GB2625248A

GB2625248A - Container

Info

Publication number: GB2625248A
Application number: GB2217843.8A
Authority: GB
Inventors: Kindness Andrew
Original assignee: Multi Packaging Solutions UK Ltd
Current assignee: Multi Packaging Solutions UK Ltd
Priority date: 2022-11-28
Filing date: 2022-11-28
Publication date: 2024-06-19
Also published as: WO2024115892A1; GB202217843D0

Abstract

A container 1 made of paper-based or card-based material comprises a sleeve 3 with and a first end and a second end closed by first and second end closures. The first end closure is a moulded pulp end plug 50. The plug includes outwardly-projecting resilient locking tabs 70, each received in a respective recess 140 in the interior of the sleeve to securely retain the plug within the end of the sleeve. The plug is formed from first and second inter-engaging portions 60, 62. The first portion includes the resilient locking tabs, and the second portion fits within the first portion and has sidewalls which engage the interior of sidewalls of the first portion to reinforce the first portion. Preferably the sleeve includes an outer shell 31 and an insert 33 having the recesses.

Description

CONTAINER

TECHNICAL FIELD

The present invention relates to containers made of card-based or paper-based materials, and in particular, although not exclusively, to a container for a bottle.

BACKGROUND

It is desirable, from an environmental and sustainability standpoint, to reduce the amount of plastic material used in packaging. To this end, containers made of cardboard or paperboard may be used. However, challenges exist in providing a container of cardboard or paperboard material that is strong enough to hold a fragile item, such as a bottle. Previous attempts to address this problem have involved the use of plastic materials in providing secure end closures for the container e.g. in providing an end plug and fixing it to the cardboard main body of the container. As well as undesirably increasing a plastic content of the container, the use of plastic materials in this way makes it more difficult for the container to be effectively recycled, since a user must separate the plastics and cardboard material components of the container from one another in order to be able to dispose of them in the appropriate dedicated recycling streams for plastics and card/paper-based materials. If the user fails to separate the materials properly and disposes of the whole container in a waste stream intended for card/paper-based materials, this may lead to contamination of a whole batch of material.

SUMMARY

In accordance with the invention, there is provided a container made of paper-based or card-based material, comprising: a sleeve having a first end and a second end, a first end closure closing the first end of the sleeve, and a second end closure closing the second end of the sleeve; the sleeve comprising a plurality of sidewalls extending between the first end and the second end thereof, wherein a first sidewall of the sleeve comprises an opening therein to provide access to an interior space of the sleeve in which a product is disposed in use; wherein the first end closure comprises a moulded pulp end plug, the moulded pulp end plug comprising resilient locking tabs projecting outwardly therefrom, each locking tab being received in a respective recess in the interior of the sleeve to securely retain the moulded pulp end plug within the first end of the sleeve.

The container is made of card-based or paper-based material, and includes a closure at the first end thereof comprising a moulded pulp end plug. The end plug includes formations, in the form of resilient tabs projecting outwardly therefrom, which engage with respective recesses formed in the interior of the sleeve. In this way, the end plug is securely held in place within the sleeve. The resilient locking tabs are provided by moulded formations of the moulded pulp end plug. The resilient locking tabs are therefore integral with (a portion of) the moulded pulp end plug. Thus, the secure fastening of the moulded pulp end plug to the sleeve is achieved without the need for any plastic fixings. This may provide a more sustainable container, and facilitate recycling, since the end plug need not be removed from the remainder of the container before disposing of the container in a recycling stream for card-based or paper-based materials. The moulded pulp end plug cooperates directly with the sleeve to provide a secure fastening of the end plug to the sleeve.

The locking tabs of the end plug may deflect inwardly as the end plug is inserted into the sleeve through the first end thereof in use springing outwardly once they are aligned with their respective recesses to retain the end plug securely in position. The locking tabs deflect inwardly as they engage the sidewalls of the sleeve in a region between the recesses and the first end of the sleeve.

Each resilient locking tab associated with the moulded pulp end plug may be configured to hook into its corresponding recess. The resilient locking tabs may be referred to as resilient locking "hooks".

Each resilient locking tab associated with the moulded pulp end plug may have a first end edge that cooperates with an edge of the recess to retain the tab in its recess. The edge of the recess is an edge at the first end of the recess i.e. a first end edge thereof. The tab thus extends into the recess. The cooperating edges of the locking tab and recess engage one another to retain the tab in the recess. In this way, the resilient locking tab defines a hook which is inserted into the recess. In embodiments the first end edge of the locking tab is a free end edge thereof. The second end of the locking tab provides a base of the locking tab and is connected to a body of a portion of the end plug (e.g. of a first portion thereof where the end plug comprises first and second portions as described herein). The second end of the locking tab may be connected to a base of the first portion of the end plug. The second end of the locking tab may extend inwardly out of the recess in the sidewall of the sleeve to engage the interior of the sidewall of the sleeve below the recess. By below the recess it is meant a position closer to the second end of the sleeve than the second end edge of the recess. This may assist in obtaining the press fit between the end plug and the sleeve.

However it is configured, the first end edge of a resilient locking tab that cooperates with a first end edge of the recess may engage the edge of the recess between inner and outer ends of the first end edge of the recess such that the resilient locking tab does not extend completely through the recess. The tab then does not extend beyond a plane in which an outermost side of the recess lies. This enables an exterior layer of the container e.g. an outer jacket or outer shell of a sleeve to be located face to face contact with the exterior of the sleeve or a layer thereof having the recess, thereby concealing the tab and recess.

In accordance with the invention in any of its aspects or embodiments each resilient locking tab of the moulded pulp end plug may curve outwardly in a direction from the second end of the tab towards the first end of the tab. The tab may comprise an outwardly curved surface on the exterior thereof extending from a second end of the tab in a direction toward the first end thereof. The curved shape extends over at least a portion of the height of the tab, and optionally over only a portion of the height thereof, from the second end thereof. The curved shape of the tab facilitates insertion of the end plug into the sleeve, and causes the first end edge of the locking tab to be disposed outwardly of the second end of the tab to facilitate hooking of the tab into its corresponding recess. The curved shape may readily be produced using the moulded pulp process. The curved shape will impart the tab with curved inner and outer surfaces. The curved outer surface may cooperate with a corresponding interior sloping surface of the sidewall of the sleeve for guiding insertion of the end plug as described below.

In embodiments each resilient locking tab of the moulded end plug is configured to hook into its corresponding recess in the sleeve, the locking tab having a first end edge that cooperates with a first end edge of the recess to retain the tab in its recess, the resilient locking tab curving outwardly in a direction from a second end of the tab towards the first end of the tab.

The moulded pulp end plug of the first closure may be secured within the first end of the sleeve without the use of adhesive. In embodiments, the moulded pulp end plug is secured to the sleeve without the aid of any external fixing means.

Thus, the moulded pulp end plug is secured to the sleeve without the need for plastic fixings.

The moulded pulp end plug may be secured within the first end of the sleeve by a press fit. The press fit and cooperation of the resilient locking tabs with the recesses securely retain the end plug in place. The moulded pulp end plug may be secured within the first end of the sleeve by press fit and the cooperation of the resilient locking tabs with the recesses and without the use of adhesive. The resilient locking tabs of the end plug clip into the recesses of the sleeve.

The sleeve may be formed of any suitable card-based or paper-based material, such as cardboard or paperboard. The sidewalls of the sleeve are hingedly connected to one another. The sidewalls of the sleeve are connected to one another along foldlines.

The sleeve has a first end and a second end. The container similarly has a first end and a second end. The first and second ends may be referred to as top and bottom (or upper and lower) ends. The container is typically used with the first end uppermost. The sidewalls of the sleeve have a height extending in the direction between the first and second ends of the sleeve, and a width in a direction perpendicular thereto. The width may be the direction perpendicular to the direction of the foldlines connecting adjacent ones of the sidewalls to one another. The sidewalls of the sleeve may be square or rectangular in shape i.e. they may be rectilinear.

The sleeve includes a first sidewall which is the sidewall having the opening therein for providing access to the interior space of the sleeve. The opening permits removal of a product contained in the container in use through the opening.

The container is therefore of a form in which a product located therein is removed through the opening in the first sidewall of the sleeve in use e.g. through a front panel of the sleeve. Thus removal of the product is achieved without removal of the first and second end closures from the first and second ends of the sleeve. The opening extends through the full thickness of the first sidewall to create a hole therethrough. The first sidewall may be the only sidewall of the sleeve having an opening extending through the full thickness thereof The opening in the first sidewall is preferably configured to permit the removal of a product in the form of a bottle, such as a beverage bottle, contained in the container in use therethrough. The bottle may be a glass bottle.

The opening in the first sidewall of the sleeve may, however, be of any suitable configuration depending upon the nature of the product to be disposed in the container. The opening may be of a shape and size to enable the product to be exposed through the opening to facilitate removal of the product through the opening and allowing the user to see the product when the opening is exposed.

The opening may, for example extend over at least 50% or at least 75% of the area of the sidewall. Such arrangements may be particularly suitable where a bottle is located in the container. The opening may be rectilinear in shape. The opening may extend over a substantial portion or all of the area of the product facing the first sidewall.

The sleeve may further comprise a second sidewall opposite the first sidewall, and a pair of opposed third and fourth sidewalls extending between the first and second sidewalls. The third sidewall is hingedly connected to the first sidewall along a foldline on one side thereof and to the second sidewall along a foldline on the other side thereof. The fourth sidewall is connected along foldlines on each side thereof to the first and second sidewalls respectively.

The resilient locking tabs of the moulded pulp end plug may each be of identical construction.

In embodiments the moulded pulp end plug of the first end closure comprises a plurality of sidewalls, each sidewall extending along a corresponding one of the sidewalls of the sleeve, wherein each one of one or more of the sidewalls of the end plug comprises one or more of the resilient locking tabs projecting outwardly therefrom. Each such locking tab is then received in a respective recess in the corresponding sidewall of the sleeve. In embodiments each of a plurality of the sidewalls of the end plug comprises one or more of the resilient locking tabs projecting outwardly therefrom. The plurality of sidewalls of the end plug having said resilient locking tabs may include at least a pair of opposed ones of the sidewalls of the end plug. By providing one or more resilient locking tabs associated with at least a pair of opposed ones of the sidewalls of the moulded pulp end plug, the security of the fixing between the moulded pulp end plug and the sleeve may be enhanced. The plurality of sidewalls of the moulded pulp end plug having said resilient locking tab(s) may further comprises a sidewall connecting the pair of opposed ones of the sidewalls.

It will be appreciated that the sleeve and the moulded pulp end plug may each comprise at least one pair of opposed sidewalls, for example first and second pairs of opposed sidewalls. The sleeve and moulded pulp end plug may each comprise four sidewalls.

In any of the embodiments, the sidewall of the moulded pulp end plug extending along the first sidewall of the sleeve may be free from said resilient locking tabs. This may facilitate insertion of the end plug, and may contribute to an alignment feature controlling the orientation with which the end plug may be inserted into the sleeve. This may also enable the first sidewall of the sleeve to be formed without recesses therein, for example using a single layer construction as discussed below. Using a single layer construction for the first sidewall may avoid the need to register openings in multiple layers to provide the opening of the first sidewall through which a product may be accessed.

In some embodiments the plurality of sidewalls of the moulded pulp end plug having resilient locking tab(s) may include all sidewalls of the end plug other than a sidewall extending along the first sidewall of the sleeve.

For example, the moulded pulp end plug of the first end closure may comprise first, second, third and fourth sidewalls extending respectively along the first, second, third and fourth sidewalls of the sleeve. The sidewalls of the end plug having said resilient locking tabs may include the third and fourth sidewalls, and optionally additionally the second sidewall. In embodiments, the first sidewall of the moulded pulp end plug is free from said resilient locking tabs.

The sidewalls of moulded pulp end plug engage corresponding sidewalls of the sleeve to assist in providing a press fit between the end plug and the interior of the sleeve. The sidewalls of the moulded pulp end plug having the resilient locking tabs provide outermost sidewalls of the end plug which engage sidewalls of the sleeve. In some embodiments as discussed below, the moulded pulp end plug may be of a two piece form, having a second inner portion having its own sidewalls disposed inwardly of such outermost sidewalls of the end plug as a whole.

The resilient locking tabs may be of the same height as the (outermost) sidewalls of the end plug which engage the sidewalls of the sleeve. The first end edges of the resilient locking tabs may provide outwardly bulging segments connecting the first end edges of the sidewall portions on either side thereof. The first end edges of the resilient locking tabs may be of the same height as the first end edges of the sidewall portions on either side thereof.

Each resilient locking tab is connected to portions of the sidewall of the end plug with which it is associated on either side thereof. The locking tab is configured such that it may flex relative to the sidewall in a direction perpendicular thereto toward the interior of the sleeve from an initial state when a force is applied thereto urging the tab inwardly and to recover toward the initial state under its inherent resilience when the force is removed. This enables the tab to deflect inwardly when engaging the interior of the sleeve at the first end thereof on insertion of the end plug into the sleeve to permit the end plug to be slid into the sleeve until the tab is aligned with its corresponding recess of the sleeve and to then spring back outwardly again to enable the tab to be locked into the recess. The first end edge of the tab may engage the first end edge of the recess to lock the tab into the recess. Each resilient locking tab may bulge outwardly from portions of the sidewall of the end plug on either side thereof. The side edges and a second end edge of each tab may each be rounded edges. The rounded edges of the tabs may facilitate smooth insertion of the end plug to a position in which the tabs are locked into their corresponding recesses, and may readily be formed using the pulp moulding process.

The one or more resilient locking tabs associated with each said sidewall of the end plug may be a plurality of resilient locking tabs. Thus, each of the sidewalls of the end plug having resilient locking tabs projecting outwardly therefrom may comprise a plurality of the resilient locking tabs projecting outwardly therefrom. For example, each sidewall of the end plug having resilient locking tabs may comprise a pair of such locking tabs. This may further help to enhance stability of the connection between the end plug and the sleeve. Each sidewall having resilient locking tabs may have two such tabs, or may have more than two locking tabs. The most suitable arrangement will depend upon factors such as the strength of the connection required, and the configuration of the locking tabs and/or recesses with which they engage. For example, the most appropriate number of the locking tabs may vary depending upon the weight and/or shape of the product to be held in the container.

The resilient locking tabs associated with a sidewall of the moulded pulp end plug are discrete locking tabs. Thus they are separate from one another.

The plurality of resilient locking tabs associated with a sidewall of the end plug are spaced from one another along the length of the sidewall. This provides a portion of the sidewall between the tabs which may engage the corresponding sidewall of the sleeve. This may assist in providing the press fit between the end plug and the sleeve. The tabs are similarly spaced from each end of the sidewall of the end plug. This again provides portions of the sidewall adjacent the ends of the sidewall which may engage the corresponding sidewall of the sleeve.

The recess(es) of the sleeve for receiving the resilient locking tabs are on the interior of the sidewalls of the sleeve. Thus they are recesses in the interior surface of the sleeve. The recesses of the sleeve for receiving the resilient locking tabs may be spaced from an edge of the sleeve at the first end thereof. Thus, each recess may comprise a first end edge closest to a first end of the sleeve, a second end edge closest to the second end of the sleeve. Each recess may further comprise a pair of side edges connecting the first and second end edges. The locking tabs deflect inwardly as they engage the sidewalls of the sleeve in a region between the recesses and the first end of the sleeve i.e. above the recesses when the end plug is inserted into the sleeve through the first end thereof. The recesses may be of any suitable shape. In some exemplary embodiments they are square or rectangular.

