Paper-based packaging film and packaging comprising said film

Abstract

The present invention relates to a paper-based packaging film having a first main outer surface and a second main outer surface, the paper-based packaging film comprising: a paper component; a polymer film; and a patterned sealable material; wherein the first major outer surface comprises one or more first surface areas provided by the patterned sealable material and one or more second surface areas provided by the paper assembly. The invention also relates to a package formed from or comprising the paper-based packaging film and optionally a product such as a product having a rectangular parallelepiped shape.

Description

Technical Field

[0001] The present disclosure relates to paper-based packaging film structures. In particular, the present disclosure relates to paper-based packaging films for packaging articles such as food and other articles. Background Art

[0002] The goal of increasing the recyclability of paper-based multilayer packaging films becomes challenging when attempting to form films intended to protect packaged products, such as food products, from their external environment. Traditionally, packaged products have been protected by forming multilayer films having multiple specific layers. As performance requirements increase, the number of layers or thickness of each layer in the multilayer film increases, while as the mass percentage of paper content decreases, the recyclability of the structure is detrimental.

[0003] Many products are packaged on high-speed packaging equipment, which places further demands on the runnability of packaging materials.

[0004] Additionally, since packaging is often the primary source of marketing for a product, the appearance of the packaging is also critical.

[0005] Typically, when high performance is required for paper-based multilayer packaging films, relatively large amounts of additional non-paper materials are added to the paper-based packaging films. For example, in order to package certain products such as food products (e.g., soup cubes), the packaging material is required to provide barrier properties against grease, odors and moisture (water and water vapor) and oxygen, most typically against grease and moisture.

[0006] Products containing grease (e.g., soup cubes) may leave grease stains on the paper material used for packaging. One solution in the art is to use grease-resistant paper material for packaging. In the past, grease resistance has been provided by adding organophilic components as quality treatments or as coatings to paper. Organophilic components used for this purpose in the art include poly or perfluoroalkyl substances (PFAS), waxes (paraffins) and polyvinylidene chloride (PVDC) and silicones. Such components may not comply with food safety regulations and / or may interfere with repulping in paper recycling processes. Therefore, these conventional solutions are not repulpable and recyclable solutions. Components (such as waxes) themselves may leave traces when heated (e.g., for sealing). In addition, waxes may produce stickies or accumulate on machine parts in the paper recycling process.

[0007] There is a need for paper-based flexible packaging films having high barrier properties (particularly against moisture and grease), folding properties and excellent sealing performance while maintaining recyclability in paper recycling processes (such as standard paper recycling processes).

[0008] There is also a need for a paper-based packaging film that can be used to package products containing grease while maintaining recyclability in a paper recycling process (such as a standard paper recycling process). Preferably, the packaging film should also be able to maintain excellent appearance (e.g., not susceptible to grease stains) during package conversion and package use and storage. In addition, the packaging film can be used on high-speed packaging machines, i.e., the packaging film has good runnability. Summary of the invention

[0009] Disclosed herein is a paper-based packaging film that meets the above needs. The paper-based packaging film disclosed herein has high barrier properties (particularly, against moisture and grease), good folding properties, and excellent sealing performance. The film also has excellent appearance and runnability while maintaining recyclability in paper recycling processes such as standard paper recycling processes.

[0010] The packaging film comprises a paper component and includes a minimum amount of non-fiber-based materials (i.e., a minimum amount of non-paper materials) to achieve high barrier properties and excellent sealing performance while maintaining paper recyclability. The paper-based flexible packaging film can be used to package products, including but not limited to cuboid food products, such as soup cubes.

[0011] The paper-based packaging film includes a polymer film, a paper component, and a patterned sealable material. The paper-based packaging film may include additional materials, such as an adhesive and / or a barrier material. The barrier material may be located between the paper component and the polymer film. The adhesive may attach the polymer film or the barrier material (if present) to the paper component. The total composition of the paper-based packaging film may be greater than or equal to 80 weight percent, greater than or equal to 85 weight percent, greater than or equal to 90 weight percent, or greater than or equal to 95 weight percent of the paper component.

[0012] In some embodiments of the paper-based packaging film, the polymer film may include an oriented or unoriented film and may optionally further include a coating of a barrier material, typically on one side thereof. Examples of barrier coatings are metal or oxide barrier coatings. A polymer film including a barrier material coated thereon (e.g., any metal or oxide barrier coating) is also referred to herein as a "polymer barrier film." In some embodiments, the polymer film may be attached to the paper component by an adhesive.

[0013] Some embodiments of the paper-based packaging film can be described as having an outer surface and an inner surface, a polymer film, a paper component, and a patterned sealable material, wherein the polymer film is any oriented or unoriented film, optionally but preferably including any metal or oxide barrier coating. Typically, the barrier coated side of the polymer film faces the paper component. For example, in an embodiment, the barrier coated side of the polymer film is attached to the paper component by an adhesive (such as a water-sensitive adhesive). In one or more embodiments, the inner surface comprises a polymer film, and the outer surface comprises each of the paper component and the patterned sealable material.

[0014] The total composition of the paper-based packaging film may be greater than or equal to 80 wt%, greater than or equal to 85 wt%, greater than or equal to 90 wt%, or greater than or equal to 95 wt% paper (ie, paper component).

[0015] The paper-based packaging film may incorporate a heat-sealable sealable material, such as a heat-seal lacquer. The paper-based packaging film may contain an adhesive, which may be a water-based adhesive. The paper component may be selected from grease-proof paper.

[0016] In typical embodiments, the paper-based packaging film has a first major outer surface and a second major outer surface, wherein the first major outer surface comprises one or more first surface regions and one or more second surface regions provided by the patterned sealable material. The second major outer surface may be provided by the polymer film.

[0017] The present invention also relates to a package formed by or comprising a paper-based packaging film as described herein. The package can be sealed by the patterned sealable material. In the package, the patterned sealable material is generally facing away from the product and generally facing the environment.

[0018] Some embodiments of the package can be described as a packaged rectangular product, which includes a paper-based packaging film as described herein and a product having a rectangular shape; wherein the paper-based packaging film is wrapped around the product so that the first major surface of the packaging film faces away from the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present disclosure may be more fully understood by considering the following detailed description of various embodiments of the present disclosure in conjunction with the accompanying drawings, in which:

[0020] Figure 1 is a perspective view of an exemplary packaged cuboid product;

[0021] Figure 2 is a cross-sectional view of an exemplary paper-based packaging film;

[0022] Figure 3a is a cross-sectional view of an exemplary paper-based packaging film;

[0023] Figure 3b is a cross-sectional view of an exemplary paper-based packaging film;

[0024] Figure 4 is a cross-sectional view of an exemplary paper-based packaging film; and

[0025] Figure 5 is a plan view of a first major surface (outer surface) of one embodiment of a paper-based packaging film.

[0026] Figure 6 is a plan view of a first major surface (outer surface) of one embodiment of a paper-based packaging film.

[0027] Figure 7 is a plan view of a first major surface (outer surface) of one embodiment of a paper-based packaging film.

[0028] The accompanying drawings show some but not all embodiments. The elements depicted in the drawings are illustrative and are not necessarily drawn to scale, and the same (or similar) reference numerals represent the same (or similar) features throughout the drawings.

[0029] definition

[0030] Unless otherwise stated, the following terms as used herein have the meanings provided below.

[0031] The terms "preferred" and "preferably" refer to embodiments of the present invention that may provide certain benefits in certain circumstances. However, other embodiments may also be preferred under the same or other circumstances. In addition, the recitation of one or more preferred embodiments does not mean that other embodiments are not useful, nor is it intended to exclude other embodiments from the scope of the present disclosure.

[0032] As used herein, the term "layer" refers to the building block of a film. A layer is a structure of a single material type or a uniform blend of materials. A layer can be a single polymer, a blend of materials within a single polymer type, or a blend of various polymers. A layer can contain a metallic material or paper, and can have additives. Paper is usually present in the form of a paper layer. As used herein, the term "paper" or "paper layer" refers to a paper material in the form of a layer (cellulose plus optionally including conventional paper additives, such as fillers, sizing agents, clay), excluding components such as inks and / or topcoats. The material layer described herein can be continuous with the paper-based packaging film, or can be discontinuous or patterned. Both layers and films have a relatively insignificant thickness (z direction) compared to their respective lengths and widths (xy directions).

[0033] All layers and films described herein have two major surfaces relative to each other, defined by the xy plane. As used herein, the term "external layer" refers to one or more layers of a film on any one major surface of the film, i.e., a layer that is not between two other layers of the film. The film has an outer surface that becomes the exterior of a package in which the film is used. When formed into a package, the outer surface of the film is exposed to the environment. The film has an inner surface that becomes the interior of a package in which the film is used. When formed into a package, the inner surface is used to form a seal and is exposed to the packaged product.

[0034] As used herein, the term "adjacent" means that the items (such as layers of a film) are close to each other with or without the use of an intermediate material (such as an adhesive). As used herein, the term "directly adjacent" or "directly in contact with" means that the items are in contact with each other without intermediate materials.

[0035] When used with respect to two adjacent structural elements of a packaging film (i.e., a paper component, material, film or layer as described herein), the term "connection" means that such structural elements are provided separately and are subsequently connected to each other by any suitable means with or without the use of an intermediate material (such as an adhesive). Therefore, as used herein, the term "connection" is intended to be distinguished from (and preferably intended to exclude) a coextrusion or coating method to provide two adjacent structural elements. For example, the term "polymer film connected to a paper component" means that the polymer layer constituting the polymer film and the paper component are provided separately and are subsequently connected to each other by any suitable means with or without the use of an intermediate material. Therefore, the polymer material of the polymer film providing the paper-based packaging film described herein is preferably not applied to the paper component by using a method involving coating the polymer material onto the paper component.

[0036] The terms "paper" or "paper layer" refer to a cellulose based material including any additives commonly used in paper commonly found in the paper industry such as fillers, sizing agents and clay coatings.

[0037] The "paper content" of a paper-based packaging film can be determined by dividing the mass of paper used (paper or paper layer, including any conventional paper additives) by the total mass of the paper-based packaging film (comprising: paper layer, polymer film and patterned sealable material, and optionally including any one or more barrier materials, adhesives, inks, topcoats and any other materials that may be present but are not "paper layers").

[0038] It should be noted that paper content is different from "recyclable content" in some cases because sometimes not all paper-based products can be fully recycled because paper combined with non-paper materials may result in a non-recyclable product. The term "recyclable content" or "recyclable pulp content" of paper-based packaging films is defined herein as the mass fraction of material that can be recycled to produce new paper (usually pulp and any other matter captured with the pulp). The recycled content can be determined by tests that simulate a repulping process (such as the repulping process described herein). Preferably, the recycled content is maximized to maximize the incentive for recyclers to collect the packaging product, so values ​​of 80% or more are considered to be a rule of thumb when designing paper-based packaging products, but in some countries, values ​​as low as 50% are considered acceptable.

[0039] The term "paper component" refers to paper or paper layers plus optionally other components added after the original manufacture of the paper, such as inks and / or topcoats.

[0040] The term "recyclability" of paper-based packaging usually relates to the unique suitability of paper-based packaging for being actually reprocessed into new paper and board at the post-use stage; in practice it means that the classified collection (where relevant, followed by sorting) and the final recycling according to EN 643 "European list of standard grades of paper and board for recycling" is carried out on an industrial scale. Standard paper recycling plants usually have equipment and processes for producing high-quality end products based on EN643 groups 1 to 4 by means of classic low-consistency pulpers (5% fiber concentration). Usually, such processes operate high-frequency deflakers to separate fiber bundles into individual fibers, as well as coarse and fine screen washers. The purpose is to separate the fibers from other materials. The end result is a fibrous material suspended in water ready for papermaking (= recycled pulp). Special recycling plants can handle mixtures of special grades (group 5 of EN 643) and grades from other groups (1-4 from EN 643). The process for preparing recycled paper stock for packaging streams (category 2) usually does not include a deinking step for removing printing inks. In contrast to a standard recycling plant, a dedicated recycling plant determines the optimal mix and adds one or more pieces of specialized equipment, such as a horizontal high-density drum pulper, a separate batch pulper with a longer pulping time, deinking, fine cleaners, hot dispersions, special processes and wastewater systems. As in a standard plant, the end result of the process is also a fibrous material suspended in water ready for papermaking.

