Recyclable flexible packaging material with embedded reinforcement

Abstract

Layers of a recyclable packaging material can include an outer layer including a polyethylene-based film layer; an interior layer including a polyethylene-based reinforcing layer; and an inner layer including a polyethylene-based sealant layer. The packaging material can further include a first polyethylene-based tie layer positioned between and adhering the polyethylene-based film layer and the polyethylene-based reinforcing layer; and a second polyethylene-based tie layer positioned between and adhering the polyethylene-based reinforcing layer and the polyethylene-based sealant layer.

Description

RECYCLABLE FLEXIBLE PACKAGING MATERIAL WITH EMBEDDED REINFORCEMENTCROSS-REFERENCE TO PRIORITY APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 470,229, filed June 1, 2023, which is hereby incorporated by reference in its entirety.BACKGROUND

[0002] Packaging materials, for example, used to form flexible packages for food or other items, are often formed from polyester / polypropylene / polyethylene film composites.However, since the component materials have different melting points and processing characteristics, and may be immiscible with respect to one another when in liquid form, packaging materials formed from polyester / polypropylene film / polyethylene composites are difficult to recycle.

[0003] Attempts have been made to form recyclable packaging materials from various polyethylenes. Unfortunately, as compared to polyester / polypropylene / polyethylene film composites, flexible packaging materials that are predominantly or completely polyethylene can lack the strength, toughness, durability, etc. needed when used to form packages for relatively dense items and / or packages needing puncture resistance, tear resistance, etc. (e.g., large packages including smaller, dense items such as pet food packaging).

[0004] Thus, there remains a need for packaging materials for a variety of applications, including packages for more dense items and / or packages needing puncture resistance, tear resistance, etc., that can be recycled.SUMMARY

[0005] The present disclosure is directed generally to various packaging materials. The packaging materials include at least one polyethylene-based reinforcing layer (e.g., a polyethylene-based textile reinforcing layer and / or other suitable reinforcing layer(s)) withopposing first and second sides or surfaces. The packaging materials can further include one or more other polyethylene-based layers in combination with the polyethylene-based reinforcing layer so that the at least one polyethylene-based reinforcing layer may be joined to (e.g., be at least partially embedded in) and reinforce the one or more other polyethylene-based layers.

[0006] For example, an aspect of this disclosure is the provision of a recyclable packaging material having a plurality of layers respectively in a facing relationship with one another, wherein the plurality of layers can include at least one polyethylene-based film layer in a face-to- face relationship with one of the opposing surfaces of the polyethylene-based reinforcing layer; and at least one polyethylene-based sealant layer (e g., at least one heat seal polyethylene-based sealant layer) in a face-to-face relationship with the other of the opposing surfaces of the polyethylene-based reinforcing layer so that the polyethylene-based reinforcing layer is between the polyethylene-based film layer and the polyethylene-based sealant layer. The packaging material can further include a first polyethylene-based tie layer positioned between and adhering the polyethylene-based film layer and the polyethylene-based reinforcing layer; and a second polyethylene-based tie layer positioned between and adhering the polyethylene-based reinforcing layer and the polyethylene-based sealant layer. The various packaging materials described herein (and variations contemplated hereby) thus can have attributes (e.g., flexibility, strength, toughness, durability, etc.) needed for various packaging applications, such as but not limited to packages for more dense items and / or packages needing puncture resistance, tear resistance, etc. (e.g., large packages including smaller, dense items such as pet food packaging), while also being recyclable.

[0007] Another aspect of this disclosure is the provision of a recyclable packaging material having a plurality of layers respectively in a facing relationship with one another, wherein the plurality of layers can include an outer layer comprising a polyethylene-based fdm layer (e.g., a printed oriented polyethylene film including an ink layer printed onto at least a portion of at least one of an inner surface of the oriented polyethylene film or an outer surface of the oriented polyethylene film); an interior layer comprising a polyethylene-based reinforcing layer (e.g., apolyethylene-based mesh textile reinforcing layer); an inner layer comprising a polyethylenebased sealant layer (e.g., a heat seal polyethylene-based sealant layer); an outer tie layer (e.g., an outer polyethylene-based tie layer) disposed between and joining the outer layer and the interior layer to one another; and an inner tie layer (e.g., an inner polyethylene-based tie layer) disposed between and joining the interior layer and the inner layer to one another. The outer polyethylene-based tie layer may comprise a coextruded composite layer or extrudate comprising an extruded polyethylene-based tie layer / an extruded ethylene vinyl alcohol (EVOH) barrier layer / an extruded polyethylene-based extruded tie layer.

[0008] Further aspects of this disclosure provide a method of forming a recyclable packaging material having at least one polyethylene-based reinforcing layer and a recyclable package (e.g., a pet food package) formed using the recyclable packaging material.

[0009] As another example, an aspect of this disclosure is the provision of a multi-layer lamination that is made from all polyethylene or substantially all polyethylene, that is capable of being used as a packaging material, and that is intended to be recyclable.

[0010] The foregoing summary provides a few brief examples and is not exhaustive, and the present invention is not limited to the foregoing examples. Various other features, aspects, and advantages of the present invention will be evident from the following description and accompanying figures.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The drawings discussed below are schematic, and features depicted therein may not be drawn to scale. The drawings are provided as examples. The present invention may be embodied in many different forms and should not be construed as limited to the examples depicted in the drawings.

