Flexible recyclable packaging

Abstract

We provide recyclable plastic packaging materials. [Solution] A flexible recyclable package comprising: a first laminate film comprising one or more polyethylene layers, one or more EVOH layers, a binder layer, and one or more adhesive layers; a second laminate film comprising one or more polyethylene layers, an EVOH layer, a binder layer, and one or more adhesive layers, wherein the first and second laminate films are sealed to each other to form a product chamber, and the first and second laminate films are sealed to each other in areas that form air pockets, providing a rigid three-dimensional air frame to the empty package, the weight of EVOH in the package is 5% or less of the package weight, it is nylon-free, and meets the recyclability criteria for curbside recycling.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the benefit and priority of U.S. Provisional Application No. 63 / 144,314, filed on February 1, 2021, the content of which is incorporated herein by reference.

Background Art

[0002] This disclosure relates to improved flexible reusable multilayer packages. More specifically, this disclosure relates to improved reusable multilayer packages that address the drawbacks 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 produce, require less material, and may be easier to decorate compared to conventional rigid containers. However, most such packages lack the recycling performance necessary for an impactful approach to reducing environmental footprint.

[0004] The recyclability of flexible packages, specifically polymer flexible packages, is mainly based on the type of material used in the package. For example, polyethylene terephthalate (PET) is one common recyclable polymer and is 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 one or more plastic materials, and such packages are difficult for recyclers to handle because different materials cannot be easily separated into different recycling streams.

[0005] Packages made from one or more layers, such as a low-density polyethylene layer combined with a PET layer, are designated as plastic packages that are not easily recyclable. Furthermore, many materials used to improve the performance of other recyclable packages, such as barrier layers made of ethyl vinyl alcohol (EVOH) or nylon, can also contribute to packages being difficult to recycle.

[0006] Many types of flexible packages exist. 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 on February 1, 2021, the contents of which are incorporated herein by reference in their entirety.

[0007] Furthermore, the presence of a PET printed layer within the film structure makes the material non-recyclable. There is a lack of suitable flexible, recyclable multilayer film structures that can be used for flexible packaging for various containers while simultaneously reducing the substantial amount of plastic introduced into the environment. [Overview of the project] [Problems that the invention aims to solve]

[0008] Therefore, there is a market need to develop sustainable alternative materials in the recyclable materials packaging industry. More specifically, there is a market need for substantially nylon-free recyclable multilayer packaging and its manufacturing methods, i.e., improved recyclable and curbside recyclable plastic packaging materials that are compatible with current technologies and manufacturing processes. [Means for solving the problem]

[0009] One object of embodiments of the present invention is to provide flexible plastic packaging suitable for curbside recycling, for example, packaging that can comply with the recyclability defined by the Association of Plastic Recyclers (APR). One such embodiment includes packaging manufactured from a material substantially free of nylon. Another or second embodiment includes packaging manufactured from a material using a certain optimized ratio of compatibilizer to achieve appropriate packaging performance and recyclability criteria.

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

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

[0012] Preferred embodiments of recyclable multilayer packaging disclosed herein and further detailed below are suitable for curbside compliance, such as adhering to industry APR requirements for recyclability. Furthermore, improved recyclable multilayer packaging that is substantially nylon-free or optimized with varying amounts of compatibilizers can be manufactured using conventional equipment and used in the manufacture of flexible containers. Finally, recyclable flexible packaging manufactured from such materials can be designated by numbers commonly used in widely available recycling flows.

[0013] The references provided above are for illustrative purposes only and do not limit the invention. It will be apparent to those skilled in the art that various modifications and changes can be made in the invention without departing from the scope or spirit of the invention. Further embodiments can be created by using features illustrated or described as part of one embodiment in another embodiment. Thus, the invention is intended to encompass modified and altered forms that fall within the scope of the appended claims and their equivalents. Other objects, features and aspects of the invention are disclosed in the following detailed description. It will be understood to those skilled in the art that this description is merely an illustrative description of exemplary embodiments and does not limit broader aspects of the invention, which are embodied in exemplary configurations. [Brief explanation of the drawing]

[0014] This disclosure will be more readily understood when accompanied by the following diagrams, and when similar reference figures represent elements, the following explanation will be taken into consideration. [Figure 1] Figure 1 shows a front view of a flexible container manufactured using a nylon-free, recyclable multilayer package according to one aspect of the present disclosure. [Figure 2] Figure 2 shows a side view of the flexible container of Figure 1 according to one aspect of the present disclosure. [Figure 3] Figure 3 shows a top view of the flexible container of Figure 1 according to one aspect of the present disclosure. [Figure 4] Figure 4 shows a bottom view of the flexible container of Figure 1 according to one aspect of the present disclosure. [Figure 5] Figure 5 shows a schematic diagram of one embodiment of a valve structure useful in relation to the present invention. [Figure 6] Figure 6 shows a lifted embodiment of the package including the valve from Figure 5.

