WO2024072373A1

WO2024072373A1 - Recyclable packaging container, packaged product and method

Info

Publication number: WO2024072373A1
Application number: PCT/US2022/044738
Authority: WO
Inventors: Haley A. OLSEN
Original assignee: Amcor Flexibles North America Inc
Current assignee: Amcor Flexibles North America Inc
Priority date: 2022-09-26
Filing date: 2022-09-26
Publication date: 2024-04-04
Anticipated expiration: 2025-03-26

Abstract

A packaged product includes an outer container and an inner container located within the outer container. The outer container includes a first polymer and a reclosable feature. The inner container includes a second polymer. The inner container contains a product. The second polymer is compatible with the first polymer in a recycling stream. A composite container includes the outer container and contains the inner container with the product removed.

Description

RECYCLABLE PACKAGING CONTAINER, PACKAGED PRODUCT AND METHOD

TECHNICAL FIELD

[001] This disclosure is related to a multicomponent recyclable packaging container and product contained therein. The packaged product may include food, pharmaceuticals, or non-food items.

BACKGROUND

[002] Many packages are designed to hold single or multiple servings of ingestible products such as food, beverages, liquids, pharmaceuticals, or non-food products. The packages include an outer package that holds one or more inner packages, for example, a meal kit (e.g., food kit, salad kit, first aid kit, etc.). Meal kits, for example, include ingredients to make a complete meal that are packaged together and delivered to consumers in one outer container that is usually a fiber-based box. The meal kit ingredients often include a protein (e.g., meat, fish, tofu, etc.), vegetables, sauces, and spices or flavorings, each packaged in separate containers that are placed into the outer container (e.g., box) that is delivered to the consumer. Other examples include salad kits (e.g., kits including lettuce, salad dressing, toppings, etc.), pharmaceutical kits (e.g., kits including bandages, ointment, etc.), or multi-packs (e.g., a box that includes individually wrapped/packaged items such as granola bars or dry drink mix stick packs ,for example). The individual packages that contain kit ingredients or products and are contained within an outer container, such as fiber-based or polymer-based containers.

[003] Global demand for plastic waste reduction and sustainable packaging solutions is on the rise. Meal kit companies often indicate that the kits are recyclable but fail to understand the capabilities and limitations of material recycling processes. For example, kit (e.g., meal or pharmaceutical) components (e.g., outer package and individual inner packages) often cannot be recycled together due to the components including a variety of materials that provide barrier to prevent the ingress of oxygen and/or moisture into the outer and/or inner packages. The combination of the materials of the outer container and the inner container can create difficulties when determining how to dispose of the kit after use. Additionally, the kit often lacks instruction regarding how the outer container and/or the inner container(s) should be placed into recycling or waste streams. As a result, containers of incompatible polymers are likely mixed when placed in store drop-off bins or curbside recycling.

[004] Some recycling processes restrict the size and volume of the packaging component (e.g., outer package, inner package). In some recycling processes, a packaging component volume larger than 7.5 liters (2 gallons) or a packaging component size smaller than 5 centimeters (cm) (2 inches (in)) in 2 dimensions is not acceptable. For example, a packaging component that measures less than 5 cm in each of 2 dimensions cannot be recycled by most current processes whether it is composed of a single polymer or a combination of polymers.

SUMMARY

[005] This disclosure relates to a packaged product (e.g., kit) that includes an outer container and one or more inner containers located within the outer container. A product is contained in the inner container. The products are not limited to food, beverages, other liquids, non-food products, or pharmaceuticals. The outer container is polymer-based and the inner container is polymer-based. The polymers of the outer container and the inner container are compatible in a recycling stream.

[006] A consumer or end user may use or consume the product contained in the inner container. The disclosure includes an unfilled inner container by way of emptying the inner container containing product. The unfilled inner container may be clean and dry or substantially free of product, to be recycled with the outer container in a recycling stream that is compatible with the polymers of the unfilled inner container and the outer container. Recycling is often efficient or may only be possible if the outer and inner container materials are of the same polymer or are compatible. For example, in many countries, there are current processes in place to collect, sort and recycle packages of a single polymer (e.g., polymer category), for example, polyethylene (PE), polyester, or polypropylene (PP). The associated unfilled inner containers and outer container of this disclosure include polymer combinations that may be recovered together and further recycled, regardless of volume or size, or clean and dry status.

[007] In a first embodiment, a packaged product may comprise an outer container comprising a first polymer. The outer container may have a reclosable feature. An inner container may comprise a second polymer and is located within the outer container. A product may be contained in the inner container. The second polymer may be compatible with the first polymer in a recycling stream.

[008] In a second embodiment, a composite container may comprise an outer container comprising a first polymer. The outer container may have a reclosable feature. An inner container may comprise a second polymer and is located within the outer container. The second polymer may be compatible with the first polymer in a recycling stream.

[009] In a third embodiment, a method of using a packaged product is disclosed. The packaged product may comprise an outer container, an inner container, and a product. The outer container may comprise a first polymer and may have a reclosable feature. The inner container may comprise a second polymer and may be located within the outer container. The product may be contained in the inner container. The method includes the operations of opening, removing, placing, and closing. For an opening operation, in one or more embodiments, the outer container is opened forming an opened outer container. For a removing operation, in one or more embodiments, the inner container is removed from the opened outer container. For a second opening operation, in one or more embodiments, the inner container is opened forming an opened inner container. For a second removing operation, in one or more embodiments, the product is removed from the opened inner container forming an unfilled inner container. For a placing operation, in one or more embodiments, the unfilled inner container is placed into the opened outer container. For a closing operation, in one or more embodiments, the opened outer container is closed forming a composite container. For a second placing operation, in one or more embodiments, the composite container is placed into a recycling stream that is compatible with the first polymer and the second polymer.

[010] Other features that may be used individually or in combination with respect to any embodiment are as follows.

[011] The outer container may comprise a base portion and a lid portion

[012] The outer container may comprise a pouch.

[013] The inner container may comprise dimensions of less than 5 centimeters (two inches) in each of two dimensions.

[014] A second inner container may comprise a third polymer. The third polymer may be compatible with the first polymer and the second polymer in a recycling stream.

[015] The first polymer may comprise polyester, polystyrene, polypropylene, polyethylene, polyamide, polycarbonate, or combinations thereof.

[016] The outer container may comprise from 95% to 100% of the first polymer, by weight.

[017] The second polymer may comprise polyester, polystyrene, polypropylene, polyethylene, polyamide, polycarbonate, or combinations thereof.

[018] The second polymer may be the same as the first polymer.

[019] The inner container may comprise from 95% to 100% of the second polymer, by weight.

[020] The product may comprise food.

[021] The product may comprise pharmaceuticals.

[022] The inner container may comprise a single serving of food.

[023] The first polymer may comprise polypropylene and the second polymer may comprise polyethylene.

[024] The outer container may comprise from 90% to 100% of the first polymer, by weight, and the inner container may comprise from 90% to 100% of the second polymer, by weight.

