Patent Description:
<CIT> discloses a container providing sensate properties to a smokeless tobacco product.

<CIT> discloses a container lid adapted to interlock with the container base having a peripheral rim.

<CIT> discloses a container configured to house a fluid, the container including a neck that has an open end and is coupled to a body.

<CIT> discloses containers for holding particulate materials.

<CIT> discloses containers for smokeless tobacco products including a layer of fibrous material, wherein the layer of fibrous material includes a moisture barrier layer embedded within the layer of fibrous material or carried on an outer surface of the layer of fibrous material as a coating.

<CIT> discloses a container adapted for storing a product. The container includes a body having a bottom wall and a side wall, the bottom wall and the side wall defining an internal storage compartment adapted for storage of a plurality of units of products.

<CIT> discloses a container including a lower body portion and an upper lid. The lower body portion includes an intermediate bottom wall separating the lower body portion into upper and lower internal storage compartments. An environmental modification material is received in the lower internal storage compartment.

Various types of containers for dispensing solid objects, particularly solid products intended for human consumption, are known in the art. Such containers are often characterized by a hand-held size that can be easily stored and transported. Exemplary consumable products that are often packaged in such containers include a wide variety of consumer products, including "smokeless" tobacco-related products.

Particularly popular smokeless tobacco products are employed by inserting some form of processed tobacco or tobacco-containing formulation into the mouth of the user. See for example, the types of smokeless tobacco formulations, ingredients, and processing methodologies set forth in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>; <CIT>; and <CIT>.

Representative smokeless tobacco products that have been marketed include those referred to as CAMEL Snus, CAMEL Orbs, CAMEL Strips and CAMEL Sticks by R. Reynolds Tobacco Company; GRIZZLY moist tobacco, KODIAK moist tobacco, LEVI GARRETT loose tobacco and TAYLOR'S PRIDE loose tobacco by American Snuff Company, LLC; KAYAK moist snuff and CHATTANOOGA CHEW chewing tobacco by Swisher International, Inc. ; REDMAN chewing tobacco by Pinkerton Tobacco Co. LP; COPENHAGEN moist tobacco, COPENHAGEN Pouches, SKOAL Bandits, SKOAL Pouches, RED SEAL long cut and REVEL Mint Tobacco Packs by U. Smokeless Tobacco Company; and MARLBORO Snus and Taboka by Philip Morris USA.

Representative types of snuff products, commonly referred to as "snus," are manufactured in Europe, particularly in Sweden, by or through companies such as Swedish Match AB, Fiedler & Lundgren AB, Gustavus AB, Skandinavisk Tobakskompagni A/S and Rocker Production AB. Snus products previously or currently available in the U. have been marketed under the trade names such as CAMEL Snus Frost, CAMEL Snus Original, and CAMEL Snus Spice, CAMEL Snus Mint, CAMEL Snus Mellow, CAMEL Snus Winterchill, and CAMEL Snus Robust by R. Reynolds Tobacco Company.

Snus products, such as CAMEL Snus Original, are commonly supplied in small teabag-like pouches. The pouches are typically a nonwoven fleece material, and contain about <NUM> to <NUM> grams of pasteurized tobacco. These products typically remain in a user's mouth for about <NUM>-<NUM> minutes. Unlike certain other smokeless tobacco products, snus does not require expectoration by the user.

Snus products have been packaged in tins, "pucks" or "pots" that are manufactured from metal or plastic such as those disclosed in <CIT>, <CIT>, and <CIT>, and <CIT>; <CIT>; <CIT>; and <CIT>.

However, it may be desirable to provide containers formed from different materials defining differing properties (e.g., texture, appearance, attractiveness) as compared to materials (e.g., plastic and metal) traditionally employed in containers.

In one aspect, a container is provided. The container includes a lid and a base. The lid includes a top wall and one or more lid sidewalls extending from the top wall to a lower lip defining a lid opening. The base is moveable with respect to the lid between a coupled configuration in which an internal storage compartment defined by the base is substantially closed and a decoupled configuration in which the internal storage compartment is open. The base comprises a bottom wall and one or more base sidewalls extending from the bottom wall to an upper lip defining a base opening. At least one of the lid and the base is pulp-molded from a pulp derived from a plant material.

In some embodiments the pulp derived from the plant material may include a wood pulp material. The plant material may be the majority of the weight of the pulp. Additionally, at least one of the lid and the base may further include a coating. The coating may be positioned at an exterior of at least one of the lid and the base and may not be positioned at an interior of the lid and the base.

In some embodiments at least one of the base and the lid may include a liner. Further, plurality of units of a smokeless tobacco product is received in the internal storage compartment. The base may include an intermediate wall including the pulp derived from the plant material.

In an additional aspect a method for manufacturing a container is provided. The method includes pulp-molding at least one of a base and a lid from a pulp derived from a plant material. The lid comprises a top wall and one or more lid sidewalls extending from the top wall to a lower lip defining a lid opening. The base comprises a bottom wall and one or more base sidewalls extending from the bottom wall to an upper lip defining a base opening. The base is moveable with respect to the lid between a coupled configuration in which an internal storage compartment defined by the base is substantially closed and a decoupled configuration in which the internal storage compartment is open.

In some embodiments constructing at least one of the base and the lid from the pulp derived from the plant material may include directing the pulp derived from the plant material into a base mold and a lid mold. The method may further include applying pressure to the pulp derived from the plant material in the base mold and the lid mold. Applying pressure to the pulp derived from the plant material may comprise expanding a base expandable device within the base mold and expanding a lid expandable device within the lid mold.

In some embodiments the method may additionally include drying the pulp derived from the plant material. Further, the method may include removing the lid from the lid mold and removing the base from the base mold. Directing the pulp derived from the plant material into the base mold and the lid mold may comprise spraying the pulp derived from the plant material into the base mold and the lid mold. The method comprises positioning at least one of a coating and a liner to an exterior of at least one of the base and the lid, and not positioned at an interior of the lid and the base.

The present disclosure now will be described more fully hereinafter with reference to certain preferred aspects. These aspects are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein.

Exemplary tobacco products include pelletized tobacco products (e.g., compressed or molded pellets produced from powdered or processed tobacco, such as those formed into the general shape of a coin, cylinder, bean, pellet, sphere, orb, strip, obloid, cube, bead, or the like), extruded or cast pieces of tobacco (e.g., as strips, films or sheets, including multilayered films formed into a desired shape), products incorporating tobacco carried by a solid substrate (e.g., where substrate materials range from edible grains to inedible cellulosic sticks), extruded or formed tobacco-containing rods or sticks, tobacco-containing capsule-like materials having an outer shell region and an inner core region, straw-like (e.g., hollow formed) tobacco-containing shapes, sachets or packets containing tobacco (e.g., snus-like products), pieces of tobacco-containing gum, and the like. Further, exemplary tobacco products include tobacco formulations in a loose form such as, for example, a moist snuff product. Exemplary loose form tobacco used with the containers of the present disclosure may include tobacco formulations associated with, for example, commercially available GRIZZLY moist tobacco products and KODIAK moist tobacco products that are marketed by American Snuff Company, LLC.

Exemplary smokeless tobacco compositions that can be packaged in the containers of the present disclosure are set forth in, for example, <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>; <CIT>, <CIT> and <CIT>; and <CIT> Examples of tobacco-containing gum are set forth in <CIT>; <CIT>; and <CIT>. Various manners or methods for packaging smokeless tobacco products are set forth in <CIT> and <CIT>; and <CIT>; and <CIT>; <CIT>; and <CIT>.