The moulded pulp end plug may further comprises an alignment feature such that the end plug may only be inserted in the sleeve in a predetermined orientation with respect to the sleeve. It may be important to ensure that the moulded pulp end plug at the first end of the sleeve can only be inserted into the sleeve in a particular orientation to ensure that a product support on a second side of the end plug is appropriately aligned with respect to the first sidewall of the sleeve having the opening therein to permit access to the product and allow the product to be removed from the sleeve through the opening in the first sidewall. For example, where the product support of the end plug comprises a moulded pulp collar, the open end of the collar is aligned so as to face the first sidewall of the sleeve to enable the product to be removed from the interior of the sleeve through the opening in the first sidewall. Otherwise, the product may become trapped in the sleeve. Where provided, such a collar may be sized and configured as appropriate to suit the product to be contained e.g. to receive the top of a bottle to be contained in the container. In embodiments, the moulded pulp end plug of the first end closure comprises a product support comprising a collar on a second side thereof, and the predetermined orientation is an orientation in which an open end of the collar faces the first sidewall of the sleeve to enable a product to be removed from the interior of the sleeve through the opening in the first sidewall. The product support e.g. collar is integrally moulded with a portion of the end plug. Thus it is a moulded pulp product support e.g. collar. The collar may be configured to receive the top of a bottle disposed in the container in use.

The use of an alignment feature enables assembly of the container reliably in an automated manner e.g. using a robot, ensuring that the first end plug is fitted in an orientation which will subsequently permit removal of the product through the opening in the first sidewall of the sleeve i.e. through a front of the sleeve in use.

During assembly, a product e.g. bottle may be inserted in the container (i.e. in the sleeve), and the first end closure then inserted into the first end of the sleeve to close the first end of the container. The predetermined orientation is a rotational orientation with respect to a longitudinal axis of the container. The alignment feature may also prevent insertion of the first end plug in an inverted condition.

An alignment feature may be provided in various ways. The alignment feature may include one or more measures that require the moulded pulp end plug to be inserted in a particular orientation. In some embodiments the moulded pulp end plug comprises one or more resilient alignment tabs projecting outwardly therefrom, each resilient alignment tab being received in a respective additional recess in the interior of the sleeve, the one or more resilient alignment tabs providing an alignment feature such that the end plug may only be inserted in the sleeve in the predetermined orientation. The additional recess(es) for receiving alignment tabs may be referred to as alignment recess(es). The resilient alignment tabs are, like the resilient locking tabs, provided by moulded formations of the end plug. The resilient alignment tabs are therefore integral with (a portion of) the moulded pulp end plug. The resilient alignment tabs are discrete tabs.

In embodiments one of the sidewalls of the moulded pulp end plug of the first end closure having one or more resilient locking tabs further comprises one or more resilient alignment tabs, and the corresponding sidewall of the sleeve comprises one or more additional recesses for receiving respective ones of the one or more resilient alignment tabs, the one or more resilient alignment tabs providing an alignment feature such that the end plug may only be inserted in the sleeve in a predetermined orientation (with respect to the sleeve). Such resilient alignment tab(s) may be associated with only one of the sidewalls of the end plug, for example the second sidewall thereof. The one or more resilient alignment tabs may comprise a plurality of such tabs, such as two tabs. Using multiple alignment tabs may enhance the ease with which the end plug can be aligned relative to the sleeve, but a single alignment tab would provide the required effect.

In some embodiments a pair of resilient alignment tabs is provided associated with the sidewall of the end plug, the alignment tabs being located outboard of the one or more resilient locking tabs associated with the sidewall. By "outboard", it is meant that the resilient alignment tabs are located closer to the ends of the sidewall (where it adjoins the adjacent sidewalls). The alignment tabs may be disposed one at each end of the sidewall with the locking tabs therebetween.

In embodiments, each recess for receiving a resilient locking tab is spaced from an edge at the first end of the sleeve, and each additional recess for receiving a respective resilient alignment tab extends to the edge at the first end of the sleeve. This may ensure that the end plug may only be slid relative to the sleeve in a direction toward the second end thereof to insert the end plug in the first end of the sleeve when each resilient alignment tab is aligned with a corresponding alignment recess of the sleeve. Otherwise the bottom of an alignment tab will abut the edge at the first end of the sleeve preventing insertion of the first end plug into the first end of the sleeve. In embodiments the one or more recesses for receiving the one or more resilient locking tabs are spaced from a first end edge of the sleeve, and the one or more recesses for receiving the one or more resilient alignment tabs extend to the first end edge of the sleeve. -10-

The resilient alignment tabs may be of different construction to the resilient locking tabs. For example, they may differ in shape and/or size. In embodiments the resilient alignment tabs are smaller than the resilient locking tabs.

The resilient locking tab(s) (and resilient alignment tabs where provided) associated with a sidewall of the moulded pulp end plug are located along the length of the sidewall and form projections relative to portions of the sidewall on either side thereof. The sidewalls of the moulded pulp end plug are continuous, with the locking (and, where applicable, alignment) tabs being defined by projecting portions of the sidewalls.

It will be appreciated that an alignment feature may alternatively or additionally comprise other measure(s) than the provision of one or more resilient alignment tabs as exemplified above. For example, whether or not alignment tabs are provided, the interior of the first end of the sleeve and the exterior of the moulded pulp end plug of the first end closure may be provided with corresponding angled surfaces which must be aligned with one another in order to permit insertion of the end plug into the first end of the sleeve.

The recesses of the sleeve with which the resilient locking tabs cooperate may be provided in any suitable manner. The recesses are provided in the interior surface of the sleeve. In embodiments, the recesses do not extend to an exterior surface of the container. This may provide a more attractive appearance. A continuous outer surface of the container may be provided, which may be e.g. printed etc with appropriate decoration e.g. branding. While in exemplary embodiments the recesses do not extend through the full thickness of the sleeve, this need not be the case, for example where the sleeve is covered by another outer component, such as a jacket, this may conceal the recesses in the sleeve.

The recesses might then be in the form of slots extending through the full thickness of the sleeve.

In embodiments the recesses do not extend through the full thickness of the sidewalls of the sleeve. For example, they may be cut into the sidewalls of the sleeve. The recesses may then be provided by notches extending through only a portion of the thickness of the sidewalls of the sleeve. The sleeve may then be of a single layer construction. Alternatively the recesses may be covered on the exterior thereof by one or more outer layers of the sleeve. For example, the recesses may be covered by an outer layer of the sleeve with the recesses being provided by slots in an inner layer thereof. The recesses may further be covered by one or more outer layers of container, such as a jacket thereof.

Where the end plug further comprises one or more resilient alignment tabs and the sleeve further comprises one or more additional recesses for cooperating therewith, such additional recesses may be provided in the same manner as the recesses for cooperating with the resilient locking tabs. Thus the recesses of the sleeve for cooperating with the resilient locking tabs, and optionally, where the end plug comprises one or more resilient alignment tabs, the recesses for cooperating with the one or more resilient alignment tabs, may be provided in any of the manners discussed in relation to the locking tabs. The difference is that the additional recess(es) may extend beyond the recesses for receiving locking tabs toward the first end edge of the sleeve.

In embodiments each sidewall of the sleeve having one or more recesses for receiving resilient locking tabs of the moulded pulp end plug of the first end closure comprises inner and outer layers at least in the region of the first end of the sleeve, wherein each recess is provided by a slot extending through the inner layer of the sidewall, and the outer layer of the sidewall covers the slot. In these embodiments, the slot extends through the full thickness of the inner layer of the sidewall. This provides a hole extending therethrough from the interior to the exterior of the inner layer of the sidewall. The sidewalls of the sleeve having the recesses may be two layered sidewalls i.e. consisting of the inner and outer layers. In embodiments in which one of the sidewalls of the moulded pulp end plug further comprises one or more resilient alignment tabs, each additional recess in a sidewall of the sleeve for receiving a respective one of the one or more resilient alignment tabs is provided by a slot extending through the inner layer of the sidewall, and the outer layer of the sidewall covers the slot. The slots may also be covered by any outer layers of the container, such as a jacket thereof.

The inner layer of the sleeve having the recesses may be provided by any suitable internal layer of the sleeve, such as an internal fitment thereof.

In embodiments the sleeve comprises an insert and an outer shell, each comprising a plurality of panels hingedly connected to one another, wherein the slots at provided in panels of the insert and are covered by panels of the outer shell. Each panel of the insert is covered by a respective panel of the outer shell. Panels of the insert face and are secured to respective ones of the panels of the -12-outer shell. The slots for providing the recesses for cooperating with the locking tabs are provided in this way. Where applicable, additional recesses for cooperating with alignment tab(s) may also be provided in this way.

The slots providing the recesses of the sleeve for receiving the resilient locking tabs are spaced from the first end edge of the insert. Thus, each slot comprises a first end edge closest to a first end of the insert and a second end edge closest to the second end of the insert. A pair of side edges may connect the first and second end edges. In embodiments in which one or more additional recesses for receiving resilient alignment tabs are provided, the additional recess(es) for receiving the resilient alignment tab(s) extend to the first end edge of the insert. The additional recesses interrupt the first end edge of the insert. The first end edge of the insert may therefore provide an edge which cooperates with the alignment tabs to prevent insertion of the moulded pulp end plug other than in a predetermined orientation in which the alignment tabs are aligned with the first ends of the alignment recesses.

The sleeve may consist of the insert and outer shell. The sidewalls of the sleeve then comprise no more than two layers, provided by panels of the insert and outer shell. The first sidewall is then of a single layer construction, and the other sidewalls of the sleeve of a two layer construction.

The insert and outer shell are each of card-based or paper-based material, such as cardboard or paperboard. Opposed faces of panels of the insert and outer shell may be bonded to one another, such as adhesively.

The insert and the outer shell may each be of a single piece construction. Each may be provided from a single piece blank. This may facilitate assembly.

The panels of the insert may or may not extend over the full height of the panels of the outer shell. The insert may be provided just where it is needed i.e. in the region of the first end of the sleeve, or extend over a greater extent of the area of the sleeve. The insert may act to reinforce the shell, and it may therefore be advantageous for it to extend over a greater extent of the shell. The outer shell defines the shape of the sleeve. The extent of the panels of the insert may be chosen based on the degree of stability required of the container. In embodiments at least one of the panels of the insert extends over substantially the full height of a corresponding panel of the outer shell. This may provide stability and also facilitate location of the insert in the outer shell i.e. the insert may be inserted until the full -13 -height panel(s) thereof reaches the bottom of the outer shell. The first end edges of the insert and outer shell may be aligned with one another.

In some embodiments the first sidewall of the sleeve is provided by a panel of the outer shell which defines an opening, and which is not lined by a panel of the insert. The first sidewall of the sleeve is then of a single layer construction. In some embodiments the insert includes only first, second and third panels covered respectively by first, second and third panels of the outer shell. The outer shell further comprises a fourth panel connecting the first and third panels thereof which provides the first sidewall of the sleeve, and including an opening therethrough for providing the opening of the sleeve. Of course, the first sidewall of the sleeve could alternatively be of a multi-layer construction, provided that each layer includes a corresponding opening to result in an opening through the first sidewall of the sleeve. However, the use of a single layer first sidewall may avoid the need to register multiple components having apertures.

In accordance with the invention in any of its embodiments, a first end edge of the sleeve may be spaced from a first end edge of the container. This may enable the first end edge of the sleeve to cooperate with a portion of the moulded pulp first end plug (e.g. a flange thereof) to provide an end stop when the end plug is inserted through the first end of the sleeve. A portion of the end plug e.g. a flange thereof may be located in the space between the first end edge of the sleeve and first end edge of the container. The space may be such that the first end closure is flush with the first end edge of the container when fully inserted in the sleeve with the portion e.g. flange thereof abutting the first end edge of the sleeve. In these embodiments the container comprises an outer component disposed outwardly of the sleeve which defines the first end edge of the container. The outer component may be an outer jacket, for example. The use of an outer jacket may be preferred in providing a uniform and neater outer appearance to the container. A cover of the first end closure (i.e. a cover of the moulded pulp end plug) may be flush with the first end edge of the jacket.

In accordance with the invention in any of its embodiments, the container may further comprise an outer jacket defining the first and second end edges of the container. The outer jacket is disposed outwardly of the sleeve.

The interior of the sleeve may be provided with guide means to guide the moulded pulp end plug of the first end closure as it is inserted into the sleeve during -14-assembly of the container. For example, at least some of the sidewalls of the sleeve may comprise internal sloping surfaces at the first ends thereof for guiding the moulded pulp end plug as it is inserted into the container. Where the sleeve comprises an insert and outer shell, at least some, and optionally each, of the panels of the insert may comprise an internal sloping surface at the first end thereof. Each internal sloping surface associated with a sidewall of the sleeve extends in a direction toward the interior of the container with distance from the first end of the sleeve. Each internal sloping surface associated with a sidewall of the sleeve define an angle of less than 90 degrees with respect to a plane defined by the interior surface of the sidewall of the sleeve in the region below the sloping surface. The region below the sloping surface is a non-sloping. Each internal sloping surface may be a planar surface.

In embodiments the sloping surfaces are associated with those sidewalls of the sleeve having recesses for cooperating with resilient locking tabs of the first end plug. One or more of the sidewalls of the sleeve may thus comprise such sloping surfaces. The first sidewall of the sleeve may be free from such sloping surfaces. The internal sloping surface associated with a sidewall is located between the first end edge of the sidewall and the one or more recesses of the sidewall. The internal sloping surface may extend over the full width of the sidewall. The sloping surfaces provide ramps along which the resilient locking tabs slide as the moulded pulp end plug is inserted into the first end of the sleeve, urging the resilient locking tabs inwardly with distance from the first end edge of the sleeve to enable them to enter the recesses in the sleeve.

Each resilient locking tab of the moulded end plug may comprise an outwardly curved surface on the exterior thereof which cooperates with a respective one of the internal sloping surfaces of the sleeve to cause the locking tab to be deflected inwardly as the end plug is inserted into the first end of the sleeve. The curved surface of a resilient locking tab extends outwardly with distance from the second end of the tab toward the first end thereof. The curved surface extends from a second end of the locking tab. The curved surface extends over at least a portion of the height of the tab, and optionally over only a portion of the height thereof, from the second end thereof. Each one of the resilient locking tabs associated with a given sidewall of the end plug will cooperate with the same sloping surface extending along the sidewall of the sleeve having the recesses with -15 -which the tabs cooperate. The curved outer surface of a locking tab may be provided as a result of an outwardly curved shape of the tab which imparts it with curved inner and outer surfaces.

The moulded pulp end plug of the first end closure at the first end of the sleeve preferably comprises first and second inter-engaging portions, wherein the first portion provides sidewalls and the one or more resilient locking tabs of the moulded pulp end plug, and wherein the second portion fits within the first portion. The moulded pulp end plug comprises sidewalls, each sidewall extending along a corresponding one of the sidewalls of the sleeve, wherein each of one or more of the sidewalls of the end plug comprises one or more of said resilient locking tabs projecting outwardly therefrom. The first portion provides the sidewalls and resilient locking tabs of the end plug.

The sidewalls of the second portion engage the interior of the sidewalls of the first portion. The first and second portions are separate parts. Each of the first and second portions is of a moulded pulp construction. The first and second portions are separately formed i.e. moulded from one another. Thus the first and second portions are separately formed and attached to one another. The first portion has the resilient locking, and, where applicable, alignment tabs. The first portion defines the sidewalls of the moulded pulp end plug which extend along corresponding ones of the sidewalls of the sleeve. The sidewalls of the first portion engage the interior of the sidewalls of the sleeve. Each portion may be produced using a pulp wet moulding process The first portion may define a base plane, the sidewalls of the first portion being upstanding therefrom. The base plane is defined by a base of the first portion. The sidewalls extend from the base plane in a direction toward the first end of the container. The resilient locking tabs are also upstanding from the base plane of the first portion. The base or second end of each resilient locking tab is connected to the base of the first portion.

In some embodiments the moulded pulp end plug is a two piece end plug i.e. having only the first and second moulded pulp portions described herein.

The moulded pulp end plug may consist i.e. be formed entirely from moulded pulp material.

A moulded pulp end plug having first and second separately formed portions as described herein may be advantageous in providing a more secure fit to the -16-sleeve without the use of adhesive or other fixing means. The second portion may assist in reinforcing the first portion, ensuring that the resilient locking tabs remain engaged in the recesses of the sleeve in use. The second portion may also assist in ensuring the sidewalls of the first portion remain engaged with the sidewalls of the sleeve to maintain the end plug in place through a press fit connection. The second portion may inhibit flexing and other movement of the first portion which may otherwise occur in use, and which might risk disengagement of the first portion from the sleeve. The first portion may have a tendency to distort under the actions of forces encountered in use e.g. during shipping or storage of the container as a result of its moulded pulp construction. Such a material is inherently resilient. The provision of the second portion is therefore particularly advantageous in the context of providing a reliable end plug of a moulded pulp construction. The second portion may also help to reinforce the first portion to ensure that the first portion may reliably support a product e.g. via a product support on the second side thereof.

