Flexible recyclable packaging

Abstract

1. A flexible recyclable package comprising: a first laminate film comprising one or more polyethylene layers, one or more EVOH layers, one or more tie layers, and one or more adhesive layers, wherein an outer layer of the first laminate film is a printable polyethylene layer; and a second laminate film comprising one or more polyethylene layers, one or more EVOH layers, one or more tie layers, and one or more adhesive layers, wherein the first laminate film and the second laminate film are sealed to each other to form a product chamber, and the first laminate film and the second laminate film are sealed to each other in areas forming air pockets to provide a rigid three dimensional air frame for the package in an empty state, wherein the amount of EVOH by weight in the package is 5% or less of the package, the flexible recyclable package is substantially free of nylon, and meets recyclability standards for curbside recycling.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 144,314, filed February 1, 2021, the contents of which are incorporated herein by reference. [Background technology]

[0002] The present disclosure relates to an improved flexible, reusable, multi-layer package. More specifically, the present disclosure relates to an improved, reusable, multi-layer package that addresses shortcomings of currently available flexible packaging and containers.

[0003] Flexible containers made from flexible materials are used across a variety of products and industries. Flexible container products made from such flexible materials can be less expensive to make, require less material, and be easier to decorate compared to traditional rigid containers. However, most such packages lack the recyclability required for an impactful approach to reducing environmental footprint.

[0004] The recyclability of flexible packaging, specifically polymeric flexible packaging, is primarily based on the type of material used in the packaging. For example, polyethylene terephthalate (PET) is one common recyclable polymer, designated by the number "1" according to a common numbering scheme created by the Society of the Plastics Industry (SPI). High density polyethylene (number "2") and low density polyethylene (number "4") are other common recycled plastics. However, many packages are made from more than one plastic material, and such packages are difficult for recyclers to handle because the different materials cannot be easily separated into different recycling streams.

[0005] Packaging made with one or more layers of low-density polyethylene combined with PET layers is designated as plastic packaging that is not readily recyclable. Additionally, many materials used to improve the performance of otherwise recyclable packaging, such as barrier layers made from ethyl vinyl alcohol (EVOH) or nylon, can also make the packaging less likely to enter the recycling stream.

[0006] There are many types of flexible packages. Examples of flexible packages that may be useful in the present invention include flexible airframe packages such as those disclosed in U.S. Patent Nos. 9,682,537 and 9,469,088, and U.S. Provisional Application No. 63 / 144,314, filed February 1, 2021, the contents of which are incorporated herein by reference in their entirety.

[0007] Furthermore, the presence of the PET printed layer in the film structure renders the material non-recyclable. There is a lack of suitable flexible, recyclable multi-layer film structures that can be used in flexible packaging for various containers while simultaneously reducing the substantial amount of plastic introduced into the environment. Summary of the Invention [Problem to be solved by the invention]

[0008] Thus, there is a market need to develop sustainable alternatives in the recyclable materials packaging industry. More specifically, there is a market need for substantially nylon-free recyclable multi-layer packages and methods for their manufacture, i.e., improved recyclable and curbside recyclable plastic packaging materials that are compatible with current technology and manufacturing processes. [Means for solving the problem]

[0009] One objective of an embodiment of the present invention is to provide flexible plastic packaging suitable for curbside recycling, e.g., packaging that may comply with recyclability defined by The Association of Plastic Recycler (APR). One such embodiment includes packaging made from materials that are substantially free of nylon. Another or second embodiment includes packaging made from materials that use an optimized ratio of compatibilizers to achieve appropriate packaging performance and recyclability criteria.

[0010] In one aspect of the disclosure, a substantially nylon-free recyclable multilayer packaging film structure includes a polyethylene (PE) base layer with an ethylene vinyl alcohol (EVOH) barrier layer having a maximum percentage (by weight) of less than 5%. In the depicted embodiment, the weight percentage of EVOH in the total structure is defined by the type of EVOH and its ethylene molecular weight percentage.

[0011] In another aspect of the present disclosure, one embodiment of a flexible package includes a polyethylene (PE) based layer with a specific percentage of a polyamide nylon (PA) layer and an ethylene vinyl alcohol (EVOH) barrier layer. In the illustrated embodiment, the PA and EVOH content dictates the amount of compatibilizer used in the packaging formulation. Various configurations of this embodiment can be produced depending on whether the printable layer is a nylon-based layer or a non-nylon-based layer.

[0012] Preferred embodiments of the recyclable multi-layer packaging disclosed herein and further detailed below are suitable for curbside compliance, such as following industry APR requirements for recyclability. Furthermore, the improved recyclable multi-layer packaging, which is substantially free of nylon or optimized using various amounts of compatibilizer, can be produced using conventional equipment and used in the manufacture of flexible containers. Finally, recyclable flexible packaging produced from such materials can be designated with a number commonly used for widely available recycling streams.

[0013] The references given above are provided for the purpose of describing the present invention, and are not intended to limit the present invention. It will be apparent to those skilled in the art that various modifications and changes can be made in the present invention without departing from the scope or spirit of the present invention. Features illustrated or described as part of one embodiment can be used in another embodiment to produce yet another embodiment. Thus, the present invention is intended to encompass such modifications and variations as fall within the scope of the appended claims and their equivalents. Other objects, features and aspects of the present invention are disclosed in the following detailed description. It will be appreciated by those skilled in the art that this description is merely an explanation of exemplary embodiments, and is not intended to limit the broader aspects of the present invention, which are embodied in the exemplary configurations. [Brief description of the drawings]

[0014] The present disclosure will be more readily understood in consideration of the following description taken in conjunction with the following figures, where like reference numerals represent elements: [Figure 1] FIG. 1 shows a front view of a flexible container manufactured using nylon-free recyclable multi-layer packaging according to one embodiment of the present disclosure. [Diagram 2] FIG. 2 illustrates a side view of the flexible container of FIG. 1 according to one embodiment of the present disclosure. [Diagram 3] FIG. 3 shows a top view of the flexible container of FIG. 1 according to one embodiment of the present disclosure. [Figure 4] FIG. 4 illustrates a bottom view of the flexible container of FIG. 1 according to one embodiment of the present disclosure. [Diagram 5] FIG. 5 shows a schematic diagram of one embodiment of a valve structure useful in connection with the present invention. [Figure 6] FIG. 6 shows an elevated embodiment of a package including the valve of FIG.

