MXPA97008351A - Composite package structure to contain articles and method for your product - Google Patents

Abstract

The present invention relates to a composite package for containing articles, wherein said composite package is comprised of: a cardboard base having first and second sides, a layer of particulate minerals located outside the first side of the cardboard base; layer of a heat-sealable polymeric material at a low temperature, located outside the second side of the cardboard base, wherein said polymeric material is further comprised of aqueous-based vinyl acetate, a printed graphics layer located outside the particulate minerals, a coating of varnish located outside the printed graphics layer, and a thermoformable polymeric cover having first and second sides, such that the first side of the cover is rigidly bonded to the heat-sealable polymeric material, and the second side includes a plurality of article fasteners, and a localized flexible spine element substantially between the plurality of article fastening elements, such that the plurality of article fastening elements provide a means for holding an article when the article fasteners are closed, and the thorn element provides support for the composite package and an alignment element for the article clamping elements mentioned

Description

COMPOSITE PACKAGE STRUCTURE TO CONTAIN ARTICLES AND METHOD FOR YOUR PRODUCTION BACKGROUND OF THE INVENTION Field of the Invention This invention relates to package structures made of cardboard and plastic that combine an intricate thermoformed cover with a cardboard base or cover. Structures of this type generally provide a lightweight package with a good surface for printing on the outside of the package. Description of the Related Art In composite package structures, the use of a book-shaped container cardboard cover and an internal plastic tray is known. The example of these structures is U.S. Patent Number 4,724,957 ('957) from O. Burgschweiger, entitled "Container". Although the '957 patent teaches a cardboard cover and an inner plastic tray, the cover does not connect with the inner tray along the spine. Also, sheet is located on the outer side of the cover. It can be seen that, if the inner tray were adhered to the cardboard cover along the length of the spine, a greater rigidity of the package would result. Also, if the foil cover was removed, a wider range of printed graphics could be used. Consequently, then a more convenient container would be presented if the stiffness and range of printed graphics were increased. In composite packages, the use of a molded inner tray and an outer cover is also known. The example of this prior art is US Pat. No. 4,635,797 ('797) of J.D. Ban ier, entitled "Pilfer Resistant Software Package". Although Patent '797 teaches the use of a package of cardboard and composite plastic, the inner plastic tray is welded to the cardboard cover by conventional radiofrequency techniques along the peripheral flange. The use of high temperature radiofrequency techniques can cause a deformation by temperature of the thermoformable inner tray. Consequently, then a composite package would be presented even more convenient if a heat-sealable, low temperature coating was used. Finally, in composite package structures, it is known to use a suitable plastic case to house objects. The example of this prior art is U.S. Patent Number 5,353,932 ('932) by K. Kollinek, entitled "Video Case and Method of Manufacturing". Although the reference '932 teaches the use of an inner lining of thermoformed plastic, a cardboard reinforcement, an outer vinyl cover, a paper sleeve, and an outer transparent plastic cover, the reinforcement can not be heat sealed, which requires extra external covers and the aggregate production expense. Also, the manufacturing method described in reference '932 requires many production steps, i.e. a transport of the intermediate product from one machine to another until the complete video cassette is constructed. Finally, because the different components of the reference '932 are cut individually, and then added together to build the final product, the differences in thermal expansion between the different materials, can cause an irregular and unattractive alignment between the different components. Accordingly, a convenient additional package would still be presented then, if a heat sealable paperboard could be used in conjunction with fewer and more efficient production steps. From the foregoing, it can be seen that there is a need in the art for a composite package that is rigid and that can employ a wide range of printed graphics, and that at the same time eliminate the use of high temperatures, but that employs a Sealable carton and in conjunction with less efficient production steps. It is a purpose of this invention to satisfy this and other needs in the art, in a manner more apparent to the skilled person once the following description is given.

SUMMARY OF THE INVENTION Broadly speaking, this invention meets these needs by providing a composite package for containing articles, which comprises a cardboard base having first and second sides, a layer of particulate minerals located outside of the first side of the cardboard base, a layer of a heat-sealable polymeric material, at low temperature, located outside the second side of the cardboard base, wherein the polymeric material is comprised in addition to a water-based vinyl acetate-ethylene, a graph printed form located outside the particle mineral layer, a layer of varnish located outside the printed graphics layer, and a thermoformable polymeric cover having first and second sides, such that the first side of the cover is rigidly bonded to the heat-sealable polymeric material, and the second side includes a plurality of article holding elements, and an flexible spine element located substantially between the plurality of article clamping elements, such that the plurality of article clamping elements provide a means for holding an article when the article clamping elements are closed, and the spine element provides support for the composite package, and an alignment element for the article holding elements.

