PULP-MOLDED CONTAINER

TECHNICAL FIELD

The instant disclosure relates to containers, such as pulp-molded containers that can, for example, be utilized in connection with food products.

BACKGROUND

Molded pulp containers used in the food service industry are generally recognized and thought of by consumers as being more biodegradable or compostable as compared to plastic containers. Molded pulp containers can be made by a wet method or a dry method, both of which have their advantages and disadvantages.

In the wet method, a mold part or intermediate structure is dipped into a slurry of liquid and pulp fibers to create a layer of liquid-soaked fibers that is placed into the mold, which is subjected to pressure and heat to squeeze out the free liquid and dry the absorbed liquid to a desired extent. The mold is then opened and the container removed.

In the dry method, pulp fiber is blown onto a carrier, such as a conveyor, to form a layer of fibers that is subjected to pressure, such as by calendaring rollers, to provide the layer or matt with a degree of rigidity. The compressed layer or matt of dry fibers is then inserted into the mold and subjected to pressure and heat as desired. The mold is then opened and the container removed.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a container having a cover mounted to a tray in a closed position according to an aspect of the disclosure.

FIG. 2 is a perspective view of a container having a cover mounted to a tray in an open position according to an aspect of the disclosure.

FIG. 3 is a partial cross-section of the container of FIG. 2 taken along the line III-III

FIG. 4 is a partial cross-section of the container of FIG. 2 taken along the line IV-IV.

FIG. 5 is a partial cross-section of the container of FIG. 1 taken along the line V-V.

FIG. 6 is a partial cross-section of the container of FIG. 1 taken along the line VI-VI.

FIG. 7 illustrates a consumer opening a container having a cover mounted to a tray according to an aspect of the disclosure.

FIG. 8 illustrates the container of FIG. 7 after it has been opened and the cover separated from the tray according to an aspect of the disclosure.

DETAILED DESCRIPTION

Disposable containers for packaging and storing edible goods are often provided with tamper resistant and tamper evident (TETR) features to prevent unauthorized access to the container and to indicate to a consumer when the container has previously been opened. The disposable containers are also provided with a fluid seal that retards the flow of liquid or vapors or both from the container. The combination of both TETR features and a fluid seal adds complexity to the container structure and manufacturing. For plastic containers, a common solution has been to provide the container lid/cover and base/tray with complementary shoulders and undercut, with the shoulder received beneath the undercut to form the fluid seal, while using tearaway portions or frangible hinges for TETR. The shoulder and undercuts are possible to manufacture using traditional injection molding or thermoforming processes because the flexibility and elasticity of the plastic prevents the container from being mold-locked onto the structures of the mold forming the shoulder and undercut. A sufficient force can be applied to the container to remove it from the mold and the plastic will flex or stretch, without tearing, to enable the removal of the container from the mold structure forming the shoulders and undercuts. In operation of the plastic container, the opening/closing of the lid/cover onto the base/tray cause the shoulder/undercuts to deflect and return into place often producing a “snapping” noise, which leads to the fluid seal being called a snap seal or similar name. When the snap seal is a peripheral seal, it normally requires pressure on all sides of he container to ensure the shoulder/undercuts have fully engage about the periphery.

For molded pulp fiber containers, the use of shoulders and undercuts to form the fluid seal is not a viable option because the molded pulp fiber lacks the flexibility and elasticity necessary to prevent mold-lock or to provide for removal from the mold structures without tearing. Said a different way, for the shoulder/undercuts in a molded pulp fiber to be structurally sufficient to perform as a fluid seal, the molded pulp fiber will mold-lock to the mold structures forming the shoulder/undercuts and/or the container will tear upon removal from the mold. If the shoulder/undercuts are sized to prevent mold-lock and/or tearing, the shoulder/undercuts will be insufficient to perform as a fluid seal. To address the tearing of the molded pulp fiber container when it is removed from the mold structures forming the shoulders and undercuts, some plastic has been introduced with the pulp fibers. While sufficient plastic can be added to address the mold-removal tearing, the addition of any plastic tends to destroy the compostable and biodegradable characteristics of molded pulp containers, which are the exact characteristics that make molded pulp containers more desirable than plastic containers. While there are compostable or biodegradable plastics, they require much longer time periods (several years) to compost or biodegrade than the pulp fibers (less than a year), and, therefore, it is not desirable to use them with the molded pulp fiber as it changes the beneficial compostable/biodegradable time frame for the container.

