Laminated constructions, blanks and containers formed from the laminated constructions, sealing devices therefor, and related methods.

Abstract

Containers according to the present disclosure can accommodate articles of many different shapes. A laminate structure for forming a barrier member of a container includes 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 being responsive to the application of radio frequency energy to promote bonding between the second functional polymer layer and the container wall of the container. A seal assembly for bonding the barrier member to the container is also disclosed.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to laminate structures / blanks, containers formed therefrom, and related methods. [Background technology]

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of each of U.S. Provisional Patent Application No. 63 / 422,631, filed November 4, 2022, and U.S. Provisional Patent Application No. 63 / 448,794, filed February 28, 2023.

[0003] Incorporation by Reference The disclosures of each of U.S. Provisional Patent Application No. 63 / 422,631, filed November 4, 2022, and U.S. Provisional Patent Application No. 63 / 448,794, filed February 28, 2023, are incorporated by reference herein for all purposes as if set forth in their entirety.

[0004] The present disclosure relates generally to laminate structures / blanks, containers formed therefrom, and related methods. More specifically, the present disclosure relates to laminate structures / blanks, containers formed therefrom, and related methods, wherein the laminate structures include at least one functional polymer layer that responds to the application of radio frequency energy. Summary of the Invention [Problem to be solved by the invention]

[0005] Containers according to the present disclosure can accommodate items of many different shapes. [Means for solving the problem]

[0006] According to one aspect, the present disclosure generally relates to a laminate structure for forming a barrier member of a container, the laminate structure having 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 being responsive to application of radio frequency energy to promote bonding between the second functional polymer layer and the container wall of the container.

[0007] According to another aspect, the present disclosure generally relates to a container for holding one or more products, the container having a container body with a container wall extending to at least partially surround the interior of the container, an upper end, a lower end, and a barrier member disposed within the container, the barrier member having 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 responsive to application of radio frequency energy to promote bonding between the second functional polymer layer and the container wall of the container.

[0008] According to another aspect, the disclosure generally relates to a method of forming a container for holding one or more products, the method including the steps of obtaining a container wall, disposing the container wall extending at least partially around an interior of the container such that the container has an upper end and a lower end, and obtaining a barrier blank, the barrier blank having a base layer, a barrier film layer, a first functional polymer layer, and a second functional polymer layer, the first functional polymer layer being responsive to the application of radio frequency energy. The method further includes the steps of disposing the barrier blank at least partially within 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 seal assembly for sealing a portion of a barrier blank to a container wall, the seal assembly including a support defining an opening, a receiver assembly having a receiving conductive member disposed to extend at least partially around the opening, and a transmitter assembly having a transmitting conductive member defining a first electrode function, a reciprocating member, a flexible member defining a sealing function and disposed between the conductive member, and a plunger plate defining a second electrode function, the transmitter assembly being movably supported relative to the receiver assembly so as to be aligned with the receiving conductive member at the opening in the support, and at least one radio frequency wave being transmitted from the first electrode function and the second electrode function of the transmitter assembly to the conductive member of the receiver assembly.

[0010] According to another aspect, the present disclosure generally relates to a method for sealing a barrier blank to a container wall of a container, the method including the steps of obtaining a seal assembly including a support defining an opening and a receiving assembly having a receiving conductive member disposed to extend at least partially around the opening, and a transmitting assembly movably supported relative to the receiving assembly, the transmitting assembly having a transmitting conductive member defining a first electrode function, a reciprocating member, a flexible member defining a seal function and disposed between the conductive member, and a plunger plate defining a second electrode function, the method further including the steps of aligning the transmitting assembly and the receiving conductive member at the opening of the support, at least partially positioning the barrier blank and the container wall between the transmitting assembly and the receiving assembly, and transmitting at least one radio frequency wave from the first electrode function and the second electrode function 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 these advantages, as well as other advantages and benefits of various additional embodiments, by reading the following detailed description of the embodiments and by reference to the drawings listed below.

[0012] According to common practice, the various features of the drawings described below are not necessarily drawn to scale. Dimensions of various features and elements within the drawings may be expanded or reduced to more clearly illustrate embodiments of the present disclosure. [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a cross-sectional schematic view of a laminate structure for use in forming blanks and containers according to the present disclosure. FIG. [Figure 1A] 2 is a cross-sectional schematic diagram of the laminate structure of FIG. 1 undergoing application of radio frequency energy. [Figure 2] FIG. 1B is a perspective view of a container at least partially formed from the laminated structure of FIGS. 1 and 1A. [Figure 3] FIG. 1 is a perspective view of a seal assembly according to an exemplary embodiment of the present disclosure. [Figure 4] FIG. 4 is a perspective view of a receiving assembly of the seal assembly of FIG. 3. [Figure 5] FIG. 4 is a perspective view of a transmitter assembly of the seal assembly of FIG. 3. [Figure 6] FIG. 6 is an exploded perspective view of the transmitter assembly of FIG. 5. [Figure 7] 6 is a perspective view of a conductive member of the transmitter assembly of FIG. 5. [Figure 8] FIG. 6 is a perspective view of a reciprocating member of the transmitter assembly of FIG. 5. [Figure 9] FIG. 6 is a perspective view of a flexible member of the transmitter assembly of FIG. 5. [Figure 10] FIG. 6 is a perspective view of a plunger plate of the transmitter assembly of FIG. 5. [Figure 11] 4 is a cross-sectional view of the seal assembly of FIG. 3 in a first configuration during a sealing operation. [Figure 12]4 is a cross-sectional view showing a second configuration of the seal assembly of FIG. 3 during a sealing operation. Corresponding parts are indicated by corresponding reference numerals throughout the drawings. DETAILED DESCRIPTION OF THE INVENTION

[0014] Various aspects of the present disclosure will be further understood by reference to the figures. For simplicity, like numerals may be used to represent like features. Where multiple similar features are shown, it will be understood that not all such features are necessarily shown in each figure. It will also be understood that the various components used to form the container may be interchangeable. Thus, although only certain combinations are illustrated herein, numerous other combinations and configurations are contemplated herein.

