MX2014010197A - Unitized package and method of making same. - Google Patents

Abstract

The invention generally relates to unitized packages for containing and dispensing a product material. In particular, the unitized packages comprise a printed base card and a fluid vessel permanently bonded to the printed base card. The fluid vessel comprises a first laminate barrier layer comprising at least one layer of a biaxially oriented thermoplastic polymer, a portion of which is formed into a modified dome shape, and a planar second laminate barrier layer. The first and second laminate barrier layers are sealed together to form a fluid-tight enclosure, wherein the product material substantially fills the enclosure and the modified dome shape is resiliently sustainable. A method of manufacturing the unitized packages as described above is also provided. In particular, the method includes forming a portion of the first laminate barrier layer comprising the biaxially oriented polymer into the modified dome shape using a force such as pressurized gas.

Description

UNIFIED PACKAGING AND MANUFACTURING METHOD FIELD OF THE INVENTION The invention relates generally to unified packages for containing and dispensing a product material. In particular, the unified packages comprise a printed base card and a fluid container permanently attached to a portion of the base card. The fluid container comprises a first barrier layer of laminated material comprising at least one layer of a biaxially oriented thermoplastic polymer, a portion of which is formed in a modified dome configuration and a second barrier layer of flat laminate material. The invention also relates to methods for manufacturing such unified packages.

BACKGROUND OF THE INVENTION Compressed containers are used in the packaging and supply of various formulations of cosmetics, personal care and household products. Metal tubes are an example of such containers. The metal tubes are hermetic and therefore offer protection to the materials of products contained in the tubes through long periods of storage. However, metal, such Like aluminum foil, it is difficult to form and often the manufacture of metal tubes is expensive.

The compressible containers have also been manufactured with plastics. Although their manufacture is relatively inexpensive, plastic containers do not provide the same level of protection to product materials as that provided by metal tubes due to the permeability of the plastic. As a result, the shelf life of the product materials contained in plastic containers is often shorter.

Flexible packages or bags, such as those used for condiments, are another example of a compressible plastic container. More recently, low volume bags have been manufactured to include a top section that is flat and unfilled without the product materials expanding their visual presence and graphic message. However, such flexible bags have a series of drawbacks. For example, the upper section of the flexible bags lacks sufficient rigidity and causes thermal distortion. In addition, since the product materials are generally distributed along a two-dimensional zone in large part, it is difficult to produce a desired fluid flow from the material of the product towards the opening of the bags. The distribution of high viscosity fluids is particularly problematic. Due to the lack of any form defined three-dimensional, flexible bags require a larger surface area to store a given volume of product material, which is often accompanied by a greater transmission of vapor by the surface area, a greater tendency to phase separation (particularly if the material of the product is an emulsion) and a greater potential to lose the material of the product due to the screening by the packaging of thermoplastics.

In addition, low-volume compressible containers often suffer from lack of visual appeal and difficulty placing them for retail sale. In particular, said compressible containers lack sufficient surface to accommodate text messages or graphics for promotional or instructional purposes. As a result, they must be packed with a secondary container such as a printed cardboard box or a blister pack containing the required text messages or graphics. However, since such compressible containers must be separated from the secondary container before use, the promotional or instructional messages printed on the secondary container are ignored or lost before use.

Therefore, there is a need for an improved compressible package that provides adequate vapor barrier characteristics and shelf life; it is capable to maintain a predetermined shape with sufficient stiffness before use; allows the supply of the material of the product in a controlled manner; and ensures the presence of promotional or instructional messages at the time of use. An economical and efficient process is also necessary to manufacture said compressible package.

SUMMARY OF THE INVENTION The present invention provides a unified package, which includes a base card and a fluid container that is permanently attached to a portion of the base card.

In one embodiment, the unified package comprises a printed base card and a fluid container. The fluid container comprises a first laminated barrier layer comprising at least one layer of a biaxially oriented thermoplastic polymer, a product material and a second barrier layer of laminated material. A portion of the first barrier layer of laminate material is formed in a modified dome configuration with a defined volume. The material of the product substantially fills the defined volume. The first barrier layer of the laminate and the second barrier layer of laminate material are sealed together at their perimeters to form a fluid-tight housing to contain the material of the product. The second barrier layer of laminated material the fluid container is permanently attached to a portion of the printed base card.

Preferably, the modified dome configuration of the first barrier layer of laminate material is elastically sustainable when the fluid container is sealed.

The biaxially oriented thermoplastic polymer may comprise a polyethylene, a polypropylene, a polyester, a polyamide, a polyarylate, or a mixture thereof. In a preferred embodiment, the biaxially oriented thermoplastic polymer comprises polyethylene terephthalate.

In one embodiment, one or both of the first and second barrier layers of laminated material comprises an aluminum foil layer. Preferably, the aluminum sheet is less than about 0.0254 mm thick.

The material of the product is preferably a liquid.

In another embodiment, the fluid container further comprises a delivery tip. The base card comprises an opening strip defined by a perforation line that crosses the supply tip. Once the opening strip is removed, the product material can be supplied from the supply tip. In a Preferred embodiment, the liquid container also comprises a flat extension flange formed by the first and second barrier layers of laminated material. The extension tab encloses the supply tip and is placed on the opening strip. The supply tip can also be closed again.

Preferably, the base card is less flexible than the first laminate barrier layer of the fluid container. The base card may comprise coarse raw paper. In addition, one or both sides of the base card can be printed with any promotional or instructional message for marketing or regulatory compliance purposes.

In another mode, the unified package can be closed again. It consists of a printed base card; and a fluid container comprising (i) a first barrier layer of laminate material comprising at least one layer of biaxially oriented thermoplastic polymer, (ii) a product material, and (iii) a second barrier layer of material laminate. The first and second barrier layers of laminate material are sealed together at their perimeters to form a fluid-tight housing for containing the material of the product. The second barrier layer of laminate material is permanently bonded to a portion of the printed base card. In addition, the accommodation fluid-tight comprises a supply tip and the printed base card comprises a dotted line crossing the delivery tip. The dotted line defines a folding fin which, when folded along the dotted line, seals so that it can re-close the supply tip. In certain embodiments, the printed base card of the unified package comprises one or more closure tabs capable of receiving the folding flap.