[0015] The accompanying drawings incorporated herein and forming part thereof illustrate several aspects of this disclosure and, together with the description, serve to illustrate the principles of the embodiments. Together with the description, the drawings serve to illustrate the principles of the present invention. The detailed descriptions and examples set forth herein are presented for illustrative and explanatory purposes only, and not limiting. Accordingly, this disclosure is intended to encompass any and all modifications, variations, or equivalents that fall within the spirit and scope of the basic principles disclosed above and claimed herein. [Modes for carrying out the invention]

[0016] The following disclosure, in whole, can be best understood by referring to the detailed description provided when read in conjunction with the accompanying drawings, descriptions of the drawings, abstract, background, field of this disclosure, and relevant headings. The objects and merits of the present invention are described below, will be apparent from the following description, and will be understood through the practice of the invention. Where the same reference numeral appears on different drawings, it identifies the same element or a functionally equivalent element. Elements listed in the abstract are not referenced, but are nevertheless referenced by their association with elements in the detailed description and relevant disclosures.

[0017] One aspect of this disclosure provides an improved nylon-free recyclable multilayer package and a method for manufacturing the same, which addresses the shortcomings of currently available recyclable materials for flexible packaging and containers.

[0018] In one aspect of the present disclosure, a recyclable multilayer package film structure substantially free of nylon includes a polyethylene (PE) base layer having an ethylene vinyl alcohol (EVOH) barrier layer with a maximum percentage (by weight) of less than 5%. In the illustrated embodiment, the percentage (by weight) of EVOH in the overall structure is defined by the type of EVOH and the percentage of its 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] A recyclable multilayer package film structure substantially free of nylon 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, and the first and second sealable layers define 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 the second sealable layer, and the first sealable layer and the second sealable layer define opposing outer layers of the second laminate film.

[0020] The first laminate film can further include, in order, a first sealable polyethylene (PE) layer having a low seal start temperature range, 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 can further include, in order, a first sealable polyethylene (PE) layer having a low seal start temperature range, a second sealable polyethylene having a specific 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 bonding 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 wt% ethylene, (5) a second bonding 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 has a thickness of 100 microns, a weight of 93.20 g / m 2 and a gas barrier thickness (EVOH) of 3 microns, and a width of from about 400 mm to about 1500 mm. Note that different types of PE layers can be used as the sealable layers of the first laminate film for an improved nylon-free recyclable multilayer package.

[0022] In yet another aspect 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 bonding 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 wt% ethylene, (5) a first bonding 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 the outer laminate film and is suitable for both laser and corona treatment. In the illustrated embodiment, the second laminate film has a thickness of 100 microns, a weight of 93.80 g / m2 It has a weight, a gas barrier thickness (EVOH) of 3 microns, and a width of approximately 400 mm to 1500 mm. Note that different types of PE layers can be used as sealable layers of the first laminate film for improved nylon-free, recyclable multilayer packaging.

[0023] In the improved substantially nylon-free recyclable multilayer packaging disclosed herein, the second laminate film has a different configuration from the first laminate film, and the lamination strength of the film can be further increased by using a binder or adhesive layer during the manufacturing of the film. The lamination strength can be adjusted by selecting the type and thickness of the binder layer. If a higher lamination strength is desired, the binder layer may have an increased thickness. In addition, as further disclosed in this detailed description, the lamination strength can be adjusted by selecting the type and thickness of the binder layer. As an example, but not an limitation, a binder layer consisting of the chemical properties of an aqueous adhesive and / or an adhesive having a thickness of less than 2 microns can be used when a lower limit of the above-mentioned lamination strength is desired.

[0024] It should be noted that the layer thickness and total film thickness may vary depending on the package size. For example, smaller packages may require more calipers in the barrier layer, while larger packages may require more calipers in the PE strength layer.

[0025] In another aspect of the present disclosure, embodiments of the flexible packaging of the present invention include a polyethylene (PE) base layer containing a specific proportion of polyamide nylon (PA) layers and an ethylene vinyl alcohol (EVOH) barrier layer. In the illustrated embodiments, the PA and EVOH content defines the amount of compatibilizer used in the packaging formulation. A flexible, recyclable multilayer film structure is provided, comprising a first laminate film and a second laminate film bonded to at least a portion of the first laminate film by at least one first seal. The first laminate film may, in turn, include a first sealable polyethylene (PE) layer having a low seal-on temperature width, a first sealable PE layer having one or more compatibilizers, a first binding layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second binding layer, and a second sealable polyethylene (PE) layer having a low seal-on temperature width and containing one or more compatibilizers. A recyclable flexible multilayer film structure disclosed herein, including a second laminate, may, in order, include a first sealable polyethylene (PE) layer having a low seal-initiating temperature width, a first sealable PE layer having a compatibilizer, a first binding layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second binding layer, a second sealable polyethylene (PE) layer having one or more compatibilizers, a second sealable PE layer, and a printed layer containing recyclable non-PET such as a polyethylene (PE) layer.

[0026] In one embodiment 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 binding layer having a thickness of about 5 microns and containing one or more compatibilizers; (4) a polyamide nylon layer having a constant thickness; (5) a first gas barrier layer of ethylene vinyl alcohol (EVOH) layer, the EVOH layer containing 3.9 wt% ethylene and having a thickness of about 3 microns; (6) a second binding layer having a thickness of about 5 microns and containing one or more compatibilizers; (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. The first laminate film, which may also be called an inner laminate film as disclosed herein, is suitable for laser treatment but not for corona treatment. In the illustrated embodiment, the first laminate film has a thickness of 100 microns and a weight of 93.20 g / m². 2 It has a weight, a gas barrier thickness (EVOH) of 3 microns, and a width of approximately 400 mm to 1500 mm. Note that different types of PE layers can be used as the sealable layer of the first laminate film in the improved nylon-free, recyclable multilayer packaging.

