U.S. patent application number 13/681950 was filed with the patent office on 2013-05-30 for consumer product package comprising a laminate structure.
This patent application is currently assigned to THE GILLETTE COMPANY. The applicant listed for this patent is The Gillette Company. Invention is credited to Stanley Michael Marcinkowski.
Application Number | 20130134066 13/681950 |
Document ID | / |
Family ID | 48465839 |
Filed Date | 2013-05-30 |
United States Patent
Application |
20130134066 |
Kind Code |
A1 |
Marcinkowski; Stanley
Michael |
May 30, 2013 |
CONSUMER PRODUCT PACKAGE COMPRISING A LAMINATE STRUCTURE
Abstract
A laminate structure for containing a consumer product
comprising: a cellulose based substrate comprising: a bamboo
derived pulp; a sugar cane derived pulp; and a bulrush derived
pulp; a polymeric laminate layer at least partially coating said
cellulosic base substrate, said laminate structure forming a tub
having a base and a perimeter wall defining a cavity for receiving
a consumer product, said cavity being in communication with an
opening that extends through the perimeter wall.
Inventors: |
Marcinkowski; Stanley Michael;
(Peabody, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Gillette Company; |
Boston |
MA |
US |
|
|
Assignee: |
THE GILLETTE COMPANY
Boston
MA
|
Family ID: |
48465839 |
Appl. No.: |
13/681950 |
Filed: |
November 20, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61565252 |
Nov 30, 2011 |
|
|
|
Current U.S.
Class: |
206/461 |
Current CPC
Class: |
Y02W 90/10 20150501;
B32B 2262/065 20130101; B65D 73/00 20130101; B32B 27/12 20130101;
Y02W 90/11 20150501; B65D 65/466 20130101; B32B 1/02 20130101; B65D
1/28 20130101 |
Class at
Publication: |
206/461 |
International
Class: |
B65D 73/00 20060101
B65D073/00 |
Claims
1. A laminate structure for containing a consumer product
comprising a. a cellulose based substrate comprising: i. from about
50% to about 75% of a bamboo derived pulp; ii. from about 15% to
about 35% of a sugar cane derived pulp; iii. up to about 25% of a
bulrush derived pulp; b. a polymeric laminate layer at least
partially coating said cellulosic base substrate having a thickness
of from about 0.02 mm to about 0.1 mm, said laminate structure
forming a tub having a base and a perimeter wall defining a cavity
for receiving a consumer product, said cavity being in
communication with an opening that extends through the perimeter
wall.
2. The laminate structure of claim 1, wherein said polymeric
laminate layer is intermediate the cellulose based substrate and
the cavity.
3. The laminate substrate of claim 1, wherein said tub has an
interior surface at least partially formed by said polymeric
laminate layer.
4. The laminate substrate of claim 3, wherein the entire interior
surface is formed by said polymeric laminate layer.
5. The laminate substrate of claim 3, wherein said tub forms an
outer flange extending about the perimeter wall.
6. The laminate substrate of claim 5, wherein the entire interior
surface formed by said tub is formed by said polymeric laminate
layer.
7. The laminate substrate of claim 5, wherein a cover is removeably
sealed onto the portion of the polymeric laminate layer of said
outer flange
8. The laminate substrate of claim 6, wherein said cover is a clear
plastic sheet.
9. The laminate substrate of claim 8, wherein said clear plastic
sheet comprises a tear away tab.
10. The laminate substrate of claim 1, further comprising a
stabilizing insert at least partially disposed within the cavity,
wherein the stabilizing insert has a retaining member removably
securing the consumer product and a support member with a foot
extending through the opening of the perimeter wall to facilitate
positioning the tub in a substantially upright position.
11. The laminate substrate of claim 1, wherein said polymeric
laminate layer has a thickness of from about 0.035 mm to about 0.04
mm.
12. The laminate substrate of claim 11, wherein said polymeric
laminate layer comprises polyethylene terephthalate.
13. The laminate substrate of claim 1, wherein said polymeric
laminate layer has an average thickness of from about 0.02 mm to
about 0.1 mm.
14. The laminate substrate of claim 1, wherein said cellulosic base
substrate is a molded pulp.
