Patent Publication Number: US-2022212830-A1

Title: Multiple-Skived Paper-Based Container

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation in part application that claims priority to, and the benefit of, U.S. Non-provisional application Ser. No. 17/315,775, which was filed on May 10, 2021, which claims priority to, and the benefit of, each of U.S. Provisional Application No. 63/088,495 which was filed on Oct. 7, 2020, and U.S. Provisional Application No. 63/147,305 which was filed on Feb. 9, 2021, all of which are incorporated herein by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a new and improved paper-based container. More specifically, the invention relates to a gable-topped paper-based container that is comprised of a low-density polyethylene coating on one or both surfaces of the container, and multiple skived flaps, wherein each of said skived flaps are created during the manufacturing process. Each skive flap comprises at least one leading edge of the container body, and prevents both moisture from entering the container along the flap and the contents of the container from saturating the paper of the material, thereby weakening the material and potentially leading to odor/product leakage. Each skive flap is preferably folded and constructed in such a manner that a portion of the outside surface of the container is adhered to the inside surface. One of the skive flaps is located on an inside portion of the container, one is located on an exterior portion of the container and one is located near the bottom of the container, thereby offering redundant protection against leakage. Additionally, the container may also comprise a plurality of additional body flaps and an extra-long neck portion to account for the extra board area created by the flap(s). Accordingly, specific reference is made thereto in the present disclosure. However, it is to be appreciated that aspects of the present invention are also equally amenable to other like applications, devices and methods of manufacture. 
     BACKGROUND OF THE INVENTION 
     Single-use plastic containers are commonly used to store and hold liquid items including juices, milks, drinks, beverages, sauces, etc., dry items including powders, mixes, etc., and semi-solid items including potato salad, coleslaw, etc. Said plastic containers also exist in the form of shampoo bottles, soap bottles, cleaning agent bottles, etc. and any other product of the like. Such plastic containers are typically disposed of after use, and unfortunately find their way into oceans, rivers, and other areas as environmental pollutants. As such, materials and practices have been developed regarding the use of bio-degradable materials in place of plastics that have been typically used in single-use solid, semi-solid and liquid food/product containers. 
     Existing bio-degradable materials are often paper-based, and because of the manufacturing process contain a paperboard section that exists in between the outside surface of the material and the inside surface of the material. Unfortunately, this type of construction has a number of inherent limitations including, for example, the possibility of moisture entering the container or the contents leaking from the container. As with paper-based containers/packaging, the probability of leakage is greater than that of a single-use plastic container due to the manufacturing process which normally involves the folding and adhesion of the paper-based body via a plurality of seams. As a result, improper adhesion or assembly near the seams may result in leakage of the contents of the container by virtue of the folding assembly that must take place with a paper-based material. However, this is not the case with a single-use plastic container, which is typically one integral body without the presence of seams (or at least having fewer seams). Seams are where improper adhesion and/or gaps and openings can occur. If leakage does occur in a paper-based container, the product contained within the container may spill to surrounding surfaces, which is undesirable and potentially damaging. 
     Further, paper-based products are normally comprised of an outer surface on the exterior of the container, an inner surface on the inside of the container and another paper layer in between said layers as noted supra. When storing liquids/foods/products, this paper layer provides a means for unwanted moisture to enter the container and/or for the contents of the container to leach into the paper-based material, therefore essentially saturating the material with the contents, and weakening the integrity of the material and subsequently the entire container. As a result, physical and/or odor leakage of the contents of the container can occur due to the structural weakening of the material. Additionally, the problem may be further exacerbated if such paper-based containers are required to sit dormant (e.g. on a supermarket shelf) for prolonged periods of time, wherein the container contents and their compounds have ample time to saturate and weaken the paper-based material. 
     Therefore, there exists a long felt need in the art for an improved paper-based container that provides greater protection against unwanted moisture entering the container and/or physical leakage/saturation of the contents of the container than existing paper-based containers. There is also a long felt need in the art for an improved paper-based container that provides greater protection against odor leakage than existing paper-based containers. Finally, there is a long felt need in the art for an improved paper-based container that is relatively inexpensive to manufacture and that is resistant to the breakdown caused by storing contents for a prolonged period of time. 