Embodiments of containers for packaging products such as smokeless tobacco products including trays slidably received in housings are described in <CIT>; <CIT>; <CIT>; <CIT>; and <CIT> and <CIT> <CIT> describes a hinged container for packaging products such as smokeless tobacco products. <CIT> and <CIT> disclose metal containers for tobacco products with a sliding lid. <CIT> describes a container for packaging products such as smokeless tobacco products including an outer casing and a dispensing tray. <CIT>describes a container for packaging products such as smokeless tobacco products including a base and a lid configured to pivot and slide between open and closed positions. <CIT> describes a container for packaging products such as smokeless tobacco products including a separable lid and base with vent channels. <CIT> discloses hinging containers with blister packs received therein.

Smokeless tobacco compositions utilized as the product contained in the containers of the present disclosure will often include ingredients such as tobacco (typically in particulate form), sweeteners, binders, colorants, pH adjusters, fillers, flavoring agents, disintegration aids, antioxidants, oral care additives, and preservatives. See, for example, <CIT>.

The tobacco formulation can be contained within a container, such as a pouch or bag, such as is the type commonly used for the manufacture of snus types of products (e.g., a sealed, moisture permeable pouch that is sometimes referred to as a "portion"). A representative moisture permeable pouch can be composed of a "fleece" type of material. The tobacco formulation is in turn contained within a package, such as the containers of the present disclosure described more fully hereinbelow. The package is sealed, and is composed of a suitable material, such that the atmospheric conditions within that sealed package are modified and/or controlled. That is, the sealed package can provide a good barrier that selectively or non-selectively inhibits the passage of compositions such as moisture and oxygen therethrough. For example, the seal or gasket can be useful for inhibiting ingress of moisture while also allowing for egress of gas. In addition, the atmosphere within the sealed package can be further modified by introducing a selected gaseous species (e.g., nitrogen, argon, or a mixture thereof) into the package prior to sealing or by drawing a vacuum therein (vacuum sealing). As such, the atmospheric conditions to which the tobacco composition is exposed are controlled during conditions of one or more of preparation, packing, storage and handling.

An exemplary pouch may be manufactured from materials, and in such a manner, such that during use by the user, the pouch undergoes a controlled dispersion or dissolution. Such pouch materials may have the form of a mesh, screen, perforated paper, permeable fabric, or the like. For example, pouch material manufactured from a mesh-like form of rice paper, or perforated rice paper, may dissolve in the mouth of the user. As a result, the pouch and tobacco formulation each may undergo complete dispersion within the mouth of the user during normal conditions of use, and hence the pouch and tobacco formulation both may be ingested by the user. Other exemplary pouch materials may be manufactured using water dispersible film forming materials (e.g., binding agents such as alginates, carboxymethylcellulose, xanthan gum, pullulan, and the like), as well as those materials in combination with materials such as ground cellulosics (e.g., fine particle size wood pulp). Preferred pouch materials, though water dispersible or dissolvable, may be designed and manufactured such that under conditions of normal use, a significant amount of the tobacco formulation contents permeate through the pouch material prior to the time that the pouch undergoes loss of its physical integrity. If desired, flavoring ingredients, disintegration aids, and other desired components, may be incorporated within, or applied to, the pouch material.

Descriptions of various components of snus products and components thereof also are set forth in <CIT> See, also, for example, <CIT>; <CIT>; <CIT>; and <CIT>, and <CIT> See, also, the representative types of pouches, and pouch material or fleece, set forth in <CIT>. Snus products can be manufactured using equipment such as that available as SB <NUM>-<NUM>/T, SBL <NUM> and SB <NUM>-<NUM>/T from Merz Verpackungmaschinen GmBH. D SpA out of Italy also supplies tobacco pouching equipment. Snus pouches can be provided as individual pouches, or a plurality of pouches and can be connected or linked together (e.g., in an end-to-end manner) such that a single pouch or individual portion can be readily removed for use from a one-piece strand or matrix of pouches.

Although example embodiments of containers are illustrated in the drawings and described herein, it should be understood that the shape of the containers of the disclosure can vary. For example, although the container embodiments illustrated in the drawings have certain contours, containers with other exterior surface designs could also be used. Further, the sides or edges of the containers of the disclosure could be flattened, rounded, or beveled, and the various surfaces or edges of the container exterior could be concave or convex. Further, the opposing sides, ends, or edges of the container can be parallel or non-parallel such that the container becomes narrower in one or more dimensions. Additionally, although the example embodiments of dimensions described herein are provided in order to achieve certain benefits, the dimensions may vary in other embodiments.

The number of solid product units stored in the containers of the disclosure can vary, depending on the size of the container and the size of the product units. Typically, the number of stored product units will vary from about <NUM> to about <NUM>, more typically about <NUM> to about <NUM>, and most often about <NUM> to about <NUM>.

<FIG> illustrates a perspective view of a container <NUM> according to an example embodiment of the present disclosure. The container <NUM> comprises a lid <NUM> and a base <NUM>. The lid <NUM> and the base <NUM> are configurable between a coupled configuration and a decoupled configuration. <FIG> illustrates the lid <NUM> and the base <NUM> in a coupled configuration in which the lid is coupled to the base. In the coupled configuration one or more units of a smokeless tobacco product are stored therein.

The lid <NUM> and the base <NUM> are configured to a decoupled configuration in which the lid and the base may be separated from one another. In this regard, <FIG> illustrates a perspective view of the base <NUM> and <FIG> illustrates a top view of the base. As illustrated, the base <NUM> comprises a bottom wall <NUM> and one or more base sidewalls <NUM>. The base sidewalls <NUM> extend from the bottom wall <NUM> to an upper lip <NUM>. The upper lip <NUM> defines a base opening <NUM> that can provide access to an internal storage compartment <NUM>. The internal storage compartment <NUM> receives one or more units of product therein in the coupled configuration (see, e.g., <FIG>) and provide access to the units of product via the base opening <NUM> in the decoupled configuration (see, e.g., <FIG> and <FIG>) in which the internal storage compartment <NUM> is open.

The base sidewalls <NUM> may comprise an outer portion <NUM>, which extends from the bottom wall <NUM>. The base sidewalls <NUM> may further comprise an inwardly offset portion <NUM> and an angled portion <NUM>. The angled portion <NUM> may extend from the inwardly offset portion <NUM> to the upper lip <NUM>. The base sidewalls <NUM> may further comprise a shoulder portion <NUM> extending substantially perpendicularly to the outer portion <NUM> and the inwardly offset portion <NUM>. The shoulder portion <NUM> may connect the outer portion <NUM> to the inwardly offset portion <NUM>.

The inwardly offset portion <NUM> of the base sidewalls <NUM> may define one or more protrusions <NUM> projecting outwardly therefrom. The base sidewalls <NUM> may further comprise one or more recessed portions <NUM>. Each recessed portion <NUM> may extend from the outer portion <NUM> to the inwardly offset portion <NUM>. However, whereas the shoulder portion <NUM> of the base sidewalls <NUM> may extend substantially perpendicularly to the outer portion <NUM> and the inwardly offset portion <NUM>, the recessed portion <NUM> may extend at an angle that is non-parallel and non-perpendicular to the outer portion and the inwardly offset portion. As described below, this configuration may allow the recessed portion <NUM> to provide a user with access to the lid <NUM> when the lid is coupled to the base <NUM>.

<FIG> illustrate the lid <NUM> of the container <NUM>. In particular, <FIG> illustrates a perspective view of the lid <NUM>, <FIG> illustrates a top view of the lid, and <FIG> illustrates a bottom view of the lid. As illustrated, the lid <NUM> comprises a top wall <NUM> defining an inner surface <NUM>. One or more lid sidewalls <NUM> extend from the top wall <NUM> to a lower lip <NUM> defining a lid opening <NUM>. Further, a sealing member <NUM> may extend around a perimeter of the top wall <NUM> at the inner surface <NUM> thereof.