[0012] Figure 1A is a cross-sectional view of a portion of a web of composite material that may be used as packaging material, wherein the cross-section is taken perpendicular to the length of a flat piece of the packaging material, in accordance with an embodiment of this disclosure.

[0013] Figure IB is like Figure 1A, except that a tie layer of Figure 1A is depicted as a plurality of coextruded layers, in accordance with an embodiment of this disclosure.

[0014] Figure 1C is like Figure IB, except that a printed ink layer of Figure IB has been relocated within the printed web, in accordance with an embodiment of this disclosure.

[0015] Figures 2A, 2B, and 2C are plan top views of a portion of webs that may be used as polyethylene-based reinforcing layers, in accordance with embodiments of this disclosure.

[0016] Figures 3 A and 3B are side views depicting aspects of methods of forming an example of the packaging material of Figure 1A, in accordance with an embodiment of this disclosure.

[0017] Figure 4A is a front view of a closed bag formed from a piece of the packaging material of Figure 1A, in accordance with an embodiment of this disclosure.

[0018] Figure 4B is a rear view of the bag of Figure 4A, in accordance with an embodiment of this disclosure.

[0019] Figures 5 A and 5B are plan top views of a portion of webs that may be used as polyethylene-based reinforcing layers, in accordance with embodiments of this disclosure.DETAILED DESCRIPTION

[0020] Examples of embodiments are disclosed in the following. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. For example, features disclosed as part of one embodiment or example can be used in the context of another embodiment or example to yield a further embodiment or example. As another example of the breadth of this disclosure, it is within the scope of this disclosure for one or more of the terms “substantially,” “about,” “approximately,” and / or the like, to qualify each of the adjectives and adverbs of the Detailed Description section of this disclosure, as discussed in greater detail below.

[0021] Figure 1A schematically depicts an exemplary recyclable packaging material / composite material / composite structure 100. The material 100 may be suitable for use as arecyclable packaging material, for example, for dog food or any other suitable items. As shown in Figure 1A, the material 100 may generally include a plurality of layers in a superposed, facing, contacting relationship with one another. The layers may generally be continuous or discontinuous, as will be understood in the art, and as will be described further below.

[0022] More particularly, in the example depicted in Figure 1A, the material 100 includes an outer layer 102 comprising a polyethylene-based film layer 112 (e.g., a printed oriented polyethylene film layer); an interior layer 104 comprising a polyethylene-based reinforcing layer 114 (e.g., a polyethylene-based mesh textile reinforcing layer); and an inner layer 106 comprising a polyethylene-based sealant layer 116 (e.g., a heat seal polyethylene-based sealant layer). The outer layer 102 and the interior layer 104 are joined to one another by an outer tie layer 108 (e.g., outer polyethylene-based tie layer(s) and / or other suitable material(s)); and the interior layer 104 and the inner layer 106 are joined to one another by an inner tie layer 110 (e.g., polyethylene-based inner tie layer(s) and / or other suitable material(s)). The polyethylene-based film layer 112 may also be referred to herein as a first polymeric film, and the poly ethylenebased sealant layer 116 may also be referred to herein as a second polymeric film and / or a polyethylene-based sealant film (e.g., a heat seal polyethylene-based sealant film). The outer tie layer 108 may also be referred to herein as a first tie layer, and the inner tie layer 110 may also be referred to herein as a second tie layer. A variety of differently configured reinforcing layers 114 (e.g., one or more polyethylene-based layers) are within the scope of this disclosure. When a package is formed from the material 100, a side or surface 118 of outer layer 102 can define an outer side or surface of the package, and a side or surface 120 of the inner layer 106 can define an inner side or surface of the package, as discussed further below. In the following, for ease of understanding, and not for the purpose of limiting the scope of this disclosure, a frame of reference defined by a package having an outer surface 118 and an inner or interior surface 120 may be used for naming some of the components of the material 100.

[0023] In accordance with an embodiment of this disclosure, the outer layer 102 includes at least one polyethylene-based film layer 112 (e.g., an oriented polyethylene-based film layer) andat least one ink layer 128; the interior layer 104 includes at least one polyethylene-based reinforcing layer 114 (e.g., a polyethylene-based mesh textile reinforcing layer); the inner layer 106 includes at least one polyethylene-based sealant layer 116 (e.g., a heat seal poly ethylenebased sealant layer); and each of the outer tie layer 108 and the inner tie layer 110 can include a polyethylene-based tie layer (e.g., a polyethylene-based extruded / extrusion layer). In some embodiments, such as depicted in Figures IB and 1C, the outer tie layer 108 may comprise a coextruded composite tie layer or extrudate 108’ comprising a first extruded polyethylene-based tie layer 122 / an extruded barrier layer 124 / a second extruded polyethylene-based tie layer 126.

[0024] Figure 1A can be described as depicting that the polyethylene-based film layer 112 includes opposing outer and inner surfaces or sides 112a, 112b, respectively, wherein printed ink layer(s) 128 may be joined directly to (i.e., in opposing face-to-face contact with) the polyethylene-based film layer’s inner side 1 12b (i.e., the surface of the polyethylene-based film layer 112 distal (opposite) the outer surface 118 of outer layer 102).

[0025] In some embodiments, such as depicted in Figures 1 A and IB, outer surface 112a may correspond to outer surface 118 of the packaging material 100 and / or the outer surface of a package formed of the packaging material 100.

