion coatings are Cupforma Natura Aqua+ commercialized by Stora Enso and ISLA commercialized by Kotkamills. Preferably, the aperture 230 can be sealed with a removable lid using a metalized laminate attached to the molded closure with a pressure sensitive adhesive (not shown).
The thickness of the overall film/individual layers is measured by cutting a 20 μm thick cross-section of a film sample via sliding microtome (e.g. Leica SM2010 R), placing it under an optical microscope in light transmission mode (e.g. Leica Diaplan), and applying an imaging analysis software.
The caliper, or thickness, of a single-layer test sample is measured under a static load by a micrometer, in accordance with compendial method ISO 534, with modifications noted herein. All measurements are performed in a laboratory maintained at 23° C.±2° C. and 50%±2% relative humidity and test samples are conditioned in this environment for at least 2 hours prior to testing. Caliper is measured with a micrometer equipped with a pressure foot capable of exerting a steady pressure of 70 kPa±0.05 kPa onto the test sample. The micrometer is a dead-weight type instrument with readings accurate to 0.1 micron. A suitable instrument is the TMI Digital Micrometer Model 49-56, available from Testing Machines Inc., New Castle, DE, or equivalent. The pressure foot is a flat ground circular movable face with a diameter that is smaller than the test specimen and capable of exerting the required pressure. A suitable pressure foot has a diameter of 16.0 mm. The test sample is supported by a horizontal flat reference platform that is larger than and parallel to the surface of the pressure foot. The system is calibrated and operated per the manufacturer's instructions. Measurements are made on single-layer test samples taken from rolls or sheets of the raw material, or test samples obtained from a finished package. When excising the test sample from a finished package, use care to not impart any contamination or distortion to the sample during the process. The excised sample should be free from residual adhesive and taken from an area of the package that is free from any seams or folds. The test sample is ideally 200 mm2 and must be larger than the pressure foot. To measure caliper, first zero the micrometer against the horizontal flat reference platform. Place the test sample on the platform with the test location centered below the pressure foot. Gently lower the pressure foot with a descent rate of 3.0 mm per second until the full pressure is exerted onto the test sample. Wait 5 seconds and then record the caliper of the test sample to the nearest 0.1 micron. In like fashion, repeat for a total of ten replicate test samples. Calculate the arithmetic mean for all caliper measurements and report the value as Caliper to the nearest 0.1 micron.
The basis weight of a test sample is the mass (in grams) per unit area (in square meters) of a single layer of material and is measured in accordance with compendial method ISO 536. The mass of the test sample is cut to a known area, and the mass of the sample is determined using an analytical balance accurate to 0.0001 grams. All measurements are performed in a laboratory maintained at 23° C.±2° C. and 50%±2% relative humidity and test samples are conditioned in this environment for at least 2 hours prior to testing. Measurements are made on test samples taken from rolls or sheets of the raw material, or test samples obtained from a finished package. When excising the test sample from a finished package, use care to not impart any contamination or distortion to the sample during the process. The excised sample should be free from residual adhesive and taken from an area of the package that is free from any seams or folds. The test sample must be as large as possible so that any inherent material variability is accounted for. For flat samples, measure the dimensions of the single layer test sample using a calibrated steel metal ruler traceable to NIST, or equivalent. For non-flat samples, the area can be calculated using 3D data. Calculate the Area of the test sample and record to the nearest 0.0001 square meter. Use an analytical balance to obtain the Mass of the test sample and record to the nearest 0.0001 gram. The weight of a coating can be obtained by subtracting the weight of the coated from the uncoated samples. Calculate Basis Weight by dividing Mass (in grams) by Area (in square meters) and record to the nearest 0.01 grams per square meter (gsm). In like fashion, repeat for a total of ten replicate test samples. Calculate the arithmetic mean for Basis Weight and report to the nearest 0.01 grams/square meter.