In this regard, as illustrated in <FIG> and <FIG>, which are sectional views through the container <NUM> in the closed position along lines <NUM>-<NUM> and <NUM>-<NUM> in <FIG>, the top wall <NUM> of the lid <NUM> may define a channel <NUM> at the inner surface <NUM> thereof in which the sealing member <NUM> may be at least partially received. The channel <NUM> may define a depth from about <NUM> millimeters to about <NUM> millimeters and/or a radius from about <NUM> millimeter to about <NUM> millimeters in some embodiments. In a preferred embodiment the channel <NUM> may define a depth of about <NUM> millimeters and define a radius of about <NUM> millimeters.

In one embodiment the sealing member <NUM> may be formed from a fluid that is directed into the channel <NUM>, such that the channel is partially or completely full, in a fluid form and thereafter cured or otherwise transformed into a solid or semi-solid form (e.g., a gel). For example, the sealing member <NUM> may comprise plastisol that is directed into the channel <NUM> and cured therein via the application of heat. As the plastisol is heated, the plastisol may transfer from a fluid form to an air-filled gel matrix. During the transformation from fluid to air-filled gel matrix, the plastisol may expand outwardly from the channel <NUM>. Accordingly, the above-noted dimensions of the channel <NUM> may be selected to result in a sealing member <NUM> defining desired dimensions.

In embodiments in which the sealing member <NUM> is applied to the lid <NUM> as a fluid and cured therein, the lid may comprise a material capable of being heating without suffering damage thereto. For example the lid <NUM> may comprise a metal such as tin, aluminum, steel, or tin coated steel plate. Wood containers (e.g., formed from a pulp material as described below) may also be capable of being heated without suffering damage. In contrast, embodiments of plastics and other materials having a melting point less than a temperature at which the plastisol is cured may not be employed to form the lid <NUM> in this embodiment, since the material may melt during the curing process.

Although the plastisol (or other fluid) is described above as being directed into the channel <NUM> to form the sealing member <NUM>, in another embodiment the entirety of the inner surface <NUM> of the top wall <NUM> of the lid <NUM> may be coated with plastisol (or other fluid), which may then be cured to form a sealing member extending across the entirety of the inner surface of the top wall of the lid. In this embodiment, the channel <NUM> may be omitted from the top wall <NUM>. However, this embodiment may employ more plastisol than is necessary, since sealing contact with the sealing member may only occur at specific locations, as will be described below, such that coating the inner surface <NUM> of the top wall <NUM> of the lid <NUM> may be more expensive and produce a container that is heavier than necessary.

Further, the sealing member <NUM> may comprise various other embodiments of materials. For example, the sealing member <NUM> may comprise rubber, plastic, or various other embodiments of elastomeric materials configured to form a seal. In particular, any material suitable for forming a resilient gasket can be used according to the present disclosure. These materials may be glued or otherwise coupled to the inner surface <NUM> of the top wall of the lid <NUM>, rather than applied as a fluid and cured therein.

As illustrated in <FIG>, an outer surface <NUM> of the top wall <NUM> of the lid <NUM> may comprise an outwardly protruding portion <NUM> at the channel <NUM>, which may extend about the perimeter of the top wall. In this regard, the channel <NUM> may be stamped or formed at the top wall <NUM> of the lid <NUM> in some embodiments such that the top wall is concave at the inner surface <NUM> and convex at the outer surface <NUM>. The outwardly protruding portion <NUM> of the top wall <NUM> at the channel <NUM> may provide a user with grip when holding the container <NUM>.

As illustrated in <FIG> and <FIG>, the outwardly protruding portion <NUM> of the top wall <NUM> at the channel <NUM> may extend past a remainder of the lid <NUM> and collectively define a planar surface. Thus, the outwardly protruding portion144 of the top wall <NUM> at the channel <NUM> may be employed to support the container <NUM> in a stable manner when the container is placed with the lid <NUM> down on a surface, and elevate the container <NUM> such that grasping and lifting the container off of the surface is facilitated.

When the lid <NUM> and the base <NUM> are moved from the decoupled configuration to the coupled configuration illustrated in <FIG>, <FIG>, and <FIG>, the angled portion <NUM> of the base sidewalls <NUM> may align the base <NUM> with respect to the lid <NUM> when the lid is placed on the base. In this regard, the angled portion <NUM> of the base sidewalls <NUM> may define an angle <NUM> with respect to the inwardly offset portion <NUM>. Accordingly, the upper lip <NUM> of the base <NUM> may be received with clearance within the lid opening <NUM> to the lid <NUM> such that a degree of tolerance is provided with respect to the lower lip <NUM> when the lid and the base are moved into contact with one another during coupling therebetween. Thus, even when a user misaligns the lid <NUM> and the base <NUM>, the angled portion <NUM> of the base sidewalls <NUM> may bring the base and the lid into alignment. Accordingly, movement of the lid <NUM> and the base <NUM> from the decoupled configuration to the coupled configuration may be facilitated.

Further, when the lid <NUM> and the base <NUM> are moved to the coupled configuration, the internal storage compartment <NUM> defined by the base is closed. Further, in some embodiments the internal storage compartment <NUM> may be substantially sealed shut. In this regard, the upper lip <NUM> of the base <NUM> may contact and seal against the sealing member <NUM> of the lid <NUM> when the lid and the base are moved to the coupled configuration. The angle <NUM> defined by the angled portion <NUM> of the base <NUM> with respect to the inwardly offset portion <NUM> may be configured to position the upper lip <NUM> in contact with the sealing member <NUM> when the upper lip, the angled portion, and the inwardly offset portion are received through the lid opening <NUM>. More particularly, the angle <NUM> defined by the angled portion <NUM> may be configured to center the upper lip <NUM> of the base <NUM> with respect to the channel <NUM> and/or the sealing member <NUM>.

In one embodiment the angle <NUM> of the angled portion <NUM> of the base sidewalls <NUM> may be from about thirty-five degrees to about forty degrees. In a preferred embodiment the angle <NUM> of the angled portion may be about <NUM> degrees. Use of these values for the angle <NUM> may provide the container <NUM> with a more compact form as compared to embodiments of containers defining a substantially straight base sidewall extending substantially perpendicular to a lid when coupled therewith. The above-noted values of the angle <NUM> may provide a desirable balance between reducing the overall height of the container <NUM> and providing a sufficient volume of the internal storage compartment <NUM> for storage of units of product therein. Note that the angled portion <NUM> of the base sidewalls <NUM> may also bend inwardly toward the internal storage compartment <NUM>. In this regard, the base sidewalls <NUM> may define an equal thickness at each of the portions thereof. For example, in one embodiment the base <NUM> and/or the lid <NUM> may be formed from single pieces of material (e.g., metal) that is stamped, bent, and/or otherwise manipulated to form the container <NUM>. By forming the angled portion <NUM> of the base sidewalls <NUM> such that it extends inwardly, the angled portion may define an overhang that facilitates scooping or otherwise engaging a unit of the product stored in the internal storage compartment <NUM> with a user's fingers.