[0041] As used herein, the term "standard paper recycling process" is or is intended to refer to a waste paper recycling process, which may include one and typically multiple or all of the common steps selected from repulping, screening, flotation, roughing, thickening, defibring, deinking, washing, purification and bleaching, as known in the art.

[0042] The paper-based packaging films described herein and the packages made therefrom are suitable for recycling in a standard recycled paper process (i.e., they can be processed in a standard paper mill). For the purposes of the present invention, recyclability (i.e., the suitability of the paper-based packaging film or package obtained therefrom for processing in a standard paper recycling process) can be established based on properties including repulpability and sheet formation using standard laboratory tests that simulate industrial standard waste paper processes on a laboratory scale. The test procedure includes a crushing step (pulping step) typically performed using a standard crusher (according to ISO 5263-1). The test procedure may include one or more of the following stages: comminution, filtrate analysis; determination of coarse waste (e.g., 5 mm hole residue); determination of consistency after coarse screening (AC); adhesion test and visual appearance test of sheets subjected to coarse screening; determination of fine waste (e.g., 150 μm slot residue); adhesion test and visual appearance test of sheets subjected to fine screening; determination of the content of adhesive particles (macro stickies). The test procedure may optionally include a sheet forming step (total stock) which may include a sheet adhesion test and a visual appearance test, both of which are generally optional. Specific tests may include one or more of the following: measurement of coarse waste, measurement of flake content (fine waste, according to TAPPI T275 sp18), calculation of the content of soluble and colloidal solids below 10 microns (measured according to ISO 4119), measurement of the area of ​​binder particles (macrostickies, according to ISO 15360-2, optional), indication of ash content (measured according to ISO 1762, optional). Standard test protocols suitable for establishing the recyclability of paper-based packaging films or packaging made therefrom in a standard paper recycling process include one or more of the following: PTS-RH 021-Catalog 2, Aticelca 501 (2019) and CEPI "Harmonized European laboratory test method to produce parameters enabling the assessment of the recyclability of paper and board products in standard paper and board recycling mills–Version 2". For the purposes of the present invention, the recyclability of a paper-based packaging film or a product made therefrom means that the film or product achieves at least a good rating according to at least one, two or all of these criteria, for example at least a B rating when rated according to Aticelca 501 (2019).

[0043] The criteria PTS-RH 021 - Catalog 2 used to assess recyclability are repulpability (mass percentage of components not usable in papermaking) and undisturbed sheet formation (purity of mass percentage of furnish usable in papermaking with respect to stickies or optical inhomogeneities).

[0044] The Aticelca 501 (2019) system is an evaluation based on laboratory analysis, developed by Aticelca since 2011 and became UNI 11743:2019. The analysis simulates the main stages of the industrial process of making paper for sheets that are recycled in a standard recycling process to produce new paper. The technical standard Aticelca 501 (2019) reproduces on a laboratory scale what happens on an industrial scale when a paper mill recycles paper for recycling. Pulping, fiber cleaning and sheet formation are performed. The following parameters are measured: coarse waste, flake content, macroscopic sticky area, sheet formation and adhesion, optical inhomogeneity and ash content (optional). The results of the laboratory tests (which analyze the main elements that characterize the recyclability of paper and paperboard and products obtained from paper and paperboard) are summarized by a scale divided into four recyclability levels in proportion: A+, A, B, C (and non-recyclable), A+ representing the highest recyclability level.

[0045] The CEPI Recyclability Test Method – 2nd Edition describes a laboratory-scale method for determining key parameters for assessing the recyclability level of paper and paperboard based materials and other cellulose fiber based products, simulating the relevant stages of a standard paper and paperboard recycling plant without de-inking technology or other special features for recycling paper to produce new paper and board. This method enables the analysis of process parameters (coarse waste, fine waste, dissolved and colloidal matter and stickies particles with a diameter less than 2 mm) and quality parameters (sheet formation and interfering materials such as adhesive and visual impurities) of products produced from recycled fibers. This document considers only the minimum characteristics of paper and paperboard products that can usually be recycled. Therefore, additional specifications required for the valorization of paper and paperboard products using de-inking technology are not taken into account. Recyclability parameters in plants involving specialized processing technologies are also not included.

[0046] As used herein, the term "fat" is intended to include fats such as those associated with the molecular form of the family of nutrients based on fatty acids. Fats can be solid or liquid (at room temperature), depending on the fatty acids contained. Liquid fats are referred to as "oils." As used herein, the term "fat" is intended to include solid fats and liquid fats, i.e., oils.

[0047] As used herein, the term "grease" is intended to include substances that have similar physical properties (e.g., in terms of melting point and density) but are not considered pure fats, for example because they do not fall into the fat category as defined herein (i.e., they are not fatty acid triglycerides) or have additional components. "Grease" as used herein is also intended to encompass fats as defined herein (including semi-solid and solid fats and oils) and substances that can be derived from fats (e.g., by chemical reactions (e.g., cleavage of ester groups, salt formation) or physical treatments (e.g., heating)), including fatty acids and their salts.

[0048] The term "barrier material" is well known in the packaging field. Barrier materials are generally understood to be single materials or combinations of materials designed to reduce the diffusion of substances such as water, gases (such as oxygen), fats (especially oils) or odors through the packaging material. Barrier materials help prevent degradation of the package and / or the packaged product, as is well known in the art.

[0049] As used herein, the "total composition" of a paper-based packaging film refers to all materials included therein. The total composition of a paper-based packaging film includes the paper content (i.e., the cellulose fiber content) and the non-paper content (i.e., all other materials, such as polymer films, patterned sealable materials, optional components such as adhesives, barrier materials, inks, and topcoats, and any other optional components that may be included).

[0050] As used herein, the term "basis weight" is used to refer to the weight of a material present in a predetermined area of ​​a component, film or layer. Typically, the defined area is a square meter, but any area can be used. The area is defined in the length-width (i.e., xy direction) of the film or layer. A material of a given thickness (z direction) and density has a specific weight when covering a defined area (i.e., square meters). Basis weight is a common weight measurement for paper because the density of paper may vary greatly. In other words, it may be difficult to measure paper by thickness. Materials applied in discontinuous layers (such as patterned sealable materials) can be defined by basis weight. In the case of a pattern, basis weight refers to the amount of material by weight present when covering a defined area. It is common in the film conversion industry to use basis weight to measure the weight of materials such as paper and patterned materials.

[0051] As used herein, the term "water sensitive" means that the adhesive layer loses its adhesive and / or bonding properties when exposed to or immersed in liquid water for a long time, thereby enabling the paper component to be delaminated (i.e., separated) from the rest of the paper-based packaging film structure during the repulping process. Water sensitivity can be established using a standard laboratory pulper using water, 40°+ / -5°C water and 30.000 revolutions. Preferably, a suitable adhesive will not interfere with recycling in a standard paper recycling process, as determined according to the recyclability criteria described herein. For example, when tested according to the Aticelca and PTS schemes, a suitable adhesive will allow the fibers to be released from the packaging film, thereby producing an acceptable recyclable content, such as at least or greater than 80%, or at least or greater than 85%, or at least or greater than 90% of the paper-based packaging film. According to Aticelca 501 (2019), the adhesive can be appropriately selected so as to preferably result in a grading of at least B grade, A grade or even A+ grade. DETAILED DESCRIPTION

[0052] Packaging film

[0053] Provided herein are paper-based packaging films that overcome the disadvantages of previously provided films. The paper-based packaging films of the present disclosure are uniquely designed to achieve the key combination of recyclability, easy packaging conversion such as by folding (e.g., when packaging cuboid-shaped products), high barrier (especially against moisture and grease), excellent sealing, excellent runnability on packaging equipment (i.e., high running speeds), and excellent appearance.

[0054] The paper-based packaging films described herein include a paper component, a polymer film, and a patterned sealable material. In certain embodiments, the paper-based packaging film includes a paper component, a polymer film, a barrier material, and a patterned sealable material. The paper-based packaging film may include additional layers. The combination of these materials may be described as a multilayer film (e.g., a structure or laminate).

[0055] The paper-based packaging film has a first major outer surface and a second major outer surface. The first major outer surface may include one or more first surface areas provided by the patterned sealable material and one or more second surface areas provided by the paper component. The second major outer surface may be provided by a polymer film, but this is not a necessary requirement.

[0056] When used for packaging, the first major surface may become the exterior surface of the package using the film (ie, it is exposed to the environment), and the second major surface may become the interior surface of the package using the film (ie, it faces the packaged product).

[0057] The total composition of the paper-based packaging film can include greater than or equal to 80% by weight, greater than or equal to 85% by weight, greater than or equal to 90% by weight, or greater than or equal to 95% by weight of paper. The total composition of the paper-based packaging film can include less than or equal to 99% by weight, less than or equal to 98% by weight, less than or equal to 97% by weight, or less than or equal to 96% by weight of paper. For example, by weight of the total composition, the paper-based packaging film can contain a paper component (cellulose fiber of paper) in the range of about 85% to about 98%. In other words, the paper content of the paper-based packaging film can be greater than or equal to 80% by weight, greater than or equal to 85% by weight, greater than or equal to 90% by weight, or greater than or equal to 95% by weight. The paper content of the paper-based packaging film can include less than or equal to 99% by weight, less than or equal to 98% by weight, less than or equal to 97% by weight, or less than or equal to 96% by weight of paper. For example, the paper content of the paper-based packaging film can be in the range of about 85% to about 98%.

[0058] Based on the total weight of the paper-based packaging film, the paper-based packaging film can achieve a recycled content of greater than or equal to 80 wt%, greater than or equal to 85 wt%, greater than or equal to 90 wt%, or greater than or equal to 95 wt% (as determined by a suitable repulpability test, such as the test described herein). Based on the total weight of the paper-based packaging film, the recycled content of the paper-based packaging film can be less than or equal to 99 wt%, less than or equal to 98 wt%, less than or equal to 97 wt%, or less than or equal to 96 wt%. For example, based on the total weight of the paper-based packaging film, the paper-based packaging film can be included in the range of about 85% to about 98%.

[0059] The paper-based packaging film described herein comprises paper (i.e., paper layer) and comprises a minimum amount of non-fiber-based material (i.e., a minimum amount of non-paper material). For example, the paper-based packaging film may include a minimum amount of non-paper material, such as provided by a polymer film, a patterned sealable material, and any optional components described herein (such as adhesives, barrier materials, inks, and topcoats), as well as any other components that may be covered and are not paper. For example, based on the total composition of the packaging film, the total composition of the paper-based packaging film may include a non-paper component equal to or less than 20% by weight, or equal to or less than 15% by weight, or equal to or less than 10% by weight, or equal to or less than 5% by weight, or equal to or less than 4% by weight, or equal to or less than 3% by weight, or equal to or less than 2% by weight, or equal to or less than 1% by weight. For example, based on the total composition of the packaging film, the total composition of the paper-based packaging film may include a non-paper component equal to or greater than 0.5% by weight, or equal to or greater than 0.8% by weight, or equal to or greater than 1% by weight, or equal to or greater than 1.5% by weight.

[0060] Paper-based packaging films and products made therefrom are generally recyclable, for example when established following one or both or all of the schemes mentioned herein. Paper-based packaging films can achieve classification B, A or even A+ according to the Aticelca standard. For example, paper-based packaging films with a paper content greater than 85% can achieve classification A according to the Aticelca standard.

[0061] Paper components

[0062] The paper-based packaging films disclosed herein include a paper component.

