Process for the manufacture of paperboard cartons

1. A process for forming a carton from paperboard stock comprising the steps:

applying an aqueous based adhesive to select parts of a paperboard carton blank obtained from a paperboard feedstock;

drying the aqueous based adhesive;

folding the select parts of the adhesive coated carton blank onto cooperating parts of the paperboard blank; and,

heat sealing the select and cooperating parts thereby forming the carton;

wherein the aqueous based adhesive is comprised of a semi-crystalline vinyl acetate/ethylene polymer emulsion formed by emulsion polymerization and having

(a) a crystalline melting point (T m ) ranging from 35 to 110° C., measured at a heat rate of 20° C./minute and,

(b) a tensile storage modulus of at least 1×10 4 dynes/cm 2 at 115° C. measured at 6.28 rad/sec.

2. The process of claim 1 wherein the polymer emulsion is comprised of a polymer comprised of from 15 to 90% by weight of polymerized units of vinyl acetate and from 10 to 85% by weight of polymerized units of ethylene based upon the total weight of the polymer.

3. The process of claim 1 wherein the polymer is comprised of from 25 to 80% by weight of polymerized units of vinyl acetate and from 20 to 75% by weight of polymerized units of ethylene based upon the total weight of the polymer.

4. The process of claim 1 wherein heat sealing is effected by contact with hot air.

5. The process of claim 1 wherein the polymer is comprised of 15 to 80% by weight of polymerized units of vinyl acetate, 20 to 85% by weight of polymerized units of ethylene, and 0 to 10% by weight of polymerized units of another monomer, based on the total weight of the polymer.

6. The process of claim 5 wherein polymerized carboxylic acid units are present in the polymer in an amount from 0.2 to 10% by weight of the polymer.

7. The process of claim 6 wherein the polymer consists essentially of polymerized units of vinyl acetate, ethylene, and acrylic acid.

8. The process of claim 1 wherein the crystalline heat of fusion of the polymer is from 5 to 100 joules per gram as measured at a heat rate of 20° C. per minute.

9. The process of claim 8 wherein the glass transition temperature of the polymer is from +25° C. to −40° C. as measured at a heat rate of 20° C. per minute.

10. The process of claim 9 wherein the crystalline thermal melting point ranges from 50 to 90° C. as measured at a heat rate of 20° C. per minute.

11. The process of claim 1 wherein the polymer is comprised of from 35 to 75% by weight of polymerized units of vinyl acetate and from 25 to 65% by weight of polymerized units of ethylene, based upon the total weight of the polymer.

12. The process of claim 1 wherein the polymer is comprised of from 30 to 50% by weight of polymerized units of vinyl acetate and from 50 to 70% by weight of polymerized units of ethylene, based upon the total weight of the polymer.

13. The process of claim 1 wherein the polymer is non-blocking at temperatures of 75° C. or less.

14. The process of claim 1 wherein the polymer is non-blocking at temperatures of 50° C. or less.

15. A process for forming a carton from paperboard stock comprising the steps:

applying an aqueous based adhesive to said paperboard feedstock;

drying the aqueous based adhesive;

forming a paperboard carton blank from the adhesive coated paperboard feedstock;

folding select parts of said paperboard carton blank onto cooperating parts of the paperboard blank; and,

heat sealing the select and cooperating parts thereby forming the carton;

wherein the aqueous based adhesive is comprised of a semi-crystalline vinyl acetate/ethylene polymer formed by emulsion polymerization and having

(a) a crystalline melting point (T m ) ranging from 35 to 110° C., measured at a heat rate of 20° C./minute and,

(b) a tensile storage modulus of at least 1×10 4 dynes/cm 2 at 115° C. measured at 6.28 rad/sec.

16. The process of claim 15 wherein the polymer is comprised of from 15 to 90% by weight of polymerized units of vinyl acetate and from 10 to 85% by weight of polymerized units of ethylene based upon the total weight of the polymer.

17. The process of claim 15 wherein the polymer is comprised of from 25 to 80% by weight of polymerized units of vinyl acetate and from 20 to 75% by weight of polymerized units of ethylene based upon the total weight of the polymer.

18. The process of claim 15 wherein the drying of said adhesive is effected by contact with hot air.

19. The process of claim 15 wherein the polymer is comprised of 15 to 80% by weight of polymerized units of vinyl acetate, 20 to 85% by weight of polymerized units of ethylene, and 0 to 10% by weight of polymerized units of another monomer, based on the total weight of the polymer.

20. The process of claim 19 wherein polymerized carboxylic acid units are present in said polymer in an amount from about 0.2 to 10% by weight of the polymer.

21. The process of claim 15 wherein the crystalline heat of fusion of the polymer is from 5 to 100 joules per gram as measured at a heat rate of 20° C. per minute.

22. The process of claim 15 wherein the crystalline heat of fusion ranges from 15 to 70 joules per gram as measured at a heat rate of 20° C. per minute.

23. The process of claim 15 wherein the polymer is non-blocking at temperatures of 75° C. or less.

24. The process of claim 15 wherein the polymer is non-blocking at temperatures of 50° C. or less.