The upper lip <NUM> may be configured to define a substantially airtight seal with the sealing member <NUM> such that the internal storage compartment <NUM> is sealed shut when the lid <NUM> and the base <NUM> are in the coupled configuration. In order to form this seal, the upper lip <NUM> may be continuous around the perimeter of the base opening <NUM> and define a constant cross-section. Accordingly, no gaps may be created between the sealing member <NUM> and the upper lip <NUM>. Further, the upper lip <NUM> may be rounded. In this regard, the upper lip <NUM> and/or the lower lip <NUM> may comprise a rolled edge, as illustrated in <FIG> and <FIG>. The upper and/or lower lips <NUM>, <NUM> may be formed by rolling or bending the material defining the lid and base sidewalls <NUM>, <NUM> at the distal end thereof. By providing the upper lip <NUM> and/or the lower lip <NUM> with a rounded shape, the possibility of injury associated with a user contacting the lips may be reduced. Further, providing the upper lip <NUM> with a rounded configuration may facilitate engagement with the sealing member <NUM>. In this regard, by rolling, bending, or otherwise transforming or forming an otherwise straight edge of the material defining the base <NUM> into the rounded upper lip <NUM>, the upper lip may define a greater surface area such that the upper lip may be more likely to form a seal with the sealing member <NUM> when the lid <NUM> is coupled to the base <NUM>.

However, the radius of the channel <NUM> may be greater than radius of the upper lip <NUM>. In this regard, when the channel <NUM> defines a relatively greater radius than the upper lip <NUM>, a sealing member <NUM> formed therein (e.g., by curing plastisol therein) may also define a greater radius (or other relatively larger dimensions) as compared to the upper lip. Providing the upper lip <NUM> with smaller dimensions as compared to the sealing member <NUM> may allow the upper lip <NUM> to compress into and be at least partially surrounded by the sealing member <NUM>. Accordingly, a relatively more secure seal may be provided. In one embodiment the upper lip <NUM> may define a radius from about <NUM> millimeters to about <NUM> millimeters and in a preferred embodiment the radius may be about <NUM> millimeters. In some embodiments the channel <NUM> may define a radius from about <NUM> millimeter to about <NUM> millimeters, and in a preferred embodiment the radius may be <NUM> millimeters. However, various other radii may be employed in other embodiments.

In order to retain coupling between the lid <NUM> and the base <NUM>, the container may include certain features. In this regard, as illustrated in <FIG>, the protrusions <NUM> extending from the base sidewalls <NUM> may be configured to engage the lower lip <NUM> of the lid <NUM> via interference fit. Accordingly, interference between the protrusions <NUM> and the lower lip <NUM> may resist separation of the lid <NUM> from the base <NUM> when the lid and the base are in the coupled configuration.

In one example embodiment the container <NUM> may be configured such that from about <NUM> grams-force to about <NUM> grams-force is required to decouple the lid <NUM> from the base <NUM>. Decoupling forces within this range may be desirable because they may provide a satisfying degree of resistance while still allowing for relatively easy decoupling of the lid <NUM> and the base <NUM>. In some embodiments the selected decoupling force may also provide child resistance.

In order to achieve a desired required decoupling force, various factors may be adjusted. In this regard, a protruding length to which the protrusions <NUM> protrude perpendicularly from the inwardly offset portion <NUM> may be controlled. Further, a width <NUM> of the protrusions <NUM> and a height <NUM> of the protrusions may be adjusted (see, e.g., <FIG>). In some embodiments the protrusions <NUM> may define a width <NUM> that is greater than the height <NUM> of the protrusions. This configuration may provide for an increased area of contact between the protrusions <NUM> and the lower lip <NUM> that may increase the decoupling force required to decouple the lid <NUM> from the base <NUM>.

In one embodiment the height <NUM> of the protrusions <NUM> may be from about <NUM> millimeters to about <NUM> millimeters, and in a preferred embodiment the height may be about <NUM> millimeters. Further, the lower lip <NUM> of the lid <NUM> may define a radius from about <NUM> millimeters to about <NUM> millimeter, and in a preferred embodiment the radius of the lower lip may be about <NUM> millimeters. Additionally, the protrusions <NUM> may define a protruding length protruding outwardly from the inwardly offset portion <NUM> of the base sidewalls <NUM> from about <NUM> millimeters to about <NUM> millimeters, and in a preferred embodiment the protruding length of the protrusions may be about <NUM> millimeters. Selection of the above-noted dimensions may be configured to produce a decoupling force required to separate the lid <NUM> from the base <NUM> in the range described above.

The protrusions <NUM> may also be configured to bias the upper lip <NUM> of the base <NUM> into contact with the sealing member <NUM> on the lid <NUM>. In this regard, engagement between the protrusions <NUM> and the lower lip <NUM> may be configured to bias the upper lip <NUM> against the sealing member <NUM>. Accordingly, a tight seal may be formed between the upper lip of the base <NUM> and the sealing member <NUM> of the lid <NUM> when the container <NUM> is in the coupled configuration.

In the coupled configuration the shoulder portion <NUM> of the base sidewalls <NUM> may be configured to define a gap <NUM> with respect to the lower lip <NUM> of the lid sidewalls <NUM> when the lid <NUM> and the base <NUM> are configured in the coupled configuration. In this regard, by providing the gap <NUM>, the lower lip <NUM> of the lid <NUM> may have room to bias downwardly due to contact with the protrusions <NUM>. Accordingly, the gap <NUM> provided by the placement of the shoulder portion <NUM> may allow the upper lip <NUM> of the base <NUM> to seal against the sealing member <NUM> of the lid <NUM> as described above.

Note that use of interference fit to hold the lid <NUM> and the base <NUM> together may be desirable as compared to other retention methods. In this regard, by way of example, a threaded connection between a base and a lid may produce a seal that is dependent on the extent to which the lid and the base are threaded together. In contrast, in the present embodiment, once the lower lip <NUM> of the lid <NUM> extends past the protrusions <NUM>, the lip and the lid may be held together by a force that is independent of the closing force imparted thereon by a user. Thus, for example, the container <NUM> may not be over or under tightened. Thereby, a desirable seal may be attained, and the decoupling force required to separate the lid <NUM> from the base <NUM> may be consistent.

The recessed portions <NUM> may be configured to align with the lower lip <NUM> of the lid sidewalls <NUM> of the lid <NUM> when the lid and the base <NUM> are configured in the coupled configuration. Thus, the recessed portions <NUM> may provide a user with access to the lower lip <NUM> of the lid <NUM> in the coupled configuration such that the lid may be decoupled from the base <NUM>. In some embodiments the recessed portions <NUM> may be positioned such that they are not vertically aligned with the protrusions <NUM>. Thus, when a user grasps the lower lip <NUM> at the recessed portions <NUM> and lifts the lid <NUM> from the base <NUM>, the users fingers may avoid contacting the protrusions <NUM>, which could otherwise potentially impede decoupling of the lid from the base. In the example embodiment, as illustrated in <FIG>, the recessed portions <NUM> may be positioned between pairs of the protrusions <NUM>, although various other configurations may be employed. Further, although described as extending from the inwardly offset portion <NUM>, the protrusions may extend from other portions of the base sidewalls <NUM> or other portions of the container <NUM> in other embodiments.

In the illustrated embodiment, the container <NUM> defines a generally rectangular shape with rounded ends. This shape may allow for placement of the protrusions <NUM> and the recessed portions <NUM> on the long sides of the base <NUM>. This configuration may be preferable in that it may allow a user to firmly grip the recessed portions <NUM>. However, various other shapes and configurations (e.g., round or square) of the container may be employed in other embodiments.

By way of example, <FIG> illustrates an embodiment of a container <NUM> that is generally cylindrical. The container <NUM> includes a lid <NUM> and a base <NUM>, which are configurable between coupled and decoupled configurations. Thus, the circular shape (when viewed from above or below) provides the container <NUM> with an alternate configuration which may be preferable to consumers in some embodiments. As may be understood, various sizes, shapes, and configurations may be employed in other embodiments, depending on consumer preferences and other factors.