[025] The first polymer may comprise polyethylene and the second polymer may comprise polyethylene. BRIEF DESCRIPTION OF THE DRAWINGS

[026] The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings, in which:

[027] Figure 1 A illustrates a schematic perspective view of an embodiment of an outer container in a closed position;

[028] Figure 1 B illustrates a schematic perspective view of an embodiment of the outer container shown in Figure 1 A in an opened position;

[029] Figure 2A illustrates a schematic perspective view of an embodiment of an outer container in a closed position;

[030] Figure 2B illustrates a schematic perspective view of an embodiment of the outer container shown in Figure 2A in an opened position;

[031] Figure 3A illustrates a schematic perspective view of an embodiment of an outer container in a closed position;

[032] Figure 3B illustrates a schematic perspective view of an embodiment of the outer container shown in Figure 3A in an opened position;

[033] Figure 4A illustrates a schematic perspective view of an embodiment of an outer container in a closed position;

[034] Figure 4B illustrates a schematic perspective view of an embodiment of the outer container shown in Figure 4A in an opened position;

[035] Figure 4C illustrates a schematic perspective view of an embodiment of the outer container shown in Figure 4B during the process of being reclosed;

[036] Figure 4D illustrates a schematic perspective view of an embodiment of the outer container shown in Figures 4B-C in a closed position;

[037] Figure 5A illustrates a schematic perspective view of an embodiment of an inner container in an opened position;

[038] Figure 5B illustrates a schematic perspective view of the embodiment of the inner container shown in Figure 5A in a closed position;

[039] Figure 5C illustrates a schematic perspective view of the embodiment of the inner container shown in Figures 5A-B in a closed position that contains a product; [040] Figure 6A illustrates a schematic perspective view of an embodiment of an inner container in an opened position that contains a product;

[041] Figure 6B illustrates a schematic perspective view of the embodiment of the inner container shown in Figure 6A in a closed position;

[042] Figure 7 illustrates a schematic perspective view of an embodiment of an inner container in a closed position that contains a product;

[043] Figure 8 illustrates a schematic perspective view of an embodiment of a packaged product;

[044] Figure 9 illustrates a schematic perspective view of an embodiment of a packaged product;

[045] Figure 10 illustrates a flowchart depicting method steps of using a packaged product in accordance with an embodiment of the present disclosure;

[046] Figure 1 1 illustrates a schematic perspective view of an embodiment of a composite container; and

[047] Figure 12 illustrates a schematic perspective view of an embodiment of a composite container.

[048] The drawings show some but not all embodiments. The elements depicted in the drawings are illustrative and not necessarily to scale, and the same (or similar) reference numbers denote the same (or similar) features throughout the drawings.

DETAILED DESCRIPTION

[049] Described herein are packaged products, a method of using the packaged products, and composite containers. The composite containers may be recycled in a recycling stream. The packaged products and composite containers include an outer container and one or more inner containers. The packaged products, for example may be kits that may include meal, food, or pharmaceutical components, for example. The inner container contains a product, such as individual ingredients or elements of a kit in various non-limiting package formats (e.g., pouch, cup, stick pack, etc.). The inner container can contain relatively small volumes of product with respect to the outer container volume. The inner container may contain, for example, single or multiple servings of food or beverage. The product may be sensitive to oxygen and/or moisture such that barrier materials may be included in the inner container and/or the outer container to prevent the ingress of oxygen and/or moisture. The outer container includes a first polymer and the inner container includes a second polymer. The second polymer is compatible with the first polymer in a recycling stream.

[050] Once the contents of the inner container or containers are used or consumed, a composite container may result by placing an emptied, or otherwise unfilled, inner container into the outer container and reclosing the outer container. The unfilled inner container may be devoid or substantially devoid of the product that was initially contained in the in the inner container (e.g., clean or mostly clean). The composite container of the present disclosure has the distinct advantage of compatible recycling of the outer and inner container. That is, the outer container and the emptied or unfilled inner container that is located within the outer container may be recycled together in the same recycling stream simultaneously.

Outer Container

[051] An outer container of the present disclosure contains at least one inner container. In some embodiments, the outer container may include rigidity such that the outer container may have a three-dimensional shape and may resist deformation from compressive forces. The outer container provides protection from an external environment to its contents (i.e., at least one inner container that can include product). The outer container may include a base portion and a lid portion. The lid portion may be separate from the base portion or integral with the base portion. The outer container may include an injection- or blow-molded component, or a thermoformed component that may include the base portion, the lid portion, or both the base and lid portions. In other embodiments, the outer container may be flexible where a three-dimensional shape is not retained, such as a flexible film package (e.g., stand up pouch, sachet, pillow pouch, etc.). In some embodiments, the outer container may include both flexible and formed (i.e., cold formed, thermoformed, or molded) regions. In some embodiments, the formed regions may include rigidity and retain a three-dimensional shape.

[052] The outer container is not limited in shape and may be rectangular, square, triangular, round, or oval shaped. For example, the outer container may resemble a box (e.g., injection-molded HDPE box), a cup, a bowl, a tray, etc. The outer container may include barrier materials. The outer container may be formed from a monolayer or multilayer film. The outer container may include tamper evidence features that are known by one of skill in the art.

[053] Further, the outer container may include or post consumer recyclate (PCR) post industrial recyclate (PIR). In some embodiments, PCR or PIR may be included in an amount of from 25% to 100%, by weight of the outer container. An outer container including high amounts of PCR or PIR may lend itself to non-direct food contact embodiments.

[054] The outer container includes at least one outer container holding area (e.g., containment area, body) to contain at least one inner container. In an embodiment, the outer container holding area may include one compartment. In other embodiments, the outer container holding area may include more than one compartment. For example, an outer container base portion in the form of a tray that includes an outer container holding area may include formations in the tray such that there are multiple compartments in the tray. In another example, an outer container may be in the form of a pouch that includes a partition in the outer container holding area such that the pouch may include two compartments.

[055] Outer containers may include features to hold inner containers in an upright position as the outer container sets on a table or shelf. For example, outer containers may include formed portions that include ridges, bumps, notches, etc., that may support the inner container in a desired position.

[056] The outer container includes a reclosable feature such that the outer container is capable of being closed to some degree after it has been initially opened. The reclosed outer container further remains closed to some degree after being handled (e.g., after being placed into in a recycling repository or being maneuvered in a recycling stream process). The outer container may be completely or partially reclosed. The outer container must be able to contain inner containers when the outer container is completely or partially reclosed.

[057] With reference to Figures 1 A-4D, non-limiting examples of outer containers are described. Figure 1A shows an outer container 10 in an initially closed position. The outer container 10 includes a base portion 12, a lid portion 14, and an outer container holding area 16. In this embodiment, the outer container holding area 16 includes the base portion 12 where the contents of the outer container 10 may be placed. The base portion 12 is shown to be a rectangularly-shaped receptacle and the lid portion 14 corresponds in shape to the base portion 12. The outer container 10 can be closed when the lid portion 14 is attached or connected to the base portion 12. The base portion 12 and the lid portion 14 are each formed such that a three-dimensional shape of each portion 12, 14 is retained. The lid portion and the base portion include the first polymer.

[058] With reference to Figure 1 B, the outer container 10 is shown in an open position with the lid portion 14 unattached from the base portion 12. From the open position, the outer container 10 may be reclosed by attaching the lid portion 14 to the base portion 12 that resembles the initially closed position of the outer container 10 shown in Figure 1A.