[0026] It is believed that the polyethylene-based film layer 112 may be, for example, high density polyethylene (HDPE) oriented in one direction (e.g., machine direction / MDO, MDOPE, or MDHDPE) or in both directions or other suitable crosswise directions (e.g., biaxially-oriented / BO, BOPE, or BOHDPE). The orienting of the polyethylene-based film layer 112 may enhance (increase) optical clarity, stiffness, and heat resistance. The polyethylene-based film layer 112 may be transparent, translucent or any combination thereof. Alternatively, it is believed that the polyethylene film layer 112 can be any other suitable polyethylene-based film layer.

[0027] As will be understood by those of skill in the art, the ink layer 128 may generally be printed (e.g., reverse printed) onto the inner surface or side 112b of the polyethylene-based film layer 112. However, in an alternative embodiment such as shown in Figure 1C, the ink layer 128may be printed onto the outer surface 112a of the polyethylene-based film layer 112 opposite inner surface 112b, such as, for example, where the ink layer 128 is formed from curable ink(s), such as energy curable ink(s) (e.g., UV or e-beam, curable ink). In some embodiments as depicted in Figure 1C, the ink layer 128 may correspond to an outer surface 118’ of outer layer 102.

[0028] Outer tie layer 108 may provide connection between the outer layer 102 and the interior layer 104 and inner tie layer 110 may provide connection between the interior layer 104 and the inner layer 106. Tie layers 108 and 110 may each comprise an extruded polyethylenebased polymer layer (i.e., a polyethylene-based extrudate / polyethylene-based extrusion lamination). Any suitable polyethylene-based extrudate may be used for tie layers 108, 110, for example, polyethylene, LDPE, or LLDPE. The tie layers 108, 110 may also be HDPE or any other suitable polyethylene.

[0029] In some embodiments, such as depicted in Figures IB and 1C, the outer tie layer 108 may comprise a coextruded composite tie layer or extrudate 108’ comprising a first extruded polyethylene-based tie layer 122 / an extruded barrier layer 124 / a second extruded polyethylenebased tie layer 126. The tie layers 122, 126 of the extrudate 108’ may provide connection between the outer layer 102 (e.g., the printed polyethylene-based film layer 112 of outer layer 102) and the interior layer 104 (e.g., the polyethylene-based reinforcing layer 114 of interior layer 104), respectively. Any suitable polyethylene-based extrudate may be used for tie layers 122 and 126, for example, polyethylene, LDPE, or LLDPE. The tie layers 122, 126 may also be HDPE or any other suitable polyethylene.

[0030] The barrier layer 124 is configured to restrict passage of gasses (e.g., air, nitrogen gas, water vaper, etc.). The material of the barrier layer 124 can have barrier properties exceeding barrier properties of other layers of the material 100. The barrier layer 124 may comprise an extruded barrier layer (i.e., a barrier extrudate). The barrier layer 124 can comprise, consist essentially of, or consist of ethylene vinyl alcohol (EVOH), although other extrudable barrier materials maybe used, such as nylon, polyvinyl alcohol (PVOH) and / or any other suitablematerial (e.g., vacuum metalized (e.g., aluminum) film). For some types of the barrier materials, compatibilization may be provided (e.g., by way of additive(s)) and / or other suitable chemical techniques may be used in a manner that seeks to facilitate recyclability.

[0031] The polyethylene-based reinforcing layer 114 is configured to provide strength properties (e.g., impact strength, tensile strength, tear strength, burst strength, etc.) to the packaging materials using recyclable materials. The polyethylene-based reinforcing layer may also be relatively thin and still strengthen the packaging materials.

[0032] In some embodiments, the polyethylene-based reinforcing layer 114 can have greater tensile strength than at least one of the polyethylene-based film layer 112 (which also may be referred to herein as the first polymeric film) and the polyethylene-based sealant layer 116 (which also may be referred to herein as the second polymeric film). In some embodiments, the polyethylene-based reinforcing layer 1 14 can have greater tensile strength than the polyethylenebased film layer 112. In some embodiments, the polyethylene-based reinforcing layer 114 can have greater tensile strength than the polyethylene-based sealant layer 116. In some embodiments, the polyethylene-based reinforcing layer 114 can have greater tensile strength than the outer tie layer 108 and / or outer tie layer 108’ (which also may be referred to herein as the first tie layer, which is some embodiments may include a coextruded tie layer). In some embodiments, the polyethylene-based reinforcing layer 114 can have greater tensile strength than the inner tie layer 110 (which also may be referred to herein as the second tie layer). In some embodiments, the polyethylene-based reinforcing layer 114 can have greater tensile strength than the polyethylene-based film layer 112; and / or the polyethylene-based reinforcing layer 114 can have greater tensile strength than the polyethylene-based sealant layer 116; and / or the polyethylene-based reinforcing layer 114 can have greater tensile strength than the outer tie layer 108 and / or outer tie layer 108’; and / or the polyethylene-based reinforcing layer 114 can have greater tensile strength than the inner tie layer 110.

[0033] The polyethylene-based reinforcing layer 114 may be, for example, a poly ethylenebased textile reinforcing material having an open mesh configuration (e.g., a reticulated and / ornet-like textile material). Non-limiting examples of polyethylene-based mesh textile reinforcing materials can include woven fabrics, knit fabrics, nonwoven fabrics, scrims, extruded nets, crosslaminated mesh fabrics, and the like, and combinations thereof.

