Flexible packaging film

Abstract

A flexible packaging film having a laminated cap layer, core layer, and seal layer. The cap layer has a first surface and a second surface. The core layer has a first surface and a second surface. The second surface of the cap layer is positioned to cover the first surface of the core layer and laminated thereto. The seal layer has a first surface and a second surface. The second surface of the core layer is positioned to cover the first surface of the seal layer and laminated thereto. One of the cap layer and the core layer contains biaxially oriented polyamide. The other of the cap layer and the seal layer contains a blow film containing polyethylene with a compatibilizer having a density of 95 g / cc.

Description

Technical Field

[0001] Cross - reference to Related Applications None applicable

[0002] Background of the Disclosure 1. Technical Field of the Disclosure The present disclosure generally relates to flexible packaging, and more particularly to films for flexible packaging. Such flexible films disclosed herein have a structure considered recyclable by conventional recycling procedures and methods, while having robustness suitable for use related to bag - in - box packaging and pouches with spouts.

Background Art

[0003] 2. Background Art The use of polymer - based films in the manufacture of flexible packaging is known in the art. Such flexible packaging, in some cases, forms the basis of bag - in - box packaging. In other cases, such flexible packaging includes pouches having spouts extending therefrom. Such films often require strict specifications due to the harsh transportation and handling environments that such flexible packaging experiences.

[0004] At the same time, increasing emphasis is being placed on the recyclability of films. For some films used in certain applications, there are problems with recycling. For example, in certain applications, combining different polymers to form a film structure suitable for a difficult environment makes recycling difficult, if not impossible. The challenge is to find a film composition that can be recycled while providing the required performance.

Summary of the Invention

Means for Solving the Problems

[0005] This disclosure relates to a flexible packaging film. The film comprises a cap layer, a core layer, and a seal layer. The cap layer has a first surface and a second surface. The core layer has a first surface and a second surface. The second surface of the cap layer is positioned to cover the first surface of the core layer and laminated thereto. The seal layer has a first surface and a second surface. The second surface of the core layer is positioned to cover the first surface of the seal layer and laminated thereto. One of the cap layer and the core layer comprises a biaxially oriented polyamide. Furthermore, one of the cap layer and the seal layer comprises a blow film containing polyethylene having a compatibilizer with a density of 95 g / cc.

[0006] In some configurations, one of the cap layer or the seal layer comprises a three-layer blow-molded film co-extruded product having a polyethylene layer on either the polyethylene or compatibilizer layer, and the other of the cap layer or seal layer comprises polyethylene.

[0007] In some configurations, the polyethylene and compatibilizer layer comprises 83% by mass of polyethylene and 17% by mass of compatibilizer to achieve a compatibilizer level of 2.9% in the laminate structure.

[0008] In some configurations, the core layer contains polyamide.

[0009] In some configurations, the sealing layer includes a blown film containing polyethylene.

[0010] In some configurations, the cap layer includes a blown film containing polyethylene.

[0011] In some configurations, the core layer contains polyamide.

[0012] In some configurations, the sealing layer comprises a three-layer blow-molded film co-extruded product in which a polyethylene layer is present on either the polyethylene or compatibilizer layer.

[0013] In some configurations, the polyethylene and compatibilizer layer comprises 90% by mass of polyethylene and 10% by mass of compatibilizer.

[0014] In some configurations, the cap layer has a thickness of 1.0 mil, the core layer has a thickness of 0.6 mil, and the seal layer has a thickness of 1.8 mil.

[0015] In some configurations, the cap layer comprises a five-layer blow-molded film co-extruded product in which the cap layer includes a central EVOH layer surrounded on one of its surfaces by a polyethylene layer and on one of its surfaces by a tie layer.

[0016] In some configurations, the core layer contains polyamide.

[0017] In some configurations, the sealing layer comprises a three-layer blow-molded film co-extruded product in which a polyethylene layer is present on either the polyethylene or compatibilizer layer.

[0018] In some configurations, the polyethylene and compatibilizer layer comprises 78% by mass of polyethylene and 22% by mass of compatibilizer.