In some embodiments of the unified package that is of the reclosable type, the thickness of the printed base card is about 0.20 mm or more or about 0.254 mm or more. In other unified packaging embodiments that are of the reclosable type, the first and second barrier layers of laminated material each have an inner surface. The supply tip is defined by portions of the inner surface of the first and second barrier layers of laminated material, in the embodiment, the thickness of the printed base card is such that when the fold flap is folded along the line marked to form a fold having a tension zone, the portions of the interior surfaces of the first and second barrier layers of laminate material defining the supply tip are substantially outside the point of the neutral fold and in the area of tension.

In addition, in some embodiments of the resealable type of package, a portion of the first laminate barrier layer has a modified dome configuration formed therein. The modified dome configuration has a defined volume and the material of the product substantially fills the defined volume. The second barrier layer of laminated material is flat.

An effective method in manufacturing costs of a unified package described above is also provided. In one embodiment, the method includes providing a printed base card, manufacturing a fluid container comprising a first barrier layer of laminated material and a second barrier layer of laminated material, and permanently attaching the fluid container to the card. of printed base. The fluid container is manufactured by: (i) forming a portion of the first barrier layer of laminate material, comprising at least one layer of a biaxially oriented thermoplastic polymer, in a modified dome configuration with a defined volume; (ii) depositing a product material on the first barrier layer of laminate material such that the material of the product substantially fills the defined volume; (iii) placing the second barrier layer of laminated material, which is flat, in the first layer of Laminated material barrier; and (iv) sealing the first and second barrier layers of laminated material together at their perimeters to form a fluid-tight housing for containing the material of the product. Preferably, the modified dome configuration of the first barrier layer of laminate material is elastically sustainable when the fluid container is sealed.

The biaxially oriented thermoplastic polymer may comprise a polyethylene, a polypropylene, a polyester, a polyamide, a polyarylate, or a mixture thereof. Preferably, the biaxially oriented thermoplastic polymer comprises polyethylene terephthalate.

In one embodiment, one or both of the first and second barrier layers of laminated material comprise an aluminum foil layer. Preferably, the aluminum sheet is less than about 0.0254 mm thick.

In one embodiment, the first and second barrier layers of laminated material are sealed together by heat sealing. In another embodiment, the first and second barrier layers of laminated material are joined together by radio frequency energy, sonic energy, or an adhesive.

In a preferred embodiment, the modified dome configuration of the first barrier layer of laminated material is formed by the application of gas pressure to a portion of the first laminated barrier layer. The gas pressure may be from about 1054 kg / cm 2 to about 9,842 kg / cm 2 and the gas pressure may be applied for a period ranging from about 0.01 seconds to about 1.0 seconds.

In another modality, the fluid container further comprises a supply tip. The base card is cut with a die to form an opening strip defined by a perforation line. The opening strip, once removed, allows access to the product material from the supply tip. In a preferred embodiment, the first and second barrier layers of laminate material are sealed together at their perimeters to form the fluid-tight housing and a flat extension flange. The extension tab encloses the supply tip and is placed on the opening strip. The supply tip can be of the type that can be closed again.

Therefore, the present invention provides an improved compressible package. In particular, a biaxially formed oriented thermoplastic polymer is used to make the present package unified. A biaxially oriented thermoplastic polymer offers several advantages over other plastic materials traditionally used in thermoformed packaging, e.g., provides superior barrier characteristics in relation to its thickness and cost benefit. However, the biaxially oriented thermoplastic polymer is routinely rejected in known formation processes, in large part because its use requires a substantially greater force to be formed in a desired configuration and the profile formed obtainable is very limited.

It has been found that a barrier layer of laminated material comprising at least one layer of a biaxially oriented thermoplastic polymer can be sufficiently formed using the forming process described herein to provide a modified dome configuration without exceeding the stress value. end of the biaxially oriented thermoplastic polymer, thus retaining its superior barrier characteristic. Additionally, the present forming process increases the degree of biaxial orientation and resistance to further deformation of the biaxially oriented thermoplastic polymer. As a result, the formed modified dome configuration can be elastically held by the material of the product and / or gases contained in the unified package until the time of its use.

BRIEF DESCRIPTION OF THE FIGURES Figure 1 is a plan view of a first dality of a unified package.

Figure Ib is a cross-sectional view of the unified package of Figure la along A-A.

Figure 2 is a plan view of a second embodiment of a package unified with a fluid container of the reclosable type.

Figure 3a is a plan view of a lower plate for manufacturing the first barrier layer of laminated material of the unified package.

Figure 3b is a cross-sectional view of the lower plate of Figure 3a along B-B.

Figure 4a is a side view of a lower plate and an upper plate for manufacturing the first barrier layer of laminated material of the unified package, before applying pressurized gas.

Figure 4b is a side view of the lower and upper plates of Figure 4a, when the pressurized gas is initially applied.

Figure 4c is a side view of the lower and upper plates of Figure 4a, when the pressurized gas is fully applied.

Figure 5a is a plan view of a unified package embodiment.

Figure 5b shows the unified package of Figure 5a with the opening strip removed.

Figure 5c shows the fold flap of the unified package of Figures 5a and 5b in a folded position.

Figure 5d shows the fold flap of the unified package of Figures 5a to 5c inserted into the closure tabs.

Figure 6a is a cross-sectional view of one embodiment of a unified package with removed opening strip.

Figure 6b shows the fold flap of the unified package of Figures 6a in a folded position.

Figure 6c is an enlarged view of the fold flap in a folded position shown in Figure 6b.

DETAILED DESCRIPTION OF THE INVENTION 1. Unified Packaging The present package generally comprises a printed base card and a fluid container permanently attached to a portion of the base card. The fluid container comprises a first barrier layer of laminated material and a second barrier layer of laminate material that borders a product material. The first laminated barrier layer comprises at least one layer of a biaxially oriented thermoplastic polymer and is forms a portion of the first barrier layer of laminated material in a modified monolithic dome configuration. The second barrier layer of laminated material is flat.

The Figure shows a first modality of the present unified packaging. The unified package 10 includes a printed base card 20 and a fluid container 30. Figure Ib shows a cross-sectional view of the unified package 10 in Figure la along A-A. As shown in Figure Ib, the fluid container 30 comprises a first barrier layer of laminate material 40 and a second barrier layer of laminate material 50. The first barrier layer of laminate material 40 has an interior surface 42 and a outer surface 44. The second barrier layer of laminate material 50 has an inner surface 52 and an outer surface 54. The inner surface 42 of the first barrier layer of laminate material 40 and the inner surface 52 of the second barrier layer Laminated material 50 is sealed to each other on its perimeters, forming a fluid-tight housing 60. A material of the product 70 substantially fills the volume of the fluid-tight housing 60.