The use of multi-piece construction for the end plug is also advantageous in facilitating moulding of features of the end plug from the pulp material, and avoiding problems which might otherwise be encountered if attempting to mould such features in a single piece end plug. Certain features may be difficult to mould in the pulp material. For example, typically the end plug may be produced using a wet moulding process. Certain features may be incompatible with such a process and/or may interfere with the ability to remove the part from a mould, at least without the potential for damage to the part. This includes so-called "undercut" features, or indeed other features having shapes which might tend to catch on the mould when it is attempted to remove the moulded part from the mould and/or which may not readily be moulded using a pulp moulding process. For example, it may be difficult to mould features which result in cavities being present in the shaped component. Such problems are exacerbated in the context of moulding pulp, in comparison to moulding plastic e.g. using an injection moulding process.

For example, when moulding plastic it may be possible to use more complex tools that open to allow release of parts.

When moulding a single piece end plug including resilient locking tabs it may be necessary to carefully design the shape of the end plug and the mould to avoid such complications. For example, it may be necessary to compromise on the -17-shape of features of the end plug in the region of the resilient locking tabs in order to avoid creating regions which are difficult to mould if a single piece end plug is to be used.

In contrast, by using a two piece construction, it has been found that it is possible to readily mould desired features without detriment to the ability to remove the end plug from the mould and in a manner which is consistent with the process used to mould the pulp material e.g. a wet moulding process. This may be achieved by designing the first and second portions in a manner such that when fitted together, formations of a desired shape are produced. However, each portion may be designed such that it may be moulded using the applicable moulding process e.g. wet moulding process without complication. The moulds for each of the first and second portions may be appropriately designed with regard to the formations they include, to enable those portions to be readily released from the mould, without risk of damage to any features of the pieces, and in a manner compatible with the moulding process to be used e.g. wet moulding. For example, the portions may be wet moulded using a simple male/female down/up type process in which, for each portion, a mould having a moulding surface shaped to provide the portion is dipped into a slurry of pulp to cause pulp material to be deposited on the moulding surface to provide a three-dimensional preform of pulp material having the intended shape of the portion of the end plug.

When the portions of the moulded pulp end plug are fitted together subsequently, it is possible to create formations in the combined structure which would not have been possible in a single piece moulding process. This may include undercut portions, other features having a shape which might otherwise catch on a mould such as overhanging features, and/or features which result in cavities within the piece. It has been found that this is particularly helpful in providing an end plug of a desired configuration in the region of the resilient locking tabs, which may interact with other formations in the vicinity thereof to create such regions which would otherwise be difficult or impossible to mould from pulp in a single piece. The increased ease of moulding provided by the multi-piece construction thus provides greater freedom in designing the formations associated with the resulting end plug, allowing features of the combined end plug structure to be optimised for a given application, but still be readily formed from features moulded into the respective separately formed portions of the end plug. For example, this may enable the -18-shape of the overall end plug to be designed in a manner to optimise desired properties e.g. strength of connection to the sleeve, ability to support the product e.g. grip the top of a bottle, without needing to compromise such properties as a result of moulding difficulties.

However, it is not essential that the moulded pulp end plug of the first end closure comprises multiple moulded pulp parts in this manner. A single piece moulded pulp end plug may alternatively be used. The resilient tabs may still provide a strong connection to the sleeve. The shape of the end plug may be chosen appropriately to allow moulding using the applicable process e.g. a wet moulding process. The choice of whether to use a single or two piece construction will depend upon the particular requirements of the container e.g. based on the intended contents, expected use conditions, desired strength of closure, any applicable regulations etc, and the intended shape of the end plug. A single piece construction may provide a simpler end closure that facilitates assembly, and is advantageous in providing a cost effective sustainable container of simple construction. However, the two part construction may provide a particularly strong first end closure where this is of importance, e.g. for a particular intended use of the container, and/or wherein the container is required to pass certain tests to guarantee the strength of the end closure. For example, it has been found that the two piece first end plug may remain securely in place even when a 10Kg weight is inserted in the container and it is shaken upside down, as may be required under certain strength test regimes. Such arrangements may provide a strength of a similar level to closures using inter-engaging plastic parts. The two part construction may facilitate moulding, and provide greater freedom in design of the parts of the end plug, allowing the features of the resulting combined end plug structure to be optimised as discussed above, for example to provide a particular level of strength required for a given context. In either case, the moulded pulp construction provides a lightweight, sustainable end closure.

Where the moulded pulp end plug comprises a single portion, that portion may have any of the features described herein in relation to the first portion of the end plug e.g. for securing the end plug to the sleeve, facilitating insertion of the end plug into the sleeve or attachment to a cover, but those features of the first portion which provide an inter-engagement with a second portion of the end plug will not be necessary. -19-

Where the moulded pulp end plug comprises first and second portions, the first portion is located closest to the second end of the sleeve. Thus the first and second portions may be referred to as lower and upper portions respectively.

The second portion of the end plug may extend beyond the first portion of the end plug on the first side thereof toward the first end of the container (i.e. it may extend beyond the first portion of the end plug in the height direction). This may allow the second portion to provide a spacer function, holding the first portion, and its resilient locking tabs at an appropriate depth in the first end of the container to enable the locking tabs to be retained in the recesses of the sleeve.

The second portion of the moulded pulp end plug comprises sidewalls disposed inwardly of the sidewalls of the first portion of the end plug, wherein the sidewalls of the second portion engage the sidewalls of the first portion. This may help to reinforce the sidewalls of the first portion, and help reduce the risk of flexing of the resilient locking tabs once inserted in their recesses in use, and hence reduce the risk of the end plug becoming disengaged from the sleeve. This may also enhance the effectiveness of the ability of the first portion to provide support to a product. The sidewalls of the second portion engage the sidewalls of the first portion at locations other than the locations of the resilient locking tabs. The sidewalls of the first portion are disposed outwardly of the sidewalls of the second portion and provide the sidewalls of the end plug as referred to herein. Thus, the sidewalls of the end plug are the outermost sidewalls thereof Each sidewall of the second portion which engages a sidewall of the first portion having one or more resilient locking tabs projecting therefrom engages the sidewall of the first portion in regions other than at the position of each of the one or more resilient locking tabs associated therewith. The resilient locking tabs thus interrupt the engagement between the sidewalls of the first and second portions. Any resilient alignment tab present may similarly interrupt the engagement between the sidewalls.

In embodiments the sidewalls of the second portion comprise recesses in positions corresponding to the positions of the resilient locking tabs associated with the sidewalls of the first portion of the moulded pulp end plug. A recess located in a position corresponding to the position of a resilient locking tab refers to the recess being in a position such that it faces the interior of the resilient locking tab. The recess facilitates inward flexing of the resilient locking tab during insertion of the -20 -end plug into the first end of the sleeve. Such recesses may enable the resilient locking tabs to more easily deflect inwardly when the end plug is inserted into the sleeve during assembly through the first end thereof. Thus, such recesses may facilitate assembly of the container, for example enabling assembly to be achieved using a robot with the end plug being inserted through the first end of the sleeve in a direction toward the second end. The recesses extend in the direction toward the interior of the container.

Each recess is defined by the applicable sidewall of the second portion. The recess if provided by a recess portion of the sidewall. Each recess associated with a sidewall of the second portion extends inwardly relative to regions of the sidewall on either side thereof (which regions of the sidewall engage the interior of a sidewall of the first portion of the end plug). Recesses in the sidewall of the second portion need not be provided for resilient alignment tabs (if provided). The sidewalls of the second portion are continuous, with the recesses being defined by recessed regions of the sidewalls. The recesses do not create openings in the sidewall. One recess is provided in respect of each resilient locking tab. The recesses may extend over the full height of the sidewalls with which they are associated.

A recess in a sidewall of the second portion at a position corresponding to that of a resilient locking tab of the first portion spaces the sidewall of the second portion from the inner surface of the locking tab to result in a cavity being defined between the outer surface of the sidewall of the second portion and the inner surface of the resilient locking tab. The separate formation of the first and second portions facilitates providing such a cavity. The cavity extends inward relative to unrecessed portions of the sidewall of the second portion on either side of the recess in the sidewall of the second portion. As mentioned above, the resilient locking tabs may have an outwardly curved shape. An outer edge of the cavity may then have a corresponding curved shape following the curved inner surface of the locking tab.

In embodiments each recess in a sidewall of the second portion at a position corresponding to that of a resilient locking tab of the first portion spaces the sidewall of the second portion from the inner surface of the locking tab to result in a cavity being defined between the outer surface of the sidewall of the second portion and the inner surface of the resilient locking tab, the separate formation of the first -21 -and second portions facilitating providing such a cavity. This cavity in the end plug may form part of a larger cavity extending in the direction of the first end of the container as discussed below.

It has been recognised that when the first and second portions are combined, the presence of such recesses in the sidewalls of the second portion in the region of the resilient locking tabs may create a shape which could not readily be moulded in a single piece. This is because the recesses create cavities in the structure between the sidewalls of the second portion and the interior of the resilient locking tabs. Such cavities may interfere from the ability to remove a moulded structure from a mould if it is attempted to mould it in a single piece and may be difficult or indeed impossible to mould using typical pulp moulding processes e.g. wet moulding. This problem is exacerbated where the resilient locking tabs have an outwardly curved shape. By providing the recesses and locking tabs on separately moulded first and second portions of the end plug, such a problem is avoided.

Each sidewall of the second portion which engages a sidewall of the first portion having one or more resilient locking tabs projecting therefrom may comprise a plurality of spaced apart first regions along the length of the wall which engage the sidewall of the first portion, each adjacent pair of first regions being separated by a second region in which the sidewall of the second portion does not engage the sidewall of the first portion, the second region being defined by a recess in the sidewall of the second portion corresponding to the position of a resilient locking tab of the sidewall of the first portion.

Each sidewall of the second portion which engages a sidewall of the first portion having one or more resilient locking tabs projecting therefrom may comprise alternating first and second regions along the length thereof, each first region engaging the sidewall of the first portion, and each second region defining a recess in the sidewall in a position corresponding to a position of a resilient locking tab of the sidewall of the first portion. The second regions are recessed relative to the first regions. Each second region is recessed relative to the first regions on either side thereof. Where the sidewall of the first portion has a plurality of resilient locking tabs a plurality of first and a plurality of second regions of the sidewall of the second portion are defined. Where the sidewall of the first portion has a single resilient locking tab, a plurality of first regions and a single second region of the sidewall of the second portion are defined.

-22 -In embodiments the recesses of the sleeve for receiving the resilient locking tabs are spaced from a first end edge of the sleeve, and the sidewalls of the second portion of the moulded pulp end plug have a height greater than that of the sidewalls of the first portion of the moulded pulp end plug so as to space the resilient locking tabs of the first portion from the first end edge of the sleeve to enable the locking tabs to be received in the recesses.

The second portion of the moulded pulp end plug may comprise a flange at a first end thereof, the sidewalls of the second portion being upstanding therefrom. The flange may cooperate with the sleeve to locate the moulded pulp end plug.

The sidewalls of the second portion extend in a direction toward the second end of the container relative to the flange. The flange may define a base plane of the second portion. The flange may assist in locating the moulded pulp end plug during insertion as described below and may also cooperate with the first end of the sleeve to maintain the end plug in position with the resilient tabs engaged in the recesses of the sleeve in use. The flange may also provide a suitable planar top surface to which a cover of the end plug may be bonded e.g. to provide a desired decorative appearance to the top of the container, concealing the moulded pulp end plug.

In some embodiments in which the second portion comprises a flange, a second side of the flange may engage the end edges of the sidewalls of the sleeve at the first end of the sleeve to locate the moulded pulp end plug. In this way, the flange and end edges of the sidewalls of the sleeve at the first end thereof cooperate to provide an end stop during insertion of the first end plug. The flange of the second portion of the end plug may extend between a first end edge of the container and the first end edge of the sleeve. The first end edge of the container may be defined by an outer jacket of the container and/or by the first end edge of the first end closure, such as a cover thereof. Where a cover is provided for the end plug, at least a portion of the cover may be located in such a region between a first end edge of the container and the first end edge of the sleeve. This may enable the first end closure to provide a flush fit with the first end of the container.

Where the sleeve comprises an insert an outer shell, a second side of the flange may engage the first end edges of the insert and outer shell of the sleeve at the first end of the sleeve.

When the second portion of the end plug is fully inserted into the first portion thereof, the second end of the sidewalls of the second portion may engage the first -23 -side of a base of the first portion. Such a fully inserted position may correspond to a portion in which a flange of the second portion engages the first end edges of the sidewalls of the sleeve.

Regardless of the construction of the flange and how it interrelates with the sleeve, in embodiments the recesses of the sleeve for receiving the resilient locking tabs are spaced from a first end edge of the sleeve, and the sidewalls of the second portion of the moulded pulp end plug have a height greater than that of the sidewalls of the first portion of the moulded pulp end plug so as to space the resilient locking tabs of the first portion from the first end edge of the sleeve to enable the locking tabs to be received in the recesses, and the flange is spaced from and overhangs the first end edges of the resilient locking tabs of the first portion. The flange may extend outwardly beyond the resilient locking tabs. Such an overhanging construction is again advantageously moulded using the multi-piece construction described herein of the end plug, since it may create a cavity within the structure of the end plug that would be difficult, or impossible to mould in a single piece from pulp material.

A cavity may be defined in the end plug in the region of each resilient locking tab, the cavity bounded on its inner side by the outer surface of the sidewall of the second portion, on the side closest to the first end of the container by a second side of the flange and on the outer side over a portion of the height of the cavity closer to the second end of the container by the inner surface of the resilient locking tab, and, on the outer side over a portion of the height of the cavity closer to the first end of the container, by the inner surface of the sleeve in a region between the first end edge of the recess of the sleeve and the second side of the flange.

The separate formation of the first and second portions facilitates providing the cavity. An opening in the structure of the end plug into the cavity is thus provided by a space defined between the second side of the flange and the first end edge of the resilient locking tab. Thus, in the structure of the end plug, the cavity is unbounded on its outer side over a portion of its height between the flange and the first end edge of the resilient locking tab. In the container this portion of the cavity is closed by the inner surface of the sleeve between in the region between the first end edge of the recess of the sleeve and the second side of the flange. The multi-piece formation of the end plug facilitates obtaining such a cavity, which is located between formations of the end plug and is overhung by the flange. It would not be -24 -possible to make such a shape using a single piece moulded pulp construction. This particular construction has been found to be particularly effective in enabling the tabs to function reliably while securely retaining the end plug in place in the first end of the sleeve, and facilitating insertion e.g. enabling robot construction.

The cavity may be bounded on a side closest to the second end of the container by a base of the first portion.

Where the sidewalls of the second portion comprise recesses in positions corresponding to the positions of the resilient locking tabs associated with the sidewalls of the first portion of the moulded pulp end plug, the cavity is bounded on its inner side by the outer surface of the recessed portion of the sidewall of the second portion. The cavity discussed above defined in the end plug between the sidewall of the second portion in the region of a recess thereof and a resilient locking tab forms part of this larger cavity extending up to the flange.

The first and second portions of the moulded pulp end plug are press fitted together. The first and second portions are mafingly engaged. The first and second portions may be attached to one another with or without the use of adhesive. In some embodiments the first and second portions may be secured to one another by press fit alone. The first and second portions are then attached to one another without the use of adhesive. The first and second portions may be attached to one another without the use of any external bonding material or other fixings. In other embodiments the first and second portions are adhesively bonded to one another in addition to being press fitted to one another.