This is a test method to detect and locate any pin hole equal or greater than 10 μm on a coated surface. The part to test is placed on an absorbent surface with the coated side facing up. Then a dye penetrant solution according to ASTM F3039-23 is spread across the surface under test, preferably using an eye dropper or pipette and a small roller to apply pressure on the surface to ensure adequate contact. The dye penetrant solution should contact all areas exhibiting questionable surface anomalies taking care not to allow dye penetrant solution to flow over the edge of the sample. Wipe excess dye from sample using a clean absorbent pad and carefully lift the sample. The test is passed if there is no evidence of dye penetration or staining to the opposite side of coated surface.
This is a test method to measure the ability of the bottle and closure system to prevent leakage when stored or transported.
A minimum of three representative empty bottles of the type being tested are preconditioned for at least 24 hours at 22±3° C., 60%±10 RH. Prepare a tap water solution at room temperature adding a dye such as Rhodamine or Toluidine to give a permanent indication where there is leakage. Fill the specimen at lab ambient temperature with the water/dye solution to expected fill capacity e.g., 150±1 ml, fitted with their respective closure (if applicable) and hermetically closed in the storage configuration. Dry (if needed) the finish and shoulder areas of the bottles with a (paper) towel so that no product remains on them. Place the specimen in a flat position on a tray capable of holding the liquid should a leak develop. Place some absorbent blotting paper beneath the specimen to detect leakage more easily. Then put the specimen in storage at 25±3° C., 60%±10 RH. No weight or other bottles must be placed on top of the specimen being tested. Alternative specimen orientations during the test can be considered such that suspected leak areas are covered with the liquid inside the container. Inspect for liquid leakage at 24 h, after 1 week and after 2 weeks. Note location(s) of any eventual leakage.
If there is leakage to the outside of the specimen, the package fails the test. If there is no leakage to the outside of the specimen the package passes the test.
The water vapor transmission rate (WVTR) is defined as the mass of water vapor penetrating through the membrane per unit area, per unit time, and it is used as a parameter for measuring water barrier properties. The measurement is conducted according to the ASTM E96 Inverted Cup Water Method. For this test, impermeable cups such as the “vapometer” E96 cups from Thwing-Albert Instrument Co. are filled with 50 g of water. The mouth of the cup is 3070 square millimeter in area. The cups are made of noncorroding material, impermeable to water or water vapor. The flat portion of the specimen under measurement is cut into circles slightly larger than the opening of the cup. At least three specimens should be tested representative of the materials and condition being tested. The test specimen is sandwiched between two gaskets and placed on the cup mouth flange assuring the correct orientation. The specimen is then secured to the cup by creating an impermeable seal by tightening an open screw lid. The cups are then weighted with a balance of a resolution of at least 0.01 g. Place the cups on a flat tray making sure the water is in direct contact covering the specimen being tested. Then put the cups in storage at 25±3° C., 60%±10 RH. Note the cups should be placed in such a way that the air flow is not restricted over the exposed surface. The cups are then weighted daily for at least 7 days. The rate of weight change of a specimen is at steady state when that rate is essentially constant over a period that is a minimum of six consecutive weight measurements. Where a straight line adequately fits the plot of at least six properly spaced points (periodic weight changes matching or exceeding 20% of the multiple of 100 times the scale sensitivity), steady state is assumed. If the rate of weight is not at steady state, the storage period should be extended.
If the target part to characterize is not flat and/or the coating is not homogeneous e.g., made from spray or dip coating application, the water transmission rate is measured on a representative flat specimen made according to the same process with the same materials and characterized such that both average substrate and coating thicknesses are matching the ones from target part's within +/−20% tolerance.