The first and second barrier layers of laminated material are barrier layers, that is, they are substantially inert and preferably impermeable to the material of the barrier. product contained in the fluid container in order to substantially avoid migration of components of the product material through the layers. Various types of plastic film with barrier properties, for example, polyethylene terephthalate ("PET"), celluloses or acetates, can be used to make the barrier layers of laminated material. Barrier layers of laminated material can also incorporate especially vapor barrier coatings to impart or improve their barrier characteristics. In addition, a material that does not have barrier properties can be coated or treated to give it barrier properties so that the material can be used to form the barrier layers of laminate material. Depending on the material components of the product, a barrier material may be chosen which is a barrier to, for example, oil, gas, water vapor, aroma, or oxygen.

The first barrier layer of laminated material and the second barrier layer of laminated material of the unified package are preferably constructed with thin barrier sheets of flexible thermoplastics. The first barrier layer of laminated material comprises at least one layer of a biaxially oriented thermoplastic polymer. A biaxially oriented thermoplastic polymer is a polymer that has been stretched in two directions (ie, machine direction and cross machine direction) in conditions that result in the reorientation of the polymer. As a result of such orientation of the polymer, the barrier characteristics and physical strength of the polymer are improved. A biaxially oriented thermoplastic polymer has a substantially high tensile strength, either in the machine or the transverse direction of the machine, and is generally resistant to further elongation.

Suitable biaxially oriented thermoplastic polymers include, but are not limited to, polyesters, polyamides that include articles of nylon and amorphous polyamides, polyarylates, polypropylenes, polyethylenes, or mixtures thereof.

A preferred biaxially oriented thermoplastic polymer is a polyester such as polyethylene terephthalate (PET), which is sold under the trade name manufactured by DuPont MYLAR® Tejlin Films, because of the comparable strength and elongation characteristics of the polyester film throughout. the directions of the machine and cross machine. Other preferred biaxially oriented thermoplastic polymers include, but are not limited to, polyamides such as nylon film, which is sold under the trade name Capran Emblem® manufactured by Honeywell and oriented polypropylene films biaxially (BOPP), such as those manufactured by Exxon-Mobil.

In addition, the first and second laminated barrier layers may each comprise more than one layer of mixed materials.

The first and second barrier layers of laminated material can also incorporate metallic, semi-metallic, metal oxide or ceramic materials to improve the moisture vapor characteristics of these layers. Examples of such a rolling construction may include those manufactured in accordance with the U.S. military specification. Mil-B-131 Class I, as well as many commercial laminate materials such as those used for medical diagnostic tests or the distribution of food service condiments.

In one embodiment, each of the first and second barrier layers of laminate material may comprise a thin gauge metal layer. The metal layer, such as an aluminum foil layer, provides low moisture vapor transmission rates that are desired in compressible containers. Any grade of aluminum can be used, although those that are more malleable are preferred. A particularly preferred aluminum is a thin gauge aluminum layer which does not cause the loss of the desirable elastic characteristics of the Sealed fluid is not easily affected or damaged in any way in transportation, and yet it provides the desired reduction in moisture vapor or oxygen transmission rate.

In one embodiment, the first barrier layer may comprise an inner thermoplastic heat seal layer having a thickness in the range of about 0.0027 mm to about 0.101 mm and an outer layer of a biaxially oriented thermoplastic polymer film having a thickness in the range from about 0.0101 mm to about 0.050 mm. An additional barrier layer, preferably an aluminum foil layer, with a thickness in the range of about 0.0068 mm to about 0.0254 mm may also be included between the thermal seal layer and the biaxially oriented thermoplastic film. Preferably, the outer layer is constructed with a biaxially oriented polyester polymer film with a thickness in the range of about 0.0123 mm to about 0.023 mm.

The second barrier layer of laminated material may have the same or different compositions as the first barrier layer of laminated material. Because the second barrier layer of laminated material is not formed, the use of a biaxially oriented thermoplastic film in the structure is not required.

As shown in Figure Ib, the first barrier layer of laminated material 40 has a modified monolithic dome configuration formed therein. The terms "modified dome configuration" "modified monolithic dome configuration", as used in this application, refers to any suitable three-dimensional protrusion with a uniform surface of a planar base, and include, but are not limited to, a hemispherical configuration, a low profile sphere configuration (for example, the height of the profile is smaller than the radius of the base in the case of a circular base), or a toroidal shape. Preferably, the modified dome configuration is a low profile sphere configuration, such as that shown in Figure Ib.

The planar base of the modified dome configuration can have any desired configuration, preferably a rounded configuration and any desired dimensions. The modified dome configuration in Figure has a circular base. Other suitable bases of the modified dome configuration include, but are not limited to, ovals, ellipses, or simple squares or rectangles with dim radius corners (as shown in Figure 2).

Any of the portions of the first barrier layer of laminate material that do not have the modified dome configuration formed (i.e., the portions that surround the flat base of the formed configuration) are preferably flat. Preferably, the second barrier layer of laminated material is also flat.

The material of the product can be any material that is suitable to be packaged and distributed in a unified package. Preferably, the material is a substantially unadulterated cosmetic product, personal care product, medical product, or home product. Examples include face cream, shampoo, toothpaste, liquid medication and detergent. Substantially adulterated products include any product material that is presented in its original or natural form, without being altered in any significant way. The material of the product can be presented in any suitable form, such as in a gel form, in powder form, in microcapsules, contained in a matrix material, or, preferably, in a liquid form. In addition, the product material may comprise volatile and / or non-volatile components. The quantity or volume of the material of the product may be suitable as a sample, or for individual or multiple uses.

Preferably, the material of the product substantially fills the volume defined by the modified dome configuration of the first barrier layer of laminated material.

The first and second barrier layers of laminated material 40 and 50 are sealed together at their perimeters. As shown in Figure Ib, the inner surface 42 of the first barrier layer of laminate material 40 and the inner surface 52 of the second barrier layer of laminate material 50 are sealed to each other on their perimeters, forming an airtight housing to the fluids 60 to contain the product material 70. The seal can be formed using any suitable method, such as by heat sealing, radio frequency or sonic energy, or by means of adhesives. Preferably, the seal is a permanent seal. Permanent seals, also known as self-destruct or detachment joints, can be formed by the methods described above.