This disclosure relates to solving the problem of providing molded pulp containers with a suitable fluid seal, without mold-lock or mold-removal tearing, which is accomplished without the use of shoulders/undercuts. The suitable fluid seal is can also accomplished without adding plastic to the pulp fibers. The suitable fluid seal is advantageously accomplished in combination with TETR features. For example, the TETR features can be used to apply a force to overlapping portions of the cover and base of the molded pulp container to form a fluid seal at the interface of the overlapping portions. The interface is resistant to separation because of the higher surface roughness of the molded pulp material, such as compared to plastic containers. The force applied by the TETR structure to the interface increases the separation force needed to open the container.

FIG. 1 illustrates a container 10 comprising a tray 12 and a cover 14 with the cover 14 in a closed configuration. The container 10 can include a first side 20 (e.g., a front side), a second side 22 (e.g., a rear side) opposite the first side 20, a third side 24 (e.g., a first lateral side), and a fourth side 26 (e.g., a second lateral side) opposite the third side 24. Collectively, the sides 20, 22, 24, 26 form an outer periphery of the container 10. As shown, the tray 12 may extend beyond the cover 14 at three or more of the sides, such as the second, third, and fourth sides 22-26 in examples including a hinge 40. For example, the cover 14 may not be visible from the bottom of the container 10 except for one or more portions, such as portions at the first side 20 proximate the hinge 40.

FIG. 2 illustrates the container 10 with the cover 14 in an opened configuration. The tray 12 can include a bottom wall 30, a peripheral side wall 32, and a tray flange 34, which defines a first seal structure 42. The peripheral side wall 32 can extend generally upward from the bottom wall 30 to the tray flange 34, and the tray flange 34 can define an open top 36. The bottom wall 30 and the peripheral side wall 32 can at least partially define a chamber 38. The chamber 38 can, for example, receive one or more food products. The cover 14 can selectively close the open top 36 to close the chamber 38. The cover 14 has a top wall 54 bounded, at least in part, by a peripheral cover flange 44, which defines a second seal structure 46. The first and second seal structures 42 and 46 cooperate to form a fluid seal 48 about at least a portion of the container 10. A hinge 40 couples the cover 14 to the tray 12. The tray flange 34 can define a channel 50 of the first sealing structure 42. The tray flange 34 can be non-detachably connected to the tray 12. The cover flange 44 can define a protrusion 52 of the second sealing structure 46. The cover flange 44 and the protrusion 52 can be non-detachably connected to the cover 14. The channel 50 may extend along at least three sides of the tray 12, such as sides 22-26 of the container 10.

The tray 12 and the cover 14 are generally illustrated with rounded rectangular configurations, but can have other configurations, such as circular configurations, oval-shaped configurations, and others. The relative height and width and depth of the container 10 can vary from what is illustrated. While the tray 12 and cover 14 are described as holding food items, the food items can be solids as well as liquids, including soups. Additionally, the tray could be in the form of a cup for holding a liquid, and the cover could be a lid for the cup. Further, while the cover 14 is shown as connected to the tray 12 by the hinge 40, the cover 14 can be completely separate from the tray 12, and the container 10 may not include a hinge 40. In examples without the hinge 40, the tray 12 may extend beyond the cover 14 at all four sides 20-26 such that, in the closed configuration, the cover 14 is not visible from the bottom of the container 10.