The barrier water vapor transmission rate (WVTR) after thermoforming process can be calculated based on water vapor permeability theory, and there are two critical information needed. The first one is the intrinsic barrier material properties of water vapor permeability coefficients changing with thickness, and the second one is the barrier thickness changing after thermoforming. In the study, the water vapor permeability coefficient relationship with thickness were achieved by data regression process using WVTR values using ASTM F1249 (AMETEK, MOCON) of different film sample thicknesses. For the thickness profiles after thermoforming, it can be attained by either physical measurement of film sample from thermoforming or virtual thermoforming model prediction. Once we have this critical information, the WVTR after the thermoforming process can be predicted according to Permeability theory. These WVTR predictions are confirmed using a modified ASTM E96 desiccant method with custom metal sample holders. The sample holders are designed to create a hermetic seal between the cavity containing the bentonite clay desiccant, the thermoformed barrier film, and the surrounding controlled atmosphere. Following the ASTM E96 method, samples are weighed at repeatedly over a specified duration; the resulting graph with time (days) and weight gain (grams) is fitted with a linear regression. The slope of the line is reported and normalized by the area of the thermoformed liner and reported as the WVTR.
This method is used to determine the water weight loss through a container or individual components such as the vessel and cover. A minimum of three representative empty specimens of the type being tested are preconditioned for at least 24 hours at 23±2° C., 60%±10 RH.
Then the specimens are filled with specified amount of tap water, or another specified personal care composition at lab ambient temperature to their filled capacity fitted with their respective closure/cover (if applicable) and hermetically closed in the storage configuration. Any different type of closure such as aluminum foil with paraffin should be noted. Dry (if needed) any outer surfaces with a (paper) towel so that no product remains on them.
For flat components, such as the lidding film, the measurement is conduced according to a variant of the ASTM E96 Inverted Cup Water Method. For this test, impermeable cups such as the “vapometer” E96 cups from Thwing-Albert Instrument Co. are filled with 50 g of water or specified personal care composition. The mouth of the cup is 3070 square millimeter in area. The cups are made of noncorroding material, impermeable to water or water vapor. The flat portion of the specimen under measurement is cut into circles slightly larger than the opening of the cup. At least three specimens should be tested representative of the materials and condition being tested. The test specimen is sandwiched between two gaskets and placed on the cup mouth flange assuring the correct orientation. The specimen is then secured to the cup by creating an impermeable seal by tightening an open screw lid.
The weight of the filled covered vessel or cup is recorded with a balance of a resolution of at least 0.01 g. Then specimens are placed in storage at 25±3° C., 60%±10 RH or another relevant testing condition. The specimen should be placed such that the water or the product under test is in direct contact with the specimen being tested. If ASTM E96 cups are used, the cups should be placed in such a way that the air flow is not restricted over the exposed surface. The weight is recorded daily for 2 weeks. The daily weight loss is calculated once the gradient is stabilized at “steady state”. The surface area of the container is calculated. The weight loss is calculated and reported averaging the daily weight loss per a square meter at 25° C., 60% RH or in the relevant tested condition. The test is not applicable if the weight loss doesn't reach a steady state such as in case of a package failure leading to a leak.
This method simulates heavy use in a wet environment. Bottles are filled with Pantene PRO-V Repair & Protect shampoo or another specified personal care composition at the specified filled capacity e.g., 150±1 g and then preconditioned for a minimum of 24 hours at 22±3° C., 60%±10 RH.
Then 5 g±1 of content is dispensed from the container; the package is submerged in water for 8 minutes and subsequently dried for 10 minutes. This sequence represents a heavy use cycle. This test cycle is repeated for 19 times. A minimum of 3 bottles are tested.
Test requirements are met if no integrity or performance failure is observed in any of the bottles which renders the package not usable at the completion of all 20 heavy use cycles.
This method is used to measure how much force is necessary to dispense a certain amount of product from a bottle. Bottles are filled with Pantene PRO-V Repair & Protect shampoo or another specified personal care composition at the specified filled capacity e.g., 150±1 g and then preconditioned for a minimum of 24 hours at 22±3° C., 60%±10 RH. The bottles are fitted with their respective closure to ensure no leaks.