15. The laminate substrate of claim 1, wherein said cellulosic base
substrate is water permeable.
16. The laminate substrate of claim 14, wherein said cellulose base
substrate comprises cellulosic fibers forming at least one
interstitial void space which is a filled by a portion of said
polymeric laminate layer.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to display packages for food
or consumer goods and more particularly, to consumer product
packages having a stabilizing insert adapted to support the package
in a substantially upright position on a support surface (such as
on a product display or a store shelf) as a freestanding
package.
BACKGROUND OF THE INVENTION
[0002] Blister-type packages are popular for storing and displaying
articles for sale. The two primary components of a blister pack are
the cavity or pocket made from a formable material, (e.g., plastic)
and a lid (e.g., paperboard or plastic). The formed cavity or
pocket contains the product and the lid seals the product within
the cavity. Other types of blister packs may consist of carded
packages where the products are contained between a paperboard card
and clear pre-formed plastic (e.g., polyvinylchloride). The
consumer can easily examine the product through the transparent
plastic. The plastic shell is vacuum-formed around a mold so it can
contain the item snugly. The card may be brightly colored and
designed depending on the item inside, and the pre-formed plastic
is affixed to the card using heat and pressure to activate an
adhesive (heat seal coating) on the blister card. The adhesive is
strong enough so that the pack may hang on a peg, but weak enough
so that the package can be easily opened. The card may also have a
perforated window for access. A more secure package is known as a
clamshell. It is often used to deter package pilferage for small
high-value items such as consumer electronics. It consists of
either two pre-formed plastic sheets or one sheet folded over onto
itself and fused at the edges. They are usually designed to be
difficult to open by hand so as to deter tampering. A pair of
scissors or a sharp knife is often required to open them. Care must
be used to safely open some of these packages.
[0003] Blister packs are typically thermoformed. Thermoforming is a
manufacturing process where a plastic sheet is heated to a pliable
forming temperature, formed to a specific shape in a mold, and
trimmed to create a usable product. The sheet (or film when
referring to thinner gauges and certain material types), is heated
in an oven to a high-enough temperature that it can be stretched
into or onto a mold and cooled to a finished shape. For high-volume
applications, very large production machines are utilized to heat
and form the plastic sheet and trim the formed parts from the sheet
in a continuous high-speed process, and can produce many thousands
of finished parts per hour depending on the machine and mold size
and the size of the parts being formed.
[0004] Consumers have been demanding environmentally friendly
changes in food and consumer product packaging, such as minimizing
the use of plastic and other non renewable materials. Many
consumers are concerned about the environmental impact of
packaging. Researchers believe that global green initiatives have
strongly influenced this consumer attitude. Researchers also
believe this new consumer attitude that will continue to push
packaging manufacturers into finding environmentally friendly
packaging alternatives. Typical plastics take an extended period of
time to compost (break down) in a land fills. New environmentally
friendly packaging materials are made from renewable materials that
can be grown quickly (unlike most trees). Renewable materials may
be recyclable and/or biodegradable. Several alternatives to
plastics have been developed for thermoforming blister packs and
trays, such as, paper board and renewable plant fiber. Despite the
environmental advantages of these materials, current manufacturing
processes (e.g., thermoforming) often limit the design and
functionality of the final package. For example, the blister pack
may require multiple angled sides because of draft angle
requirements in order to remove the pack from a mold or tool during
manufacturing. Graphics to draw a consumer's attention are often
placed on the front of the package, thus it is advantageous for the
pack to be positioned vertically in a substantially upright
position so the consumer can see the graphics on the front of the
package. Due to manufacturing limitations, the formed pack may not
be displayed properly (e.g., vertically in a substantially upright
position) on a shelf resulting in no consideration by a consumer or
retailer and thus a missed sale. In addition, many irregular shaped
packages do not provide for proper facing. For example, an oblong
or circular package may not stand in an upright position by itself.
Accordingly the consumer may not see the front panel of the package
unless it is being suspended from a display peg or hook.