[0019] In some configurations, the cap layer has a thickness of 1.7 mils, the core layer has a thickness of 0.4 mils, and the seal layer has a thickness of 1.4 mils.

[0020] In some configurations, the cap layer contains polyamide.

[0021] In some configurations, the core layer contains an adhesive.

[0022] In some configurations, the sealing layer comprises a seven-layer blow-molded film co-extruded product in which the sealing layer is surrounded by polyethylene and compatibilizer layers surrounded by polyethylene layers, and a central EVOH layer surrounded by tie layers on any of its surfaces.

[0023] In some configurations, the polyethylene and compatibilizer layer contains 93% by weight of polyethylene and 7% by weight of compatibilizer.

[0024] In some configurations, the EVOH layer contains 29 mol% of EVOH.

[0025] In some configurations, the cap layer has a thickness of 0.48 mils, the core layer has a thickness of 0.1 mils, and the seal layer has a thickness of 5.50 mils.

[0026] In another aspect of the present disclosure, the present disclosure is directed to a flexible packaging for bag-in-box packaging that includes a first film and a second film. Each film is formed from a flexible packaging film as described herein. Further, the first film and the second film are positioned such that the seal layer of the first film and the seal layer of the second film overlap and contact each other. The seal seals the first film to the second film to form a cavity. In some such configurations, the film includes a configuration in which the cap layer has a thickness of 1.0 mils, the core layer has a thickness of 0.6 mils, and the seal layer has a thickness of 1.8 mils. In some such configurations, the cap layer has a thickness of 1.7 mils, the core layer has a thickness of 0.4 mils, and the seal layer has a thickness of 1.4 mils.

[0027] In another aspect of the present disclosure, the present disclosure is directed to a flexible packaging that forms a pouch including a first film and a second film. Each such film is formed from a flexible packaging film as described herein. Further, the first film and the second film are positioned such that the seal layer of the first film and the seal layer of the second film overlap and contact each other. The seal seals the first film to the second film to form a cavity. In some such configurations, the cap layer has a thickness of 0.48 mils, the core layer has a thickness of 0.1 mils, and the seal layer has a thickness of 5.50 mils.

[0028] Here, the present disclosure will be described while referring to the drawings.

Brief Description of the Drawings

[0029] [Figure 1] It is a schematic diagram of the configuration of the flexible packaging film of the present disclosure. [Figure 2] It is a top view of the flexible packaging for use related to bag-in-box packaging. [Figure 3] It is a top view of the flexible packaging constituting a pouch having a spout. [Figure 4] For example, but not limited to this, it is a schematic diagram of the configuration of the flexible packaging film of the present disclosure, suitable for use in the formation of a flexible bag for bag-in-box packaging. [Figure 5] For example, but not limited to this, it is a schematic diagram of the configuration of the flexible packaging film of the present disclosure, suitable for use in the formation of a flexible bag for bag-in-box packaging. [Figure 6] For example, but not limited to this, it is a schematic diagram of the configuration of the flexible packaging film of the present disclosure, suitable for use in the formation of a flexible bag for bag-in-box packaging. [Figure 7] For example, but not limited to this, it is a schematic diagram of the configuration of the flexible packaging film of the present disclosure, suitable for use in the formation of a pouch.

Modes for Carrying Out the Invention

[0030] Although the present disclosure can have many different forms of embodiments, it should be regarded as an exemplification and is not intended to be limited to the embodiments described. Based on this understanding, specific embodiments are shown in the drawings and will be described in detail herein.

[0031] It is understood that similar or identical elements and / or components referenced herein may be identified by the same reference letters throughout the drawings. Furthermore, it is understood that the drawings are merely schematic diagrams of the invention, and some of the components may deviate from the actual scale for clarity in the drawings.

[0032] Referring here to the drawings, particularly Figure 1, the flexible packaging film 10 is shown to include a cap layer 20, a core layer 30, and a seal layer 40, the layers being laminated to each other. The film can be used to form flexible bags and pouches. For example, in some configurations, the film can be used to form a flexible bag 70 which can be used for bag-in-box applications, such as shown in Figure 2. Such a flexible bag has a first film 71 and a second film 72, the respective seal layers of the first and second films covering each other and adhering together by a seal 73 to form a cavity 74.