<FIG> illustrates a sectional view through the container <NUM>. As illustrated, the lid <NUM> includes a top wall <NUM> and one or more lid sidewalls <NUM> extending from the top wall to a lower lip <NUM> defining a lid opening <NUM>. The base <NUM> includes a bottom wall <NUM> and one or more base sidewalls <NUM> extending from the bottom wall to an upper lip <NUM> defining a base opening <NUM> (see, <FIG>).

The lid <NUM> may be configured to engage the base <NUM> via any of a variety of mechanisms, such as a threaded connection or interference fit. As illustrated, in one embodiment the base <NUM> may define an outer protrusion <NUM> at the base sidewalls <NUM>, which may extend around the perimeter of the base, and the lid <NUM> may define a corresponding inner recesses <NUM> extending around the inside thereof. Thereby, the outer protrusion <NUM> of the base <NUM> may engage the inner recess <NUM> of the lid <NUM>. As may be understood, in an opposite configuration the lid may define an inner protrusion that engages an outer recess in the base. In an additional embodiment the base and the lid may each define a respective recess, and a gasket (e.g., an O-ring) may be received in the recess in the base and configured to engage the lid to provide for engagement and optional sealing therebeween. Containers including gaskets configured to seal the connection between a lid and a base are disclosed, for example, in <CIT> and <CIT> In another embodiment the container may include a gasket a sidewall of the base as disclosed, for example, in <CIT>.

As further illustrated in <FIG>, in some embodiments the container <NUM> may include an intermediate wall <NUM>. In the illustrated embodiment the base <NUM> includes the intermediate wall <NUM>. However, the lid <NUM> may include an intermediate wall in other embodiments. The intermediate wall <NUM> may divide an internal space <NUM> defined by the base <NUM> into an internal storage compartment <NUM> and a secondary compartment <NUM>.

The internal storage compartment <NUM> receives a plurality of units of a smokeless tobacco product <NUM>.

Further, the secondary compartment <NUM> may be configured to receive an environment modification material <NUM> in the secondary compartment <NUM> between the intermediate wall <NUM> and a bottom wall <NUM> of the base <NUM>. The environment modification material <NUM> may be configured to affect the atmosphere within the internal space <NUM> and in particular within the internal storage compartment <NUM> in which the units of the product <NUM> are positioned. For example, the environment modification material <NUM> may be configured to control a humidity level in the internal space <NUM>, affect gas levels therein, provide or remove scents, or perform other functions. In this regard, the intermediate wall <NUM> may allow for fluid flow therethrough. For example, the intermediate wall <NUM> may include apertures <NUM> extending therethrough, wherein the apertures are configured to resist clogging by the units of the product <NUM> and/or movement of the units of the product therethrough due to the apertures defining an appropriately small size. Various other details with respect to environment modification materials and intermediate walls are provided in <CIT>.

The container <NUM> may additionally include a valve assembly <NUM>. The valve assembly <NUM> may be configured to affect an atmosphere within the internal space <NUM>. The valve assembly <NUM> may be engaged with the lid <NUM> or the base <NUM>. In this regard, in the illustrated embodiment the valve assembly <NUM> is engaged with (e.g., coupled to or embedded within) the base <NUM> of the container <NUM>. In particular, in the illustrated embodiment the valve assembly <NUM> is engaged with the bottom wall <NUM> of the base <NUM>. However, in another embodiment the valve assembly <NUM> may be additionally or alternatively engaged with (e.g., coupled to or embedded within) the one or more base sidewalls <NUM>. Regardless, by coupling the valve assembly <NUM> to the base <NUM>, the valve assembly may be in fluid communication with both the internal space <NUM> within the container <NUM> and an external environment surrounding the container.

Accordingly, the valve assembly <NUM> may affect the atmosphere within the internal space <NUM> so as to facilitate storage of the units of the product <NUM> therein. For example, the valve assembly <NUM> may be configured to vent the internal space <NUM>. Thereby, the valve assembly <NUM> may release pressure from the internal space <NUM> to avoid issues with respect to the container <NUM> bulging or otherwise deforming or breaking as a result of gas buildup therein. Further, venting of the internal space <NUM> may avoid issues with respect to the container <NUM> releasing gas defining an undesirable odor at the time of opening the container. Various other details with respect to containers including valve assemblies are provided in <CIT>.

Although the base <NUM> is described above as including the valve assembly <NUM>, in some embodiments the lid <NUM> and/or the base may include additional or alternative features configured to affect the atmosphere within the internal space <NUM>. In this regard, as illustrated in <FIG>, in some embodiments the base <NUM> may include a rib structure <NUM>. The rib structure <NUM> may project from an outer peripheral surface <NUM> of the base <NUM> at an upper portion <NUM> of the one or more base sidewalls <NUM>.

In some embodiments, the rib structure <NUM> may be integrally formed with the one or more base sidewalls <NUM>. In other instances, the rib structure <NUM> may be a separate and discrete component secured or otherwise affixed to the one or more base sidewalls <NUM> with appropriate mechanical fasteners or adhesive (e.g., an epoxy adhesive).

The rib structure <NUM> may be configured to allow for venting of the internal storage compartment <NUM>. In this regard, the rib structure <NUM> may comprise a plurality of rib segments <NUM> arranged in spaced relation around the periphery of the one or more base sidewalls <NUM> (e.g., positioned circumferentially about the one or more base sidewalls when the container <NUM> is cylindrical). Any number of the rib segments <NUM> may be provided in accordance with the present disclosure (e.g., often about <NUM> to about <NUM> rib segments, and frequently about <NUM> to about <NUM> rib segments), although a preferred embodiment includes about <NUM> to about <NUM> rib segments. Each rib segment <NUM> may include a rib wall <NUM> projecting outwardly from the one or more base sidewalls <NUM> and a rib projection <NUM> projecting outwardly from the rib wall.

Exemplary dimensions for the rib projections <NUM> include heights in the range of about <NUM> millimeters to about <NUM> millimeters, and widths in the range of about <NUM> millimeter to about <NUM> millimeters. As used herein in reference to the rib projections <NUM>, height refers to the major dimension of the rib projection that extends outwardly, away from the peripheral surface <NUM>. The rib projections <NUM> may be positioned below the upper lip <NUM> of the one or more base sidewalls <NUM> in the range of about <NUM> millimeters to about <NUM> millimeters below the upper lip.

Each rib segment <NUM> is separated from an adjacent rib segment by a vent channel <NUM>. Exemplary dimensions for the vent channels <NUM> include lengths in the range of about <NUM> millimeters to about <NUM> millimeters, and depths in the range of about <NUM> millimeters to about <NUM> millimeters. The vent channels <NUM> may extend from the upper lip <NUM> of the one or more base sidewalls <NUM> downwardly past the rib segments <NUM> to a shoulder <NUM>. In this regard, a plurality of bumps or protrusions <NUM> may be positioned on the upper lip <NUM> of the base <NUM>. Thereby, the protrusions <NUM> may separate the lid <NUM> (see, e.g., <FIG>) from the upper lip <NUM> of the base <NUM> such that air may flow therebetween and through the vent channels <NUM>. Such vent channels <NUM> provide venting when the lid <NUM> (see, e.g., <FIG>) is fully seated on the base <NUM>, such that issues with respect to gas build-up within the internal storage compartment <NUM> are avoided. Thus, the vent channels <NUM> may be provided as an alternative to, or in addition to the valve assembly <NUM> (see, <FIG>). Various other details with respect to embodiments of rib structures and venting arrangements are provided in <CIT> and <CIT>.