[0034] A top plan view of at least a portion of an exemplary polyethylene-based mesh textile reinforcing layer 114 is schematically depicted in Figure 2A. The polyethylene-based mesh textile reinforcing layer 114 comprises a plurality of first flexible tensile members 130 (e.g., polyethylene-based strands, filaments, yarns, threads, fibrils, ribbons, tapes, etc.) generally aligned in a first direction (e.g., in a machine direction as shown in Figure 2A) and a plurality of second flexible tensile members 132 (e.g., second polyethylene-based strands, filaments, yams, threads, fibrils, ribbons, tapes, etc.) generally aligned in a second direction (e.g., aligned in a direction that is not parallel to the direction of the plurality of the first flexible tensile members, such as in a cross machine direction as shown in Figure 2A). At least some (e.g., at least half, more than half, a majority, etc.) of the first flexible tensile members 130 intersect at least some (e.g., at least half, more than half, a majority, etc.) of the second flexible tensile members 132 to define borders of a plurality of open spaces 134 of the polyethylene-based mesh textile reinforcing layer 114. The first and second flexible tensile members 130, 132 can be disposed in a regular and / or irregular pattern, and the open spaces 134 (openings, open areas, holes, voids, etc.) may generally have the same size and shape or may be of different sizes and / or shapes. In the example depicted in Figure 2A, the open spaces 134 are holes that that extend all the way through the thickness of the reinforcing layer 114 (e.g., through holes). In alternative reinforcing layers, the open spaces 134 may be in the form of holes that do not extend all the way through the thickness of the reinforcing layer 114 (e.g., blind holes, indentations, depressions, etc.).

[0035] In some embodiments, at least some (e.g., at least half, more than half, a majority, etc.) of the first and second flexible tensile members 130, 132 may be bonded (e.g., thermally bonded) at at least some of the contact (intersecting) points.

[0036] The borders or margins of the reinforcing layer 114 can define open areas (e.g., openings, open spaces, holes, voids, etc.) having a variety of shapes, such as parallelogram-typeshapes (e.g., square, rectangle, diamond, etc.), ellipse-type shapes (e.g., circle, ellipse, etc ), and the like. Material of one or more of the tie layers 108, 110 can extend into or through one or more of, a majority of, or each of the openings or holes in the reinforcing layer 114.

[0037] As a non-limiting example, Figure 2A depicts a mesh configuration having a plurality of square shaped open spaces or openings 134. As another non-limiting example, Figure 2B depicts a top plan view of at least a portion of an exemplary polyethylene-based mesh textile reinforcing layer 114’ including a plurality of first flexible tensile members 130’ and a plurality of second flexible tensile members 132’ intersecting and defining borders of a plurality of diamond shaped open spaces or openings 134’. In the packaging materials 100, 100’, 100” (Figs. 1A-1C), the reinforcing layer 114 can be replaced with the reinforcing layer 114’.

[0038] In some embodiments, such as schematically depicted in Figure 1A, the outer tie layer 108 may be in direct contact with a first surface (also referred to herein as an outer surface) 114a of the reinforcing layer 114. In some embodiments, such as schematically depicted in Figures IB and 1C, the tie layer 126 may be in direct contact with the first surface 114a of the reinforcing layer 114. In some embodiments, such as schematically depicted in Figures 1 A, IB, and 1C, the inner tie layer 110 may be in direct contact with an opposite second surface (also referred to herein as an inner surface) 114b of the reinforcing layer 114. Figures 1A, IB, and 1C also schematically depict embodiments in which a material (e.g., a polyethylene-based extrudate) of the outer tie layer 108 and / or 108’ and / or a material (e.g., a polyethylene-based extrudate) of the inner tie layer 110 may extend into (e.g., at least partially into and / or completely through) one or more (e.g., a plurality of, half of, a majority of, substantially all of, etc.) openings or holes (e.g., openings 134 of the reinforcing layer 114 and / or openings 134’ of Figures 2A and 2B, respectively).

[0039] The polyethylene-based mesh textile reinforcing material can include one or more layers of a polyethylene-based mesh textile reinforcing material. In some embodiments, the packaging material can include a single layer of a polyethylene-based mesh textile reinforcing material. In some embodiments, the packaging material can include two or more layers of apolyethylene-based mesh textile reinforcing material (e.g., a cross-laminated polyethylene-based mesh textile reinforcing material).

[0040] Cross-laminated polyethylene-based mesh textile reinforcing materials can include at least a first polyethylene-based mesh textile reinforcing material oriented in a first direction laminated to at least a second polyethylene-based mesh textile reinforcing material oriented in a second direction that is different from the first direction. The first polyethylene-based mesh textile reinforcing material can be laminated to the second polyethylene-based mesh textile reinforcing material such that the angle between the direction of orientation of each material is about 20° to about 90° (e.g., the machine direction of a first polyethylene-based mesh textile reinforcing layer can be oriented at an angle from about 20° to about 90° relative to the machine direction of a second polyethylene-based mesh textile reinforcing layer).

[0041] Figure 2C depicts a top plan view of at least a portion of an exemplary crosslaminated polyethylene-based mesh textile reinforcing layer 114” including a first poly ethylenebased mesh textile reinforcing material 136 oriented in a first direction laminated to a second polyethylene-based mesh textile reinforcing material 138 oriented in a second direction. The cross-laminated polyethylene-based mesh textile reinforcing layer 114” includes numerous flexible tensile members respectively extending cross-wise (e.g., obliquely) relative to one another and defining open spaces (e.g., through holes) therebetween. For example, the reinforcing material 136 may include a plurality of first flexible tensile members 140 and a plurality of second flexible tensile members 142 intersecting and defining borders of a plurality of open spaces or openings; and the reinforcing material 138 may include a plurality of first flexible tensile members 146 and a plurality of second flexible tensile members 148 intersecting and defining borders of a plurality of other open spaces or openings. In the packaging materials 100, 100’, 100” (Figs. 1 A-1C), the reinforcing layer 114 can be replaced with the reinforcing layer 114”.