[0063] The paper component is located at the outer layer of the paper-based packaging film, and preferably at the outer surface of the paper-based packaging film (ie, relative to the package in which the film is used).

[0064] The paper component may comprise any type of paper. A suitable type of paper may have a basis weight of 30 g / m 2 Up to 360g / m 2 , preferably 30g / m 2 Up to 100g / m 2 , more preferably 30g / m 2 Up to 70g / m 2 , most preferably 50g / m 2 Low paper component weight is possible while maintaining easy recyclability because additional components (ie, non-cellulose fiber content) are minimized.

[0065] The paper component may comprise any type of paper. The paper used is preferably selected from paper types that can be processed in standard paper recycling processes. Suitably, the paper used may be repulpable, for example mechanically and / or chemically. The paper may be selected based on the repulpability test as described herein for packaging films.

[0066] The paper component may consist of a paper layer (i.e., cellulose fibers and optionally including any conventional paper additives and / or surface treatments). The paper component may also comprise a paper layer and optionally one or more additional elements, such as one or more of a paper surface treatment, ink, and topcoat. Such additional elements, if present, may be located on the outer surface of the paper layer and may consist of a second surface region.

[0067] As used herein, the term "paper surface treatment" refers to one or more types of conventional paper treatments applied to one or both major surfaces of a paper layer. The surface treatment may include physical and / or chemical surface treatments, as known in the art.

[0068] Physical treatments include calendering and supercalendering.The paper component may comprise calendered or supercalendered paper, such as glassine.

[0069] Exemplary chemical surface treatments can include applying one or more preparations selected from the following preparations: inorganic surface treatment agents, organic surface treatment agents and combinations thereof. Exemplary inorganic agents can be selected, for example, from kaolin, calcium carbonate, bentonite and talc and chalk or clay, as well known in the art. Exemplary organic preparations can be selected, for example, from starch, alginate, carboxymethyl cellulose and polyvinyl alcohol and combinations thereof. In an embodiment, a paper component includes a paper layer having at least one surface treatment on one or both sides thereof, wherein the at least one surface treatment has one or more (independently) selected from the following preparations: starch, alginate, carboxymethyl cellulose, polyvinyl alcohol, from kaolin, calcium carbonate, bentonite and talc and chalk and combinations thereof.

[0070] Surface treatments can be applied to one or both sides of the paper.Surface treatments can produce a coating on one or both sides of the paper layer.

[0071] Thus, the paper component may include a coating (e.g., a conventional paper surface coating used to make paper), as is well known in the papermaking art (i.e., excluding inks and topcoats). The paper component may or may not include such conventional paper coatings. The paper content of the paper-based packaging film includes such conventional paper coatings, if present.

[0072] Suitably, any surface treatment and coating (if present) are selected so that they do not interfere with recyclability, in particular repulpability, in a standard paper recycling process. Preferably, the coating (if present) is selected so that it does not interfere with recyclability in a standard paper recycling process. In a preferred embodiment, the paper component is not quality treated with components that may interfere with recyclability in a standard paper recycling process. The paper component preferably does not contain conventional grease-resistant coatings and quality treatments based on silicone, PVCD and fluoroalkyl and wax. The paper component as described herein preferably does not include non-repulpable paper or paper that has been quality treated, for example, with a wet strength treatment. Examples of non-repulpable paper that will not be usable in the paper-based packaging film described herein include, but are not limited to, parchment paper, double-sided wax-treated paper, paper in combination with a tacky adhesive, or siliconized paper.

[0073] Examples of paper types that may be suitable for use in paper-based packaging films include, but are not limited to, kraft paper, bleached paper, and microfibrillated paper (eg, MFC paper). Thus, the paper component may comprise paper selected from kraft paper, bleached paper, and microfibrillated paper.

[0074] Specific examples of surface-treated paper suitable for use in the present invention are clay-coated papers such as single-sided clay-coated paper (C1S) or double-sided clay-coated paper (C2S).

[0075] Thus, examples of commonly used paper types in packaging that are acceptable in the paper-based packaging films described herein may include machine light bleached kraft paper (MGBK), single-sided clay-coated paper (C1S), and double-sided clay-coated paper (C2S), but less commonly used papers that provide improved mechanical or barrier properties through the use of special fibers or additives may also be part of the paper-based packaging films described herein.

[0076] The paper-based packaging film can be described as having a first major outer surface and a second major outer surface. Preferably, the first major outer surface comprises one or more first surface areas provided by the patterned sealable material and one or more second surface areas provided by the paper assembly. In an embodiment, the paper assembly can be described as having a top surface and a back surface opposite to the top surface, wherein the top surface comprises the one or more second surface areas, and wherein the one or more second surface areas independently comprise one or more of the following: paper (i.e., cellulose fiber), surface treatment, ink, and topcoat. In certain embodiments, the back surface is uncoated and / or untreated. The specific example of a suitable paper assembly comprises a supercalendered paper layer, an untreated paper layer on the back surface, an uncoated paper layer on the top surface, and a machine-processed paper layer.

[0077] The paper component can comprise greaseproof paper. Greaseproof paper is the paper that is impermeable to grease (that is, fat (including oil), fat derivative and fatty acid), and is generally used for cooking or food packaging. The greaseproof paper is usually produced by refining paper stock to produce a sheet with very low porosity. It can be subsequently passed (through super calendering) between hard pressure rollers to further increase density, thereby producing the paper that is called as cellophane. Cellophane PVOH, starch, alginate and / or carboxymethyl cellulose (CMC) can be processed, for example, in size press to fill surface holes.

[0078] The selected paper can provide grease barrier properties without reducing its recyclability in a standard paper mill. In particular, this can be achieved by using microfibrillated paper or paper that has been coated with an anti-grease coating. Typical anti-grease coatings used in the industry and also useful herein are, for example: based on PVOH, starch and / or carboxymethyl cellulose (CMC) and alginates. For example, paper can be selected to provide an oil and grease resistance equal to or less than about 4, as measured by the "TAPPI-454 rosin oil test for grease resistance of paper", where turpentine is replaced with Crisco pure vegetable oil run at a temperature of 140°F for 24 hours under TAPPI conditions. In particular, when the product is a grease-containing product (e.g., soup cubes), the paper is most appropriately selected from grease-proof paper.

[0079] In addition to the paper layer and optional conventional paper surface treatments (if present), the paper component may optionally contain inks and / or topcoats. The paper content of the paper-based packaging film excludes inks and topcoats (if present).

[0080] Each in ink and / or topcoat can be continuous or independently discontinuous (i.e., patterned) with other layers of film independently. In an embodiment, the topcoat is discontinuous (i.e., patterned topcoat), and the patterned topcoat and patterned sealable material occupy complementary parts of the first major surface of the packaging film.

[0081] Inks can contain pigments and varnishes or water-based primers. Topcoats can contain varnishes or water-based primers. Topcoats usually do not contain pigments. The same or different varnishes or water-based paints can be used for inks and topcoats.

[0082] Thus, in embodiments, the one or more second surface regions independently comprise one or more of paper (ie, cellulose fibers), optionally a surface treatment, ink, and a topcoat.

[0083] The paper-based packaging film may include ink and / or topcoat on the first major outer surface. The ink and / or topcoat may (independently) cover a portion or all of the first major surface. Thus, with respect to the packaging in which the film will be used, the packaging film may also include ink and / or topcoat on the outer surface of the paper-based packaging film.

[0084] In some embodiments, the paper-based packaging film includes an ink layer on the outer surface of the paper component. The paint coating (topcoat) can be in direct contact with the ink layer. In some embodiments, the patterned sealable material is adjacent to the paint coating and is located on the surface of the paint coating opposite to the ink layer. The outer surface of the paper-based packaging film can be composed of both the paint coating and the patterned sealable material. In the area of ​​the patterned sealable material, the outer surface is the sealable material, and in other areas the outer surface is the paint coating.

[0085] In some embodiments, the packaging film may also include ink on the outer surface of the paper-based packaging film. The ink may be in direct contact with the paper component and have a lacquer coating in direct contact with the sealable material so that the ink may be located between the paper component layer and the sealable material. The type and amount of the ink may vary within the requirements of the local paper recycling guidelines. The ink may contain pigments and / or dyes known in the art.

[0086] The ink and / or topcoat may be applied to the first major surface (ie, the outer surface) by any known printing method, including but not limited to flexographic gravure, rotogravure, gravure coating, and digital printing methods.

[0087] Polymer film

[0088] The paper-based package comprises a polymer film. Advantageously, the polymer film is very thin. The thickness of the polymer film may be greater than or equal to 2 microns, greater than or equal to 3 microns, or greater than or equal to 4 microns. The thickness of the polymer film may be less than or equal to 15 microns, less than or equal to 10 microns, less than or equal to 9 microns, or less than or equal to 8 microns. For example, the thickness of the polymer film may be in the range of greater than or equal to 2 microns to less than or equal to 10 microns, or in the range of greater than or equal to 2 microns to greater than or equal to 8 microns. Preferably, the thickness of the polymer film is in the range of 4 microns to 8 microns.

[0089] The polymer film may comprise a single layer or multiple layers. A single layer comprises one building block (ie, layer) of one or more polymers. A multilayer may comprise one or more of the same or different polymers in multiple building blocks (ie, layers).

[0090] The polymer film may comprise or consist of an oriented or unoriented film. The orientation may be in the machine direction (MD), in the transverse direction (TD) or biaxially (BO), i.e. in the machine direction and in the transverse direction. In order to obtain a thin polymer film with good barrier properties, it may be beneficial to use an oriented polymer film, preferably a biaxially oriented polymer film. Methods for orienting polymer films are well known in the art.

[0091] Suitable polymer materials constituting the polymer film are not particularly limited and can be selected from a wide range of known polymer materials for packaging purposes. Suitable materials can be selected, for example, from one or more of the following: polypropylene (PP), polyester (e.g., PET), polyethylene (PE), polyamide (PA) and polylactic acid (PLA).

[0092] For example, one or more layers can be independently selected from uniaxially oriented polypropylene (OPP, MD or TD, preferably MD) films, biaxially oriented polypropylene (BOPP) films, uniaxially oriented polyethylene (OPE, MD or TD) films, biaxially oriented polyethylene (BOPE, MD or TD) films, uniaxially oriented polyester (MD polyester or TD polyester, such as OPET, MD or TD) films, biaxially oriented polyester films, such as BOPET films, uniaxially oriented polyamide (OPA, MD or TD) films, biaxially oriented polyamide (BOPA) films, uniaxially oriented polylactic acid (OPLA, MD or TD) films, and biaxially oriented polylactic acid (BOPLA) films. In some embodiments, a biaxially oriented polypropylene film is used.

[0093] The polymer film may be an unoriented material, such as but not limited to unoriented PLA.

[0094] In some embodiments, the second major outer surface is provided by a polymer film.The inner surface may consist essentially of or consist of a polymer film.

[0095] In some embodiments, the paper component is attached to a polymer film.The paper component can be attached to a polymer film as known in the art, such as by lamination, with or without the use of an adhesive, as known in the art.

[0096] Preferably, the polymer film does not extend into the fiber network of the paper component. In the present disclosure, it is preferred that the polymer film is not coated onto the paper component. Coating a polymer material onto a paper structure may result in the coating material penetrating and adhering to the fiber network, which in turn may result in difficulty in separating the composite fiber polymer structure and loss of pulp during the recycling process.

[0097] Patterned sealable materials

[0098] The paper-based packaging film comprises at least one patterned sealable material.

[0099] As used herein, the term "patterned" means that the layer of sealable material is discontinuous with the paper-based packaging film. The sealable material is discontinuous with the paper component on which the sealable material is applied. For example, the patterned sealable material can be applied to greater than or equal to 5%, greater than or equal to 10%, or greater than or equal to 15% of the surface of the paper component. The patterned sealable material can cover, for example, less than or equal to 30%, less than or equal to 25%, or less than or equal to 20% of the paper component. Without intending to be bound by theory, it is believed that the use of patterned sealable materials helps to recycle and reduce material usage.