For example, <FIG> and <FIG> illustrate a container <NUM>' according to an additional example embodiment of the present disclosure. In some embodiments the container <NUM>' may define a substantially cylindrical configuration. Accordingly, the container <NUM>' may define an exterior appearance that is substantially similar to that of the container <NUM> (see, e.g., <FIG>). However, as may be understood, the container may define other configurations (e.g., oblong, square, triangular, oval, rectangular, elongated, etc.) in other embodiments, such that, for example, the exterior appearance of the container is substantially similar to that of the container <NUM> (see, e.g., <FIG>).

The container <NUM>' includes a lid <NUM>' and a base <NUM>'. The lid <NUM>' and the base <NUM>' are configurable between coupled and decoupled configurations. The decoupled configuration is illustrated in <FIG>, and the coupled configuration is illustrated in <FIG>, wherein these figures illustrate sectional views through the container <NUM>'.

The container <NUM>' may define a relatively less complex structure as compared to the embodiments of the containers <NUM>, <NUM> illustrated in <FIG>. For example, although the container <NUM> described above includes the protrusions <NUM>, the recessed portions <NUM>, a sealing member <NUM>, and the upper and lower lips <NUM>, <NUM>, some or all of these features may not be included in the container <NUM>' in some embodiments. Further, although the container <NUM> described above includes the intermediate wall <NUM> and the rib structure <NUM>, some or all of these features may not be included in the container <NUM>' in some embodiments. Accordingly, the container <NUM>' may define a relatively less complex configuration that may simplify the formation thereof.

As noted elsewhere herein, the containers of the present disclosure may be formed from alternative materials not traditionally employed therein. In some embodiments such materials may define sufficient structural rigidity so as to be self-supporting. However, in other embodiments the containers may include one or more additional components configured to provide structural rigidity to the containers or perform other functions.

In this regard, <FIG> and <FIG> illustrate sectional views through an embodiment of a container <NUM>" according to an additional embodiment of the present disclosure. The container <NUM>" may be substantially similar to the container <NUM>' described above. The container <NUM>" may include a lid <NUM>" and a base <NUM>". However, as illustrated in <FIG> and <FIG>, the container <NUM>" may additionally include a structural member <NUM>". The structural member <NUM>" may extend around an inner surface or an outer surface of the lid <NUM>" or the base <NUM>". For example, in the illustrated embodiment the structural member <NUM>" extends around the inner surface of the base <NUM>". In embodiments in which the structural member <NUM>" extends around the inner surface of the lid <NUM>" or the base <NUM>", the outer surfaces of the lid and the base may be flush with one another so as to provide the container <NUM>' with a pleasing integral appearance. The structural member <NUM>" may define an annular configuration in embodiments of the container <NUM>" in which the container <NUM>" is cylindrical.

In some embodiments the structural member <NUM>" may extend outwardly from the lid <NUM>" or the base <NUM>" such that a portion thereof is exposed. The exposed portion of the structural member <NUM>" may be configured to releasably engage one of the base <NUM>" and the lid <NUM>". A remaining portion of the structural member <NUM>" may be permanently coupled to the other of the lid <NUM>" and the base <NUM>". For example, in the illustrated embodiment the structural member <NUM>" is affixed (e.g., adhered, glued, or otherwise permanently coupled) to the base <NUM>" and configured to releasably engage the lid <NUM>". In this regard, the structural member <NUM>" may be configured to seal against the lid <NUM>" when engaged therewith. In some embodiments the structural member <NUM>" may comprise a material that is relatively rigid, such as plastic or metal.

As noted above, the containers of the present disclosure comprise a plurality of units of a smokeless tobacco product. As part of the final packaging process, once each container is filled with the one or more units of a smokeless tobacco product, the container may be sealed with a circumferential label or wrapper of a pervious or impervious material. In one embodiment a tamper evident shrink band may be wrapped and shrunken around the container such that the lid and the base may not be decoupled without damaging the shrink band. The label or wrapping material useful in accordance with the present disclosure can vary. Typically, the selection of the packaging label or wrapper is dependent upon factors such as aesthetics, tamper resistance and/or indication, desired barrier properties (e.g., so as to provide protection from exposure to oxygen, or so as to provide protection from loss of moisture), or the like.

At least one of the lid and the base is pulp-molded from a pulp derived from a plant material. In one embodiment the lid may comprise a metal material or a plastic material and the base may comprise the pulp derived from the plant material, or vice versa. In another embodiment the lid and the base may each comprise the pulp derived from the plant material.

The pulp derived from the plant material may be produced by grinding, steaming, pressurizing, heating, or otherwise processing plant material. Examples of plants and plant materials from which the pulp may be derived include corn, cornstalks, bamboo, bamboo stalks, flax, flax fiber, hemp, hemp pulp, tobacco, grains, wood, wood pulp (e.g., hard or soft), and etc. Further, the pulp derived from the plant material may include one or more of various other materials such as filers, calcium carbonate, colorants, dye pigments, binders, glossy materials, calcium sulfate fibers, glass fibers, carbon fibers, and ceramics.

Various types of wood may be employed, and the type of wood selected may depend on the desired characteristics thereof. For example, each type of wood may define a differing color, differing strength, differing aroma, and/or other characteristics. In some embodiments the wood may comprise an aromatic wood such as cedar, pine, balsam, oak, pinon, fir, juniper, sandalwood, rose wood, moon beam, etc. Aromatic woods may affect the flavor and/or aroma of the units of the product in the container. Various other details with respect to the pulp material and molds configured to mold pulp material are disclosed in <CIT> and <CIT>; English Pat. <CIT> and <CIT>; and <CIT> Further, <CIT> discloses a composite material which may comprise wood fiber and which employs a liquid binder using waste coating powder together with a water-based acrylic paint.

Usage of pulp derived from the plant material may provide certain benefits in addition to those noted above. In this regard, pulp derived from the plant material may be biodegradable. Further, pulp derived from the plant material, and in particular wood pulp material, may provide the container with the appearance of a wood product such as a solid piece of wood, which may be desirable to consumers. According to the invention, the pulp derived from the plant material is a mixture incorporating the plant material so that the plant material is the majority of the weight of the pulp. Similarly, wood pulp material, as used herein refers to a formulation (e.g., mixture) incorporating wood material (e.g., wood pulp and/or wood fibrous material), and preferably wherein the wood material is the majority of the weight thereof.

Note that while the pulp derived from the plant material is generally described herein as comprising a wood pulp material, various other materials may be employed in other embodiments. For example, in some embodiments the pulp derived from the plant material may comprise a tobacco pulp material. Embodiments of methods for processing tobacco plant material, and the resultant tobacco pulp material, are disclosed in <CIT>.

<FIG> schematically illustrates a sectional view through a portion of a container 300A (e.g., a lid or base thereof) wherein the container comprises a pulp derived from a plant material <NUM>. As illustrated, in some embodiments not according to the invention, the container 300A may be formed substantially entirely from the pulp derived from the plant material <NUM>. Thus, the pulp derived from the plant material <NUM> may extend between, and define, an interior <NUM> and an exterior <NUM> of the container 300A. In this regard, the pulp derived from the plant material <NUM> (e.g., wood pulp material) may define sufficient strength so as to not require additional structural elements. Exemplary wall thicknesses of the container 300A may range from about <NUM> to about <NUM>, and more typically from about <NUM> to about <NUM>. In another embodiment the wall thicknesses may be double or triple these ranges in order to provide the container 300A with increased structural integrity and rigidity. Such wall thicknesses may also be applicable to each of the other containers described herein.

