Disposable pouch

Abstract

A disposable pouch includes a first laminated structure, a second laminated structure, and a cavity between the first laminated structure and the second laminated structure for positioning a product therein. The first and the second laminated structure each have a cellulosic substrate, an innermost heat seal layer, and an intermediate polymer film coated with a barrier material disposed between the cellulosic substrate and the innermost heat seal layer. The innermost heat seal layers of the first and second laminated structures are heat sealed together at peripheral portions of the first and second laminated structures at edges of the cavity.

Description

DISPOSABLE POUCHP RI O RIT Y

[0001] This application claims priority from U.S. Ser. No. 63 / 508,052 filing on June 14, 2023, the entire contents of which are incorporated herein by reference.FIELD

[0002] The present description relates to the field of sustainable packaging solutions. More particularly, the present description relates to a disposable pouch, which may be used for various purposes, including the packaging of food items, cosmetics, and liquid or gel products, having high barrier integrity for water vapor and oxygen, and being predominantly paper-based.B AC KG R O UN D

[0003] Single-use plastic pouches have been widely used in various industries for years due to their convenience, portability, and ability to effectively contain various types of products, ranging from dry goods to liquids, gels, and more. These pouches provide high barrier integrity, protecting the products inside from water vapor, oxygen, and other environmental factors that could affect their quality and lifespan.

[0004] However, in recent years, concerns have risen over the environmental impact of singleuse plastics. These materials often end up in landfills or oceans where they do not degrade naturally, leading to significant pollution and ecological harm. Recycling efforts can mitigate some of this harm, but plastic pouches present unique challenges in this regard.

[0005] While paper-based packaging solutions have been suggested as an eco-friendlier alternative, they come with their own set of challenges. Traditional paperboard, though renewable and more readily recycled, lacks the barrier necessary to protect sensitive products from the damaging effects of water vapor and oxygen exposure.

[0006] Barrier-coated paperboard solutions have been introduced to improve the protective capabilities of paper-based packaging. These coatings can enhance the resistance of paperboard to moisture and oxygen, addressing one of the key limitations of conventional paperboard.

[0007] Some forms of barrier paperboard offer a potential solution to this challenge, but they may still not reach the same performance level as plastic pouches, especially after undergoing the converting process to form a pouch. In particular, the barrier properties can be compromised, undermining the protection of the product.

[0008] Therefore, a need remains for a sustainable, paperboard-based disposable pouch that combines the convenience and protective properties of a traditional plastic pouch, with a high paperboard content, and the barrier properties necessary to keep products safe from environmental factors. This invention proposes to address these and other challenges.

[0009] Accordingly, those skilled in the art continue with research and development in the field of sustainable packaging solutions.S U MM ARY

[0010] In one example, a disposable pouch includes a first laminated structure, a second laminated structure, and a cavity between the first laminated structure and the second laminated structure for positioning a product therein. The first laminated structure has a cellulosic substrate, an innermost heat seal layer, and an intermediate polymer film coated with a barrier material disposed between the cellulosic substrate and the innermost heat seal layer. The second laminated structure has a cellulosic substrate, an innermost heat seal layer, and an intermediate polymer film coated with a barrier material disposed between the cellulosic substrate and the innermost heat seal layer. The innermost heat seal layers of the first and second laminated structures are heat sealed together at peripheral portions of the first and second laminated structures at edges of the cavity.

[0011] Other examples of the disclosed disposable pouch will become apparent from the following detailed description, the accompanying drawings and the appended claims.B R IEF D ES CR IPTIO N O F THE D R AW IN G S

[0012] Fig. 1 is a cross-section of an exemplary structure for a first and second laminated structure of the present description;

[0013] Fig. 2 is a graph showing Oxygen Transmission Rate (OTR) and Water Vapor Transmission Rate (WVTR) for exemplary flat laminated sheets of the present description;

[0014] Fig. 3 shows Oxygen Transmission Rate (OTR) and Water Vapor Transmission Rate (WVTR) properties for flat, creased, embossed, and folded laminated sheets according to an example of the present description;

[0015] Fig. 4 shows Oxygen Transmission Rate (OTR) and Water Vapor Transmission Rate (WVTR) properties for flat, creased, embossed, and folded laminated sheets according to another example of the present description;

[0016] Fig. 5 is a perspective view of an exemplary pouch of the present description formed from separate laminated sheets;