     The present invention, in one exemplary embodiment, discloses an improved container, such as a gable-top container or carton, that is comprised of a bio-degradable paper-based material having a relatively low-density polyethylene coating on one or both surfaces/sides of the material, and a related method of manufacture. The container is further comprised of a plurality of extra carton flaps, a relatively long carton neck area, and multiple skiving flaps that engage the inside/outside surfaces of the container to ensure that, when completed, there are no exposed board fibers on the bottom or sides of the formed carton. 
     In this manner, the improved paper-based container device of the present invention accomplishes all of the forgoing objectives, thereby providing a paper-based container that is more resistant to unwanted moisture entering the container, saturation of the paperboard, and physical and odor leakage of the contents of the container than existing paper-based containers. 
     SUMMARY 
     The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later. 
     The subject matter disclosed and claimed herein, in one embodiment thereof, comprises an improved paper-based container and a method of manufacturing the same. The container is preferably comprised of a bio-degradable and paper-based material that is coated on one or both sides with a relatively low-density polyethylene coating. The container is also comprised of a plurality of flaps that fold in the assembly process to allow the container to form a retained shape. In addition, the container is comprised of a plurality of additional flaps (e.g. flaps that would not typically be found on containers of similar construction) that allow for extra board coverage that is needed by virtue of the assorted or multiple skiving processes. Covering the raw or otherwise exposed edges of the container results in a multi-skived hemmed carton that prevents wicking, odor or moisture absorption. 
     More specifically, the skiving process occurs during the manufacturing/assembly of the container, and involves shaving-off the thickness of a paper-based material such as, but not limited to, paper-based and low-density polyethylene coated “milk stock”, wherein the material is planed down, folded from the outside surface onto the inside surface, and adhered thereto with heat from a flame. The manner in which the container is planed, folded and heated produces multiple skived flaps that are adhered to both the inside and outside surfaces of the container. Said multiple skived flaps then prevent unwanted moisture from entering the container and/or the saturation of the material by the contents of the container permeating the paperboard material. This multiple skived process in turn creates a container that is in essence “seamless”, wherein the multiple skived container also becomes incredibly resistant to unwanted moisture entering the container and/or container breakdown as a result of the solid, semi-solid or liquid contents of the container permeating the paperboard material, and any subsequent content/odor leakage that could occur as a result of said permeation. 
     To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed and is intended to include all such aspects and their equivalents. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  illustrates a perspective view of an improved paper-based container device of the present invention in an unassembled/unfolded state with the inside surface facing upward in accordance with the disclosed architecture; 
         FIG. 1B  illustrates an enlarged detailed view of a first skived edge of the improved paper-based container device of the present invention of  FIG. 1A  in accordance with the disclosed architecture; 
         FIG. 1C  illustrates an enlarged detailed view of a second skived edge of the improved paper-based container device of the present invention of  FIG. 1A  in accordance with the disclosed architecture; 
         FIG. 1D  illustrates an enlarged detailed view of a third skived edge of the improved paper-based container device of the present invention of  FIG. 1A  in accordance with the disclosed architecture; 
         FIG. 2A  illustrates a top view of an improved paper-based container device of the present invention of in an unassembled/unfolded state with the printed outside surface facing upward in accordance with the disclosed architecture; 
         FIG. 2B  illustrates an enlarged detailed view of the second skived edge of the improved paper-based container device of the present invention of  FIG. 2A  showing the skived flap in both a skived condition and a folded condition in accordance with the disclosed architecture; 
         FIG. 2C  illustrates an enlarged detailed view of the first skived edge of the improved paper-based container device of the present invention of  FIG. 2A  showing the skived flap in both a skived condition and a folded condition in accordance with the disclosed architecture; 
         FIG. 2D  illustrates an enlarged detailed view of a third skived edge of the improved paper-based container device of the present invention of  FIG. 2A  showing the skived flap in both a skived condition and a folded condition in accordance with the disclosed architecture; 
         FIG. 3  illustrates an end view of how the two corner folds are formed to facilitate the joining of the two skived flaps of an improved paper-based container device of the present invention in accordance with the disclosed architecture; 
         FIG. 4  illustrates an end view of how the two skived flaps of an improved paper-based container device of the present invention are joined together in accordance with the disclosed architecture; 
         FIG. 5  illustrates a perspective view of an improved paper-based container device of the present invention in a partially assembled/folded state resembling an open-ended box-like structure in accordance with the disclosed architecture; 
         FIG. 6A  illustrates a diagrammatic view of a generalized skiving process that is used on a container template body of the present invention in accordance with the disclosed architecture; 
         FIG. 6B  illustrates a top perspective view of the first pass skiving process that is used on a container template body of the present invention in accordance with the disclosed architecture; 
         FIG. 6C  illustrates a top perspective view of the second pass skiving process that is used on a container template body of the present invention in accordance with the disclosed architecture; 
         FIG. 7  illustrates a diagrammatic view of a generalized creasing process that is used on a container template body of the present invention in accordance with the disclosed architecture; 
         FIG. 8  illustrates a diagrammatic view of a generalized heating process that is used on a container template body of the present invention in accordance with the disclosed architecture; 
         FIG. 9  illustrates a diagrammatic view of a generalized folding process that is used on a container template body of the present invention in accordance with the disclosed architecture; 
         FIG. 10  illustrates a diagrammatic view of a generalized compressing process that is used on a container template body of the present invention in accordance with the disclosed architecture. 