SUMMARY OF THE INVENTION
[0005] One aspect of the present invention provides for a laminate
structure for containing a consumer product such as a razor, said
laminate structure comprising: a cellulose based substrate
comprising: from about 50% to about 75% of a bamboo derived pulp;
from about 15% to about 35% of a sugar cane derived pulp; up to
about 25% of a bulrush derived pulp; a polymeric laminate layer at
least partially coating said cellulosic base substrate having a
thickness of from about 0.02 mm to about 0.1 mm, said laminate
structure forming a tub having a base and a perimeter wall defining
a cavity for receiving a consumer product, said cavity being in
communication with an opening that extends through the perimeter
wall.
[0006] Another aspect of the invention provides for a method of
forming a laminate substrate comprising the steps of: forming a
pulp mixture comprising: a bamboo derived pulp feed; a sugar cane
derived pulp feed; a bulrush derived pulp feed; and a soda ash
feed; molding said pulp mixture into a cellulosic substrate with an
optional colorant additive; and laminating at least a portion of
said cellulosic substrate with a polymeric laminate layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of a consumer product package
having a cover.
[0008] FIG. 2A is a side view of a stabilizing insert that may be
incorporated into the display package of FIG. 1.
[0009] FIG. 2B is a perspective view of the optional stabilizing
insert of FIG. 2A in a second position.
[0010] FIG. 3 is a side view of a consumer product with the
stabilizing insert of FIG. 2B.
[0011] FIG. 4 is perspective view of a tub that may be incorporated
into the display package of FIG. 1.
[0012] FIG. 5 is perspective view of the consumer product package
of FIG. 1 without a cover.
[0013] FIG. 6 is a side view of a plurality of consumer product
packages arranged on a shelf.
[0014] FIG. 7 is a cross sectional simplified view of the laminate
substrate suitable for forming a consumer product package taken
along view line A-A of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Referring to FIG. 1, one possible embodiment of the present
invention is shown illustrating a consumer product package 10 made
from the laminate substrate of the present invention. The package
may be mounted to a hanging display (e.g., a peg board) and/or
displayed on a store shelf. It is understood that the consumer
product package 10 may include any type of blister packs,
including, but not limited to card blisters and clamshells. The
consumer product package 10 may include a tub 12 for holding and
displaying one or more food or consumer articles and a cover 18
affixed to the tub 12.
[0016] The laminate structure of the present invention comprises: a
cellulose based substrate and a polymeric laminate. The cellulosic
based substrate comprises a blend of grass based pulp materials
such as, bamboo derived pulp, sugar cane derived pulp (commonly
referred to as bagasse pulp), bulrush derived pulp, and mixture
thereof. In one embodiment, the cellulosic based substrate
comprises from about 50% to about 75%, or from about 60% to about
70%, or about 65% of a bamboo derived pulp; from about 15% to about
35%, or from about 20% to about 30%, or about 25% of a sugar cane
derived pulp; and up to about 25%, or from about 5% to about 15%,
or about 10% of a bulrush derived pulp. Other pulps may also be
included as needed (e.g., wheat stalk, rice hull, etc, and
combinations thereof available from BeGreen Packaging LLC, Santa
Barbara, Calif.). Without intending to be bound by theory, it is
believed that this blend of grass based pulps provides desirable
container strength and flexibility. For example, if insufficient
amounts of bamboo derived pulps are used, the container may not be
sufficiently rigid. If too much is used, the container may not be
sufficiently flexible.
[0017] The polymeric laminate layer at least partially coats said
cellulosic base substrate, said polymeric laminate layer has a
thickness of from about 0.02 mm to about 0.1 mm, or from about
0.025 mm to about 0.05 mm, or from about 0.035 mm to about 0.04 mm,
or about 0.038 mm. In one embodiment, polymeric laminate layer has
an average thickness of from about 0.02 mm to about 0.1 mm. The
polymeric laminate layer can be made from a clear polymer material,
including, but not limited to polyvinyl chloride (PVC),
polyethylene terephthalate (PET), high density polyethylene (HDPE),
and low density polyethylene (LDPE), polypropylene (PP), or any
combination thereof. In one embodiment, the laminate is made of
PET. Without intending to be bound by theory, it is believed that
although thicker laminate layers can be applied, the thickness of
the polymeric laminate layer of the present invention importantly
provides sufficient air and/or water resistance and load strength
while not being overly rigid that the laminate will peal off the
cellulosic based substrate when the package is deformed during
handling or manufacture. Further by providing a sufficiently thin
laminate thickness, the polymeric material can breakdown in similar
time with the cellulose based substrate. By water resistant or
water proof, it is meant that water will not readily enter and pass
through the laminate structure during normal handling and usage
conditions. Those of skill in the art will understand that given
sufficient time and pressure of deformation or structural damage to
the laminate substrate, water and air will eventually be able to
enter and likely pass through. By water resistant or water proof,
it is meant that certain embodiments of the present invention can
withstand water entry following making and before the package is
opened by the user, during the normal course of shipping, handling
and stocking.