[0015] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of the present disclosure and, together with the description, serve to explain the principles of the embodiments. Together with the description, the drawings serve to explain the principles of the present invention. The detailed description and examples described herein are presented for the purpose of illustration and description only, and not for limitation. Therefore, the present disclosure is intended to embrace any and all modifications, variations, or equivalents that fall within the spirit and scope of the basic underlying principles disclosed above and claimed herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] The following disclosure may be best understood in its entirety by reference to the detailed description provided when read in conjunction with the accompanying drawings, drawing description, abstract, background, field of the disclosure, and associated headings. Objects and advantages of the invention will be set forth in and apparent from the following description, or will be learned by practice of the invention. The same reference numbers, when found on different drawings, identify the same or functionally equivalent elements. Elements listed in the abstract are not referenced, but are nevertheless referenced by association to elements of the detailed description and associated disclosure.

[0017] In one aspect of the present disclosure, an improved nylon-free recyclable multi-layer package and method of manufacture thereof is provided that addresses shortcomings of currently available recyclable materials for flexible packaging and containers.

[0018] In one aspect of the present disclosure, a substantially nylon-free recyclable multilayer packaging film structure includes a polyethylene (PE) base layer with an ethylene vinyl alcohol (EVOH) barrier layer having a maximum percentage (by weight) of less than 5%. In the illustrated embodiment, the percentage (by weight) of EVOH in the total structure is defined by the type of EVOH and its percentage of ethylene molecular weight. As disclosed herein, the improved recyclable multilayer film structure is recyclable under industry standard recyclability guidelines as long as the EVOH does not exceed 5%.

[0019] The substantially nylon-free recyclable multilayer packaging film structure includes a first laminate film and a second laminate film joined to at least a portion of the first laminate film by at least one seal. The first laminate film includes a first gas barrier layer disposed between a first sealable layer and a second sealable layer, the first and second sealable layers defining opposing outer layers of the first laminate film. The second laminate film also includes a first gas barrier layer disposed between the first sealable layer and a second sealable layer, the first and second sealable layers defining opposing outer layers of the second laminate film.

[0020] The first laminate film may further comprise, in order, a first sealable polyethylene (PE) layer having a low initial seal band, a second sealable polyethylene having a certain predetermined thickness, a first tie layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second tie layer, a second sealable polyethylene (PE) layer, and a third sealable polyethylene layer. The second laminate film may further comprise, in order, a first sealable polyethylene (PE) layer having a low initial seal band, a second sealable polyethylene having a certain predetermined thickness, a first tie layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second tie layer, a second sealable polyethylene (PE) layer, and a third sealable polyethylene layer.

[0021] In one aspect of the present disclosure, the first laminate film includes, in order, (1) a first sealable layer of polyethylene (PE) having a thickness of about 28 microns, (2) a second sealable layer of PE having a thickness of about 15 microns, (3) a first tie layer having a thickness of about 5 microns, (4) a first gas barrier layer of an ethylene vinyl alcohol (EVOH) layer having a thickness of about 3 microns and containing 3.9% ethylene by weight, (5) a second tie layer having a thickness of about 5 microns, (6) a second sealable layer of PE having a thickness of about 15 microns, and (7) a third sealable layer of PE having a thickness of about 29 microns. As disclosed herein, the first laminate film, which may also be referred to as the inner laminate film, is suitable for laser treatment rather than corona treatment. In the illustrated embodiment, the first laminate film is 100 microns thick, 93.20 g / m 2 weight, 3 micron gas barrier thickness (EVOH), and width of about 400 mm to about 1500 mm. It is noted that different types of PE layers can be used as the sealable layer of the first laminate film for improved nylon-free recyclable multi-layer packaging.

[0022] In yet another aspect of the present disclosure, the second laminate film comprises, in order, (1) a first sealable layer of polyethylene (PE) having a thickness of about 28 microns, (2) a first sealable layer of PE having a thickness of about 15 microns, (3) a first tie layer having a thickness of about 5 microns, (4) a first gas barrier layer of an ethylene vinyl alcohol (EVOH) layer containing 3.9% ethylene by weight having a thickness of about 3 microns, (5) a first tie layer having a thickness of about 5 microns, (6) a second sealable layer of PE having a thickness of about 15 microns, and (7) a third sealable layer of PE having a thickness of about 28 microns. As disclosed herein, the second laminate film may also be referred to as an outer laminate film suitable for laser and corona treatment. In the illustrated embodiment, the second laminate film is 100 microns thick, 93.80 g / m 2 weight, 3 micron gas barrier thickness (EVOH), and width of about 400 mm to about 1500 mm. It is noted that a different type of PE layer can be used as the sealable layer of the first laminate film for improved nylon-free recyclable multi-layer packaging.

[0023] In the improved substantially nylon-free recyclable multi-layer package disclosed herein, the second laminate film has a different composition than the first laminate film, and the laminate strength of the film can be further increased by using a tie or adhesive layer during the manufacture of the film. The laminate strength can be adjusted by selecting the type of tie layer as well as the thickness of the tie layer. If a higher laminate strength is desired, the tie layer can have an increased thickness. In addition, as further disclosed in this detailed description, the laminate strength can be adjusted by selecting the type of tie layer as well as the thickness of the tie layer. By way of example and not limitation, a tie layer made of an adhesive having a water-based adhesive chemistry and / or a thickness of less than 2 microns can be used when a laminate strength at the lower end of the aforementioned range is desired.