[0042] With continued reference to Figure 1A, inner layer 106 may include at least one polyethylene-based sealant layer 116 (e.g., at least one heat seal polyethylene-based sealantlayer). In some embodiments, the polyethylene-based sealant layer 116 may include at least one polyethylene-based sealant film (e.g., at least one heat seal polyethylene-based sealant film.) For the heat seal polyethylene-based sealant layer 116, any suitable polyethylene-based heat seal adhesive may be used, for example, a LDPE and / or LLDPE heat seal adhesive material. As noted herein, the inner tie layer 110 may be an extruded polymer layer (i.e., a polyethylene-based extrudate / polyethylene-based extrusion lamination). As depicted in Figures 1 A-1C, inner tie layer 110 provides connection between the interior layer 104 including the polyethylene-based reinforcing layer 114 and the inner layer 106 including the polyethylene-based sealant layer 116.

[0043] Figures IB and 1C schematically depict exemplary variations of the material 100 of Figure 1A. As described herein, Figures IB and 1C each depict an exemplary embodiment of a material 100’ and 100”, respectively, wherein the outer tie layer 108 may comprise a coextruded composite tie layer or extrudate 108’ comprising a first extruded polyethylene-based tie layer 122 / an extruded barrier layer 124 / a second extruded polyethylene-based tie layer 126. In addition, in Figure 1C, the material 100” generally includes a similar configuration of layers as the material 100’ of Figure IB, except that the positions of the polyethylene-based film layer 112 and ink layer(s) 128 are reversed / interchanged. Additionally, in this example, the ink layer(s) 128 may be curable ink (e.g., an energy-curable ink, such as an electron beam curable ink or ultraviolet light curable ink).

[0044] In some embodiments, the packaging material may include one or more additional layers (may include a plurality of layers). The outer layer, the interior layer, the inner layer and / or the additional layer(s) may overlie any layer and / or be disposed between layers as needed for a particular application. Non-limiting examples of additional layer(s) may include polymer films (e.g., joined to a surface of a layer of the packaging material by adhesive, extrusion, or any other suitable technique), ink layers, and the like. Other layers may include functional coatings, such as antifog coating, anti-blocking coating, protective coating, cold seal coating, other barrier layers (oxygen and / or water vapor transmittable), and so on. The ink layer may be a printed ink layer. In some embodiments, the ink layer may include a single ink layer or may include aplurality of ink layers. The plurality of ink layers may be formed using ink including the same or different colorants. The ink(s) can at least partially define indicium, indicia, graphics, logos and / or any other suitable artwork that is included in the packaging material.

[0045] Exemplary methods of manufacturing the material 100 are described in the following, with reference to Figures 3A and 3B. In some embodiments, such as depicted in Figure 3A, the manufacturing of the packaging material 100 can occur in a system 300 that includes sequentially (in series): laminating the interior layer 104 and one of the outer layer 102 or the inner layer 106 (e.g., laminating the outer and interior layers 102, 104 to one another) through the use of an extmded polyethylene-based material 302 (e.g., LLDPE) that forms a first tie layer (e g., the outer tie layer 108) to form an intermediate material 308; and thereafter laminating the intermediate material 308 to the other of the outer layer 102 or the inner layer 106 (e.g., laminating the intermediate material 308 and the inner layer 106 to one another) through the use of an extruded polyethylene-based material 304 (e.g., LLDPE) that forms a second tie layer (e.g., the inner tie layer 110) to form the material 100.

[0046] For example, a first pair of rollers 306 can form a first nip toward which the outer and interior layers 102, 104 are drawn, and in which the outer and interior layers 102, 104 and extruded polyethylene-based material 302 are received as part of the laminating process. The extruded polyethylene-based material 302 can cool to form the outer tie layer 108 and secure the outer and interior layers 102, 104 to one another to form the intermediate material 308. Then, the intermediate material 308 can be drawn towards a second pair of rollers 310 forming a second nip, and in which the intermediate material 308 and inner layer 106 and a second extruded polyethylene-based material 304 are received also as part of the laminating process. The second extruded polyethylene-based material 304 can cool to form the inner tie layer 110 and secure the intermediate material 308 and the inner layer 106 so that the interior layer 104 is positioned between and secured to the outer layer 102 and the inner layer 106 to form the material 100.

[0047] In other embodiments, such as depicted in Figure 3B, the manufacturing of the packaging material 100 can occur in a system 300’ that includes simultaneous laminating (e.g., trilaminating) the outer layer 102, the interior layer 104, and the inner layer 106 to one another through the use of extruded polyethylene-based materials 312, 314 (e.g., LLDPE) that form first and second tie layers (e.g., the outer tie layer 108 and inner tie layer 110), respectively, to form the material 100.

[0048] For example, again as depicted in Figure 3B, a pair of rollers 316 can form a nip toward which the outer, interior, and inner layers 102, 104, 106 are drawn, and in which the outer, interior, and inner layers 102, 104, 106 and extruded polyethylene-based materials 312, 314 are simultaneously received as part of the laminating process (e.g., are trilaminated together at a single nip). The extruded polyethylene-based materials 312, 314 can cool to form the outer and inner tie layers 108, 1 10, respectively, and secure the outer, interior, and inner layers 102, 104, 106 to one another to form the material 100 (so that the interior layer 104 is positioned between and secured to the outer layer 102 and the inner layer 106 to form the material 100).