[0018] In certain embodiments, the tub 12 may be formed from a
cellulosic material such as paperboard and/or renewable materials
as described above. The tub 12 may be the natural color of the
paperboard and/or renewable material or may alternatively contain a
dye (e.g., orange or blue) for enhanced consumer appeal. The cover
18 may be transparent and/or translucent such that a consumer can
see the articles disposed within the tub 12. In certain
embodiments, the cover 18 may be injection molded or thermoformed
from a clear polymer material, including, but not limited to
polyvinyl chloride (PVC), polyethylene terephthalate (PET), high
density polyethylene (HDPE), and low density polyethylene (LDPE),
polypropylene (PP), or any combination thereof. Alternatively, the
cover 18 may include a flat or formed paperboard or polymeric
material with a heat sealable coating and/or an anti-theft coating.
The cover 18 may also include thin polymeric films that are sealed
to the tub 12. The tub 12 may comprise similar of different
materials as the cover 18. In one embodiment, the package may be
formed to include a tear away tab by including a cut out in the
outer flange so the cover is exposed and can be easily pulled away
from the tub. Other suitable methods to provide a tear away tab can
include purposefully not sealing a discrete region of the cover and
outer flange. These and other easy opening mechanisms are known and
suitable for use herein.
[0019] The demand for environmentally packaging materials is
constantly increasing. Currently it is difficult to manufacture
packages (e.g., blister packs) from environmentally packaging
materials (e.g., paperboard or renewable plant fibers) with
features to support the package in a vertical and substantially
upright position. Unlike polymeric materials, materials such as
paperboard or renewable plant fibers have manufacturing limitations
which limit the shape and design of the package.
[0020] In one embodiment, the cover is sealed directly onto the
portion of the outer flange formed by the polymeric laminate layer
which in part forms the interior surface of the tub. Without
intending to be bound by theory, it is believed that by removably
sealing the cover onto the polymeric laminate layer, a strong seal
can be achieved which is sufficiently resistant to air and water
passage. In one embodiment, the strength of the seal between the
cover and outer flange polymeric laminate layer forming is from
about 6 to about 10 Newtons, or from about 7 to 8 Newtons
preferably at least 6 Newtons. It is believed that comparable seals
made directly to the cellulosic based substrate may not provide
seal strength of up to 6 Newtons, possibly even as low as 3
Newtons. Furthermore, it may be preferable to use embodiments where
the entire interior surface is formed of said polymeric laminate
layer as this may allow for better sealing given any pulling force
on the cover would be transferred to the touching outer flange
polymeric laminate layer and at least in part transferred along
other portions of the laminate layer forming the rest of the
interior surface. It is believed that the rest of the polymeric
laminate layer would provide a further "anchoring" effect as it
increases the amount of contact between polymeric laminate layer
and cellulosic based substrate. Of course, it is also within the
scope of the invention for portions of the interior surface not to
be coated with said laminate. In one embodiment, at least 50% by
area, or at least 75%, or at least 95%, or at least 99%, up to 100%
by area of the portion of the cellulosic based substrate facing the
interior surface is coated with said polymeric laminate layer. In
another embodiment, the entirety of the exterior surface of the
cellulosic based substrate is such coated, or any of the ranges
previously described in the preceding sentence.