[0017] Fig. 6 is a plan view of a laminated structure of the present description having lines of preformed weakness;

[0018] Fig. 7 is a plan view of a single laminated structure for forming a disposable pouch of the present description;

[0019] Fig. 8 is a top view of a disposable pouch of the present description formed from the single laminated structure of Fig. 7;

[0020] Fig. 9A is a perspective view of a disposable pouch comprising an embossed laminated structure;

[0021] Fig. 9B is a plan view of the disposable pouch of Fig. 9A;

[0022] Figs. 10A and 10B are cross-sectional views depicting two different examples of the female die of an embossing mold;

[0023] Fig. 1 1 A and 1 IB are plan views of a disposable pouch with its peripheral portions heat scaled;

[0024] Figs. 12A, 12B and 12C are plan views depicting various access features with notches and creases;

[0025] Figs. 13A, 13B and 13C are plan views depicting various access features with notches and solid partial cuts;

[0026] Fig. 14 is a cross-sectional view of a portion of a laminated structure with a partial cut;

[0027] Figs. 15A, 15B, 15C, 15D and 15E are plan views depicting various partial cut pattern examples;

[0028] Fig. 16 is a detailed plan view of the disposable pouch of Fig. 11; and

[0029] Fig. 17 is a close-up view of a portion of the disposable pouch of Fig. 16.D ETA ILED D E S C RIP TIO N

[0030] According to the present description, a disposable pouch comprises a first laminated structure, a second laminated structure, and a cavity between the first and second laminated structures. The first and second laminated structures of the present description include a cellulosic substrate and an innermost heat seal layer. The innermost heat seal layers of the first and second laminated structures are heat sealed together at peripheral portions of the first and second laminated structures at edges of the cavity. The heat sealing of the innermost heat seal layers at the peripheral portions of the cavity helps to define the edge of the cavity and binds the first and second laminated structures together to provide rigidity to the disposable pouch.

[0031] In an aspect, the first laminated structure and the second laminated structure may be folded portions of a single laminated structure connected by a fold line. In this case, the innermost heat seal layers of the first and second laminated structures may omit heat sealing at the fold line. Alternatively, the first laminated structure and the second laminated structure may be separate laminated structures and may be heat sealed about the perimeter of the cavity except for the opening for product loading. Thus, the design of the pouch is flexible, being made eitherfrom two separate laminated structures or from a single laminated structure that has been folded and connected at a fold line. In the latter case, the heat seal may be avoided at fold line, which may increase the volume of the cavity for holding an increased amount of product.

[0032] In an aspect, the first laminated structure and / or the second laminated structure may include one or more preformed weaknesses about which the respective laminated structure may be bent to facilitate opening / expanding the cavity. The preformed weaknesses may be formed in any suitable manner, such as by creasing. The preformed weaknesses are formed prior to heat sealing the first laminated structure to the second laminated structure, preferably at the time of a die-cutting of the laminated structure to form the overall desired shape. In this case, the preformed weakness may be formed by pressing a line in the laminated structure to form a crease. The one or more preformed weaknesses may facilitate loading of a product into the cavity, and particularly an automated loading of a product into the cavity by ensuring a consistent shape of the opened cavity.

[0033] In an aspect, the first laminated structure and / or the second laminated structure may be embossed. Embossing of the laminated structures may facilitate loading of a product into the cavity, and may increase the volume of the cavity, thereby increasing the capacity of the disposable pouch.

[0034] In another aspect, the disposable pouch may include a feature whereby an unsealed peripheral portion is preserved between the first and second laminated structures. This unsealed portion creates an opening for product loading into the cavity. For example, when the first and second laminated structures are heat sealed along their peripheral edges, they create an enclosed cavity between them. This cavity is intended to hold the product therein. However, a section along the periphery of these layers remains unsealed, forming an opening into the cavity. The position of the opening can be varied depending on the specifics of the product filling process, the nature of the product, or the intended direction of product entry. This unsealed peripheral portion enables direct access to the interior cavity, easing the process of product loading. After product loading, the unsealed peripheral portion may be sealed such as by heat sealing, or the unsealed peripheral portion may remain unsealed for some applications. Alternatively, theproduct could be positioned in the cavity before the entirety of the peripheral edge is sealed, transitioning the pouch from a completely open state to a completely scaled state.

