Pulp bottle with molded interior lining and methods of making same
A container with a shell and lining within its interior is provided. The shell and/or lining can be fabricated from a biodegradable, recyclable, and/or compostable material. The lining can be configured as a parison, a preform, and/or other mass that is capable of being expanded. The lining can be inserted within a cavity of the shell and caused to expand to form an expanded state. The lining, in the expanded state, may be used as a barrier, preventing beverage that is inserted into the container from making contact with the shell. The lining, in the expanded state, may be configured to maintain contact with an inner surface of the shell so as to provide adequate shock absorption. The lining can be a thin film, providing an overall thinner construction and/or an overall lighter construction can be used to fabricate the container.
1 . A method of fabricating a lined molded pulp container, the method comprising:
generating a molded pulp shell, the shell comprising a top opening, a sidewall, and/or a bottom to the shell defining a cavity within the pulp shell;
providing a polymer blank, the blank comprising a neck and an expandable portion;
at least partially inserting the expandable portion of the blank into the shell via the top opening; and
extending the expandable portion of the blank to make contact of an interior of the cavity of the pulp shell by,
heating and softening at least the expandable portion of the blank,
applying positive pressure to at least an interior of the expandable portion of the blank,
concurrently applying vacuum around the pulp shell,
wherein the extended expandable portion of the blank forms a lining of the interior of the cavity of the pulp shell,
adhering the lining to the interior of the cavity of the pulp shell.
2 . The method recited in claim 1 , wherein the molded pulp shell further comprising a shoulder, wherein inserting the expandable portion of the blank comprising of securing at least a portion of a rim of the blank to at least a portion of a shoulder of the shell.
3 . The method recited in claim 1 , wherein extending the expandable portion of the blank is by blow molding.
4 . The method recited in claim 1 , wherein generating the molded pulp shell comprises forming an upper shell, forming a lower shell, and joining the upper and lower shells.
5 . The method recited in claim 1 , wherein generating the molded pulp shell comprises forming the molded pulp shell as a unitary piece.
6 . The method recited in claim 1 , wherein the expandable portion of the blank comprises at least a tube-like piece, which is then expanded.
7 . The method recited in claim 1 , wherein the polymer blank comprises thermal plastic and/or bioplastic or compostable material.
8 . The method recited in claim 1 , wherein the polymer blank comprises high, medium, and/or low density polyethylene, polyethylene terephthalate, polypropylene, and/or polyvinyl chloride.
9 . The method recited in claim 1 , wherein extending the expandable portion of the blank comprising elongating the at least the expandable portion of the blank with a push rod or mandrel.
10 . The method recited in claim 1 , wherein the expanded lining makes contact of substantially the entire interior of the cavity of the pulp shell.
11 . The method recited in claim 1 , further comprising forming at least one aperture in the bottom of the pulp body.
12 . The method recited in claim 1 , wherein adhering the lining to the interior of the cavity of the pulp shell is by heat bonding.