[0015] Containers according to the present disclosure can accommodate articles of many different shapes, and for purposes of explanation, and not to limit the scope of the disclosure, the following detailed description describes articles such as food products disposed at least partially on or within embodiments of the container.

[0016] The article can include a flowable product or material, e.g., an article such as a granular material / ingredient having a relatively small particle size, such as a flowable food product. In one embodiment, the article described herein can be a flowable product, such as, for example, infant formula, powdered coffee, powdered dietary supplement, cereal, granola, trail mix, candy, pasta, or any other food product, such as a liquid or powdered food or beverage product. In other embodiments, the flowable product can be a non-food product (e.g., detergent, cat litter, etc.) without departing from the disclosure.

[0017] As used herein, the terms "inside," "inner," "outside," "external," "lower," "lower," "upper," and "top" refer to directions determined with respect to a container held perfectly upright.

[0018] As described herein, a container may be formed from a plurality of overlapping panels, end flaps, and / or other portions of a blank. Without departing from this disclosure, such panels, end flaps, and / or other portions of a blank may be designated relative to one another in sequential or non-sequential reference, e.g., "first," "second," "third," etc.

[0019] 1, there is shown a schematic cross-sectional view of a laminated structure 102 for at least partially forming a blank and / or container 1 (FIG. 2) in accordance with one exemplary embodiment of the present disclosure. Container 1 can be used to support or hold one or more flowable products, as described above.

[0020] As shown, the laminate structure 102 may 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 by the adhesive layer, a primer layer 110 applied to the barrier film 108, a first functional polymer layer 112 applied to the primer layer 110 and configured to have adhesive properties 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.

[0021] The base layer 104 can be a composite material, such as paper or a paper-based product (e.g., paperboard, etc.), and supports 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 be the same size, shape, and / or dimensions as one or more of these components, although the base layer 104 can also be configured differently without departing from the disclosure. In some embodiments, the base layer 104 can provide mechanical strength, printability, and recyclability to the laminate structure 102 and the container formed therefrom.

[0022] The adhesive layer 106 can include one or more adhesives, such as a solvent-based polyurethane adhesive. In some embodiments, such adhesives can be derived from the reaction of an organic (poly)diisocyanate with an (oligomeric) diol compound, which results in urethane linkages in the associated backbone (—NH—C(═O)—O—).

[0023] In some embodiments, the adhesive layer 106 is applied to the base layer 104 and / or the barrier film layer 108 through an extrusion process, which can provide high interlayer adhesion between the adhesive applications that form the adhesive layer 106.

[0024] In one embodiment, the adhesive layer 106 has a thickness of about 2-4 g / m 2 Although adhesive layer 106 may be applied in an amount corresponding to the adhesive layer 106, it will be understood that adhesive layer 106 may be provided in different configurations and / or amounts without departing from this disclosure.

[0025] 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 opposite the adhesive layer 106 and the carrier film portion 118 can be disposed opposite the primer layer 110, although the barrier film layer 108 can be disposed in different positions without departing from this disclosure.

[0026] In some embodiments, the carrier film portion 118 of the barrier film layer 108 can be configured as a carrier film, typically a biaxially oriented polyene terephthalate (BOPET) layer or a biaxially oriented polypropylene (BOPP) layer. The carrier film portion 118 can be provided with a thickness of about 8 microns to about 25 microns, although the carrier film portion 118 can have different configurations and / or arrangements without departing from the disclosure.

[0027] In some embodiments, the barrier coating portion 116 of the barrier film layer can include one or more barriers vacuum-deposited onto the carrier film portion 118, and can include aluminum, silicon oxide (SiOx), and / or aluminum oxide (AlOx). In some embodiments, the barrier coating portion 116 can be at least partially protected from mechanical damage, such as material stresses, stresses associated with forming the laminate structure 102, etc., by one or more additional protective coatings.

[0028] The barrier film layer 108 described above can have beneficial environmental impact profiles compared to other layer structures, such as aluminum foil. In some embodiments, the barrier film layer 108 is 0.1 cm 3 / m 2 / day (under an environment of 1 atmosphere, 23°C, and 50% relative humidity), and an oxygen permeability of 0.1 g / m 2 / day (under an environment of 25°C and 70% relative humidity).

[0029] Optionally, a primer layer 110 can be applied to the barrier layer film 108. In some embodiments, the primer layer 110 has a thickness of from about 0.05 to about 0.2 g / m 2 For example, in embodiments where the first functional polymer layer 112 and / or the second functional polymer layer 114 are applied at a lower coating weight, a lower amount of primer layer 110 can be applied.