The adhesives must be compatible with the material of the product, that is, they must not react or be plasticized when they come into contact with the material of the product or with the components of the material of the product. This reaction can cause undesirable deterioration of the product material or sealing.

In one embodiment, at least one of the internal surfaces 42 and 52 comprises a pressure-sensitive adhesive, such as a low-odor pressure-sensitive adhesive that has been applied from a base emulsion. of water. The pressure sensitive adhesive can cover the entire contact area between the first barrier layer of laminate material and the second barrier layer of laminate material. Alternatively, the adhesive can be applied in a specific pattern of lines or dots. Another example specialty grades of hot melt adhesive, especially those that can provide interlacing functionality. Also, the adhesives can be formulated to provide additional barrier properties. Such adhesives may contain agents such as oxygen scavengers or consist of film-forming precursors of high barrier materials, such as latex grade polyvinylidene chloride (PVDC).

If a permanent seal is used, the unified package 10 must also be provided with a means for opening the fluid container 20, such as by detachment from one of the first barrier layer of laminate material or the second barrier layer of laminate material. , or both. The opening means may include a supply tip 100 as shown in Figure 1, a slot or a chain to cause or facilitate detachment. The opening means can also be of the type that can be resealed or resealed.

When the first and second barrier layers of laminate material 40 and 50 are sealed together at their perimeters to form a fluid-tight housing 60, the material of the product 70 substantially fills the volume of the housing (i.e., the volume defined with the modified dome configuration formed of the first barrier layer of laminated material) and leaves in the housing a minimum upper space (i.e., the space that is occupied by ambient air). By using the defined volume of the housing to the fullest degree, maximum stability of the contained product material can be achieved. In addition, the material of the product, especially when in the housing in the form of liquid and other fluids (i.e., liquid or gas), if any, provide internal pressure and force to maintain the formed configuration of the first barrier layer. laminated material. In this way, when sealing the fluid container, the shaped dome configuration formed by the first barrier layer of laminated material is elastically sustainable, i.e., the layer will show deformation by less pressure when force is applied to its outer surface, but it will be restored substantially automatically to its original form by releasing force. Also once formed and sealed, the fluid container is resistant to bending and can contribute to the stiffness of the base card.

In a preferred embodiment, the interior surface 42 of the first barrier layer of laminate material 40 is heat sealed to the interior surface 52 of the second barrier layer of laminate material 50 before joining the fluid container 30 to the lamination card. base 20.

The outer surface 54 of the second barrier layer of laminate 50 is permanently bonded to a portion of the base card 20. The second barrier layer of laminate material may be bonded with a lamination adhesive, or by any other means of suitable adhesives, such as by means of adhesives activated by heat, moisture, pressure, drying or radiation curing. In one embodiment, a complete purge adhesive system is incorporated in the exterior surface 54 of the second barrier layer of laminate material 50. Preferably, the entire purge adhesive system comprises a permanent pressure sensitive adhesive, such as an acrylic adhesive. sensitive to permanent pressure. The permanent pressure sensitive adhesive can be covered and protected by a release liner such as a disposable silicone coated release liner.

Any desired material can be used for the manufacture of the base card. Since the accommodation formed by the first and second barrier layers of laminated material is fluid-tight and is also preferably formed prior to attachment to the base card, the base card material will not be exposed to the material of the product contained in the housing; nor will it be exposed to heat or other energies used for sealing the first and second barrier layers of laminate material. Suitable materials for the base card include, but are not limited to, raw paper, such as grade of cover or light gauge label material. You can also use synthetic raw paper or other plastic materials. Preferably, the base card comprises a raw paper material for environmental reasons and overall cost efficiency. Crude paper of different grades and compositions can be used, including recycled, colored, textured, coated or uncoated. In one embodiment, the base card is made from the grades of solid cardboard bleached to sulfite or coating material and has a thickness in the range of about 0.152 mm to about 0.609 mm. The base card can also be coated with various water-cured or energy-cured polymer coatings, or overlaminated with thermoplastic films to protect raw paper and printed graphics against moisture damage.

Preferably, the base card has a sufficiently large surface that extends beyond the fluid container so that any desired artwork, text, graphics, product information or information can be printed on any surface of the base card. instructions, or information on drug ingredients. In addition, the fluid container can be placed or sized so that sufficient surface area on the base card is available to achieve brand promotion, consumer education or compliance with all applicable regulatory requirements such as those imposed by the US Food and Drug Administration Since the fluid container is permanently attached to the printed base card, the presence of any marketing product or instructional information printed on the base card is assured at the time of its issuance. use.

The printed base card can be of any suitable dimension or configuration as long as it is not a flat surface so that the fluid container can be permanently attached. As shown in Figure la, the printed base card can be flat. The printed base card can also be dotted or somehow folded to form a 4 or 6 common page format. Such configuration functions to increase substantially the useful surface of the base card, while limiting the dimensions of the finish. The printed base card can also be folded so that it can be placed upright. The base card may also comprise a portion of a built-in panel such as a part of a die cutting box or a greeting card. As a further example, the folded base card can provide reduced final dimensions to facilitate placement of the unified package in an existing guest container or that is within the scope of the U.S. desired. The base cards may also contain a hanging hole for detailed viewing purposes for retail sale.

As shown in Figure la, the printed base card 20 may have an opening strip 80 defined by a perforation line 90 intersecting the supply tip 100. When the opening strip 80 is removed by peeling or cutting as Along the perforation line 90, the fluid container 30 will open, thus allowing access to the material of the product 70.

The fluid container 30 may also comprise a flat extension flange 110 that is permanently attached to the printed base card 20. As shown in Figure 1, the extension flange 110 is formed from the first barrier layer of laminate material 40 and from the second barrier layer of laminate material 50. The delivery tip 100 is confined between the lower edge 112 and the upper edge 114 of the extension flange 110. The flange extension 110 is placed on the opening strip 80, with its lower edge 112 and the perforation line 90 is superimposed on the printed base card 20. Therefore, when the base card is peeled off or cut along the length of the perforation line 90, extension tab 110 and opening strip 80 can both be removed and product material 70 can be accessed.