Each bottle is then placed in a compression tester using a fixture to simulate a squeezing event. An example of compression tester is Z010TN All-round by ZwickRoell GmbH & Co. KG. The load probe has a ¾ inch stainless steel ball attached simulating a thumb pressing on the bottle panel. The bottle is placed horizontally relatively to the load column with the front panel facing up by fixing one bottle extremity at one end resting on two curved aluminum supports (simulating fingers) just about the opposite direction where the load is applied. The bottle is adjusted to ensure the load is applied in the center of the panel and in the middle between the neck (or the bottle base) and the other bottle extremity. Then the probe is lower to contact the bottle reaching a max preload of 0.5 N. A scale with a precision of +0.01 g with a collector plate is placed underneath the package to collect the product dispensed from the orifice during squeezing. The closure is opened making sure no product is leaking from the orifice before the squeeze test. Sometimes it is necessary to re-orient the bottle.
Then the load is applied to the filled bottle at 20 mm/sec until a 10 mm displacement is reached. Then, the probe is returned to the start position and another 2 load cycles are performed. The total amount of product dispensed is weighted. A minimum of 3 bottles are tested in total.
Test requirements are met if both the average product collected from each dispensing event from all tested bottles is at least 1 g and all bottles survive the test with no catastrophic failures compromising the bottle functions such as leaking.
The test is conducted with a TOMRA Autosort NIR Equipment (TOMRA ACT operation system). The whole package is placed in the NIR testing stand, and test result is report of the main classifier in the field of view. Those classifiers are specific for each sorting plant installation, and we report here the predominate classifier form key sorting plant in Europe. If the classifier is “Tetrapak” then this indicates that the package is diverted to the Used Beverage Carton bale in the sorting center.
The testing is carried out with a representative amount of at least 250 g of oven-dry material of the packaging type under test as intended to be disposed by consumers. The first step is to isolate, dry remove and weight non-paper constituents which can be easily separated such as closures, etc. The test material is reduced to specimens of about 2 cm×2 cm and the moisture content determined according to DIN EN ISO 287:2009-09. About 50±1 g of the test material is then disintegrated in a procedure according to DIN EN ISO 5263-1:2004-12. For this purpose, a total volume of 2,000 ml of specimen is defibrated in a standard disintegrator without prior swelling at a consistency of 2.5%. The disintegration time is 20 minutes, the speed is 3000 rpm, and the temperature of the tap water 40° C. Then, the fiber suspension such obtained is homogenized according to ZM V/6/61. For this purpose, the specimen is transferred into a distributor, diluted with tap water to a form a diluted stock with a consistency of 0.5% and homogenized for about 5 minutes.
Then, the disintegratability is tested after the Zellcheming method ZM V/18/62. For this purpose, the total stock is screened for 5 minutes without any further chemical additive by means of a Brecht-Holl fractionator using a perforated plate with a hole diameter of 0.7 mm. The residue is washed into a 2 liters tank and dewater it through a filter inserted in a Büchner funnel. The filter is folded once and placed in an oven to dry at 105° C. up to weight constancy. Then, the reject is visually inspected and the weighted. To calculate the total reject content, the proportion of removed-dry non-pulp constituents is also included. The fiber yield can be derived from the difference between the (oven-dry, 100%) initial material and the total reject. Products are rated “recyclable” is the total reject does not exceed 20%; “recyclable, but worthy of product design improvement” if the total reject is between 20% to 50%; and “not reasonably usable in paper recycling” if the total reject is above 50% to the initial material input respectively.
For evaluating the undisturbed sheet formation criterion, the total stock is first screened in a procedure after the Zellcheming method ZM V/1.4/86. For this purpose, the total stock is fractionated for 2 minutes by means of a Haindl fractionator using a slot plate of 0.15 mm. The passing fraction, which is hereinafter referred as to ‘accept’ is then collected. Then, the accept is used to form a sheet on a Rapid Köthen sheet former after DIN EN ISO 5269-2:2005-03. Two handsheets of 1.8 g are formed of about 60 gsm. The drying temperature is about 96° C. For the sheet adhesion test, a dried handsheet together with a couch carrier board and a cover sheet are sandwiched between two brass plates and placed in a drying oven where a full surface pressure of 1.18 kPa is applied for 2 minutes. Next, the specimens are placed in an exicator where they are allowed to cool down for 10 minutes, then they undergo the sheet adhesion test and the visual inspection for any optical inhomogeneities.