[059] With reference to Figures 2A-B, an outer container 20 is shown that is rectangularly-shaped. In this embodiment, a lid portion 24 is integral with and hingedly attached to a base portion 22 (e.g., clamshell package format). The outer container 20 includes an outer container holding area 26. The base portion 22 and the lid portion 24 are each formed such that a three-dimensional shape is retained. The outer container 20 is shown in a closed position in Figure 2A and in an open position in Figure 2B. The lid portion and the base portion include the first polymer.

[060] For outer container embodiments that include a three-dimensional lid portion and a three-dimensional base portion, the reclosable feature may include interlocking (e.g., snap on, snap close, button press locks, etc.) lid and base portions, adhesive engagement between the lid portion and the base portion, or any other reclosable feature or mechanism known by one of skill in the packaging arts.

[061] With reference to Figures 3A-B, an outer container 30 is shown that is rectangularly-shaped. In this embodiment, the outer container 30 includes a reclosable, peelable seal between a lid portion 34 and a base portion 32 that allows the outer container 30 to be manually opened and reclosed. The outer container 30 includes an outer container holding area 36. The lid portion 34 is a flexible film and is a peelably sealed to the base portion 32. Base portion 32 is formed to retain a three-dimensional shape. The outer container 30 is shown in a closed position in Figure 3A and in a partially open position in Figure 3B. As used herein, the terms “peelable seal” or “peelably sealed” refer to a seal that can be opened manually (i.e., by hand without the use of tools). A manually openable package is one in which the peel strength between the packaging components (e.g., lid portion and base portion) can be controlled over a wide temperature range. As used herein, “peel strength” is the measure of the average force to part two bonded materials like tape, labels, textile, or plastic films. Peelable seals are generally defined within the packaging industry as seals that can be separated by a peel strength (e.g., force) of less than 2,500 g/24.5 mm when measured according to ASTM F88/F88M - 09. The outer container 30 may be reclosed, for example, by reseal technology that includes adhesive (e.g., pressure sensitive adhesive) in the structure of the lid portion 34. The lid portion may be a monolayer or multilayer film. Seals may be formed by heat, adhesive, or ultrasonics, for example. The lid portion and the base portion include the first polymer. In some embodiments, the outer container may include a feature the allows the lid portion to be removed from the base portion except in an area that keeps the lid portion tethered to the base portion for convenience to reclose and recycle the lid portion and the base portion together.

[062] With reference to Figures 4A-D, an outer container 40 is shown as a pouch that includes flexible film. In this embodiment, the flexible film does not retain a permanent three-dimensional shape (i.e., the film is free of cold formed, thermoformed, or molded regions). The outer container 40 is shown as a pouch and is formed from a single flexible film 41 folded over itself longitudinally and fastened along a longitudinal seal 43. The outer container 40 is closed at its lower end, for example, as it would sit on a shelf, by a first transverse seal 45 and is closed at an end opposing the first transverse seal 45 by a second transverse seal 47. The outer container 40 includes an outer container holding area 46. An integral flap 49 is detachable from the longitudinal seal 43 along a line of weakness 50. A pressure-sensitive adhesive 51 is placed on the side of the flap 49 facing the outer container 40.

[063] The outer container 40 may be opened at the second transverse seal 47 as shown in Figure 4B. With reference to Figures 4C-D, the outer container 40 may be closed by first detaching the flap 49 along the line of weakness 50, folding the open portion of the outer container 40 over itself forming a roll 53, and then securing the pressure sensitive adhesive 51 of flap 49 onto the roll 53.

[064] The outer container formed from flexible film is not limited to the pouch format shown in Figures 4A-D and may be in the format of a pillow pouch, sachet, double gusset pouch, or flow wrap pouch, for example. The outer container 40 is formed from a single flexible film, although outer containers may be formed from more than one film (e.g., pouch with a first panel of one film and a second panel of another film). Further, outer containers that include flexible film may include portions of the film that have been exposed to a forming process (e.g., cold forming, thermoforming, or molded) as known by one of skill in the packaging arts. The outer container may include other features to reclose the pouch such as an adhesive label, mechanical fasteners (e.g., press and seal zippers, hook and loop fasteners, etc.), or any other reclose feature known to one of skill in the packaging arts. The outer container may include opening features such as peelable seals, tear notches, or press and seal zippers, for example. Outer containers may include seals formed from heat, adhesive, or ultrasonics, for example. The outer container may include tamper evidence features known by one of skill in the art.

[065] Outer containers may include various dimensions to contain the intended contents. In one embodiment, outer containers may include meal kits that contain inner products containing a variety of food ingredients. In this example, the outer container may include an injection-molded base portion and an integral lid portion with each having dimensions of approximately 46 cm (18 inches) in length and 20 cm (8 inches) in width. The base portion may include a depth of 15 cm (6 inches). In another embodiment, outer containers may include first aid kits that contain a variety of medical and pharmaceutical ingredients. In this example, the outer container may include an injection-molded base portion and a lid portion with each having dimensions of 13 cm (5 inches) in length, 19 cm (7.5 inches) in width, and a depth of 7 cm (2.75 inches). In a further embodiment, the outer container may include a flow-wrap pouch that contains a variety of ingredients to make a lettuce-based salad. The pouch may have dimensions of 30 cm (12 inches) in height and 24 cm (9.5 inches) in width. The outer container may include any dimensions and the given examples are intended to be non-limiting.

[066] In other embodiments, the outer container may be sized appropriately to be recycled. For example, in many countries, there are current processes in place for a consumer to place recyclable packages or containers into a curbside recycling program where the outer container may be collected, sorted, and recycled. Qualification as a recyclable material is not regulated by any specific agencies but can be obtained from groups such as the Association of Plastic Recyclers (APR) and How2Recycle™. For example, curbside recycling programs may include restrictions on the size of a recyclable item. In some embodiments, an outer container may include a volume equal to or less than 7.5 liters (2 gallons).

[067] Outer containers or portions of outer containers (i.e., formed portions that include cold or thermoformed portions, or flexible film) may be formed from monolayer or multilayer films. The monolayer or multilayer films are based on the requirements of the contents of the outer container. For example, the contents may require barrier to oxygen and/or moisture. Multilayer layer films often include multiple layers of polymeric films, other substrates, or coatings to achieve the desired properties that may include barrier, sealing functionality, and abuse resistance to an environment external to the outer container. Monolayer films may also include coatings to achieve barrier properties, sealing functionality, and abuse resistance. The monolayer or multilayer films are not limited to any particular structure.

[068] As used herein, the term “film” is a monolayer or multilayer web that has an insignificant z-direction dimension (thickness) as compared to the x- and y- direction dimensions (length and width). Films are generally regarded as having two major surfaces, opposite each other, expanding in the length and width directions.

[069] The term “layer”, as used herein, refers to a building block of films that is a structure of a single polymer or a homogeneous or heterogeneous blend of polymers or materials. A layer may contain other non-polymeric materials and may have additives. Layers may be continuous or discontinuous (i.e., patterned) with the length and width of the film. In a monolayer film, “film”, “sheet” and “layer” are synonymous.

[070] The term “multilayer”, as used herein, refers to a single substrate structure (e.g., film, ply, etc.), which may have a plurality of layers, generally in the form of a sheet or web that can be made from a polymeric material or a non-polymeric material bonded together by any conventional means known in the art, (i.e., coextrusion, lamination, coating, or a combination thereof).