[0027] In yet another aspect of this 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 binding layer having a thickness of about 5 microns and containing one or more compatibilizers; (4) a polyamide nylon layer having a specific thickness; (5) a first gas barrier layer of ethylene vinyl alcohol (EVOH) containing 3.9 wt% ethylene having a thickness of about 3 microns; (6) a second binding layer having a thickness of about 5 microns and containing one or more compatibilizers; (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 has a thickness of 100 microns and a density of 93.80 g / m². 2 It has a weight of , a gas barrier thickness (EVOH) of 3 microns, and a width of 1100. Note that different types of PE layers can be used as sealable layers of the first laminate film for improved recyclable multilayer packaging.

[0028] In the improved compatibilizer-based recyclable multilayer packaging disclosed herein, the second laminate film has a different configuration from the first laminate film, and the lamination strength of the film can be further increased by using a binder or adhesive layer during the manufacturing of the film. The lamination strength can be adjusted by selecting the type and thickness of the binder layer. If a higher lamination strength is desired, the binder layer may have an increased thickness. In addition, as will be further disclosed in the detailed description, the lamination strength can be adjusted by selecting the type and thickness of the binder layer. As an example, but not an limitation, a binder layer consisting of the chemical properties of an aqueous adhesive and / or an adhesive having a thickness of less than 2 microns can be used when a lower limit of the above-mentioned lamination strength is desired.

[0029] It should be noted that the layer thickness and total film thickness may vary depending on the package size. For example, smaller packages may require more calipers in the barrier layer, while larger sizes require more calipers in the PE strength layer. Various structures of this embodiment can be manufactured depending on whether the printable layer is a nylon-based or non-nylon-based layer. In the improved recyclable multilayer packaging disclosed herein, the second laminate film has a different configuration from the first laminate film, and the lamination strength of the film can be further increased by using a binding layer or adhesive layer during the manufacture of the film. The lamination strength can be adjusted by selecting the type and thickness of the binding layer. If higher lamination strength is desired, the binding layer may have an increased thickness. The lamination strength can be adjusted by selecting the type and thickness of the binding layer. As an example, but not an limitation, a binding layer consisting of an adhesive with the chemical properties of an aqueous adhesive and / or an adhesive with a thickness of less than 2 microns can be used when a lower limit of the above range of lamination strength is desired. As an example, rather than being limited, laser additives and UV inhibitors can be added to a portion of the PE layer to prevent the photosensitivity of such products.

[0030] In embodiments disclosed above where higher laminate strength is desired, the binder layer may have an increased thickness, for example, about 2 microns to about 5 microns, and a solvent-based two-component adhesive may be used. Furthermore, the binder layer may include a polymer binder layer. The laminate strength between the two layers of the laminate can also be increased by using a binder layer having a higher anhydride content in the polymer layer, for example, an anhydride content exceeding 150 ppm. Flexible containers with larger structural support volumes may require a flexible material having a laminate with higher laminate strength to avoid delamination of the flexible material when formed into flexible containers with expanded structural support volumes.

[0031] It should be noted that containers manufactured using the recyclable multilayer film structures disclosed herein are formed with sufficient structural integrity to withstand external forces and environmental conditions from handling without breakage. Furthermore, these containers may be constructed in a manner 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 embodiments of this disclosure, the term “gas barrier layer” refers to a layer of a laminate of flexible material, and the gas barrier layer is a material or coating material 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 embodiments, the gas permeability of the EVOH gas barrier layer can be adjusted by changing the thickness and molar percentage of ethylene content in the layer. The EVOH gas barrier layer may contain about 24 mol% to about 48 mol% of ethylene, and a lower ethylene content results in a gas barrier layer with lower gas permeability. Furthermore, the gas permeability of the gas barrier layer can be reduced by providing a thicker layer. Furthermore, the gas permeability of the EVOH gas barrier layer can be adjusted by changing the molar percentage of ethylene in the barrier material and / or the thickness of the gas barrier layer. Generally, increasing the molar percentage of ethylene in 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 this disclosure, the term “printed layer” means a laminate layer of a flexible material, the printed layer being a material having at least one main surface configured to receive and retain ink, and including a material that is at least partially treated to have sufficient surface energy to receive and retain ink.

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

[0035] As disclosed herein in one or more embodiments of the present disclosure, the term “sealable layer” means a laminate layer of a flexible material, the sealable layer being a material configured to be sealed to itself or to another sealable layer using any type of sealing method known in the art, including, for example, thermal sealing (e.g., conductive sealing, impulse sealing, ultrasonic sealing, etc.), welding, crimping, bonding, etc., and / or any combination thereof.

[0036] It should be further noted that various embodiments of the improved flexible multilayer recyclable packaging that are formed are substantially nylon-free and recyclable under industry standard recycling criteria, provided that the EVOH content does not exceed 5%.

[0037] In another aspect of the present disclosure, a flexible container is formed comprising one or more recyclable multilayer film structures, configured to have a specific product volume, wherein the packaging material forms 50–100% of the total surface area of ​​one or more materials defining the three-dimensional space of the product volume of the flexible container. Not limited to, but as an example, the flexible container may be configured such that one or more flexible materials form a specific percentage of the total area of ​​one or more materials defining the three-dimensional space, where the specific percentage is any integer value of the 50–100% percentage, or any other range formed by any of these values, e.g., 60–100%, 70–100%, 80–100%, or 90–100%.