     
    
    
     DETAILED DESCRIPTION 
     The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate a description thereof. 
     As noted above, there is a long felt need in the art for an improved paper-based container that provides greater protection that existing paper-based containers against unwanted moisture entering the container and/or physical leakage/saturation of the contents of the container. Moreover, there is a long felt need in the art for an improved paper-based container that provides greater protection against odor leakage than existing paper-based containers. Finally, there is a long felt need in the art for an improved paper-based container that is relatively inexpensive to manufacture, and that is resistant to the breakdown caused by storing contents for a prolonged period of time. 
     The device of the present invention is designed to provide a user with a bio-degradable and environmentally-friendly paper-based alternative to single-use plastic containers for storing goods such as, but not limited to, dry ingredients, liquids, solids, semi-solids, liquid soap, shampoo, body wash, cleaning agents, detergents, etc. The additional viscosity of these types of pressurized or non-pressurized contents while in a temperature-controlled environment make them particularly prone to leakage. The container is preferably comprised of a bio-degradable paper-based material that is further comprised of an outside surface, a paperboard material (e.g., an SBS paperboard) and an inside surface, wherein the inside surface is in direct contact with the contents of the container (e.g., a juice) and the outside surface is in contact with the external environment. As used herein, “milk stock” or “paperboard material” is preferably comprised of a paperboard constructed with a polyethylene liner on the inside and on the outside, though other embodiments are also contemplated. 
     Referring initially to the drawings,  FIG. 1A  illustrates a perspective view of an improved paper-based container device  100  of the present invention in an unassembled/unfolded state with the inside surface  112  facing upward in accordance with the disclosed architecture. More specifically, the device  100  is comprised of a container template body  110  that is folded to assemble the device  100  into, for example, a gable-topped container. However, differing embodiments of the device  100  may comprise a plurality of differing container shapes, types, sizes, etc., and the present invention is not necessarily limited to gable top containers. 
     The template body  110  is comprised of a plurality of panels that correspond and create the various surfaces/sides of the container device  100  when folded along the various scores  1100  formed within the surface of the container template body  110 . In the shown embodiment of the device  100 , the body  110  is comprised of a first panel  113 , a second panel  114 , a third panel  115 , a fourth panel  116  and a fifth panel  117 . Specifically, panels  113 ,  114 ,  115 , and  116  will form the sides of an open-ended box-like structure after the scores  1110 ,  1120 ,  1130 ,  1140  are folded. It is contemplated that the printed outside surface  111  and inside surface  112  of the body  110  are comprised of a paper-based or paperboard material that is further coated in a film/coating of relatively low-density polyethylene (LDPE) on one or both of the inside  112  and outside  111  surfaces. Said material may hereinafter be referred to as “milk stock”. However, in differing embodiments the body  110  may be additionally or alternatively comprised of LDPE-coated paperboard, SBS paperboard, or other suitable materials. 