[071] Multilayer structures include as many layers as desired and, preferably, at least two layers. In multilayer structures that include at least three layers, the structure includes an inner layer. As used throughout this application, the term “inner layer” refers to a layer that is positioned between two other layers. As used throughout this application, the term “surface layer” refers to a layer that does not have another layer on at least one of its major surfaces, (i.e., a surface layer that is on the exterior of the multilayer structure).

[072] The monolayer films and/or multilayer films may include a barrier layer. The term “barrier layer”, as used herein, refers to a layer that significantly reduces the transmission of one or more molecular species through the layer. A barrier layer may be a surface layer or an inner layer of the multilayer film. In a monolayer film embodiment, the monolayer film may be the barrier layer. A barrier layer may limit or reduce the permeation of migratory species such as moisture, oxygen, and/or other gasses. Barrier layers typically include metals or polymers that are referred to as “barrier materials”. Barrier polymeric materials are not limited to polymers including ethylene vinyl alcohol copolymer (EVOH), PVDC, high density polyethylene (HDPE), cyclic olefin copolymers (COC), polyamides, polyacrylates, and polypropylenes. Useful barrier metallic materials may include aluminum or polymeric films coated with metal oxides. Barrier layers may include coatings that include barrier materials. Barrier layers may include blends of materials. The multilayer films may contain multiple barrier layers. The film may include one, two, three, four, or more separate layers comprising barrier materials. The barrier layer may be accompanied by other minor components such as slip, antiblock, processing aid, nucleation additives, or hydrocarbon additives, such that the blend consists of at least 80% of the barrier polymer. In some embodiments, the film may include more than one barrier layer where each barrier layer includes a barrier material that is different from at least one of the other barrier layers.

[073] In some embodiments, the barrier material includes an ethylene vinyl alcohol copolymer. The terms “ethylene vinyl alcohol copolymer” or “EVOH”, as used herein, refer to copolymers comprised of repeating units of ethylene and vinyl alcohol. Ethylene vinyl alcohol copolymers can be represented by the general formula: [(CH2-CH2)m-(CH2-CH(OH))_n]. Preferably, ethylene vinyl alcohol copolymers comprise from about 25 mole percent to about 48 mole percent ethylene. EVOH is known to reduce the permeation of oxygen and other gasses through polymeric based packaging films. EVOH includes a density from 1.12 g/cm³ to 1 .24 g/cm³.

[074] The barrier layer may provide moisture barrier. Some embodiments of the barrier layer may include high density polyethylene (HDPE) for moisture barrier improvements. The terms “high density polyethylene” or “HDPE”, as used herein, refer to both (a) homopolymers of ethylene that may have densities from about 0.960 g/cm³ to about 0.970 g/cm³ and (b) copolymers of ethylene and an alphaolefin (usually 1 -butene or 1 -hexene) that may have densities from about 0.940 g/cm³ to about 0.958 g/cm³. HDPE includes polymers made with Ziegler or Phillips type catalysts, polymers made with single-site metallocene catalysts, and polymers made with non-metallocene single-site catalysts. HDPE also includes high molecular weight polyethylenes.

[075] Some embodiments of the barrier layer may include polypropylene (PP) for moisture barrier improvements.

[076] The film may include a sealing layer that permits the film to be sealed to itself, another film, or packaging component. The sealing layer may be a layer of the monolayer film or multilayer film or includes heat seal coatings. The sealing layer should be capable of forming a bond upon exposure to heat and pressure for a short dwell time to form a heat seal. In the case of a multilayer film, a sealing layer may be a surface layer or may include more than one layer that may be intricately involved in sealing.

[077] The outer container may include printed indicia. The printed indicia may be positioned between layers of a multilayer film. The printed indicia may be surface printed on a monolayer or multilayer film. The outer container may include a label that includes printed indicia. The outer container may further include coatings or lacquers on the surface exposed to an external environment. The coatings or lacquers may provide abuse resistance or aesthetics, among other things as known in the art.

[078] The outer container includes a first polymer. In an embodiment, the first polymer may be selected for contributions towards aesthetics, rigidity, thermoformability, or abuse resistance. In an embodiment, the first polymer is selected for compatibility with a recycling stream or process that may be a single polymer recycling stream or process. As used in this application, the term “single polymer” may include an individual polymer or a blend of individual polymers from the same category. For example, “polyethylene”, as used herein, may be considered a category of polymers that are polyethylene-based and includes individual polymers of high density polyethylene (HDPE), medium density polyethylene (MDPE), or low density polyethylene (LDPE), among others. “Polyester”, as used herein, may be considered another category of polymers that are polyester-based and includes individual polymers of polyethylene terephthalate (PET), poly(butylene terephthalate) (PBT), or poly(butylene adipate- co-terephthalate) (PBAT), for example. Other non-limiting polymer categories include “polystyrene” that includes polystyrene-based polymers, “polyamide” that includes polyamide-based polymers, and “polycarbonate” that includes polycarbonate-based polymers, for example.

[079] In an embodiment, the first polymer may include an individual polymer or a blend of individual polymers from the same category of polymers. In an embodiment, the first polymer includes polypropylene or a blend of polypropylene- based polymers. In another embodiment, the first polymer includes polyester or a blend of polyester-based polymers. In a further embodiment, the first polymer includes polyethylene or a blend of polyethylene-based polymers. In an embodiment, the first polymer includes high density polyethylene (HDPE).

[080] In some embodiments, the outer container may include barrier material and/or other additives in addition to the first polymer in an amount of up to and including 10% by weight of the outer container. In an embodiment, an outer container includes a first polymer in a range of from 90% to 100% by weight of the outer container. In an embodiment, an outer container includes a first polymer in a range of from 95% to 100% by weight of the outer container. For example, an outer container may include a first polymer of polyethylene or a blend of polyethylenebased polymers in an amount of from 90% to 100% by weight of the outer container.

[081] As used throughout this application, the terms “polystyrene”, “PS”, or “styrenic-based polymers” refer to a homopolymer or copolymer having at least one styrene monomer linkage (such as benzene (i.e., CeHe) having an ethylene substituent (i.e., phenyl group, CeHs) pendant to the repeating backbone of the polymer. The styrene linkage can be represented by the general formula: [CH2 - CH(C₆H₅)]n.