In certain preferred embodiments, the particulate minerals are clay. Also, the thermoformable shell is constructed of polyvinyl chloride or a similar plastic material. Finally, the varnish is an electron beam curable varnish. In yet another preferred embodiment, the structure of the composite package provides a lightweight package with a good printing surface on the outside of the package. The preferred composite package, in accordance with this invention, offers the following advantages: light weight; the use of a wider range of printed graphics, - greater rigidity; lower manufacturing temperatures; good stability; good durability; greater resistance to wear, -more resistance to moisture; and good economy. In fact, in many of the preferred modalities, these lightweight factors, a wider range of graphics, higher stiffness, and lower temperatures, are optimized to the extent that they are considerably higher than what has been achieved so far. in the above known composite packages. The foregoing and other features of the present invention, which will become clearer as the description proceeds, are best understood by considering the following detailed description in conjunction with the accompanying drawings, in which like characters represent equal parts through of the different views, and in which. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic illustration of a method for producing a composite package, in accordance with the present invention. Figure 2 is a side view separated into parts of the composite package according to the present invention. Figure 3 is a cross-sectional view of a composite cover in accordance with the present invention. Figure 4 is a side view of the composite package constructed of Figure 2, and folded, in accordance with the present invention. DETAILED DESCRIPTION OF THE INVENTION Referring first to Figure 1, a system 2 for manufacturing a composite package 22 is illustrated. In particular, the system 2 includes in part, the thermoformable polymer roll 4, the thermoformable polymer sheet 6, the conventional thermoformer 8, the thermoformed polymeric trays 10, the flexible spine 11, the conventional feeder 12, the cardboard covers 14, the heat sealer / trimmer 16, and the composite packages 22. The thermoformable polymer roll 4 and the sheet 6 , preferably, they are constructed of polyvinyl chloride (PVC), polystyrene, polyethylene terephthalate (PET), or any plastic material that can be thermoformed to create an internal tray configured to be coupled with the product of interest. As more clearly shown in Figure 3, the cardboard covers 14 preferably include a cardboard base 30, a coating 32 of particulate minerals on one side, a layer 33 of printed graphics, a coating 34 of a curable varnish conventional electron beam, and a coating 24 of a heat-sealable polymeric material, at low temperature, on the other side. The particulate minerals are preferably clay. The low temperature heat-sealable polymeric material preferably is an aqueous-based ethylene vinyl acetate (EVA), produced by Pierce &; Stevens, Inc. of Buffalo, New York, under the trade name Latiseal. "The polymeric material is applied at a coating weight of 6.6-19.8 kilograms / 278.7 m2 (3-9 pounds / 3,000 ft2). of the coating is 13.2 kilograms / 278.7 m2 (6 pounds / 3,000 ft2) It should be understood that the coating 34 can be applied to the cover 14 by a conventional in-line process, in combination with the printing and curing with electron beam It should be understood that the coating 24 and the layer 33 can be applied to the cover 14 by conventional techniques.

During the construction of the composite packages 22, the roll 4 is unwound, in such a way that the sheet 6 is formed. The sheet 6 is transferred through thermoformer 8, in such a way that a core of trays 10 having the flexible spine 11. After the core of trays 10 is produced, a cardboard cover 14 is placed on one side of the trays 10, such that the coating 24 (Figure 2) is adjacent to the tray 10. The cover 14 has preferably been printed with the graphics layer 33, and has been coated with the varnish and cured with a conventional electron beam, such that as the electron beam contacts the coating 34, it is achieves crosslinking between the different components of the coating 34, which improves the moisture resistance and the wear resistance, and the durability of the coating 34. After the cardboard cover 14 is placed on the tray 10, the tray 10 and the CU 14 are heat sealed, and cut into the heat sealer / trimmer 16, such that composite packages 22 are produced. It should be understood that the heat sealer 16 employs a conventional stage heat sealer that contacts the coating 34, in such a way that adhesion is achieved between the different components of the cover 34 and the tray 10.

It should also be understood that the construction of the composite package 22 is accomplished in one pass, that is, the package 22 is not transferred from one production line to another in order to build the package 22. Also, due to the establishment of the construction of the package 22, the cover 14 and the tray 10 are heat sealed and then trimmed, although in a relatively short period of time. In this way, care must be taken of any differences in the coefficient of thermal expansion between the different elements and their possible resulting misalignment, by subsequent trimming. Accordingly, heat sealing and subsequent trimming create a clean and coupled edge that must be resistant to any bending or fraying that is commonly referred to as "dog ear". Figure 3 illustrates, in greater detail, the final construction of the composite package 22. In particular, the composite package 22 includes, in part, the thermoformed polymer tray 10, the flexible spine 11, the cardboard cover 14, the sealable coating heat at low temperature 24, flange 26, marked lines 28, cardboard base 30, particulate coating 32, printed graphics layer 33 and varnish layer 34. Coating 24 is preferably the same sealable coating by heat at low temperature 24, which was described above. Also, coatings 32, 33 and 34 are the same coatings 32, 33 and 34 as described above. Also, the marked lines 28 are placed on the cardboard cover 14 in order to provide the desired flexibility inside the cardboard cover 14. However, it should be understood that the lines marked 28 may be omitted in certain cases. In order to secure the items inside the package 22, the package 22 is oriented in such a way that the items are placed in a section of the tray 10 as shown in Figure 4. The other section of the tray 10 is then doubled. in a book-like manner, along the marked lines 28, and engages with the section of the tray 10 containing the articles. In this manner, the articles are retained inside the tray 10 and the package 22. Finally, the flexible corner 11 is used to add structural rigidity to the package 22, and to provide an alignment element, such that the separate sections of the tray 10, which are used to contain articles. Once given the above description, the expert in this field will be able to see many other features, modifications or improvements. Accordingly, those features, modifications or improvements are considered a part of this invention, the scope of which should be determined by the following claims.