The first and second portions are each of a moulded pulp construction. Each portion comprises formations defining a pattern of recesses and projections on each side thereof, the formations on one side being the reverse of those on the opposite side. The formations are imparted during the moulding process. Each one of the first and second portions is of a single piece construction. Each is defined by a single shell of moulded pulp material. Each may be of a single layer construction.

The corners at which the sidewalls of the first portion are joined to one another may be rounded to facilitate insertion of the end plug into the first end of the sleeve.

-25 -The first and second portions may include any suitable complementary formations which cooperate with one another to provide an appropriate inter-engagement of the first and second portions.

The first portion defines a first side and an opposite second side, the second side of the first portion facing the second end of the sleeve. The second side may comprise a product support. In embodiments the second side comprises one or more formations for supporting the top of a product, such as a bottle, when located in the container. The first and second sides are located respectively closer to the first and second ends of the sleeve. The second side may comprise one or more projections defining a collar for receiving the top of a product in the form of a bottle, wherein the open end of the collar faces the first sidewall of the sleeve. This enables the bottle to be removed with ease through the opening in the first sidewall, with the first and second end closures remaining in place. The collar may be defined by a single projection on the second side of the first portion of the end plug.

The collar may be C-shaped. Thus, the collar may be defined by a single C-shaped projection.

The one or formations for supporting the top of a product may extend in a direction opposite to that of the sidewalls of the first portion relative to a base plane thereof The one or more formations for supporting the top of the product extend toward the second end of the container.

The second portion defines a first side and an opposite second side, the second side of the first portion facing the second end of the sleeve. The first and second sides are located respectively closer to the first and second ends of the sleeve. The second side of the second portion may comprise one or more projections for supporting the collar, each being received in respective recess defined on the first side of the first portion by the reverse of the one or more projections defining the collar. Where the collar is defined by a single projection, the one or more projections on the second side of the second portion are each received in a single recess defined on the first side of the first portion by the reverse of the projection defining the collar. In some embodiments the second portion comprises a pair of such projections which are received in respective ones of the arms of a C-shaped recess on the first side of the first portion defined by the reverse of a C-shaped projection defining the collar. In other embodiments the second side of the second portion includes a single such projection in the form of a -26 -C-shaped rib which is received in the C-shaped recess on the first side of the first portion. In either case, the outer edges of the or each projection on the second side of the second portion engage against the interior of the walls of the recess on the first side of the first portion to support the collar.

Alternatively or additionally, the first side of the first portion may comprise a central projection, such as a substantially cylindrical projection, which is received in a complementary recess on the second side of the second portion to assist in locating the first and second portions relative to one another. The cooperating protuberance and recess may alternatively be reversed, with such a projection on the second side of the second portion being received in a recess on the first side of the first portion.

The first end closure may further comprise a cover for the moulded pulp end plug at the first end of the container. The cover may be bonded to the first side of the moulded pulp end plug e.g. adhesively.

The cover may be a laminate comprising an outer layer and an inner layer.

The inner layer may be chosen to facilitate bonding to the pulp material of the end plug. The outer layer may be chosen to match the appearance of the exterior of the remainder of the container e.g. of a jacket thereof. It is envisaged that one or more intermediate layer may be provided, although, in embodiments, the cover is of a two layer construction, comprising the inner and outer layers aforementioned. The cover is of card-based or paper-based material, such as cardboard or paperboard.

The cover may provide a planar surface at the first (top) end of the container. The edges of the cover may be flush with the tops of the sidewalls of the container. The tops of the sidewalls of the container may be provided by the tops of the edges of an outer jacket of the container, where provided, and/or by the tops of the edges of the sleeve (e.g. an outer shell thereof).

Where the moulded pulp end plug comprises first and second portions, the first side of the second portion may be bonded to the cover, e.g. adhesively. A flange of the second portion may engage, and optionally be bonded, to the cover.

The edges of the flange may be flush with the edges of the cover.

Where the moulded pulp end plug of the first end closure comprises first and second portions, the second portion may comprise one or more, such as a pair of, projection(s) on the first side thereof, each defining a planar surface bonded to the cover. This may facilitate bonding of the pulp material of the end plug to a cover.

-27 -The planar surface is a top surface i.e. a surface closest to the first end of the container.

Multiple instances of the second portion of the moulded pulp end plug may be provided and bonded to a sheet of the cover material, such as a laminate material, with assemblies of the second portion of the moulded pulp end plug and a cover therefor then being cut out from the sheet of cover material. This may avoid the need to register cut pieces of cover material with the second portions of the moulded pulp end plugs, and facilitate the bonding of the cover material to the pulp material of the end plug. The sub-assembly of the cover and second portion may then be assembled with the first portion of the first end plug. Of course other techniques may be used. For example, the first and second portions of the end plug may be assembled before bonding of the second portion to the cover.

In accordance with any of the embodiments of the invention, the container may comprise an outer jacket. This may be of any suitable form. The outer jacket defines an outermost surface of the container. The first and second ends of the outer jacket may define the first and second ends of the container.

The second end closure may be of any suitable type provided that it is of a card-based or paper-based construction. The second end closure may comprise a moulded pulp end plug, but this need not be the case In contrast to the moulded pulp end plug at the first end of the container, a moulded pulp end plug used at the second end of the container may be of any construction. The second end closure may be adhesively secured in place. It is envisaged that the second end closure could alternatively be provided e.g. using a set of inter-engaging flaps associated with the second end of the container. For example, these could be integral with an outer shell of the sleeve.

In some embodiments, the second end closure comprises a moulded pulp end plug having a flange which engages the interior of the sleeve. The end plug may comprise a central projection on a second side thereof. One or more apertured supports may optionally be located over the projection to support the flange. The supports may or may not be used depending upon the desired strength of the second end closure. The support(s) may be of cardboard or paperboard. Where the first and second end closures both comprise moulded pulp end plugs, the end plugs may be referred to as first and second moulded pulp end plugs respectively.

-28 -A first sidewall of the sleeve comprises an opening therein to provide access to the interior space of the sleeve. This enables a product to be removed from the interior of the sleeve through the opening in use. The container may comprise a door rotatable about a foldline between a closed state in which the door covers the opening in the first sidewall, and an open state in which the opening is uncovered for providing access to the interior of the sleeve therethrough. This permits removal of a product from the interior of the sleeve through the opening.

The door may be provided in any suitable manner. For example, the door may be provided by a flap in the first sidewall of the sleeve. In embodiments, the container comprises an outer jacket secured to the exterior thereof, the outer jacket comprising a set of panels hingedly connected to one another, and wherein the door is provided by a panel of the jacket. An outer jacket may provide a suitable surface which provide an attractive appearance to a consumer. For example, the exterior of the outer jacket may be printed or otherwise provided with appropriate decoration.

The outer jacket is of card-based or paper-based material, such as cardboard or paperboard.

The outer jacket may further comprise one or more additional panels hingedly connected to the door panel on one side thereof, each additional panel being secured to a respective sidewall of the sleeve, and a closure mechanism attached to the door panel on the other side thereof for releasably fastening the door in the closed state. The closure mechanism may be in the form of a flap. The closure mechanism may be attached to the door panel via one or more intervening jacket panel.

In one exemplary embodiment, a panel at one end of the set of jacket panels is secured to its respective sidewall of the sleeve with a spacer therebetween such that a gap is defined between the jacket panel and the sleeve, and the closure mechanism is in the form of a flap which tucks into the gap to releasably fasten the door in the closed state. The interior of the spacer is bonded to the exterior of the sidewall of the sleeve and the exterior of the spacer may be bonded to the jacket panel, e.g. adhesively. The spacer is of card-based or paper-based material, such as cardboard or paperboard. The spacer extends over only a portion of the width of the sidewall of the sleeve to which it is affixed. The jacket then wraps around the sleeve to close the opening.

-29 -The jacket panel secured to the sidewall of the sleeve via a spacer may be a first jacket panel, the jacket further comprising a second panel adjacent thereto and secured to an adjacent sidewall of the sleeve, a third panel providing the door and extending over the first sidewall of the sleeve when the door is in a closed state, the closure flap being connected to the third panel of the jacket via a fourth jacket panel, the fourth jacket panel extending over a sidewall of the sleeve adjacent the sidewall having the spacer when the flap is tucked into the gap. The fourth jacket panel and flap are pivotable with the door panel about a foldline connecting the door panel to the second jacket panel when the door is moved between its open and closed states. Thus, the first and second panels of the jacket are secured e.g. bonded to sidewalls of the sleeve, while the third and fourth panels of the jacket are unsecured to the sleeve to enable them to move relative to the sleeve when the door is moved between its open and closed states. The second panel of the jacket may be directly bonded to the exterior of applicable sidewall of the sleeve.

In one example, the first and second jacket panels may be secured to the second and one of the third and fourth sidewalls of the sleeve respectively, with the first jacket panel being secured to the second sidewall via the spacer, and the third jacket panel extending over the other of the third and fourth sidewalls of the sleeve and tucking into the gap between the first jacket panel and the second sidewall of the sleeve.

Of course, other closure mechanisms may be used. However, the use of a flap which tucks into a space between panels of the container is advantageous in that this may provide a secure releasable and refastenable closure without using non paper or card-based materials, facilitating recycling of the container, and reducing environmental impact. By associating the flap with a jacket, such an advantageous closure may be obtained while also providing the container with an attractive outer appearance by selecting the material/any decoration of the jacket appropriately. When in the closed state, the jacket may cover over all of the sidewalls of the sleeve. The panels of the jacket may cover the entire area of the respective sidewalls of the sleeve.

The container may be for any suitable product. However, it has been found that the container is particularly useful where it is desired to provide a container of card-based or paper-based material that is of high strength. Thus, the container is particularly useful in the context of fragile products, such as glass bottles. In exemplary embodiments the container is for a bottle, such as a beverage bottle. The present invention extends to the container of any of the embodiments of the invention having a product located therein, optionally wherein the product is a bottle. The bottle may be a glass and/or beverage bottle. The bottle is located in the interior of the sleeve. The bottom end of the bottle is supported on the second end closure. The top end of the bottle may be supported by a product support provided on the second side of the moulded pulp end plug of the first end closure. The container may contain a single product e.g. bottle.

The invention extends to a method of assembling the container comprising inserting the moulded pulp end plug of the first end closure into the sleeve through the first end thereof until the resilient locking tabs of the moulded pulp end plug of the first end closure are engaged in the recesses of the sleeve. This may be achieved robotically. The method may comprise assembling the sleeve and second end closure, inserting a product through the open first end of the sleeve to be supported on the second end closure, and then inserting the moulded pulp end plug of the first end closure into the sleeve to close the first end of the sleeve. The moulded pulp end plug for the first end closure described herein is advantageous in allowing such assembly of the first end closure with the sleeve through the first end thereof after the product has been located in the sleeve. The use of the moulded pulp end plug advantageously allows the end plug to be assembled with the sleeve in this way without the use of adhesive. This may facilitate assembly using a robot. The ability to avoid the use of adhesive may provide a cleaner process with fewer steps and may therefore be advantageous.

The step of inserting the moulded pulp end plug of the first end closure into the sleeve may involve inserting the assembled first end closure into the sleeve in the manner specified. Thus, the moulded pulp end plug may advantageously be assembled with any other components e.g. a cover before being inserted into the sleeve.

It has been found that embodiments of the container described herein may enable the container to pass a strength test involving locating a 10Kg weight in the container, closing the end closures, inverting the container, and shaking the container with the weight inside for a predetermined time. The first end closure may remain securely fixed to the sleeve by cooperation of the resilient tabs with the recesses, during such a test.

The invention may extend to producing the first moulded end plug of any of its embodiments, and, in embodiments in which it comprises first and second portions, each of the first and second portions of the first moulded pulp end plug, using a pulp moulding process e.g. wet moulding process. Each of the first and second portions where present is produced using a respective mould configured to provide the respective one of the first and second portions. For example, producing the first and second portions of the first moulded pulp end plug using a wet moulding process may involve separately moulding each of the first and second portions using a respective mould having a shaped moulding surface configured to provide the formations of the respective one of the first and second portions. The method may comprise depositing pulp material onto the shaped moulding surface of the mould to produce the respective one of the first and second portions. The shaped moulding surface provides the respective portion of the first end plug with its intended three-dimensional shape Each mould may be a male type mould, although this need not be the case.

The method may comprise moulding each of the first and second portions by a method comprising; lowering a mould having a shaped moulding surface for providing the formations of the respective one of the moulded pulp first and second portions of the moulded pulp end plug into a container of pulp slurry, causing pulp material to accumulate on the shaped moulding surface, raising the mould out of the container of pulp slurry with pulp material deposited on the moulding surface thereof to provide a preform for the one of the respective one of the first and second portions. The preform has a three-dimensional shape imparted by the moulding surface corresponding to the intended shape of the first or second portion. The method may involve using a vacuum to assist in causing the pulp material to become accumulated on the shaped moulding surface. The moulding surface may be any suitable porous surface. The moulding surface may comprise for example a mesh upon which the pulp material is collected.

The method may further comprise drying the preform. The method may further comprise removing the preform from the shaped moulding surface. This may occur before or after drying thereof, or between steps involved in the drying process. The step of drying the preform may involve one or more steps which may involve dewatering the deposited pulp material thereof e.g. through pressing and/or heating the material. The step of drying the preform may or may not involve transferring the preform to a further supporting surface e.g. of another mould or conveyor.

The method may involve mating the shaped moulding surface having the preform thereon with a cooperating shaped moulding surface of a further mould after raising of the (first) mould out of the slurry. The preform may be pressed between the moulding surfaces e.g. to dewater and further assist in shaping the material. Of course, other techniques may alternatively be used to produce the moulded pulp end plug (and its portions where applicable).

In embodiments, the first and second portions of the first end plug are each formed by (or are shaped such that they may be formed by) depositing pulp material on to the shaped moulding surface of a respective mould, the shaped moulding surface being configured to produce the formations of the respective one of the first and second portions. The shaped moulding surface thus provides the respective one of the first and second portions with its intended 3-dimensional shape. A preform having the intended three dimensional shape of the respective one of the first and second portions may be provided by dipping the shaped moulding surface into a pulp slurry. The portion may have a mould facing side and an opposite side. The opposite side does not contact the mould when the mould is dipped into the pulp slurry.

All components of the container may be formed of card-based or paper-based material.

The term "moulded pulp" is used herein in its usually understood manner.

As known in the art, a moulded pulp material comprises cellulosic fibers. The fibers may include recycled fibers and/or virgin fibers. The moulded pulp material may be produced in any suitable moulding process. For example, a wet moulding process may be used. Each of the first and second portions of the first moulded pulp end plug described herein are of a moulded pulp construction, and may be of a single wall moulded pulp construction. Each portion, and the moulded pulp end plug as a whole, may consist of the moulded pulp material.

Unless the context demands otherwise, any reference to bonding herein may refer to adhesive bonding, or any other type of bonding, such as thermal bonding.

References to inward or inwardly herein refer to directions closer to an axial centreline of the container i.e. in a direction into the interior of the container unless the context demands otherwise. Conversely, references to outward or outwardly herein refer to directions further from an axial centreline of the container i.e. in a direction toward the exterior of the container unless the context demands otherwise A fold line as referred to herein refers to any line about which components have been folded. The fold line may comprise a line of weakness, crease line and/or perforations.

The resilient locking tab(s) may be referred to as "locking tab(s)" for brevity herein.

Unless the context demands otherwise, any reference to a height refers to a dimension as measured in the direction extending between the first and second ends of the container (or sleeve, jacket, outer shell, insert or container as appropriate). A width of a sidewall or sidewall panel is measured in the direction connecting the opposed side edges of the sidewall or sidewall panel. The width dimension may be measured in a direction perpendicular to a direction connecting the first and second ends of the sidewall or sidewall panel.

