Pliable ground calcium carbonates storage articles and method of making same

Abstract

The present invention is directed to a storage article, such as a retail and/or shipping package, having an environmentally friendly pliable composite structure that has a high degree of pliability and flexibility and is highly attractive in look and feel. The pliable composite structure has a base layer and a ground calcium carbonate-containing layer covering the base layer. The base layer and ground calcium carbonate-containing layer are shaped, sized and manufactured such that the pliable composite structure formed therefrom is sufficiently pliable and flexible to form the storage article.

1 . A storage article comprising:
 a pliable composite structure comprising;
 (a) a base layer; and 
 (b) a ground calcium carbonate-containing layer covering the base layer; 
 wherein the base layer and ground calcium carbonate-containing layer are shaped, sized and manufactured such that the pliable composite structure formed therefrom is sufficiently pliable and flexible to form the storage article. 
   
   
   
       2 . The storage article of  claim 1  wherein the pliable composite structure is formed into the shape of at least one of a retail box and shipping box. 
   
   
       3 . The storage article of  claim 2  wherein the pliable composite structure is sufficiently pliable to allow for formation of the box shape by at least one of folding and creasing of the pliable composite structure. 
   
   
       4 . The storage article of  claim 1  wherein the pliable composite structure contains a prescribed amount of a thermo-formable bonding agent in the ground calcium carbonate-containing layer that is sufficient to form the storage article shape via thermoforming or vacuum forming. 
   
   
       5 . The storage article of  claim 1  wherein the base layer is formed from at least one of cellulosic fibers, chemical pulps, thermochemical pulps, natural starch-based foams, plastic, paper, paperboard, felt, non-woven mats, kraft linerboard and fiberboard. 
   
   
       6 . The storage article of  claim 1  wherein the ground calcium carbonate-containing layer is of a thickness in the range of from about 2 to about 30 mils. 
   
   
       7 . The storage article of  claim 1  wherein the pliable composite structure is in the shape of a shipping mailer. 
   
   
       8 . The storage article of  claim 1  wherein the pliable composite structure is in the shape of at least one of a retail box liner and a shipping box liner. 
   
   
       9 . The storage article of  claim 1  wherein the pliable composite structure is in the shape of at least one of a retail display and display tray. 
   
   
       10 . The storage article of  claim 1  wherein the pliable composite structure comprises a portion of a corrugated structure. 
   
   
       11 . The storage article of  claim 1  wherein the pliable composite structure comprises a portion of a protective interior packaging component. 
   
   
       12 . A method of making a component for a storage article, comprising the steps of:
 (a) preparing a pliable composite structure by adhering a ground calcium carbonate-containing layer to a base layer; and   (b) shaping the pliable composite structure to form the component for the storage article;
 wherein the ground calcium carbonate-containing layer and base layer are shaped, sized and manufactured such that the pliable composite structure formed therefrom is sufficiently pliable and flexible to form the component for the storage article. 
   
   
   
       13 . The method according to  claim 12  wherein the component comprises at least one of a retail box and shipping box, and wherein step (b) comprises shaping the pliable composite structure to form the component by at least one of folding and creasing of the pliable composite structure into a shape corresponding to the at least one retail box and shipping box. 
   
   
       14 . The method according to  claim 12  wherein step (a) comprises providing a prescribed amount of a bonding agent in the ground calcium carbonate-containing layer that is sufficient to allow for vacuum forming or thermo-forming of the pliable composite structure, and step (b) comprises shaping the pliable composite structure into the component by thermo-forming or vacuum-forming of the pliable composite structure. 
   
   
       15 . The method according to  claim 12  wherein step (a) comprises preparing a pliable composite structure having a ground calcium carbonate-containing layer having a thickness of from about 2 to about 30 mils. 
   
   
       16 . A method of shipping a product or displaying a product for retail, the method comprising the steps of:
 (a) providing a storage article comprising:
 a pliable composite structure comprising; 
 (i) a base layer; and 
 (ii) a ground calcium carbonate-containing layer covering the base layer; 
 wherein the base layer and ground calcium carbonate-containing layer are shaped, sized and manufactured such that the pliable composite structure formed therefrom is sufficiently pliable and flexible to form the storage article; 
   (b) placing the product within the storage article; and   (c) shipping the storage article or displaying the storage article for retail.   
   
   
       17 . The method of shipping a product or displaying a product for retail according to  claim 16 , wherein step (a) comprises providing a storage article comprising a pliable composite structure that is formed into the shape of at least one of a retail box and shipping box. 
   
   
       18 . The method of shipping a product or displaying a product for retail according to  claim 17 , wherein step (a) comprises providing a storage article comprising a pliable composite structure that is sufficiently pliable to allow for formation of the box shape by at least one of folding and creasing of the pliable composite structure. 
   
   
       19 . The method of shipping a product or displaying a product for retail according to  claim 16 , wherein step (a) comprises providing a pliable composite structure containing a prescribed amount of a thermo-formable bonding agent in the ground calcium carbonate-containing layer that is sufficient to form the storage article shape via thermoforming or vacuum forming. 
   
   
       20 . The method of shipping a product or displaying a product for retail according to  claim 16 , wherein step (a) comprises providing a pliable composite structure having a ground calcium carbonate-containing layer having a thickness of from about 2 to about 30 mils.