Housing for explosive device and method of assembly

An explosive device housing comprising:

• a housing formed from a substrate layer, wherein the substrate layer includes at least one layer of paper-based material, the substrate layer forming a tubular structure, the tubular structure having a first flap member formed at a first open end and a second flap member formed at a second open end with a tube body disposed in between the first and second open ends, the tube body being collinear with a longitudinal axis of the tubular structure and wherein each of the flap members are configured to be radially oriented about 180 degrees with respect to each other, each flap member having an inside surface, an outside surface and a distal end portion away from the tube body;
• a first seal forming a base for the housing, the first seal formed from a folded over first flap member that covers the first open end such that the inside surface of the flap member is in contact with and adhered to the tube body, wherein the outside surface is exposed and the distal end portion of the first flap member is substantially perpendicular to the longitudinal axis of the tubular structure;
• and
• a second seal forming a top for the housing, the second seal formed from a folded over second flap member that covers the second open end such that the inside surface and distal end portion of the second flap member is in contact with and adhered to the tube body, thereby forming a top for the casing or housing, wherein the housing has a tubular shape.

A method of forming a robust casing or housing adapted to receive and contain therein an explosive or combustible material, the method comprising the steps of:

• forming a substrate from a sheet of paper-based material and a sheet of fiber reinforcement material disposed on the paper-based material sheet;
• forming a tube from the substrate having a first open end and a second open end and a tube body therebetween, the tube body being collinear with a longitudinal axis of the tube;
• removing material from the first and second end of the tube so as to form a first flap member at the first end and a second flap member at the second end of the tube, each of the flap members configured to be radially oriented about 90 degrees with respect to each other, each flap member having an inside surface, an outside surface and a distal end away from the tube body;
• folding over the first flap member to cover the first open end such that the inside surface of the flap member is in contact with and adhered to the tube body, wherein the outside surface is exposed and the distal end of the flap member is substantially perpendicular to the longitudinal axis of the tube, thereby forming a base for the casing;
• and
• folding over a second flap member to cover the second open end such that the inside surface and distal end of the second flap member is in contact with and adhered to the tube body, thereby forming a top or cover for the housing or casing.