[0021] The tub 12 may have a base 20 and a perimeter wall 22
configured to receive one or consumer products. The perimeter wall
22 may have a plurality of nesting members 24 For example, the
nesting members 24 may include recesses and/or protrusions located
at a junction of the base 20 and the perimeter wall 22. The nesting
members 24 may provide a gap between the tubs 12 when they are
stacked together during shipping and storage. The gap allows the
packs 12 to be separated easily with minimal damage to the tub 12.
As will be explained in greater detail below, the perimeter wall 22
of the tub 12 may define an opening 30 that is dimensioned to
receive a foot 54 to support the consumer product package 10 in a
substantially upright and vertical position (e.g., freestanding) on
a support surface (such as on a product display or on a store
shelf).
[0022] In certain embodiments, the tub 12 may have a hanging member
14 to facilitate the displaying (e.g., centering) the consumer
product package 10 on a hanging display. Hanging displays, such as
peg boards offer increased versatility for presenting articles to
consumers. For example, pegboard racks that revolve or spin work
extremely well for stores that have limited floor space. The
hanging member 14 may have an opening 16 extending therethrough
that is dimensioned to receive a peg or hook of a peg board style
display. The opening 16 may be circular, a slot, or any other
geometry known to those skilled in the art for easy placement of
the tub 12 on a peg or hook. The hanging member 14 may have other
configurations, such as a hook, to facilitate the mounting of the
consumer product package 10 to a string or wire. The hanging member
14 may be integral with the tub 12 or may be a separate member that
is joined (e.g., adhesives) to the tub 12. Although the opening 16
is shown extending through the hanging member 14, it is understood
that the hanging member 14 is part of the tub 12 and the opening 16
may extend directly through the tub 12. In other embodiments, the
consumer product package 10 may not have a hanging member 14 (e.g.,
the consumer product package 10 may be displayed on a store shelf
and not on a peg board).
[0023] Referring to FIGS. 2A and 2B a side view of and a
perspective view of the optional stabilizing insert 40 is
illustrated, respectively. Importantly, the stabilizing insert is
optional due in part to the added strength and rigidity provided by
the laminate substrate of the present invention. In one embodiment,
no additional stabilizing insert is used and the laminate substrate
is molded to include one or more retaining structures integral to
the tub, i.e. formed of the same laminate substrate. The
stabilizing insert 40 may be a separate component that is placed
within the tub 12 to allow the tub 12 and/or the stabilizing insert
40 to be properly recycled. For example, if the tub 12 in made from
plant fiber and the stabilizing insert 40 is made from plastic, a
consumer can easily separate and recycle the stabilizing insert 40
with other plastics and compost the tub 12 by itself. The
stabilizing insert 40 may include a support member 42 and an
optional retaining member 44 (e.g., the support member 42 may be
used independently of the retaining member 44). The support member
42 may have a lower surface 50 and an upper surface 48. The lower
surface 50 of the support member 42 may have a flange 52 and a foot
54. As best shown in FIG. 2B, the foot 54 may be spaced apart from
the flange 52 to provide a gap 56 extending around the foot 54. The
retaining member 44 may have a side surface 60 and a base 62
generally transverse to the side surface 60. A top surface 64 of
the retaining member 44 may define a recess 66 extending into the
top surface 64 that is dimensioned to receive and hold at least a
portion of one or more consumer products (not shown).
[0024] The stabilizing insert 40 (e.g., the support member 42
and/or the retaining member 44) may be thermoformed or injection as
two separate units or a single unit. For example, the stabilizing
insert 40 may be molded or thermoformed as a single unit with a
hinge 46 (e.g., a living hinge or a thin piece of material)
interconnecting the support member 42 and the retaining member 44.
The stabilizing insert 40 (e.g., the support member 42 and/or the
retaining member 44) may be molded from a polymeric materials
including, but not limited to polyethylene, polypropylene,
polyvinyl chloride, polyethylene terephthalate, and any combination
thereof. The stabilizing insert 40 (e.g., the support member 42
and/or the retaining member 44) may also be manufactured from
renewable plant fibers or paperboard. The stabilizing insert 40 may
be initially manufactured in a first configuration, as shown in
FIG. 2A. In a subsequent assembly operation, the stabilizing insert
40 may be flexed into a second configuration, as shown in FIG. 2B.