[0100] Thus, the first major surface of the paper-based packaging film is partly a paper component surface (which may optionally contain ink and / or a topcoat as described herein) and partly a sealable material.

[0101] For example, the first major surface of a paper-based film may be approximately 80% paper (with or without ink and / or topcoat) and 20% patterned sealable material.

[0102] In other words, the patterned sealable material (eg, a layer of patterned sealable material) covers only portions of the area of ​​the multilayer packaging film (eg, the first outer major surface of the paper-based packaging film).

[0103] In an embodiment, the first major outer surface of the paper-based packaging film includes one or more first surface areas provided by a patterned sealable material. In an embodiment, the first major surface also includes one or more second surface areas provided by a paper component (and optionally includes ink and / or topcoat). In other words, the first major surface includes each of the paper component (and optionally includes ink and / or topcoat) and the patterned sealable material. In a typical embodiment, one or more second surface areas occupy an area complementary to one or more first surface areas on the first major outer surface of the paper-based packaging film. The first surface area may include greater than or equal to 5%, greater than or equal to 10%, or greater than or equal to 15% of the first major outer surface of the paper-based packaging film. The first surface area may be applied to less than or equal to 30%, less than or equal to 25%, or less than or equal to 20% of the first major outer surface of the paper-based packaging film.

[0104] The first surface area may have one or more interconnections. For example, the location of the first surface area on the first major outer surface may be selected to provide a fully or partially connected first surface area on the paper-based packaging film (or sheet thereof), such as a U-shaped, V-shaped, W-shaped, O-shaped, square, rectangular or other polygonal configuration or a ring-shaped configuration. The location of one or more first surface areas may be selected to provide a fully or partially avoidance configuration on the first major outer surface of the paper-based packaging film (or sheet thereof), such as Figure 6 Avoidance configuration shown.

[0105] The patterned sealable material can be applied to the area of ​​the paper-based packaging film involved in closing the package by sealing. When formed into a package, the first major surface becomes the outer surface and is used to form a seal, combined with another portion of the paper-based packaging film that overlaps the first surface area of ​​the first major outer surface (referred to herein as the overlap portion).

[0106] Therefore, although the position of the first surface area can be freely selected, when the paper-based packaging film (or its sheet) is formed into a three-dimensional package, one or more first surface areas can generally be located in the area of ​​the first main outer surface of the paper-based packaging film (or its sheet) forming the overlapping portion. The overlapping portion can vary based on the packaging forming process and the packaging machine used. For example, when the paper-based packaging film (or its sheet) is formed into a package by folding around a product such as a rectangular product, the folding sequence used can determine which areas of the first main outer surface of the packaging film are involved in generating the overlapping portion. Therefore, the configuration of one or more first surface areas on the first main outer surface can vary according to the product to be wrapped and the folding sequence used. When forming the package, the other parts of the paper-based packaging film that overlap with the first surface area of ​​the first main outer surface can be included in the first main surface of the paper-based packaging film and / or the second main surface. In other words, the overlapping portion can contain the same type of surface (to combine the surface of the type to itself) or different types of surfaces (to combine different types of surfaces to each other). The overlapping portion includes at least a patterned sealable material and optionally one or more portions selected from a second surface region (i.e., a paper component optionally including ink and / or topcoat), a second major outer surface of a paper-based packaging film (i.e., a polymer film in an embodiment), and combinations thereof. Thus, the overlapping portion may include a patterned sealable material (e.g., in an area of ​​a first surface region), and one or more of 1) another area of ​​the first surface region including the patterned sealable material (i.e., for sealing itself), 2) an area of ​​the second surface region (i.e., for sealing paper, optionally ink and / or topcoat (if present)), and 3) a second major outer surface (i.e., for sealing a polymer film). Depending on the application, the patterned sealable material may be selected to provide adhesion between surfaces of the same or different types.

[0107] The overlapping portion typically includes at least a portion (e.g., 60% or more, 70% or more, 80% or more, 90% or more or even 100%) of the first surface area (i.e., on the first major outer surface of the paper-based packaging film, which becomes the outer surface of the paper-based packaging film when formed into a package), and may further include a portion of the second surface area of ​​the first major outer surface of the paper-based packaging film (i.e., as provided by the paper component) and / or a portion of the second major outer surface of the paper-based packaging film (the surface becomes the inner surface of the packaging film when formed into a package, and is provided by a polymer film in a typical embodiment).

[0108] In the present invention, the patterned sealable material can include one or more different patterned sealable materials. One or more first surface areas can be provided by a patterned sealable material. One or more first surface areas can also be provided by two or three or even more different patterned sealable materials, i.e., by more than one patterned sealable material that is different from each other in at least one aspect. The difference can be based on one or more aspects, including, for example, adhesive types (e.g., heat seal (lacquer), hot melt, cold seal), chemical composition and pattern of the sealable material.

[0109] The patterned sealable material (and the first surface area in the embodiment) can form any suitable pattern (such as any suitable figure, graphic and / or text term) and / or define a pattern with any suitable shape, including but not limited to dots, points, lines, cross lines, diamonds or checkerboards. The patterned sealable material can emphasize the overall appearance of the packaged product.

[0110] In embodiments involving two or more different types of patterned sealable materials, one or more first surface areas may, for example, include a first patterned sealable material and a second patterned sealable material. The first patterned sealable material and the second patterned sealable material may provide the one or more first surface areas together. The first patterned sealable material and the second patterned sealable material may be provided in mutually exclusive areas of the first surface area and / or in the same area of ​​the first surface area. The first patterned sealable material and the second patterned sealable material may be provided by sealable materials of two different adhesive categories. For example, the first sealable material may be selected from heat seal lacquer and hot melt material, and the second sealable material may be selected from cold seal material, and vice versa. The first patterned sealable material and the second patterned sealable material may provide the same or different patterns. For example, the two patterned sealable materials may be applied together on a surface greater than or equal to 5%, greater than or equal to 10%, or greater than or equal to 15% of the first main outer surface of the paper-based packaging film. For example, the two patterned sealable materials may be applied together on a first main surface of the paper-based packaging film less than or equal to 30%, less than or equal to 25%, or less than or equal to 20%.

[0111] In an embodiment, a paper-based packaging film can be described as comprising a patterned sealable material as an outer (usually discontinuous) layer at an outer surface. The outer surface of the paper-based packaging film (also referred to herein as the first major outer surface) is partly the paper component (or paper layer) surface and partly the sealable material (plus optional ink and / or topcoat, if present).

[0112] The adhesive category of patterned sealable material is not particularly limited, and can be selected from the category of sealable material commonly used in packaging structure. The category of sealable material can be based on the requirements of specific packaging application, the product to be packaged (taking into account the heat sensitivity of, for example, the product) and according to which overlapping parts of the paper-based packaging film involve forming a seal in the relevant packaging application to select. For example, the category of sealable material can be selected according to which parts on the two main outer surfaces of the paper-based packaging film involve the overlapping area for forming a seal when the paper-based packaging film forms a package. The seal is at least related to patterned sealable material, and can additionally relate to one or more other elements of the paper-based packaging film, such as the second main surface area (provided by the paper component, optionally including ink and / or topcoat) part and / or the second main outer surface (provided by polymer film in a typical embodiment) (part). Therefore, the seal can be formed between the same or different kinds of materials, such as between the sealable material and itself, or between different kinds of materials, such as between the sealable material and the paper component (or ink and / or topcoat) and / or the second main outer surface (that is, between the polymer film in a typical embodiment). If used, the seal may also involve two or more different types of patterned sealable materials.

[0113] The patterned sealable material is used to form a bond when forming a package, which may be hermetically sealed or not, depending on the packaging application.The first surface region may be configured to provide a sealed package, such as a hermetically sealed package or a non-hermetically sealed package.

[0114] Suitable classes of patterned sealable materials from which to select can be broadly divided into cold sealable materials or "cold seals" and heat sealable materials or "heat seals" (including hot melts). The sealable material may be applied from a suitable physical form known in the art.

[0115] The patterned sealable material can be or can be incorporated into a cold sealable material. The sealable material can have a composition that will allow a cold seal to be formed. Cold seals as used herein do not require heat (i.e., temperatures above 50°C), solvents or water to activate the sealable material to form a bond, i.e., they are typically non-reactive adhesives. Typically, a temperature range including the ambient temperature of the location where the packaging unit is located is suitable for forming a cold seal, such as 15°C to 30°C (as an example).

[0116] Cold seals can be used to provide one or more self-sealing areas on the first major surface of a paper-based packaging film (i.e., when formed into a package). A cold seal may only require (usually light) pressure to seal, i.e., to bond the cold seal material to the surface in the overlap. Using a cold seal can also provide benefits in terms of packaging speed.

[0117] The patterned sealable material can be a pressure-sensitive cold seal material. This embodiment of the paper-based packaging film is advantageous because the formation of the package does not require heat. Without intending to be bound by theory, the pressure-sensitive cold seal may be advantageous for the packaging of heat-sensitive products (such as products containing low melting point fats). Embodiments of the paper-based packaging film may include a pressure-sensitive cold seal system, which includes but is not limited to natural or synthetic polyisoprene latex or styrene-butadiene copolymer latex. The cold seal material may include a blend comprising acrylates and / or tackifiers.

[0118] Alternatively, the patterned sealable material may be or may be incorporated into a heat sealable material.The heat sealable material may be applied from any physical form, for example from a heat seal lacquer or hot melt adhesive.

[0119] The paper-based packaging film can be incorporated with a heat-sealable sealable material such as a heat-sealable lacquer or a hot melt adhesive. The sealable material of the paper-based packaging film can have a composition that will allow a heat seal to be formed. As used herein, the term "heat seal", "heat-sealable" or "heat-sealable" refers to two or more surfaces that have been or can be combined together by applying both heat and pressure. Heat sealing is a well-known and commonly used method for producing packaging, and is familiar to those skilled in the art. It is not intended to be bound by theory, during heat sealing, the sealing material softens due to the application of heat, thereby allowing the formation of a heat-sealable bond. Since heat must be driven through the entire paper-based packaging film to increase the temperature of the sealable material, and the paper component often absorbs most of the heat, it is advantageous if the heat-sealable material softens and seals at a relatively low temperature. A lower seal initiation temperature (SIT) can achieve a faster packaging line speed. For example, some embodiments of the paper-based packaging film may include a heat-sealable material that exhibits a SIT of less than or equal to 110°C, less than or equal to 100°C, or less than or equal to 90°C. Possible heat sealable materials may include, but are not limited to, acrylate copolymers, PET, PE, PP or EVA copolymers. Such materials may be provided by lacquers as known in the art.

[0120] Suitable heat sealable materials can also be selected from hot melts. Hot melts or hot melt adhesives are well known in the field of packaging. Hot melts absorb heat and are converted into liquid form, and can be applied by coating the desired part before the hot melt material cools to a solid polymer. Hot melts rely on cooling to solidify (rather than evaporating, as in the case of heat seal or cold seal lacquer). Suitable hot melt adhesives can include but are not limited to EVA-based, amorphous poly-α-olefin-based (APAO) hot melt adhesives. Suitable hot melts can also include pressure-sensitive hot melts. Hot melts generally have a composition that is formulated to have a glass transition temperature (brittle start) lower than the minimum use temperature and a suitable high melting temperature. The degree of crystallinity should be as high as possible, but within the limits of allowing shrinkage. Melt viscosity and crystallization rate (and corresponding air-drying time) can be set for application. Hot melt adhesives have a fast solidification rate and are suitable for a wide range of temperatures.

[0121] The sealable material may be applied as a lacquer or from a water-based dispersion. For example, the heat sealable may comprise a water-based dispersion based on an EVA copolymer resin.