[0024] Note that layer thickness and total film thickness may vary depending on package size. For example, smaller packages may require more caliper in the barrier layer, while larger sizes require more caliper in the PE strength layer.

[0025] In another aspect of the disclosure, an embodiment of a flexible package of the present invention includes a polyethylene (PE) base layer with a specific percentage of a polyamide nylon (PA) layer, and an ethylene vinyl alcohol (EVOH) barrier layer. In the illustrated embodiment, the content of PA and EVOH defines the amount of compatibilizer used in the packaging formulation. A flexible, recyclable multi-layer film structure is provided that includes a first laminate film and a second laminate film joined to at least a portion of the first laminate film by at least one first seal. The first laminate film can include, in order, a first sealable polyethylene (PE) layer with a low initial seal band, a first sealable PE layer with one or more compatibilizers, a first tie layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second tie layer, a second sealable polyethylene (PE) layer with a low initial seal band and with one or more compatibilizers. The recyclable flexible multilayer film structures disclosed herein including the second laminate can include, in order, a first sealable polyethylene (PE) layer having a low initial seal band, a first sealable PE layer having a compatibilizer, a first tie layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second tie layer, a second sealable polyethylene (PE) layer having one or more compatibilizers, a second sealable PE layer, and a printed layer comprising a recyclable non-PET such as a polyethylene (PE) layer.

[0026] In one embodiment of the present disclosure, the first laminate film comprises, in order, (1) a first sealable layer of polyethylene (PE) having a thickness of about 28 microns, (2) a second sealable layer of PE having a thickness of about 15 microns, (3) a first tie layer comprising one or more compatibilizers and having a thickness of about 5 microns, (4) a polyamide nylon layer having a thickness, (5) a first gas barrier layer of an ethylene vinyl alcohol (EVOH) layer, the EVOH layer comprising 3.9% by weight ethylene and having a thickness of about 3 microns, (6) a second tie layer comprising one or more compatibilizers and having a thickness of about 5 microns, (7) a second sealable layer of PE having a thickness of about 15 microns, and (8) a third sealable layer of PE having a thickness of about 29 microns. As disclosed herein, the first laminate film, which may be referred to as the inner laminate film, is suitable for laser treatment and not suitable for corona treatment. In the illustrated embodiment, the first laminate film is 100 microns thick and weighs 93.20 g / m 2 weight, 3 micron gas barrier thickness (EVOH), and width of about 400 mm to about 1500 mm. It is noted that different types of PE layers can be used as the sealable layer of the first laminate film in the improved nylon-free recyclable multi-layer package.

[0027] In yet another embodiment of the present disclosure, the second laminate film includes, in order, (1) a first sealable layer of polyethylene (PE) having a thickness of about 28 microns, (2) a first sealable layer of PE having a thickness of about 15 microns, (3) a first tie layer containing one or more compatibilizers and having a thickness of about 5 microns, (4) a polyamide nylon layer having a specific thickness, (5) a first gas barrier layer of an ethylene vinyl alcohol (EVOH) layer containing 3.9% ethylene by weight having a thickness of about 3 microns, (6) a second tie layer containing one or more compatibilizers and having a thickness of about 5 microns, (7) a second sealable layer of PE having a thickness of about 15 microns, and (8) a third sealable layer of PE having a thickness of about 28 microns. As disclosed herein, the second laminate film may also be referred to as an outer laminate film suitable for laser and corona treatment. In the illustrated embodiment, the second laminate film is 100 microns thick and weighs 93.80 g / m 2 It has a weight of 100 mm, a gas barrier thickness of 3 microns (EVOH), and a width of 1100 mm. It is noted that a different type of PE layer can be used as the sealable layer of the first laminate film for improved recyclable multi-layer packaging.

[0028] In the improved compatibilizer-based recyclable multi-layer packaging disclosed herein, the second laminate film has a different composition than the first laminate film, and the laminate strength of the film can be further increased by using a tie or adhesive layer during the manufacture of the film. The laminate strength can be adjusted by selecting the type of tie layer as well as the thickness of the tie layer. If a higher laminate strength is desired, the tie layer can have an increased thickness. In addition, as further disclosed in the detailed description, the laminate strength can be adjusted by selecting the type of tie layer as well as the thickness of the tie layer. By way of example and not limitation, a tie layer made of an adhesive with a water-based adhesive chemistry and / or a thickness of less than 2 microns can be used when a laminate strength at the lower end of the aforementioned range is desired.

[0029] It should be noted that the thickness of the layers and the total film thickness may vary depending on the package size. For example, smaller packages may require more caliper in the barrier layer, while larger sizes require more caliper in the PE strength layer. Various structures of this embodiment can be produced depending on whether the printable layer is a nylon-based layer or a non-nylon-based layer. In the improved recyclable multi-layer package disclosed herein, the second laminate film has a different composition than the first laminate film, and the laminate strength of the film can be further increased by using a tie or adhesive layer during the manufacture of the film. The laminate strength can be adjusted by the selection of the tie layer type as well as the tie layer thickness. If a higher laminate strength is desired, the tie layer can have an increased thickness. The laminate strength can be adjusted by the selection of the tie layer type as well as the tie layer thickness. By way of example and not limitation, a tie layer consisting of an adhesive with a water-based adhesive chemistry and / or a thickness less than 2 microns can be used when a laminate strength at the lower end of the range mentioned above is desired. By way of example and not limitation, laser additives and UV inhibitors may be added to some of the PE layers to prevent photosensitivity of such products.

[0030] In the above disclosed embodiments where higher laminate strength is desired, the tie layer can have an increased thickness, for example, from about 2 microns to about 5 microns, and a solvent-based two-part adhesive can be used. Additionally, the tie layer can include a polymer tie layer. A tie layer with a higher anhydride content in the polymer layer, for example, an anhydride content of more than 150 ppm, can also be used to increase the laminate strength between the two layers of the laminate. Flexible containers with larger size structural support volumes may require flexible materials with laminate bodies with higher laminate strengths to avoid delamination of the flexible material when formed into flexible containers with expanded structural support volumes.