However in other embodiments of the container additional materials may be employed. For example, although the pulp derived from the plant material <NUM> may provide sufficient structural integrity, in some embodiments such a material may not provide fluid barrier properties. In this regard, it may be desirable to provide the container with a moisture transfer barrier and/or an air flow barrier, for example, in order to prevent a product such as tobacco material stored therein from drying out.

For example, <FIG> illustrates a container 300B comprising a combined material <NUM>. The combined material <NUM> may include the pulp derived from the plant material <NUM> and one or more additional materials that may be combined in any manner therewith. For example, the materials may be mixed together, or one of the materials may be imbedded in the other.

By way of example, the pulp derived from the plant material <NUM> may be combined with one or more waxes (e.g., beeswax, Chinese, lanolin, shellac, spermaceti, bayberry, carnauba, candelilla, castor, esparto, Japan, jojoba, ouricury, rice bran, soy, tallow tree, ceresin, montan, ozocerite, peat, paraffin, microcrystalline, petroleum jelly, polyethylene wax, Fischer-Tropsch, esterified, saponified, substituted amide, and polymerized α-olefins) and/or one or more resins (e.g., mastic, pitch, and polyresin). Such materials added to the pulp derived from the plant material <NUM> to form the combined material <NUM> may provide the container 300B with moisture and/or air barrier properties. In one example embodiment a polymer may be dissolved in an acetone solvent, and infused in the pulp derived from the plant material <NUM>. When the acetone evaporates, the polymer may remain infused with the pulp derived from the plant material <NUM> and form the combined material <NUM>. In another embodiment a material in particulate form such as polyethylene or polypropylene may be dispersed in the pulp derived from the plant material <NUM> and then heated to form the combined material <NUM>.

By way of further example, <FIG> illustrates a container 300C not according to the invention, said container comprising the pulp derived from the plant material <NUM> and a liner <NUM>. The liner <NUM> may define moisture and/or air barrier properties. In some embodiments the liner <NUM> may be relatively thin. For example, the liner <NUM> may define a thickness of less than about one mil (one thousandth of an inch; <NUM>).

The liner <NUM> may be formed in various manners. For example, the liner <NUM> may be formed in place, formed prior to attachment to the pulp derived from the plant material <NUM>, thermoformed, injection molded, etc. In some embodiments the liner <NUM> may be coupled to the pulp derived from the plant material <NUM> via interference fit. However, in other embodiments connectors and/or an adhesive may be employed to retain engagement between the liner <NUM> and the pulp derived from the plant material <NUM>. In some embodiments the liner may comprise, by way of example, plastic, aluminum, tin, a polymer resin, polyethylene (e.g., high or low density), polypropylene, nitrocellulose, polyvinylidene, acrylonitrile butadiene styrene (ABS), and/or polyvinyl alcohol (PVA).

As illustrated in <FIG>, in one embodiment not according to the invention, the liner <NUM> may be positioned at the interior <NUM> of the container 300C. In this regard, the liner <NUM> may be configured to protect the units of the produce received in the container 300C and/or provide the container with additional support and structure, whereas the pulp derived from the plant material <NUM> may be positioned at the exterior <NUM> of the container. Thereby, for example, when a user views the exterior <NUM> of the container 300C, the container may appear to define one or more solid pieces of wood.

However, as illustrated in <FIG>, in another embodiment of a container 300D according to the invention, the liner <NUM> is positioned at the exterior <NUM>, and the pulp derived from the plant material <NUM> is positioned at the interior <NUM>. The units of the product are exposed to the pulp derived from the plant material <NUM> so as to receive the aroma, flavor, or other sensory characteristics therefrom. Further, the pulp derived from the plant material <NUM> may be visible to a consumer when the container <NUM> is opened, such that the interior <NUM> is exposed.

<FIG> illustrates an alternate embodiment of a container 300E not according to the invention, wherein the container includes a coating <NUM>. The coating <NUM> may be applied as a spray, via immersion, applied via a role, or in any other manner. In some embodiments the coating <NUM> may comprise, by way of example, a varnish, a paint, a wax (e.g., beeswax, Chinese, lanolin, shellac, spermaceti, bayberry, carnauba, candelilla, castor, esparto, Japan, jojoba, ouricury, rice bran, soy, tallow tree, ceresin, montan, ozocerite, peat, paraffin, microcrystalline, petroleum jelly, polyethylene wax, Fischer-Tropsch, esterified, saponified, substituted amide, and polymerized α-olefins), paper-type coatings, polyvinylidene chloride (PVDC), nitrocellulose (e.g., in solution form with an alcohol or an acetate), vinyl acetate (e.g., in wax form), polyvinyl alcohol (PVA), polyethylene, a sealant, or anything configured to form a film. Example embodiments of commercially available coatings that may provide moisture resistance include Durata® finishes available from The Grothouse Lumber Company of Germansville, PA. As illustrated, the coating <NUM> may be positioned at the interior <NUM> of the container 300E in some embodiments. This configuration may provide the exterior <NUM> of the container 300E with a natural wood finish and appearance, while the coating <NUM> provides additional moisture resistance to protect the units of the product or performs other functions.

In an embodiment according to the invention, as illustrated in <FIG>, a container 300F includes the coating <NUM> at the exterior <NUM>. This configuration may allow the coating <NUM> to perform sealing or other functions as noted above at the exterior <NUM> of the container 300F. According to the invention, the coating <NUM> is positioned at the exterior <NUM> of at least one of the lid and the base and not positioned at an interior of the lid and the base. In other words, in one embodiment according to the invention, the coating <NUM> is positioned at the exterior of the lid, but not at the interior of the lid. Alternatively or additionally, in some embodiments according to the invention, the coating <NUM> is positioned at the exterior of the base, but not the interior of the base. Thereby, the units of the product are exposed to the pulp derived from the plant material <NUM> at the interior <NUM>, such that the units of the product may receive flavor, aroma, or other sensory characteristics from the pulp derived from the plant material.

In a further embodiment not according to the invention, as illustrated in <FIG>, a container <NUM> may include the coating <NUM> at both the interior <NUM> and the exterior <NUM>, with the pulp derived from the plant material <NUM> positioned therebetween. Thereby, for example, the coating <NUM> may substantially entirely surround the pulp derived from the plant material <NUM> such that the pulp derived from the plant material is enclosed. However, the coating <NUM> may be transparent or translucent such that the pulp derived from the plant material <NUM> is visible in some embodiments, so as to provide the container with a solid wood-like appearance. <FIG> illustrates a container <NUM> not according to the invention, said container including the pulp derived from the plant material <NUM>, the liner <NUM>, and the coating <NUM>. In the illustrated embodiment, the liner <NUM> is positioned at the interior <NUM>, the coating <NUM> is positioned at the exterior <NUM>, and the pulp derived from the plant material <NUM> is positioned therebetween. However, these elements may be configured in various other manners, optionally including additional layers or elements, in other embodiments. For example, although the coating <NUM> is illustrated as being applied to the pulp derived from the plant material <NUM>, in other embodiments the coating may be additionally or alternatively applied to the liner <NUM>. <FIG> schematically illustrates the formation of a container <NUM> comprising a pulp derived from a plant material <NUM>. As illustrated, the pulp derived from the plant material <NUM> is directed into a mold <NUM>. The mold <NUM> may comprise a base mold configured to form a base or a lid mold configured to form a lid, and the shape of the mold may depend on the desired final shape of the component (e.g., the lid or the base) being produced.