[082] As used throughout this application, the term “polyester” refers to a homopolymer or copolymer having an ester linkage between monomer units which may be formed, for example, by (a) condensation polymerization reactions between a dicarboxylic acid and a diol, (b) condensation reaction of hydroxy acids, or (c) ring opening of glycolide, lactide, (d) transesterification of a diol and a diester known as bis-HET, etc. The ester linkage can be represented by the general formula: [O-R-OC(O)-R'-C(O)]n where R and R' are the same or different alkyl (or aryl) group and may be generally formed from the polymerization of dicarboxylic acid and diol monomers containing both carboxylic acid and hydroxyl moieties. The dicarboxylic acid (including the carboxylic acid moieties) may be linear or aliphatic (e.g., lactic acid, oxalic acid, maleic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, and the like) or may be aromatic or alkyl substituted aromatic (e.g., various isomers of phthalic acid, such as paraphthalic acid (or terephthalic acid), isophthalic acid and naphthalic acid). Specific examples of a useful diol include but are not limited to ethylene glycol, propylene glycol, trimethylene glycol, 1 ,4-butane diol, neopentyl glycol, 1 ,4-cyclohexane dimethanol (CHDM), cyclohexane diol, and the like. Polyesters may include (a) a homopolymer or copolymer of alkyl-aromatic esters including but not limited to polyethylene terephthalate (PET), amorphous polyethylene terephthalate (APET), crystalline polyethylene terephthalate (CPET), glycol-modified polyethylene terephthalate (PETG) and polybutylene terephthalate, (b) a copolymer of terephthalate and isophthalate including but not limited to polyethylene terephthalate/isophthalate copolymer, (c) a homopolymer or copolymer of aliphatic esters including but not limited to polylactic acid (PLA), (d) polyhydroxyalkonates including but not limited to polyhydroxypropionate, poly(3-hydroxybutyrate) (PH3B), poly(3-hydroxyvalerate) (PH3V), poly(4- hydroxybutyrate) (PH4B), poly(4-hydroxyvalerate) (PH4V), poly(5- hydroxyvalerate) (PH5V), poly(6-hydroxydodecanoate) (PH6D), (e) polyethylene furanoate (PEF), and blends of any of these materials. Other non-limiting polyesters include poly(butylene terephthalate) (PBT), polyethylene naphthalate) (PEN), polypropylene furanoate) (PPF), poly(butylene adipate-co-terephthalate) (PBAT), poly(glycolic acid) (PGA), poly(caprolactone), poly(butyrolactone), poly(hydroxy butyrate) (PHB), and poly(hydroxy valerate) (PHV).

[083] As used throughout this application, the term “copolymer” refers to a polymer product obtained by the polymerization reaction or copolymerization of at least two different monomer species. The term “copolymer” is also inclusive of the polymerization reaction of three, four, or more monomer species having reaction products referred to terpolymers, quaterpolymers, etc.

[084] As used throughout this application, the term "modified" refers to a chemical derivative, such as one having any form of anhydride functionality (e.g., anhydride of maleic acid, crotonic acid, citraconic acid, itaconic acid, fumaric acid, etc.), whether grafted onto a polymer, copolymerized with a polymer, or blended with one or more polymers. The term is also inclusive of derivatives of such functionalities, such as acids, esters and metal salts derived from such.

[085] As used throughout this application, the term “polypropylene” or “PP” refers to a homopolymer or copolymer having at least one propylene monomer linkage within the repeating backbone of the polymer. The propylene linkage can be represented by the general formula: -CH2-CH(CH3)-.

[086] As used throughout this application, the term "polyethylene" or “PE” refers to, unless indicated otherwise, ethylene homopolymers as well as copolymers of ethylene with at least one alpha-olefin. Suitable alpha-olefins include, for example, (C3 to C4) alpha-olefins such as 1 -propene, 1 -butene, 1 - pentene, 1 -hexene, 1 - octenes 1 -decene, or blends of such materials. The polyethylene basic structure is characterized by the chain -(CH2- CH2-)n. Ethylene alpha-olefin copolymers may include, for example, linear low density polyethylene (LLDPE), metallocene- catalyzed LLDPE (mLLDPE), very low density polyethylene (VLDPE), metallocene-catalyzed VLDPE (mVLDPE), ultra low density polyethylene (ULDPE), and plastomers. Other examples of polyethylene copolymers include, but are not limited to, ethylene vinyl acetate copolymer (EVA), ethylene methyl methacrylate copolymer (EMMA), ethylene-methacrylic acid (EMAA) and ethylene acrylic acid (EAA).

[087] "High density polyethylene" (HDPE) is ordinarily used in the art to refer to both (a) homopolymers of densities between about 0.960 to 0.980 grams per cubic centimeter and (b) copolymers of ethylene and an a-olefin (usually 1 -butene, 1 - hexene or 1 -octene) which have densities between 0.940 and 0.958 grams per cubic centimeter. [088] "Medium density polyethylene" (MDPE) typically has a density from 0.928 to 0.940 grams per cubic centimeter. Medium density polyethylene includes linear medium density polyethylene (LMDPE).

[089] Another grouping of polyethylene is "high pressure, low density polyethylene" (LDPE). LDPE is used to denominate branched homopolymers having densities between 0.915 and 0.930 grams per cubic centimeter. LDPEs typically contain long branches off the main chain (often termed "backbone") with alkyl substituents of 2 to 8 carbon atoms.

[090] The terms “polyamide” or “nylon”, as used herein, refer to homopolymers or copolymers having recurring amide linkages and may be formed by any method known in the art. Recurring amide linkages may be formed by the reaction of one or more diamines and one or more diacids. Non-limiting examples of suitable diamines include 1 ,4-diamino butane, hexamethylene diamine, decamethylene diamine, metaxylylene diamine, and isophorone diamine. Non-limiting examples of suitable diacids include terephthalic acid, isophthalic acid, 2,5-furandicarboxylic acid, succinic acid, adipic acid, and azelaic acid.

[091] Polyamides may also be formed by the ring-opening polymerization of suitable cyclic lactams like s-caprolactam, co-undecanolactam and co- dodecalactam.

[092] Non-limiting examples of suitable polyamides include poly(£-caprolactam) (nylon 6), poly(co-undecanolactam) (nylon 1 1 ), poly(co-dodecalactam) (nylon 12), poly(hexamethylene adipamide) (nylon 6,6), poly(hexamethylene adipamide-co- caprolactam) (nylon 66/6), poly(caprolactam-co-hexamethylene adipamide) (nylon 6/66), poly(caprolactam-co-hexamethylene azelamide) (nylon 6/69), poly(m- xylylene adipamide) (MXD6) and poly(hexamethylene terephthalamide-co- hexamethylene isophthalamide) (nylon 6I/6T).

[093] As used throughout this application, the term “polycarbonate” refers to an oligomer or polymer including residues of one or more dihydroxy compounds (e.g., dihydroxy aromatic compounds) joined by carbonate linkages. This encompasses homopolycarbonates, copolycarbonates, and (co)polyester carbonates. The polycarbonate may include any polycarbonate material or mixture of polycarbonate materials. The polycarbonate may be a homopolymer including repeating units derived from bisphenol A. The polycarbonate may include polycarbonate monomers such as, but not limited to, 2-phenyl-3,3’-bis (4-hydroxy phenyl) phthalimidine (PPPBP) and dimethyl bisphenol cyclohexane (DMBPC).

[094] The outer containers described herein may be suitable for recycling. As used in this application, the term “suitable for recycling” is meant to indicate that the outer container can be converted into a new, useful item by means of reprocessing in a recycle stream. Reprocessing may entail washing, separating, melting, and forming, among many other steps. Typically, when polymeric items are recycled by reprocessing, the material is mechanically chopped into small pieces (e.g., granulated, flaked, etc.), melted, mixed, and reformed into the new product. If multiple incompatible materials are present in the items to be recycled, interactions occur during reprocessing that can cause gels, brittle material, poor appearance, and generally unusable or poor quality products. Using the term “recyclable” indicates that these drawbacks generally are not present.

Inner Container

[095] The outer container may contain one or more inner containers. Each inner container contains a product (e.g., an ingredient or element of a packaged product). The inner containers described herein may be recycled after their primary use is completed such that the inner container is suitable for recycling.

