Laminated structures, blanks and containers formed therefrom, sealing apparatus therefor, and related methods

Abstract

A laminate structure for forming a barrier member of a container, the laminate structure comprising a base layer, a barrier film layer, a first functional polymer layer, and a second functional polymer layer configured to at least partially seal the laminate structure to a container wall of the container, the first functional polymer layer is reactive to applied radio frequency energy for facilitating bonding of the second functional polymer layer to the container wall of the container. A sealing assembly for joining a barrier member to a container is also disclosed.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 422,631, filed on November 4, 2022, and U.S. Provisional Patent Application No. 63 / 448,794, filed on February 28, 2023.

[0003] Incorporation by Reference

[0004] The disclosures of U.S. Provisional Patent Application No. 63 / 422,631, filed on November 4, 2022, and U.S. Provisional Patent Application No. 63 / 448,794, filed on February 28, 2023, are hereby incorporated by reference in their entireties for all purposes as if fully set forth herein. Background of the Disclosure

[0005] The present disclosure generally relates to laminated structures / blanks, containers formed therefrom, and related methods. More particularly, the present disclosure relates to laminated structures / blanks, containers formed therefrom, and related methods, wherein the laminated structure includes at least one functional polymer layer that is reactive to applied radio - frequency energy. Summary of the Invention

[0006] According to one aspect, the present disclosure generally relates to a laminated structure for forming a barrier member of a container. The laminated structure includes a base layer, a barrier film layer, a first functional polymer layer, and a second functional polymer layer. The second functional polymer layer is configured to at least partially seal the laminated structure to a container wall of the container, and the first functional polymer layer is reactive to applied radio - frequency energy to facilitate the bonding of the second functional polymer layer to the container wall.

[0007] According to another aspect, the present disclosure generally relates to a container for holding one or more products. The container includes a container body that includes a container wall that at least partially surrounds the interior of the container, a top end, a bottom end, and a barrier member located within the interior of the container. The barrier member includes a base layer, a barrier film layer, a first functional polymer layer, and a second functional polymer layer. The second functional polymer layer is configured to at least partially seal the laminated structure to the container wall of the container, and the first functional polymer layer is reactive to applied radio - frequency energy to facilitate the bonding of the second functional polymer layer to the container wall of the container.

[0008] According to another aspect, the present disclosure generally relates to a method of forming a container for holding one or more products, the method comprising: obtaining a container wall; positioning the container wall, the container wall extending at least partially around an interior of the container and defining a top end and a bottom end of the container; and obtaining a barrier blank, the barrier blank including a base layer, a barrier film layer, a first functional polymer layer, and a second functional polymer layer, the first functional polymer layer being reactive to applied radio frequency energy. The method further comprises positioning the barrier blank at least partially within the interior of the container; and applying radio frequency energy to the barrier blank to bond the second functional polymer layer to the container wall of the container.

[0009] According to another aspect, the present disclosure generally relates to a sealing assembly for sealing a portion of a barrier blank to a container wall, the sealing assembly including a receiving assembly and a transmitting assembly, the receiving assembly including a support defining an opening and a receiving conductive member positioned at least partially around the opening; the transmitting assembly including: a reciprocating member, a transmitting conductive member defining a first electrode feature, a flexible member defining a sealing feature and positioned between the conductive members, and a plunger plate defining a second electrode feature, the transmitting assembly being movably supported relative to the receiving assembly such that the transmitting assembly is aligned with the receiving conductive member in the opening of the support, such that at least one radio frequency wave is transmitted from the first electrode feature and the second electrode feature of the transmitting assembly to the conductive member of the receiving assembly.

[0010] According to another aspect, the present disclosure generally relates to a method of sealing a barrier blank to a container wall of a container, the method comprising: obtaining a sealing assembly, the sealing assembly including a receiving assembly and a transmitting assembly, the receiving assembly including a support defining an opening and a receiving conductive member positioned at least partially around the opening, the transmitting assembly including: a reciprocating member, a transmitting conductive member defining a first electrode feature, a flexible member defining a sealing feature and positioned between the conductive members, and a plunger plate defining a second electrode feature, the transmitting assembly being movably supported relative to the receiving assembly. The method further comprises: aligning the transmitting assembly with the receiving conductive member in the opening of the support; positioning the barrier blank and the container wall at least partially between the transmitting assembly and the receiving assembly; and transmitting at least one radio frequency wave from the first electrode feature and the second electrode feature of the transmitting assembly to the conductive member of the receiving assembly to heat one or more portions of the barrier blank.

[0011] Those skilled in the art will appreciate the above-described advantages as well as other advantages and benefits of various additional embodiments by reading the following detailed description of the embodiments with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] By convention, the various features in the accompanying drawings discussed below are not necessarily drawn to scale. To more clearly illustrate embodiments of the present disclosure, the dimensions of various features and elements in the drawings may be enlarged or reduced.

[0013] Figure 1 is a cross-sectional schematic view of a laminated structure for forming a blank and a container according to the present disclosure.

[0014] Figure 1A is Figure 1 a cross-sectional schematic view of the laminated structure when applying radio frequency energy.

[0015] Figure 2 is at least partially formed by Figure 1 and Figure 1A a perspective view of a container formed from the laminated structure.

[0016] Figure 3 is a perspective view of a sealing assembly according to an exemplary embodiment of the present disclosure.

[0017] Figure 4 is Figure 3 a perspective view of a receiving assembly of the sealing assembly.

[0018] Figure 5 is Figure 3 a perspective view of a transmitting assembly of the sealing assembly.

[0019] Figure 6 is Figure 5 an exploded perspective view of the transmitting assembly.

[0020] Figure 7 is Figure 5 a perspective view of a conductive member of the transmitting assembly shown.

[0021] Figure 8 is Figure 5 a perspective view of a reciprocating member of the transmitting assembly.

[0022] Figure 9 is Figure 5 a perspective view of a flexible member of the transmitting assembly.

[0023] Figure 10 is Figure 5 a perspective view of a plunger plate of the transmitting assembly.

[0024] Figure 11 is Figure 3 a cross-sectional view of the first configuration of the sealing assembly during the sealing operation.