The printed base card may also incorporate a feature into the fluid container to be resealed or resealed. The manufacturing method and the unified design of the present invention is highly advantageous to achieve this desirable function. The manufacturing cost and the reliability of the closure provided by this modality are highly effective compared to that of the previous devices. For example, as shown in Figure 2, the printed base card may incorporate two intersecting lines of the supply tip 100. The first line 120 is a perforation and defines an opening strip 80. The second line 130, is a dotted line and defines a folding flap 140. The distance between the two lines can be any desired distance. In certain embodiments, the distance is preferably about 6.35 mm or more, or about 12.7 mm or more.

The printed base card of the product embodiment shown in Figure 2 can be of any thickness determined to adequately provide the stiffness and thickness necessary to ensure that it works. In certain embodiments, the thickness of the printed base card is about 0.127 mm or greater; about 0.20 mm or greater; or about 0.254 mm or more. The fluid container is reclosed by folding the printed carrier card and the corresponding supply tip along dotted line 130. In a preferred embodiment, the fold flap 140 is folded or folded so that the card The printed carrier is folded completely on itself. Alternative designs also include folding or flexing the carrier card to form a right angle. The printed carrier is designed in such a way that it is ensured that after bending, the supply tip of the fluid container is at the outer corner of the fold.

The base card further contains design means for retaining the printed support in a bent state in order to ensure the sustained tension of the flexible barrier layers and the proper seal. According to the modality illustrated in Figure 2, the base card further contains at least one closure flange 145. When the open unified packaging of Figure 2 is not in use, the fold flap 140 can be folded along the dotted line 130 and inserted below the closing tabs 145, thus preventing the product 70 from being released from the housing 60.

Various alternative means for retaining the printed support in a folded state can be used in addition to the embodiment illustrated in Figure 2 without departing from the spirit of the invention. For example, pressure-sensitive tape tabs, disabled bent wire closures, cords and buttons, loops and hooks may be used. The dotted fold line 130 can also be retained by the incorporation of printed carrier designs that include composite pleats, or slip and sleeve designs.

Figures 5A through 5D illustrate the manner in which the foldable flap of a unified package is folded or bent and inserted into one or more closure tabs. Figure 5a shows a unified package 10 having two lines that intersect with the supply tip 100. The perforation line 120 defines an opening strip 80. The marked line 130 defines a folding flap 140. In Figure 5b, the aperture strip 80 has been eliminated along perforation line 120. In Figure 5c, crease tab 140 it is folded along the dotted line 130 to seal so that the supply tip 100 can be closed again, which prevents the product contained in the fluid-tight housing 60 from being released from the housing. Distribution can be opened by unfolding the fold. The supply tip can be repeatedly sealed and opened. In Figure 5d, the fold flap 140 is inserted into one or more closure tabs 145. In other embodiments, the fold flap does not have to be inserted into any closure flap.

By folding the printed support and the assembled delivery tip it places the first and second barrier layers of laminated material of the container in a state of static tension around the radius of flexure. The thickness of the printed support is most desirably selected with the intention of placing the portions of the interior surfaces of the flexible barrier layers defining the supply tip or nozzle to be substantially outside the point of the neutral fold and in the tension zone of the unified packing on dotted line 130. Although the main stress applied to the barrier layer of laminate material is in a direction perpendicular to dotted line 130, there is also a tendency for a secondary physical response that results in barrier layers of laminated material are also under tension in the direction parallel to the dotted line 130. This secondary tension advantageously serves to uniform and further narrow the portions of the internal surfaces of the first and second barrier layers of laminate material defining the supply tip or nozzle. The result is a fluid-tight mechanical seal capable of resisting penetration or migration by even lower viscosity fluid materials.

Figure 6a shows an embodiment of a unified package 10, comprising a supply tip 100. A portion of the inner surface of the first laminate barrier layer 42a and a portion of the inner surface of the second barrier layer laminate material 52a defines supply tip 100. Printed card holder or base 20 has a dotted line 130. In Figure 6b, fold flap 140 is folded along dotted line 130 to form a crease or fold. bending 130a. When the fold flap 140 is folded, the portions of the inner surfaces of the first and second barrier layers of laminate material defining the delivery tip 42a, 52a come into contact with each other along an interface 133. The Figure 6c is an elongated view of the fold 130a of Figure 6b. In the crease 130a, the first and second barrier layers of laminated material 40, 50 are in tension and the printed support 20 is under compression. He The thickness of the printed support 20 is selected such that the portions of the inner surfaces of the first and second barrier layers of laminate material defining the delivery tip 42a, 52a are substantially outside the neutral point of the fold 130a, (which is not it is under tension or compression), and in the tension zone of the unified packing on dotted line 130.

The practical application of a re-closing feature in a current unified packaging mode is commercially viable due to the method of construction and manufacture of the unified package. More significantly, it forms, fills, seals and then the fluid container is attached to a flat support substrate. The thickness, rigidity and physical nature of the support do not influence the sealing process. In addition, the bonded process advantageously does not require the use of heat. Moreover, the joining method allows full, smooth and uniform contact between the flat surface of the printed support and the barrier laminate. The strength, uniformity and continuity of this joint is important for the ability of the supply tip to achieve a hermetic seal to the fluids when flexing.

II. Manufacturing method of the unified packaging The present unified packages can be manufactured using various methods. The methods generally include the following stages of manufacture: providing a printed base card; form a fluid container; and permanently attaching the fluid container to a portion of the printed base card. In general, the fluid container is manufactured by forming a portion of the first barrier layer of laminate material in a modified dome configuration; deposit the material in the volume defined by the modified dome configuration; placing the second barrier layer of laminated material on the first barrier layer of formed laminate material; and sealing the first barrier layer of laminate material and the second barrier layer of laminate material together at their perimeters to form a fluid-tight housing for containing the material of the product. The materials described above in Section I for unified packaging can also be used in the method.

The printed base card can be formed before or after the manufacture of the liquid container. Preferably, the printed base card is formed prior to manufacture of the fluid container.

As described above, the base card can be made of a variety of substrates, preferably of solid bleached sulfite board grades or raw paper. Texts or graphics with respect to product information may be printed or otherwise decorated on any surface of the base card using any suitable method. Preferred printing methods include, but are not limited to, sheet feed offset, mesh offset, digital image creation. The surface of the printed base card may also be coated with a UV cured polymerization coating, film lamination, or alternative coatings to impart water resistance and improved layup character to the base card material.

In one embodiment, the base card is further cut by precision punch to form a perforation line or other dotted line by defining an aperture strip that facilitates the clean opening of the fluid container.