[0033] In other configurations, the film may be used to form a pouch, for example, the pouch 80 shown in Figure 3. In such a configuration, similarly, the first film 81 and the second film 82 are positioned to cover each other (with an additional gusset between them if desired), and the sealing layers overlap each other and adhere together by a seal 83 to form a cavity 84.

[0034] In any such configuration, the cap layer forms the outer surface while the film's sealing layer forms the inner layer, and they can be sealed together by forming a seal (i.e., by RF, ultrasound, thermal welding, among other techniques). The spouts 75, 85 may extend through the film or be sandwiched between the films and sealed by a seal.

[0035] Flexible bags formed from the films of this disclosure can typically be used to hold fluid materials in a substantially fluid-sealed configuration. Such fluid materials may include solids, such as foods, syrups, oils, purees, beverages, dressings, condiments, liquids, pastes, sauces, and suspended solids and granular materials. Naturally, the above are merely examples of fluid materials that may be housed in flexible bags made from the disclosed films and should not be considered limiting, but rather used only as examples.

[0036] Returning to Figure 1, the cap layer 20 includes a first surface 22 and a second surface 24 opposite to the first surface 22. The core layer 30 includes a first surface 32 and a second surface 34 opposite to the first surface 32. The seal layer 40 includes a first surface 42 and a second surface 44 opposite to the first surface 42. As described above, the layers are laminated to one another.

[0037] More specifically, the second surface 24 of the cap layer 20 is laminated to the first surface 32 of the core layer 30. The second surface 34 of the core layer 30 is laminated to the first surface 42 of the seal layer 40. In the configuration described herein, lamination may be by adhesive, extrusion, or heat lamination.

[0038] In one configuration shown in Figure 4, which demonstrates sufficient robustness for use in bag-in-box applications, a cap layer 120, a core layer 130, and a seal layer 140 are shown. Different components have the same numbers as shown in Figure 1 plus 100. The overall thickness of the laminate is intended to be between 2.4 mils and 4.9 mils. In such bag-in-box applications, it is understood that such flexible bags, when filled, can weigh on the order of, for example, approximately 23 kg, etc. Such filled flexible bags are often slid into the outer box on an inclined surface, dropped into the outer box, or otherwise handled somewhat roughly.

[0039] In the configuration shown in Figure 4, the cap layer 120 comprises a three-layer co-extruded blow film having a thickness of approximately 1.0 mil, although a thickness of 0.7 mil to 1.3 mil is intended. The co-extruded blow film comprises a first layer 125 containing polyethylene, a second layer 126 containing polyethylene mixed with a compatibilizer, and a third layer 127 containing polyethylene. The first and third polyethylene layers 125 and 127 contain 70% EVA and 30% LLDPE. The second layer contains approximately 83% by mass PE and 17% by mass compatibilizer to achieve a compatibilizer level of 2.9% by mass in the film 10. The amount of compatibilizer in the second layer depends on the layer ratio selected for the cap layer 120. In the configuration shown, the selected layer ratios are 20 / 60 / 20 for layers 125 / 126 / 127, respectively. The layer ratio in the cap layer is intended to be further adjusted while maintaining the level of compatibilizer by mass in film 10, which is 2.9% in this particular configuration. The level of compatibilizer by mass in film 10 is intended to be approximately 1% to 6%. In the shown configuration, the compatibilizer has a density of 0.95 g / cc. The density range of the compatibilizer is intended to be 0.87 g / cc to 0.95 g / cc.

[0040] In the shown configuration, the core layer 130 comprises a polyamide (PA) which is biaxially oriented nylon. In the shown configuration, the PA has a thickness of approximately 0.60 mils, but a thickness of 0.32 mils to 1.0 mils is intended. Furthermore, in the shown configuration, the seal layer 140 has a thickness of 1.8 mils, but a thickness of 1.4 mils to 2.6 mils is intended. The seal layer 140 comprises a blown layer of film.