[0030] The first functional polymer layer 112 can be applied to the primer layer 110 or, in some embodiments, directly to the barrier film layer 108. In some embodiments, the first functional polymer layer 112 can comprise, for example, a copolymer of ethylene and methyl acrylate, including a methyl acrylate content of about 15% by weight or greater. It will be appreciated that the first functional polymer layer can be configured to undergo one or more changes thereof in response to the application of radio frequency energy (RF), as further described herein. In some embodiments, the first functional polymer layer 112 has a thickness of about 2 g / m 2 to about 50 g / m 2 can be applied in an amount of

[0031] In the illustrated embodiment, the second functional polymer layer 114 can include one or more materials including polyolefins such as polyethylene (e.g., LDPE, LLDPE, mLLDPE, plastomers, etc.). In some embodiments, the second functional polymer layer 114 can have a density of about 2 g / m 2 to about 50 g / m 2 can be provided in an amount of

[0032] In some embodiments, the first functional polymer layer 112 and the second functional polymer layer 114 can be applied to the base layer 104 / adhesive layer 106 / barrier film layer 108 substrate by co-extrusion. Co-extrusion of the layers 112, 114 in this manner can minimize the total amount of polymer material required.

[0033] 1A and as described herein, forming the laminate structure 102 can include the application of radio frequency (RF) energy, e.g., electromagnetic waves in the range of about 10 GHz to about 300 GHz. In some embodiments, the laminate structure 102 can be subjected to electromagnetic waves in the range of about 10 MHz and about 50 MHz. In some embodiments, electromagnetic waves in the range of about 20 MHz to about 30 MHz can be applied to the laminate structure 102.

[0034] The application of such RF energy to the laminate structure 102 can realign dipoles within the first functionalized polymer layer 112 in the presence of an alternating electric field, inducing molecular rotation and subsequent intramolecular friction, thereby generating heat within the first functionalized polymer layer 112.

[0035] RF energy can then be applied to the laminate structure 102 to at least partially heat, soften, melt, or otherwise react the first functional polymer layer 112 so that it has adhesive properties that bond the layers of the laminate structure 102. In some embodiments, such heating of the first functional polymer layer 112 promotes bonding of the second functional polymer layer 114 to the remainder of the laminate structure 102, forming a sealing film or barrier thereon.

[0036] Thus, the laminate structure 102 is configured to allow the application of RF energy to facilitate sealing and bonding of the laminate structure 102, while minimizing the use of conventional adhesives for such purposes.

[0037] It will be understood that one or more components of laminate structure 102 can have different configurations and / or arrangements without departing from this disclosure.

[0038] In forming the laminated structure 102 as described herein, the laminated structure 102 may be cut, folded, and / or otherwise shaped to form a blank or other substrate from which one or more containers may be formed.

[0039] 2, there is shown a container formed at least in part from a laminate structure 102 in the form of a paperboard packaging container 1 for products such as bulk solids. The particular shape of the container 1 shown in the figure should not be considered limiting. Thus, a paperboard packaging container according to the present disclosure can have any shape or size suitable for a desired purpose.

[0040] The packaging container 1 has a container body 2 formed of a tubular container wall 3, and in some embodiments, this container wall 3 can be constructed from a laminated structure 102. The container wall 3 extends from a lower end 4 to an upper end 5 of the opening of the container body, which opens in a height direction H of the packaging container 1. The container wall 3 has an inner surface 7 facing an inner compartment 8 (broadly speaking, the "interior") within 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.

[0041] The container body 2 can be formed by bringing the side edges of a laminated structure or other piece of material together so that the material assumes a tubular shape and sealing the side edges together. Sealing the side edges can be done by any suitable method known in the art, such as welding or adhesive, with welding being preferred. Sealing the side edges of the container body mesh may include the use of sealing strips, as known in the art. The container body can be formed into any desired tubular shape, including circular, oval, polygonal, rectangular, and modified rectangular shapes, such as modified rectangular shapes with rounded corners as shown in the figures.

[0042] The packaging container 1 can be closed at its bottom end 4 by a base disc 11 attached adjacent to the bottom end 4 of the container body 2. The base disc 11 can comprise a laminated base sheet material. Such a base sheet material can include a structural layer, such as a carton layer, and a thermoplastic welding layer. The base sheet material can optionally be of the same type as the laminated structure 102.

[0043] The base disc 11 is attached to the container wall 3 by folding an edge out of the plane of the base disc 11, aligning the folded edge with the inner surface 7 of the container wall 3, and welding or otherwise attaching the folded edge of the base disc 11 to the inner surface 7 of the container wall 3 to form a tight seal between the base disc 11 and the container wall 3.

[0044] The packaging container 1 may also include a lower rim (not shown) attached to the inner surface 7 of the container wall 3 between the base disc 11 and the lower end 4 of the container body 2. The lower rim will reinforce the lower edge of the container body 2 and protect it from mechanical deformation.

[0045] The packaging container 1 comprises a lid body arrangement including a lid 12 and an upper reinforcing rim 13 that extends around the periphery of the container body opening 6, the upper reinforcing rim 13 being hingedly connected to the lid 12.

[0046] The upper reinforcing rim 13 may be a plastic rim, such as a thermoplastic rim, and is attached to the inner surface 7 of the container body wall 3 at the container body opening 6. The upper reinforcing rim 13 may alternatively be a molded rim comprising pulp fibers. Similarly, the lid may be a plastic lid or a molded lid comprising pulp fibers.

[0047] The paperboard packaging container 1 may be an all-paperboard packaging container, for example, to avoid polymeric and / or metallic materials.

[0048] The provision of at least an upper reinforcing rim ensures that the wall maintains a selected shape, such as an outward curvature, which can prevent the wall from bulging inward, a phenomenon known to occur in paperboard packages and which is problematic in that it can adversely affect the stability and crush resistance of the package. The reinforcing rim is an optional component of the paperboard containers disclosed herein.

[0049] The upper reinforcing rim 13 extends in the height direction H of the container 1 and has a lower rim edge 14 facing the container lower end 4 and an upper rim edge 15 facing away from the container lower end 4.