[0025] Figure 12 is Figure 3 a cross-sectional view of the second configuration of the sealing assembly during the sealing operation.

[0026] In all the figures, corresponding components are denoted by corresponding reference numerals. Detailed Description

[0027] Referring to the accompanying drawings, various aspects of the present disclosure can be further understood. For the sake of simplicity, the same reference numerals may be used to describe similar features. It should be understood that in the case of depicting multiple similar features, not all of these features need to be labeled in each figure. It should also be understood that the various components used to form the container may be interchangeable. Thus, although only certain combinations are shown herein, many other combinations and configurations are contemplated herein.

[0028] The container according to the present disclosure can accommodate a variety of items of different shapes. By way of illustration and not limitation of the scope of the present disclosure, the following detailed description describes items, such as food, that are at least partially disposed above or within a container embodiment.

[0029] The items can include items such as flowing products or substances, such as particulate matter / substances having a relatively small particle size, such as flowable food. In one embodiment, the items described herein can be flowable products, such as infant formula, ground coffee, powdered nutritional supplements, grains, granola, trail mix, candies, pasta, or any other food product, such as a liquid or powdered food or beverage product. In other embodiments, without departing from the present disclosure, the flowable product can be a non-food product (such as a detergent, cat litter, etc.).

[0030] In this specification, the terms "inner", "interior", "outer", "exterior", "lower", "bottom", "upper", and "top" denote directions determined relative to a fully upright and vertical container.

[0031] As described herein, the container can be composed of a plurality of overlapping plates, end caps, and / or other portions of the blank. Without departing from the present disclosure, these plates, end caps, and / or other portions of the blank can be designated in terms relative to each other, such as "first", "second", "third", etc., and can be referred to in sequence or non-sequence.

[0032] Reference Figure 1 , according to an exemplary embodiment of the present disclosure, a schematic cross-sectional view of a laminated structure 102 for at least partially forming a blank and / or a container 1 ( Figure 2 ) is shown. The container 1 can be used to support or hold one or more of the flowable products as described above.

[0033] As shown, the laminate structure 102 can include: a base layer 104; an adhesive layer 106 applied to the base layer 104; a barrier film layer 108 applied to the adhesive layer 106 and the base layer 104; a primer layer 110 applied to the barrier film layer 108; a first functional polymer layer 112 applied to the primer layer 110 and configured to be adhesive when subjected to radio frequency (RF) energy; and a second functional polymer layer 114 applied to the first functional polymer layer and configured to seal one or more portions of the laminate structure 102.

[0034] The base layer 104 can be a composite material, such as paper or a paper-based product (e.g., cardboard, etc.), and support one or more of the adhesive layer 106, the barrier film layer 108, the primer layer 110, the first functional polymer layer 112, and the second functional polymer layer 114. Thus, the base layer 104 can generally be configured to have the same dimensions, shape, and / or specifications as one or more of these components, but the base layer 104 can also have a different configuration without departing from the present disclosure. In some embodiments, the base layer 104 can provide mechanical strength, printability, and recyclability to the laminate structure 102 and a container formed from the laminate structure.

[0035] The adhesive layer 106 can include one or more adhesives, such as a solvent-based polyurethane adhesive. In some embodiments, such adhesives can be formed by reacting an organic (poly)diisocyanate with an (oligo)diol compound to form urethane bonds on the relevant main chain (-NH-C(=O)-O-).

[0036] In some embodiments, the adhesive layer 106 can be applied to the base layer 104 and / or the barrier film layer 108 by an extrusion process to provide a high interlayer adhesion during the application of the adhesive forming the adhesive layer 106.

[0037] In one embodiment, the application amount of the adhesive layer 106 corresponds to about 2 g / m² to 4 g / m², but it should be understood that the adhesive layer 106 can have a different configuration and / or amount without departing from the present disclosure.

[0038] The barrier film layer 108 can include a carrier film portion 118 and a barrier coating portion 116 applied to the carrier film portion 118. In the illustrated embodiment, the barrier coating portion 116 can be disposed facing the adhesive layer 106, while the carrier film portion 118 can be disposed facing the primer layer 110, but different arrangements of the barrier film layer 108 can also be provided without departing from the present disclosure.

[0039] In some embodiments, the carrier film portion 118 of the barrier film layer 108 may be configured as a carrier film, typically a biaxially oriented polyethylene terephthalate (BOPET) or biaxially oriented polypropylene (BOPP) layer. The thickness of the carrier film portion 118 may be from about 8 microns to about 25 microns, but the carrier film portion 118 may have different configurations and / or arrangements without departing from the present disclosure.

[0040] In some embodiments, the barrier coating portion 116 of the barrier film layer may include one or more barriers vacuum deposited on the carrier film portion 118, which may include aluminum, silicon oxide (SiOx), and / or aluminum oxide (AlOx). In some embodiments, the barrier coating portion 116 may be at least partially protected from mechanical damage, such as material stress, stress generated during the formation of the laminate structure 102, etc., by one or more additional protective coatings.

[0041] Compared with other layer configurations such as aluminum foil, the above-mentioned barrier film layer 108 may provide favorable environmental impact characteristics. In some embodiments, the oxygen transmission rate of the barrier film layer 108 is less than 0.1 cm 3 / m 2 / day (in an environment of 1 atmosphere, 23 °C, and 50% relative humidity), and the water vapor transmission rate is less than 0.1 g / m 2 / day (in an environment of 25 °C and 75% relative humidity).

[0042] Optionally, a primer layer 110 may be applied to the barrier film layer 108. In some embodiments, the primer layer 110 may be an aqueous primer, and its dosage is about 0.05 g / m 2 to about 0.2 g / m 2 . For example, in embodiments where the coating weights of the first functional polymer layer 112 and / or the second functional polymer layer 114 are relatively low, a relatively small amount of the primer layer 110 may be applied.