[0038] Embodiments of recyclable multilayer film structures used in flexible containers meet standard curbside recycling requirements. Examples of standard curbside recycling requirements in the United States are published by APR, as further detailed below. Another example of standard curbside recycling requirements in Europe is published by RecyClass, as further detailed 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: / / 7plasticsrecycling.org / recyclingdefinitions). (1) At least 60% of consumers or communities have access to a collection system that accepts items in accordance with the U.S. 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 correctly classified into market bales of specific plastics that meet industry standard specifications through commonly used material recovery systems, including single-stream and dual-stream systems that handle deposit system containers, 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 supply raw materials suitable for use in identifiable new products.

[0040] Embodiments of the recyclable packaging of the present invention meet all APR functionality and compliance requirements in accordance with the APR design guide for the relevant materials. Each designed package embodiment is evaluated according to industry-accepted standards to ensure that it is truly recyclable in accordance with the above criteria.

[0041] To be recyclable, various embodiments of polyethylene-based flexible materials must either meet the protocols for reusability under the APR Critical Guidance for HDPE rigid containers, or not be worse under relevant standards than LDPE, which is widely accepted as reusable. There is a standard that the EVOH content of polyethylene-based flexible packages (without compatibilizers) must be 5% by weight or less of the package.

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

[0043] [Table 1]

[0044] Embodiments of the present invention satisfy the requirements for recyclability, as they do not measure any of the above-mentioned characteristics as being equivalent to or worse than those of HDPE packages.

[0045] Critical Guidance from RecyClass relating 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, in particular from the Criteria for RecyClass Pellet Characterization and Bottle Blow Molding.

[0046] [Table 2]

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

[0048] Embodiments of the present invention are considered to satisfy the recyclability of curbside recycling if they meet or exceed generally accepted standards for the recyclability of rigid polyethylene containers, for example, if they meet the relevant standards for rigid HDPE containers, or if the package does not meet the specific measurement standards for rigid HDPE, or if it is not bad under the same measurement characteristics as LDPE.

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

[0050] [Table 3]

[0051] In another aspect of this disclosure, “flexible container” means a container in which one or more flexible, improved nylon-free, recyclable multilayer packaging materials are configured such that the product volume forms 50–100% of the total surface area defining the three-dimensional space of the product volume.

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

[0053] As further disclosed herein, flexible containers manufactured from improved nylon-free recyclable multilayer materials may be configured to have a flexibility coefficient that falls within a specific range. For example, the flexibility factor of an improved nylon-free recyclable multilayer package may be in the range of 1,000 to 2,500,000 N / m, or 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, The flexibility factor may have any integer value in the following ranges: 000 N / m, 15,000-500,000 N / m, 20,000-400,000 N / m, 25,000-300,000 N / m, 30,000-200,000 N / m, 35,000-100,000 N / m, 40,000-90,000 N / m, or 45,000-85,000 N / m.

[0054] In another aspect of the present disclosure, a flexible, reusable packaging material or film includes a first laminate film further comprising a first sealable polyethylene layer having a low seal-on temperature range defining the outer layer of a first laminate, and a second sealable polyethylene layer having a predetermined thickness. In the illustrated embodiment, the second sealable polyethylene layer comprises a compatibilizer, a first binder layer, a third sealable layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a fourth sealable layer, a second binder layer, a fourth sealable polyethylene layer having a predetermined thickness and containing a compatibilizer, and a fifth sealable polyethylene layer.

[0055] In yet another aspect of the present disclosure, a flexible, reusable packaging material or film comprises, in turn, a second laminate film comprising a first sealable polyethylene layer having a low seal-on temperature range defining the outer layer of a second laminate. Note that the package further comprises a second sealable polyethylene layer having a specific predetermined thickness, the second sealable polyethylene layer comprising a compatibilizer, a first binder layer, a third sealable layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a fourth sealable layer, a second binder layer, a fourth sealable polyethylene layer having a certain predetermined thickness and containing a compatibilizer, and a fifth sealable polyethylene layer.

[0056] In another aspect of this disclosure, the above-described embodiments of multilayer flexible recyclable packaging materials can be manufactured by varying the amount of compatibilizer, thereby improving the bonding and sealing strength of the final product. Nylon-free flexible recyclable packaging materials or films can be manufactured with a 5% or 8% compatibilizer content, and the improved bonding and sealing strength of the multilayer final product will be closer to that of the original material or film used in its manufacture.

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

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

[0059] [Table 4]

[0060] In another aspect of this disclosure, a flexible, reusable package is provided. In the illustrated embodiment, the recyclable flexible package includes a substantially nylon-free, recyclable multilayer package that is recyclable according to industry standard recyclability guidelines, wherein at least a portion of the first sealable layer of a second laminate is bonded to at least a portion of the fifth sealable polyethylene layer of the first laminate to form at least one bonded seal portion. The flexible packaging structure is formed such that at least one bonded seal portion defines at least one boundary of a structural support volume located between the first laminate and the second laminate. By example, but not limited to, the recyclable flexible packaging material is 100 microns thick and 95.85–95.26 g / m². 2It has a weight range of 8 micron PA / 8 micron gas barrier thickness (EVOH) and a width of approximately 400 mm to 1500 mm.