[0122] The patterned sealable material may be applied by any suitable method, such as by printing using, for example, any known printing method, including but not limited to flexographic gravure printing, rotogravure printing, gravure coating, and digital printing methods.

[0123] The sealable material is applied at a thickness that allows for sealing in the selected application. In some embodiments, the sealable material may be applied at a thickness greater than or equal to 1 g / m 2 Or greater than or equal to 3g / m 2 In other embodiments, the sealable material may be applied at a basis weight of less than or equal to 8 g / m 2 , less than or equal to 9g / m 2 Or less than or equal to 10g / m 2 For example, the sealable material may have a basis weight of about 1 g / m 2 About 10g / m 2 In the range of about 3g / m 2 About 9g / m 2 within the range.

[0124] Barrier materials

[0125] The paper-based packaging film may further include a barrier material. In some embodiments, the barrier material is located between the paper component and the polymer film. In some embodiments, the polymer film includes a top coating between the barrier material and the paper component. The top coating can be applied directly to the barrier material.

[0126] A paper-based packaging film according to any one of the preceding claims, wherein each of the paper component, the polymeric film and the barrier material, if present, are fully coextensive with each other.

[0127] The barrier material is not particularly limited and can be selected from organic and inorganic barrier materials known in the art. The barrier material can be a blend of multiple barrier materials. The barrier material can be contained in a single layer or can be contained in multiple layers and contain different layers of barrier materials.

[0128] For example, the barrier material may be selected from metals (e.g., aluminum), inorganic oxides (e.g., AlOx, where AlOx refers to aluminum oxide having the formula AlyOz, where the ratio y / z is a number from 0.2 to 1.5, preferably y is 2 and z is 3 (i.e., Al2O3); or SiOx, where x is a number from 1 to 2, preferably from 1.5 to 1.8 (i.e., SiOx, where 1≤x≤2, preferably where 1.5≤x≤1.8)) or combinations thereof. As known in the art, these barrier materials are applied to the polymer film by a vapor deposition type process, and the thickness of these barrier materials is negligible relative to the packaging film (i.e., less than 1 micron or less than 0.5 micron).

[0129] The barrier material may also be polymeric in nature and may be selected from polymeric barrier materials such as polyamides, ethylene vinyl alcohol copolymers or polyvinyl alcohol copolymers.

[0130] The barrier material preferably provides a layer with a maximum thickness equal to or less than 1 micron, preferably equal to or less than 0.5 micron.

[0131] In a preferred embodiment, the barrier material is not applied to the paper component. Applying the barrier material to the paper component may interfere with recyclability. The barrier material is suitably applied to the polymer film. The barrier material may be coated directly onto the polymer film, or there may be a primer layer between the barrier material and the polymer film.

[0132] Some embodiments of the paper-based packaging film can be described as having an outer surface and an inner surface, a polymer film, a paper component, and a patterned sealable material, wherein the polymer film is any oriented or unoriented film, optionally but preferably includes any metal or oxide barrier coating. In an embodiment, the barrier coated side of the polymer film is attached to the paper component by an adhesive (such as a water-sensitive adhesive). In one or more embodiments, the inner surface comprises a polymer film, and the outer surface comprises each of the paper component and the patterned sealable material, wherein the polymer barrier film is an oriented or unoriented film with a metal or oxide coating, and wherein optionally the barrier coated side of the polymer film is attached to the paper component by an adhesive.

[0133] Combinations of polymer films and barrier materials that have been found to be useful for paper-based packaging films include SiOx-coated OPET and BOPET, SiOx-coated OPP and BOPP, AIOx-coated OPET and BOPET, AIOx-coated OPP and BOPP, aluminum metal-coated OPET and BOPET, and aluminum metal-coated OPP and BOPP, and specifically a combination of polymer films and barrier materials selected from the group consisting of SiOx-coated OPET, SiOx-coated BOPP, AlOx-coated OPET, AlOx-coated BOPP, aluminum metal-coated OPET, and aluminum metal-coated BOPP.

[0134] Barrier materials can reduce the transmission of oxygen, moisture, or both.

[0135] In some embodiments, the average oxygen transmission rate (OTR) value of the paper-based packaging film containing the barrier material and the polymer film (e.g., containing the barrier material coated on the polymer film) is less than or equal to 5 cm 3 / m 2 / day, less than or equal to 1cm 3 / m 2 / day or less than or equal to 0.5cm 3 / m 2 / day, the value is measured according to ASTM F1927 using the conditions of 1 atmosphere, 23°C and 50% RH.

[0136] In some embodiments, the average water vapor transmission rate (MVTR) value of the paper-based packaging film containing the barrier material coated on the polymer film is less than or equal to 1 g / m 2 / day or less than or equal to 0.3g / m 2 / day, the value is measured according to ASTM F1249 using the conditions of 1 atmosphere, 38°C and 90% RH.

[0137] Adhesives

[0138] The paper-based packaging film may further comprise an adhesive. For example, the adhesive may be located between the paper component and the polymer film or between the paper component and the barrier material (if present). The adhesive and at least one patterned sealable material may be composed of the same or different materials. For example, in a typical embodiment, the patterned sealable material and the additional optional adhesive are composed of or provided by different materials. For example, the patterned sealable material is provided by a heat sealable material, and the adhesive is provided by a material different from the heat sealable material (such as by a water-sensitive adhesive).

[0139] The adhesive can provide an adhesive layer that bonds the paper component to the polymer film or barrier material (if present). The adhesive can be in direct contact with the paper. The adhesive can be in direct contact with the polymer film. The adhesive can be in direct contact with the barrier layer (if present). The adhesive can be applied by any known web-to-web lamination method (such as dry bond lamination, wet bond lamination, or heat lamination). The dry basis weight of the adhesive (i.e., after solvent removal) can be between 0.5 g / m 2 Up to 8.0g / m 2 Between or between 0.5g / m 2 Up to 4.0g / m 2 between.

[0140] Advantageously, the binder may be selected so as not to interfere with the release of fibers from the paper component during the paper recycling process.

[0141] In an advantageous embodiment, the adhesive comprises a water-sensitive material. Embodiments of the present disclosure advantageously provide a paper-based packaging film comprising an adhesive layer with a water-sensitive adhesive. As used herein, the term "water-sensitive" means that when exposed to or immersed in liquid water for a long time, the adhesive loses its adhesive and / or adhesive properties. Therefore, the use of a water-sensitive adhesive enables the paper component to be layered (i.e., separated) with the remainder of the paper-based packaging film structure during the repulping process. The adhesive can be a water-based adhesive formulated using a synthetic and / or natural polymer. The example of the material that can be used in the adhesive layer between the paper component and the barrier layer includes but is not limited to latex / casein blends, starch, sugar derivatives, cellulose, amino resins, (poly) acrylates, polyvinyl alcohol (PVOH), polyvinyl acetate, polyacrylic acid, maleic acid-modified ethylene copolymers, methylcellulose, carboxymethylcellulose, carboxyl-functional polyesters, polyethylene succinate, polybutylene succinate, ionomers, or hydrophilic polyurethanes.

[0142] Solvent-based / solvent-free adhesives are not preferred for use in the present invention because they are absorbed into the fibrous cellulose matrix and form an insoluble layer after solidification, and therefore may generally cause significant problems during recycling. However, some combinations of paper and solvent-based / solvent-free adhesives can minimize fiber loss during recycling because they only interact on the surface or with a small amount of fibers. Therefore, in certain embodiments, such adhesives can still be used in the present invention. Water sensitivity can be established using a standard laboratory pulper using water, 40°+ / -5°C water and 30.000 revolutions. Preferably, suitable adhesives will not interfere with recycling in a standard paper recycling process, as determined according to the recyclability criteria described herein.

[0143] manufacture

[0144] The paper-based packaging film can be obtained by methods known in the field of packaging films. Suitable methods may, for example, include providing a paper component, providing a patterned sealable material on a first major surface of the paper component, providing a polymer barrier film, and connecting the second major surface of the paper component to the polymer barrier film by methods known in the art, so that the first major surface of the paper component provides the outer surface of the packaging film. In an embodiment, the method provides a polymer film as the second major outer surface of the paper-based packaging film. The connection can be achieved by methods known in the art (such as by lamination) with or without the use of an intermediate material (using, for example, a water-sensitive adhesive as described herein). Additionally, the method may include applying a barrier material to the surface of the polymer film, and connecting the polymer film to the paper material so that the barrier material is located between the paper component and the polymer film.

[0145] The method may also include cutting the packaging film into individual sheets, which are designed for packaging applications that may have any form. Suitable sheets may, for example, be designed for wrapping packaging, such as for use with the product to be wrapped. The sheet may also be in the form of a cutout adapted to the geometry of the product to be packaged and / or the packaging machine used. For example, a suitable sheet may be rectangular or have the form of an open envelope.

[0146] use

[0147] The packaging materials disclosed herein are suitable for packaging various types of products, including food and non-food products. The packaging materials are particularly suitable for packaging food products. It has been found that the packaging materials described herein are particularly useful for packaging products having a rectangular parallelepiped shape. It has also been found that the packaging materials described herein are particularly useful for packaging food products, such as food products containing fats and oils, including products such as soup or broth cubes, candies or chocolates.

[0148] Therefore, in an embodiment, the present invention relates to a paper-based packaging film for packaging cuboid food products (e.g., soup cubes or broth cubes). The term "broth cube" is known in the art and refers to a type of product. In the context of the present invention, it is not necessarily limited to and should not be interpreted as a product that is only used to prepare soup or broth, but it may be suitable for preparing soups, stews, sauces, gravies or as a condiment. Therefore, the broth cubes are usually at least partially diluted in a hot water solution (such as water), or the product is at least partially broken up on a plate during preparation (e.g., in a cooking pot) or before consumption (e.g., on a consumer's plate).

[0149] In an embodiment, the product may be a food product comprising one or more components selected from the group consisting of fats, salts, sugars, food concentrates, dry food components and spices.

[0150] The food products to be packaged include, but are not limited to, for example, food products containing fats and oils, food concentrates, spice blends, condiments and dry food blends. A specific application area is for packaging soup cubes or bouillon cubes. However, the packaging film described herein can also be used for packaging other types of products, such as non-food products, for example tobacco or soap.

[0151] The product to be packaged may be in any form, such as in loose or compressed powder form, concentrated form, loose or compressed granular form, loose or compressed fibrous form, loose or compressed chopped form, semi-solid form or shaped form. The compressed form may have any shape suitable for packaging this type of product.

[0152] A particularly suitable shape is a cuboid shape. The cuboid may be of any size or cuboid shape. The packaging material may be particularly useful for forming cuboid packages, such as for packages for soup cubes.

[0153] However, the invention is not limited to this particular use, but the packaging material itself is useful and can, for example, be used to wrap products of any shape or used as a lining for secondary packaging or part thereof (i.e., it is not necessary to provide a packaged cuboid product). The term "secondary packaging" as used in this context means secondary packaging that must not be made from the packaging film described herein (although making from the packaging film described herein is not excluded).

[0154] Package

[0155] The present invention also relates to a package formed by or comprising the paper-based packaging film as described herein. The package can be sealed by the patterned sealable material. In the package, the patterned sealable material generally faces away from the product and generally faces the environment.

[0156] The package is typically formed by sealing. Sealing can include bonding the patterned sealable material to itself (i.e., in an overlap) or to another surface portion on the paper-based packaging film (i.e., in an overlap), such as in an overlap that includes the second surface area (provided by the paper component, optionally including ink and / or topcoat) and the second major exterior surface of the paper-based packaging film (provided by a polymer film in a typical embodiment).

[0157] In an embodiment, the package is a folded package formed from a paper-based packaging film as described herein, for example, by folding and wrapping the paper-based packaging film around a product to be packaged (e.g., a cuboid product). The folded package can have any size or shape, such as a cuboid of any size and cuboid shape. The folded package typically contains the packaged product.