Looking at the tray flange 34 in greater detail, the tray flange 34 can extend outward from the peripheral side wall 32, relative to a center of the tray 12, and can define the channel 50 of the first sealing structure 42. The channel 50 can be configured to at least partially receive the protrusion 52 of the cover 14, such as to provide a sealing interface (e.g., sealing contact) between the first sealing structure 42 and the second sealing structure 46. The protrusion 52 may extend from the cover flange 34 about some or all of a periphery of the cover 14. The top wall 54 can include an inner recessed portion 56, one or more outer recessed portions 58, or a combination thereof. The top wall 54 can include a structural rib 60 that can at least partially define the inner recessed portion 56. The inner recessed portion 56 may be centered at the center of the top wall 54. The one or more outer recessed portions 58 may be disposed at or proximate corners of the top wall 54. In the opened configuration illustrated in FIG. 2, the protrusion 52 can extend generally upward. In the closed configuration illustrated in FIG. 1, the protrusion 52 can downward into the channel 50.

Referring to FIG. 3, the tray flange 34 can include an inner channel wall 70 and an outer channel wall 72 spaced from the inner channel wall 70. The inner channel wall 70 and the outer channel wall 72 can be connected by a bottom channel wall 74 that can be parallel with the bottom wall 30 (FIG. 2) of the tray 12. While illustrated as parallel to the bottom wall 30 (FIG. 2), the bottom channel wall 74 can include other non-parallel configurations. The channel walls 70-74 can define the channel 50 and can be disposed such that the channel 50 includes a U-shaped configuration that opens upward (e.g., away from the bottom wall 30). A distance between the inner channel wall 70 and the outer channel wall 72 can define a channel width 50w. The inner channel wall 70 can include an inner channel wall length 70L that extends between the bottom channel wall 74 and a top 76 of the inner channel wall 70. The top 76 of the inner channel wall 70 can be disposed at a top 78 of the peripheral side wall 32. The outer channel wall 72 can include an outer channel wall length 72L that extends from the bottom channel wall 74 to a top 80 of the outer channel wall 72. The outer channel wall length 72L can be shorter than the inner channel wall length 70L. Additionally or alternatively, the top 80 of the outer channel wall 72 can be a lower height, relative to the bottom wall 30 (FIG. 2), than the top 76 of the inner channel wall 70.

The inner channel wall 70 can be vertical or can be angled such that a bottom portion 82 of the inner channel wall 70 angles away from the peripheral side wall 32, which may include the bottom portion 82 being disposed farther from the center of the container 10 than the top 76. In some configurations, the inner channel wall 70 can include a vertical portion and an angled portion.

The outer channel wall 72 can be vertical or can be angled such that a bottom portion 84 of the outer channel wall 72 angles toward the peripheral side wall 32, which may include the bottom portion 84 being disposed closer to the center of the container 10 than the top 80. In some configurations, the outer channel wall 72 can include a vertical portion and an angled portion. Angling of at least some portions of the channel walls 70, 72 can facilitate removal of the tray 12 from a mold during the molding process. Angling of at least some portions of one or both of the channel walls 70, 72 can result in the width 50w of the channel 50 decreasing toward the bottom channel wall 74 such that the width 50w is smallest at the bottom channel wall 74. The channel walls 70, 72 and the resilient members 110, 112 can be angled at the same angles, respectively.

The bottom channel wall 74 can include a planar portion 90, a first curved portion 92, and a second curved portion 94 (e.g., a pair of curved portions). The first curved portion 92 can extend from the planar portion 90 and can be connected to the inner channel wall 70, such as to the bottom portion 82. The second curved portion 94 can extend from an opposite side of the planar portion 90 than the first curved portion 92 and can be connected to the outer channel wall 72, such as to the bottom portion 84. The planar portion 90 can be parallel to the bottom wall 30 (FIG. 2) but can include non-parallel configurations. One or both of the inner channel wall 70 or the outer channel wall 72 can be planar and extend from the respective curved portion 92, 94.