[0061] Flexible containers manufactured 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 manufactured using an embodiment of the 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 to 4, a flexible container 1001 manufactured using an embodiment of a flexible material includes a cut-out top 104, an intermediate fragile line such as a cut or perforation 106, a bottom product-holding portion 108, a front portion 110, a rear portion 112, and left and right portions 114. The top portion 104 is separated from the intermediate portion 106 by a reference plane 100 parallel to the XZ plane. The intermediate portion 106 is separated from the bottom portion 108 by a reference plane 101 also parallel to the XZ plane. The container 1001 has a total height 116. In this embodiment, the front portion 110 and the rear portion 112 of the container are joined together at a seal 120, which extends around the outer circumference of the container 1001, crosses the top portion 104, descends the side portion 114, and then, at the bottom of each side portion 114, divides outward and continues around the outer extent of the front and rear portions of the base portion 125.

[0063] Furthermore, as shown in detail in Figures 1 and 2, the peel-off top 104 is peeled off by the user to access the valve, examples of which are disclosed in U.S. Patents 9,694,965 and 10,138,049, particularly in Figures 16 and 18, both patents in their entirety which are incorporated herein by reference. The characteristics of the valve according to the present invention are described further below.

[0064] A valve according to one embodiment of the present invention, described with reference to Figure 5. Figure 5 shows a top view of a flexible valve 500 comprising two opposing tension-inducing elements 501 having an expandable volume 502 and a flow path 503. A fluid product enters the flow path 503 through an inlet 504 and exits the flow path 503 through an outlet 505 when a critical compressive force is applied and the flexible valve 500 opens. When the critical compressive force is released and the flexible valve 500 closes, the tension gradient in the flow path 503 creates a suck-back effect, causing the fluid product in the flow path 503 to move in the opposite direction and return through the inlet 504. An indicator 506 positioned on the flow path 503 signals to the user whether the flexible valve 500 is open or closed. The flexible material forms the flow path 503. The tension-inducing elements 501 can hold the flexible material forming the flow path 503 in a fixed position when a critical compressive force is applied, thereby distributing the fluid product. In some embodiments, the flexible material forming the channel 503 between the tension-inducing elements 501 may be curved upward or downward relative to the two tension-inducing elements 501. In some embodiments, the flexible material forming the channel 503 should be relatively flat, and in some embodiments, it should not have any twists or bends that obstruct the channel 503.

[0065] The width of the outlet 505 strongly influences what the critical compressive force is. The smaller the width of the outlet 505, the greater the critical compressive force. The stiffness of the flexible material forming the flow path 503 should also be adjusted to help achieve the desired critical compressive force. The shape, size, relative orientation, and pressure of the tension-inducing element 501 affect the critical compressive force and mass flow rate achievable through the flexible valve 500. The mass flow rate of the fluid product passing through the flexible valve 500 and the critical compressive force of the flexible valve 500 are also adjustable by the operation of the vessel containing the flexible valve 500. Numerous parameters of the material forming the vessel, the geometric shape and arrangement of the tension-inducing element 501 (e.g., separation distance, shape, size), the size, shape, and width of the seal used to create an expandable volume, and the fluid properties of the fluid product all 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 path. For example, the channel 503 may be trapezoidal or any other suitable type of contour shape. The angle at which the channel 503 constricts the flow of the fluid product may be any value, e.g., 0, 40, 60, or 75 degrees. The size and shape of each expandable volume 502 may be constant or variable. For example, each expandable volume 502 may have a width of about 0.1 inches to about 1.5 inches, or any range within that, e.g., 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 at its widest point. The opening of the outlet 505 may have a width of about 0.2 inches to about 1 inch, or any range within that, e.g., 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 fluid product to be dispensed may be approximately 0.1 g to approximately 100 g, or any range within that range, for example, approximately 0.5 g to approximately 10 g, approximately 56 g to approximately 99 g, or approximately 2 g to approximately 43 g. The critical compressive force may be approximately 0.1 N to approximately 550 N, or any range within that range, for example, approximately 0.5 N to approximately 110 N, approximately 125 N to approximately 130 N, or approximately 500 N to approximately 540 N. The impulse (N*s) before dispensing may be in the range of approximately 1 Ns to approximately 1000 Ns and is calculated as the area under the force-time curve before any mass flow rate begins.The impulse (N*s) for distribution can range from approximately 1 Ns to approximately 1500 Ns and is calculated as the area under the force-time curve during distribution. The total effort (N*s / g) for distribution can range from approximately 1 to approximately 1200 Ns / g and is calculated by applying impulses before and during distribution and dividing by the distributed mass.

[0066] Figure 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 Figure 6 is a peel-off top. The peel-off top may have any preferred shape to help the consumer handle, grasp, and remove the airtight seal 602. The sealing seal 602 may include artwork and may be appropriately molded to complement the package design. The sealing seal 602 may also include a sensory experience sampling mechanism (not shown). The flexible valve 601 further comprises two tension-inducing elements 603 which have an expandable volume 604.

[0067] Flexible containers manufactured from recyclable materials disclosed herein should be constructed with sufficient structural integrity so that they can be handled by consumers in many ways, or by any other way known in the art, without being damaged as intended. For example, a self-supporting flexible container having a product volume and a structural support volume may be manufactured with a flexible valve mechanism to facilitate the dispensing of a fluid product from the product support volume. One or more tension induction elements may be used to provide the flexible valve with the ability to allow the dispensing of a fluid product from the product volume when a compressive force is applied to the outside of a flexible container manufactured from the flexible packaging material disclosed herein that exceeds a minimum threshold but is less than a maximum threshold. The flexible valve may also be re-closable 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. Patents 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 to each other to form a product chamber. The first and second laminate films are sealed to each other in areas that form air pockets to provide a rigid three-dimensional airframe in the empty package.