[0158] As is known in the art, folding wrapping generally involves wrapping a packaging film tightly around the product to be packaged along a fold line. A typical folding operation may include a series of folding steps to produce at least two superimposed folded regions (i.e., overlapping portions) that can be superimposed on each other and used to seal with a patterned sealable material to form a permanent and stable folded wrap. The patterned sealable material is located on the surface of the paper-based packaging film facing away from the product.

[0159] For example, the product can be individually wrapped using a sheet of paper-based packaging film of appropriate size and shape (e.g., a rectangular sheet suitable for the size of the product to be packaged). The product to be packaged can be, for example, in the shape of a cuboid, typically placed in the center of the second major outer surface of the paper-based packaging film. The first major surface of the paper-based packaging film faces away from the product and faces the environment. Depending on the orientation of the product on the sheet and the selected folding sequence, one or more sides of the sheet are turned up or down along the three-dimensional shape of the product to be packaged, thereby producing an overlapping area in one or more folding steps. The patterned sealable material can help keep the folded structure in place during the packaging process. The patterned sealable material provides a joint in the overlapping area of ​​the paper-based packaging film, as described with respect to the paper-based packaging film. In an embodiment, the folded piece can be fixed by applying light pressure and by superimposing certain areas of the sealable material on each other (i.e., in the overlapping portion).

[0160] The patterned sealable material can provide a hermetically sealed package, but this is not required. Thus, the package can be a hermetically sealed package or a non-hermetically sealed package.

[0161] In some embodiments, the present invention provides a packaged cuboid product, comprising: a paper-based packaging film as described herein and a product having a cuboid shape; wherein the paper-based packaging film is wrapped around the product so that the first major surface of the packaging film faces away from the product. The packaged cuboid product may comprise a paper-based packaging film as described herein, and wherein the second major surface comprises a polymer film and faces the product. The second major surface may be in contact with each side of the product.

[0162] The packaged rectangular parallelepiped product may include individually wrapped products having a rectangular parallelepiped shape. Alternatively, the packaged rectangular parallelepiped product may include a rectangular parallelepiped block product consisting of a plurality of separable rectangular parallelepiped compartments, and a paper-based packaging film is wrapped around the rectangular parallelepiped block product.

[0163] The packaged cuboid product may be sealed by the patterned sealable material.

[0164] Detailed description with drawings

[0165] Figure 11 is a perspective view of an embodiment of a packaged cuboid product 10. A paper-based packaging film 100 having a first major outer surface 102 forming an outer surface and facing away from the product is wrapped around a cuboid product (not shown) and sealed closed with the edges folded over the top. The packaged cuboid product can have any size or cuboid shape.

[0166] Figure 2 1 is an embodiment of a cross-sectional view of a paper-based packaging film 100. The packaging film 100 includes a paper component or paper layer 110 and a polymer film 120. The paper-based packaging film 100 also includes a patterned sealable material 140 located on the surface of the paper component or paper layer 110. In this configuration, the polymer film 120 is located at the second major surface (inner surface) of the packaging film 104, and the patterned sealable material 140 and the paper component or paper layer 110 are located at the outer surface 102. In some embodiments, the polymer film 120 forms an inner layer (i.e., provides a second major outer surface), and the outer layer is located at the inner surface 104 of the paper-based packaging film 100. In some embodiments, the polymer film 120 is adhered to the paper component or paper layer 110 by an adhesive (layer) 150 (not shown). In some embodiments, the patterned sealable material 140 is adjacent to the paper component or paper layer 110 and is located on the surface of the paper component or paper layer 110 opposite to the adhesive (layer) 150 (not shown). The outer surface 102 of the paper-based packaging film 100 is formed by both the paper component or paper layer 110 and the patterned sealable material 140. In the area of ​​the patterned sealable material 140, the outer surface 102 is the patterned sealable material, and in other areas the outer surface 102 is the paper component or paper layer 110.

[0167] Figure 3a 2 is another embodiment of a cross-sectional view of a paper-based packaging film 200a. The packaging film 200a includes, in sequence, a paper component or paper layer 210, an adhesive 250, and a polymer film 220. Preferably, the adhesive attaches the paper component or paper layer 210 to the polymer film 220. The paper-based packaging film 200a also includes a patterned sealable material 240 located on the surface of the paper component or paper layer 210. In this configuration, the polymer film 220 is located at the second major surface (inner surface) 204, and the patterned sealable material 240 and the paper component or paper layer 210 are located at the first major surface (outer surface) 202.

[0168] Figure 3b2 is another embodiment of a cross-sectional view of a paper-based packaging film 200b. The packaging film 200b includes, in the following order: a paper component or paper layer 210, a barrier material 230, and a polymer film 220. The barrier material is located between the polymer film 220 and the paper component or paper layer 210. The paper-based packaging film 200b also includes a patterned sealable material 240 located on the surface of the paper component or paper layer 210. In this configuration, the polymer film 220 is located at the second major surface (inner surface) 204, and the patterned sealable material 240 and the paper component or paper layer 210 are located at the first major surface (outer surface) 202.

[0169] Figure 4 3 is another embodiment of a cross-sectional view of a paper-based packaging film 300. The packaging film 300 includes, in sequence, a paper component or paper layer 310 and an adhesive 350, a barrier material 330, and a polymer film 320. The paper component or paper layer 310 is attached to the barrier material 330 by the adhesive (layer) 350. The paper-based packaging film 300 also includes a patterned sealable material 340 located on a surface of the paper component or paper layer 310. In this configuration, the polymer film 320 is located at the second major surface (inner surface) 304, and the patterned sealable material 340 and the paper component or paper layer 310 are located at the first major surface (outer surface) 302.

[0170] In some embodiments, the polymer film 320 forms an inner layer (i.e., provides a second major outer surface of the packaging film), and the inner layer is located at the inner surface 304 of the paper-based packaging film 300. In some embodiments, the barrier material 330 is adjacent to the paper component 310. In some embodiments, the paper component 310 and the barrier material 330 are bonded to each other by an adhesive (layer) 350. In some embodiments, the paper-based packaging film (100, 200a, 220b, 300) includes an ink layer (not shown) located on the outer surface of the paper component (110, 210, 310). The paint coating (topcoat, not shown) is in direct contact with the ink layer. In some embodiments, the patterned sealable material (140, 240, 340) is adjacent to the paint coating and is located on the surface of the paint coating opposite to the ink layer. The outer surface (101, 202, 302) of the paper-based packaging film (100, 200a, 200b, 300) is formed by both the paint coating and the patterned sealable material (140, 240, 340). In areas of the patterned sealable material (140, 240, 340) the outer surface (102, 202, 302) is the sealable material and in other areas the outer surface (102, 202, 302) is the paint coating.

[0171] Figure 52 is an exemplary plan view of an outer surface 202 (or 102 or 302, not shown) of an embodiment of a paper-based packaging film 200a or 200b (or a paper-based packaging film 100 or 300, not shown). The outer surface 202 (or 102 or 302, not shown in the case of a paper-based packaging film 100 or 300) is composed of a paper component or paper layer 210 (or 110 or 310, not shown in the case of a paper-based packaging film 100 or 300) and a patterned sealable material 240 (or 140 or 340, not shown in the case of a paper-based packaging film 100 or 300). Although a specific pattern of the sealable material is shown, the material can be in any pattern suitable for the application.

[0172] Figure 6 2 is another exemplary plan view of an outer surface 202 (or 102 or 302, not shown) of an embodiment of a paper-based packaging film 200a or 200b (or paper-based packaging film 100 or 300, not shown). The outer surface 202 (or 102 or 302, not shown in the case of paper-based packaging film 100 or 300) is composed of a paper component or paper layer 210 (or 110 or 310, not shown in the case of paper-based packaging film 100 or 300) and a patterned sealable material 240 (or 140 or 340, not shown in the case of paper-based packaging film 100 or 300). Although a specific pattern of the sealable material is shown, the material can be in any pattern suitable for the application.

[0173] Figure 7 2 is another exemplary plan view of an outer surface 202 of an embodiment of a paper-based packaging film 200a or 200b (or paper-based packaging film 100 or 300, not shown). The outer surface 202 (or 102 or 302, in the case of paper-based packaging film 100 or 300, not shown) is composed of a paper layer 210 (or 110 or 310, in the case of paper-based packaging film 100 or 300, not shown) and two different patterned sealable materials, a first patterned sealable material 240a and a second sealable material 240b (or 140a / 140b or 340a / 340b, in the case of paper-based packaging film 100 or 300, not shown). In the illustrated embodiment, the first sealable material 240a covers 2.5% of the surface, and the second sealable material 240b covers 14% of the surface. Although a particular pattern of sealable materials is shown, the first sealable material 240a and the second sealable material 240b may each be in any pattern and cover any area suitable for the application. Figure 7The pattern shown in indicates how one can produce the material in roll-to-roll form. The pattern shown is a portion of the length of the film. The two side-by-side repeating patterns will eventually separate from each other so that the product can be wrapped therein. When the packaging film is folded, the first sealing material in section 240b seals itself. The second sealing material in section 240a seals the package against the outer surface, thereby sealing the closed package.

[0174] List of key terms: 10 packaged rectangular product; 100, 200a, 200b, 300 paper-based packaging film; 102, 202, 302 outer surface of the paper-based packaging film; 104, 204, 304 inner surface of the paper-based packaging film; 110, 210, 310 paper component or paper layer; 120, 220, 320 polymer film; 230, 330 barrier material; 140, 240, 340 patterned sealable material; 140a, 240a, 340a first patterned sealable material; 140b, 240b, 340b second patterned sealable material; 250, 350 adhesive.

[0175] Advantages

[0176] It has been found that the paper-based packaging film as described herein can solve the problems outlined herein. The packaging film has high barrier properties (particularly, for moisture and grease), good folding properties and excellent sealing properties while maintaining recyclability in a paper recycling process (such as in a standard paper recycling process). The paper-based packaging film and the packaging made therefrom are recyclable, as determined by at least one, both or all of PTS-RH 021-Catalog 2, Aticelca 501 (2019) and CEPI Coordinated European Laboratory Test Method-2nd Edition. For example, the paper-based packaging film as described herein can be graded as B, A or A* according to Aticelca 501 (2019).

[0177] In order to maintain the recyclability of the paper-based packaging film, the paper component thickness and / or weight is increased so as to obtain the paper content required to designate the packaging material as "recyclable". The packaging film can be used to package products containing grease while maintaining recyclability in a paper recycling process (such as a standard paper recycling process). Advantageously, the packaging film described herein can maintain an excellent appearance (e.g., it is not susceptible to grease stains) during packaging conversion and packaging use and storage. In addition, the packaging film can be used on a high-speed packaging machine, i.e., the packaging film has good runnability. The paper-based packaging film performs particularly well in cuboid products and products containing grease (including but not limited to soup cubes). When the paper-based packaging film is folded around the soup cube product and stored, there is no grease stain, as is visible on other coated paper structures. The inclusion of a thin polymer barrier film provides excellent barrier, excellent runnability and recyclability.

[0178] Example

[0179] The present disclosure also extends to the following embodiments:

[0180] Embodiment 1: A paper-based packaging film, which generally has a first major outer surface and a second major outer surface, the paper-based packaging film comprising: a paper component; a polymer film; and a patterned sealable material. The first major outer surface generally (preferably) comprises one or more first surface areas provided by the patterned sealable material and one or more second surface areas provided by the paper component.

[0181] Embodiment 2: The paper-based packaging film of embodiment 1, wherein the second major outer surface is provided by the polymer film.

[0182] Embodiment 3: The paper-based packaging film of any of the preceding embodiments, wherein the paper component is attached to the polymer film.

[0183] Embodiment 4: The paper-based packaging film of any of the preceding embodiments, wherein the polymer film does not extend into the fiber network of the paper component.

