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.

Description

FIELD OF THE INVENTION

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

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.

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.

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

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.

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

FIG. 1 is a perspective view of a consumer product package having a cover.

FIG. 2A is a side view of a stabilizing insert that may be incorporated into the display package of FIG. 1.

FIG. 2B is a perspective view of the optional stabilizing insert of FIG. 2A in a second position.

FIG. 3 is a side view of a consumer product with the stabilizing insert of FIG. 2B.

FIG. 4 is perspective view of a tub that may be incorporated into the display package of FIG. 1.

FIG. 5 is perspective view of the consumer product package of FIG. 1 without a cover.

FIG. 6 is a side view of a plurality of consumer product packages arranged on a shelf.

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

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.

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.

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.

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.

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.

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.

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).

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).

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).

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.

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.

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.

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.

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.

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.

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.

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.

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.”

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.

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.

Claims

1. A laminate structure for containing a consumer product comprising 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.

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,

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.