[0069] As disclosed herein, the term “valve” refers to a mechanism for selectively distributing a product contained within a flexible container. For example, a valve may include a flow path containing tension-inducing elements such as an activated portion, an expandable volume, and / or other structures that prevent the product from being distributed when a force below a critical compressive force is applied to the container and a pressure below a critical pressure rise is present in the product volume, but allow the product to be distributed when the force applied to the container exceeds the critical compressive force or the pressure in the product volume exceeds the critical pressure rise. A valve may further include an indicator that generates a signal to inform the user whether the valve is open or closed. Embodiments of an integrated valve may include a tab having a tear-opening force necessary to obtain access to the contents of the package. Embodiments of valves suitable for the present invention are disclosed in U.S. Patents 9,694,965 and 10,138,049, which are incorporated herein by reference as a whole.

[0070] As used herein, the term “critical pressure rise” refers to the pressure sufficient to dispense the product when such pressure arises within the product volume and is therefore exerted on the valve. For example, the critical pressure rise that would be acceptable to consumers would be in the range of gauge pressure from about 0 Pa to about 90,000 Pa, 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 does not depend on the container material, container shape, or where the force is applied to the container.

[0071] As used herein, the term “critical compressive force” refers to a force sufficient to disperse the product from the container when such a force is applied. For example, consumer-acceptable critical compressive forces are in the range of about 0.1N to about 550N, or any range formed by these values, e.g., about 0.15N to about 470N, about 5N to about 230N, about 55N to about 549N, about 0.5N to about 4N, about 4N to about 8N, about 40N to about 240N, about 410N to about 475N, about 10N to about 530N, about 100N to about 200N, about 250N to about 300N, or about 400N to about 500N. The critical compressive force depends on the container material, the container shape, and where the force is applied.

[0072] In the context describing the present invention (particularly in the context of the following claims), the use of the terms “a,” “an,” and “the,” and similar reference subjects, should be interpreted as encompassing both singular and plural forms unless otherwise indicated herein or explicitly denied by the context. The terms “comprising,” “having,” “including,” and “containing” should be interpreted as open-ended terms (i.e., “including, but not limited to”) unless otherwise stated.

[0073] The enumeration of value ranges herein is intended, unless otherwise indicated herein, merely as an abbreviation for referring individually to each distinct value faffing within the range, and each distinct value is incorporated herein as if it were individually enumerated herein. All methods described herein may be performed in any suitable order unless otherwise indicated herein or expressly contradicted by the context. Any and all examples or exemplary language provided herein (e.g., "etc.") is intended merely to better illustrate the invention and, unless otherwise asserted, does not limit the scope of the invention. No language herein should be construed as indicating any unclaimed element essential to the practice of the invention.

[0074] Various embodiments of the present invention satisfy both performance and recyclability criteria. The first embodiment includes a plastic airframe package having an integrated valve in the form shown in Figure 1, which has the following multilayer structure.

[0075] [Table 5]

[0076] Embodiments of Structure I meet both 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 individual layers may range from 0.002 mm to 0.075 mm depending on the layer. Structure I is substantially nylon-free.

[0077] A second embodiment includes a plastic airframe package having an integrated valve in the form shown in Figure 1, having the following multilayer structure.

[0078] [Table 6]

[0079] Embodiments of Structure II satisfy both performance and recyclability criteria. The PE layer of Structure II may be low-density PE, medium-density PE, or high-density PE. The thickness of individual layers may range from 0.002 mm to 0.075 mm depending on the layer. Structure II contains one or more compatibilizers. Alternatively, the compatibilizers may be in one or more PE layers or in the PA (nylon) layer. The compatibilizers may be those listed in Table D in the proportions shown therein.

[0080] A third embodiment was created, which includes a plastic airframe package having an integrated valve in the form shown in Figure 1, having the following multilayer structure.

[0081] [Table 7]

[0082] Embodiments of Structure III satisfy both performance and recyclability criteria. The PE layer of Structure III may be low-density PE, medium-density PE, or high-density PE. The thickness of individual layers may range from 0.002 mm to 0.075 mm depending on the layer. Structure III contains one or more compatibilizers. Alternatively, the compatibilizers may be present in one or more PE layers or in the PA (nylon) layer. The compatibilizers may be those listed in Table D in the proportions shown therein.

[0083] Embodiments of the present invention are suitable for consumer packaging as they conform to the performance criteria in Table C. Furthermore, the novel compositions and packaging meet recycling standards for PE packaging, such as the criteria in Table A or Table B. In addition, the packaging is independently recyclable in a curbside recycling model for the additional reason that it can be easily classified as a three-dimensional package thanks to its airframe structure and can therefore be easily removed visually and mechanically from the recycling stream of two-dimensional films. Conventional recyclable polyethylene flexible packaging consists of pouches that fold almost two-dimensionally when empty. However, by combining this new material property with an air-frame structure, a three-dimensional flexible polyethylene-based package has been realized that meets performance and recyclability standards and can be easily integrated into local recycling programs. A further advantage of these embodiments is an integrated, resealable valve that does not utilize separate parts and spouts that must be removed or disassembled in the recirculating flow. The present invention overcomes the performance and recyclability problems of current flexible packaging, including current air-frame flexible packaging. Finally, unlike "clean and dry" grocery bags or dry food pouches that can be dropped in store collection systems, liquid packaging is always "wet and dry" packaging that is not accepted by any store collection system. The present invention overcomes such problems in current flexible packaging, including current air-frame flexible packaging, by making "wet and dry" packaging curbside recyclable.