[0049] At least one of the tie layers (e.g., the outer tie layer 108) can be a multilayer coextrusion (e.g., formed by coextruding before or during the laminating) comprising, consisting essentially of, or consisting of a barrier layer positioned between first and second polyethylenebased tie layers (e.g., the multilayer coextrusion 108’ comprising first extruded polyethylenebased tie layer 122 / extruded barrier layer 124 / second extruded polyethylene-based tie layer 126 depicted in Figure IB and / or Figure 1C).

[0050] The forming of the material 100 (e.g., laminating, trilaminating, etc.), including the forming of a multilayer coextruded tie layer and / or trilaminating outer, interior, and inner layers 102, 104, 106, can be performed in any suitable manner.

[0051] Upstream from the portion of the system 300 or 300’ depicted in Figures 3 A and 3B, the outer layer 102 can be at least partially formed inline by drawing the polyethylene-based fdm 112 along a web travel path through one or more printing devices (not depicted), wherein the one or more ink layers 128 are formed by printing (e.g., reverse printing) on the polyethylene-basedfilm 112. The one or more printing devices can each be a flexographic press, rotogravure press, inkjet printer, and / or any other suitable device for applying the ink layer(s) 128, wherein the ink of the ink layer(s) 128 is typically applied in a predetermined manner (e.g., reverse printed to provide text and / or graphics). Alternatively, the outer layer 102 including polyethylene-based film layer 112 and ink layer(s) 128 (e.g., reverse printed polyethylene-based film layer 112) can be at least partially formed “out of line” by a separate system(s).

[0052] The present disclosure also relates to packages (e.g., bags) manufactured from the flexible multilayer packaging material 100 described herein. For example, in the embodiment depicted in FIG. 1A, the multilayer packaging material 100 may provide one or more pieces for use in the production of packages for relatively dense items and / or packages needing puncture resistance, tear resistance, etc. (e.g., large packages including smaller, dense items such as pet food packaging) and that can be recycled. In some embodiments, it is currently believed that the packaging material 100 can be used to produce packages using conventional automated vertical or horizontal form-fdl-seal (FFS) packaging equipment and / or processes.

[0053] Figures 4A and 4B are front and back views, respectively, of an exemplary closed package, or more specifically a closed bag 400, formed from a piece of the packaging material 100. For example, the material 100 may be sufficiently flexible to be formed into bags in a conventional form-fill-seal packaging machine. In the example of Figures 4A and 4B, at least a portion of the outer surface 118 of the packaging material 100 defines the exterior surface of the bag 400 and at least a portion of the inner surface 120 of the packaging material 100 defines the interior surface of the bag 400. The piece of the packaging material 100 of the bag 400 extends around an interior space of the bag, and the interior space is closed by seams configured to at least partially (e.g., temporarily) obstruct access to the interior space of the bag.

[0054] In some embodiments, such as the example depicted in Figures 4A and 4B, the seams of the bag 400 can respectively be in the form of, or can be defined by, seals. The seals can be overlap seals, fin seals, and / or any other suitable seals. As depicted in the examples of Figure 4A and 4B, the seals may include opposite end seals 402 (e.g., crosswise seals); and as depictedin the example of Figure 4B, the seals may include a fin seal 410 (e.g., a lengthwise seal). The lengthwise or fin seal typically extends from one to the other of the end seals 402.

[0055] The bag 400 can be formed by folding the piece of packaging material 100 onto itself, so that respective marginal portions of the heat-sealable layer 116 are in opposing face-to-face contact with one another, and heat and pressure can be applied to those marginal portions to form the seals. Alternatively, the seals can be formed using a cold-seal adhesive, or in any other suitable manner. The package, or more specifically the bag 400, can completely enclose one or more articles (e.g., dog food products or any other suitable articles) in a hermitically sealed manner. A wide variety of differently configured packaging materials, wrappers, packages, seals and articles are within the scope of this disclosure.

[0056] In the example of Figures 4A and 4B, ink(s) of the printed ink layer 128 may at least partially define indicium, indicia, graphics, logos, and / or other suitable artwork that is included in the packaging material 100. As an example, as depicted in Figure 4A, the outer polyethylenebased film layer 112 can be transparent and / or translucent so that ink(s) of reverse printed ink layer 128, and more specifically graphics that are at least partially defined by the inks, are visible through the outer polyethylene-based film layer. In the example depicted in Figure 4A, the inks and / or graphics can define a background portion 404 extending around and between indicia 406 (e.g., “DOG FOOD”) and an image 408 (e.g., a dog). The ink defining the background portion 404 is typically a different color than the other one or more inks defining the other graphics portions 406, 408, and / or one or more of the graphics portions 406, 408 may not be printed / may not include ink so as to be at least partially defined by void(s) in the background portion 404.

[0057] As one of numerous examples of a method of forming packages from the packaging material 100, the packaging material can be cut into lengthwise strips that extend in the machine direction. Each of such strips of the packaging material 100 can be unwound from a roll and supplied to a conventional form-fill-seal machine (e.g., flow wrapping machine) that converts the strip into bags, overwraps, or the like.

