Granted Patent B2

US 8,578,684 · App. 13/423,692 · Granted Nov 12, 2013

Abstract

Claims (26)

1. A method of manufacturing a unitized package comprising a printed base card and a fluid vessel, comprising:

(a) providing a printed base card;

(b) forming a fluid vessel by:

(i) forming a portion of a first laminate barrier layer of the fluid vessel into a modified dome shape with a defined volume by biaxial elongation of the first laminate barrier layer, wherein the first laminate barrier layer comprises at least one layer of a biaxially oriented thermoplastic polymer and a portion that is planar;

(ii) depositing a product material onto the first laminate barrier layer such that the product material substantially fills the defined volume;

(iii) disposing a second laminate barrier layer of the fluid vessel on the first laminate barrier layer, wherein the second laminate barrier layer is planar;

(iv) sealing the first and second laminate barrier layers together at their perimeters to form a fluid-tight enclosure for containing the product material; and

(c) permanently bonding the second laminate barrier layer of the fluid vessel to a portion of the printed base card.

2. The method of claim 1 , wherein the modified dome shape of the first laminate barrier layer is resiliently sustainable when the fluid vessel is sealed.

3. The method of claim 1 , wherein the biaxially oriented thermoplastic polymer comprises one or more of a polyethylene, a polypropylene, a polyester, a polyamide, a polyacrylate, or a mixture thereof.

4. The method of claim 3 , wherein the biaxially oriented thermoplastic polymer comprises a polyethylene terephthalate.

5. The method of claim 1 , wherein one or both of the first and second laminate barrier layers comprise a layer of aluminum foil.

6. The method of claim 5 , wherein the aluminum foil is less than about 0.001 inches in thickness.

7. The method of claim 1 , wherein the first and second laminate barrier layers are sealed together by heat sealing.

8. The method of claim 1 , wherein the first and second laminate barrier layers are sealed together with an adhesive.

9. The method of claim 1 , wherein step (i) comprises applying gas pressure to the first laminate barrier layer to form the modified dome shape.

10. The method of claim 9 , wherein the gas pressure is about 10 psi to about 140 psi.

11. The method of claim 9 , wherein the gas pressure is applied for a time period ranging from about 0.01 seconds to about 1 seconds.

12. The method of claim 1 , wherein the fluid vessel comprises a dispensing tip.

13. The method of claim 12 , further comprising die cutting the base card to form an opening strip defined by a first line of perforation, wherein the line of perforation intersects the dispensing tip.

14. The method of claim 13 , wherein the first and second laminate barrier layers are sealed together at their perimeters to form the fluid-tight enclosure and a planar extension tab, wherein the planar extension tab encloses the dispensing tip and overlays the opening strip.

15. The method of claim 13 , wherein the base card comprises a second line of perforation intersecting the dispensing tip, in which the second line of perforation defines a folding flap.

16. The method of claim 15 , wherein the base card comprises one or more locking tabs under which the folding flap may be inserted.

17. The method of claim 12 , wherein the dispensing tip is reclosable.

18. The method of claim 1 , wherein the base card is less flexible than the first laminate barrier layer.

19. The method of claim 1 , wherein the base card comprises a paper stock.

Assignments (11)