[0043] The first functional polymer layer 112 may be applied on the primer layer 110, or in some embodiments, directly on the barrier film layer 108. In some embodiments, the first functional polymer layer 112 may include a copolymer of ethylene and methyl acrylate. For example, the weight ratio of the content of methyl acrylate is greater than about 15%. It should be understood that the first functional polymer layer may be configured to be reactive to the application of radio frequency energy (RF) so as to achieve one or more of its variations, as further described herein. In some embodiments, the application amount of the first functional polymer layer 112 may be from about 2 g / m² to about 50 g / m².

[0044] In the illustrated embodiment, the second functional polymer layer 114 may be composed of one or more materials including polyolefins such as polyethylene (low density polyethylene (LDPE), linear low density polyethylene (LLDPE), metallocene linear low density polyethylene (mLLDPE), plastomers, etc.). In some embodiments, the amount of the second functional polymer layer 114 may be from about 2 g / m² to about 50 g / m².

[0045] In some embodiments, the first functional polymer layer 112 and the second functional polymer layer 114 may be applied to the substrate of the base layer 104 / adhesive layer 106 / barrier film layer 108 by a coextrusion process. This coextrusion process of layer 112 and layer 114 can minimize the total amount of polymer materials involved.

[0046] Referring again to Figure 1A , as described herein, the formation of the laminate structure 102 may include applying radio frequency (RF) energy, such as electromagnetic waves in the range of about 10 GHz to about 300 GHz. In some embodiments, the laminate structure 102 may withstand electromagnetic waves in the range of about 10 MHz to about 50 MHz. In some embodiments, radio waves in the range of about 20 MHz to about 30 MHz may be applied to the laminate structure 102.

[0047] Applying RF energy to the laminate structure 102 may cause the dipoles in the first functional polymer layer 112 to reorient under the action of the alternating electric field, thereby triggering molecular rotation and subsequent intermolecular friction to generate heat in the first functional polymer layer 112.

[0048] In this regard, RF energy may be applied to the laminate structure 102 to cause the first functional polymer layer 112 to react so as to be at least partially heated, softened, melted, etc., thereby having adhesive properties to join the layers of the laminate structure 102. In some embodiments, heating of the first functional polymer layer 112 promotes the joining of the second functional polymer layer 114 to the rest of the laminate structure 102 to form a sealing film or barrier on the laminate structure.

[0049] Thus, the laminate structure 102 is configured such that applying RF energy can promote the sealing and joining of the laminate structure 102 while minimizing the use of conventional adhesives for sealing and joining purposes.

[0050] It should be understood that one or more components of the laminate structure 102 may have different configurations and / or arrangements without departing from the present disclosure.

[0051] After forming the laminate structure 102 described herein, the laminate structure 102 can be cut, folded, and / or otherwise shaped to form a blank or other substrate from which one or more containers can be formed.

[0052] Go to Figure 2 , which shows a container formed at least in part from the laminate structure 102 in the form of a cardboard packaging container 1 for containing products such as bulk solids. The specific shape of the container 1 shown in the figure should not be considered restrictive. Thus, the cardboard packaging container according to the present disclosure can have any desired shape or size to suit the desired use.

[0053] The packaging container 1 includes a container body 2 formed by a tubular container wall 3 which, in some embodiments, can be constituted by the laminate structure 102. The container wall 3 extends from a bottom end 4 to a top end 5 at an opening of the container body in the height direction H of the packaging container 1. The container wall 3 has an inner surface 7 facing an inner compartment 8 (broadly referred to as "the interior") in the packaging container 1 and an outer surface 9 facing away from the inner compartment 8 and exposed to the outside of the packaging container 1.

[0054] The container body 2 can be formed by bringing together the side edges of a section of the laminate structure or other material so that the material is in a tubular form and sealing the side edges together. The sealing of the side edges can be performed by any suitable method known in the art, such as welding or gluing, preferably welding. The sealing of the side edges of the container body web can use a sealing strip known in the art. The container body can be formed into any desired tubular shape, including circular, oval, polygonal, the polygons including rectangular and deformed rectangles, such as the deformed rectangle with rounded corners shown in the figure.

[0055] The packaging container 1 can be closed at the bottom end 4 by a chassis 11 attached proximal to the bottom end 4 of the container body 2. The chassis 11 can include a laminated base sheet material. The base sheet material can include a structural layer (such as a carton layer) and a thermoplastic welding layer. The base sheet material is optionally of the same type as the laminate structure 102.

[0056] The chassis 11 is attached to the container wall 3 by folding an edge portion of the chassis 11 out of its plane so that the folded edge portion is aligned with the inner surface 7 of the container wall 3 and then attaching the folded edge portion of the chassis 11 to the inner surface 7 of the container wall 3 by welding or other means to form a coherent seal between the chassis 11 and the container wall 3.

[0057] The packaging container 1 can be provided with a bottom rim (not shown) attached to the inner surface 7 of the container wall 3 and located between the chassis 11 and the bottom end 4 of the container body 2. The bottom rim can reinforce the bottom edge of the container body 2 and can protect the bottom edge of the container body from mechanical deformation.

[0058] The packaging container 1 is provided with a closing device, which includes a lid 12 and an upper reinforcing edge 13 extending along the periphery of the opening 6 of the container body. The upper reinforcing edge 13 is hingedly connected to the lid 12.

[0059] The upper reinforcing edge 13 can be a plastic edge, such as a thermoplastic edge and is attached to the inner surface 7 of the container body wall 3 at the opening 6 of the container body. The upper reinforcing edge 13 can alternatively also be a molded edge containing pulp fibers. Similarly, the lid can be a plastic lid or a molded lid containing pulp fibers.

[0060] The cardboard packaging container 1 can be, for example, a full cardboard packaging container that is free from the use of polymer and / or metal materials.

[0061] By providing at least one upper reinforcing edge, it is ensured that the wall portion maintains a selected shape, such as being bent outward, which prevents the wall portion from bulging inward. The inward bulging of the wall portion is a known phenomenon in cardboard packaging containers, and the problem is that the inward bulging of the wall portion may have a negative impact on the stability and compressive resistance of the packaging container. The reinforcing edge is an optional component of the cardboard container disclosed herein.

[0062] The upper reinforcing edge 13 extends along the height direction H of the container 1 and has a lower edge 14 facing the bottom end 4 of the container and an upper edge 15 facing away from the bottom end 4 of the container.