The tray flange 34 can include an outer flange wall 100 that extends (e.g., downward) from the top 80 of the outer channel wall 72 such that at least some of the outer flange wall 100 is spaced from the outer channel wall 72. The outer channel wall 72 and the outer flange wall 100 can be disposed in a U-shaped configuration that opens downward.

Referring to FIG. 4, the protrusion 52 of the cover 14 can include an inner resilient member 110 and an outer resilient member 112. In some examples, the inner resilient member 110, the outer resilient member 112, or both, can be configured as resilient walls. The inner resilient member 110 can extend downward from the top wall 54. The outer resilient member 112 can extend outward and upward from a bottom portion 114 of the inner resilient member 110 such that at least some of the outer resilient member 112 is spaced from the inner resilient member 110. The inner resilient member 110 and the outer resilient member 112 can be disposed in a J-shaped configuration. For example, a length 110L of the inner resilient member 110 can be longer than a length 112L of the outer resilient member 112, the bottom portion 114 of the inner resilient member 110 can be curved, and a bottom portion 116 of the outer resilient member 112 can be curved. The protrusion 52 can include an unflexed configuration, such as generally illustrated in FIG. 4. In the unflexed configuration, the protrusion 52 can include a width 52w that is wider than channel width 50w. For example, in the unflexed configuration, a maximum of the protrusion width 52w may be greater than a maximum of the channel width 50w, a minimum of the protrusion width 52w may be greater than a minimum of the channel width 50w, or both.

The protrusion 52 can include an outer edge 140 that is disposed at a distal end of the outer resilient member 112. The outer resilient member 112 can define an outer resilient member plane 142. The protrusion 52 can include an angled tab 144 at the distal end of the outer resilient member 112 that defines the outer edge 140. The angled tab 144 can extend at an angle, such as an oblique or right angle, relative to the outer resilient member plane 142.

The structural rib 60 can be disposed about a periphery of the cover 14, such as between the cover flange 44 and the inner recessed portion 56. The structural rib 60 can increase a strength of the cover 14. The inner recessed portion 56 may, for example, be used to at least temporarily store one or more items, such as napkins, utensils, or the like. Additionally or alternatively, the inner recessed portion 56 may, when the container 10 is in the closed configuration, receive at least a portion of a second container configured in the same manner as the container 10. For example, the inner recessed portion 56 may receive the bottom wall and a portion of the peripheral side wall of the second container.

Referring to FIG. 5, portions of the container 10 in the closed configuration are generally illustrated. In the closed configuration, the protrusion 52 of the cover 14 is disposed in a flexed configuration at least partially in the channel 50. The protrusion 52 may be inserted at least partially in the channel 50 with an interference fit, which may involve the protrusion 52 transitioning from the unflexed configuration (FIG. 4) to the flexed configuration. In the flexed configuration, at least one of the inner resilient member 110 or the outer resilient member 112 is flexed from its position in the unflexed configuration. For example, the inner resilient member 110 can be flexed outward relative to the center of the container 10, at least to some degree, the outer resilient member 112 can be flexed inward, at least to some degree, or a combination thereof. In the flexed configuration, the inner resilient member 110 can be in contact with and biased against the inner channel wall 70, the outer resilient member 112 can be in contact with and biased against the outer channel wall 72, and the inner resilient member 110 and the outer resilient member 112 can be spaced from and not in contact with the bottom channel wall 74, such that a gap 130 is present between the bottom channel wall 74 and the protrusion 52. For example, the inner resilient member 110 may apply a first biasing force F1 to the inner channel wall 70 and the outer resilient member 112 may apply a second biasing force F2 to the outer channel wall 72. The biasing forces F1, F2 may correspond to the protrusion width 52w being greater than the channel width 50w and the corresponding flexing of at least one of the inner resilient member 110 or the outer resilient member 112 from the unflexed configuration to the flexed configuration resulting from insertion of the protrusion 52 into the channel 50. The first biasing force F1 may be directed inward relative to the center of the container 10. The second biasing force F2 may be directed outward relative to the center of the container 10.