The hinge 36 may facilitate the bending of the stabilizing insert
40 from the first configuration to the second configuration.
Alternatively, the support member 42 and the retaining member 44
may be separated and then positioned in the second configuration.
In the first configuration, the upper surface 48 of the support
member 42 may be generally transverse to the side surface 60 of the
retaining member 44, as shown in FIG. 1. In the second
configuration, the upper surface 48 of the support member 42 may be
generally parallel to the side surface 60, as shown in FIG. 2B. In
certain embodiments, the upper surface 48 of the support member 42
may contact the side surface 60 in the second configuration.
[0025] Referring to FIG. 3, a side view of the stabilizing insert
40 in the second configuration is illustrated with a consumer
product 100. The consumer product 100 may include one or more
items, for example, the consumer product 100 may include a shaving
razor 102, a shaving tray 110, a cartridge organizer 120, and a
display card 130. The shaving razor 102 may releaseably engage the
cartridge organizer 120. The cartridge organizer 120 may hold
and/or display one of more shaving cartridges. The display card 130
may be positioned between the shaving tray 110 and the cartridge
organizer 120. The display card 130 may have various graphic design
elements and relevant information about the consumer product 100.
At least a portion of the shaving razor 102 may be removably
retained by the shaving tray 110. The shaving tray 110 may be used
to store the shaving razor 102 during periods of non use. The
shaving razor 102 and/or the shaving tray 110 may be supported by
both the stabilizing insert 40 and the cartridge organizer 120 so
that the shaving razor 102 appears generally level when placed
within the tub 12 or on a level surface. Accordingly, the base 62
of the support member 42 and a bottom surface 122 of the cartridge
organizer 120 may rest on a common plane P1. The shaving razor 102
may have a handle 104 that is removably mounted to the retaining
member 44 of the stabilizing insert 40. For example, the handle 102
may be removably secured within the recess 66 (see FIG. 2A) of the
retaining member 44 to minimize movement of the shaving razor 102
during shipping and handling. Once purchased, a consumer can open
the consumer product package 10 and easily remove the shaving razor
102 from the retaining member 44.
[0026] Referring to FIG. 4, a perspective view of the tub 12 is
shown. The tub 12 may have a base 20 and a perimeter wall 22 that
defines a cavity 74 dimensioned to receive the consumer product 100
(shown in FIG. 3) and at least a portion of the stabilizing insert
40. The base 20 may be generally flat to receive the stabilizing
insert 40 within the cavity 74. An inner and/or outer surface of
the base 20 may also accommodate packaging graphics and labeling.
The base 20 may have a generally flat rear outer surface 75 to
facilitate stacking the consumer product packages 10 on top of each
or on a flat shelf. As will be explained in greater detail below,
the generally flat rear outer surface 75 of the base 20 may
facilitate indexing of the consumer product packages 10. However,
the rear outer surface 75 need not be flat because the tub 12 may
be vertically supported by the stabilizing insert 40 or suspended
from a hook utilizing the hanging member 14. An outer flange member
76 may extend about the perimeter wall 22 of the tub 12. The outer
flange member 76 may extend continuously around the perimeter wall
22 or may along or only along a portion of the perimeter wall 22.
In certain embodiments, the outer flange member 76 may be generally
parallel to the base 20 and provide an area for the cover 18 (see
FIG. 1) to seal against. As explained above, the outer flange
member 76 may be laminated with the same or similar polymeric
material (e.g., polyethylene terephthalate) as the cover 18 (see
FIG. 1) for an improved seal (e.g., a required removal force
greater than 10 Newtons). The outer flange member 76 may extend
outward beyond the perimeter wall 22 by about 2 mm, 4 mm, or 6 mm
to about 8 mm, 10 mm, or 12 mm.