[0063] The upper reinforcing edge 13 is connected to the inner surface 7 of the container wall 3 through, for example, a welded seal extending around the opening of the container body. The welded seal preferably extends continuously around the opening of the container body to provide a seal between the upper reinforcing edge 13 and the container wall 3. This seal is preferably leak-proof, more preferably moisture-proof, and most preferably airtight.

[0064] The inner compartment 8 of the packaging container is sealed with a fully or partially removable inner sealing member 16 (broadly referred to as a "barrier member" or "barrier blank"), which forms a transport seal for the packaged bulk solid and is sealed relative to the inner surface by welding to the inner surface of the container body wall 3. The removable inner sealing member 16 can be attached to the container body wall 3 from the top end 5 or the bottom end 4 of the container body 2. To first access the packaged bulk solid, the user opens the lid 13 and exposes the packaged bulk solid by fully or partially removing the inner sealing member 16.

[0065] The inner sealing member 16 can include a laminated seal member sheet material, which includes a structural layer (e.g., a paper box or aluminum foil) and a thermoplastic welding layer. In this regard, as further described herein, the inner sealing member 16 can be at least partially formed by a laminated structure 102.

[0066] See also Figure 3 , a sealing assembly for use with one or more laminated structures is generally labeled 200. The sealing assembly 200 can be used alone with the laminated structure 102 and / or the remainder of the packaging container 1 described herein, or can be used with laminated structures and / or packaging containers of different configurations without departing from the present disclosure.

[0067] As Figure 3 shown, the sealing assembly 200 can include a receiving assembly 203 and a transmitting assembly 205. As further described herein, the receiving assembly 203 and the transmitting assembly 205 can be configured to receive and transmit electromagnetic waves, respectively.

[0068] See also Figures 4 to 6 , the receiving assembly 203 can include a support 207 having a body 209, wherein a receiving conductive member 211 is attached to the body 209.

[0069] As shown, the body 209 of the support 207 can at least partially define an opening 213 / at least partially extend around the opening, the opening being configured and sized to at least partially receive a portion of the transmitting assembly 205. In some embodiments, the support 207 / the body 209 can be formed of at least partially electrically insulating materials (e.g., polymers and / or composites).

[0070] In some embodiments, the receiving conductive member 211 can be attached to a portion of the body 209 surrounding the opening 213, e.g., such that the receiving conductive member 211 can at least partially extend around the opening 213. In some embodiments, the receiving conductive member 211 can be attached to the outer surface of the support 207 / the body 209, and in some embodiments, the receiving conductive member 211 can be at least partially recessed into the body 209, e.g., recessed into a groove or channel formed along the body. The receiving conductive member 211 can be formed of at least partially conductive materials (e.g., metallic materials such as copper).

[0071] In this regard, the receiving conductive member 211 can have at least partially a ring-shaped / annular arrangement. As further described herein, the receiving conductive member 211 can have the general configuration of a loop antenna for receiving one or more electromagnetic waves transmitted / emitted by the transmitting assembly 205.

[0072] See also Figures 4 to 10 , which shows a transmitting assembly 205 according to an exemplary embodiment of the present disclosure. As Figure 6As shown in the assembly diagram of , the firing assembly 205 may include a firing conductive member 217, a reciprocating member 219, a flexible member 221, and a plunger plate 225. The firing assembly 205 may be at least partially supported on an overhead support 226 (eg, a rod, a piston, a frame member, etc.).

[0073] As further described herein, an actuator movably coupled or integrated with the overhead support 226 can move the launch assembly 205 movably supported thereon upon receiving one or more electrical signals from a controller C, which is in electrical communication (e.g., wired or wireless) with the launch assembly 205 and / or the receiving assembly 203. The controller C may include a processor configured to execute one or more instructions stored on a non-transitory storage medium and may be configured for operator input and / or manual control. In this regard, the controller C may be or may form part of a software program running on a computer, a programmable logic controller (PLC), a controller implemented by another processor, or other control feature. In some embodiments, the position of the overhead support 226 and the launch assembly 205 may be configured for manual actuation, adjustment, etc.

[0074] like Figure 7 As shown, the emission conductive member 217 may include a generally annular body 227 defining an opening 229 on its upper surface communicating with the interior 231. The body 227 of the emission conductive member 217 may have a generally vertical upper portion 233 and an outwardly inclined lower portion 235 extending from the upper portion 231.

[0075] As also shown, the angled lower portion 235 of the emission conductive member 217 can intersect with an electrode feature (broadly referred to as a "first electrode feature") and / or at least partially define an electrode feature 236. In this regard, the emission conductive member 217 can be formed of an at least partially conductive material (e.g., a metallic material such as copper) and can be configured to be electrically coupled to a power source P, such as a battery, a generator, a power grid, etc.

[0076] refer to Figure 8 , the reciprocating member 219 can be a block-shaped member that is configured and arranged to be at least partially received in the interior 231 of the firing conductive member 217. As shown, the reciprocating member 219 can have: a body 237 that at least partially defines an internal hollow or recessed portion 239; a generally vertical lower portion 241; a generally vertical upper portion 243 extending outwardly from the lower portion 241, so that a flange or step portion 245 is defined thereby; and a collar 247 extending upwardly from the upper portion 243. As shown, the collar 247 can be arranged to at least partially receive the support 226 so that the reciprocating member 219 and the firing assembly 205 can be coupled to the support.

[0077] The upper portion 243 of the reciprocating member 219 may be configured to attach a pair of biasing members 249, which may extend through one or more openings in the upper surface of the upper portion 243 and into the interior recess 239 for positioning. In the illustrated embodiment, the biasing members 249 may be generally curved metal or other elastic materials, but biasing members of different configurations, such as helical springs or linear springs, may also be provided without departing from the present disclosure. As further described herein, the biasing members 249 assist the reciprocating member 219 in reciprocating relative to other parts of the firing assembly 205. Also as described herein, the biasing members 249 may facilitate electrical communication between the components of the firing assembly 205.