As further illustrated in <FIG>, the pulp derived from the plant material <NUM> may be sprayed into the mold <NUM> in some embodiments. For example, a spray head <NUM> or other dispensing device coupled to a reservoir <NUM> may direct the pulp derived from the plant material <NUM> into the mold <NUM>. Thereby, the pulp derived from the plant material <NUM>, which may include water or other liquid and which may be provided in a slurry or other partially or substantially fluid form, may conform to the shape of the mold <NUM>. Thus, for example, the mold <NUM> may define the shape of an exterior surface <NUM> of the container <NUM>.

As illustrated in <FIG>, in order to form the shape of an interior surface <NUM> of the container <NUM>, a moveable mold <NUM> (e.g., a moveable lid mold configured to form the lid or a moveable base mold configured to form the base) may be directed into contact with the pulp derived from the plant material <NUM>. Thereby, the moveable mold <NUM> may apply pressure to the pulp derived from the plant material <NUM>. Thus, the mold <NUM> (which may also be referred to as a fixed, or primary mold) may cooperate with the moveable mold <NUM> (which may also be referred to as a secondary mold), to form the container <NUM>.

For example, in some embodiments the moveable mold <NUM> may comprise an expandable device (e.g., a lid expandable device configured to form the lid or a base expandable device configured to form the base) configured to expand within the mold <NUM> to apply pressure to the pulp derived from the plant material <NUM>. Thereby, the pulp derived from the plant material <NUM> may be formed into a shape defined by the moveable mold <NUM> and the mold <NUM>. Although the moveable mold <NUM> is illustrated as defining the shape of the interior <NUM> of the container <NUM>, and the mold <NUM> is illustrated as defining the shape of the exterior <NUM> of the container <NUM>, in other embodiments this arrangement may be reversed such that the moveable mold defines the shape of the exterior of the container and the mold defines the shape of the interior of the container.

Suitable components, formulations and processing techniques useful for the preparation of suitable pulp derived from a plant material, and representative types of packaging formulations and constructions that can be suitably modified for use to provide containers in accordance with the present invention, are set forth Mohan, Packaging World (Jan. <NUM>, <NUM>); Bouckley, BeverageDaily. <NUM>, <NUM>); Bouckley, BeverageDaily. <NUM>, <NUM>); and Pierce, Packaging Digest (May <NUM>, <NUM>). Further, <CIT>discloses a tobacco bioplastic composition; <CIT> discloses a container including a moisture barrier layer or coating, <CIT> discloses a pulp molded container with a resin layer; and <CIT> discloses a molded fiber bottle. See also, the types of components and processing techniques useful for production of the so-called EarthCoating Technologies by Planet Technologies, Inc.

Further example embodiments of commercially available products including materials that may be employed in embodiments of containers not according to the invention include thermoformed and molded fiber packaging from Plastic Ingenuity of Cross Plains, WI; FreeFormPack containers comprising a base fiber material with poly-laminates from FibreForm Packaging AB of NorrKöping, Sweden; EARTHCOATING EC-<NUM>, EC-PP-<NUM>, and EC-Hyper-Barrier coatings from Planet Technologies, Inc. of Newport Beach, CA; Natural 4X Laundry Detergent molded pulp bottles with inner polyethylene bags from Ecologic Brands of Oakland, CA; wine bottles including a molded pulp outer shell and a plastic liner available from Truett-Hurst of Healdsburg, CA; and paint roller trays comprising wood pulp fibers and a molded plastic inner layer from Bio Pulp Works of San Antonio, TX.

A method for assembling a packaged product assembly is also provided. As illustrated in <FIG>, the method may include providing a lid at operation <NUM>. The lid may comprise a top wall defining an inner surface, a sealing member extending around a perimeter of the top wall at the inner surface, and one or more lid sidewalls extending from the top wall to a lower lip defining a lid opening. The method may also include providing a base defining an internal storage compartment at operation <NUM>. The base may comprise a bottom wall and one or more base sidewalls extending from the bottom wall to an upper lip defining a base opening. The base sidewalls may comprise an outer portion extending from the bottom wall, an inwardly offset portion, and an angled portion extending from the inwardly offset portion to the upper lip, the angled portion defining an angle with respect to the inwardly offset portion. The method may additionally include providing a plurality of units of a product at operation <NUM>. Further, the method may include inserting the units of the product into the internal storage compartment at operation <NUM>. The method may also include coupling the lid to the base such that the inwardly offset portion of the base sidewalls is at least partially received within the lid sidewalls and the upper lip seals against the sealing member at operation <NUM>.

In some embodiments coupling the lid to the base at operation <NUM> may comprise aligning the base with respect to the lid by contacting the angled portion of the base sidewalls with the lower lip of the lid. Coupling the lid to the base at operation <NUM> may also comprise biasing the upper lip against the sealing member. Biasing the upper lip against the sealing member may comprise directing the lower lip over one or more protrusions projecting outwardly from the base sidewalls.

In an additional embodiment, a method for manufacturing a container is provided. As illustrated in <FIG>, the method may include constructing at least one of a base and a lid from a pulp derived from a plant material at operation <NUM>. The lid may include a top wall and one or more lid sidewalls extending from the top wall to a lower lip defining a lid opening. The base may include a bottom wall and one or more base sidewalls extending from the bottom wall to an upper lip defining a base opening. The base may be moveable with respect to the lid between a coupled configuration in which an internal storage compartment defined by the base is substantially closed and a decoupled configuration in which the internal storage compartment is open.

In some embodiments constructing at least one of the base and the lid from the pulp derived from the plant material at operation <NUM> may include directing the pulp derived from the plant material into a base mold and a lid mold. Further, the method may include applying pressure to the pulp derived from the plant material in the base mold and the lid mold. Applying pressure to the pulp derived from the plant material may comprise expanding a base expandable device within the base mold and expanding a lid expandable device within the lid mold.

In some embodiments the method may further comprise drying the pulp derived from the plant material. Additionally, the method may include removing the lid from the lid mold and removing the base from the base mold. Directing the pulp derived from the plant material into the base mold and the lid mold may include spraying the pulp derived from the plant material into the base mold and the lid mold.

The method may further include applying a coating to at least one of the base and the lid. Applying the coating to at least one of the base and the lid may comprise applying the coating to an exterior of the lid and the base without applying the coating to the interior of the lid and the base. The method may additionally include coupling a liner to the pulp derived from the plant material.

Claim 1:
A container (<NUM>), comprising:
a lid (<NUM>), comprising:
a top wall (<NUM>); and
one or more lid sidewalls (<NUM>) extending from the top wall (<NUM>) to a lower lip (<NUM>) defining a lid opening (<NUM>); and
a base (<NUM>) moveable with respect to the lid (<NUM>) between a coupled configuration in which an internal storage compartment (<NUM>) defined by the base (<NUM>) is substantially closed and a decoupled configuration in which the internal storage compartment (<NUM>) is open, the base (<NUM>) comprising:
a bottom wall (<NUM>);
one or more base sidewalls (<NUM>) extending from the bottom wall (<NUM>) to an upper lip (<NUM>) defining a base opening (<NUM>); and
a plurality of units of a smokeless tobacco product (<NUM>) received in the internal storage compartment (<NUM>), wherein at least one of the lid (<NUM>) and the base (<NUM>) is pulp-molded from a pulp derived from a plant material (<NUM>), the pulp being a mixture incorporating the plant material (<NUM>) so that the plant material (<NUM>) is a majority of the weight of the pulp, and
wherein at least one of a coating (<NUM>) and a liner (<NUM>) is positioned at an exterior of the at least one of the lid (<NUM>) and the base (<NUM>) and not positioned at an interior of the lid (<NUM>) and the base (<NUM>) such that the units of the product (<NUM>) are exposed to the pulp derived from the plant material (<NUM>), so as to receive aroma, flavor, or other sensory characteristics therefrom.