[0027] The perimeter wall 22 may be generally transverse to the
base 20. For example, the perimeter wall 22 may taper inwardly from
the outer flange member 76 toward the base 20 at an angle greater
than zero to about 3 degrees per side. However, it is understood a
greater taper angle may be used if desired. The taper of the
perimeter wall 22 may improve the manufacturability of the tub 12
(i.e., improved release of the tub 12 from a mold or tool). The
perimeter wall 22 may define one or more openings 30 that are in
communication with the cavity 74. In certain embodiments, the
opening 30 may be located at a bottom portion (e.g., an end wall
80) of the tub 12 opposite the hanging member 14 and transverse to
the base 20. The opening 30 may be dimensioned to receive the foot
member 54 of the stabilizing insert 40. The opening 30 may be die
cut or laser cut into the bottom portion 80 of the tub 12 (e.g.,
the end wall 82). Although only one opening 30 is shown, it is
understood that the tub 12 may have a plurality of openings 30 each
dimensioned receiving one or more feet 54.
[0028] Referring to FIG. 5, a perspective view of the consumer
product package 10 is illustrated without the cover 18 for clarity.
The stabilizing insert 40 may provide for multiple functions. For
example, the stabilizing insert 40 may provide for a structural
support of the consumer product package 10 to facilitate
positioning the tub 12 in a substantially upright position. The
stabilizing insert 40 may also provide a structural retaining
feature within the tub 12 for the consumer product 100. At least a
portion of the shaving razor 102 (e.g., the handle 104) may be
engaged by the retaining member 44 to secure the shaving razor 102
to the stabilizing insert 40. For example, the handle 104 may be
positioned within the recess 66 of the retaining member 44. The
stabilizing insert 40 and the consumer product 100 may be disposed
within the cavity 74. The stabilizing insert 40 may be flexed into
the second configuration and the foot 54 may be positioned at least
partially within and extend through the opening 30 of the tub 12.
The foot 54 and the flange member 76 may support the tub 12 in a
substantially upright (e.g., vertical) position. In certain
embodiments, one or more feet 54 may support the consumer product
package without the need of the flange member 76. The support
member 42 may contact the perimeter wall 76 and the foot 54 may be
spaced apart from (e.g., suspended above) the base 20 of the tub
12. The retaining member 44 may contact the base 74 to facilitate
properly positioning the foot 54 within the opening 30. In certain
embodiments, the hinge 46 (not shown) may press the consumer
product 100 (e.g., the shaving tray 110) against the perimeter wall
22 to limit movement of the consumer product 100. The opening 30
and the foot 54 may be dimensioned to provide either a slip fit
(i.e., opening 30 is larger than foot 54) or an interference fit
(i.e., opening is smaller than foot 54). The cartridge organizer
120 may lay flat on the base 20 of the tub 12. The consumer product
100 may be held securely between the retaining member 44 of the
stabilizing insert 40 and the perimeter wall 22 of the tub 12. The
retaining member 44 and the perimeter wall 22 may minimize lateral
movement (side to side and forward to back) of the consumer product
100. The consumer product 100 may also be held securely between the
cover 18 and the base 20 of the tub 12 to limit up and down
movement of the consumer product within the tub 12. In certain
embodiments, the consumer product 100 may compressed between the
cover 18 and the base 20 of the tub 12 to prevent movement of the
consumer product during shipping and handling.
[0029] Referring to FIG. 6, a plurality of consumer product
packages 10 are shown in a freestanding and self indexing position
on a shelf 85. Self indexing refers to maintenance of proper
spacing on a store shelf, for example, when a pressure applicator
moves the aligned packages forward in a display or on a shelf. In
certain embodiments, the foot 54 may extend out from the perimeter
wall 22 as far as the flange member 76 at the bottom portion 80 of
consumer product package 10 (i.e., the foot 54 and the flange
member 76 lay on a common plane P2). The foot 54 and the flange
member 76 may be spaced apart from each other and support the
consumer product package 10 on the shelf 85 in an upright or
substantially upright position. The foot 54 may be configured to
have a width, depth and height sufficient to allow the consumer
product package 10 to be free standing on a support surface (e.g.,
a store shelf). The foot 54 may have a width of about 4 mm, 6 mm,
or 13 mm to about 15 mm, 20 mm, or 25 mm and a length of about 10
mm, 15 mm, or 20 mm to about 30 mm, 40 mm, or 50 mm. In certain
embodiments, the width and length of the foot 54 may be greater
than 50% of the width and length of the end wall 80. The foot 54
may have a depth (i.e., a distance the foot 54 extends beyond the
perimeter wall 22 or the end wall 80 of the tub 12) of about 4 mm,
6 mm, or 8 mm to about 10 mm, 12 mm, or 14 mm. It is understood
that the depth of the foot 54 may be greater depending on the size
and geometry of the tub 12. The consumer product package 10 may
have the advantage of not requiring any additional assembly by
store clerks position the tub 12 in a substantially upright
vertical position. For example, some self supporting packages, such
as the package generally disclosed in U.S. Pat. No. 3,785,546,
require the store clerk to unfold a support structure that has been
fixed to a wall of the package. These types of packages rely on the
store clerk to assemble (e.g., unfold) the support structure
properly. The support structure may also become damaged during
assembly or as the product is handled by prospective consumers. In
addition, these types of support structures take up additional
space on the store shelf and do not allow the packages to be self
indexing. For example, typical support structures do not allow for
consistent spacing because the front of one package may not
directly contact the rear face of an adjacent package. Furthermore,
a pressure applicator may contact and deform the folding support
structure.