[096] An inner container may be selected from a variety of package formats. The inner container may include rigidity. The inner container may have a three- dimensional shape and may resist deformation from compressive forces that provides protection to product contained therein. The inner container may only include a base portion. The inner container may include a base portion and a lid portion. For example, the inner container may include an injection-molded component or a thermoformed component that may include the base portion, the lid portion, or both the base and lid portions. The lid portion may be separate from the base portion or integral with the base portion. The lid may remain attached to the base portion (e.g., punctured for product removal) or partially attached to the base portion. The inner container is not limited in shape and may be rectangular, square, triangular, round, or oval shaped. For example, the inner container may resemble a box, a cube, a cup, a bowl, a tray, etc. In other embodiments, the inner container may be flexible, such as a flexible film package (e.g., pouch, sachet, stick pack, pillow pouch, form-fill-seal (FFS) pouch, stand up pouch, etc.). In some embodiments, the inner container may include both flexible and formed (i.e., cold formed, thermoformed, or molded) regions, for example, a blister pack. The inner container is not limited by package format.

[097] The inner container may be any size or dimensions that is less than an outer container size that the inner container is associated with. That is, the inner container must be able to be placed into an outer container holding area and be contained within the outer container. In some embodiments, an inner container may include a size that is 5 cm (2 in) in 2 dimensions, or smaller. In an embodiment, an inner container may be contained within an outer container. In other embodiments, multiple inner containers may be contained within an outer container, for example, a second inner container, a third inner container, a fourth inner container, and so on. There is no limit to how many inner containers may be contained within the outer container.

[098] The inner container may include components such as straws, spouts, labels, zippers, tape, etc., that may aid in emptying product from the inner container or communicating information to a consumer, for example. Components may be selected to be compatible with the inner container in a recycling stream. In some embodiments, the inner container may include a reclosable feature.

[099] The inner container may include printed indicia, such as those described for the outer container. The inner container may be formed from a monolayer or multilayer film, such as those described for the outer container.

[100] The inner container includes a second polymer. In an embodiment, the second polymer may be selected for contributions towards aesthetics, rigidity, thermoformability, abuse resistance, or compatibility with a recycling stream or process that may be a single polymer recycling stream or process. The second polymer may be an individual polymer or a blend of individual polymers from the same categories of polymers as previously described for the first polymer (e.g., polyethylene, polyester, polystyrene, etc.). In an embodiment, the second polymer may include an individual polymer or a blend of individual polymers from the same category of polymers. In an embodiment, the second polymer includes polypropylene or a blend of polypropylene-based polymers. In another embodiment, the second polymer includes polyester or a blend of polyester-based polymers. In a further embodiment, the second polymer includes polyethylene or a blend of polyethylene-base polymers.

[101] In some embodiments, the inner container may include barrier material and/or other additives in addition to the second polymer in an amount of amount of up to and including 10% by weight of the inner container. In an embodiment, an inner container includes a second polymer in a range of from 90% to 100% by weight of the inner container. In an embodiment, an inner container includes a second polymer in a range of from 95% to 100% by weight of the inner container. For example, an inner container may include a second polymer of polyethylene or a blend of polyethylene-based polymers in an amount of from 90% to 100% by weight of the inner container.

[102] Non-limiting examples of second polymers include polystyrene, polyester, polypropylene, polyethylene, polyamide, and blends thereof. Examples include, but are not limited to, high impact polystyrene (HIPS), polyethylene terephthalate (PET), amorphous polyethylene terephthalate (APET), crystalline polyethylene terephthalate (CPET), glycol-modified polyethylene terephthalate (PETG), polyethylene (PE) homopolymer, high density polyethylene (HDPE), polypropylene (PP) homopolymer, PP copolymer, and polycarbonate. In some embodiments, the second polymer may include thermoformable functionality.

[103] In any embodiment, the second polymer of the inner container is selected for its compatibility with the first polymer of the outer container that the inner container is contained within, with respect to a recycling stream or process. In an embodiment, an outer container having a first polymer contains one inner container having a second polymer and the first polymer is compatible with a second polymer in a recycling stream that may be a single polymer recycling stream. The first polymer and the second polymer may be from the same polymer category or from different polymer categories, although the first polymer and the second polymer must be compatible in a recycling stream or process. In an embodiment, the first polymer and the second polymer may each be polyethylene or a blend of polyethylene-based polymers. In another embodiment, the first polymer may be polyethylene or a blend of polyethylene-based polymers and the second polymer may be polypropylene or a blend of polypropylene-based polymers.

[104] In another example, an outer container may contain more than one inner container. In an embodiment, and outer container having a first polymer contains a first inner container having a second polymer and a second inner container having a third polymer. In an embodiment, the second polymer and the third polymer are of the same polymer category as the first polymer and all are compatible in a single polymer recycling stream. In another embodiment, the second polymer and the third polymer are from different polymer categories, and each is compatible with the first polymer in a single polymer recycling stream. The outer container having a first polymer may contain any number of inner containers with each inner container having a polymer that corresponds with each inner container. That is, there may be a second polymer for an inner container (e.g., first inner container), a third polymer for a second inner container, a fourth polymer for a third inner container, and so on. In embodiment including multiple inner containers, each polymer associated with each inner container (e.g., second polymer, third polymer, fourth polymer, etc.) may be from differing polymer categories. In other embodiments including multiple inner containers, each polymer associated with each inner container may be from the same polymer category. In any embodiment, each polymer of each inner container (e.g., second polymer, third polymer, fourth polymer, etc.) is compatible with the first polymer in a recycling stream and the recycling stream may be a single polymer recycling stream. Product

[105] An inner container contains a product. The products are not limited and may include food, pharmaceuticals, utensils (e.g., fork, spoon, etc.), hardware (e.g., screws, nails, wire, etc.), or tools (screwdriver, hammer, etc.), for example. Products with respect to meal kits may include spices, powdered mixes, sauces, beverages, vegetables, or a protein (e.g., meat, fish, tofu, etc.), among others. Products with respect to pharmaceuticals may include, for example, cannabis- related items, prescription medication, over the counter (OTC) medication, mouthwash or alcohol-based shots (e.g., a single serving), shampoo or hair care- related products, bandages, or hand sanitizers. Products with respect to laundry may include laundry detergent, fabric softener, and stain removal wipes, for example.

[106] The products are contained in inner containers that are suitable for the given product. For example, a powdered product may be contained in a stick pack and a liquid product may be contained in a cup with a peelably, removable sealed lid. The inner container may be selected with respect to variables that may include barrier requirements of the product (e.g., moisture, oxygen, and/or light barrier), aesthetics, and ease of use by end user (i.e., consumer).

[107] The product quantity or volume contained in an inner container may be selected based on the packaged product. Considering a packaged product that is a meal kit, each inner container may include multiple servings of each ingredient. Nutritional labels are found on packaged food products in the United States that include nutritional information for a single serving (e.g., portion) of the food product that is to be consumed at one time by one person. For example, a meal kit that is intended to contain ingredients for four servings may have each inner container contain four servings of an ingredient. In another meal kit example that is intended to contain ingredients for four servings, each inner container may contain two servings of an ingredient and include twice as many inner containers when compared to inner containers that contain four servings of each ingredient. In an example where the packaged product is a meal kit for one meal, each inner container may include one serving of an ingredient. The combinations of how the product is contained in the inner container is not limited by these examples.