For the sheet adhesion test, the carrier board and the cover sheet are one by one slowly peeled off the handsheets. While doing so, the test operator checks for potential adhesion effects. Also, the surfaces of the handsheet, cover sheet and carrier board are inspected for any damage or adhesion of the handsheet. The product is considered “recyclable” is no adhesion effect is observed; “limitedly recyclable due to the tackiness in the prepared fiber stock” if some little adhesion effects are observed with slight damage; “not recyclable due to the tackiness in the prepared fiber stock” if adhesion effect with damage is observed.
Then the handsheets are inspected under transmitted light for the presence of any flaws, transparent and white spots, or dirt specks from inks, coating, paint, lamination, and adhesive particles. In addition, the sheets are evaluated for stain from any dark colorants. The product is considered “recyclable” if no or non-disturbing optical inhomogeneities are observed, “limitedly recyclable due to optical inhomogeneities in the prepared fiber stock” if disturbing optical inhomogeneities are observed and “not recyclable due to optical inhomogeneities in the prepared fiber stock” if unacceptable optical inhomogeneities are observed.
In a flat crush test, the empty bottle is placed sideways on a plate. A vertical load of 45 N with a cylinder of 6 cm of diameter is applied on the bottle body. The test is passed if the bottle is permanently deformed in a substantially flat configuration.
In a burst strength test, the empty bottle or tube is screwed into a neck gauge fitment and placed between two pressure blocks mounted on a vice. Pressure is applied slowly and evenly through the valve or tube opening until 20 psi (137.89 kPa) is reached and maintained for 15 seconds. During the test, the valve area should be properly sealed to ensure that the applied pressure is directed exclusively through the valve to prevent any leakage or bypass of pressure. Repeat for 3 samples. The test is passed if the empty bottle or tube withstands the specified pressure range without failure.
The Adhesion bond test is used to determine the strength of the bond between the sidewall and the base of the bottle. First, points must be marked on side wall where the impermeable seal intersects the minor and major axis of the base. Then 4 vertical lines needs to be drawn orthogonal to the impermeable seal. Taking these lines as center, strips 12.7 mm wide must be cut starting as close as possible to the base without compromising the impermeable seal. Place two opposing strips in the grips of the instrument. Set the crosshead speed at 12.7 cm/min. Record the maximum force and note whether the failure was a peel from the shoulder or a tear of the material. Repeat the test on the remaining two strips of the sample. Repeats for 3 samples. No peel failures with force values <45 N for 12.7 mm (½ inch) strips.
Table 1 includes examples of squeezable bottles that could be used to store and dispense consumer products. All bottles of these examples have a comparable size and filled weight. All bottles assessed were found not leaking and free of pinholes larger than 10 microns. The bottles were tested for fiber content, shower integrity according to the water resistance method, squeezability, flat crush, sorting using NIR and re-pulpability. The side wall and the base of the bottles of these examples were also assessed for moisture vapor barrier performance.
Example 1 discloses a commercially available paper tube using a liquid carton board for the side wall, a welded polyethylene shoulder with integrated cap. The squeeze test was performed using tubes filled with a commercially available leave-on conditioner commercialized by Garnier in Germany as Wahre SchätzeHonig Schätze. While this tube can be considered squeezable by the test method disclosed, the dispensing experience is sub-optimal. By applying a deflection of 10 mm, it was found that an average squeezing force of 38N for an average product dispensed 1.6 g when the tube is full. By using pressure sensors, it was found that consumers typically exert squeezing forces around 20-30N, rarely exceeding 50 N. A squeezing force of above 35N producing a deflection of 10 mm is not desired. It was also found that an average product tube dispensed at least 5 g of product by squeezing the tube with a 20 mm deflection. However, this required squeezing forces exceeding 50N and resulted in permanent indentation/deformation of the tube.
Example 2 discloses a squeezable fiber-based bottle as shown in
| Number | Date | Country | |
|---|---|---|---|
| 63559403 | Feb 2024 | US | |
| 63589372 | Oct 2023 | US |