[0030] Referring now to FIG. 7, taken along view line A-A of FIG.
1, consumer product package 10 is shown comprising a laminate
structure formed of cellulosic based substrate 200 and polymeric
laminate 100. The laminate structure forms tub having a base 20 and
perimeter wall 22. The tub also forms an outer flange formed by
said laminate structure. The portions of the laminate structure
forming the outer flange include outer flange cellulosic based
substrate 276 and outer flange polymeric laminate 176. Cover 18 is
removably attached to said outer flange polymeric laminate 176. As
shown herein, the polymeric laminate layer is intermediate the
cellulose based substrate and the cavity formed in the tub. In one
embodiment, the tub forms an interior surface which defines the
cavity. The interior surface can be at least partially coated with
the polymeric laminate layer, preferably entirely coated. Without
intending to be bound by theory, it is believed that adding the
specific polymeric laminate layer to the cellulosic based substrate
of the present invention allows the structure to be desirably
strong and resilient to collapse upon applied pressure. Further, it
is believed that the present laminate structure can provide
sufficiently air tight and/or water tight seal to protect the
contents stored within. In one embodiment, the cavity can be
hermetically sealed. Moreover, it is importantly believed that by
selecting a cellulosic based substrate being somewhat porous with
sufficiently large interstitial spaces formed by the fibers,
amounts of the polymeric laminate can fill the voids formed in the
cellulosic based substrate thereby enhancing the adhesion between
the two layers and additionally strengthening the laminate compared
to similar non-laminated structures or those using cellulose pulps
which form more closed cell surfaces.
[0031] One embodiment of the present invention relates to a method
of forming a laminate substrate comprising the steps of: forming a
pulp mixture comprising: a bamboo derived pulp feed; a sugar cane
derived pulp feed; a bulrush derived pulp feed; and a soda ash
feed; molding said pulp mixture into a cellulosic substrate with an
optional colorant additive; and laminating at least a portion of
said cellulosic substrate with a polymeric laminate layer. Each of
the feeds can include the cellulose based material at varying
concentrations as they are commercially available as a raw
material, such as for example bagasse at 0.3% to 0.4% by weight
with water. The soda ash can be added at a rate of 7% to 8% by
weight in water. Depending on the amounts of each pulp desired, the
relative feed rates can be varied. The molding step can be by
thermoforming said pulp mixture. In one embodiment, said step of
forming said pulp mixture is performed at an elevated temperature
from about 35 C to about 60 C, or from about 50 C to about 55 C. In
another embodiment, said step of molding comprises thermoform
molding said pulp mixture at a temperature of from about 180 C to
about 220 C, or about 200 C and a pressure of from about 28 tons to
about 32 tons, or about 30 tons.
[0032] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0033] Every document cited herein, including any cross referenced
or related patent or application is hereby incorporated herein by
reference in its entirety unless expressly excluded or otherwise
limited. The citation of any document is not an admission that it
is prior art with respect to any invention disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
invention. Further, to the extent that any meaning or definition of
a term in this document conflicts with any meaning or definition of
the same term in a document incorporated by reference, the meaning
or definition assigned to that term in this document shall
govern.
[0034] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
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