[0031] It is noted that containers manufactured using the recyclable multilayer film structures disclosed herein are formed with sufficient structural integrity to withstand environmental conditions from external forces and handling without breaking. Furthermore, these containers can be constructed in a structure that allows them to be displayed for sale and used as intended without any structural problems or failures.

[0032] As disclosed herein in one or more aspects of the present disclosure, the term "gas barrier layer" refers to a layer of a laminate of flexible material, the gas barrier layer being a material or coating that resists the permeation of gas through the layer. The gas barrier layer provides at least partial resistance to the permeation of gas through the flexible material. In the illustrated embodiment, the gas permeability of the EVOH gas barrier layer can be adjusted by varying the thickness and the mole percentage of ethylene content in the layer. The EVOH gas barrier layer can include about 24 mole % to about 48 mole % ethylene, with lower contents of ethylene resulting in a gas barrier layer with lower gas permeability. Additionally, the gas permeability of the gas barrier layer can be reduced by providing a thicker layer. Additionally, the gas permeability of the EVOH gas barrier layer can be adjusted by varying the mole percentage of ethylene in the barrier material and / or the thickness of the gas barrier layer. In general, increasing the mole percentage of ethylene in the EVOH increases the gas permeability, while increasing the thickness of the gas barrier layer decreases the gas permeability.

[0033] As disclosed herein in one or more aspects of the present disclosure, the term "printing layer" refers to a laminated layer of flexible material, the printing layer being a material having at least one major surface configured to accept and retain ink, including a material at least a portion of which has been treated to have sufficient surface energy to accept and retain ink.

[0034] In one embodiment of the present disclosure, the material can be treated by corona treatment, plasma treatment, laser treatment, and / or oxidation by flame. Exemplary print layer materials include, but are not limited to, paper, oriented and non-oriented polyester, PEF, PBT, PLA, polyamide, cellulose or cellulose esters, PHA, PVC, ionomers such as sodium ionomers or zinc ionomers, thermoplastic starch, polyolefins including cyclic polyolefins, LLDPE and PP produced using Ziegler-Natta catalysts, LDPE, HDPE, MDPE, chromium catalysts, metallocene-based catalysts, single-site catalysts, and other types of catalysts such as homopolymers or copolymers.

[0035] As disclosed herein in one or more aspects of the present disclosure, the term "sealable layer" refers to a laminate layer of flexible material, where the sealable layer is a material that is configured to be sealed to itself or to another sealable layer using any type of sealing method known in the art, including, for example, heat sealing (e.g., conductive sealing, impulse sealing, ultrasonic sealing, etc.), welding, crimping, bonding, etc., and / or any combination of these methods.

[0036] It is further noted that the various embodiments of the improved flexible multi-layer recyclable packaging that is formed are recyclable under industry standard recycling criteria so long as they are substantially free of nylon and do not contain more than 5% EVOH.

[0037] In another aspect of the present disclosure, a flexible container is formed that is configured to have a specific product volume, including one or more of the recyclable multilayer film structures, and the packaging material forms 50-100% of the total surface area of ​​the one or more materials that define the three-dimensional space of the product volume of the flexible container. By way of example and not limitation, the flexible container can be configured to have a product volume in which the one or more flexible materials form a specific percentage of the total surface area of ​​the one or more materials that define the three-dimensional space, the specific percentage being any integer value of a percentage between 50% and 100%, or within any other range formed by any of these values, such as, for example, 60-100%, 70-100%, 80-100%, or 90-100%, etc.

[0038] Embodiments of the recyclable multilayer film structures used in flexible containers meet standard curbside recycling requirements. An example of standard curbside recycling requirements in the United States is published by APR, as described in further detail below. Another example of standard curbside recycling requirements in Europe is published by RecyClass, as described in further detail below.

[0039] In some embodiments, plastic packaging is considered "recyclable according to the APR definition" if it meets all of the recycling criteria listed below (listed at https: / / www.recycling.org / recyclingdefinitions). (1) At least 60 percent of consumers or communities have access to a collection system that accepts items in accordance with the Federal Trade Commission's Green Guides. (2) The item must have market value or be supported by a legally mandated program. (3) The items are most likely to be properly sorted into marketable bales of certain plastics that meet industry standard specifications through commonly used material recovery systems, including deposit system bins, single-stream and dual-stream systems that handle grocery store rigid plastics and film collection systems. (4) The articles can be cost-effectively further processed through typical recycling processes into post-consumer plastic feedstock suitable for use in identifiable new products.

[0040] Recyclable packaging embodiments of the present invention meet all functionality and compliance requirements of the APR according to the APR Design Guide for the relevant materials. Each aspect of the designed packaging is evaluated according to industry accepted criteria to ensure it is truly recyclable according to the above criteria.

[0041] To be recyclable, various embodiments of polyethylene-based flexible materials must either meet protocols for reusability under the APR Critical Guidance for HDPE rigid containers or be no worse under relevant standards than LDPE, which is widely accepted as recyclable. There is a standard that polyethylene-based flexible packaging (not including compatibilizers) must have EVOH at or below 5% by weight of the package.

[0042] Critical Guidance from the APR relevant to embodiments of the present invention includes the following criteria taken from the APR Critical Guidance regarding HDPE recyclability:

[0043] [Table 1]

[0044] For each of the above properties, embodiments of the present invention meet the requirements for HDPE packaging or measure no worse than LDPE, and therefore meet the requirements for recyclability.

[0045] Critical Guidance from RecyClass relevant to embodiments of the present invention includes the following criteria taken from the RecyClass Recyclability Assessment Protocol for HDPE Containers, Version 2.0, published in July 2019, specifically, RecyClass's Criteria for Pellet Characterization and Bottle Blow Molding:

[0046] [Table 2]

[0047] Other third parties, such as Interseroh Zero Waste Solutions of Cologne, Germany, have also promulgated generally accepted recyclability standards that are relevant to embodiments of the present invention.