[0058] Reiterating from above, a variety of differently configured reinforcing layers 114 (e.g., one or more polyethylene-based layers) are within the scope of this disclosure. As an additional example, Fig. 5A depicts an enlarged view of a portion of a polyethylene-based reinforcing layer 114 that is a nonwoven fabric and, more specifically, a spunbond nonwoven fabric. The spunbond fabric reinforcing layer 114 of Fig. 5A can be manufactured in a conventional manner that includes a fiber spinning process, as will be understood by those of ordinary skill in the art. In the spunbond reinforcing layer 114 of Fig. 5A, at least some of the flexible tensile members 130, 132 may be bonded (e.g., thermally bonded) at at least some of the contact (intersecting) points of the flexible tensile members, and the open spaces 134 are respectively defined between segments of the flexible tensile members 130, 132. It is believed that in the packaging material 100 (see, e.g., Figs. 1 A-1C) formed with the spunbond fabric reinforcing layer 1 14 of Fig. 5 A, material of one or more of the tie layers 108, 110 can extend at least partially into and / or completely through one or more of, a majority of, substantially each of, or each of the open spaces 134 in the reinforcing layer 114 of Fig. 5A.

[0059] As another example, the spunbond fabric 114 of Fig. 5A can be a precursor to the polyethylene-based nonwoven fabric reinforcing layer 114 of Fig. 5B. For example, the fabric reinforcing layer 114 of Fig. 5B can be formed from the spunbond fabric 114 of Fig. 5 A by further processing the spunbond fabric. The further processing can include or consist of a calendering finishing process that is carried out with rollers that apply pressure and define at least one nip through which the spunbond fabric is drawn. At least one of the rollers can have a patterned surface defining a pattern corresponding to the resulting pattern of open spaces 134 defined in the nonwoven fabric reinforcing layer 114 of Fig. 5B. It is believed that, in the packaging material 100 (see, e.g., Figs. 1A-1C) formed with the nonwoven fabric reinforcing layer 114 of Fig. 5B, material of one or more of the tie layers 108, 110 can extend at least partially into and / or completely through one or more of, a majority of, substantially each of, or each of the open spaces 134 in the reinforcing layer 114 of Fig. 5B.

[0060] For one or more of, a majority of, or each of the above-described polyethylene-based layers (e.g., polyethylene-based fdm layers, polyethylene-based reinforcing layers, polyethylenebased sealant layers, polyethylene-based tie layers), the polyethylene can be a majority component of the layer, the amount of polyethylene in the layer can be at least about 50 weight percent, the amount of polyethylene in the layer can be at least about 60 weight percent, the amount of polyethylene in the layer can be at least about 70 weight percent, the amount of polyethylene in the layer can be at least about 80 weight percent, the amount of polyethylene in the layer can be at least about 90 weight percent, the amount of polyethylene in the layer can be at least about 95 weight percent, the amount of polyethylene in the layer can be at least about 98 weight percent, the amount of polyethylene in the layer can be at least about 99 weight percent, the amount of polyethylene in the layer can be about 100 weight percent, and / or any values or subranges therebetween.

[0061] In some of the above examples, extrusion lamination is described. Alternatively, it is believed that one or more of the extrusion laminations may each be replaced with adhesive lamination.

[0062] Reiterating from above, it is within the scope of this disclosure for one or more of the terms “substantially,” “about,” “approximately,” and / or the like, to qualify each of the adjectives and adverbs of the foregoing disclosure, for the purpose of providing a broad disclosure. As an example, it is believed that those of ordinary skill in the art will readily understand that, in different implementations of the features of this disclosure, reasonably different engineering tolerances, precision, and / or accuracy may be applicable and suitable for obtaining the desired result. Accordingly, it is believed that those of ordinary skill will readily understand usage herein of the terms such as “substantially,” “about,” “approximately,” and the like.

[0063] Numerical values provided throughout this disclosure can be approximate, and for each range specified in this disclosure, all values within the range (including end points) and all subranges within the range are also disclosed. The term “about” can indicate that a numeric value can vary by plus or minus 25%, for example plus or minus 20%, for example plus or minus 15%,for example plus or minus 10%, for example plus or minus 5%, for example plus or minus 4%, for example plus or minus 3%, for example plus or minus 2%, for example plus or minus 1%, for example plus or minus less than 1%, for example plus or minus 0.5%, for example less than plus or minus 0.5%, including all values and subranges therebetween for each of the above ranges.

[0064] While the present invention is described herein in detail in relation to specific aspects and embodiments, it is to be understood that this detailed description is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the present invention and to set forth the best mode of practicing the invention known to the inventors at the time the invention was made. The detailed description set forth herein is illustrative only and is not intended, nor is to be construed, to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications, and equivalent arrangements of the present invention. All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are used only for identification purposes to aid the reader’ s understanding of the various embodiments of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention unless specifically set forth in the claims. Joinder references (e.g., joined, attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily imply that two elements are connected directly and in fixed relation to each other. Also, descriptions of sequences of steps or other actions are described for purposes of providing examples, and not for the purpose of limiting the scope of this disclosure (e.g., where appropriate, steps or actions may be performed in different sequences than described above, and steps and actions may be omitted and / or added). Further, various elements discussed with reference to the various embodiments may be interchanged to create entirely new embodiments coming within the scope of the present invention. The figures are schematic representations and so are not necessarily drawn to scale.

[0065] The use of the term “and / or” includes any and all combinations of one or more of the associated listed items (e.g., can refer to elements that are conjunctively present in some embodiments and elements that are disjunctively present in other embodiments), and in some embodiments optionally in combination with other elements not specifically identified by the “and / or” phrase. As non-limiting examples, “A and / or B” can refer in some embodiments to A without B; in some embodiments to B without A; in some embodiments to both A and B; etc.