[0078] Turning to Figure 9A and Figure 9B , the flexible member 221 may be at least partially flexible and / or elastic, such as formed of a polymeric material, and has a body 251, and the body is arranged in a generally annular configuration around an opening 253 passing through the body. The opening 253 may extend from the upper edge or surface 255 of the body 251 / member 221 to the lower edge or surface 257 of the body 251 / member 221. As shown, the generally inclined sidewalls 259 may extend from the upper surface 255 to the sealing feature 261, and the sealing feature projects outward from the sidewalls 259 and defines the lower surface 257.

[0079] As further described herein, the flexible member 221 may be reconfigured between a first / initial / stress-free configuration (as Figure 9A shown) and a second / actuated / stressed configuration (as Figure 9B shown).

[0080] Referring again to Figure 10 , the plunger plate 225 may have a body 275, the body having a protruding upper portion 277 and a generally inclined lower portion 279 extending from the upper portion 277. As further described herein, the protruding upper portion 277 may be configured to contact a portion of the reciprocating member 219, while the lower portion 279 may be configured to contact the blocking member during the sealing operation.

[0081] In addition, as further described herein, the lower portion 279 of the plunger plate 225 may define an electrode feature 280 (broadly referred to as the "second electrode feature"). In this regard, the plunger plate 225 may be formed of at least partially conductive material (such as a metal material such as copper), and may be configured to be electrically coupled to the power source P, as further described below. In this regard, the firing conduction member 217, the plunger plate 225, and the power source P may form a circuit. In this regard, one or more parts of the firing assembly 205 may be connected to a ground source or a ground element (not shown).

[0082] After the launch assembly 205 is formed, the reciprocating member 219 can be at least partially received within the interior 231 of the launch conduction member 217 such that the collar 247 of the reciprocating member 219 can extend upwardly through the opening 229 in the launch conduction member 217 to at least partially receive the support member 226.

[0083] The flexible member 221 can be positioned to at least partially extend around the lower portion 241 of the reciprocating member 219 such that the upper surface 253 is positioned to engage the step portion 245 of the reciprocating member 219. In this arrangement, the flexible member 221 can also be at least partially received within the interior 231 of the launch conduction member 217 such that a portion of the launch conduction member 217 is coextensive with the sidewall 259 of the flexible member 221. In some embodiments, the flexible member 221 can engage the lower portion 241 of the reciprocating member 219 in a friction and / or press-fit manner. In some embodiments, the flexible member 221 can be at least partially attached to the lower portion 241 and / or the step portion 245 of the reciprocating member 219, for example, by bonding using one or more adhesives, by welding, by an interference mechanical arrangement (e.g., by at least partially receiving in a groove or channel), etc.

[0084] The plunger plate 225 can also be at least partially positioned within the interior 231 of the launch conduction member 217. The protruding portion 277 of the plunger plate 225 can be configured to directly engage the lower portion 241 of the reciprocating member 219 or to engage via a connecting structure such as a post, rod, etc. In some embodiments, the protruding portion 227 of the plunger plate 225 can include a pair of recesses 281 for at least partially receiving the lower portions of the respective biasing members 249 to movably couple the reciprocating member 219 to the plunger plate 225. As shown, the lower portion 279 of the plunger plate 225 can be at least partially adjacent to the slope of the lower portion 235 of the launch conduction member 217.

[0085] Thus, the components of the launch assembly 205 can be assembled as described above, where one or more components are interconnected via mating mechanical features and / or one or more fasteners (e.g., bolts, screws, rivets, etc.).

[0086] Reference Figure 11 and Figure 12 , the triggering of the launch assembly 205 during one or more sealing operations of the sealing assembly 200 will be described in accordance with exemplary embodiments of the present disclosure.

[0087] The barrier member or blank B can be positioned on the distal portion of the firing assembly 205, for example, proximal to the lower surface of the plunger plate 225. In some embodiments, the barrier member or blank B can be attached to the firing assembly 205. As shown, the barrier member or blank B can include a central portion D and an edge portion M. In some embodiments, the edge portion M can be attached to the central portion D at one or more score lines.

[0088] The container wall 3 associated with one or more containers or vessels (e.g., container 1) can be arranged to at least partially extend through the opening 213 of the receiving assembly 203 such that, as further described below, the firing assembly 205 can be at least partially positioned within the opening 213 inside the container wall 3 such that at least a portion of the container wall 3 is positioned between the firing assembly 205 and the receiving assembly 203.

[0089] When receiving one or more signals from the controller C and / or being manually triggered, the overhead support 226 can push the firing assembly 205 downward in the direction shown by arrow A1 towards the receiving assembly 203 ( Figure 3 ). The firing assembly 205 can be inserted along the container wall 3 to a desired depth which, in some embodiments, can correspond to the vertical alignment with the receiving conductive member 211 of the receiving assembly 203. In such an arrangement, the edge portion M of the barrier member or blank B can catch or otherwise engage with the upper edge of the container wall 3, and / or can frictionally engage with the inner surface of the container wall 3 such that the edge portion M of the barrier member or blank B can extend upward relative to the central portion D of the barrier member or blank B.

[0090] In some embodiments, a back pressure plate or other support can be provided inside the container wall 3 to at least partially support the barrier member or blank B and / or resist the movement of the firing assembly 205 relative to the container wall 3 at the desired depth.

[0091] Thus, and as Figure 12 shown, when the lower surface of the firing assembly 205 encounters such resistance, the support 226 can press the reciprocating member 219 downward via the collar 247 to move the plunger plate 225 downward in the direction of arrow A1.

[0092] As the lower portion 279 of the plunger plate 225 engages the barrier member or blank B and any underlying support structure, continued movement of the support 226 can cause the reciprocating member 219 to compress the biasing member 249 to move the reciprocating member 219 and the plunger plate 225 closer to each other.

[0093] This downward movement of the reciprocating member 219 relative to the plunger plate 225 can cause the flexible member 221 and the firing conductive member 217 to move downward together.