[0050] The upper reinforcing rim 13 is joined to the inner surface 7 of the container wall 3, for example by a weld seal that extends around the periphery of the container body opening. The weld seal preferably extends continuously around the periphery of the container body opening and provides a seal between the upper reinforcing rim 13 and the container wall 3. The seal is preferably sieve-resistant, more preferably moisture-resistant, and most preferably airtight.

[0051] The inner compartment 8 of the package is sealed with a fully or partially removable inner seal member 16 (broadly known as a "barrier member" or "barrier blank"), which provides a shipping seal over the packaged bulk solids and is sealed by being welded to the inner surface of the container body wall 3. The removable inner seal member 16 may be attached to the container body wall 3 from either the top end 5 of the container body 2 or the bottom end 4 of the container body 2. To gain initial access to the packaged bulk solids, a user opens the lid 13 and fully or partially removes the inner seal member 16 to expose the packaged bulk solids.

[0052] The inner seal member 16 may comprise a laminate seal member sheet material including a structural layer, such as carton or aluminum foil, and a thermoplastic weld layer. In this regard, and as further described herein, the inner seal member 16 may be at least partially formed from a laminate structure 102.

[0053] 3, a seal assembly for use with one or more laminate structures is generally designated 200. Seal assembly 200 may be used separately with laminate structure 102 and / or with the remainder of packaging container 1 described herein, or may be used with laminate structures and / or packaging containers of different configurations without departing from this disclosure.

[0054] 3, the seal 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.

[0055] 4-6, the receiving assembly 203 can include a support 207 having a body 209 with a receiving conductive member 211 attached to the body 209.

[0056] As shown, the body 209 of the support 207 can be at least partially defined / extend around an opening 213 configured and dimensioned to at least partially receive a portion of the transmitter assembly 205. In some embodiments, the support 207 / body 209 can be at least partially formed of an electrically insulating material, such as a polymeric material and / or a composite material.

[0057] In some embodiments, the receiving conductive member 211 can be attached to a portion of the body 209 that surrounds the opening 213, for example, such that the receiving conductive member 211 can extend at least partially around the opening 213. In some embodiments, the receiving conductive member 211 can be adhered to an outer surface of the support 207 / body 209, and in some embodiments, the receiving conductive member 211 can be at least partially recessed within the body 209, for example, within a groove or channel formed therealong. The receiving conductive member 211 can be at least partially formed of a conductive material, for example a metallic material such as copper.

[0058] In this regard, the receiving conductive member 211 may have an at least partially ring-shaped / annular arrangement. As further described herein, the receiving conductive member 211 may have the general configuration of a loop antenna for receiving one or more electromagnetic waves transmitted by / emitted from the transmitting assembly 205.

[0059] 4-10, a transmitter assembly 205 is shown in accordance with an exemplary embodiment of the present disclosure. As shown in the assembly view of FIG. 6, the transmitter assembly 205 can include a transmitter conductive member 217, a reciprocating member 219, a flexible member 221, and a plunger plate 225. The transmitter assembly 205 can be at least partially supported by an overhead support 226, such as a rod, piston, frame member, or the like.

[0060] As further described herein, an actuator movably coupled to or integrated with the overhead support 226 can move the transmitting assembly 205, which is movably supported on the overhead support, upon receiving one or more electrical signals from a controller C in electrical communication (e.g., wired or wireless) with the transmitting assembly 205 and / or the receiving assembly 203. Such controller C can include a processor configured to execute one or more instructions stored on a non-transitory storage medium and can be configured for operator input and / or manual control. In this regard, the controller C can be part of or form part of a software program running on a computer, a programmable logic controller (PLC), another processor-implemented controller, or other control function. In some embodiments, the position of the overhead support 226 and the transmitting assembly 205 can be configured for manual actuation, adjustment, etc.

[0061] 7, the transmitting conductive member 217 can include a generally annular-shaped body 227 defining an opening 229 in its upper surface that communicates with the interior 231. The body 227 of the transmitting conductive member 217 can have a generally vertical upper portion 233 and an outwardly sloping lower portion 235 extending from the upper portion 231.

[0062] Also as shown, the angled lower portion 235 of the transmitting conductive member 217 can intersect with and / or at least partially define the electrode feature 236 (broadly, the "first electrode feature"), which can be at least partially formed of a conductive material, e.g., a metallic material such as copper, and can be configured to be electrically coupled to a power source P, e.g., a battery, a generator, a power grid, or the like.

[0063] 8, the reciprocating member 219 may be a block-like member constructed and arranged to be at least partially received within the interior 231 of the transmitting conductive member 217. As shown, the reciprocating member 219 may have a body 237 at least partially defining an interior hollow or recess 239, a generally vertical lower portion 241, a generally vertical upper portion 243 extending outwardly from the lower portion 241 so as to define a flange or step 245, and an annulus 247 extending upwardly from the upper portion 243. As shown, the annulus 247 may be arranged to at least partially receive the support 226 such that the reciprocating member 219 and the transmitting assembly 205 can be coupled to the support.

[0064] The upper portion 243 of the reciprocating member 219 can be configured to be attached to a pair of biasing members 249, which can be positioned to extend into the internal recess 239 through one or more openings in the upper surface of the upper portion 243. In the illustrated embodiment, the biasing members 249 can be a generally curved metallic or other resilient material, although biasing members of different configurations, such as coil springs or linear springs, can be provided without departing from the disclosure. As described further herein, the biasing members 249 facilitate the reciprocating movement of the reciprocating member 219 relative to other portions of the transmitter assembly 205. As also described herein, the biasing members 249 can facilitate electrical communication between components of the transmitter assembly 205.