[0041] In the configuration shown in Figure 5, the cap layer 220 contains polyethylene with a thickness of approximately 1.0 mil, but a thickness of 0.7 mil to 1.3 mil is intended. The cap layer 220 includes a blown film layer.

[0042] In the shown configuration, the core layer 230 comprises a biaxially oriented nylon polyamide (PA). In the shown configuration, the PA has a thickness of approximately 0.60 mils, but a thickness of 0.32 mils to 1.0 mils is intended.

[0043] Furthermore, in the configuration shown, the seal layer 240 comprises a three-layer co-extruded blow film having a thickness of 1.8 mils, although a thickness of 1.4 mils to 2.6 mils is intended. The co-extruded blow film comprises a first layer 225 containing polyethylene, a second layer 226 containing polyethylene mixed with a compatibilizer, and a third layer 227 containing polyethylene. The first and third polyethylene layers 225 and 227 contain 70% EVA and 30% LLDPE. The second layer contains approximately 90% PE and 10% compatibilizer to achieve a compatibilizer level of 3.1% by mass in the film. The amount of compatibilizer in the second layer depends on the layer ratio selected for the seal layer 140. In this configuration, the selected layer ratios are 20 / 60 / 20 for layers 225 / 242 / 227, respectively. The layer ratio in the sealing layer 240 can be adjusted as long as the mass-based level of the compatibilizer in the film remains the same, i.e., 3.1% in the shown configuration. The mass-based level of the compatibilizer in the film is intended to be approximately 1% to 6%. In the film according to this disclosure, the compatibilizer is intended to have a density of 0.95 g / cc. Furthermore, the density of the compatibilizer may be in the range of 0.87 g / cc to 0.95 g / cc.

[0044] In the configuration shown in Figure 6, the cap layer 320 includes a five-layer co-extruded material with a thickness of approximately 1.7 mils, although a thickness of 1.2 mils to 2.2 mils is intended. Furthermore, the cap layer includes a blow-molded layer. The five-layer co-extruded material includes layers 350, 352, 353, 354, and 356. Layers 350 and 356 contain polyethylene, which has a thickness of 0.25 mils to 0.88 mils.

[0045] The Tie layers 352 and 354 have a thickness of 0.1 to 0.4 mil and contain anhydrous modified LLDPE. The EVOH layer 353 contains a 29 mol% EVOH layer with a thickness of 0.1 to 0.5 mil.

[0046] In the shown configuration, the core layer 330 comprises a polyamide (PA) which is biaxially oriented nylon. In the shown configuration, the PA has a thickness of approximately 0.40 mils, but a thickness of 0.32 mils to 0.6 mils is intended.

[0047] Furthermore, in the configuration shown in Figure 6, the seal layer 340 includes a three-layer co-extruded blow film having a thickness of 1.4 mils, although a thickness of 1.1 mils to 1.7 mils is intended. The co-extruded blow film includes a first layer 325 containing polyethylene, a second layer 326 containing polyethylene mixed with a compatibilizer, and a third layer 327 containing polyethylene. The first polyethylene layer 325 contains 65% mPE and 35% EVA. The third layer 327 contains LLDPE with a density of 0.921 g / cc and mPE with a density of 0.911 g / cc. The second layer contains approximately 78% mPE and 22% compatibilizer to achieve a compatibilizer level of 4.9% by mass in the film. The amount of compatibilizer in the second layer depends on the layer ratio selected for the seal layer. In the configuration shown, the selected layer ratios are 20 / 60 / 20 for layers 325 / 326 / 327, respectively. The layer ratio in the sealing layer is intended to be modified so that the mass of the compatibilizer in the film is 4.9%. Furthermore, the mass of the compatibilizer in the film is intended to be approximately 2% to 7%. In the configuration described, the compatibilizer has a density of 0.95 g / cc. Furthermore, the density of the compatibilizer is intended to be 0.87 g / cc to 0.95 g / cc.