Claims (19)

1. NOVELTY OF THE INVENTION Having described the foregoing invention, it is considered as a novelty and, therefore, the content of the following is claimed as property: CLAIMS 1. A composite package for containing articles, wherein this composite package is comprised of : a cardboard base that has first and second sides; a layer of particulate minerals located outside the first side of the cardboard base; a layer of a heat-sealable polymeric material at a low temperature, located outside the second side of the cardboard base, wherein said polymeric material is further comprised of water-based ethylene vinyl acetate; a printed graphics layer located outside the particle mineral layer; a coating of varnish located outside the printed graphics layer; and a thermoformable polymeric cover having first and second sides, such that the first side of the cover is rigidly bonded to the heat sealable polymeric material, and the second side includes a plurality of article fasteners, and an element of flexible spine located substantially between the plurality of article clamping elements, such that the plurality of article clamping elements provide a means for holding an article when the article clamping elements are closed, and the spine element provides support for the composite package and an alignment element for the mentioned article fasteners. The composite package according to claim 1, characterized in that the particulate mineral layer is further comprised of: clay. 3. The composite package according to claim 1, characterized in that the varnish layer is substantially resistant to moisture. 4. The composite package according to claim 1, characterized in that the varnish layer is substantially resistant to wear. 5. The composite package according to claim 1, characterized in that the varnish layer has a greater durability. 6. The package composed in accordance with claim 1, characterized in that the package is further comprised of: a flange element. A method for producing a composite package for containing articles, wherein this method is comprised of the steps of: forming a sheet of polymeric material in a core of a plurality of polymeric trays, each of these trays having a flexible spine; coating a first side of a cardboard cover element with a coating of a low temperature heat sealable polymeric material, wherein said low temperature heat sealable polymeric material is further comprised of water based ethylene vinyl acetate; coating a second side of the cardboard cover element with a layer of particulate minerals; coating said layer of particulate minerals with a layer of printed graphics; coat the printed graphics layer with a varnish coating; superficially treat the aforementioned varnish; placing the coated cardboard cover element substantially over one of the plurality of polymeric trays, the polymeric coating being located adjacent said tray, - securing and trimming the tray of the plurality of polymer trays to the coated cardboard cover element to form a package final compound; inserting an article substantially inside the final composite package; and retaining this article substantially within the aforementioned final composite package. 8. The method according to claim 7, characterized in that the step of forming is further comprised of the step of: thermoforming the aforesaid sheet of polymeric material. 9. The method of compliance with the claim in claim 7, characterized in that the material of the polymeric shell is further comprised of: polyvinyl chloride. 10. The method according to claim 7, characterized in that the material of the polymer tray is also comprised of: polystyrene. 11. The method according to claim 7, characterized in that the material of the polymer tray is also comprised of: polyethylene terephthalate. 12. The method according to claim 7, characterized in that this method is further comprised of the step of: coating the second side of the cardboard cover element with a layer of particulate minerals, such that said layer of particulate minerals is located substantially between the cardboard cover element and the aforementioned varnish coating. 13. The method according to claim 7, characterized in that the particulate minerals are also comprised of: clay. The method according to claim 7, characterized in that the step of securing is further comprised of the step of: heat sealing one of the cardboard covers to the tray of said polymeric trays. 15. The method according to claim 7, characterized in that the step of retaining is further comprised of the step of: doubling the mentioned final composite package. 16. The method according to claim 7, characterized in that the polymeric material heat sealable at low temperature is applied at a coating weight of at least 6.6-19.8 kg / 278.7 m2. 17. The method according to claim 7, characterized in that the step of surface treatment is further comprised of the step of: employing an electron beam to make contact with the varnish, in such a way that the crosslinking is substantially achieved between the components of said varnish. 18. The method according to claim 7, characterized in that the step of sealing by heat is further comprised of the step of: heating in plates the trays with the aforementioned cover elements. 19. The method according to claim 7, characterized in that the varnish is further comprised of: an electron beam curable varnish.