[0065] 9A and 9B, flexible member 221 may be a flexible and / or resilient member, formed at least in part, for example, of a polymeric material, and has a body 251 arranged in a generally annular configuration about an opening 253 extending therethrough. Opening 253 may extend from an upper edge or surface 255 of body 251 / member 221 to a lower edge or surface 257 of body 251 / member 221. As shown, a generally sloped sidewall 259 may extend from upper surface 255 to a sealing feature 261 that projects outwardly from sidewall 259 and defines lower surface 257.

[0066] As further described herein, flexible member 221 is reconfigurable between a first / initial / unstressed configuration, as shown in FIG. 9A, and a second / actuated / stressed configuration, as shown in FIG. 9B.

[0067] 10, the plunger plate 225 can have a body 275 having a protruding upper portion 277 and a generally sloped lower portion 279 extending from the upper portion 277. As further described herein, the protruding upper portion 277 can be configured to contact a portion of the reciprocating member 219, and the lower portion 279 can be configured to contact the barrier member during a sealing operation.

[0068] It should be noted that, as further described herein, the lower portion 279 of the plunger plate 225 can define an electrode feature 280 (broadly, a "second electrode feature"). In this regard, the plunger plate 225 can be formed at least in part from a conductive material, for example, a metallic material such as copper, and can be configured to be electrically coupled to a power source P, as further described below. In this regard, the transmitting conductive member 217, the plunger plate 225, and the power source P can form an electrical circuit. In this regard, one or more portions of the transmitting assembly 205 can be connected to a ground source or element (not shown).

[0069] When forming the transmitting assembly 205, the reciprocating member 219 can be at least partially received within the interior 231 of the transmitting conductive member 217 such that the collar 247 of the reciprocating member 219 can extend upwardly through the opening 229 of the transmitting conductive member 217 to at least partially receive the support 226.

[0070] 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 shoulder 245 of the reciprocating member 219. In such an arrangement, the flexible member 221 can also be at least partially received within the interior 231 of the transmitting conductive member 217 such that a portion of the transmitting conductive member 217 is coextensive with the sidewall 259 of the flexible member 221. In some embodiments, the flexible member 221 can frictionally and / or compressively engage the lower portion 241 of the reciprocating member 219. In some embodiments, the flexible member 221 can be at least partially attached to the lower portion 241 and / or shoulder 245 of the reciprocating member 219 via, for example, bonding with one or more adhesives, welding, an interfering mechanical arrangement (e.g., via being at least partially received within a groove or channel), etc.

[0071] The plunger plate 225 can also be at least partially disposed within the interior 231 of the transmitting conductive member 217. The protrusion 277 of the plunger plate 225 can be configured to engage the lower portion 241 of the reciprocating member 219 directly or via a connecting structure, such as a post, rod, or the like. In some embodiments, the protrusion 227 of the plunger plate 225 can include a pair of recesses 281 for at least partially receiving the lower portions of the respective bias members 249 to movably couple the reciprocating member 219 to the plunger plate 225. Also as shown, the lower portion 279 of the plunger plate 225 can at least partially approximate the slope of the lower portion 235 of the transmitting conductive member 217.

[0072] Thus, the components of the transmitter assembly 205 can be assembled as described above, with one or more components connected to one another via engagement mechanisms and / or one or more fasteners such as bolts, screws, rivets, etc.

[0073] 11 and 12, actuation of transmitter assembly 205 during one or more sealing operations of seal assembly 200 will be described in accordance with an exemplary embodiment of the present disclosure.

[0074] The barrier member or barrier blank B can be positioned proximate a distal portion of the transmitter assembly 205, such as the underside of the plunger plate 225. In some embodiments, the barrier member or barrier blank B can be attached to the transmitter assembly 205. The barrier member or barrier blank B can include a central portion D and a peripheral portion M, as shown. In some embodiments, the peripheral portion M can be attached to the central portion D by one or more lines of weakness.

[0075] As described further below, the container wall 3 associated with one or more containers or cans, such as container 1, can be positioned to extend at least partially through the opening 213 in the receiving assembly 203, such that at least a portion of the container wall 3 is positioned between the transmitting assembly 205 and the receiving assembly 203, so that the transmitting assembly 205 can be positioned at least partially within the opening 213 within the container wall 3.

[0076] Upon receiving one or more signals from the controller C and / or via manual actuation, the overhead support 226 can urge the transmitter assembly 205 downward toward the receiver assembly 203 in the direction indicated by arrow A1 (FIG. 3). The transmitter assembly 205 can be inserted to a desired depth along the container wall 3, which in some embodiments can accommodate vertical alignment of the receiver assembly 203 with the receiving conductive member 211. In such an arrangement, the peripheral edge M of the barrier member or barrier blank B can capture or otherwise engage the upper edge of the container wall 3 and / or pseudo-engage with the inner surface of the container wall 3, such that the peripheral edge M of the barrier member or barrier blank B can extend upward relative to the central portion D of the barrier member or barrier blank B.

[0077] In some embodiments, a back pressure plate or other support may be provided within the vessel wall 3 to at least partially support the barrier member or barrier blank B and / or resist movement of the transmitting assembly 205 at a desired depth relative to the vessel wall 3.

[0078] Therefore, as shown in FIG. 12, when the underside of the transmitting assembly 205 meets such resistance, the support 226 can push the reciprocating member 219 downward via the ring 247, causing the plunger plate 225 to move downward in the direction of arrow A1.