[0048] In the film configurations shown in Figures 4, 5, and 6, it is understood that the cap layers 120 / 220 / 320, core layers 130 / 230 / 330, and seal layers 140 / 240 / 340 are heat-laminated to one another, but other lamination processes are similarly intended for other configurations. Furthermore, a flexible bag formed from such a film has a cap layer as the outer layer of the flexible bag and a seal layer as the inner layer of the flexible bag, and it is understood that the seal layer of the opposing film may be formed by any number of different methods known in the art, at least some of which are described above.

[0049] For example (but not limited to), in another configuration of the film 410 shown in Figure 7, suitable for forming a pouch having a fin seal spout formed in the seal between opposing films, a cap layer 420, a core layer 430, and a seal layer 440 are shown. Different components have the same numbers as shown in Figure 1 plus 400.

[0050] In such a configuration, the cap layer 420 includes PA, particularly biaxially oriented nylon, having a thickness of approximately 0.48 mils, but a thickness of 0.32 mils to 0.6 mils is intended.

[0051] The core layer 430 in the configuration shown in Figure 7 includes an adhesive that can be applied by roller application or otherwise. In the configuration shown, the adhesive includes a solvent-free adhesive having a thickness of about 0.04 to 0.12 mils, more preferably about 0.10 mils, when applied by roller application.

[0052] The seal layer 440 is shown as comprising a 7-layer co-extruded material having a thickness of approximately 5.50 mils, although a thickness of 2.0 mils to 6.0 mils is intended. Furthermore, the seal layer includes a blown layer. The 7-layer co-extruded material comprises layers 450, 451, 452, 453, 454, 455, and 456. Layers 450 and 456 contain polyethylene, which has a thickness of 0.4 mils to 1.3 mils. Layers 451 and 455 contain polyethylene and a compatibilizer, and have a thickness of 0.5 mils to 1.4 mils. In the shown configuration, layers 451 and 455 contain approximately 93% by mass polyethylene and 7% by mass compatibilizer to achieve a compatibilizer level of 2.8% by mass in the film. The amount of compatibilizer in layers 451 and 455 depends on the layer ratio selected for the film. In this configuration, the selected layer ratios are 22 / 23 / 4 / 4 / 4 / 23 / 22 for layers 450 / 451 / 452 / 453 / 454 / 455 / 456, respectively. The layer ratio in the sealing layer can be adjusted as long as the mass-based compatibilizer level in the film remains the same at 2.8% in the indicated configuration. The mass-based compatibilizer level in the film is intended to be approximately 1% to 3%. In the indicated configuration, the compatibilizer has a density of 0.95 g / cc. The density of the compatibilizer may be 0.87 g / cc to 0.95 g / cc. The polyethylene in layers 450, 451, 455, and 456 includes LLDPE with a density of 0.921 g / cc and mPE with a density of 0.911 g / cc.

[0053] The Tie layers 452 and 454 have a thickness of 0.1 to 0.4 mil and contain anhydrous modified LLDPE. The EVOH layer 453 contains a 29 mol% EVOH layer with a thickness of 0.1 to 0.5 mil.

[0054] Advantageously, the use of a biaxial polyamide layer combined with a blown PE base layer, and the use of a compatibilizer as shown, results in a film that is robust for its intended application while providing recyclability.

[0055] The above description is merely illustrative of and illustrates the present disclosure, and the present disclosure is not limited to it unless so limited by the attached claims, and a person skilled in the art who has come before the present disclosure may modify it without departing from the scope of the present disclosure. [Explanation of symbols]

[0056] 10 Flexible packaging film, film 20 cap layers 22 First side 24. The second side 30 core layers 32 First side 34. The second side 40 sealing layers 42 First side 44. The second side 70 Flexible Bags 71 First film 72 The second film 74 Cavity 75 Spout 80 pouches 81 First film 82 The second film 83 Seals 84 Cavity 85 Spout 120 cap layer 125 The first layer 126 The second layer 127 The third layer 130 core layers 140 sealing layers 220 cap layer 225 First layer 226 The second layer 227 The third layer 230 core layers 240 sealing layers 320 cap layer 325 First layer 326 Second Layer 327 The third layer 330 core layers 340 sealing layer 350 layers 352 layers, Thai layer 353 layers, EVOH layer 354 layers, Thai layer 356 layers 410 film 420 Cap Layer 430 core layers 440 sealing layer 450 layers 451 layers 452 layers, Thai layer 453 layers, EVOH layer 454 layers, Thai layer 455 layers 456 layers