[0048] An embodiment of the invention is considered to meet recyclability for curbside recycling if it meets or exceeds the generally accepted standards for recyclability of rigid polyethylene containers, e.g., if it meets the relevant standards for rigid HDPE containers, or if the package does not meet specific metric standards for rigid HDPE, or is no worse under the same metric properties as LDPE.

[0049] In addition, flexible package embodiments made using the recyclable multilayer film structures disclosed herein are suitable for consumer packaging. In particular, such packages meet one or more of the following performance criteria:

[0050] [Table 3]

[0051] In another aspect of the disclosure, "flexible container" refers to a container configured to have a product volume in which one or more flexible modified nylon-free recyclable multi-layer packaging materials form 50-100% of the total surface area defining the three-dimensional space of the product volume.

[0052] In yet another aspect of the present disclosure, flexible containers made from the improved nylon-free recyclable multi-layer packaging generally refer to thin, easily deformable sheet-like materials having a flexibility modulus within a certain range, for example, between 1,000 and 2,500,000 N / m.

[0053] As further disclosed herein, flexible containers manufactured from the improved nylon-free recyclable multi-layer materials can be configured to have a flexibility modulus that falls within a particular range. For example, the flexibility factor of the improved nylon-free recyclable multi-layer packaging may be in the range of 1,000 to 2,500,000 N / m, or may be in the range of 1,000 to 1,500,000 N / m, 1,500 to 1,000,000 N / m, 2,500 to 800,000 N / m, 5,000 to 700,000 N / m, 10,000 to 600,000 N / m, 15,000 to 500,000 N / m, 20,000 to 400,000 N / m, 25,000 to 300,000 N / m, 30,000 to 200,000 N / m, 35,000 to 100,000 N / m, 40,000 to 90,000 N / m, or may be in the range of 1,000 to 2,500,000 N / m, 1,000 to 3,000,000 N / m, 2,500 to 4,000,000 N / m, 3,000 to 5,000,000 N / m, 4,000 to 6,000,000 N / m, 5,000 to 7,000,000 N / m, 6,000 to 8,000,000 N / m, 7,000 to 9,000,000 N / m, 8,000 to 10,000,000 N / m, 9,000 to 10,000,000 N / m, 10,000 to 15,000,000 N The flexibility factor may be any integer value between 45,000 and 85,000 N / m or between 45,000 and 85,000 N / m.

[0054] In another aspect of the disclosure, a flexible reusable packaging material or film includes a first laminate film further including, in order, a first sealable polyethylene layer having a lower initial seal band defining an outer layer of the first laminate, and a second sealable polyethylene layer having a predetermined thickness. In the illustrated embodiment, the second sealable polyethylene layer includes a compatibilizer, a first tie layer, a third sealable layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a fourth sealable layer, a second tie layer, a fourth sealable polyethylene layer having a predetermined thickness and including a compatibilizer, and a fifth sealable polyethylene layer.

[0055] In yet another aspect of the present disclosure, a flexible reusable packaging material or film includes a second laminate film including, in turn, a first sealable polyethylene layer having a lower initial seal band defining an outer layer of the second laminate. It is noted that the package further includes a second sealable polyethylene layer having a certain predetermined thickness, the second sealable polyethylene layer including a compatibilizer, a first tie layer, a third sealable layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a fourth sealable layer, a second tie layer, a fourth sealable polyethylene layer having a certain predetermined thickness and including a compatibilizer, and a fifth sealable polyethylene layer.

[0056] In another aspect of the present disclosure, the above-mentioned embodiments of the multi-layer flexible recyclable packaging material can be produced with varying amounts of compatibilizer, thereby improving the bond and seal strength of the final product. Nylon-free flexible recyclable packaging materials or films can be produced with 5% or 8% compatibilizer content, with the improved bond and seal strength of the multi-layer final product being closer to the original material or film used in production.

[0057] It should be noted that compatibilizers are primarily used to promote enhanced adhesion between polyolefins and polar polymers, such as ethylene vinyl alcohol (EVOH), polyamides and other blends of polar polymers. By way of example and not limitation, the compatibilizers used in various embodiments of the present invention include Dow RETAIN TM It can be a Dow brand compatibilizer such as Polymer Modifier.

[0058] The recyclable film formulations disclosed above can be made by iteratively selecting different amounts of compatibilizer to find the right balance of synergistic performance and / or reduced manufacturing costs of the film structure for flexible packaging. The following table shows various compatibilizer compositions based on two different types of compatibilizers and dependent on the film composition. Ampacet's rEVive TM (Compatibilizer No. 1) and Dow's RETAIN TM (Compatibilizer No. 2) Compatibilizer. The amounts of compatibilizer listed are approximate.

[0059] [Table 4]

[0060] In another aspect of the present disclosure, a flexible reusable package is provided. In an illustrated embodiment, the recyclable flexible package comprises a multi-layer package that is substantially free of nylon and recyclable according to industry standard recyclability guidelines, where at least a portion of a first sealable layer of a second laminate body is bonded to at least a portion of a fifth sealable polyethylene layer of a first laminate body to form at least one bonded seal portion. The flexible packaging structure is formed such that the at least one bonded seal portion defines at least one boundary of a structural support volume disposed between the first laminate body and the second laminate body. By way of example and not limitation, the recyclable flexible packaging material may be a 100 micron thick, 95.85-95.26 g / m 2It has a weight ranging from 1000 to 2000 mm, a thickness of 8 micron PA / 8 micron gas barrier (EVOH), and a width of about 400 mm to about 1500 mm.