[0079] When the lower portion 279 of the plunger plate 225 engages the barrier member or barrier blank B and the underlying support structure, continued movement of the support 226 causes the reciprocating member 219 to compress the bias member 249, bringing the reciprocating member 219 and plunger plate 225 into a closer position relative to one another.

[0080] Moving the reciprocating member 219 downward relative to the plunger plate 225 in this manner can have the effect of carrying not only the transmitting conductive member 217 downward, but also the flexible member 221 therewith.

[0081] As the shoulder 245 of the reciprocating member 225 biases the flexible member 221 further downward, the flexible member 221 can be at least partially reconfigured from a first or initial configuration (shown in FIG. 9A ) to a second configuration (shown in FIG. 9B ) by sliding along the sloped lower portion 279 of the plunger plate 225 to have a relatively larger base area, e.g., such that the sealing feature 261 at least partially expands in the direction indicated by arrow A2. Accordingly, the sealing feature 261 can have a first lateral direction D1 in the first configuration of the flexible member 221 and a second, larger lateral direction D2 in the second configuration of the flexible member 221. In doing so, the sealing feature 261 of the flexible member 221 can be urged to approach and / or compress the peripheral edge M of the barrier member or barrier blank B against the container wall 3.

[0082] In this regard, while the plunger plate 225 is in contact with the central portion D of the barrier member or barrier blank B, the electrode functional portion 236 of the transmitting conductive member 217 and the electrode functional portion 280 of the plunger plate 225 are adjacent to each other, and the sealing functional portion 261 of the flexible member 221 is positioned therebetween, and the transmitting conductive member 217 and the flexible member 221 move downward in the direction of arrow A1.

[0083] In this regard, the transmitter assembly 205 is reconfigurable from a first configuration (shown in FIG. 11) in which the reciprocating member is positioned a first vertical distance D3 from the plunger plate 225, and a second configuration (shown in FIG. 12) in which the reciprocating member 219 is positioned a second vertical distance D4 from the plunger plate 225.

[0084] In the second configuration of the transmitter assembly 205, the power source P can provide an electrical signal to the transmitter conductive member 217 and the plunger plate 225 to generate a desired electric field that has the effect of generating one or more electromagnetic waves, e.g., radio waves, RF. In some embodiments, the biasing member 249 can be constructed from a conductive material, e.g., a metallic material, such that the transmitter conductive member 217 and the plunger plate 225 can be in electrical communication via the biasing member 249 extending therebetween.

[0085] In some embodiments, such RF waves can have a frequency between about 30 Hz and about 300 GHz, although the wavelength of the RF waves can vary without departing from this disclosure. In one embodiment, the RF waves can have a wavelength of about 27.12 MHz.

[0086] In some embodiments, the power source P can provide one or more electrical pulses to provide RF waves with desired characteristics. In some embodiments, the power source P can provide such electrical pulses in coordination with a suitable controller, such as controller C or another controller. In some embodiments, such a controller can be configured to provide current to the transmitter assembly 205 to generate RF waves having a general waveform, such as a square wave, to minimize energy spikes, for example. In some embodiments, one or more inert gases, carbon dioxide, Group 18 gases, etc., can be provided near the electrode features 236, 280 to minimize the occurrence and / or effects of arcing.

[0087] Such RF waves generated in proximity to the electrode features 236, 280 may be transmitted / radiated outward through the peripheral edge M of the barrier member or barrier blank B and may be picked up by the receiving assembly 203, for example at the conductive element 211. The transmission of such RF waves through the peripheral edge M of the barrier member or barrier blank B disposed between the transmitting assembly 205 and the receiving assembly 203 may have the effect of exciting molecules associated with one or more polymeric portions of the barrier member or barrier blank B, causing the polymeric portions to heat and at least partially soften and / or melt, and the pressing action of the sealing feature 261 of the flexible member 221 may have the effect of bonding the peripheral edge M of the barrier member or barrier blank B to the container wall 3 via the softened and / or melted portions.

[0088] After a predetermined sealing or curing time has elapsed, the overhead support 226 may cease applying pressure to the transmitting assembly 205 and / or retract, for example under the action of the controller C, causing the biasing member 249 to resiliently return from the compressed state to its initial state so as to allow at least the reciprocating member 219 and the transmitting conductive member 217 to move upward relative to the barrier member or barrier blank B. Such movement of the reciprocating member 219 may resiliently return the flexible member 221 to an initial configuration in which the sealing feature 261 of the flexible member 221 is moved away from the peripheral edge M of the barrier member or barrier blank B and the container wall 3. In so doing, the biasing member 249 is arranged to bias the transmitter assembly 205 from the second configuration to the first configuration.

[0089] As described herein, the barrier member or barrier blank B can have the form of a laminated construction or structure comprising at least one polymer layer laminated to at least one other layer. In some embodiments, the laminated structure forming the barrier member or barrier blank B can comprise at least one composite layer in addition to the at least one polymer layer, for example, a cellulosic fiber arrangement, paper or paper-based product such as paperboard, cardboard, etc. In some embodiments, at least one polymer layer of the laminated structure forming the barrier member or barrier blank B can comprise one or more additional polymer layers. In some embodiments, at least one polymer layer of the laminated structure forming the barrier member or barrier blank B can comprise an ethylene or methyl acrylate copolymer. In some embodiments, the barrier blank B can have the same or similar configuration as the laminated structure 102 described herein.