Contact between the protrusion 52 and the channel 50, such as between the inner and outer channel walls 70, 72 and the inner and outer resilient members 110, 112 can provide a sealing interface between at least one of (i) the inner channel wall 70 and the inner resilient member 110, or (ii) the outer channel wall 72 and the outer resilient member 112. For example, in the flexed configuration, the protrusion 52 and the channel 50 can cooperate to provide a liquid seal between the tray 12 and the cover 14.

One or more of the inner channel wall 70, the outer channel wall 72, the inner resilient member 110, or the outer resilient member 112 can include an increased surface roughness relative to other designs. For example, one or more the walls 70, 72 or the resilient members 110, 112 can comprise a paper pulp, which can have increased surface roughness relative to other materials, such as plastics and metals. In some examples, the surface roughness of one or more of the inner channel wall 70, the outer channel wall 72, the inner resilient member 110, or the outer resilient member 112 can be equal to or between 200 and 1020 Sheffield Units, such as equal to or between 800 and 1020 Sheffield Units, but can have other roughness values.

Increased surface roughness can increase a force involved to remove the protrusion 52 from the channel 50, which can limit unintended opening of the container 10, make the container 10 tamper resistant, make the container tamper evident (e.g., attempts to remove the protrusion 52 may damage the protrusion 52, the channel 50, or both), or a combination thereof.

In the closed configuration of the container 10 and with the protrusion 52 in the flexed configuration, the outer edge 140 of the protrusion 52 can be disposed in the channel 50 below the top 80 of the outer channel wall 72. For example, the length 72L of the outer channel wall 72 can be longer than the length 112L of the outer resilient member 112. In some examples, the outer edge 140 can be aligned between 20% and 80% of the outer channel wall length 72L, where the bottom channel wall 74 represents 0% and the top 80 of the outer channel wall 72 represents 100%. Disposing the outer edge 140 below the top 80 can make the outer edge 140 less accessible, which can make the container 10 tamper resistant, tamper evident, or both. For example, it may be challenging for a user to grasp the outer edge 140 in the channel 50, which may make it challenging to remove the protrusion 52 from the channel 50 and improperly open the container 10 without damaging one or both of the protrusion 52 or the channel 50.

Referring to FIG. 6, portions of an example of the container 10 having the hinge 40 are generally illustrated. The hinge 40 can be located at the first side 20 of the container 10. The hinge 40 can comprise a weakened line 160 in the form of a score line, a series of perforations, or a combination thereof, to weaken the hinge 40 such that the hinge 40 can be torn along the weakened line 160 to separate the cover 14 from the tray 12. The weakened line 160 can form a hinge line or hinge axis about which the tray 12 and the cover 14 can relatively rotate to move the container 10 between the opened and closed configurations.

Referring to FIG. 7, the tray 12 can include one or more tray tabs 170 that can extend outward from the tray flange 34, such as from a corner at the intersection of the first side 20 and the third side 24, from a corner at the intersection of the first side 20 and the fourth side 26, or both. The cover 14 can include one or more cover tabs 172 spaced laterally from the tray tabs 170. The tray tabs 170 and cover tabs 172 can be labeled with the words “LIFT” and “HOLD”, respectively, as illustrated, to guide the consumer in opening the container. The cover tabs 170 and tray tabs 172 can be labeled with different words or not be labeled at all.

The tray 12 and the cover 14 can be integrally formed, such as via wet or dry pulp molding. If the container 10 includes a hinge 40, the hinge 40 can be integrally formed with the tray 12, the cover 14, or both. Non-limiting examples of suitable materials for the container 10 include paper pulp, such as from recycled paper. All or a portion of the container 10 can be compostable.

While the cover 14 has a generally rectangular shape and can be thought of as comprising opposing front and rear sides 20, 22 and opposing lateral sides 24, 26, the container 10, including the tray 12 and the cover 14, may have a variety of different shapes, including non-rectilinear shapes, such as circles, ovals, hexagons, etc.