[0094] As the stepped portion 245 of the reciprocating member 225 further pushes the flexible member 221 downward, the flexible member 221 can be reconfigured at least partially from a first or initial configuration (as Figure 9A shown) to a second configuration (as Figure 9B shown) so as to have a relatively wide coverage area. For example, such that the sealing feature 261 extends at least partially in the direction indicated by arrow A2. Thus, in the first configuration of the flexible member 221, the sealing feature 261 can have a first transverse direction D1, while in the second configuration of the flexible member 221, the sealing feature can have a greater second transverse direction D2. In this regard, the sealing feature 261 of the flexible member 221 can be pushed to abut against the container wall 3 and approach and / or compress the edge portion M of the barrier member or barrier blank B.

[0095] In this regard, when the plunger plate 225 remains in contact with the central portion D of the barrier member or barrier blank B, the emission conduction member 217 and the flexible member 221 have moved downward in the direction of arrow A1, wherein the electrode feature 236 of the emission conduction member 217 and the electrode feature 280 of the plunger plate 225 are close to each other, and the sealing feature 261 of the flexible member 221 is located between the two electrode features.

[0096] In this regard, the emission assembly 205 can be reconfigured from a first configuration (as Figure 11 shown) and a second configuration (as Figure 12 shown), in the first configuration, the reciprocating member is positioned at a first vertical distance D3 above the plunger plate 225, and in the second configuration, the reciprocating member 219 is positioned at a second vertical distance D4 above the plunger plate 225.

[0097] In the second configuration of the emission assembly 205, the power supply P can supply an electrical signal to the emission conduction member 217 and the plunger plate 225 to generate a desired electric field, which has the effect of generating one or more electromagnetic waves (e.g., radio wave RF). In some embodiments, the biasing member 249 can be made of a conductive material (e.g., a metallic material) such that the emission conduction member 217 and the plunger plate 225 can be electrically connected via the biasing member 249 extending therebetween.

[0098] In some embodiments, the frequency of such radio frequency waves can be between about 30 Hz and about 300 GHz, but radio frequency waves with different wavelengths can be provided without departing from the present disclosure. In one embodiment, the wavelength of the radio frequency wave can be about 27.12 MHz.

[0099] In some embodiments, a power supply P can provide one or more electrical pulses to provide one or more radio frequency waves having desired characteristics. In some embodiments, the power supply P can cooperate with a suitable controller (e.g., controller C or a separate controller) to provide such electrical pulses. In some embodiments, the controller can be configured to supply current to the transmitting assembly 205 to generate a radio frequency wave having an approximate square wave waveform, e.g., to minimize energy spikes. In some embodiments, one or more inert gases, carbon dioxide, Group 18 gases of the periodic table, etc. can be provided near the electrode features 236, 280 to minimize the occurrence and / or effects of arcing.

[0100] The radio frequency waves generated near the electrode features 236, 280 can be emitted / transmitted outward through the edge portion M of the barrier member or barrier blank B and absorbed by the receiving assembly 203 (e.g., at the conductive element 211). The emission of one or more radio frequency waves through the edge portion M of the barrier member or barrier blank B positioned between the transmitting assembly 205 and the receiving assembly 203 can excite the molecules associated with one or more polymer portions of the barrier member or barrier blank B, causing the polymer portions to heat up and at least partially soften and / or melt, while the squeezing action of the sealing feature 261 of the flexible member 221 has the effect of adhering the edge portion M of the barrier member or barrier blank B to the container wall 3 via its softened and / or melted portion.

[0101] When a predetermined sealing or curing time has elapsed, the overhead support 226 can stop applying pressure to the transmitting assembly 205 and / or retract (e.g., under the action of the controller C), such that the biasing member 249 elastically returns from the compressed state to the initial state, such that at least the reciprocating member 219 and the transmitting conductive member 217 can move upward relative to the barrier member or barrier blank B. This movement of the reciprocating member 219 can cause the flexible member 221 to elastically return to the initial configuration, in which the sealing feature 261 of the flexible member 221 moves away from the edge portion M of the barrier member or barrier blank B and the container wall 3. In this regard, the biasing member 249 is positioned to bias the transmitting assembly 205 from the second configuration to the first configuration.

[0102] As described herein, the barrier member or blank B may have a configuration of a laminated construction or structure, the configuration including at least one polymer layer laminated to at least one other layer. In some embodiments, the laminated structure forming the barrier member or blank B may further include at least one composite layer in addition to the at least one polymer layer, for example, an arrangement of cellulose fibers, paper, or paper-based products (such as cardboard, paperboard, etc.). In some embodiments, the at least one polymer layer of the laminated structure forming the barrier member or blank B may include one or more additional polymer layers. In some embodiments, the at least one polymer layer of the laminated structure forming the barrier member or blank B may include a copolymer of ethylene or methyl acrylate. In some embodiments, the arrangement of the barrier blank B may be the same as or similar to the arrangement of the laminated structure 102 described herein.

[0103] In some embodiments, it should be understood that one or more of the blanks and members described herein may be shaped, sized, or otherwise configured to engage with other container structures including the container wall 3. Such container structures may include, for example, Boardio® (provided by Graphic Packaging International, LLC, Atlanta, Georgia), Sealio® (provided by Graphic Packaging International, LLC, Atlanta, Georgia), and Cekacan® (provided by Graphic Packaging International, LLC, Atlanta, Georgia). In some embodiments, the basis weight of the container wall 3 may be from about 170 g / m² to about 500 g / m².

[0104] It should be understood that, without departing from the present disclosure, the sealing assembly 200 may have different arrangements. For example, in some embodiments, the sealing assembly 200 may not be provided with the emission conduction member 217, and the reciprocating member 219 cooperates with the plunger plate 225 to generate the radio frequency energy described herein, for example, such that the reciprocating member 219 may provide or define electrode features. As another example, in some embodiments, electrical power P may be supplied to the receiving assembly 203 to generate radio frequency energy received by the transmitting assembly 205, the effect being the same as or similar to sealing one or more portions of the blank B to the container wall 3.