[0084] The foregoing is merely a detailed description of some examples and embodiments of the Disclosure, and it should be understood that numerous modifications to the disclosed embodiments can be made in accordance with the disclosures made herein without departing from the spirit or scope of the Disclosure. Accordingly, the foregoing description does not limit the scope of the Disclosure and provides sufficient disclosure to enable a person skilled in the art to implement the Disclosure without undue burden. The scope of the Disclosure fully encompasses other embodiments that may become apparent to a person skilled in the art. Features illustrated or described as part of one embodiment can be used in another embodiment to result in further embodiments. Accordingly, the Disclosure is intended to encompass modifications and variations that fall within the scope of the appended claims and their equivalents. A person skilled in the art should understand that this description is merely a description of exemplary embodiments and does not limit broader aspects of the Disclosure, which are embodied in 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, one or more nylon 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, one or more nylon 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 the region that forms an air pocket, providing a rigid three-dimensional air frame to the empty package. In the first laminate film, at least one of the binding layer, polyethylene layer, EVOH layer, or nylon layer further contains one or more compatibilizers. In the second laminated film, at least one of the binder layer, polyethylene layer, EVOH layer, or nylon layer further contains one or more compatibilizers, The flexible recyclable package that meets the recyclability standards for curbside recycling.

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 first binder and compatibilizer, a first nylon layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second nylon layer, a second binder and compatibilizer, a second binder, and a third 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 first binding layer of the first laminate film further comprises one or more compatibilizers and has a thickness in the range of 0.015 to 0.030 mm.

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

10. The flexible recyclable package according to claim 2, wherein the second bonding layer of the first laminate film further comprises one or more compatibilizers and has a thickness in the range of 0.015 to 0.030 mm.

11. 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.

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 first binder and compatibilizer, a first nylon layer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second nylon layer, a second binder and compatibilizer, and a second 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 first bonding layer of the second laminate film further comprises one or more compatibilizers and has a thickness in the range of 0.015 to 0.030 mm.

15. The flexible recyclable package according to claim 12, wherein the first nylon layer of the second laminate film has a thickness in the range of 0.002 to 0.010 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 nylon layer of the second laminate film has a thickness in the range of 0.002 to 0.010 mm.

18. The flexible recyclable package according to claim 12, wherein the second bonding layer of the second laminate film further comprises one or more compatibilizers and has a thickness in the range of 0.015 to 0.030 mm.

19. The flexible recyclable package according to claim 12, wherein the 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 of the first laminate film have a lamination strength between each layer ranging from approximately 10 N / 25 mm to approximately 20 N / 25 mm.

22. The flexible recyclable package according to claim 1, wherein the layers of the second laminate film have a lamination strength between each layer ranging from approximately 10 N / 25 mm to approximately 20 N / 25 mm.

23. The material is 0.7 cc / m ２ ~Approx. 2.5cc / m ２ A flexible recyclable package according to claim 1, having a gas permeability of .

24. The flexible recyclable package according to claim 1, wherein one or more compatibilizers comprise at least two compatibilizers.

25. The flexible recyclable package according to claim 24, wherein one or more compatibilizers comprise a first and a second compatibilizer.

26. The flexible recyclable package according to claim 25, wherein the first compatibilizer is approximately 1 to 5% by weight.

27. The flexible recyclable package according to claim 26, wherein the second compatibilizer is approximately 8 to 20% by weight.

28. The flexible recyclable package according to claim 25, wherein the first compatibilizer is present in an amount of about 1% by weight and the second compatibilizer is present in an amount of about 14 to 20% by weight.

29. The flexible recyclable package according to claim 25, wherein the first compatibilizer is present in an amount of about 2% by weight and the second compatibilizer is present in an amount of about 12 to 15% by weight.

30. The flexible recyclable package according to claim 25, wherein the first compatibilizer is present in an amount of about 3% by weight and the second compatibilizer is present in an amount of about 11 to 15% by weight.

31. The flexible recyclable package according to claim 25, wherein the first compatibilizer is present in an amount of about 4% by weight and the second compatibilizer is present in an amount of about 8 to 15% by weight.

32. The flexible recyclable package according to claim 25, wherein the first compatibilizer is present in an amount of about 5% by weight and the second compatibilizer is present in an amount of about 8 to 15% by weight.

33. The flexible recyclable package according to claim 1, wherein one or more compatibilizers are present in the binding layer.

34. The flexible recyclable package according to claim 1, wherein one or more compatibilizers are present in the EVOH layer.

35. The flexible recyclable package according to claim 1, wherein one or more compatibilizers are present in the polyethylene layer.

36. Flexible recyclable packaging, A first laminate film comprising one or more polyethylene layers, one or more EVOH layers, one or more binding layers, one or more nylon layers, and one or more adhesive layers, wherein the outer layer of the first laminate film is a printable nylon layer, A second laminate film comprising one or more polyethylene layers, one or more EVOH layers, one or more binding layers, one or more nylon 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 the region that forms an air pocket, providing a rigid three-dimensional air frame to the empty package. In the first laminate film, at least one of the binding layer, polyethylene layer, EVOH layer, or nylon layer further contains one or more compatibilizers, In the second laminate film, at least one of the binding layer, polyethylene layer, EVOH layer, or nylon layer further contains one or more compatibilizers, The flexible, recyclable package that meets the recycling standards for curbside recycling.