Referring to FIG. 7, to open the container 10, a consumer 180 separates the cover 14 from the tray 12, such as via the hinge 40. The outer edge 140 being disposed or recessed in the channel 50 may limit or prevent access to the outer edge. To separate the cover 14 from the tray 12, the consumer 180 grasps the cover tab 172 and the tray tab 170 and pulls on the cover tab 172 to separate the cover 14 from the tray 12. As the consumer 180 pulls on the cover tab 172, the protrusion is unseated from its location within the channel 50 and the hinge 40 tears along the weakened line 160. In this manner, the recessed position of the outer edge 140, relative to the open top of the channel 50, provides the container 10 with a tamper resistant feature in that the container 10 is not easily opened except in a manner which provides evidence that the container 10 has been opened (e.g., tearing the hinge 40).

In examples with the hinge 40, once the container 10 is completely opened, the tray 12 and cover 14 can be separated along the hinge 40, as illustrated in FIG. 8. The tearing of the hinge 40 provides evidence to a consumer that the container 10 has been opened or that an attempt to open the container 10 has been made. Once the cover 14 has been separated from the tray 12 to gain access to the contents of the container 10, the cover 14 can be replaced on the tray 12 and held in place by the interface between the protrusion 52 and the channel 50. The consumer 180 may apply force to one or more of the recessed portions 56, 58 one or more of which may be labeled with the word “LOCK”, with a different label, or no label. The torn hinge 40 serves as a visual indicator that the container 10 has been opened and provides the container 10 with a tamper evident feature.

The hinge 40 may not extend along the full length of the first side 20 of the container 10 and may extend only along a portion of the first side 20 between the cover tabs 172. The tray tabs 170 can be spaced laterally from both the hinge 40 and cover tabs 172. The length of the hinge 40 and the spacing of the tray tabs 170 from the hinge 40 and cover tabs 172 provides room underneath the cover tabs 172 for the consumer 180 to grasp the cover tab 172, thus making it easier for the consumer 180 to adequately grasp the cover tabs 172 and provide enough force to overcome the peripheral seal between the tray 12 and the cover 14 (e.g., between the protrusion 52 and the channel 50) to separate the tray 12 and cover 14.

While the container 10 is illustrated as having a pair of tray and cover tabs 170 and 172, respectively, on each side of the hinge 40, the container 10 may have other numbers of tabs, such as a single tray tab 170 and a single tray tab 172, more than two tray tabs 170, or more than two cover tabs 172.

The container 10 can include some amount of plastic to modify certain characteristics or can be devoid of plastic.

While the tray 12 is described as including the channel 50 and the cover 14 is described as including the protrusion 52, that configuration can be reversed such that the tray 12 includes the protrusion 52 and the cover 14 includes the channel 50, or a combination thereof (e.g., with the tray 12 and cover 14 each include a portion of the channel 50 and the protrusion 52).

The following clauses define additional aspects of the present disclosure which are encompassed herein. These aspects can be combined as desired to form combinations that are encompassed by the present disclosure.

A pulp-molded container comprising: a tray comprising: a bottom wall; a peripheral side wall extending upwardly from the bottom wall and terminating in a flange that at least partially defines an open top, the flange having a channel defined by spaced inner and outer channel walls connected by a bottom channel wall; and a cover closing the open top in a closed configuration, the cover including a protrusion biased against at least one of the inner channel wall or the outer channel wall and forming a sealing interface between the protrusion and at least one of the inner channel wall or the outer channel wall.

The container of any preceding clause, wherein the inner channel wall includes a surface roughness equal to or between 200 and 1020 Sheffield Units.

The container of any preceding clause wherein the surface roughness is equal to or between 800 and 1020 Sheffield Units.

The container of any preceding clause, wherein, in the closed configuration, the protrusion is in contact with the inner and outer channel walls and is spaced from the bottom channel wall.