Any suitable method can be used to manufacture the fluid container of the present package. The various steps for forming the fluid container can be carried out continuously in different stations of a manufacturing sequence. The container of fluid can be manufactured individually or, more preferably, in multiple quantities. An example of a method for manufacturing multiple fluid containers is described below.

The first laminated barrier layer 40 of the fluid container can be cold formed in the first station of the manufacturing sequence. Any suitable tensile force can be used in the cold forming process, for example, fluid pressure or vacuum. Preferably, the tension force is pressurized gas.

Figures 3a to 4c show an example of an assembly in a first manufacturing station that can be used to form the modified dome configuration in the first barrier layer of laminate material. As shown in Figure 4a, the first manufacturing station is composed of an assembly of high pressure plates with two opposed surfaces, ie, an upper plate 150 and a lower plate 160. Preferably, vertical movement of at least one of the upper or lower plates.

The upper surface of the lower plate 160 comprises a plurality of liners 170 with a uniform profile. Each of the coatings contains a cavity 180. Figures 3a-4c show one such front 170. The Coating can be manufactured with any suitable elastic material using any suitable method. Preferably, the coating is made of silicone rubber with a hardness value in the range of about 40 to about 80 and a thickness in the range of about 3.17 mm to about 6.3 mm. The silicone rubber face can be used as the bottom plate face or further laminated or bonded in some way to a malleable and pressure resistant material, eg, medium density fibreboard (MDF), to form the lower plate face 170. The lower plate face day thickness 170 can be adjusted in accordance with the specific design of the fluid container. For example, it is in the range of about 3.17 mm to about 25.4 mm.

The lower plate faces 170 may be cut or in some way malleable to form a plurality of cavities therein. Figures 3a-4c show a cavity 180. The planar configuration of the cavity 180 determines the configuration of the base of the modified formed dome configuration of the first barrier layer of laminate material, including, but not limited to, circles , ovals, ellipses or squares or rectangles with attenuated radius corners. The side wall 182 of the cavity 180, in general, a single cut perpendicular to the flat surface of the lower plate 160, which does not come into contact with the configuration formed by the first barrier layer of laminated material and, therefore, does not need to be polished. The cavity face of the lower plate operates in place of a forming die used otherwise in conventional thermoforming processes.

The lower surface of the lower plate face 170 is constructed to facilitate the limited flow of air between the lower plate face 170 and the lower surface of the lower plate 160. As shown in Figures 3a and 3b, each plate face lower 170 may comprise one or more vent holes 190.

As shown in Figure 4a, the upper plate 150 is equipped with air supply channels 200 corresponding to each cavity 180 in the lower plate faces 170.

The preferred manufacturing process uses intermittent mesh movement. The first barrier layer of laminate material 40 is drawn forward in the first station as a flat mesh in a horizontal orientation. The outer surface 44 of the first laminate barrier layer 40 faces downwards and engages with the bottom plate 160 and the interior surface 42 is engaged by the top plate 150. The top plate 150 and the bottom plate 160 are then coupled. by the force of and the first barrier layer of laminated material 40 is secured in the perimeters of the cavity 180 of the face of the lower plate 170.

The pressurized gas 210 is introduced into the upper plate 150 through the air supply channels 200. As shown in Figure 4b, as the pressure of the fluid gas imposed on the inner surface 42 of the first barrier layer accumulates. of laminate material 40 (the presence of ventilation holes 190 in lower plate face 170 projects or reduces any opposite pressure), the portion of the first barrier layer of laminate material 40 within side wall 182 of cavity 180 begins to deform under tension and protrude into cavity 180 to form a modified dome configuration. The gas pressure is controlled such that the force of the corresponding tension does not exceed the ultimate tensile strength of the biaxially oriented thermoplastic polymer. As such, the deformation does not significantly alter the desirable physical properties of the original biaxially oriented thermoplastic polymer; instead, the degree of polymer orientation increases.

A suitable gas pressure is in the range of about 0.703 kg / cm2 to about 9.84 kg / cm2, preferably in the range of about 2.81 kg / cm2 to about 7.03 kg / cm2. Under this pressure, The first barrier layer of laminated material comprising a layer of biaxially oriented thermoplastic polymer can be subjected to a further biaxial elongation typically in the range of about 10 to about 25% before reaching its breaking point.

In Figure 4c, the gas pressure is fully applied. After the pressure reaches the desired level, the pressurized gas 210 is turned off and the pressure is removed. Less containment of the fluid formed container profile may occur subsequently due to the partial elastic recovery of the biaxially oriented thermoplastic polymer. This partial recovery is not detrimental to the resulting profile.

The modified dome configuration formed by virtue of the present process has a large radius of curvature extending from the flat base where the first barrier layer of laminated material is located before the forming process. The maximum depth of extension is highly influenced by the geometrical shape of the original flat area subject to the forming process (ie, the flat shape of the cavity 180), therefore, the configuration formed by the first barrier layer of material Laminate is a result of the response of the flat film of laminated material to the internal pressure. On the other hand, this shaped configuration is sustained elastically up to the time of its use by the internal gas or fluid inflation provided by the materials of the product and the ambient air confined in the fluid container, without the need for any rigid vertically oriented side wall to impart structural strength. Other portions of the first barrier layer of laminated material that have not undergone the forming process remain flat.

The use of a biaxially oriented thermoplastic polymer and pressurized gas allows controlled redistribution of the tensile force with progressive sliding of the polymer chain and prohibits mechanical "hot spots" that somehow weaken the film or cause ultimate failure. Additionally, since the biaxially oriented thermoplastic polymer is elongated under tension tension, the resistance to a greater elongation is increased. The increased orientation degree and the additional elongation resistance are also biaxial in nature. As a result, the stress polymer uniformly redistributes the strain deformation and prevents thinning of the polymer that would occur in some way. The biaxially oriented PET, with its mechanical values that are closely comparable in the machine and transverse to the machine, is a preferred biaxially oriented polymer. The use of elastic rubber on the plate The lower coating also avoids mechanical hot spots or stress points in the perimeter of the cavity 180 that can otherwise lead to stress failure. The present process eliminates complications and quality problems such as deformations, wrinkles or tears commonly associated with the stretching methods commonly used in training processes.