[0105] Generally speaking, the blank or substrate described herein can be composed of cardboard having a certain thickness, making it heavier and harder than ordinary paper. The substrate can also be composed of other materials, such as cardboard, or any other material having properties suitable for making the structure function at least generally as described above. The substrate can be coated with, for example, a clay coating. Then, products, advertisements, and other information or images can be printed on the clay coating. Then, a varnish can be applied to the substrate to protect the information printed on the substrate. The substrate can also be coated with, for example, a moisture-proof layer on one or both sides of the substrate. The substrate can also be laminated or coated with one or more sheet materials at selected plates or plate sections.

[0106] It is obvious that many other step sequences can be used to form the structure as described herein. It is also obvious that many other materials or structures can be used to form the structure according to the present disclosure. Any such materials can be used alone or in combination and can form the structure in any configuration. When multiple materials (or multiple layers of the same material) are used, these materials can be partially or completely joined together or can be separated from each other (i.e., not connected).

[0107] The laminated structures and blanks / constructions disclosed herein can be formed according to various processes known to those skilled in the art, and various components used to form the packaging can be provided as sheets, rolls, or die-cut materials of the material in the shape of the construction to be formed (e.g., a blank or a substrate).

[0108] All directional references (e.g., up, down, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are for identification purposes only to assist the reader in understanding the various embodiments of the present disclosure and do not constitute a limitation, particularly to the position, orientation, or use of the disclosed embodiments, unless expressly specified otherwise in the claims. Connectivity references (e.g., connect, attach, couple, link, etc.) should be understood broadly and can include intermediate members between element connections and relative movement between elements. Thus, a connectivity reference does not necessarily mean that two elements are directly connected and fixed relative to each other. Additionally, the various elements discussed with reference to the various embodiments can be interchanged to create entirely new embodiments within the scope of the present disclosure.

[0109] The foregoing description has illustrated and described various embodiments of the present disclosure. Since various changes can be made to the above construction without departing from the scope of the present disclosure, all of the content included in the foregoing description or shown in the accompanying drawings should be construed as illustrative rather than restrictive. In addition, the scope of the present disclosure covers various modifications, combinations, variations, etc. of the above embodiments. In addition, the present disclosure has only shown and described selected embodiments, but various other combinations, modifications, and environments are within the scope of the present disclosure, commensurate with the above teachings, and / or within the skill or knowledge of the relevant art. In addition, certain features and characteristics of each embodiment can be selectively interchanged and applied to other illustrated and unillustrated embodiments of the present disclosure.

[0110] The foregoing description has illustrated and described various embodiments of the present disclosure. Since various changes can be made to the above construction, all of the content included in the foregoing description or shown in the accompanying drawings should be construed as illustrative rather than restrictive. In addition, various modifications, combinations, and variations, etc. of the above embodiments are within the scope of the present disclosure. In addition, the present disclosure has only shown and described selected embodiments, but various other combinations, modifications, and environments are within the scope of the present disclosure, consistent with the above teachings, and / or within the skill or knowledge of the relevant art. In addition, without departing from the scope of the present disclosure, certain features and characteristics of each embodiment can be selectively interchanged and applied to other illustrated and unillustrated embodiments.

Claims

1. A laminate structure for forming a barrier member of a container, the laminate structure comprising: A base layer; A barrier film layer; A first functional polymer layer; And A second functional polymer layer configured to at least partially seal the laminate structure to a container wall of a container, The first functional polymer layer being reactive to applied radio frequency energy to facilitate bonding of the second functional polymer layer to the container wall of the container.

2. The laminated structure according to claim 1, characterized in that, The first functional polymer layer is configured to at least partially melt when subjected to radio frequency energy.

3. The laminate structure according to claim 2, wherein the barrier film layer is adhered to the base layer, the first functional polymer layer is applied to the barrier film layer, and the second functional polymer layer is applied to the first functional polymer layer.

4. The laminated structure according to claim 3, wherein The first functional polymer layer comprises a copolymer of ethylene and methyl acrylate.

5. The laminated structure according to claim 3, characterized in that, The copolymer of ethylene and methyl acrylate comprises a weight ratio of methyl acrylate above about 15%.

6. The laminated structure according to claim 5, wherein The content of the first functional polymer layer is between about 2 g / m 2 and about 50 g / m 2 .

7. The laminated structure according to claim 6, wherein The second functional polymer layer comprises one or more polyolefins.

8. The laminated structure according to claim 7, characterized in that, The barrier film layer includes a carrier film and at least one barrier deposited on the carrier film, the at least one barrier selected from the group consisting of aluminum, silica, and alumina.

9. A container for holding one or more products, the container comprising: A container body including a container wall extending at least partially around an interior of the container; A top end; A bottom end; And A barrier member positioned within the interior of the container, the barrier blank comprising: A base layer; A barrier film layer; A first functional polymer layer; and A second functional polymer layer configured to at least partially seal the laminate structure to the container wall of the container, The first functional polymer layer being reactive to applied radio frequency energy to facilitate bonding of the second functional polymer layer to the container wall of the container.

10. The container according to claim 9, characterized in that, The first functional polymer layer is configured to at least partially melt when subjected to radio frequency energy.

11. The container according to claim 10, wherein the barrier film layer is adhered to the base layer, the first functional polymer layer is applied to the barrier film layer, and the second functional polymer layer is applied to the first functional polymer layer.

12. The container according to claim 11, characterized in that, The first functional polymer layer comprises a copolymer of ethylene and methyl acrylate.

13. The container according to claim 11, wherein, The copolymer of ethylene and methyl acrylate comprises a weight ratio of methyl acrylate above about 15%.

14. The container according to claim 13, wherein The content of the first functional polymer layer is between about 2 g / m 2 and about 50 g / m 2 .

15. The container according to claim 14, characterized in that, The second functional polymer layer comprises one or more polyolefins.

16. The container according to claim 15, wherein The barrier film layer includes a carrier film and at least one barrier deposited on the carrier film, the at least one barrier selected from the group consisting of aluminum, silica, and alumina.