The container of any preceding clause, wherein the channel is U-shaped and opens upward; and wherein the protrusion is J-shaped and opens upward.

The container of any preceding clause, wherein a distance between the inner channel wall and the outer channel wall defines a channel width; and in an unflexed configuration of the protrusion, a width of the protrusion is greater than the channel width.

The container of any preceding clause, wherein insertion of the protrusion into the channel flexes the protrusion from the unflexed configuration to a flexed configuration such that the protrusion applies a biasing force against the at least one of the inner channel or the outer channel wall.

The container of any preceding clause, wherein, in a flexed configuration of the protrusion, the protrusion applies an inward force to the inner channel wall and applies an outward force to the outer channel wall, relative to a center of the tray.

The container of any preceding clause, wherein in the flexed configuration, an outer edge of the protrusion is disposed in the channel below a top of the outer channel wall.

The container of any preceding clause, wherein the outer channel wall defines an outer channel wall length between the bottom channel wall and the top of outer channel wall; and in the flexed configuration, the outer edge of the protrusion is aligned between 65% and 75% of the outer channel wall length.

The container of any preceding clause, wherein at least one of the inner channel wall or the outer channel wall is planar.

The container of any preceding clause, wherein the inner channel wall and the outer channel wall are planar, and the bottom channel wall has a planar portion and a pair of curved portions extending from the planar portion and connected to the inner channel wall and the outer channel wall.

The container of any preceding clause, wherein, in the flexed configuration, the protrusion and the channel cooperate to provide a liquid seal between the tray and the cover.

The container of any preceding clause, wherein the outer channel wall is shorter than the inner channel wall.

The container of any preceding clause wherein the protrusion includes an outer resilient member that defines an outer resilient member plane; and the protrusion includes an angled tab defining the outer edge, the angled tab extending at an angle relative to the outer resilient member plane.

The container of any preceding clause, wherein, in the flexed configuration, the protrusion is in contact with the inner channel wall and the outer channel wall and the protrusion is not in contact with the bottom channel wall.

The container of any preceding clause, wherein the inner channel wall is vertical or angled such that a bottom portion of the inner channel wall angles away from the peripheral side wall; and wherein the outer channel wall is vertical or angled such that a bottom portion of the outer channel wall is angled toward the peripheral side wall.

The container of any preceding clause, wherein the flange includes an outer flange wall extending downward from a top of the outer channel wall such that at least some of the outer flange wall is spaced from the outer channel wall; and wherein the outer channel wall and the outer flange wall are disposed in a U-shaped configuration that opens downward.

The container of any preceding clause, wherein the cover has a rectangular configuration, a circular configuration, or an oval-shaped configuration; and the container is devoid of plastic.

The container of any preceding clause, comprising a hinge rotatably connecting the tray with the cover.

The container of any preceding clause, wherein the tray, the cover, and the hinge are integrally formed via pressed paper pulp fibers.

The container of any preceding clause, wherein the channel extends along at least three sides of the tray.

The container of any preceding clause, wherein the tray and the cover are compostable.

The container of any preceding clause, wherein the flange is non-detachably connected to the tray, and the protrusion is non-detachably connected to the cover.

The container of any preceding clause, wherein the cover and the tray have rectangular configurations, circular configurations, or oval-shaped configurations.

To the extent not already described, the different features and structures of the various aspects of the present disclosure may be used in combination with each other as desired. For example, one or more of the features illustrated and/or described with respect to one of the aspects of the present disclosure can be used with or combined with one or more features illustrated and/or described with respect to the other aspects. That one feature may not be illustrated in all aspects of the present disclosure is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different aspects may be mixed and matched as desired to form new aspects, whether or not the new aspects are expressly described.

While aspects of the present disclosure have been specifically described in connection with certain specific aspects thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the present disclosure which is defined in the appended claims.

PULP-MOLDED CONTAINER

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