[0061] Flexible containers made from the materials disclosed herein can be used across a variety of products and industries. Figure 1 shows a front view of a flexible container made using an embodiment of a flexible material. Figure 2 shows a side view of the flexible container of Figure 1. Figure 3 shows a top view of the flexible container of Figure 1. Figure 4 shows a bottom view of the flexible container of Figure 1.

[0062] As shown in Figures 1-4, a flexible container 1001 manufactured using an embodiment of a flexible material includes a cut-away top portion 104, a middle line of weakness such as a cut or perforation 106, a bottom product-containing portion 108, a front portion 110, a back portion 112, and left and right sides 114. The top portion 104 is separated from a middle portion 106 by a reference plane 100 that is parallel to the XZ plane. The middle portion 106 is separated from a bottom portion 108 by a reference plane 101 that is also parallel to the XZ plane. The container 1001 has an overall height 116. In this embodiment, the front 110 and rear 112 of the container are joined to one another at a seal 120 that extends around the periphery of the container 1001, across the top 104, down the sides 114, and then splits outward at the bottom of each side 114 to continue around the outer extents of the front and rear of the base 125.

[0063] 1 and 2, a tear-away top 104 may be peeled away by a user to access the valve, examples of which are disclosed in U.S. Patent Nos. 9,694,965 and 10,138,049, particularly Figures 16 and 18 thereof, both of which are incorporated herein by reference in their entireties. The properties of the valve of the present invention are further described below.

[0064] A valve according to an embodiment of the present invention is described with reference to Fig. 5. Fig. 5 shows a top view of a flexible valve 500 comprising two tension-inducing elements 501 facing each other, which are expandable volumes 502, and a flow channel 503. The fluent product enters the flow channel 503 through an inlet 504 and leaves the flow channel 503 through an outlet 505 when a critical squeezing force is applied and the flexible valve 500 opens. When the critical squeezing force is released and the flexible valve 500 closes, the tension gradient in the flow channel 503 creates a suck-back effect, and the fluent product in the flow channel 503 reverses its movement direction and moves back through the inlet 504. An indicator 506 located on the flow channel 503 signals the user as to whether the flexible valve 500 is open or closed. A flexible material forms the flow channel 503. The tension-inducing element 501 can hold the flexible material forming the flow channel 503 in a fixed position when a critical squeezing force is applied to dispense the fluent product. In some embodiments, the flexible material forming the flow path 503 between the tension-inducing elements 501 may curve upwards or downwards relative to the two tension-inducing elements 501. In some embodiments, the flexible material forming the flow path 503 should be relatively flat, and in some embodiments, does not have any kinks or bends that would block the flow path 503.

[0065] The width of the outlet 505 strongly influences what the critical squeeze force is. The smaller the width of the outlet 505, the greater the critical squeeze force. The stiffness of the flexible material forming the flow passage 503 should also be adjusted to help achieve the desired critical squeeze force. The shape, size, relative orientation, and pressure of the tension-inducing element 501 affect the critical squeeze force and mass flow rate achievable through the flexible valve 500. The mass flow rate of the fluent product through the flexible valve 500 and the critical squeeze force of the flexible valve 500 can also be adjusted by manipulation of the container comprising the flexible valve 500. Numerous parameters of the material forming the container, the geometry and arrangement (e.g., separation distance, shape, size) of the tension-inducing element 501, the size, shape, and width of the seal used to create the expandable volume, and the fluid properties of the fluent product affect the performance and optimization of the flexible valve 500. The inlet 504 and outlet 505 can have different sizes, resulting in a non-rectangular flow passage. For example, the flow passages 503 can be trapezoidal or any other suitable type of contoured shape. The angle at which the flow passages 503 constrict the flow of the fluent product can be any value, such as 0, 40, 60, or 75 degrees. The size and shape of each expandable volume 502 can be fixed or variable. For example, each expandable volume 502 can have a width at its maximum point of about 0.1 inches to about 1.5 inches, or any range therein, such as about 0.1 inches to about 1.1 inches, about 0.3 inches to about 0.4 inches, or about 1.1 inches to about 1.5 inches. The opening of the outlet 505 can have a width in the range of about 0.2 inches to about 1 inch, or any range therein, such as about 0.3 inches to about 0.8 inches, about 0.6 inches to about 0.9 inches, or about 0.2 inches to about 0.25 inches. The mass of the dispensed flowable product can be from about 0.1 g to about 100 g, or any range therein, such as from about 0.5 g to about 10 g, from about 56 g to about 99 g, or from about 2 g to about 43 g. The critical squeeze force can be from about 0.1 N to about 550 N, or any range therein, such as from about 0.5 N to about 110 N, from about 125 N to about 130 N, or from about 500 N to about 540 N.The impulse before dispensing (N*s) may range from about 1 N s to about 1000 N s and is calculated as the area under the force versus time curve before any mass flow rate begins. The impulse to dispense (N*s) may range from about 1 N s to about 1500 N s and is calculated as the area under the force versus time curve during dispensing. The total effort to dispense (N*s / g) may range from about 1 to about 1200 N s / g and is calculated from adding the impulses before and during dispensing and dividing by the mass dispensed.

[0066] FIG. 6 shows an isometric view of a container 600 comprising a flexible valve 601 having an initial airtight seal 602. The initial airtight seal 602 shown in FIG. 6 is a peel-off top. The peel-off top may have any suitable shape that aids the consumer in handling, gripping, and removing the airtight seal 602. The hermetic seal 602 may include artwork and may be suitably shaped to complement the package design. The hermetic seal 602 may also include a sensory experience sampling mechanism (not shown). The flexible valve 601 further comprises two tension-inducing elements 603 that are expandable volumes 604.