17. A method of forming a container for holding one or more products, the method comprising: Obtaining a container wall; Positioning the container wall to extend at least partially around an interior of the container and such that the container has a top end and a bottom end; Obtaining a barrier blank comprising: A base layer; A barrier film layer; A first functional polymer layer; and A second functional polymer layer, the first functional polymer layer being reactive to applied radio frequency energy; Positioning at least a portion of the barrier blank within the interior of the container; and Applying radio frequency energy to the barrier blank to bond the second functional polymer layer to the container wall of the container.

18. The method according to claim 17, wherein Applying radio frequency energy to the barrier blank includes at least partially melting the first functional polymer layer.

19. The method according to claim 18, wherein The barrier film layer adheres to the substrate layer, the first functional polymer layer is applied to the barrier film layer, and the second functional polymer layer is applied to the first functional polymer layer.

20. The method according to claim 19, wherein The first functional polymer layer comprises a copolymer of ethylene and methyl acrylate.

21. The method according to claim 19, wherein The copolymer of ethylene and methyl acrylate comprises greater than about 15% by weight of methyl acrylate.

22. The method according to claim 21, wherein The content of the first functional polymer layer is about 2 g / m 2 to about 50 g / m 2 .

23. The method according to claim 22, characterized in that, The second functional polymer layer comprises one or more polyolefins.

24. The method according to claim 23, wherein The barrier film layer includes a carrier film and at least one barrier deposited on the carrier film, the at least one barrier selected from the group consisting of aluminum, silicon oxide, and aluminum oxide.

25. A sealing assembly for sealing a portion of a barrier blank to a container wall, the sealing assembly comprising: A receiving assembly including a support defining an opening and a receiving conductive member positioned to at least partially extend around the opening; And A transmitting assembly including: a transmitting conductive member defining a first electrode feature; a reciprocating member; a flexible member defining a sealing feature and positioned between the conductive members; and a plunger plate defining a second electrode feature, The transmitting assembly is movably supported relative to the receiving assembly such that the transmitting assembly is aligned with the receiving conductive member in the opening of the support such that at least one radio frequency wave is emitted from the first electrode feature and the second electrode feature of the transmitting assembly to the conductive member of the receiving assembly to heat one or more portions of the barrier blank positioned between the transmitting assembly and the receiving assembly.

26. The sealing assembly according to claim 25, characterized in that, The conductive member has a body defining an interior, and the reciprocating member and the flexible member are at least partially received within the interior of the conductive member.

27. The sealing assembly according to claim 26, wherein The reciprocating member is attached to the flexible member such that the flexible member is capable of reconfiguring as the reciprocating member moves.

28. The sealing assembly according to claim 27, wherein The flexible member is capable of reconfiguring between a first configuration and a second configuration, in the first configuration, the sealing feature defines a first lateral distance, and in the second configuration, the sealing feature defines a second lateral distance, the second lateral distance being greater than the first lateral distance.

29. The sealing assembly according to claim 28, wherein The plunger plate has a body defining an outer surface that is at least partially inclined, and as the flexible member reconfigures between the first configuration and the second configuration, the sealing feature of the flexible member is configured to slidably move along the inclined outer surface of the body of the plunger plate.

30. The sealing assembly according to claim 29, wherein The reciprocating member is movably coupled to the plunger plate by at least one biasing member.

31. The sealing assembly according to claim 30, wherein The emission assembly is capable of reconfiguring between a first configuration and a second configuration. In the first configuration, the reciprocating member is spaced apart from the plunger plate by a first vertical distance. In the second configuration, the reciprocating member is positioned at a second vertical distance above the plunger plate, and the first vertical distance is greater than the second vertical distance.

32. The sealing assembly according to claim 31, wherein When the emission assembly is in the second configuration, the first electrode feature and the second electrode feature are arranged to emit the at least one radio frequency wave to the receiving conductive member.

33. The sealing assembly according to claim 32, wherein The at least one biasing member is positioned to bias the emission assembly to the first configuration.

34. A method of sealing a barrier blank to a container wall of a container, the method comprising: obtaining a sealing assembly, the sealing assembly comprising: a receiving assembly, the receiving assembly comprising a support defining an opening and a receiving conductive member positioned to at least partially extend around the opening; and an emission assembly, the emission assembly comprising: an emission conductive member defining a first electrode feature; a reciprocating member; a flexible member defining a sealing feature and positioned between the conductive members; and a plunger plate defining a second electrode feature, the emission assembly being movably supported relative to the receiving assembly; aligning the emission assembly with the receiving conductive member in the opening of the support; positioning the barrier blank and the container wall at least partially between the emission assembly and the receiving assembly; and emitting at least one radio frequency wave from the first electrode feature and the second electrode feature of the emission assembly to the conductive member of the receiving assembly to heat one or more portions of the barrier blank.

35. The method according to claim 34, wherein The conductive member has a body defining an interior, and the reciprocating member and the flexible member are at least partially received within the interior of the conductive member.

36. The method according to claim 35, wherein The reciprocating member is attached to the flexible member such that the flexible member is capable of reconfiguring as the reciprocating member moves.

37. The method according to claim 36, the method further comprising moving the reciprocating member such that the flexible member reconfigures from a first configuration to a second configuration. In the first configuration, the sealing feature defines a first lateral distance, and in the second configuration, the sealing feature defines a second lateral distance, and the second lateral distance is greater than the first lateral distance.

38. The method according to claim 37, wherein The plunger plate has a body defining an outer surface that is at least partially inclined, and moving the reciprocating member includes slidably moving the sealing feature of the flexible member along the inclined outer surface of the body of the plunger plate.

39. The method according to claim 38, wherein The reciprocating member is movably coupled to the plunger plate by at least one biasing member.

40. The method according to claim 39, the method further comprising reconfiguring the emission assembly from a first configuration to a second configuration. In the first configuration, the reciprocating member is spaced a first vertical distance above the plunger plate, and in the second configuration, the reciprocating member is positioned at a second vertical distance above the plunger plate, and the first vertical distance is greater than the second vertical distance.

41. The method according to claim 40, wherein The first electrode feature and the second electrode feature are arranged to emit the at least one radio frequency wave to the receiving conductive member when the transmitting assembly is in the second configuration.

42. The method according to claim 41, wherein The at least one biasing member is positioned to bias the transmitting assembly towards the first configuration.

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