37. The flexible recyclable package according to claim 36, wherein the first laminate film comprises, in order, a sealable nylon layer having a low seal-start temperature range defining the outer layer of the first laminate, an adhesive layer, a first sealable polyethylene, a first binder and compatibilizer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second binder and compatibilizer, and a second sealable polyethylene layer.

38. The flexible recyclable package according to claim 37, wherein the first sealable polyethylene layer of the first laminate film has a thickness in the range of 0.010 to 0.075 mm.

39. The flexible recyclable package according to claim 37, wherein the adhesive layer of the first laminate film has a thickness in the range of 0.002 to 0.010 mm.

40. The flexible recyclable package according to claim 37, wherein the second sealable polyethylene layer of the first laminate film has a thickness in the range of 0.015 to 0.050 mm.

41. The flexible recyclable package according to claim 37, wherein the first bonding layer of the first laminate film further comprises one or more compatibilizers and has a thickness in the range of 0.015 to 0.030 mm.

42. The flexible recyclable package according to claim 37, wherein the first nylon layer of the first laminate film has a thickness in the range of 0.002 to 0.010 mm.

43. The flexible recyclable package according to claim 37, 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.

44. The flexible recyclable package according to claim 37, wherein the second nylon layer of the first laminate film has a thickness in the range of 0.002 to 0.010 mm.

45. The flexible recyclable package according to claim 37, wherein the second bonding layer of the first laminate film further comprises one or more compatibilizers and has a thickness in the range of 0.015 to 0.030 mm.

46. The flexible recyclable package according to claim 37, wherein the third sealable polyethylene layer of the first laminate film has a thickness in the range of 0.015 to 0.050 mm.

47. The flexible recyclable package according to claim 36, 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, a first binder and compatibilizer, a first gas barrier layer of ethylene vinyl alcohol (EVOH), a second binder and compatibilizer, and a second sealable polyethylene layer.

48. The flexible recyclable package according to claim 47, wherein the first sealable polyethylene layer of the second laminate film has a thickness in the range of 0.010 to 0.050 mm.

49. The flexible recyclable package according to claim 47, wherein the first binding layer of the second laminate film further comprises one or more compatibilizers and has a thickness in the range of 0.015 to 0.030 mm.

50. The flexible recyclable package according to claim 47, wherein the first nylon layer of the second laminate film has a thickness in the range of 0.002 to 0.010 mm.

51. The flexible recyclable package according to claim 47, 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.

52. The flexible recyclable package according to claim 47, wherein the second nylon layer of the second laminate film has a thickness in the range of 0.002 to 0.010 mm.

53. The flexible recyclable package according to claim 47, wherein the second bonding layer of the second laminate film further comprises one or more compatibilizers and has a thickness in the range of 0.015 to 0.030 mm.

54. The flexible recyclable package according to claim 47, wherein the sealable polyethylene layer of the second laminate film has a thickness in the range of 0.015 to 0.050 mm.

55. The flexible recyclable package according to claim 36, 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.

56. The flexible recyclable package according to claim 36, wherein the first laminate layer has a laminate strength between each layer of approximately 10 N / 25 mm to approximately 20 N / 25 mm.

57. The flexible recyclable package according to claim 36, wherein the second laminate layer has a laminate strength between each layer of approximately 10 N / 25 mm to approximately 20 N / 25 mm.

58. The material is 0.7 cc / m ２ ~Approx. 2.5cc / m ２ A flexible recyclable package according to claim 36, having a gas permeability of .

59. The flexible recyclable package according to claim 36, wherein one or more compatibilizers comprise at least two compatibilizers.

60. The flexible recyclable package according to claim 36, wherein one or more compatibilizers comprise a first and a second compatibilizer.

61. The flexible recyclable package according to claim 60, wherein the first compatibilizer is approximately 1 to 5% by weight.

62. The flexible recyclable package according to claim 61, wherein the second compatibilizer is approximately 8 to 20% by weight.

63. The flexible recyclable package according to claim 60, wherein the first compatibilizer is present in an amount of about 1% by weight and the second compatibilizer is present in an amount of about 14 to 20% by weight.

64. The flexible recyclable package according to claim 60, wherein the first compatibilizer is present in an amount of about 2% by weight and the second compatibilizer is present in an amount of about 12 to 15% by weight.

65. The flexible recyclable package according to claim 60, wherein the first compatibilizer is present in an amount of about 3% by weight and the second compatibilizer is present in an amount of about 11 to 15% by weight.

66. The flexible recyclable package according to claim 60, wherein the first compatibilizer is present in an amount of about 4% by weight and the second compatibilizer is present in an amount of about 8 to 15% by weight.

67. The flexible recyclable package according to claim 60, wherein the first compatibilizer is present in an amount of about 5% by weight and the second compatibilizer is present in an amount of about 8 to 15% by weight.

68. The flexible recyclable package according to claim 36, wherein one or more compatibilizers are present in the binding layer.

69. The flexible recyclable package according to claim 36, wherein one or more compatibilizers are present in the EVOH layer.

70. The flexible recyclable package according to claim 36, wherein one or more compatibilizers are present in the polyethylene layer.

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