[0066] As used herein, the phrase “at least one” in reference to a list of one or more elements can refer to at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. In some embodiments, elements may be optionally present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. As non-limiting examples, “at least one of A and B”; “at least one of A or B”; and / or “at least one of A and / or B” can refer in some embodiments to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in some embodiments to at least one, optionally including more than more one, B, with no A present (and optionally including elements other than A); in some embodiments to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

[0067] As used herein, indefinite articles “a” and “an” refer to at least one (“a” and “an” can refer to singular and / or plural element(s)).

[0068] In the specification and drawings, examples of embodiments have been disclosed. The present invention is not limited to such exemplary embodiments. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.

Claims

What is claimed is:

1. A recyclable, multilayer, flexible packaging material comprising a laminate, the laminate comprising: a first polymeric film, wherein polyethylene is a majority component of the first polymeric film; a second polymeric film, wherein polyethylene is a majority component of the second polymeric film; a reinforcing layer connected between the first and second polymeric films, wherein polyethylene is a majority component of the reinforcing layer; wherein the reinforcing layer has greater tensile strength than at least one of the first and second polymeric films.

2. The packaging material of claim 1, further comprising ink on at least a portion of at least one of an inner surface of the first polymeric film or an outer surface of the first polymeric film.

3. The packaging material of claim 2, comprising ink on at least a portion of an inner surface of the first polymeric film.

4. The packaging material of claim 1, wherein the reinforcing layer comprises a sheet of textile material comprising a plurality of holes.

5. The packaging material of claim 1, further comprising: a first tie layer in direct contact with the reinforcing layer, wherein polyethylene is a majority component of the first tie layer, and at least a portion of the first tie layer is positioned between the reinforcing layer and the first polymeric film; and a second tie layer in direct contact with the reinforcing layer, wherein polyethylene is a majority component of the second tie layer, and at least a portion of the second tie layer is positioned between the reinforcing layer and the second polymeric film.

6. The packaging material of claim 5, wherein material of the first tie layer extends into openings of the reinforcing layer.

7. The packaging material of claim 5, wherein material of the second tie layer extends into openings of the reinforcing layer.

8. The packaging material of claim 5, wherein: the reinforcing layer has greater tensile strength than the first polymeric film; and / or the reinforcing layer has greater tensile strength than the second polymeric film; and / or the reinforcing layer has greater tensile strength than the first tie layer; and / or and the reinforcing layer has greater tensile strength than second tie layer.

9. The packaging material of claim 5, wherein: the amount of polyethylene in the first polymeric film is at least about 90 weight percent; and / or the amount of polyethylene in the second polymeric film is at least about 90 weight percent; and / orthe amount of polyethylene in the reinforcing layer is at least about 90 weight percent; and / or the amount of polyethylene in the first tie layer is at least about 90 weight percent; and / or the amount of polyethylene in the second tie layer is at least about 90 weight percent.

10. The packaging material of claim 5, wherein the reinforcing layer comprises a sheet of textile material comprising a plurality of holes.

11. The packaging material of claim 10, wherein material of the first tie layer extends into at least some of the holes of the reinforcing layer.

12. The packaging material of claim 10, wherein material of the second tie layer extends into at least some of the holes of the reinforcing layer.

13. The packaging material of claim 1, further comprising a barrier layer positioned between the reinforcing layer and the first polymeric film.

14. The packaging material of claim 5, wherein the first tie layer is a coextruded composite tie layer comprising a first extruded tie layer in direct contact with the first polymeric film, a second extruded tie layer in direct contact with the reinforcing layer, and an extruded barrier layer positioned between the first extruded tie layer and the second extruded tie layer.

15. A package formed from the packaging material of claim 1, wherein: the packaging material extends around an interior space of the package, and sections of the second polymeric film are heat-sealed together to form a seal that closes an opening to the interior of the package.

16. A method of at least partially forming a recyclable, multilayer, flexible packaging material comprising a laminate, the method comprising: extruding a first polymeric material to form a first tie layer laminating a first polymeric film to a first surface of a reinforcing layer; and extruding a second polymeric material to form a second tie layer laminating a second polymeric film to a second surface of the reinforcing layer opposite the first surface of the reinforcing material to at least partially form the laminate of the recyclable, multilayer, flexible packaging material, wherein: polyethylene is a majority component of the first polymeric film, the first tie layer, the reinforcing layer, the second tie layer, and the second polymeric film, and the reinforcing layer has greater tensile strength than the first polymeric film and / or the reinforcing layer has greater tensile strength than the second polymeric film and / or the reinforcing layer has greater tensile strength than the first tie layer and / or and the reinforcing layer has greater tensile strength than second tie layer.

17. The method of claim 16, comprising sequentially extruding the first polymeric material and the second polymeric material.

18. The method of claim 16, comprising simultaneously extruding the first polymeric material and the second polymeric material.

19. The method of claim 16, wherein the reinforcing layer comprises a sheet of textile material comprising a plurality of holes.

20. The method of claim 16, wherein the first polymeric film has opposite outer and inner surfaces, the inner surface of the first polymeric film is positioned between the outer surface of the first polymeric film and the reinforcing layer, and the method comprises printing ink on at least a portion of the inner surface of the first polymeric film before extruding the first polymeric material to form the first tie layer laminating the first polymeric film to the first surface of the reinforcing layer.