BRIEF DESCRIPTION OF DRAWINGS

Some preferred embodiments of the invention will now be described by way of example only and with reference to the following drawings, of which; Figure 1 is a perspective view of a container of card-based or paper-based material in accordance with an embodiment of the invention, and showing a bottle located in the container. Figure 1 shows the container 1 with a door of the container in an open state; Figure 2 shows the container 1 of the embodiment of Figure 1 with the door in a closed state; Figure 3 is a further view with the jacket of the container and outer shell of the sleeve thereof omitted, to illustrate the interaction between the first end closure and the insert part of the sleeve, and between the bottle and the first and second end closures, in more detail; Figure 4 shows the jacket and sleeve parts of the container 1, with the bottle and end closures omitted, and with the door in an open position, to illustrate certain features of the container in further detail; Figure 5 shows the sleeve part of the container with the end closures, jacket and bottle omitted; Figure 6 shows the insert part of the sleeve; Figure 7 is a perspective view of the first portion of the moulded pulp first end plug, with the side which lies lower most in use being uppermost; Figure 8 is a perspective view from the top side of the first portion of the first end plug; Figure 9 is a view of the first portion of the first end plug from above with the side which is uppermost in use being uppermost; Figure 10 is a view of the first portion of the first end plug from the side which extends along the second sidewall of the sleeve in use; Figure 11 is a perspective view of the second portion of the first end plug, with the side which lies lower most in use being uppermost; Figure 12 is a perspective view from the top side of the second portion of the first end plug; Figure 13 is a view of the second portion of the first end plug from above with the side which is lowermost in use being uppermost; Figure 14 is a view of the second portion of the first end plug from the side which extends along the second sidewall of the sleeve in use; Figure 15A shows the second moulded pulp end plug of the second end closure from the topside thereof which faces the first end of the container; Figure 15B shows a combination of the second end plug and a support of the second end closure; Figure 16 is an exploded view of the moulded pulp end plug of the first end closure, showing the first portion and second portions thereof separated from one another as in an intermediate stage in the assembly of the first end plug, and with a cover assembled with the second portion; Figure 17 is a similar exploded view of the moulded pulp end plug of the first end closure to that of Figure 16, but taken from above, showing the upper or first side of the first portion of the end plug; -3--Figure 18 is a section through the container as shown in Figure 3, with the jacket and outer shell omitted, showing the cooperation of the moulded pulp end plug of the first end closure with the top of the bottle in more detail; Figure 19 is a more detailed view showing the cooperation of the moulded pulp end plug of the first end closure with the top of the insert, and the engagement of the resilient locking tabs with the slots in the insert, again with the jacket and outer shell omitted; Figure 20 shows the first end closure being inserted into the top end of the insert, with the jacket and outer shell omitted for ease of illustration; Figure 21 shows the top end of the insert 33 in more detail; Figure 22 shows the cooperation between sloping surfaces of the interior of the insert at the top of the walls thereof and the resilient locking tabs of the first portion of the moulded pulp end plug of the first end closure as it is inserted into the top of the insert (again with the jacket and outer shell omitted); Figure 23 shows the first moulded pulp end plug in its final position inserted in the first end of the insert, with the locking tabs inserted in the slots of the insert, and the alignment tabs inserted in the alignment slots (again with the jacket and outer shell omitted); Figure 24 shows the assembly of the jacket and sleeve in the region of the first end thereof; Figure 25 is a similar view to Figure 24, but with the jacket omitted to enable the spacer to be more clearly seen; Figure 26 shows the assembly of the insert with the outer shell to provide the sleeve; Figure 27 is a view from the second side of the first portion of an alternative first end plug usable in accordance with a further embodiment of the invention; Figure 28 is a view from the first side of the first portion of the alternative first end plug; Figure 29 is a view from the second side of the second portion of the alternative first end plug; Figure 30 is a view from the first side of the second portion of the alternative first end plug; and Figure 31 is a detail of the arrangement shown in Figure 19.

With reference in particular to Figures 1 and 2, a container 1 in accordance with an embodiment of the invention includes a sleeve 3 having a first sidewall 5, a second sidewall 7, a third sidewall 9 and a fourth sidewall 11. The sleeve has a first end 2 and a second end 4. The first and second ends 2,4 may be referred to as the upper and lower ends of the sleeve. The container has corresponding first and second ends. The first sidewall 5 of the sleeve includes an opening 12 which permits access to the interior of the container i.e. for removing a bottle when located therein.

The first sidewall 5 of the sleeve is connected to the third sidewall 9 along a foldline 13 along one edge of the first sidewall 5, and is connected to the fourth sidewall 11 along a foldline 19 along an opposite edge thereof The second sidewall 7 is connected to the third sidewall 9 along a foldline 15 along one edge thereof and to the fourth sidewall 11 along a foldline 17 along an opposite edge thereof The first and second sidewalls 5, 7 form a first pair of opposed sidewalls of the sleeve 3, while the third and fourth sidewalls 9, 11 form a second pair of opposed sidewalls of the sleeve.

In the embodiment illustrated, the container further includes an outer jacket 20. The outer jacket may be referred to herein as a "jacket" for brevity. The sleeve and jacket parts of the container are shown in Figures 1 and 4. With reference in particular to Figures 1,2 and 4, the jacket includes first and second panels 21,22 which wrap around and are secured to the second and third sidewalls of the sleeve 7, 9 respectively. The second panel 22 of the jacket is bonded e.g. adhesively directly to the outer surface of the third sidewall 9 of the sleeve, while the first panel 21 is bonded e.g. adhesively to the outer surface of a spacer 26 bonded e.g. adhesively to the outer surface of the second sidewall 7 of the sleeve. The spacer 26 is therefore sandwiched between the second sidewall 7 of the sleeve and the first panel 21 of the jacket 20. The spacer 26 extends over only a portion of the width of the second sidewall 7, to leave a gap 18 of width W between the edge of the spacer furthest from the foldline 15 at which the third sidewall 9 is connected to the second sidewall 7 and the foldline 17 at which the edge of the second sidewall 7 is connected to the edge of the fourth sidewall 11. The gap 18 extends over the full height of the sleeve between the first and second ends thereof, and is located between the outer surface of the second sidewall 7 of the sleeve and the inner surface of the first panel 21 of the jacket. The width of the second sidewall 7 refers to the direction extending between the edges of the second sidewall 7 which are connected respectively to the third and fourth sidewalls 9, 11 i.e. the direction extending between foldlines 15 and 17.

In addition to the first and second panels 21, 22, the jacket also includes third and fourth panels 23, 24. The first, second, third and fourth panels 21, 22, 23, 24 are hingedly connected to one another along foldines 25, 27, 29. Unlike the first and second panels 21, 22 of the jacket, the third and fourth panels 23, 24 are not secured to the outer surface of the sleeve, but are rotatable about the foldline 27 connecting the second and third panels 22, 23 of the jacket (which overlies foldline 15 of the sleeve) so as to be movable relative to the sleeve between a position in which the third and fourth panels 23, 24 of the jacket overlie the first and fourth sidewalls 5, 11 of the sleeve respectively (as shown in Figure 2) and the position shown in Figure 1 in which the third panel 23 and fourth panel 24 of the jacket are located away from the first and fourth sidewalls 5, 11 of the sleeve respectively. In this way, the third panel 23 of the jacket 20 provides a door, hingeable about the foldline 27 between an open state, as shown in Figure 1, and a closed state, as shown in Figure 2, with the third panel 23 closing the opening 12 in the first sidewall 5 when in the closed state (as shown in Figure 2) and leaving the opening 12 uncovered when in the open state of the door (as shown in Figure 1) so as to permit access to a bottle within the container through the opening 12.

A flap 28 is connected to the fourth panel 24 of the jacket along a foldine 31. The flap 28 of the jacket provides a releasable closure device for the door. When in the closed state as shown in Figure 2, the fourth panel 24 of the jacket extends over the fourth sidewall 11 of the sleeve, and the flap 28 is tucked into the gap 18 between the first panel of the jacket 21 and the second sidewall 7 of the sleeve to retain the third and fourth panels of the jacket in position with the third panel 23 closing the opening 12.

Of course, other arrangements may be used to provide a door for covering the opening 12 in the first sidewall 5 of the sleeve, rather than using a jacket as shown. For example, the door could be provided by a flap cut into the first sidewall 5. Similarly, where the door is provided by a separate component e.g. a jacket attached to the sleeve 3, the jacket need not be of the configuration shown. Alternative closure mechanisms may also be used, rather than tucking a flap into a gap as shown. The arrangement shown is advantageous as it enables a secure closure to be obtained without the use of any materials not of a card-based or paper-based construction e.g. magnets or the like, thus providing greater ease of recycling. The jacket 20 also provides a surface which may be printed or otherwise decorated to provide a desired appearance to the container.

The container 1 also includes a first end closure 150 comprising a first moulded pulp end plug 50 ("first end plug") inserted in the first end thereof and a second end closure 154 comprising a second moulded pulp end plug 52 ("second end plug") inserted in the second end thereof. This is shown more clearly in Figures 1 and 3.

In the illustrated embodiment, the first end closure 150 further comprises a cover 51 for the first moulded pulp end plug 50. The cover 51 is optional. The cover 51 is in the form of a piece of card-based or paper-based material, such as cardboard or paperboard. The cover 51 is bonded e.g. adhesively to the upper surface of the first end plug 50. The cover 51 provides an attractive appearance to the top of the container, concealing the undulating upper surface of the moulded pulp first end plug 50. The cover 51 may be flush with the top of the container (corresponding to the first end edges of the jacket 20 in the illustrated embodiments). The cover and first moulded pulp end plug therefore form part of a single unit, the first end closure, which is inserted into and closes the first end of the sleeve.

The sleeve 3 includes a pair of locking recesses 140 on the interior of each of the second, third and fourth sidewalls 7, 9,11 thereof, which do not extend through the full thickness of the sidewalls. The locking recesses 140 are located at the top or first end of the sleeve and receive locking tabs 70 of the first end plug 50 as will be described in more detail below, to enable the first end plug 50 to be clipped into position. The second sidewall 7 also includes a pair of alignment recesses 142 extending from the top or first edge thereof on the interior surface thereof a short distance toward the second end of the sleeve. These alignment recesses 142 are located only on one of the sidewalls of the sleeve, and cooperate with alignment tabs 72 of the first end plug 50 in a manner described below to ensure that the first end plug 50 may only be inserted into the sleeve in a given orientation. The alignment recesses 142 also do not extend through the full thickness of the sidewalls of the sleeve.

-39 -As may be seen in Figures 1-3, and in particular in Figure 3, the bottle is supported on the second end closure 154 i.e. second end plug 52 thereof. The second end closure includes a flange 54 engaging the interior of the sidewalls of the sleeve. In the illustrated embodiment, a recess 59 is defined in the upper, first side of the second end plug 52 for receiving the bottom end of the bottle. A corresponding projection is defined on the second (i.e. lower) side of the second end plug 52. In the illustrated embodiment, the second end closure 154 further comprises a support 57. The projection of the second end plug 52 is received in the central aperture of the support 57, which is of card-based or paper-based material. The support 57 is, in the illustrated embodiment of a corrugated cardboard construction and enhances the strength of the closure at the second end of the container 1, supporting the flange 54. Such a support 57 is optional, and if present, the construction and/or properties of the support 57 may vary from that illustrated, depending upon the desired strength of the closure at the second end.

The support 57 may enhance the strength of the closure at the second end where it is necessary, for example, to pass a particular strength test in relation to a desired use scenario. For example, some packaging is required to pass tests for assessing shipping strength involving dropping the container repeatedly on its different sides. The second end closure 154 may be of a different configuration from that shown, and need not include a moulded pulp end plug. However, the second end closure is of card-based or paper-based material.

The first end plug 50 of the first end closure 150 closes the first, upper end of the sleeve 3, with the top of the bottle being retained within a C-shaped projection on an underside of the first end plug 50. The construction of the first end plug 50 is described in more detail below. The first end plug 50 providing the first end closure includes integrally moulded features which enable it to be securely fixed by a press fit into the first end of the sleeve without the need for adhesive. The first end plug 50 is held in place by the press fit and cooperation of the resilient tabs and recesses.

The container is made of a card-based or paper-based material. The sleeve (including the insert and outer shell) and jacket are each made of such material, for example of cardboard or paperboard, as are the end closures. In addition to the moulded pulp first end plug, the first end closure may comprise a cover of cardboard or paperboard material. The second end closure may comprise a -40 -combination of a moulded pulp end plug and optionally a cardboard or paperboard support, or may be of any other suitable form, provided that it is of card-based or paper-based material. Thus, the second end closure need not comprise a moulded pulp end plug. This permits all components of the container to be recycled in the same waste stream for card-based and paper-based materials, without the user needing to separate any components prior to recycling to avoid contamination of dedicated waste streams.

The construction of the sleeve 3 will now be described in more detail, with particular reference to Figures 5 and 6. The sleeve part of the container is shown in isolation in Figure 5, with the other parts of the container, i.e. first and second end closures, spacer and jacket omitted, while Figure 6 illustrates the insert part of the sleeve.

The sleeve 3 is formed from an outer shell 31 and an insert 33. The insert 33 has first, second and third panels 35, 37, 39 hingedly connected to one another along foldlines 36, 38. The outer shell 31 has first, second, third and fourth panels 40, 41, 43, 45 hingedly connected to one another along foldlines. The first panel 40 is connected to the third panel 43 along foldline 47, and to the fourth panel 45 along foldline 49. The second panel 41 is connected along a foldline 51 to the third panel 43 and along a foldline 53 to the fourth panel 45. The outer shell may be erected from a single piece blank. For example, the outer shell may include a construction flap (not shown) attached to one of the longitudinally extending edges of one of the panels thereof along a foldline, the construction flap being bonded to the interior of an adjacent one of the panels to retain the outer shell in an erect configuration.

As shown in in more detail in Figure 6, which is a view showing the first end of the sleeve, each of the first, second and third panels 35, 37, 39 of the inner shell 33 of the sleeve 3 includes a pair of locking slots 120 therein for receiving locking tabs 70 of the first end plug 50 as will be described in more detail below. The locking slots 120 are spaced from the edges of the panels at the first ends thereof. The second panel 37 additionally includes a pair of alignment slots 122 which do extend to the edge of the panel at the first end thereof. The locking slots 120 form the locking recesses 140 and the alignment slots 122 form the alignment recesses 142 in the interior of the sidewalls of the sleeve 3 mentioned above.

The top or first ends of the panels 35, 37, 39 include a sloping surface on the interior thereof. The sloping surfaces are denoted 131, 133, 135. The sloping -41 -surface extends from the first end edge of the respective panel at the first end thereof inwardly toward the interior of the sleeve adjacent the first end edge of the panel and in a direction toward the second end of the sleeve. The sloping surface is provided in a region above the locking slots 120 in each panel. This may facilitate insertion of the first end plug 50 as described below. The sloping surface defines an angle a of less than 90 degrees with respect to the plane in which the interior (non-sloping) surface of the panel below the sloping surface lies.

As shown in Figure 5, the insert 33 is bonded e.g. adhesively to the interior of the outer shell 31, with the first, second and third panels 35, 37, 39 of the insert 33 bonded e.g. adhesively to the third, second and fourth panels 43, 41,45 of the outer shell 31. The second, third and fourth sidewalls of the sleeve are therefore of a multi-layer construction, including an inner layer provided by a respective panel of the insert, and an outer layer provided by a respective panel of the outer shell. The first sidewall of the sleeve is provided as a single layer construction, by the corresponding first panel 40 of the outer shell. A window in the first panel 40 provides the opening 12 of the container.

In the embodiment illustrated, the insert 33 extends over substantially the full height of the outer shell 31, although it is envisaged that it could extend over only an upper portion of the sidewalls of the outer shell 31. The insert 33 provides the sidewalls of the sleeve with recesses in their upper portions which cooperate with the resilient tabs of the first end closure in the manner described below. In the illustrated embodiment the top end of the insert includes certain further features which cooperate with the first end closure to provide a directional fit and to facilitate insertion of the first end closure into the top end of the sleeve. Thus, provided that it includes the necessary features to cooperate with the first end closure, the insert need not extend over the full height of the sidewalls of the outer shell. A full height extent may provide greater rigidity to the sleeve, however, and assist in providing a strong container ideal for holding a fragile bottle. It is preferred that at least one panel of the insert extends over the full height of the corresponding sidewall of the outer shell to facilitate location of the insert in the outer shell, and to provide stability to the resulting sleeve.