[0184] Embodiment 5: A paper-based packaging film according to any one of the preceding embodiments, wherein the total composition of the paper-based packaging film comprises greater than or equal to 80 wt. % paper, or greater than or equal to 85 wt. % paper, or greater than or equal to 90 wt. % paper, or greater than or equal to 95 wt. % paper, based on the total weight of the paper-based packaging film, and or wherein the paper-based recycled content is greater than or equal to 80 wt. %, or greater than or equal to 85 wt. %, or greater than or equal to 90 wt. %.

[0185] Embodiment 6: The paper-based packaging film of any of the preceding embodiments, wherein the polymer film is unoriented, uniaxially oriented, or biaxially oriented.

[0186] Embodiment 7: The paper-based packaging film of any preceding embodiment, wherein the polymer film is oriented.

[0187] Embodiment 8: The paper-based packaging film according to any one of the preceding embodiments, wherein the polymer film has a thickness ranging from 2 μm to 15 μm.

[0188] Embodiment 9: The paper-based packaging film according to any one of the preceding embodiments, wherein the polymer film comprises one or more materials selected from the group consisting of polypropylene (PP), polyester, polyethylene (PE), polyamide (PA) and polylactic acid (PLA).

[0189] Embodiment 10: According to any one of the preceding embodiments, the paper-based packaging film, wherein the polymer film comprises one or more layers independently selected from the following: uniaxially oriented polypropylene (OPP) film, biaxially oriented polypropylene (BOPP) film, uniaxially oriented polyethylene (OPE) film, biaxially oriented polyethylene (BOPE) film, uniaxially oriented polyester film, biaxially oriented polyester film, uniaxially oriented polyamide (OPA) film, biaxially oriented polyamide (BOPA) film, uniaxially oriented polylactic acid (OPLA) film and biaxially oriented polylactic acid (BOPLA) film.

[0190] Embodiment 11: The paper-based packaging film according to any one of the preceding embodiments, wherein the sealable material is a heat-sealable material or a pressure-sensitive cold-seal material.

[0191] Embodiment 12: The paper-based packaging film according to any one of the preceding embodiments, wherein the heat-sealable material is a heat-sealable lacquer or a hot melt adhesive.

[0192] Embodiment 13: The paper-based packaging film according to any one of the preceding embodiments, further comprising a barrier material.

[0193] Embodiment 14: The paper-based packaging film of Embodiment 13, wherein the barrier material is located between the paper component and the polymer film.

[0194] Embodiment 15: The paper-based packaging film according to embodiment 13 or 14, wherein the barrier material is selected from metals, oxides or combinations thereof deposited by vapor deposition.

[0195] Embodiment 16: The paper-based packaging film according to any one of embodiments 13 to 15, wherein the barrier material provides a layer with a maximum thickness of less than 1 micrometer, preferably less than 0.5 micrometer.

[0196] Embodiment 17: The paper-based packaging film according to any one of embodiments 13 to 16, which comprises a combination of a polymer film and a barrier material, wherein the polymer film and the barrier material are selected from SiOx-coated OPET, SiOx-coated BOPP, AlOx-coated OPET, AlOx-coated BOPP, aluminum metal-coated OPET and aluminum metal-coated BOPP.

[0197] Embodiment 18: The paper-based packaging film of any preceding embodiment, wherein each of the paper component, the polymeric film, and the barrier material, if present, are fully coextensive with one another.

[0198] Embodiment 19: The paper-based packaging film of any preceding embodiment, wherein the paper component comprises a paper layer and optionally one or more of the following: a paper surface treatment, an ink, and / or a topcoat.

[0199] Embodiment 20: The paper-based packaging film according to any one of the preceding embodiments, further comprising ink, the ink being located on the first major outer surface and covering a portion or all of the first major surface.

[0200] Embodiment 21: The paper-based packaging film of Embodiment 20, wherein the ink comprises a pigment.

[0201] Embodiment 22: The paper-based packaging film according to any one of the preceding embodiments, wherein the basis weight of the paper component is 30 g / m 2 Up to 360g / m 2 within the range.

[0202] Embodiment 23: The paper-based packaging film of any one of the preceding embodiments, wherein the paper component comprises calendered paper or supercalendered paper.

[0203] Embodiment 24: A paper-based packaging film according to any of the preceding embodiments, wherein the paper component comprises a paper layer having at least one surface treatment on one or both sides thereof, wherein the at least one surface treatment has one or more (independently) selected from the following preparations: starch, alginate, carboxymethyl cellulose, polyvinyl alcohol, clay and combinations thereof.

[0204] Embodiment 25: According to any one of the preceding embodiments, the paper-based packaging film, wherein the paper component comprises a paper selected from the group consisting of kraft paper, bleached paper, microfibrillated cellulose (MFC) paper, greaseproof paper, machine-glazed kraft paper (MGBK), single-sided clay-coated paper (C1S) and double-sided clay-coated paper (C2S).

[0205] Embodiment 26: The paper-based packaging film according to any of the preceding embodiments, wherein the paper component has a top surface and a back surface opposite the top surface, wherein the top surface comprises the one or more second surface regions, and wherein the one or more second surface regions independently comprise one or more of the following: paper, surface treatment, ink, and topcoat.

[0206] Embodiment 27: The paper-based packaging film of any of the preceding embodiments, further comprising an adhesive located between the paper component and the polymer film or between the paper component and the barrier material, if present.

[0207] Embodiment 28: The paper-based packaging film of Embodiment 30, wherein the adhesive attaches the paper component to the polymeric film or the barrier material, if present.

[0208] Embodiment 29: The paper-based packaging film of Embodiment 27 or 28, wherein the adhesive comprises a water-sensitive material.

[0209] Embodiment 30: According to the paper-based packaging film described in embodiment 29, the material is selected from latex / casein blends, starch, sugar derivatives, cellulose, amino resins, polyacrylates, polyvinyl alcohol, polyvinyl acetate, polyacrylic acid, maleic acid modified ethylene copolymers, methyl cellulose, carboxymethyl cellulose, carboxyl functional polyesters, polyethylene succinate, polybutylene succinate, ionomer hydrophilic polyurethanes and combinations thereof.

[0210] Embodiment 31: The paper-based packaging film of any preceding embodiment, wherein the second major surface is a product contact surface.

[0211] Embodiment 32: The paper-based packaging film according to any of the preceding embodiments, wherein the paper component is located at the outer surface of the paper-based packaging film; the polymer film is located at the inner surface of the paper-based packaging film; and the patterned sealable material is located at the outer surface of the paper-based packaging film.

[0212] Embodiment 33: The paper-based packaging film of any preceding embodiment, wherein the polymer film is located at the inner surface.

[0213] Embodiment 34: A paper-based packaging film according to any of the preceding embodiments, comprising a polymeric barrier film, wherein the polymeric barrier film is an oriented or unoriented film having a metal or oxide coating, and wherein optionally the barrier-coated side of the polymeric film is attached to the paper component by an adhesive.

[0214] Embodiment 35: The paper-based packaging film according to any one of the preceding embodiments, comprising

[0215] - a barrier material, said barrier material being located between said paper component and said polymer film, and

[0216] - an adhesive located between the barrier material and the paper component.

[0217] Embodiment 36: A paper-based package according to embodiment 35, wherein:

[0218] - the heat sealable comprises a water-based dispersion based on an EVA copolymer resin; and / or

[0219] - the paper assembly comprises a supercalendered paper layer, a backside untreated paper layer, a top side uncoated paper layer, a machine-processed paper layer; and / or

[0220] - the polymer film is oriented polypropylene; and / or

[0221] - the barrier material comprises a metal vapour deposited onto the polymer film; and / or

[0222] - The adhesive is a water-based adhesive formulated using synthetic or natural based polymers.

[0223] Embodiment 37: A package formed from or comprising the paper-based packaging film according to any one of embodiments 1 to 36.

[0224] Embodiment 38: A folding package formed from the paper-based packaging film according to any one of Embodiments 1 to 37.

[0225] Embodiment 39: The package of Embodiment 37 or Embodiment 38, further comprising a packaged product.

[0226] Embodiment 40: A packaged rectangular parallelepiped product comprising:

[0227] - a paper-based packaging film according to any one of embodiments 1 to 36, and

[0228] - a product having a rectangular parallelepiped shape;

[0229] The paper-based packaging film is wrapped around the product such that the first major surface of the packaging film faces away from the product.

[0230] Embodiment 41: The packaged cuboid product of Embodiment 40, wherein the second major surface of the paper-based packaging film comprises the polymer film and faces the product.

[0231] Embodiment 42: The packaged cuboid product of Embodiment 40 or 41, wherein the second major surface contacts each side of the product.

[0232] Embodiment 43: The packaged cuboid product according to any one of Embodiments 40 to 42, comprising individually wrapped products having a cuboid shape.

[0233] Embodiment 44: The packaged cuboid product according to any one of embodiments 40 to 42, wherein the product comprises a cuboid block product composed of a plurality of separable cuboid compartments, and the paper-based packaging film is wrapped around the cuboid block product.

[0234] Embodiment 45: The packaged cuboid product of any one of Embodiments 40 to 45, wherein the packaged product is sealed by the patterned sealable material.

[0235] Embodiment 46: The packaged cuboid product according to any one of embodiments 40 to 45, wherein the product is a food product comprising one or more components selected from the group consisting of fats, salts, sugars, food concentrates, dry food components and spices.

[0236] Embodiment 47: The packaged cuboid product of any one of Embodiments 40 to 46, wherein the product is a soup cube.

[0237] Embodiment 48: A paper-based packaging film (which can be a flexible paper-based packaging film in a typical embodiment) comprising a polymer film, optionally a barrier material, a paper component, and a patterned sealable material. The total composition of the paper-based packaging film can be greater than or equal to 80 wt%, greater than or equal to 85 wt%, greater than or equal to 90 wt%, or greater than or equal to 95 wt% of the paper component; and a package comprising the paper-based packaging film and optionally a product.

[0238] Embodiment 49: The paper-based packaging film or product of Embodiment 48, wherein the inner surface comprises the polymeric film and the outer surface comprises each of the paper component and the sealable material.

[0239] Embodiment 50: The paper-based packaging film according to Embodiment 48 or 49, wherein the film is characterized as described in any one or more of Embodiments 1 to 36; and / or the product is characterized as described in any one or more of Embodiments 37 to 47.

[0240] Examples

[0241] Measurement results

[0242] In some embodiments, the paper-based packaging film may be used in a repulping process. The repulping process, as described further below, removes paper content from the paper-based packaging film and measures the non-paper content of the paper-based packaging film.

[0243] Recyclability can be assessed by recycled content, which is all the material that can be recycled to create new paper. The following procedure can be used to determine the recycled content of paper after the repulping process.

[0244] In some embodiments, a test method for separating paper content from non-paper content is used for the purpose of recycling materials. This test consists of soaking the starting material (i.e., paper-based packaging film) in a beaker containing hot water and mixing it to separate the paper from the polymer film and measuring the amount of pulp recovered. In general, the equipment used includes:

[0245] -5x 5cm cutting templates

[0246] - Graduated beaker that can hold 500ml of water

[0247] - Heating plate pre-set to 45°C

[0248] - Propeller stirrer with adjustable speed

[0249] - Thermometer for controlling water temperature

[0250] -Precision scales

[0251] - Oven set at 70°C

[0252] Generally speaking, methods used to measure the amount of recycled paper content include:

[0253] 1. Turn on the hot plate.

[0254] 2. Cut ten 5*5cm samples from the approximately 1m sample.

[0255] 3. Weigh ten samples (P1).

[0256] 4. Fill the beaker with 500 ml of water at 45°C + / - 2°C.

[0257] 5. Place the filled beaker on the pre-set hot plate.

[0258] 6. Use a thermometer to measure the temperature of the water regularly.

[0259] 7. Introduce a rotating support with the propeller closest to the bottom of the beaker.

[0260] 8. Place the sample in water in a beaker.

[0261] 9. Start the agitator by adjusting the agitator to a speed of 1100 rpm.