[108] With reference to Figures 5A-7, non-limiting examples of inner containers containing product are described. Figure 5A shows an inner container 60 to be cup-shaped and in an open position. Inner container 60 includes a lid portion 64 and a base portion 62 that includes an inner container holding area 66. Figure 5B shows the inner container 60 in a closed position where the lid portion 64 is attached to the base portion 62 by interlocking means. Figure 5C shows the inner container 60 in a closed position and containing a product 68.

[109] With reference to Figure 6A, an inner container 70 is shown to be a cubeshaped cup. Inner container 70 includes a lid portion 74 that is partially opened from a base portion 72. Inner container 70 includes an inner container holding area 76 and a product 78. Figure 6B shows the inner container 70 in a closed position where the lid portion 74 is sealed to the base portion 72. The lid portion includes the second polymer of the base portion such that the inner container may be recyclable. In some embodiments, the inner container may include a feature that allows the lid portion to be removed from the base portion except in an area that keeps the lid portion tethered to the base portion for convenience to recycle the inner container.

[110] With reference to Figure 7, an inner container 80 is shown to be a stick pack in a closed (e.g., sealed) position. The inner container 80 includes flexible film 81 folded over itself longitudinally and fastened along a longitudinal seal 83. The inner container 80 is sealed at a first end by a first transverse seal 85 and is closed at its end opposing the first transverse seal 85 by a second transverse seal 87. The inner container 80 includes an inner container holding area 86 containing a product 88. The inner container 80 may be opened along a line of weakness 89.

Packaged Product [111] A packaged product includes an outer container that includes a reclosable feature. The outer container contains one or more inner containers and each inner container includes a product. The packaged product includes the outer container that may be in a first closed position.

[112] In one embodiment, packaged products may include an outer container that contains an inner container that contains a product. In other embodiments, packaged products may be kits that generally include multiple, related products towards a common theme or goal with each product contained in individual inner containers. In some embodiments, an outer container may include multiple inner containers with each inner container including the same product. The packaged product disclosed herein may provide convenience to an end user.

[113] Non-limiting examples of packaged products are shown in Figures 8-9. With reference to Figure 8, a packaged product 90 is shown that includes multiple, related products. In some embodiments, the packaged product contains inner containers that contain multiple, different products (e.g., ingredients or components) where the packaged products may be food kits, meal kits, picturehanging kits, or cleaning kits. An outer container 91 is shown to be a reclosable, clamshell package format in a first closed position. The outer container 91 includes a lid portion 94, a base portion 92, and an outer container holding area 96. The outer container 91 is shown to include a first inner container 93 that contains a first product 97 and a second inner container 95 that contains a second product 99. The first inner container 93 is shown as a cup-shaped container including a peelable lid. The second inner container 95 is shown as a stick pack.

[114] With reference to Figure 9, a packaged product 100 is shown that includes one product in multiple inner containers. For example, the packaged product may contain inner containers that contain a single serving of a nutritional ingredient that may be a powdered beverage mix. An outer container 101 is shown to be a reclosable pouch format. The outer container 101 is in a first closed position and includes a flexible film 102, a longitudinal seal 103, a first transverse seal 105, an outer container holding area 106, a second transverse seal 107, a flap 109, and a line of weakness 110. The outer container 101 contains a first inner container 120, a second inner container 130, and a third inner container 140, with each inner container 120, 130, 140, shown as a stick pack and containing a first product 121.

[115] In some embodiments that include more than one inner container, the inner containers may be the same package format. In other embodiments that include more than one inner container, each inner container may be a different package format from another inner container. In an embodiment, each inner container may include a different volume, shape, or dimensions from another inner container. In some embodiments that include one product, the product may be contained in multiple inner containers.

Composite Container

[116] A method of using a packaged product is disclosed herein. The method forms a composite container. The composite container facilitates simplified recycling for the consumer by minimizing confusion on how to separate the packaging materials and the number of steps involved. The composite container includes an outer container that includes a first polymer. The outer container is capable of being reclosed, that is, being in a second closed position with respect to the first closed position of the packaged product. The outer container of the composite container includes the first polymer previously described for the outer container of the packaged product. The composite container includes an inner container that includes the second polymer previously described for the inner container of the packaged product. The second polymer is compatible with the first polymer in a recycling stream, and in some embodiments, a single polymer recycling stream.

[117] With reference to Figure 10, a method 200 of using a packaged product is shown. At operation 202 of method 200, an outer container of a packaged product is opened from a first closed position to a first opened position, forming an opened outer container.

[118] At operation 204 of method 200, an inner container that contains a product is removed from the opened outer container. In embodiments that include more than one inner container, each inner container may be removed from the opened outer container.

[119] At operation 206 of method 200, the inner container or inner containers are opened forming an opened inner container.

[120] At operation 208 of method 200, product is removed or emptied from the opened inner container, forming an unfilled inner container. In other words, the product is consumed or used by an end user. Depending on the number of products in an embodiment, one or more products may be removed from one or multiple inner containers. Each inner container may be free or substantially free of product. “Free of product” or “substantially free of product”, as used in this application, refers to an inner container that is devoid of product or almost devoid of product. For example, an inner container may include a food product. The food products may be removed from the inner container without food product remaining in the inner container. In other instances, there may be residual food product remaining in the inner container after use, such that the inner container is substantially free of product. With respect to many recycling process streams, items to be recycled should be free or substantially free of product. Some recycling streams require items to be clean and dry to prevent contamination in the recycling stream. That is, the inner container may be rinsed with water or washed and dried before it would be exposed to a recycling steam.

[121] At operation 210 of method 200, the unfilled inner container is placed into the opened outer container.

[122] At operation 212 of method 200, the opened outer container is closed at least to some degree to a second closed position forming a composite container.

[123] At operation 214 of method 200, the composite container may be placed into a recycling stream that is compatible with the first polymer of the outer container and the second polymer of the inner container. Recyclable Packaged Product and Composite Container

[124] The packaged product and associated composite container provide recycling convenience to an end user. The packaged product is purchased at the point of sale, an outer container is opened to access an inner container(s), and product(s) is used accordingly. After the product has been consumed, the inner container(s) may simply be placed into the outer container, the outer container is reclosed, and the resulting composite container may be placed into curbside recycling programs. End users are not required to sort inner containers and outer containers into appropriate waste or recycling streams because the packaged product is configured such that the associated composite container is recyclable.

[125] In some recycling processes, inner containers may need to be clean and dry if the inner container were being recycled individually (i.e., not contained within an outer container having a compatible first polymer). For example, flexible pouches may not be able to be recycled unless they are clean and dry before being placed into a recycling stream that reprocesses pouches. However, the composite containers of the present disclosure possibly remedy this problem. Many recycling processes do not require rigid (e.g., molded, formed, or otherwise three- dimensional shape-retaining) containers to be clean and dry. Accordingly, a flexible inner container having a second polymer, regardless of the inner container being clean and dry, may be contained in a closed, rigid, outer container having a first polymer that allows for the compatible recycling of the flexible inner container held within the outer container. The composite container remains closed to some degree such that the inner container is contained in the outer container during the recycling process such that the outer container and the inner container are processed simultaneously.