Other arrangements may be used which result in the recesses for receiving the resilient locking tabs of the first end plug (and any alignment recesses present) not extending through the full thickness of the walls of the container to the exterior -42 -thereof. For example, a slot might extend through the full thickness of the sleeve of the container, being covered by an outer layer of the container, e.g. a jacket or other exterior component which provides the outermost surface of the container. The two part construction of the sleeve described herein is not essential. It is desirable that the recesses do not extend to the exterior surface of the container so as to conceal the tabs and avoid interrupting the outermost surface of the container, which is typically provided with branding or other decorative finish.

The present invention is concerned with the construction of the first end closure 50, and its cooperation with the sleeve, which will be described in more detail below.

Figure 3 is a longitudinal section through the container 1 with a bottle 36 in situ within the interior space thereof. The outer shell 31 of the sleeve is omitted in Figure 3 as is the jacket 20. The view is taken from the same side of the container as Figures 1 and 2 and corresponds thereto other than the removal of the jacket 20 and outer shell 31 of the sleeve 3. The open front of the insert 33 will therefore underlie the first panel 40 of the outer shell 31, and the first sidewall 35 of the insert will underlie, and be bonded to, the third panel 43 thereof.

Figure 3 illustrates certain features of the first end plug 50 of the first end closure 150 which cooperate with sidewalls of the sleeve 3 in order to retain the first end plug 50, and hence first end closure 150, in place.

Figure 3 also facilitates understanding of the second end plug 52 of the second end closure 154 (which is shown in more detail in Figures 15A and B). Figure 15A shows the moulded pulp second end plug 52 from the topside thereof which faces the first end of the container. As may be seen in Figure 15A, the central portion of the second end plug 52 defines a recess 59 on the first, upper side thereof in which a bottom of the bottle 36 is received, and a corresponding projection on the second (lower) side of the end plug 52. A flange 54 surrounds the central portion of the end plug 52. The second end plug 52 is, in contrast to the first end plug, adhesively secured in place to provide a strong bottom closure. The second end closure 154 may take other forms, provided that it provides sufficient strength for the intended purpose of the container. As shown in Figure 15B in the illustrated embodiment, a support 57 of card-based or paper-based material, which is not of a moulded pulp construction, receives the projection on the second, lower side of the end plug 52 to reinforce the end closure. This may enhance the strength -43 -of the closure, for example where it is desired to meet certain standards regarding the strength of the closure for particular applications of the container. In the exemplary arrangement, the support 57 is of a corrugated cardboard construction, and is of a laminate construction, including multiple layers of cardboard material.

The support 57 Is adhesively attached to the underside of the flange 54. The underside of the support 57 also provides a flat surface on which the container may stand, and reinforces the lower end of the sleeve 3.

The first end plug 50 of the first end closure 150 will now be described in more detail, with additional reference to Figures 7-14. The first end plug 50 is formed from two inter-engaging pieces. Each piece is formed of moulded pulp.

These are the first portion 60 and second portion 62. It is envisaged that the second portion 62 could be omitted. The first and second portions 60, 62 each include formations defining a pattern of recesses and projections in their upper and lower surfaces, imparted by the moulding process used to form the respective portion. The pattern of recesses and projections of one of the first and second surfaces (i.e. upper and lower surfaces) of the first or second portion is the reverse of that of the opposite one of the first and second surfaces thereof.

The first portion 60 is the lowermost portion when the first end plug is disposed in the first end of the sleeve i.e. is located closest to the second end of the sleeve, and is shown in Figures 7-10.

Figure 7 is a perspective view of the first portion 60 of the first end plug 52, with the side which lies lower most in use (the second side) being uppermost. Figure 8 is a perspective view from the top (or first) side of the first portion 60. Figure 9 is a view of the first portion 60 from above with the side which is uppermost in use (i.e. the first side) being uppermost, and Figure 10 is a view of the first portion 60 from the side which extends along the second sidewall 7 of the sleeve 3 in use.

The second portion 62 of the first end plug 52 is shown in Figures 11-14. Figure 11 is a perspective view of the second portion 62 of the first end plug 50, with the side which lies lower most in use (the second side) being uppermost.

Figure 12 is a perspective view from the top side (first side) of the second portion 62. Figure 13 is a view of the second portion 62 from above with the side which is lowermost in use (the second side) being uppermost, and Figure 14 is a view of the -44 -second portion 62 from the side which extends along the second sidewall 7 of the sleeve 3 in use.

For ease of reference, the terms upper and lower will be used to denote positions toward the first and second ends of the container in use, but do not imply that any particular orientation of the container is used. Typically the container will be oriented with the first end uppermost. References to an upper and lower side of a component may be replaced by reference to first and second sides, being those sides closer to the first end and second end of the sleeve or container in use instead and vice versa.

The features of the first portion 60 of the first end plug 50 will now be described in more detail with reference to Figures 7-10.

The first portion 60 includes first, second, third and fourth sidewalls 61, 63, 65, 67 which extend respectively along the first, second, third and fourth sidewalls 5, 7, 9, 11 of the sleeve. Each sidewall of the first portion 60 is in contact with the respective one of the sidewalls of the sleeve. The sidewalls 61, 63, 65, 67 are upstanding from a base 66 of the first portion. The base 66 defines a base plane of the first portion 60. As shown in Figure 10, a rounded edge is defined where the base of the sidewalls meets the base plane 66 of the first portion 60 to facilitate insertion of the first end portion into the sleeve of the container.

The second, third and fourth sidewalls 63, 65, 67 of the first portion 50 each include two resilient locking tabs 70 projecting outwardly therefrom. These locking tabs 70 cooperate with the interior of the sleeve in the manner described below to securely fix the first end plug 50 in the first end of the sleeve 3, without the need for adhesive. The resilient locking tabs 70 extend the full height of the sidewalls in the illustrated embodiments. The second sidewall 63 of the first portion 60 includes a further pair of resilient tabs 72, which, in the illustrated embodiment, are of lesser width than the locking tabs 70 (it will be appreciated that the configuration of the resilient tabs 70 and 72 may vary depending upon the desired properties of the container, the security of the locking effect to be achieved etc).

The further tabs 72 provide an alignment feature, preventing the first end plug 50 from being located in the first end of the sleeve other than in the intended rotational orientation i.e. with the first sidewall 61 of the first portion 60 of the end plug 50 extending along the first sidewall 5 of the sleeve and so on. This ensures that the locking tabs 70 are able to be located in corresponding recesses 140 of the -45 -interior of the sleeve 3 to secure the end plug 50 in position, and that the bottle may be removed through the open end of the collar 80. If the end plug were inserted in the wrong orientation, the collar would effectively block the removal of the bottle through the opening 16 in the first sidewall 5 of the sleeve 3. The use of the alignment tabs 72 is optional. Other alignment feature(s) may instead or additionally be used, or an alignment feature may be omitted. The alignment tabs 72 and the locking tabs 70 are each integrally moulded with the first portion 60 of the first end plug. Thus they are provided by moulded formations of the moulded pulp first portion 60 of the end plug. The tabs 70, 72 are inherently resilient by virtue of their moulded pulp construction.

It is envisaged that the number of locking tabs 70 used on each sidewall (having locking tabs) of the first portion 60 of the first end plug 50 may vary from that illustrated. Rather than having a pair of such locking tabs, the sidewalls provided with locking tabs may have a single tab, or more than two tabs, or combinations thereof. Furthermore, while three sidewalls are shown as having such locking tabs, it is envisaged that all sidewalls might have such locking tabs, or fewer than three, such as two or even one of the sidewalls. For example, the third and fourth opposed sidewalls 9, 11 might be the only sidewalls having such locking tabs. If the first sidewall 61 is provided with locking tabs, some cooperating formation would need to be provided on the interior of the sleeve for receiving the tabs. At least one pair of opposed ones of the sidewalls ideally have the tabs to provide improved stability. It has been found that a pair of locking tabs associated with each of at least two, for example three of the sidewalls may provide a balance between secure locking of the end plug and ease of moulding and reliable operation of the locking tabs of the end plug. The number of locking tabs present will depend upon factors such as the shape and weight of the intended product.

The underside of the first portion 60 of the first end plug 50 (i.e. the second side which is closest to the second end of the sleeve/container and which is lowermost in use) also includes a collar 80 for supporting the top of a bottle when located in the container. The collar is upstanding from the base 66, and extends in a direction toward the second end of the container in use. Thus, the collar 80 and sidewalls 61, 63, 65, 67 of the first portion 60 extend in opposite directions from the base 66 of the first portion 60 i.e. being upstanding from the second and first sides of the first end portion 60 respectively. The opening 81 in the collar is disposed -46 -closest to the side of the first portion 60 which extends along the first sidewall 5 of the sleeve 3 when the first end plug 50 is located in the first end of the sleeve i.e. in the container. Thus, it faces the sidewall 61 of the first portion 60. This helps to retain the bottle in a desired position within the container, while allowing the bottle to be removed through the opening 12 provided in the first sidewall 7 of the sleeve in use (when the door of the container is in an open state). The collar 80 is shown as being provided by a single C-shaped projection on the second side of the first portion 60 of the first end plug 50. The C-shaped projection extends around a central recess. However, the shape of the bottle support may vary from that illustrated, and might, for example, be provided using a plurality of discrete projections rather than a single C-shaped projection.

The upper i.e. first side of the first portion 60 also includes a central projection 114 to assist in locating the first portion 60 relative to the second portion 62 as described below.

The second portion 62 of the first end plug 50 is shown in figures 11-14.

The second portion 62 includes a peripheral flange 90, and first, second, third and fourth sidewalls 91, 93, 95, 97 upstanding therefrom. The part of the second portion 62 upstanding from the flange 90 is fitted within the first side of the first portion 60 of the first end plug 50, with the first, second, third and fourth sidewalls 91, 93, 95, 97 of the second portion 62 engaging the corresponding sidewalls 61, 63, 65, 67 of the first portion 60.

The flange 90 sits on top of the first end edges of the sleeve i.e. of the insert and outer shell thereof, with the underside of the flange cooperating with the end edges of the sleeve to provide an end stop during insertion of the first end closure through the first end of the sleeve during assembly of the container. This is best shown, for example, in Figures 19 and 23. The flange may be disposed in the space between the end edges of the sleeve and the first end edge of the container once the first end closure is fully inserted. The cover may be flush with the first end edges of the container at the first end thereof (e.g. as provided by the jacket in the illustrated embodiment).

Each sidewall of the second portion 62 includes recesses 100 corresponding to the position of the locking tabs 70 of the sidewall of the first portion 60 which it engages. The remainder of each sidewall 91, 93, 95, 97 engages the corresponding sidewall 61, 63, 65,67 of the first portion 60 to reinforce -47 -the wall, and inhibit flexing of the wall, which might otherwise enable the locking tabs 70 to move out of engagement with their corresponding recesses 140 in the interior of the sleeve. The reinforcement also helps to ensure the product support provided by the collar on the second side of the first portion of the end plug remains engaged with the product. The use of a two piece first end plug 50 is therefore advantageous in helping to ensure that the locking tabs 70 may function reliably to secure the first end plug 50 in the first end of the sleeve and to enable the end plug to function to provide a reliable product support. However, the second portion 62 of the first end plug 50 could be omitted in some situations. The recesses 100 mean that the sidewalls of the second portion 62 of the first end plug 50 do not contact the sidewalls of the first portion 60 in the region of the resilient locking tabs, to enable the locking tabs to retain their natural resilience to facilitate locking the tabs into the recesses 140 in the interior of the sleeve when the end plug 50 is inserted in the first end thereof. The sidewalls of the second portion 62 of the end plug 50 thus have a pattern of alternating recessed and non-recessed regions along their length, with the recessed regions aligned with the positions of the resilient locking tabs of the first portion, and the non-recessed regions disposed therebetween and engaging the sidewalls of the first portion 60.

The use of a two piece end plug is also advantageous in facilitating moulding of the end plug. The end plug includes the resilient locking tabs projecting therefrom. By moulding the end plug in two pieces, it is possible to design each piece so that it may be readily moulded, and removed from the mould using the intended pulp moulding process. Certain features may be difficult or even impossible to mould from the pulp material, for example using a wet moulding process, at least without complication and risk of damage upon removal from the mould, using pulp forming techniques. These include configurations in which features interact to provide cavities in the piece, overhanging portions, undercut portions etc. Instead, by using a two piece construction, desired formations may be produced from the combination of features moulded as part of the independently moulded first and second portions, rather than needing to attempt to provide such features in a single piece. This provides greater design freedom in relation to the resulting end plug structure, allowing formations to be provided which are beneficial, without needing to compromise on the configuration of the end plug due to constraints of a single piece moulding process, and enabling features to be -48 -produced in the end plug which previously could not have been moulded from a pulp material. It will be appreciated that the use of the pulp material constrains the shapes which may be produced in the moulding process, e.g. in comparison to when moulding a plastic material, and that the two piece construction described herein opens up possibilities in relation to creating the shape of the end plug enabling features that may enable the end plug to function particularly effectively e.g. in providing a strong end closure while still being of a sustainable pulp material to be produced as discussed herein. This is discussed in more detail in relation to Figure 31 below. The two part construction enables desired features to be included without detriment to the ability to be able to mould the individual first and second portions and remove them from their mould without damage, by appropriate design and moulding of the first and second portions.

The second portion 62 also includes projections 112 on the first side thereof. These may provide flat surfaces to which the cover 51 can be bonded. The second portion includes a central recess in the second, lower surface thereof, which receives the projection 114 in the first, upper side of the first portion 60 in order to locate the portions relative to one another and assist in providing a press fit between the portions. A projection in the form of a C-shaped ridge 110 is also disposed on the second, lower surface of the first end portion 60 for cooperating with the recess defined by the reverse of the collar 80 of the first portion 60 to assist in providing a press fit between the first and second portions of the first end plug, and to support the collar and prevent deformation thereof in use. This helps to ensure stability of the collar, enabling it to reliably support the bottle in use. While the projection for supporting the collar is shown as being C-shaped, roughly corresponding in shape to the collar, other forms of support may be used. For example, a plurality of projections rather than a single projection may be used. An alternative configuration is shown in Figure 27.

The first and second portions 60, 62 may include various other recesses and projections which will not be described here. The exact formations present may vary depending upon the desired properties of the first end plug, its intended use etc. For example, the pattern of formations may help to provide a desired level of strength to the end plug, and may contribute to the inter-engagement between the first and second portions. Provided the end plug includes resilient locking tabs which cooperate with the sleeve to retain the end plug in place, the exact -49 -configuration of the end plug, and indeed, whether it includes one or two (or even more) moulded pulp parts, may vary.

Figure 16 is an exploded view of the first end plug 50, showing the first portion 60 and second portion 62 thereof separated from one another. This would be as in an intermediate stage in the assembly of the first end plug 50 and of the overall first end closure 150. The cover 51 is shown secured to the first side of the second portion 62, and is flush with the flange 90 thereof. The first and second portions 60, 62 are pushed together so as to inter-engage with one another by a press fit by cooperation between the formations on the second side of the second portion 62 and the first side of the first portion 60. The first and second portions 60, 62 may additionally be bonded to one another adhesively, or, in some embodiments, are held together by press fit alone, and without the use of adhesive or any other bonding material. Adhesive may be applied, for example, to the side of the base of the first portion that faces the second portion of the end plug.

Figure 16 more clearly shows the C-shaped projection 110 on the second side of the second portion 62 which fits within the recess corresponding to the reverse of the collar 80 on the first side of the first portion 60 to assist in providing a press fit between the first and second portions and to support the collar in use.

Figure 17 is a similar exploded view of the first end plug 50 to that of Figure 16, but taken from above, showing the upper or first side of the first portion 60 of the end plug.