[0067] Flexible containers made from recyclable materials disclosed herein should be constructed with sufficient structural integrity so that they can be handled by consumers in many ways, or any other way known in the art, as intended, without breakage. For example, a freestanding flexible container having a product volume and a structural support volume can be manufactured with a flexible valve mechanism to facilitate the dispensing of a fluid product from the product support volume. One or more tension-inducing elements may be used to provide the flexible valve with the ability to allow the dispensing of a fluid product from the product volume upon application of a squeeze force above a minimum threshold but below a maximum threshold to the exterior of a flexible container made from a flexible packaging material disclosed herein. The flexible valve may also be reclosable to prevent the fluid product from being dispensed after use.

[0068] Examples of flexible packages that may be useful in the present invention include flexible airframe packages, such as those disclosed in U.S. Patent Nos. 9,682,537 and 9,469,088, which are incorporated herein by reference in their entirety. In such packages, a first laminate film and a second laminate film are sealed together to form a product chamber. The first laminate film and the second laminate film are sealed together in areas that form air pockets to provide a rigid three-dimensional airframe for the package in an empty state.

[0069] As disclosed herein, the term "valve" refers to a mechanism for selectively dispensing a product contained within a flexible container. For example, the valve may include a flow path including a tension-inducing element such as an activated portion, an expandable volume, and / or other structure that prevents the product from being dispensed when a force less than a critical squeeze force is applied to the container and a pressure less than a critical pressure rise exists within the product volume, but allows the product to be dispensed when the force applied to the container exceeds the critical squeeze force or the pressure within the product volume exceeds a critical pressure rise. The valve may further include an indicator that generates a signal to inform the user as to whether the valve is open or closed. An embodiment of an integral valve may include a tab that has a tear-open force required to gain access to the contents of the package. Valve embodiments suitable for the present invention are disclosed in U.S. Pat. Nos. 9,694,965 and 10,138,049, which are incorporated herein by reference in their entirety.

[0070] As used herein, the term "critical pressure rise" refers to a pressure sufficient to cause a product to be dispensed when such pressure is generated within the product volume and thus exerted on the valve. For example, a critical pressure rise that would be acceptable to a consumer would be in the range of about 0 Pa to about 90,000 Pa gauge pressure, or any range formed by these values, such as about 10,000 Pa to about 60,000 Pa, about 25,500 Pa to about 90,000 Pa, or about 2 Pa to about 4562 Pa. The pressure values ​​referred to herein are gauge pressures, or pressures measured above atmospheric pressure. The critical pressure rise is independent of the container material, container shape, or where the force is applied to the container.

[0071] As used herein, the term "critical squeeze force" refers to a force sufficient to cause the product to be dispensed from the container when such force is applied to the container. For example, the critical squeeze force acceptable to consumers is in the range of about 0.1 N to about 550 N, or any range formed by these values, such as about 0.15 N to about 470 N, about 5 N to about 230 N, about 55 N to about 549 N, about 0.5 N to about 4 N, about 4 N to about 8 N, about 40 N to about 240 N, about 410 N to about 475 N, about 10 N to about 530 N, about 100 N to about 200 N, about 250 N to about 300 N, or about 400 to about 500 N. The critical squeeze force depends on the container material, the container shape, and the location where the force is applied.

[0072] Use of the terms "a," "an," and "the" and similar referents in the context of describing the invention (particularly in the context of the claims which follow) should be construed to encompass both the singular and the plural, unless otherwise indicated in the specification or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" should be construed as open-ended terms (i.e., meaning "including, but not limited to"), unless otherwise indicated.

[0073] The recitation of ranges of values ​​herein is intended to serve merely as a shorthand method of individually referring to each separate value within the range, unless otherwise indicated herein, and each separate value is incorporated herein as if it were individually recited herein. All methods described herein can be performed in any suitable order, unless otherwise indicated herein or clearly contradicted by context. Any and all examples provided herein, or the use of exemplary language (e.g., "etc.") are intended merely to better illustrate the invention, and do not impose limitations on the scope of the invention unless otherwise asserted. No language in this specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0074] Various embodiments of the present invention meet both performance and recyclability criteria. A first embodiment includes a plastic airframe package with an integral valve of the form shown in Figure 1 having the following multi-layer construction:

[0075] [Table 5]

[0076] The embodiment of Structure I meets both the performance and recyclability criteria. The PE layers of Structure I may be low density PE, medium density PE, or high density PE. The thickness of the individual layers may be 0.002 mm to 0.075 mm depending on the layer. Structure I is substantially free of nylon.

[0077] A second embodiment includes a plastic airframe package with an integral valve in the form shown in FIG. 1 having the following multi-layer construction:

[0078] [Table 6]

[0079] The Structure II embodiment meets both performance and recyclability criteria. The PE layers of Structure II may be low density PE, medium density PE, or high density PE. The thickness of the individual layers may be 0.002 mm to 0.075 mm depending on the layer. Structure II contains one or more compatibilizers. Alternatively, the compatibilizer may be in one or more of the PE layers or in the PA (nylon) layer. The compatibilizer may be a compatibilizer shown in Table D in the ratios listed in Table D.

[0080] A third embodiment was made that includes a plastic airframe package with an integral valve in the form shown in FIG. 1 having the following multi-layer construction:

[0081] [Table 7]

[0082] The embodiment of Structure III meets both performance and recyclability criteria. The PE layers of Structure III may be low density PE, medium density PE, or high density PE. The thickness of the individual layers may be 0.002 mm to 0.075 mm depending on the layer. Structure III contains one or more compatibilizers. Alternatively, the compatibilizer may be in one or more of the PE layers or in the PA (nylon) layer. The compatibilizer may be a compatibilizer shown in Table D in the ratios listed in Table D.

