Abstract:
The invention teaches a container formed from a synthetic substrate. The synthetic substrate is substantially tear resistant and includes polyethylene and inorganic minerals. The synthetic substrate is cut and scored to form a container blank of desired shapes and sizes. At least some portion of the container blank is coated with an adhesive. The container blank is folded and or otherwise manipulated so that at least some portion of the container blank is secured to another surface of the container blank to form a partially closed container with at least one opening.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of U.S. patent application Ser. No. 10/409,540 filed on Apr. 8, 2003, now abandoned, which claims the benefit of U.S. provisional application No. 60/370,357 filed on Apr. 8, 2002. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     This invention relates to a container and method of forming a container from a synthetic substrate. 
     DESCRIPTION OF RELATED ART 
     Conventional containers, such as retail containers for cosmetics, pharmaceutical, and computer related items are typically made from conventional substrates, such as paperboard and the like, that are easily torn. Typically, at least one side of the conventional substrate is printed with information, such as product description, graphic, and advertising information. The conventional substrate is then formed into individual container blanks, typically by cutting the substrate using well-known techniques. An exemplary technique is to feed a continuous web substrate into a die cutting assembly. Individual container blanks are cut from the web by a die cutter. An exemplary cutting technique involves the use of a platten die cutter assembly. After the individual container blank is cut from the web, fold lines and the like can be formed on the container blank typically after exiting the die cutting apparatus. Conventional containers are formed by securing parts of the container blank to each other with adhesives. One end is left open so that a product can be placed in the container. The container is closed by securing a flap over the opening. 
     A major drawback of containers made from conventional substrates is the relative ease with which the container can be opened after it is closed. The adhesive bonds of conventional containers are generally weak. In general, the adhesive bonds are designed to quickly close the container during a fast moving container fill operation. The bond must only be sufficient to keep the container closed until it is opened by the end user. In fact conventional containers typically can be opened without any mechanical assistance, such as knives or scissors. High value items, such as cosmetics, pharmaceuticals, and computer items are often placed in conventional containers. In a retail setting, these conventional containers are easily opened by shoplifters with minimal effort. After removing the item from the conventional container, the shoplifter can simply place the empty conventional container back on the shelf or display leaving little notice that the container is empty. 
     One option to replace conventional containers is the use of expensive plastic “clam shell” containers or packages. “Clam shell” containers typically require the use of mechanical assistance, such as scissors, to open them. However, a major drawback of “clam shell” containers is the requirement for expensive container and product fill line equipment. Another drawback is that “clam shell” containers often limit the amount of printable surfaces on the container. Thus “clam shell” containers often require a separate means for placing printed information inside or external to the container. Other alternative containers have used substrates such as TYVEK® by Dupont, composite substrates, such as plastic and metallized films laminated to paperboard substrates, and polymeric materials substrates to increase the difficulty in opening the container. However these alternative containers have numerous limitations such as poor printing surfaces, high cost of material, and often require new expensive equipment to work on existing product fill operations, etc. 
     What is needed is a container formed from a substantially tear resistant substrate that offers the printing quality of a conventional paperboard container, can operate with existing conventional paperboard container product fill lines, and after closure is difficult to open without mechanical assistance. 
     SUMMARY OF THE INVENTION 
     The invention teaches a container formed from a synthetic substrate. The synthetic substrate is substantially tear resistant and comprises polyethylene and inorganic minerals. The synthetic substrate is cut and scored to form a container blank of desired shapes and sizes. At least some portion of the container blank is coated with an adhesive. The container blank is folded and or otherwise manipulated so that at least some portion of the container blank is secured to another surface of the container blank to form a partially closed container with at least one opening. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  shows a plan view of an exemplary container blank according to the invention. 
         FIG. 2  is a top view of a partially formed container from the blank of  FIG. 1 . 
         FIG. 3  is a front elevation view of an exemplary container formed from the partial container of  FIG. 2 . 
         FIG. 4  is a top view of  FIG. 3 . 
     
    
    
     The features of the invention are best understood by considering the following detailed description in conjunction with the accompanying figures. 
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  illustrates an exemplary container blank  100  according to the invention. The blank  100  has four main panels  10 ,  12 ,  14 ,  16 . A glue flap  18  is shown secured to a first panel  10 . Also illustrated are fold lines  40  that separate the main panels  10 ,  12 ,  14 ,  16  from the remainder of the blank  100 . Flaps  20 ,  22 ,  24 ,  26  are shown secured to one end of the main panels  10 ,  12 ,  14 ,  16  and flaps  30 ,  32 ,  34 ,  36  are shown secured to an opposite end of the main panels. It is to be understood that many other shapes and configurations for a container blank are possible. For example, a container could have more of less main panels as well as more or less flaps than illustrated. The container blank  100  of  FIG. 1  is provided as a general illustration of a container blank. It is to further be understood that a container blank could also be designed to mate with a blister container or a packaging shell. A container blank could also be designed to wrap around another box, container, package, or product. In addition, the container blank could have one of more apertures. For example, the container could also have a folding flap to secure a blister package containing disposable razors or pills. Furthermore, any apertures could be covered with transparent materials. 