     The body  110  is further comprised of multiple skived flaps  120 . Each of the skived flaps  120  is created during a manufacturing method (that will be explained more fully below) from the milk stock material using a cutting die to initially plane the material down. The planed material is then folded onto itself such that a portion of the outside surface  111  becomes relatively flush with and is “folded over” and adhered to the inside surface  112  with heat from a flame to form the skived flap  120 , which is shown in  FIGS. 2B, 2C and 2D . Each skived flap  120  then forms the first skived edge  122  and the second skived edge  123  of the container  100 , as shown in  FIGS. 1B and 1C , respectively. It is contemplated that in differing embodiments of the device  100 , the skived flap  120  may comprise any skived edge, like  122  or  123 , of any side (including the top or the bottom, as shown in  FIGS. 1A and 2A ), and the device  100  may be comprised of any number of skived flaps  120 . 
     Each of the skived flaps  120  positioned along the side edges of the device  100  is further comprised of a first end  126  that is preferably located at the top edge  118  and a second end  128  that is preferably located at the bottom edge  119 , wherein said first and second ends  126 ,  128  may be rounded, beveled, chamfered, etc, so as to not interfere with the folding/assembling of the container  100 . The adhesion (via heat from a flame) of the skived flap  120  to the inside surface  112  (as shown in  FIGS. 1C and 2B ) and to the printed outside surface  111  (as shown in  FIGS. 1B and 2C ) ensures that the contents of the container  100  do not come into direct contact with the paperboard material, wherein said contents could saturate the milk stock or paperboard material as described supra. The container  100  may also comprise a plurality of extra flaps (not shown), and a relatively long neck region (not shown) to compensate for the additional coverage required to provide a surface for the adhesion of the skived flap  120 . 
       FIG. 1B  illustrates an enlarged detailed view of the first skived edge  122  of the improved paper-based container device of the present invention of  FIG. 1A  in accordance with the disclosed architecture. The first skived edge  122  is created by forming a skived flap  120  using material from the fifth panel  117 . In doing so, the raw or exposed carton edge  121  will be sealed from any moisture exposure after the novel sealing process is completed, as best shown in  FIG. 4 . 
       FIG. 1C  illustrates an enlarged detailed view of the second skived edge  123  of the improved paper-based container device of the present invention of  FIG. 1A  in accordance with the disclosed architecture. The second skived edge  123  is created by forming a skived flap  120  using material from the first panel  113 . In doing so, the raw or exposed fiber carton edge  121  will be sealed from any moisture exposure after the novel sealing process is completed, as best shown in  FIG. 4 . 
       FIG. 1D  illustrates an enlarged detailed view of a third skived edge  124  of the improved paper-based container device of the present invention of  FIG. 1A  in accordance with the disclosed architecture. The third skived edge  124  is created by forming a skived flap  120  using material from the first panel  113  and also the third panel  115  in the manner described above. 
       FIG. 2A  illustrates a top view of an improved paper-based container device  100  of the present invention in an unassembled/unfolded state with the printed outside surface  111  facing upward in accordance with the disclosed architecture. Referring initially to  FIG. 1A  where the inside surface  112  is shown,  FIG. 2A  will now be similarly described with the printed outside surface  111  of a novel container template body  110  being shown. Any number of printed images  900  can be placed on the printed outside surface  111  of the container template body  110 . 
     It should be noted that since the container template body  110  has now been flipped-over as shown in  FIGS. 2A-2D , panels  113 ,  114 ,  115 ,  116 , and  117  will now be shown in a reversed order from what was shown in  FIGS. 1A-1C . Further, it should be noted that due to the change in orientation of the figures, the first skived edge  122  as shown on the left-hand side of the container template body  110  in  FIG. 1A  will now be shown on the right-hand side of the container template body  110  in  FIG. 2A . Likewise, the second skived edge  123  as shown on the right-hand side of the container template body  110  in  FIG. 1A  will now be shown on the left-hand side of the container template body  110  in  FIG. 2A . The item numbering in both figures remains the same. 
       FIGS. 2A-2D  further include details related to the multi-skiving and folding process of the present invention container device  100 . Skiving flaps  120  created on both the left and right sides as well as the bottom of the container template body  110  serve to protect the raw or exposed carton edges  121 .  FIG. 2B  illustrates an enlarged detailed view of the second skived edge  123  of the improved paper-based container device  100  of the present invention of  FIG. 2A  showing the skived flap  120  in both a skived condition and a folded condition in accordance with the disclosed architecture, which will be more fully described if  FIGS. 6A-6C, and 7-10  herein. Additionally,  FIG. 2C  illustrates an enlarged detailed view of the first skived edge  122  of the improved paper-based container device  100  of the present invention of  FIG. 2A  showing the skived flap  120  in both a skived condition and a folded condition in accordance with the disclosed architecture. Further,  FIG. 2D  illustrates an enlarged detailed view of the bottom skived edge of the improved paper-based container device  100  of the present invention of  FIG. 2A  showing the skived flap  120  in both a skived condition and a folded condition in accordance with the disclosed architecture. 