As described above, a thin gauge metal layer, such as an aluminum layer, can also be incorporated into the first barrier layer of laminate material. The presence of a biaxially oriented thermoplastic polymer in the same barrier layer of laminated material as the aluminum layer also prevents cracking or stress failure of the gauge metal during the forming process, since it distributes the tensile force during the formation process and avoids the elongation of metal located at the point of failure.

Other suitable methods may be used to apply pressure to the first barrier layer of laminate material to form the modified dome configuration therein.

Subsequent to the formation, the upper plate 150 is raised and the first formed laminated barrier layer 40 is advanced to the second station of the manufacturing sequence where the product material 70 is filled. For example, the product material 70 can be Dosing and discharging of the fluid nozzles mounted directly on the volume defined by each of the modified dome shapes. Dosing and pumping can take place while intermittent mesh movement is stopped and can be achieved by using a variety of appropriate pumping and dosing systems. The supplied product material preferably substantially fills the volume of the modified dome configuration formed. No material leveling of the product is required and the product material with higher viscosity can temporarily remain above the plane of the inner surface 42 of the first barrier layer of laminate material 40. Furthermore, by supplying the product material in the configuration of Modified shaped dome can prevent unwanted propagation to the outside of the material of the product that somehow occurs due to a pulse associated with the preferred intermittent mesh movement process.

At the next manufacturing station, a second barrier layer of laminated material 50 is then placed on the inner surface 42 of the first barrier layer of laminated material 40. Preferably, the second barrier layer of laminated material 50 comprises an adhesive sensitive to pressure on its inner surface 52, which is covered and protected by a release liner disposable silicone coated (not shown). The first and second barrier layers of laminate material 40 and 50 are then indexed and changed to a hot plate, where these two layers are sealed together at their perimeters to form a fluid-tight housing 60. The material of the product 70 it is automatically smoothed and redistributed in the housing 60 by the flat inner surface 52 of the second barrier layer of laminated material 50 just before or during the thermal sealing process. In a preferred embodiment, a supply tip 100 is formed by the use of a simple machined undercut on the lower surface of the hot top plate. The remaining seal takes place in such a way that only the flat portion of the first barrier layer of laminate material is hermetically sealed and the modified dome configuration is not altered.

The first and second barrier layers of laminated material are then cut by precision punch to form individual fluid containers. In a preferred method, the first and second barrier layers of laminate material are semi-cut together with a permanent full pressure purge-sensitive adhesive such as an acrylic permanent pressure sensitive adhesive against a release coating such as a coating disposable release coated with silicone. The containers of individual fluid are mounted in a predetermined pattern in the disposable release liner coated with silicone. Liquid containers are generally not flexible when sealed.

The fluid container is then permanently attached to the printed base card. This step can be achieved by any suitable method. In a preferred embodiment, the disposable silicone-coated release liner is removed and the second barrier layer of laminated material is attached to the base card by the permanent full pressure purifying permanent pressure acrylic adhesive.

The present unified packaging can be used as a product for single use or multiple uses. It can also be used as a sampling package. A consumer may open the fluid container, for example, by detaching the opening strip along the perforation line in the base card. The material of the product can then be supplied by applying a gentle pressure on the outer surface of the first barrier layer of the laminate. Because the perforation line provides a clean opening point of the fluid container, the product material can be supplied in a controlled manner. Alternative methods for opening the fluid container include, but are not limited to; to break the chains, detaching the tabs, tapping one or both of the laminated barrier layers such as with lasers, detaching the upper strips or breakable or removable perimeter seals. In addition, since the fluid container is permanently attached to the printed base card, any marketing or product information printed on the base card is readily available at the time of use.

The description contained in this document is for illustration purposes and not for limitation purposes. Changes and modifications can be made to the embodiments of the description and still be within the scope of the invention. In addition, all references cited above are incorporated herein, in their entirety, for all purposes related to this description.

Claims (46)

1. - A unified package comprising: (a) a printed base card; Y (b) a fluid container comprising (i) a first barrier layer of laminate material comprising at least one layer of biaxially oriented thermoplastic polymer, (ii) a product material, and (iii) a second barrier layer of laminated material, wherein a portion of the first barrier layer of laminated material has formed a modified dome configuration therein, the modified dome configuration has a defined volume, and the material of the product substantially fills the defined volume, wherein the second layer barrier of laminated material is flat, wherein the first and second barrier layers of laminated material are sealed together at their perimeters to form a fluid-tight housing for containing the material of the product, and wherein the second barrier layer of laminate material is permanently bonded to a portion of the printed base card.

2. - The unified package of claim 1, wherein the modified dome configuration of the first layer The barrier of laminated material is elastically sustainable when sealing the fluid container.

3. - The unified package of claim 1, wherein the biaxially oriented thermoplastic polymer comprises a polyethylene, a polypropylene, a polyester, a polyamide, a polyarylate, or a mixture thereof.

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

5. - The unified package of claim 1, wherein one or both of the first and second barrier layers of laminated material comprises a layer of aluminum foil.

6. - The unified package of claim 5, wherein the aluminum sheet is less than about 0.0254 mm thick.

7. - The unified package of claim 1, wherein the material of the product is a liquid.

8. - The unified package of claim 1, wherein the fluid container comprises a supply tip.

9. - The unified package of claim 8, wherein the base card comprises an opening strip.

10. - The unified package of claim 9, wherein the opening strip is defined by a perforation line intersecting the supply tip.

11. - The unified package of claim 9, wherein the fluid container further comprises a flat extension flange formed by the first and second barrier layers of laminate material, wherein the flat extension flange confines the supply tip and is placed on the opening strip.

12. - The unified package of claim 8, wherein the supply tip is of the type that can be reclosed.

13. - The unified package of claim 1, wherein the base card is less flexible than the first barrier layer of laminate material.

14. - The unified package of claim 1, wherein the base card comprises a raw paper.

15. - A method of manufacturing a unified package comprising a printed base card and a fluid container, comprising: (a) provide a printed base card; (b) forming a fluid container by: (i) the formation of a portion of a first barrier layer of fluid laminate material, in a modified dome configuration container with a defined volume, wherein the first barrier layer of laminate material comprises at least one layer of a biaxially oriented thermoplastic polymer; (ii) depositing a product material on the first barrier layer of laminate material such that the material of the product substantially fills the defined volume; (iii) placing a second barrier layer of laminate material of the fluid container over the first barrier layer of laminate material, wherein the second barrier layer of laminate material is flat; (iv) sealing the first and second barrier layers of laminated material together at their perimeters to form a fluid-tight housing for containing the product material; Y (c) permanently joining the second barrier layer of laminate material of the fluid container to a portion of the printed base card.