[126] The composite container of the present disclosure is recyclable when the first polymer and the second polymer are compatible in a recycling stream. With reference to Figures 11-12, non-limiting composite containers are shown. [127] A composite container 98 is shown in Figure 11. Figure 11 includes the outer container 91 of the packaged product 90 shown in Figure 8. The outer container 91 is in a second closed position. The first inner container 93 and the second inner container 95 are shown to be in an opened position and free of product. The first inner container 93 includes a second polymer and the second inner container 95 includes a third polymer. The first polymer of the outer container 91 is compatible with the second polymer and the third polymer of the first and the second inner containers 93, 95 such that the composite container 98 may be recycled in a recycling stream that may be a single polymer recycling stream. That is, the first and second inner containers 93, 95 may be recycled simultaneously with the outer container 91 when in the configuration of the composite container 98. In some embodiments, the inner container may be reclosed when contained in the composite container.

[128] A composite container 108 is shown in Figure 12. Figure 12 includes the outer container 102 of the packaged product 100 shown in Figure 9. The outer container 102 is in a second closed position. The first inner container 120 includes a second polymer, the second inner container 130 includes a third polymer, and the third inner container 140 includes a fourth polymer. The inner containers 120, 130, 140 are shown to be in an opened position and free of product.

[129] The first polymer of the outer container 102 is compatible with the second, third, and fourth polymers of the first, second, and third inner containers 120, 130, 140 such that the composite container 108 may be recycled in a recycling stream that may be a single polymer recycling stream. That is, the first, second, and third inner containers 120, 130, 140 may be recycled simultaneously with the outer container 102 when in the configuration of the composite container 108.

[130] The combination of an outer container with an inner container is limited only by the first polymer being compatible with the second polymer in a given recycling stream. In embodiments that include multiple inner containers, the combination of an outer container with one or more inner containers is limited only by the first polymer being compatible with the second, third, fourth, or subsequently numbered polymer in a given recycling stream. [131] In an embodiment, a packaged product may include an outer container having a first polymer that includes polypropylene. The outer container is reclosable, may be formed, and may include rigidity or rigid portions. An inner container may have a second polymer that includes polyethylene. The inner container is contained within the outer container. A product is contained in the inner container. The associated composite container includes the outer container having polypropylene as the first polymer. The inner container includes polyethylene as the second polymer. The inner container may not be clean and dry and may have dimensions less than 5 cm in each of two directions. The composite container may be recyclable in a recycling stream.

[132] In another embodiment, a packaged product may include an outer container having a first polymer that includes polyethylene. The outer container is reclosable, may be formed, and may include rigidity or rigid portions. An inner container may have a second polymer that includes polyethylene. The inner container is contained within the outer container. A product is contained in the inner container. The associated composite container includes the outer container having polyethylene as the first polymer. The inner container includes polyethylene as the second polymer. The inner container may not be clean and dry and may have dimensions less than 5 cm in each of two directions. The composite container may be recyclable in a recycling stream, which may be a single polymer recycling stream. In some embodiments, the first polymer may include high density polyethylene.

[133] In an embodiment, a packaged product includes an outer container that includes a first polymer in a range of from 90% to 100% by weight of the outer container. The packaged product includes a second polymer in a range of from 90% to 100% by weight of the inner container. In other embodiments, the packaged product may include additional inner containers (i.e., second inner container, third inner container, etc.) in addition to the inner container, with each inner container having a polymer associated with it in succession (i.e., third polymer, fourth polymer, etc.). The packaged product may include the polymer associated with each additional inner container in a range of from 90% to 100% by weight of each inner container.

[134] In an embodiment, a composite container includes an outer container that includes a first polymer in a range of from 90% to 100% by weight of the outer container. The composite container includes a second polymer in a range of from 90% to 100% by weight of the inner container. In other embodiments, the composite container may include additional inner containers (i.e., second inner container, third inner container, etc.) in addition to the inner container having a polymer associated with each additional inner container in succession (i.e., third polymer, fourth polymer, etc.). The composite container may include the polymer associated with each additional inner container in a range of from 90% to 100% by weight of each inner container.

[135] Table 1 includes non-limiting examples of first polymer and second polymer combinations that may be compatible in a recycling stream or process.

TABLE 1

[136] The above description and examples illustrate certain embodiments of the present disclosure and are not to be interpreted as limiting. Selection of particular embodiments, combinations thereof, modifications, and adaptations of the various embodiments, conditions and parameters normally encountered in the art will be apparent to those skilled in the art and are deemed to be within the spirit and scope of the present invention.

Claims

What is claimed is:

1 . A packaged product comprising: an outer container comprising a first polymer, the outer container having a reclosable feature; an inner container comprising a second polymer, the inner container being located within the outer container, and a product contained in the inner container; wherein the second polymer is compatible with the first polymer in a recycling stream.

2. The packaged product of claim 1 , wherein the outer container comprises a base portion and a lid portion.

3. The packaged product of claim 1 , wherein the outer container comprises a pouch.

4. The packaged product of claim 1 , wherein the inner container comprises dimensions of less than 5 centimeters (two inches) in each of two dimensions.

5. The packaged product of claim 1 , further comprising a second inner container comprising a third polymer, wherein the third polymer is compatible with the first polymer and the second polymer in a recycling stream.

6. The packaged product of claim 1 , wherein the first polymer comprises polyester, polystyrene, polypropylene, polyethylene, polyamide, polycarbonate, or combinations thereof.

7. The packaged product claim 1 , wherein the outer container comprises 95% to 100% of the first polymer, by weight. The packaged product of claim 1 , wherein the second polymer comprises polyester, polystyrene, polypropylene, polyethylene, polyamide, polycarbonate, or combinations thereof. The packaged product claim 1 , wherein the second polymer is the same as the first polymer. The packaged product claim 1 , wherein the inner container comprises 95% to 100% of the second polymer, by weight. The packaged product of claim 1 , wherein the product comprises food. The packaged product of claim 1 , wherein the product comprises pharmaceuticals. The packaged product of claim 1 , wherein the inner container comprises a single serving of food. The packaged product of claim 1 , wherein the first polymer comprises polypropylene and the second polymer comprises polyethylene. The packaged product of claim 1 , wherein the outer container comprises from 90% to 100% of the first polymer, by weight, and wherein the inner container comprises from 90% to 100% of the second polymer, by weight. A method of using a packaged product comprising an outer container comprising a first polymer, the outer container having a reclosable feature, an inner container comprising a second polymer, the inner container being located within the outer container, and a product contained in the inner container, the method comprising the steps of: opening the outer container forming an opened outer container; removing the inner container from the opened outer container; opening the inner container forming an opened inner container; removing the product from the opened inner container forming an unfilled inner container; placing the unfilled inner container into the opened outer container; closing the opened outer container forming a composite container; and placing the composite container into a recycling stream that is compatible with the first polymer and the second polymer. A composite container comprising: an outer container comprising a first polymer, the outer container having and a reclosable feature; and an inner container comprising a second polymer, the inner container being located within the outer container; wherein the second polymer is compatible with the first polymer in a recycling stream. The composite container of claim 17, wherein the first polymer comprises polyethylene and the second polymer comprises polyethylene. The composite container of claim 17, wherein the first polymer comprises polypropylene and the second polymer comprises polyethylene. The composite container of claim 17, wherein the outer container comprises from 90% to 100% of the first polymer, by weight, and wherein the inner container comprises from 90% to 100% of the second polymer, by weight.