Claims

1. - A cap layer having a first surface and a second surface; - A core layer having a first surface and a second surface, wherein the second surface of the cap layer is positioned to cover the first surface of the core layer and laminated thereto; - A flexible packaging film comprising a seal layer having a first surface and a second surface, wherein the second surface of the core layer is positioned to cover the first surface of the seal layer and laminated thereto, - One of the cap layer and the core layer comprises biaxially oriented polyamide; - A flexible packaging film comprising a blow-molded film containing polyethylene having a compatibilizer with a density of 95 g / cc, wherein one of the cap layer and the seal layer is a flexible packaging film.

2. The flexible packaging film according to claim 1, wherein one of the cap layer or the seal layer comprises a three-layer blow-molded film co-extruded product having a polyethylene layer on either the polyethylene or compatibilizer layer surface, and the other of the cap layer or the seal layer comprises polyethylene.

3. The flexible packaging film according to claim 2, wherein the compatibilizer accounts for between 1% by mass and 6% by mass of the film.

4. The flexible packaging film according to claim 2, wherein the core layer contains polyamide.

5. The flexible packaging film according to claim 4, wherein the core layer has a thickness between 0.32 mils and 1.0 mils.

6. The flexible packaging film according to claim 4, wherein the sealing layer includes a blow film.

7. The flexible packaging film according to claim 6, wherein the cap layer includes a blow film.

8. The flexible packaging film according to claim 1, comprising a seven-layer blow film co-extruded product, wherein the cap layer comprises a polyethylene layer surrounded by polyethylene and a compatibilizer layer, and a central EVOH layer surrounded by tie layers on any of its surfaces.

9. The flexible packaging film according to claim 8, wherein the EVOH layer contains EVOH in the range of 27 to 32 mol%.

10. The flexible packaging film according to claim 8, wherein the sealing layer comprises a three-layer blow-molded film co-extruded product having a polyethylene layer on either the polyethylene layer or the compatibilizer layer.

11. The flexible packaging film according to claim 10, wherein the core layer contains polyamide.

12. The flexible packaging film according to claim 11, wherein the core layer has a thickness between 0.32 mils and 0.6 mils.

13. The flexible packaging film according to claim 10, wherein the compatibilizer accounts for between 2% by mass and 7% by mass of the film.

14. The flexible packaging film according to claim 1, wherein the cap layer contains polyamide and the core layer contains an adhesive.

15. The flexible packaging film according to claim 14, comprising a seven-layer blow film co-extruded product, wherein the sealing layer includes a polyethylene layer surrounded by a polyethylene and compatibilizer layer, and a central EVOH layer surrounded by a tie layer on any of its surfaces.

16. The flexible packaging film according to claim 15, wherein the EVOH layer contains EVOH in the range of 27 to 32 mol%.

17. The flexible packaging film according to claim 15, wherein the compatibilizer accounts for 1% to 3% by mass of the film.

18. The flexible packaging film according to claim 15, wherein the cap layer has a thickness between 0.32 mils and 0.6 mils.

19. - A first film and a second film, each formed from the flexible packaging film of claim 7, wherein the first film and the second film are positioned such that the sealing layer of the first film and the sealing layer of the second film overlap and are in contact with each other; - A seal that seals the first film to the second film to form a cavity, Flexible packaging for bag-in-box packaging, including...

20. - A first film and a second film, each formed from the flexible packaging film of claim 11, wherein the first film and the second film are positioned such that the sealing layer of the first film and the sealing layer of the second film overlap and are in contact with each other; - A seal that seals the first film to the second film to form a cavity, Flexible packaging for bag-in-box packaging, including...

21. - A first film and a second film, each formed from the flexible packaging film of claim 15, wherein the first film and the second film are positioned such that the sealing layer of the first film and the sealing layer of the second film overlap and are in contact with each other; - A seal that seals the first film to the second film to form a cavity, Flexible packaging that forms a pouch, including [the specified material].

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