[0262] 10. Allow it to run for 15 minutes, checking the water temperature periodically.

[0263] 11. At the end of the measurement, turn off the hot plate and remove the stirrer.

[0264] 12. Take out the beaker, and take out ten pieces of polymer film and place them on paper towels to drain the water, and put them in an oven set at 70°C between two paper towels to dry them for 24 hours.

[0265] 13. Allow the ten polymer films to recondition at room temperature for at least 24 hours and weigh the ten films (P2).

[0266] 14. Determine the recycled content as P2 divided by P1 x 100 wt.-%.

[0267] Examples

[0268] The present disclosure will now be described with reference to the following examples of the invention.

[0269] Inventive Example 1 is an example based on a paper-based packaging film having one or more components / layers / films as described above. The general structure of the paper-based packaging film of Inventive Example 1 is described below.

[0270] structure:

[0271] Patterned Sealable: Heat Seal Lacquer (“HSL”, Registered): EVA based (2gsm)

[0272] Topcoat ("OVL", registered): Nitrocellulose based

[0273] Ink: Nitrocellulose based

[0274] Paper: MGBK paper (50gsm)

[0275] Water sensitive adhesive: (1.5gsm)

[0276] Polymer film 8μm metOPP (7.3gsm)

[0277] Inventive Example 1 was produced by a method of applying ink, HSL and OVL using water-based lamination and gravure printing. More specifically, Inventive Example 1 was produced by laminating a paper assembly to the metallized side of metOPP using a water-sensitive adhesive. On the first major exterior surface (i.e., the first major exterior surface of the paper), ink was applied by gravure printing, and then a topcoat and heat seal lacquer were applied in registration. Figure 6 The pattern of application of heat sealing material is shown.

[0278] Based on the total composition of the paper-based packaging film, the calculated paper content of the film of Example 1 is greater than about 80% by weight. The packaging film of Example 1 can be repulped using a standard laboratory crusher. When tested according to the Aticelca 501 (2019) method, the packaging film of Example 1 of the present invention can be certified as a "B" grade. In this test, 13.6% of the weight was lost to coarse waste, and 2.1% of the weight was lost to "fiber flakes", and the content of the retained paper-based packaging film was 84.3% by weight. It is believed that the use of a higher paper content (for example, using 100gsm paper instead of 50gsm paper in the structure exemplified above) can further increase the recycled content, thereby achieving an A-level rating determined according to the Aticelca 501 (2019) standard. The paper-based packaging film described and exemplified herein is suitable for recycling in a standard paper recycling process and is suitable for packaging rectangular products (such as soup cubes).

[0279] The paper-based packaging films described and exemplified herein exhibit high barrier properties (particularly, against moisture and grease), folding properties, and excellent sealing properties while maintaining recyclability in standard paper recycling processes. The packaging films maintain excellent appearance during package conversion and package use and storage, and do not show grease stains when packaging soup cubes. The packaging films described and exemplified herein can be run on high-speed packaging machines.

[0280] Although the present disclosure has been described herein with reference to specific embodiments and examples of the invention, it should be understood that these embodiments and examples of the invention are merely illustrative of the principles and applications of the present disclosure.

Claims

1. A paper-based packaging film having a first major outer surface and a second major outer surface, the paper-based packaging film comprising: Paper components; polymer films; and Patterned sealable materials; Wherein the first major exterior surface comprises one or more first surface regions provided by the patterned sealable material and one or more second surface regions provided by the paper component.

2. The paper-based packaging film of claim 1, wherein the second major outer surface is provided by the polymer film.

3. The paper-based packaging film according to any one of the preceding claims, wherein the paper component is attached to the polymer film.

4. The paper-based packaging film according to any of the preceding films, wherein the polymer film does not extend into the fiber network of the paper component.

5. The paper-based packaging film according to any one of the preceding claims, wherein the paper content of the paper-based packaging film comprises greater than or equal to 80 wt% paper, or greater than or equal to 85 wt% paper, or greater than or equal to 90 wt% paper, or greater than or equal to 95 wt% paper, based on the total weight of the paper-based packaging film.

6. The paper-based packaging film according to any one of the preceding claims, wherein the recycled content of the paper-based packaging film is greater than or equal to 80 weight %, or greater than or equal to 85 weight %, or greater than or equal to 90 weight %, based on the total weight of the paper-based packaging film.

7. The paper-based packaging film according to any one of the preceding claims, wherein the polymer film is unoriented, uniaxially oriented or biaxially oriented.

8. The paper-based packaging film according to any one of the preceding claims, wherein the polymer film is oriented.

9. The paper-based packaging film according to any one of the preceding claims, wherein the polymer film has a thickness in the range of 2 to 15 μm.

10. The paper-based packaging film according to any one of the preceding claims, wherein the polymer film comprises one or more materials selected from the group consisting of polypropylene (PP), polyester, polyethylene (PE), polyamide (PA) and polylactic acid (PLA).

11. The paper-based packaging film according to any one of the preceding claims, wherein the polymer film comprises one or more layers independently selected from the group consisting of a uniaxially oriented polypropylene (OPP) film, a biaxially oriented polypropylene (BOPP) film, a uniaxially oriented polyethylene (OPE) film, a biaxially oriented polyethylene (BOPE) film, a uniaxially oriented polyester film, a biaxially oriented polyester film, a uniaxially oriented polyamide (OPA) film, a biaxially oriented polyamide (BOPA) film, a uniaxially oriented polylactic acid (OPLA) film, and a biaxially oriented polylactic acid (BOPLA) film.

12. The paper-based packaging film according to any one of the preceding claims, wherein the sealable material is a heat sealable material or a pressure sensitive cold seal material.

13. The paper-based packaging film according to any one of the preceding claims, wherein the heat sealable material is a heat sealable lacquer or a hot melt adhesive.

14. The paper-based packaging film according to any one of the preceding claims, further comprising a barrier material.

15. The paper-based packaging film of claim 14, wherein the barrier material is located between the paper component and the polymer film.

16. The paper-based packaging film according to claim 14 or 15, wherein the barrier material is selected from metals, oxides or combinations thereof deposited by vapor deposition.

17. A paper based packaging material according to any one of claims 14 to 16, wherein the barrier material provides a layer having a maximum thickness of less than 1 micron, preferably less than 0.5 micron.

18. The paper-based packaging film according to any one of claims 14 to 17, comprising a combination of a polymer film and a barrier material selected from the group consisting of SiOx-coated OPET, SiOx-coated BOPP, AlOx-coated OPET, AlOx-coated BOPP, aluminum metal-coated OPET and aluminum metal-coated BOPP.

19. The paper-based packaging film of any one of the preceding claims, wherein each of the paper component, the polymeric film, and the barrier material, if present, are fully coextensive with one another.

20. The paper-based packaging film according to any one of the preceding claims, wherein the paper component comprises a paper layer and optionally one or more of the following: a paper surface treatment, an ink and / or a topcoat.

21. The paper-based packaging film of any one of the preceding claims, further comprising an ink located on the first major outer surface and covering a portion or all of the first major surface.

22. The paper-based packaging film of claim 21, wherein the ink comprises a pigment.

23. The paper-based packaging film according to any one of the preceding claims, wherein the basis weight of the paper component is between 30 g / m 2 Up to 360g / m 2 within the range.

24. The paper-based packaging film according to any one of the preceding claims, wherein the paper component comprises calendered paper or supercalendered paper.

25. The paper-based packaging film according to any one of the preceding claims, wherein the paper component comprises a paper layer having at least one surface treatment on one or both sides thereof, the at least one surface treatment having one or more (independently) agents selected from the group consisting of starch, alginates, carboxymethyl cellulose, polyvinyl alcohol, clay, and combinations thereof.

26. The paper-based packaging film according to any one of the preceding claims, wherein the paper component comprises a paper selected from the group consisting of kraft paper, parchment-type paper, bleached paper, microfibrillated cellulose (MFC) paper, greaseproof paper, machine-glazed kraft paper (MGBK), single-sided clay-coated paper (C1S) and double-sided clay-coated paper (C2S).

27. The paper-based packaging film of any one of the preceding claims, wherein the paper component has a top surface and a back surface opposite the top surface, wherein the top surface comprises the one or more second surface regions, and wherein the one or more second surface regions independently comprise one or more of the following: paper, surface treatment, ink, and topcoat.

28. The paper-based packaging film of any one of the preceding claims, further comprising an adhesive located between the paper component and the polymer film or between the paper component and the barrier material, if present.

29. The paper-based packaging film of claim 28, wherein the adhesive attaches the paper component to the polymeric film or the barrier material, if present.

30. The paper-based packaging film according to claim 28 or 29, wherein the adhesive comprises a water-sensitive material.

31. The paper-based packaging film of claim 30, wherein the material is selected from the group consisting of latex / casein blends, starch, sugar derivatives, cellulose, amino resins, polyacrylates, polyvinyl alcohol, polyvinyl acetate, polyacrylic acid, maleic acid modified ethylene copolymers, methyl cellulose, carboxymethyl cellulose, carboxyl functional polyesters, polyethylene succinate, polybutylene succinate, ionomeric hydrophilic polyurethanes, and combinations thereof.

32. The paper-based packaging film according to any one of the preceding claims, wherein the second major surface is a product contact surface.

33. The paper-based packaging film of any of the preceding claims, wherein the paper component is located at an outer surface of the paper-based packaging film; the polymer film is located at an inner surface of the paper-based packaging film; and the patterned sealable material is located at an outer surface of the paper-based packaging film.

34. The paper-based packaging film of any one of the preceding claims, wherein the polymer film is located at the inner surface.

35. The paper-based packaging film according to any one of the preceding claims, comprising a polymeric barrier film, wherein the polymeric barrier film is an oriented or unoriented film having a metal or oxide coating, and wherein optionally the barrier coated side of the polymeric film is attached to the paper component by an adhesive.

36. A paper-based packaging film according to any one of the preceding claims, comprising - a barrier material, said barrier material being located between said paper component and said polymer film, and - an adhesive located between the barrier material and the paper component.

37. A paper based package according to claim 36, wherein: - the heat sealable comprises a water-based dispersion based on an EVA copolymer resin; and / or - the paper assembly comprises a supercalendered paper layer, a backside untreated paper layer, a top side uncoated paper layer, a machine-processed paper layer; and / or - the polymer film is oriented polypropylene; and / or - the barrier material comprises a metal vapour deposited onto the polymer film; and / or - The adhesive is a water-based adhesive formulated using synthetic or natural based polymers.

38. A package formed from or comprising the paper-based packaging film according to any one of claims 1 to 37.

39. A folding package formed from the paper-based packaging film according to any one of claims 1 to 37.

40. The package of claim 38 or claim 39 further comprising a packaged product.

41. A packaged cuboid product comprising: - A paper-based packaging film according to any one of claims 1 to 37, and - a product having a rectangular parallelepiped shape; The paper-based packaging film is wrapped around the product such that the first major surface of the packaging film faces away from the product.

42. The packaged cuboid product of claim 41, wherein the second major surface of the paper-based packaging film comprises the polymer film and faces the product.

43. A packaged cuboid product according to claim 41 or claim 42 wherein the second major surface is in contact with each side of the product.

44. A packaged cuboid product according to any one of claims 41 to 43, comprising individually wrapped products having a cuboid shape.

45. The packaged cuboid product according to any one of claims 41 to 44, wherein the product comprises a cuboid block product consisting of a plurality of separable cuboid compartments, and the paper-based packaging film is wrapped around the cuboid block product.

46. ​​A packaged cuboid product according to any one of claims 41 to 44, wherein the packaged product is sealed by the patterned sealable material.

47. A packaged cuboid product according to any one of claims 41 to 46, wherein the product is a food product comprising one or more components selected from the group consisting of fats, salts, sugars, food concentrates, dry food components and spices.

48. A packaged cuboid product according to any one of claims 41 to 47, wherein the product is a stock cube.

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