     An exemplary container or package according to the invention is formed from a tear resistant synthetic substrate. In an exemplary embodiment, the substrate is a synthetic substrate, such as POLYLITH® GC-3 manufactured by Nanya Plastics of Taiwan and distributed in the United States by Granwell Products, Inc. of West Caldwell, N.J. The referenced POLYLITH® substrate referred to as synthetic paper and is manufactured under a proprietary manufacturing process and an exact chemical composition is not known. However the two main components of the synthetic substrate are polypropylene resin and minerals comprising inert calcium carbonate and titanium dioxide. The synthetic substrate is strengthened by calendering the synthetic substrate. The minerals form a smooth surface that improves printing on the synthetic substrate. In addition, they provide a surface appearance and texture similar to coated paperboard. The synthetic substrate is further believed to contain a high density polyethylene (HDPE). The synthetic substrate exhibits some orientation in the machine direction and cross direction. The synthetic substrate is optionally corona treated on both sides and optionally at least one side is gloss finished. 
     An exemplary synthetic substrate also has an opacity in excess of about 85, whiteness in excess of about 86, tensile strength in the machine direction in excess of about 3,000 pounds per square inch (ASTM D-638), and tear strength in the machine direction in excess of about 2,100 grams per millimeter (ASTM D-1922). In addition the exemplary synthetic substrate has a thickness range of about 4.0 to about 20 mil, with an exemplary range of about 10 mil or greater. 
     It is well known to use POLYLITH® synthetic substrates of various grades and the like in a wide range of products such as posters, labels, maps, menus, cards, tags, charts, placemats, and banners. However, POLYLITH® synthetic substrates and the like have not been used for containers prior to this invention due to the previously unsolved problem of securing the surfaces of the synthetic substrate to each other using adhesives and the lack of operational knowledge to use them with conventional carton forming equipment. 
     It is to be understood that the above description is not intended to limit the scope of the claimed invention to containers formed from the exemplary POLYLITH® GC-3 synthetic substrate. Other suitable synthetic substrates include products manufactured by USI Plastics of France and Kimberly Clark Corporation of the United States. In general, synthetic substrates made from polyolefin, polypropylene or other suitable compounds that are tear resistant at desirable container thickness ranges are within the scope of the invention. In addition the synthetic substrates can be formed with many variation or combination of orientations that improve their tear resistance. 
     In general, suitable synthetic substrates should work with conventional packaging equipment as a substitute for conventional paperboard substrates. Suitable synthetic substrates should also be dimensionally stable when exposed to moisture and humidity. In addition they should resist cracking, shrinking or distortion in both size and color. Suitable synthetic substrates should generally work well with the following printing techniques: flexographic, lithographic, gravure, letterpress, screen-printing, and thermal transfer. Suitable synthetic substrates should have good ink coverage and superior print fidelity qualities. Suitable inks include ultra violet lithography or electron beam curable inks as well as solvent and water-based inks. It is to be understood that the printed layer may also be coated with varnish such as ultraviolet curable acrylate. Moreover suitable synthetic substrates should be capable of being embossed, foil stamped, scored, perforated, die cut, or thermal formed using conventional techniques and equipment. 
     In accordance with the invention, substantially tear resistant containers can be made using suitable synthetic substrates. First, the appropriate shape and size of the container&#39;s main panels and flaps must be properly dimensioned to provide an adequate surface contact and overlap area for the various flaps and panels after folding. Second, the adhesive to secure the flaps and panels must be properly selected so that conventional container manufacturing and conventional product fill line techniques can be used. Third, the container blank should be laid out to maximize the tear resistant properties of the synthetic substrate. For example, if the synthetic substrate has a stronger tear strength in one direction, than the panels and flaps can be laid out and the adhesive applied in an optimal location so that any exposed tearing surface would be along the strongest orientation. In addition, the container blanks could be also printed and cut along a 45-degree alignment or any other optimal alignment to maximize the tear strength orientations of the synthetic substrate. 