16. The method of claim 15, wherein the modified dome configuration of the first barrier layer of laminate material is elastically sustainable when the fluid container is sealed.

17. - The method of claim 15, wherein the biaxially oriented thermoplastic polymer comprises a polyethylene, a polypropylene, a polyester, a polyamide, a polyarylate, or a mixture thereof.

18. - The method of claim 17, wherein the biaxially oriented thermoplastic polymer comprises a polyethylene terephthalate.

19. - The method of claim 15, wherein one or both of the first and second barrier layers of laminated material comprises an aluminum foil layer.

20. - The unified package of claim 19, wherein the aluminum sheet is less than about 0.0254 mm thick.

21. - The method of claim 15, wherein the first and second barrier layers of laminated material are sealed to each other by heat sealing.

22. - The method of claim 15, wherein the first and second barrier layers of laminate material are sealed together with an adhesive.

23. - The method of claim 15, wherein step (i) comprises applying gas pressure to the first barrier layer of laminate material to form the modified dome configuration.

24. - The method of claim 23, wherein the gas pressure is from about 0.703 kg / cm2 to about 9.84 kg / cm2.

25. - The method of claim 23, wherein the gas pressure is applied for a period ranging from about 0.01 seconds to about 1 second.

26. - The method of claim 15, wherein the fluid container comprises a supply tip.

27. - The method of claim 26, further comprising die cutting the base card to form an aperture strip defined by a perforation line, wherein the perforation line intersects the supply tip.

28. - The method of claim 27, wherein the first and second barrier layers of laminate material are sealed together at their perimeters to form the fluid-tight housing and a flat extension flange, wherein the flat extension flange confines The supply tip and is placed on the opening strip.

29. - A unified package of the type that can be reclosed, comprising: (a) a printed base card; Y (b) a fluid container comprising (i) a first barrier layer of laminated material comprising at least one biaxially oriented thermoplastic polymer layer, (ii) a product material, and (iii) a second barrier layer of laminated material, wherein the first and second barrier layers of laminate material are sealed to each other on their perimeters to form a fluid-tight housing to contain the material of the product, wherein the second barrier layer of laminate material is permanently attached to a portion of the printed base card; wherein the fluid-tight housing comprises a supply tip and the printed base card comprises a dotted line intersecting the supply tip, wherein the dotted line defines a folding fin which when folded along the dotted line Seals the supply tip so it can be closed again.

30. - The unified package of claim 29, wherein the printed base card comprises one or more fastening tabs capable of receiving the folding flap.

31. - The unified package of claim 29, wherein the thickness of the printed base card is about 0.20 mm or greater.

32. - The unified package of claim 29, wherein the thickness of the printed base card is about 0.254 mm or greater.

33. - The unified package of claim 29, wherein the first barrier layer of laminate has an interior surface and the second barrier layer of laminate has an interior surface, and wherein the dispensing tip is defined by a portion of the inner surface of the first barrier layer of laminated material and a portion of the inner surface of the second lamination layer; Y wherein the thickness of the printed base card is such that when the fold flap is folded along the dotted line to form a fold having a tension zone, the portions of the inner surfaces of the first and second layers barrier of laminated material defining the supply tip are substantially outside the point of the neutral fold and in the tension zone.

34. - The unified package of claim 29, wherein the modified dome configuration of the first barrier layer of laminate material is elastically sustainable when the fluid container is sealed.

35. - The unified package of claim 29, wherein the biaxially oriented thermoplastic polymer comprises a polyethylene, a polypropylene, a polyester, a polyamide, a polyarylate, or a mixture thereof.

36. - The unified package of claim 29, wherein the biaxially oriented thermoplastic polymer comprises a polyethylene terephthalate.

37. - The unified package of claim 29, wherein one or both of the first and second layers of Laminated material barrier comprise a layer of aluminum foil.

38. - The unified package of claim 37, wherein the aluminum sheet is less than about 0.0254 mm thick.

39. - The unified package of claim 29, wherein the material of the product is a liquid.

40. - The unified package of claim 29, wherein the base card comprises an opening strip.

41. - The unified package of claim 40, wherein the opening strip is defined by a perforation line intersecting the supply tip.

42. - The unified package of claim 41, wherein the distance between the perforation line and the dotted line is about 6.35 mm or greater.

43. - The unified package of claim 29, wherein the fluid container further comprises a flat extension flange formed by the first and second barrier layers of laminate material, wherein the flat extension flange confines the delivery tip and is placed on the opening strip.

44. - The unified package of claim 29, wherein the base card is less flexible than the first barrier layer of laminate material.

45. - The unified package of claim 29, wherein the base card comprises raw paper.

46. - A unified package of the type that can be reclosed, comprising: (a) a printed base card; Y (b) a fluid container comprising (i) a first barrier layer of laminate material comprising at least one layer of biaxially oriented thermoplastic polymer, (ii) a product material, and (iii) a second barrier layer of laminated material, wherein a portion of the first barrier layer of laminate material has formed a modified dome configuration therein, the modified dome configuration has a defined volume and the material of the product substantially fills the defined volume, wherein the second layer of The laminated material barrier is flat, wherein the first and second barrier layers of laminated material are sealed together at their perimeters to form a fluid-tight housing for containing the material of the product, wherein the second barrier layer of laminate material is permanently attached to a portion of the printed base card; wherein the fluid-tight housing comprises a supply tip and the base card printed comprises a dotted line intersecting the supply tip, wherein the dotted line defines a folding flap that when folded along the dotted line seals the delivery tip so that it can be reclosed. SUMMARY The invention generally relates to unified packages for containing and supplying a product material. In particular, the unified packages comprise a printed base card and a fluid container permanently attached to the printed base card. The fluid container comprises a first barrier layer of laminated material comprising at least one layer of a biaxially oriented thermoplastic polymer, a portion of which is formed in a modified dome configuration and a second barrier layer of laminate material. The first and second barrier layers of laminated material are sealed together to form a fluid-tight housing, wherein the product material substantially fills the housing and the modified dome configuration is elastically sustainable. A method of manufacturing the unified packages as described above is also provided. In particular, the method includes the formation of a portion of the first barrier layer of laminate material comprising the biaxially oriented polymer in the modified dome configuration using a force such as pressurized gas.