       FIG. 3  illustrates an end view of how the two corner folds  1210  and  1220  are formed to facilitate the joining of the two skived flaps  120  of an improved paper-based container device  100  of the present invention in accordance with the disclosed architecture. After the completion of the skiving and folding process is completed, the first corner fold  1210  is made along the location of the second score  1120  by folding the portion of the container template body  110  containing the fourth panel  116  and the fifth panel  117  as shown. The second corner fold  1220  is made along the location of the fourth score  1140  by folding the portion of the container template body  110  containing the first panel  113  as shown. Both corner folds are made such that the inside surface  112  of container template body  110  form two acute angles as shown. The remaining two corner folds  1230  and  1240 , made along the first score  1110  and the third score  1130 , will be made in a later operation more fully described in  FIG. 5 . 
       FIG. 4  illustrates an end view of how two of the skived flaps  120  of the improved paper-based container device  100  of the present invention are joined together in accordance with the disclosed architecture. The two corner folds  1210  and  1220  that were described in  FIG. 3  are now completely or sustainably closed, thereby bringing the skived flap  120  of the first panel  113  into direct contact with the printed outside surface  111  of the fifth panel  117 . At the same time, the skived flap  120  of the fifth panel  117  is brought into direct contact with the inside surface  112  of the first panel  113 . The two skived flaps  120  form a leakproof connection, thereby protecting each of the raw or exposed carton edges  121 . The skived flaps  120  are bonded to panels  113  and  117 , either by a melting process or adhesive process. This bonding process will be more fully described in  FIGS. 8 and 10  herein. It should be noted that no bonding between inside surfaces  112  of panels  114 ,  115 ,  116 , or  117  can occur. If this were to happen, inadvertent bonding would prevent the forming of the remaining corner folds, which will be located along the first score  1110  and the third score  1130 . The forming of the remaining corners will be more fully described in  FIG. 5 . 
       FIG. 5  illustrates a perspective view of an improved paper-based container device  100  of the present invention in a partially assembled/folded state resembling an open-ended box-like structure in accordance with the disclosed architecture. The third corner fold  1230  is made along the first score  1110 , forming an approximate perpendicular angle between the fourth panel  116  and the fifth panel  117 . At the same time, the fourth corner fold  1240  is made along the third score  1130 , forming an approximate perpendicular angle between the second panel  114  and the third panel  115 . Finally, both the first corner fold  1210  and the second corner fold  1220  return to a perpendicular angle as well. Thus, the four corner folds now forming the novel open-ended box-like structure have an air-tight “seamless” connection formed by the two skived flaps  120  as shown. The remaining folds of the gable-end box can now be made at the remaining score  1100  locations. It should be noted that the novel air-tight “seamless” connection of the novel container device  100  can be applied to any number of geometric container shapes including cylindrical, which would not require corner folds as shown in the box-like geometry of  FIG. 5 . Importantly, during the manufacturing process, the skived flap  120  positioned along the bottom of the carton is formed first and before the two additional skives are created. 
     This relatively seamless construction gives the container  100  the improved structural properties of one-piece/molded single-use plastic containers. Further, the direct bonding of each skived flap  120  ensures that unwanted moisture will not enter the container  100  and that the contents of the container  100  will not saturate the milk stock material via each flap&#39;s  120  exposed raw edge  121  due to the fact that each edge  121  is now protected and therefore cannot be saturated by any contents of the container  100 . 
       FIG. 6A  illustrates a diagrammatic view of a generalized skiving process  400  that is used on a container template body  110  of the present invention in accordance with the disclosed architecture. In general, the container template body  110  is fed into the feed roll  410  and is held tightly against the feed roll  410  by a presser foot  420 . The feed direction  440  is from left to right as shown, with the feed roll  410  turning in a clockwise rotation direction  450 . A cut-away portion of the bell knife  430  is shown creating the skiver chip  460  on the bottom surface of the container body template  110 , thus forming the skived flap  120  at the appropriate locations. 