     As illustrated in  FIG. 2  a partial container  200  is formed from the blank of  FIG. 1 . The container  200  is formed by securing two regions of the blank to each other. An exemplary technique is illustrated by securing glue flap  18  to main panel  16 . Typically this is done on a high-speed container forming machine (not shown). The flap  18  and panel  16  surfaces are secured to each other using adhesives. It is to be understood that after the adhesive is applied to either flap  18  or panel  16  they may also be mechanically pressed or squeezed together for at least some period of time to facilitate adhesion of the two surfaces  16 ,  18 . The partially formed container  200  is illustrated with two open ends  210 ,  220 . 
     It has been discovered that certain adhesives allow the exemplary synthetic substrates to be formed into a suitable container using conventional container forming equipment. Exemplary commercial adhesives include moisture cured reactive polyurethane adhesives, such as PUR-FECT LOK® 34-9000 urethane adhesive manufactured by National Starch &amp; Chemical, a member of the ICI Group, of Bridgewater, N.J. Additional exemplary adhesives include: non-reactive polyurethane, cyanoacrylate, modified polyester resins, acrylic hot melts, and ultra-violet cured acrylic. The exemplary adhesives bond or fuse the panels or flaps together and create a bond between the two surfaces with a tear strength approximately equal to or greater than that of the synthetic substrate. 
     For securing the open ends  210 ,  220 , a fast curing adhesive is desirable. A suitable adhesive must develop a bond in sufficient time to maintain the container&#39;s shape during the fill operation. An exemplary adhesive will develop additional bond strength during “cure time” (prior to the container reaching the end user). 
     A first exemplary adhesive for open ends  210 ,  220  includes a blend of ethylene vinyl acetate (EVA) co-polymer and styrene-butadiene-styrene (SBS) or styrene-ethylene-butadiene-styrene (SEBS) resins with exemplary additives such at antioxidants, tackifiers and plasticizers. Commercial brands of EVA, SBS or SEBS, antioxidants, and plasticizers are acceptable such as Dupont&#39;s ELVAX 150W®, Shell&#39;s KRATON G or D®, antioxidants, and plasticizers, such as, SHEREX 770® or PARAPLEX G90®, respectively. An exemplary adhesive mixture includes by weight approximately 48.5% EVA, 48.5% SBS, 1% antioxidants, and 2% polymeric plasticizers. Another exemplary adhesive mixture includes by weight approximately 68.5% EVA, 28.5% SBS, 1% antioxidants, and 2% polymeric plasticizers. 
     A second exemplary adhesive includes a blend of ethylene vinyl acetate (EVA) co-polymer, styrene-butadiene-styrene (SBS) or styrene-ethylene-butadiene-styrene (SEBS) resins, and hydrocarbon, with exemplary additives such at antioxidants, tackifiers and plasticizers. An exemplary adhesive mixture includes by weight approximately 66.5% EVA, 26.5% SBS, 4.0% hydrocarbon, 1% antioxidants, and 2% polymeric plasticizers. 
     A third exemplary adhesive includes a blend of ethylene vinyl acetate (EVA) co-polymer, styrene-butadiene-styrene (SBS) or styrene-ethylene-butadiene-styrene (SEBS) resins, and isoprene, with exemplary additives such at antioxidants, tackifiers and plasticizers. An exemplary adhesive mixture includes by weight approximately 46.5% EVA, 46.5% SEBS, 4.0% isoprene, 1% antioxidants, and 2% polymeric plasticizers. Another exemplary adhesive mixture includes by weight approximately 66.5% EVA, 26.5% SBS, 4.0% isoprene, 1% antioxidants, and 2% polymeric plasticizers. 
     As illustrated in  FIGS. 3 and 4 , the partially formed container  200  ( FIG. 2 ) is expanded into its final shape using conventional techniques (not shown). A first open end  210  of the partial container  200  is closed using the adhesives described above. Container  300  is illustrated with a closed end  52  and an open end  56 . Closed end  52  is exemplary formed by folding flaps  20 ,  22 ,  24 ,  26  and securing at least two opposing flaps  20 ,  24  to each other. An exemplary method is to secure the opposing flaps using the exemplary adhesives described above. It is also possible that flaps  20 ,  22 ,  24 ,  26  could be secured to each other in numerous combinations. Container  300  is now ready to be filled with a product (not shown). 
     A product can be placed into container  300 , via the container&#39;s open end  56 . The product is exemplary supported by the closed end  52 . The filled container (not shown) is then typically advanced on a product fill line and the second open end  56  is closed in a conventional manner using adhesives as described above. 
     Once given the above detailed description, many other features, modifications or improvements will become apparent to the skilled artisan. Such features, modifications or improvements are, therefore, considered to be a part of this invention, the scope of which is to be determined by the following claims.