In the illustrated embodiment, the cover 51 of the first end closure 150 is in the form of a piece of card-based or paper-based material, such as cardboard or paperboard. The cover 51 is shaped to correspond to the shape of the sleeve 3 at the first end thereof, being of rectangular shape in this embodiment. The cover 51 provides a uniform appearance to the first end of the container, consistent with the material forming the sidewalls of the sleeve. The cover 51 covers the upper side of the first end plug 50, concealing the moulded pulp material. The cover 51 may be omitted where it is not necessary to provide a uniform appearance to the exterior of the first end of the container. In the illustrated embodiment the cover 51 is of a laminate construction, comprising inner and outer layers 151, 152. The inner (or lower) layer 152 is bonded to the first, upper side of the second portion 62. The cover may include more or fewer layers. The cover may be of a single layer construction. All layers of the cover are of card-based or paper-based material, -50 -such as cardboard. The inner layer 152 may facilitate attachment of the cover 51 to the moulded pulp material of the second portion 62. The cover 51 (including any layer(s) thereof) is of a non moulded pulp material, such as cardboard. The outer layer of the cover 51 forms part of the exterior of the container, and may be selected to match the appearance of the other outer surfaces of the container (e.g. as provided by the jacket in the illustrated embodiments). A single layer cover may be used. However, the use of a laminate cover enables inner and outer layers to be selected specifically in relation to their intended use i.e. attachment to the moulded pulp end plug, or providing a visible exterior surface of the container. The attachment of the cover to the second portion 62 is by bonding to the surfaces defined on the first side thereof by the projections 112.

It is envisaged that components including the cover 51 and the second moulded pulp portion 62 as shown in Figures 16 or 17 may be achieved by bonding multiple instances of the moulded pulp second portions 62 to a sheet of the cover material, and then cutting out the components from the sheet. This may allow components to be obtained in which the edges of the flange of the second pulp portion and the cover 51 are flush with one another as shown in Figures 16 and 17, avoiding any complication in having to register the edges of the moulded pulp component with that of the cover. However, other assembly techniques may be used.

Figure 18 is a section through the container as shown in Figure 3, with the jacket and outer shell removed, showing the cooperation of the first end plug 50 of the first end closure 150 with the top of the bottle 36 in more detail. It may be seen that the top of the bottle is received within the collar 80 of the first portion 60 of the first end plug 50. Here it may be seen how the tabs 70 is inserted in one of the slots 120 in the panel 39 of the insert 33 to resiliently clip the first end plug into the insert, and hence sleeve. It may also be seen that the locking tab 70 is adjacent one of the recessed portions 100 of the sidewall of the second portion 62 of the first end plug 50, enabling the locking tab 70 to exhibit its resilient behaviour and to flex when introduced into the slot 120 when the first end plug 50 is inserted (from above) into the first end of the sleeve 3. In other regions, away from the recesses 100, which are aligned with the locking tabs 70, the sidewalls of the second portion 62 of the first end plug press against the sidewalls of the first portion 60, inhibiting flexing of the sidewalls, to help maintain the locking tabs 70 in engagement with the -51 -slots 120 once inserted therein in use. The engagement between the sidewalls of the first and second portions 60, 62 may be seen in the region to the top left of Figure 18, where the first sidewall 91 of the second portion 62 is seen engaging the interior of the first sidewall 61 of the first portion 60. The engagement of the sidewalls of the first and second portions of the first end plug assists in obtain the press fit therebetween.

It may also be seen in Figure 18 how the upper surfaces of the projections 112 of the second portion 62 engage, and are bonded to, the lower surface of the lower layer 152 to bond the cover 51 to the second portion 62 of the first end plug 50. The cooperation between the projection 110 and the interior of the recess defined by the reverse side of the collar 80 may also be seen, which assists in providing the press fit between the first and second portions 60, 62 of the end plug 50 and support the collar to provide stability thereto in use. The recess 116 on the lower surface of the second portion 60 receives the projection 114 on the upper side of the first portion 62 to further assist in locating the first and second portions 60, 62 relative to one another and obtaining a press fit therebetween. The projection provided in the upper surface of the second portion 62 by the reverse side of the recess 116 on the second/lower side thereof may be seen in Figure 18.

Figure 19 is a more detailed view showing the cooperation of the first end plug 50 of the first end closure 150 with the top of the insert 33, and the engagement of the locking tabs 70 with the slots 120. The slots are spaced a distance A from the top of the insert 33. Here it may be seen that the locking tab includes a bottom or second end 71 which is connected to the base of the first portion of the end plug, and an outwardly curved portion 137 having a curved exterior surface upstanding therefrom. This curved portion cooperates with a sloping surface on the interior of the sleeve (here being the sloping surface at the top of the insert, which is planar) during insertion of the first end plug to facilitate insertion of the end plug and to deflect the tab inwardly to the extent necessary to allow it to enter the slot 120 once the end plug has been inserted sufficiently into the first end of the sleeve. The sloping surfaces associated with the insert are described in more detail below by reference to Figure 21.

The locking tab 70 also includes a free, first end 73, which is located in the slot 120, with the first end 73 of the tab engaging the edge 121 at the first end of the slot 120 to retain the tab engaged in the slot 120. The tab thus hooks into the slot.

-52 -The second end of the tab 71 engages the interior of the sidewall of the insert below the second, or lower end 123 of the slot 120 to facilitate in retaining the tab in its slot, and contributing to the press fit between the end plug and the first end of the sleeve. Each resilient locking tab 70 is of the form illustrated in Figure 19 and engages with its corresponding slot in the same manner.

Figure 19 also shows that the height H of the sidewalls of the second portion of the end plug (i.e. upstanding from the flange 90) is greater than the height h of the sidewalls of the first portion (i.e. upstanding from the base thereof). This results in the second portion of the end plug extending beyond the first portion of the end plug toward the first end of the container. This enables the first end plug to be located with the flange 90 of the second portion thereof located on the top of the sleeve, and with the resilient locking tabs 70 disposed in their slots 120. The difference in height between the sidewalls of the first and second portions of the end plug may be chosen based on the spacing of the top of the slots 120 for receiving the locking tabs 70 from the top of the sleeve. The first end edges 121 of the locking slots 120 are spaced a distance A from the first end edge of the insert 33. It may be seen that the flange 90 overhangs the first end edge of the locking tab 70.

Figure 31 corresponds to Figure 19, illustrating certain features in more detail. Here it may be seen that a cavity C is defined in the end plug resulting from the combined first and second portions 60, 62, represented by the cross hatching. The cavity is bounded at its inner side by the sidewall of the second portion in the region of a recess 100 thereof The cavity is bounded on its top or first end by the underside of the flange 90, and at its bottom or second end by the first side of the base of the first portion 60 of the end plug. On its outer side the cavity is bounded, toward its second end, by the interior of the resilient locking tab 70. The cavity is open or unbounded toward its first or upper end in the end plug alone, while, when located in the top of the sleeve in the manner shown in Figure 19, is bounded by the interior surface of the insert in the region between the first end edge of the slot 120 which receives the locking tab and the first end edge thereof.

The formation of an end plug including such a cavity is allowed by the two piece construction thereof. This enables the first and second portions to be independently moulded, being designed to facilitate ease of moulding, but, when combined, a desired configuration of the end plug including this shape of cavity is obtained, which would not be possible in a single piece using pulp moulding processes e.g. wet moulding. The shape of the cavity results from the interaction between the resilient tabs with surrounding formations which are desirable to support the function of the resilient tabs and more generally the functionality of the end plug as described herein. The multi-piece moulding process enables such formations to be designed with greater freedom to provide these advantages, without needing to be constrained by the limitations of a single piece moulding process, since they may be provided as a result of combining separately moulded pieces. For example, the shape of the cavity resulting from the spacing between the recess in the sidewall of the second portion and the interior of the curved locking tab is an example of a shape which would tend to interfere with the ability to remove a single piece moulded component from its mould, and which may not be compatible with pulp moulding processes e.g. wet moulding. This is exacerbated by the presence of the flange overhanging this region. To provide such features in a single piece pulp formed end plug would be complex, if not impossible. In contrast, the multi piece construction enables each part to be separately moulded using straightforward moulds e.g. an up down male female type arrangement, and enables the moulded pieces to be removed without risk of damage to the formations.

Figure 20 shows the first end closure 150 being inserted into the top end of the insert 33. Other components of the sleeve e.g. outer shell and jacket are omitted. Here it may be seen that the alignment tabs 72 slide into the additional (alignment) slots 122 of the second panel 37 of the insert 33. As alignment slots extending to the top of the panel are associated only with the second panel 37 of the insert 33, it is ensured that the first end plug 50 (and thus first end closure) can only be inserted in the shown orientation into the top of the sleeve, i.e. with the first sidewalls 61, 91 of the first and second portions 60, 62 being disposed to the open side of the insert (so that they will be adjacent the first sidewall 5 of the sleeve). The locking tabs 70 are able to flex inwardly as they contact the material of the respective insert panels above the slots 120 in which they are to be received, enabling the first end plug 50 to be slid into position. The locking tabs 70 will then recover by virtue of their inherent resilience, moving outwardly into the recess 120 to lock the first portion 62 and hence first end plug 50 to the sleeve.

-54 -The connection between the first end plug 50 and the sleeve 3 is achieved by press fit and cooperation of the locking tabs with their corresponding recesses, and without the use of adhesive or any other external bonding material. The first and second portions of the first end plug 50 are connected to one another by a press fit, and optionally without any external bonding material. In some embodiments they are not adhesively bonded to one another.

As may be seen in more detail in Figure 21, which shows the top end of the insert 33 in more detail, each panel of the insert 33 includes a sloping surface on the interior thereof adjacent the top edge of the panel. These sloping surfaces 131, 133, 135 guide insertion of the first end plug 50 as shown in Figure 22, cooperating with corresponding sloping surfaces 137 at the second end of the resilient locking tabs 70 to urge the resilient locking tabs inwardly to enable the end plug to be inserted into the first end of the sleeve to the degree necessary for the locking tabs to enter the locking slots 120. The shape of the resilient locking tabs 70 of the first portion 60 of the first end plug is shown most clearly in Figure 22, and Figure 19, for example. The locking tabs 70 have a sloping exterior surface 137 adjacent a second (or bottom) end of the locking tab configured to cooperate with the sloping face of the adjacent sidewall of the sleeve upon insertion of the end plug into the sleeve, and cause the locking tab to be deflected inwardly.

Figure 23 shows the first end plug 50 in its final position inserted in the first end of the insert 33, with the locking tabs 70 inserted in the slots 120 of the insert 33, and the alignment tabs 72 inserted in the alignment slots 122.

As may be seen, for example in Figures 1, 2, 4 and 5, which include the jacket and outer shell 31 as well as the insert 33, the slots 120, 122 in the insert are covered, on their outer surfaces, by the panels of the outer shell 31. In this way, the slots provide recesses 140 and 142 respectively in the inner surface of the sidewalls of the sleeve 3, which do not extend through the full thickness of the sidewalls. The outer shell covers the recesses, to help maintain the locking tabs 70 in position in use, and provide greater integrity to the sleeve structure and avoid the recesses being visible from the exterior of the sleeve.

Figure 24 shows the assembly of the jacket and sleeve in the region of the first end thereof, showing how the panel of the outer sleeve covers the exterior of the slots 120 to provide the recesses 140 in the sidewall of the sleeve 3 provided by the combination of the outer shell 31 and insert 33. In this view, the closure flap 28 -55 -of the jacket is shown tucked into the space provided by spacer 26 between the panel 41 of the jacket and the second panel 7 of the sleeve. Figure 25 is a similar view, but with the jacket omitted to enable the spacer 26 to be more clearly seen. Assembly of the container in accordance with one exemplary arrangement will now be described. The sequence of steps and exact operations performed may vary from this example.

As shown in Figure 26, the insert 33 is inserted into the outer shell 31 from the top or first end thereof, in the direction of the arrow. The adjacent panels of the outer shell and insert are bonded e.g. adhesively to one another. This provides the sleeve 3, as shown in Figure 5.

Next the spacer 26 is bonded to the exterior of the second sidewall 7 of the sleeve 3 (as shown in Figure 25). The spacer is extends over only a portion of the width of the second sidewall 7 to define a gap 18.

The second end closure 154 including the second end plug 52 and support 57 is then inserted into the bottom end of the insert so as to plug the bottom end thereof and adhesively secured in the second end of the sleeve. The second end plug 52 and support 57 may be assembled together prior to insertion into the end of the sleeve as a single component, or, alternatively, the second end plug 52 and support 57 could be inserted sequentially into the bottom end of the insert and then secured to one another and the interior of the sleeve. Any suitable arrangement may be used. As stated above, the support may be omitted in some cases, and the form of the second end closure and/or plug may differ from that shown. In particular, it need not be of a moulded pulp construction. However, the second end closure should be of a card-based or paper-based material to allow recycling of the container without needing to separate it into individual components.

Next the jacket 20 is wrapped around the outside of the sleeve, with the panels 21 and 22 thereof overlying and being bonded e.g. adhesively to the second and third sidewalls 7, 9 of the sleeve. This provides an arrangement as shown in Figure 4, but with the second end closure already inserted in the bottom of the sleeve.

The bottle 36 is now dropped into the sub-assembly of the sleeve 3, second end closure 154 and jacket 20 through the open first or top end of the sleeve. The bottle is supported on the second end closure 154.

-56 -As part of the method, the first end closure 150 is assembled. This may occur separately or simultaneously to assembly of the sleeve, jacket and second end closure. The assembly of the first end closure 150 involves bonding e.g. adhesively the cover 51 to the second portion 62 of the first end plug 50, and then press fitting this sub-assembly of the cover and second portion 62 into the first portion 60 of the first end plug 50 as shown in Figures 17 and 18, to produce the first end closure 150 in the form shown in Figure 20. In one exemplary arrangement of mass producing a component including the second portion 62, multiple instances of the second portion 62 are bonded to the cover material.

Components including the second portion and cover are then cut out from the sheet. This avoids the need to register the second portions with the cover. However, other assembly techniques may be used, and the cover may be bonded to the second portion before or after it is assembled with the first portion of the moulded pulp end plug. The first and second portions 60, 62 are press fitted together, optionally without the use of adhesive or any other bonding agent or other external fixing agent.

Next the assembled first end closure 150 is pushed into the top or first end of the assembled jacket and sleeve. This could be performed by a robot. The first end plug 50 slides into the top end of the insert 33 as illustrated in Figure 20 until it is securely locked in place as shown in Figure 23 through engagement between the locking tabs 70 and the slots 120 (but with the outer shell 31 and jacket 20 already in position). No adhesive is required to fix the first end plug in position within the sleeve. The alignment tabs 72 align with the slots 122 to allow insertion of the first end plug 50 only in the intended orientation with the open end of the collar adjacent the first sidewall 5 of the sleeve. The underside of the flange 90 of the second portion 62 engages against the top of the sidewalls of the insert to locate the first end closure.

Once the first end closure 150 has been inserted in this way, the top of the bottle supported within the collar of the first portion 60 of the first end plug as shown in Figure 1. The door is then closed by folding the jacket around the sleeve and securing it in place by tucking the closure tab 28 into the space 18 between the second sidewall of the sleeve and the jacket to releasably fasten it into position to provide a construction as shown in Figure 2. The side edges of the cover 51 are -57 -flush with those of the jacket when closed around the sleeve to provide an attractive appearance to the container.

In use, the user may then untuck the closure tab 28, open the door to reveal the opening 12 in the first sidewall of the sleeve, and remove the bottle through the opening 12.

An alterative first end plug 50' is shown in Figures 27-30. The end plug is similar to that of the first embodiment described by reference to Figures 7 to 14. The two portions 60', 62' are fitted together in the same manner using a press fit. A cover (not shown) may be provided, and the resulting first end closure inserted into the first end of the sleeve to cooperate with recesses on the interior thereof in the same manner as previously described in relation to the first embodiment. Corresponding parts are labelled with the same references as the earlier embodiment, annotated by a ". This further embodiment will be described only by reference to those features which differ.

The first portion 60' of the first end plug 50' is shown in Figures 27 and 28 and is of the same configuration as the first portion 60 of the first end plug 50 of the first embodiment described earlier. Figure 27 is a view from the second side of the first portion 60' which lies lowermost, or closest to the second end of the container in use. As in the earlier embodiment, a collar 80' is provided for supporting the top of a bottle. Figure 28 is a view from the first side of the first portion 60' which lies uppermost in use.