[0083] The present invention is suitable for consumer packaging because it meets the performance criteria of Table C. Furthermore, the novel compositions and packages meet recycling standards for PE packaging, such as those of Table A or Table B. Additionally, the packages are uniquely recyclable in a curbside recycling model for the additional reason that the packages are easily classifiable as three-dimensional packages by virtue of their airframe construction, and therefore can be easily visually and mechanically removed from the recycling stream of two-dimensional films. While typical recyclable polyethylene flexible packaging has a pouch structure that folds approximately two-dimensionally when empty, the new material properties combined with the air frame structure result in a three-dimensional flexible polyethylene-based package that meets performance and recyclability standards and can be easily incorporated into local recycling programs. An additional advantage of these embodiments is the integral resealable valve that does not utilize separate parts and spouts that must be removed or broken down in the recycle stream. The present invention overcomes performance and recyclability issues in current flexible packaging, including current air frame flexible packaging. Finally, unlike a "clean and dry" grocery bag or dry food pouch that can be dropped off in a store's collection system, liquid packaging has always been a "wet and dry" package that is not accepted by any store's collection system. The present invention overcomes such issues in current flexible packaging, including current air frame flexible packaging, by making "wet and dry" packages curbside recyclable.

[0084] The above is merely a detailed description of some examples and embodiments of the present disclosure, and it is understood that many modifications to the disclosed embodiments may be made according to the disclosure made herein without departing from the spirit or scope of the present disclosure. Thus, the foregoing description is not intended to limit the scope of the present disclosure, but rather to provide sufficient disclosure to enable those skilled in the art to practice the present disclosure without undue burden. The scope of the present disclosure fully encompasses other embodiments that may become apparent to those skilled in the art. Features illustrated or described as part of one embodiment may be used in another embodiment to produce further embodiments. Thus, the present disclosure is intended to encompass such modifications and variations as fall within the scope of the appended claims and their equivalents. Those skilled in the art should appreciate that the present description is merely an explanation of exemplary embodiments, and is not intended to limit the broader aspects of the present disclosure, which are embodied in the exemplary configurations.

Claims

1. Flexible recyclable packaging, A first laminate film comprising one or more polyethylene layers, one or more EVOH layers, one or more binding layers, and one or more adhesive layers, wherein the outer layer of the first laminate film is a printable polyethylene layer, A second laminate film comprising one or more polyethylene layers, one or more EVOH layers, one or more binding layers, and one or more adhesive layers, The first laminate film and the second laminate film are sealed to each other to form a product chamber. The first laminate film and the second laminate film are sealed to each other in regions that form air pockets, providing a rigid three-dimensional air frame to the empty package. The amount of EVOH by weight in the package is 5% or less of the package. The flexible, recyclable package substantially free of nylon.

2. The flexible recyclable package according to claim 1, wherein the first laminate film comprises, in order, a first sealable polyethylene layer having a low seal-start temperature range defining the outer layer of the first laminate film, an adhesive layer, a second sealable polyethylene layer, a third sealable polyethylene layer, a first binding layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second binding layer, a fourth sealable polyethylene layer, and a fifth sealable polyethylene layer.

3. The flexible recyclable package according to claim 2, wherein the first sealable polyethylene layer of the first laminate film has a thickness in the range of 0.010 to 0.075 mm.

4. The flexible recyclable package according to claim 2, wherein the adhesive layer of the first laminate film has a thickness in the range of 0.002 to 0.010 mm.

5. The flexible recyclable package according to claim 2, wherein the second sealable polyethylene layer of the first laminate film has a thickness in the range of 0.015 to 0.050 mm.

6. The flexible recyclable package according to claim 2, wherein the third sealable polyethylene layer of the first laminate film has a thickness in the range of 0.015 to 0.050 mm.

7. The flexible recyclable package according to claim 2, wherein the first bonding layer of the first laminate film has a thickness in the range of 0.005 to 0.025 mm.

8. The flexible recyclable package according to claim 2, wherein the first gas barrier layer of ethylene vinyl alcohol (EVOH) of the first laminate film has a thickness in the range of 0.002 to 0.005 mm.

9. The flexible recyclable package according to claim 2, wherein the second bonding layer of the first laminate film has a thickness in the range of 0.005 to 0.025 mm.

10. The flexible recyclable package according to claim 2, wherein the fourth sealable polyethylene layer of the first laminate film has a thickness in the range of 0.015 to 0.050 mm.

11. The flexible recyclable package according to claim 2, wherein the fifth sealable polyethylene layer of the first laminate film has a thickness in the range of 0.015 to 0.050 mm.

12. The flexible recyclable package according to claim 1, wherein the second laminate film comprises, in order, a first sealable polyethylene layer having a low seal-start temperature range defining the outer layer of the second laminate film, a second sealable polyethylene layer, a first binding layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second binding layer, a third sealable polyethylene layer, and a fourth sealable polyethylene layer.

13. The flexible recyclable package according to claim 12, wherein the first sealable polyethylene layer of the second laminate film has a thickness in the range of 0.010 to 0.050 mm.

14. The flexible recyclable package according to claim 12, wherein the second sealable polyethylene layer of the second laminate film has a thickness in the range of 0.015 to 0.050 mm.

15. The flexible recyclable package according to claim 12, wherein the first bonding layer of the second laminate film has a thickness in the range of 0.005 to 0.025 mm.

16. The flexible recyclable package according to claim 12, wherein the first gas barrier layer of ethylene vinyl alcohol (EVOH) of the second laminate film has a thickness in the range of 0.002 to 0.005 mm.

17. The flexible recyclable package according to claim 12, wherein the second bonding layer of the second laminate film has a thickness in the range of 0.005 to 0.025 mm.

18. The flexible recyclable package according to claim 12, wherein the third sealable polyethylene layer of the second laminate film has a thickness in the range of 0.015 to 0.050 mm.

19. The flexible recyclable package according to claim 12, wherein the fourth sealable polyethylene layer of the second laminate film has a thickness in the range of 0.015 to 0.050 mm.

20. The flexible recyclable package according to claim 1, wherein the seal between the first laminate film and the second laminate film has a seal strength of 40 N / 25 mm to about 140 N / 25 mm.

21. The flexible recyclable package according to claim 1, wherein the layers constituting each of the first and second laminate films have an interlayer lamination strength of about 10 N / 25 mm to about 20 N / 25 mm.

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