     In a preferred embodiment, the container  100  may also be comprised of a three-pass method of creating a multiple-skived paper-based container  100 . The three-pass method of the novel container device  100  includes: (i) forming and sealing a skived flap on the printed outside surface  111  of the fifth panel  117 , (ii) forming and sealing a skived flap on the inside surface  112  of the first panel  113 , and (iii) forming and sealing a joint formed by overlapping both skived flaps  120 . Specifically, each pass will include a heating of a specific location on the container template body  110  for the purpose of softening and/or melting the polyethylene surface layer. Once the polyethylene surface layer has been heated, bonding and sealing of specific locations on container template body  110  can then take place. Compressive pressure is then applied to the top and bottom locations of the newly bonded joint until the polyethylene has had a chance to cool. The preferable bonding and sealing method will be further described in  FIGS. 8 and 10 . Notwithstanding, the present invention is not so limited and other methods involving more or less passes are also contemplated. Further, adhesives may also be used in place of, or in addition to, the heating of the polyethylene surface to create an air-tight joint. Returning now to the three-pass method, the two skiving operations will now be described. 
       FIG. 6B  illustrates a top perspective view of the first pass skiving process  400  that is used on a container template body  110  of the present invention in accordance with the disclosed architecture. The first pass of the method is comprised of placing the container template body  110  of the novel container  100  into a skiving machine  400  with the inside surface  112  facing up and the top edge  118  of the container template body  110  oriented as the leading edge (i.e., the edge that enters the skiving machine first), and wherein the fifth panel  117  is fed into the feed roll  410  from the left side. Then, the container template body  110  is pressed between the presser foot  420  and the feed roll  410 , wherein a bell knife  430  cuts the thickness of the container template body  110  to at least fifty to sixty percent of the container&#39;s  100  original thickness and to create a skived flap  120 . 
       FIG. 6C  illustrates a top perspective view of the second pass skiving process  400  that is used on a container template body  110  of the present invention in accordance with the disclosed architecture. The second pass of the method is comprised of placing the container template body  110  of the novel container  100  into a skiving machine  400  with the printed outside surface  111  facing up and the top edge  118  of the container template body  110  oriented as the leading edge (i.e., the edge that enters the skiving machine first), and wherein the first panel  113  is feed into the feed roll  410  from the left side. Then, the container template body  110  is pressed between the presser foot  420  and the feed roll  410 , wherein a bell knife  430  cuts the thickness of the container template body  110  to at least fifty to sixty percent of the container&#39;s  100  original thickness and creates a second skived flap  120 . 
       FIG. 7  illustrates a diagrammatic view of a generalized creasing process  500  that is used on a container template body  110  of the present invention in accordance with the disclosed architecture. Each skived flap  120 , which was created using a previous skiving process  400 , is then pushed between the upper crease roll  520  and the lower crease roll  530 , thereby creating a crease  510  in skived flap  120 . The creasing rule  540  provides support for the skiving flap  120  during the creasing process  500 . The crease rolls  520  and  530  are spring-loaded with two springs at roughly a total of 400 pounds total pre-loaded compressive pressure, though other pressures are also contemplated (e.g., between 300-500, etc.). 
       FIG. 8  illustrates a diagrammatic view of a generalized heating process  600  that is used on the container template body  110  of the present invention in accordance with the disclosed architecture. The container template body  110  is then heated to create a softened/melted polyethylene zone  620 , which is adjacent to the skived flap  120  for the purpose of adhering the skived flap  120  to the softened/melted polyethylene zone  620  on the surface of container template body  110 . The softened/melted polyethylene zone  620  is heated by the burner unit  610  via an open flame  615 , which activates the polyethylene lining of the container template body  110  material and causes it to become molten. The heating process  600  tends to work best when the burner unit  610  is in the range of 350-400° F. with a residence time over the flame of 0.2-0.35 seconds, though other temperature ranges and residence times are also contemplated and will depend upon the type and thickness of the particular materials being used. The equipment and the surrounding portion of the container template body  110  may then be cooled to approximately room temperature on each side by a plurality of water tubes  630 , but the softened/melted polyethylene zone  620  and the skived flap  120  are not cooled. 