[0090] It will be appreciated that in some embodiments, one or more of the blanks and members described herein can be shaped, sized, or otherwise configured to engage with other container structures, including container wall 3. Such container structures can include, to name a few, Boardio® available from Graphic Packaging International, LLC of Atlanta, Georgia, Sealio® available from Graphic Packaging International, LLC of Atlanta, Georgia, and Cekacan® available from Graphic Packaging International, LLC of Atlanta, Georgia. In some embodiments, container wall 3 can be made of a material having a weight of about 170 g / m 2 to approximately 500 g / m 2 The substrate surface weight may be

[0091] It will be understood that seal assembly 200 can have different configurations without departing from the disclosure. For example, in some embodiments, seal assembly 200 can be provided without transmitting conductive member 217, with reciprocating member 219 acting in cooperation with plunger plate 225 to generate RF energy as described herein, e.g., allowing reciprocating member 219 to provide or define an electrode function. As another example, in some embodiments, power P can be provided to receiving assembly 203 to generate RF energy that is received by transmitting assembly 205 and has the same or similar effect of sealing one or more portions of blank B to container wall 3.

[0092] Generally, the blank or base layer described herein can be constructed from paperboard having a caliper such that it is heavier and more rigid than regular paper. The base layer can also be constructed from other materials, such as cardboard, or any other material having suitable properties to enable the construct to function at least generally as described above. The base layer can be coated, for example, with a clay coating. The clay coating can then be printed with product, advertising, and other information or images. The base layer can then be coated with varnish to protect the information printed on the base layer. The base layer can also be coated on one or both sides with, for example, a moisture barrier. The base layer can also be laminated or coated with one or more sheet-like materials at selected panels or panel segments.

[0093] It will be apparent that numerous other sequences of steps can be used to form constructs as described herein. It will also be apparent that numerous other materials or structures can be used to form constructs in accordance with the present disclosure. Any of such materials can be used alone or in combination, and in any configuration, to form a construct. When multiple materials (or multiple layers of the same material) are used, the materials may be partially or completely bonded to one another, or may remain separate from one another (i.e., unbonded).

[0094] The laminate structures and blanks / constructs disclosed herein can be formed according to a number of processes known to those skilled in the art, and any of the various components used to form the package may be provided as a sheet of material, a roll of material, or a die-cut material in the shape of the construct to be formed (e.g., a blank or base layer).

[0095] All directional references (e.g., top, bottom, upward, downward, left, right, left-hand side, right-hand side, upper, lower, above, below, vertical, horizontal, clockwise, counterclockwise) are used solely for identification purposes to aid the reader in understanding the various embodiments of the present disclosure and are not intended to pose any particular limitation on the location, orientation, or use of the disclosed embodiments, unless specifically stated in the claims. Joint references (e.g., joined, attached, coupled, connected, etc.) should be interpreted broadly and may include intermediate members between the connection of elements and relative movement between elements. Thus, joint references do not necessarily imply that two elements are connected in a direct and fixed relationship to each other. Additionally, various elements described with respect to various embodiments may be interchanged to create entirely new embodiments that fall within the scope of the present disclosure.

[0096] The foregoing description of the present disclosure illustrates and describes various embodiments. Because various changes can be made to the above configurations without departing from the scope of the present disclosure, all matter contained in the above description or shown in the accompanying drawings is intended to be illustrative and not limiting. Moreover, the scope of the present disclosure encompasses various modifications, combinations, variations, etc. of the above-described embodiments. Furthermore, while the present disclosure illustrates and describes only selected embodiments, various other combinations, modifications, and environments are within the scope of the present disclosure as described herein, equivalent to the above teachings, and / or within the skill or knowledge of the relevant art. Furthermore, specific features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the present disclosure.

[0097] The foregoing description illustrates and describes various embodiments of the present disclosure. Because various modifications may be made to the above configurations, all matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not limiting. Various modifications, combinations, and variations of the above-described embodiments are within the scope of the present disclosure. Furthermore, while the present disclosure illustrates and describes only selected embodiments, various other combinations, modifications, and environments are within the scope of the present disclosure, equivalent to the above teachings, and / or within the skill or knowledge of the relevant technical field. Furthermore, specific features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments without departing from the scope of the present disclosure.

Claims

1. 1. A laminate structure for forming a barrier member of a container, comprising: 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; Including, A laminate structure wherein the first functional polymer layer is responsive to the application of radio frequency energy to promote bonding between the second functional polymer layer and a container wall of the container.

2. The laminate structure of claim 1 , wherein the first functional polymer layer is configured to at least partially melt when subjected to radio frequency energy.

3. 3. The laminate structure of 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 laminate structure of claim 3 , wherein the first functional polymer layer comprises a copolymer of ethylene and methyl acrylate.

5. 4. The laminate structure of claim 3, wherein the copolymer of ethylene and methyl acrylate comprises at least about 15 weight percent methyl acrylate.

6. The first functional polymer layer has a thickness of about 2 g / m ２ to about 50 g / m ２ 6. The laminate structure of claim 5, wherein the amount of

7. The laminate structure of claim 6 , wherein the second functional polymer layer comprises one or more polyolefins.

8. 8. The laminate structure of claim 7, wherein the barrier film layer comprises 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.

9. A container for holding one or more products, comprising: a container body having a container wall extending to at least partially surround an interior of the container; Upper end; a lower end; and a barrier member disposed within the container, the barrier blank comprising: 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; Including, The container, wherein the first functional polymer layer is responsive to the application of radio frequency energy to promote bonding between the second functional polymer layer and a container wall of the container.

10. 10. The container of claim 9, wherein the first functional polymer layer is configured to at least partially melt when subjected to radio frequency energy.

11. 11. The container of 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. 12. The container of claim 11, wherein the first functional polymer layer comprises a copolymer of ethylene and methyl acrylate.