The first end plug 50' differs from the first end plug 50 of the first embodiment in the construction of the second portion 62' thereof The second portion 62' is shown in Figures 29 and 30, which show respectively, the second portion 62' from the second, or lower side thereof, and from the first, or upper side thereof. Rather than having a single C-shaped projection defining a ridge on the second side thereof, which is inserted into the recess on the first side of the first portion of the first end plug corresponding to the reverse of the collar 80' in order to support the collar and assist in providing a press fit between the portions, the second portion 62' has a pair of projections 210, 212 on the second side thereof, which are inserted into the recess corresponding to the reverse of the collar 80'. These projections 210, 212 are located in the recess at the base of the arms thereof, on either side of the recess, closest to the corners where sidewalls 63' and 65' and 63' and 67' join one another respectively. Projections 112' comprising -58 -planar surfaces for bonding to a cover of the end plug 50' are provided on the first, or upper side of the portion 62' similar to the first embodiment, but extend over only a portion of the length of the sidewalls 95', 97' respectively of the second portion 62' in order to accommodate the pair of projections 210, 212.

This alternative arrangement for supporting the collar of the first portion may provide greater stability in certain contexts. The most appropriate configuration of projection(s) on the second side of the second portion of the first end plug to support a collar of the first portion ay be selected as desired, depending e.g. upon the type of product, or indeed bottle, to be supported by the collar, and likely forces to be withstood in use. The shape of the collar and/or its support may vary from that shown. Thus, where the first portion comprises a product support in the form of a collar, the second portion may comprise a collar support in the form of one or more projections inserted into the recess provided in the first side of the first portion corresponding to the reverse of the collar.

Of course, alternative forms of product support, not necessarily comprising a collar, may be used, depending upon the intended content of the container. It will also be understood that the configuration of the moulded formations of the first and second portions of the first end plug may differ from those shown, and may be selected to provided desired functionality of the first end plug or either portion thereof, e.g. in assisting in supporting the product and/or providing an inter-engagement between the first and second portions and/or providing attachment to other portions of the container, such as a cover of the first end closure, or to the sleeve. The shape and/or size of the alignment and/or locking tabs may differ from that shown.

It has been found that the container of the present invention in any of its embodiments may provide a sustainable container of paper or card-based material, which may be readily recycled, allowing all components to be disposed of via the same recycling waste stream for such materials, and which may be readily manufactured, for example using robot assembly techniques. The container enables the bottle to be loaded from the top end, with the moulded pulp first end plug then being pressed into the top of the sleeve. The resilient tabs of the first end plug enable the plug to be secured in place by a simple press fit operation, which may be performed by a robot. It is advantageous to be able to avoid the need to -59 -perform a gluing operation at this stage in assembly, after insertion of the bottle. This may provide a simpler and cleaner process, with fewer steps.

The container is suitable for fragile products, such as glass bottles. It has been found that the construction may withstand required tests for such bottles, involving inserting a 10Kg weight in the container and shaking it while upside down.

The first end plug secured to the sleeve in the manner described has been found to provide a sufficiently secure fit to pass such a test.

The first end plug of the first end closure described herein may provide a closure that is of a strength that allows it to provide a sustainable alternative to conventional closures using plastic material e.g. involving interlocking plastic parts.

While the container has been described in the context of being for a bottle, it is envisaged that other types of product may be housed in the container. The container may be advantageous in any context where a strong container is required, for example in the context of any fragile item. However, the containers of the present invention are particularly useful in housing fragile items, such as bottles, for example drinks bottles. The container may house a single drinks bottle. Moulded pulp as used herein refers to a material comprising cellulosic fibers. The material may be moulded using any suitable process. The material is sustainable in that it may be recycled along with other card and/or paper-based materials. The moulded pulp material may be formed at least partially from recycled material, i.e. recycled fibres obtained from recycling card-based or paper-based materials.

The invention may extend to producing each of the first and second portions of the first moulded pulp end plug using a pulp moulding process e.g. wet moulding process. Each portion is produced using a respective mould configured to provide the respective one of the first and second portions. For example, producing the first and second portions of the first moulded pulp end plug using a wet moulding process may involve separately moulding each of the first and second portions using a respective mould having a shaped moulding surface configured to provide the formations of the respective one of the first and second portions. The moulding surface may be a male moulding surface, for example.

The method may comprise moulding each of the first and second portions by a method comprising; lowering a mould having a shaped moulding surface for providing the formations of the respective one of the moulded pulp first and second -60 -portions of the moulded pulp end plug into a container of pulp slurry, causing pulp material to accumulate on the shaped moulding surface and raising the mould out of the container of pulp slurry with pulp material deposited on the moulding surface thereof to provide a preform of the respective one of the moulded pulp first and second portions. The method may involve using a vacuum to assist in causing the pulp material to become accumulated on the shaped moulding surface. The moulding surface may be any suitable porous surface. The moulding surface may comprise for example a mesh upon which the pulp material is collected.

The method may further comprise drying the preform. The method may further comprise removing the preform from the shaped moulding surface. This may occur before or after drying thereof, or between steps involved in the drying process. The step of drying the preform may involve one or more steps which may involve dewatering the pulp material e.g. through pressing and/or heating the material. The step of drying the deposited material may or may not involve transferring the preform to a further supporting surface e.g. of another mould or conveyor.

The method may involve mating the shaped moulding surface having the deposited pulp material thereon providing the preform with a cooperating shaped moulding surface of a further mould after raising of the (first) mould out of the slurry.

The deposited material may be pressed between the moulding surfaces e.g. to dewater and assist in shaping the material. The further mould may be a female mould where the male mould was dipped into the pulp slurry, although the reverse arrangement may be envisaged.

While various pulp moulding techniques may be used to produce the moulded pulp end plug, and, where applicable, the first and second portions thereof, not limited to the above example, in embodiments, the first and second portions of the first end plug are each formed by (or may be formed by) depositing pulp material on a shaped moulding surface of a mould, the shaped moulding surface being configured to produce the formations of the respective one of the first and second portions. -61 -

Claims

CLAIMS1. A container made of paper-based or card-based material, comprising: a sleeve having a first end and a second end, a first end closure closing the first end of the sleeve, and a second end closure closing the second end of the sleeve; the sleeve comprising a plurality of sidewalls extending between the first end and the second end thereof, wherein a first sidewall of the sleeve comprises an opening therein to provide access to an interior space of the sleeve in which a product is disposed in use; wherein the first end closure comprises a moulded pulp end plug, the moulded pulp end plug comprising resilient locking tabs projecting outwardly therefrom, each locking tab being received in a respective recess in the interior of the sleeve to securely retain the moulded pulp end plug within the first end of the sleeve.
2. The container of claim 1 wherein the moulded pulp end plug of the first end closure comprises sidewalls, each sidewall extending along a corresponding one of the sidewalls of the sleeve, wherein each one of a plurality of the sidewalls of the end plug comprises one or more of said resilient locking tabs projecting outwardly therefrom and being received in a respective recess in the corresponding sidewall of the sleeve.
3. The container of claim 2 wherein the plurality of sidewalls of the end plug having said resilient tabs includes at least a pair of opposed sidewalls of the end plug; optionally wherein the plurality of sidewalls of the moulded pulp end plug having said resilient locking tab(s) further comprises a sidewall connecting the pair of opposed ones of the sidewalls.
4. The container of claim 2 or claim 3 wherein the sidewall of the moulded pulp end plug extending along the first sidewall of the sleeve is free from said resilient locking tabs.
5. The container of any one of claims 2 to 4 wherein each one of the sidewalls of the end plug having resilient locking tabs projecting outwardly therefrom -62 -comprises a plurality of the resilient locking tabs projecting outwardly therefrom, such as a pair of the resilient locking tabs.
6. The container of any preceding claim wherein the moulded pulp end plug further comprises an alignment feature such that the end plug may only be inserted in the sleeve in a predetermined orientation with respect to the sleeve.
7. The container of claim 6 wherein the moulded pulp end plug comprises a product support comprising a moulded pulp collar on a second side of the end plug, and the predetermined orientation is an orientation in which an open end of the collar faces the first sidewall of the sleeve to enable a product to be removed from the interior of the sleeve through the opening in the first sidewall.
8. The container of claim 6 or 7 as dependent upon any one of claims 2 to 5 wherein one of the sidewalls of the moulded pulp end plug of the first end closure having one or more resilient locking tabs further comprises one or more resilient alignment tabs projecting outwardly therefrom, and the corresponding sidewall of the sleeve comprises one or more additional recesses for receiving respective ones of the one or more resilient alignment tabs.
9. The container of claim 8 wherein the one or more recesses for receiving the one or more resilient locking tabs are spaced from a first end edge of the sleeve, and the one or more recesses for receiving the one or more resilient alignment tabs extend to the first end edge of the sleeve.
10. The container of any preceding claim wherein each resilient locking tab of the moulded end plug is configured to hook into its corresponding recess in the sleeve, the locking tab having a first end edge that cooperates with a first end edge of the recess to retain the tab in its recess, the resilient locking tab curving outwardly in a direction from a second end of the tab towards the first end of the tab.
11. The container of any preceding claim wherein each sidewall of the sleeve having one or more recesses for cooperating with one or more respective resilient -63 -locking tabs of the moulded pulp end plug comprises an internal sloping surface at the first end thereof and located between the first end edge of the sidewall and the one or more recesses of the sidewall for guiding the moulded pulp end plug as it is inserted into the container.
12. The container of claim 11 wherein each resilient locking tab of the moulded end plug comprises an outwardly curved surface on the exterior thereof which cooperates with a respective one of the internal sloping surfaces of the sleeve to cause the locking tab to be deflected inwardly as the end plug is inserted into the first end of the sleeve.
13. The container of any preceding claim wherein the moulded pulp end plug of the first end closure comprises first and second separately formed and inter-engaging moulded pulp portions, the first portion being located closest to the second end of the sleeve, wherein the moulded pulp end plug comprises sidewalls, each sidewall extending along a corresponding one of the sidewalls of the sleeve, wherein each of one or more of the sidewalls of the end plug comprises one or more of said resilient locking tabs projecting outwardly therefrom, wherein the first portion provides the sidewalls of the moulded pulp end plug and the one or more resilient locking tabs of the end plug, and wherein the second portion fits within the first portion.
14. The container of claim 13 wherein sidewalls of the second portion engage the interior of the sidewalls of the first portion to reinforce the first portion.
15. The container of claim 13 or 14 wherein the sidewalls of the second portion comprise recesses in positions corresponding to the positions of the resilient locking tabs associated with the sidewalls of the first portion of the moulded pulp end plug.
16. The container of claim 15 wherein each sidewall of the second portion which engages a sidewall of the first portion having one or more resilient locking tabs projecting therefrom comprises alternating first and second regions along the length thereof, each first region engaging the sidewall of the first portion, and each second -64 -region defining a recess in the sidewall in a position corresponding to a position of a resilient locking tab of the sidewall of the first portion.
17. The container of claim 15 or 16 wherein each recess in a sidewall of the second portion at a position corresponding to that of a resilient locking tab of the first portion spaces the sidewall of the second portion from the inner surface of the locking tab to result in a cavity being defined between the outer surface of the sidewall of the second portion and the inner surface of the resilient locking tab, the separate formation of the first and second portions of the end plug facilitating providing such a cavity.
18. The container of any of claims 13 to 17 wherein the second portion of the moulded pulp end plug comprises a flange at a first end thereof, the sidewalls of the second portion being upstanding therefrom, wherein the flange cooperates with the first end of the sleeve to locate the moulded pulp end plug.
19. The container of any of claims 13 to 18 wherein the recesses of the sleeve for receiving the resilient locking tabs are spaced from an edge of the sleeve at the first end thereof, and sidewalls of the second portion of the moulded pulp end plug have a height greater than that of the sidewalls of the first portion of the moulded pulp end plug so as to space the resilient locking tabs of the first portion from the first end of the sleeve to enable the locking tabs to be received in the recesses.
20. The container of claim 19 as dependent upon claim 18 wherein the flange is spaced from and overhangs the first end edges of the resilient locking tabs of the first portion.
21. The container of any one of claims 18-20 wherein a cavity is defined in the moulded pulp end plug in the region of each resilient locking tab, the cavity bounded on its inner side by the outer surface of a sidewall of the second portion, on the side closest to the first end of the container by a second side of the flange and on the outer side over a portion of the height of the cavity closer to the second end of the container by the inner surface of the resilient locking tab, and, over a portion of the height of the cavity closer to the first end of the -65 -container, by the inner surface of the sleeve in the region between the first end edge of the recess of the sleeve and the second side of the flange, the separate formation of the first and second portions facilitating providing such a cavity.
22. The container of any one of claims 13 to 21 wherein the first and second portions of the moulded pulp end plug are secured to one another by press fit; and optionally are adhesively bonded to one another.
23. The container of any one of claims 13 to 22 wherein the first portion defines a first side and an opposite second side, the second side facing the second end of the sleeve, wherein the second side comprises one or more projections defining a collar for receiving a top of a product in the form of a bottle, wherein the open end of the collar faces the first sidewall of the sleeve.
24. The container of claim 23 wherein the second portion defines a first side and an opposite second side, the second side of the first portion facing the second end of the sleeve, wherein the second side of the second portion comprises one or more projections for supporting the collar, each projection being received in a respective recess defined on the first side of the first portion by the reverse of the one or more projections defining the collar; optionally wherein the collar is defined by a single C-shaped projection on the second side of the first portion, and wherein the second side of the second portion comprises a pair of projections which are received in respective ones of the arms of a C-shaped recess defined on the second side of the first portion by the reverse of the C-shaped projection defining the collar; or wherein the second side of the second portion includes a single projection in the form of a C-shaped rib which is received in a C-shaped recess defined on the second side of the first portion by the reverse of the C-shaped projection defining the collar.
25. The container of any preceding claim wherein the recesses of the sleeve for receiving the resilient locking tabs do not extend through the full thickness of the sleeve.
-66 - 26. The container of any preceding claim wherein each sidewall of the sleeve having one or more recesses for receiving respective resilient locking tabs of the moulded pulp end plug of the first end closure comprises inner and outer layers at least in the region of the first end of the sleeve, wherein each recess is provided by a slot extending through the inner layer of the sidewall, and the outer layer of the sidewall covers the slot.
27. The container of claim 26 wherein the sleeve comprises an insert and an outer shell, each comprising a plurality of panels hingedly connected to one another, wherein the slots are provided in panels of the insert, the slots being covered by panels of the outer shell.
28 The container of claim 27 wherein the first sidewall of the sleeve is provided by a panel of the outer shell which defines the opening providing access to the interior of the sleeve, and which is not lined by a panel of the insert.
29. The container of any one of claims 27 or 28 wherein the panels of the insert comprise sloping surfaces at the first ends thereof to guide the moulded pulp end plug of the first end closure as it is inserted into the sleeve during assembly of the container.
30. The container of any preceding claim comprising a door rotatable about a foldline between a closed state in which the door covers the opening in the first sidewall of the sleeve, and an open state in which the opening is uncovered for providing access through the opening to a product when located in the interior space of the sleeve in use.
31. The container of any preceding claim wherein the container further comprises an outer jacket.
32. The container of claim 31 as dependent upon claim 30, wherein the jacket comprises a set of panels hingedly connected to one another, wherein the door is provided by a panel of the jacket, the jacket further comprising one or more additional panels hingedly connected to the door panel on one side thereof, each -67 -additional panel being secured to a respective sidewall of the sleeve, and a closure mechanism attached to the door panel on the other side thereof for releasably fastening the door in the closed state.
33. The container of claim 32 wherein a panel at one end of the set of jacket panels is secured to its respective sidewall of the sleeve via a spacer such that a gap is defined between the jacket panel and the sleeve, and the closure mechanism is in the form of a flap which tucks into the gap to releasably fasten the door in the closed state.
34. The container of any preceding claim wherein the moulded pulp end plug is secured within the sleeve by a press fit and cooperation of the resilient locking tabs with the recesses of the sleeve, and without the use of adhesive.
35. The container of any preceding claim further comprising a product in the form of a bottle located therein.-68 -