       FIG. 9  illustrates a diagrammatic view of a generalized folding process  700  that is used on a container template body  110  of the present invention in accordance with the disclosed architecture. After the heating process  600  has occurred and while the softened/melted polyethylene zone  620  is still at the proper temperature, the skived flap  120  will now undergo the folding process  700 . With the container template body  110  held in place by a backer support  720 , a vacuum  730 , a vacuum belt  740 , and possibly a vacuum plate  750 ; the hem spiral  710  now rotates in a counter-clockwise rotation, thus folding the skiving flap  120  along the folding path  760  until it comes to rest on the softened/melted polyethylene zone  620 . 
       FIG. 10  illustrates a diagrammatic view of a generalized compressing process  800  that is used on a container template body  110  of the present invention in accordance with the disclosed architecture. Finally, a bond is formed between the skiving flap  120  and the softened/melted polyethylene zone  620  by the compressing process  800 . Immediately following the previous folding process  700 , the skiving flap  120  and the softened/melted polyethylene zone  620  are positioned between the upper pressure roll  810  and the lower pressure roll  820 . Compressive force  830  is applied to rolls  810  and  820 , thereby compressing the skived flap  120  and container template body  110  and held in place until the elevated temperature in the softened/melted polyethylene zone  620  is reduced. The bond at the skived flap  120  is now complete. The compressive force  830  is preferably between 575 and 625 pounds. 
     The third pass of the method ultimately creates the final seal of the container  100 . To begin this step, the printed outside surface  111  of the fifth panel  117  near the first skived edge  122  is heated by a burner unit  610  via an open flame  615 , which causes the polyethylene lining of the container  100  to soften and/or become molten, as described above and best shown in  FIGS. 3 and 8 . To aid in cooling, the container template body  110  may be cooled on each side  111 ,  112  by a plurality of water tubes  630 , as also described above and as best shown in  FIG. 8 . Then, the inside surface  112  of the first panel  113  near the second skived edge  123  is then heated by a burner unit  610  via an open flame  615  which activates the polyethylene lining of the container  100  and causes it to become molten, as best shown in  FIGS. 3 and 8 . To aid in cooling, the container template body  110  may then be cooled on each side  111 ,  112  by a plurality of water tubes  630  as best shown in  FIG. 8 . 
     The container template body  110  is then folded along the second score  1120 , which allows the fourth panel  116  and fifth panel  117  to be folded over inward towards the center of the body  110 , as best shown in  FIG. 3 . Then, the body  110  is folded along the fourth score  1140 , which allows the first panel  113  to be folded over inwards and over top of the fifth panel  117 , as best shown in  FIGS. 3 and 4 . Once in this orientation, the raw carton edge  121  of each skived flap  120  that was created from the first panel  113  and the fifth panel  117  is sealed inside and is not exposed to the inside surface  112  or outside surface  111  of the container  100 , as best shown in  FIG. 4 . Finally, the folded container  100  is pushed through an upper pressure roll or belt  810  and lower pressure roll or belt  820 , which seals the bond between both skived flaps  120  created from the first and fifth panels  113 ,  117  on both surfaces  111 ,  112  of the body  110 , as best shown in  FIGS. 4 and 10 . Once sufficient cooling has taken place, the folded container  100  as shown in  FIG. 4  can be opened into a box-like structure by folding along the first score  1110  and the third score  1130  as shown in  FIG. 5 . 
     Notwithstanding the foregoing, the improved paper-based container device  100  can be of any suitable size, shape, and configuration as is known in the art without affecting the overall concept of the invention, provided that it accomplishes the above-stated objectives. One of ordinary skill in the art will appreciate that the shape and size of the container device  100  and its various components, as show in the FIGS. are for illustrative purposes only, and that many other shapes and sizes of the container device  100  are well within the scope of the present disclosure. Although dimensions of the container device  100  and its components (i.e., length, width, and height) are important design parameters for good performance, the container device  100  and its various components may be any shape or size that ensures optimal performance during use and/or that suits user need and/or preference. As used herein, the term biodegradable means fully or partially biodegradable. Further, the container device  100  may also be renewable, recyclable, and is considered green or eco-friendly. 
     What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the claimed subject matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.