13. 12. The container of claim 11, wherein the copolymer of ethylene and methyl acrylate comprises about 15% by weight or more of methyl acrylate.

14. The first functional polymer layer has a thickness of about 2 g / m ２ to about 50 g / m ２ 14. The container of claim 13, wherein the amount of

15. 15. The container of claim 14, wherein the second functional polymer layer comprises one or more polyolefins.

16. 16. The container of claim 15, wherein the barrier film layer comprises 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.

17. 1. A method of forming a container for holding one or more products, comprising: obtaining a vessel wall; disposing a container wall extending to at least partially surround an interior of the container such that the container has an upper end and a lower end; obtaining a barrier blank; The barrier blank comprises: Base layer, a barrier film layer; a first functional polymer layer, and a second functional polymer layer, the first functional polymer layer being responsive to application of radio frequency energy; placing the barrier blank at least partially within a container; and applying radio frequency energy to the barrier blank to bond the second functional polymer layer to a container wall of the container; A method comprising:

18. 20. The method of claim 17, wherein applying radio frequency energy to the barrier blank comprises at least partially melting the first functional polymer layer.

19. 20. The method of claim 18, 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.

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

21. 20. The method of claim 19, wherein the copolymer of ethylene and methyl acrylate comprises about 15 weight percent or more of methyl acrylate.

22. The first functional polymer layer has a thickness of about 2 g / m ２ to about 50 g / m ２ 22. The method of claim 21 , wherein the amount of

23. 23. The method of claim 22, wherein the second functional polymer layer comprises one or more polyolefins.

24. 24. The method of claim 23, wherein the barrier film layer comprises 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. 1. A seal assembly for sealing a portion of a barrier blank to a container wall, said seal assembly comprising: a receiving assembly having a support defining an opening and a receiving conductive member disposed to extend at least partially around the opening; a transmitter assembly including a transmitter conductive member defining a first electrode function, a reciprocating member, a flexible member defining a sealing function and disposed between the conductive member, and a plunger plate defining a second electrode function; The transmitting assembly is supported movably relative to the receiving assembly so as to be aligned with the receiving conductive member in the opening of the support, and at least one high frequency wave is transmitted from the first electrode functional portion and the second electrode functional portion of the transmitting assembly to the conductive member of the receiving assembly to heat one or more portions of a barrier blank disposed therebetween.

26. The seal assembly of claim 25, wherein the conductive member has a body defining an interior, the reciprocating member, and the flexible member at least partially received within the interior of the conductive member.

27. The seal assembly of claim 26, wherein the reciprocating member is attached to the flexible member such that the flexible member is reconfigurable upon movement of the reciprocating member.

28. 28. The seal assembly of claim 27, wherein the flexible member is reconfigurable between a first configuration in which the seal feature defines a first lateral distance and a second configuration in which the seal feature defines a second lateral distance, the second lateral distance being greater than the first lateral distance.

29. 29. The seal assembly of claim 28, wherein the plunger plate has a body defining an at least partially sloped outer surface, and wherein the seal feature of the flexible member is configured to slidably move along the sloped outer surface of the plunger plate body when the flexible member is reconfigured between the first configuration and the second configuration.

30. The seal assembly of claim 29, wherein the reciprocating member is movably coupled to the plunger plate with at least one biasing member.

31. 31. The seal assembly of claim 30, wherein the transmitter assembly is reconfigurable between a first configuration in which the reciprocating member is spaced a first vertical distance above the plunger plate and a second configuration in which the reciprocating member is spaced a second vertical distance above the plunger plate, the first vertical distance being greater than the second vertical distance.

32. 32. The seal assembly of claim 31, wherein the first electrode function and the second electrode function are configured to transmit the at least one radio frequency wave to the receiving conductive member when the transmitting assembly is in the second configuration.

33. 33. The seal assembly of claim 32, wherein the at least one biasing member is positioned to bias the transmitting assembly toward the first configuration.

34. 1. A method of sealing a barrier blank to a container wall of a container, comprising the steps of: obtaining a seal assembly, said seal assembly comprising: a receiving assembly having a support defining an opening and a receiving conductive member disposed to extend at least partially around the opening; a transmitter assembly having a transmitter conductive member defining a first electrode function, a reciprocating member, a flexible member defining a sealing function and disposed between the conductive member, and a plunger plate defining a second electrode function, the transmitter assembly being movably supported relative to the receiver assembly; aligning the transmitting assembly and the receiving conductive member in the openings in the support; positioning a barrier blank and a 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 function and the second electrode function of the transmitter assembly to the conductive member of the receiver assembly to heat one or more portions of the barrier blank; A method comprising:

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

36. 36. The method of claim 35, wherein the reciprocating member is attached to the flexible member such that the flexible member is reconfigurable upon movement of the reciprocating member.

37. 37. The method of claim 36, further comprising moving the reciprocating member such that the flexible member is reconfigured from a first configuration in which the sealing feature defines a first lateral distance to a second configuration in which the sealing feature defines a second lateral distance, the second lateral distance being greater than the first lateral distance.

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

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

40. 40. The method of claim 39, further comprising reconfiguring the transmitter assembly from a first configuration in which the reciprocating member is spaced a first vertical distance above the plunger plate to a second configuration in which the reciprocating member is spaced a second vertical distance above the plunger plate, the first vertical distance being greater than the second vertical distance.

41. 41. The method of claim 40, wherein the first electrode function and the second electrode function are configured to transmit the at least one radio frequency to the receiving conductive member when the transmitting assembly is in the second configuration.

42. 42. The method of claim 41, wherein the at least one biasing member is positioned to bias the transmitter assembly toward the first configuration.

Images