[0035] In another aspect, the disposable pouch can incorporate a variety of access features to facilitate access to the pouch contents after sealing. One such feature is a perforated tear line with notches — which provide an initial tearing point and an ending point — at both ends of the tear line. This tear line, situated at a sealed peripheral portion of the cavity, can provide a simple and direct method for accessing the contents within the pouch post-sealing. The consumer can easily tear along this line, creating an opening in the pouch to retrieve the contents. The tear line may be formed prior to heat sealing the first laminated structure to the second laminated structure, preferably at the time of a die-cutting of the laminated structure to form the overall desired shape. The tear line may be formed by, for example, scoring the laminated structure. Any other access features could also be employed based on the product’s needs and consumer preferences. These could include, for example, resealable openings, slider mechanisms, spouts, dispensing nozzles, pull-tabs, peelable seals, adhesive flaps, twist caps, press-to-seal closures, zippers, snap-on lids, and push-through foil seals.

[0036] Grain direction of the cellulosic board or paperboard may be one of the factors to consider when designing the disposable pouch. The more parallel the grain is oriented with the tearing direction, the better the performance of the tearing, without deviating from the predetermined direction of the access feature. Assuming that the direction of the access feature is horizontal, the grain direction should also be relatively horizontal in order to achieve better tearing performance. On the other hand, the pouch may provide better support for a heavier product if the grain direction is more perpendicular to the tearing direction. Those skilled in the art may need to consider these factors in choosing an appropriate grain direction for a given application.

[0037] Some access features may interfere with graphics on the disposable pouch because they require permanent markings including, but not limited to, perforated tear lines and partial cuts as tear guidance.

[0038] Access features that do not involve a predetermined directional tear may be utilized to mitigate both grain direction and graphics interference concerns. For example, comer peelmethod may be advantageous because it may enable the manufacturer to keep vertical grain direction without compromising the performance of the access feature. This method also docs not interfere with the packaging graphics because this access feature does not make any permanent tear lines on the outer surface of the laminated structure. A higher caliper may be necessary to achieve a better corner peel experience, but it also may lead to an increase in the overall cost of manufacturing.

[0039] Another example of an access feature may involve strip reinforced tear' line that provides much stronger guidance, which may negate any resistance that stems from non-parallel grain direction. The strip may be embedded underneath the cellulosic substrate layer, the outermost layer, keeping the surface area free from any interference with graphics. In another example, the strip may be at least partially embedded within the cellulosic substrate layer. In another example, the strip may be embedded on the outer surface of the cellulosic substrate layer to minimize possibility of chemical interaction with a product. However, the strip reinforced tear line access feature may incur higher manufacturing costs.

[0040] As the embossed area may interfere with the guided tearing of the access feature, it may be better to place the access feature away from the location of the emboss. For example, the perforated tear line may be placed at least 5 mm above the top of the emboss, ensuring that the tear is not negatively disrupted by the embossed area. However, if the embossed area does not interfere with tearing, the entire area of the first and second laminated structures may be embossed, excluding the heat sealing areas.

[0041] The cellulosic substrate serves as a primary structural component of the disposable pouch. This substrate imparts the pouch with a balance of stiffness and flexibility, ensuring that it retains its shape and structural integrity, even when filled with a product. It can provide a smooth surface, ideal for printing or labeling, thereby serving as a platform for branding, information display, and aesthetic appeal. The cellulosic substrate may originate from renewable and recycled sources. This aligns with environmentally conscious manufacturing practices, underscoring the sustainability of the disposable pouch as a packaging solution.

[0042] The cellulosic substrate may include a wide range of cellulose sources such as wood pulp, cotton fibers, recycled paper, bagasse (a byproduct of sugar cane processing), bamboo, orany other plant-based material high in cellulose content. The cellulosic substrate may receive various treatments and coatings to tailor it to specific use-cases. One type of cellulosic substrate that may be used in this context is paperboard which is made by a papermaking process. One preferred paperboard is solid bleached paperboard (SBS), which offers a high degree of brightness and cleanliness and provides excellent printing properties. Additionally, SBS paperboard has high strength and rigidity, making it an excellent choice for a cellulosic substrate that maintains its shape and resists damage. However, other types of paperboard or cellulosic substrates are suitable.

[0043] The cellulosic board, or paperboard (for example, solid bleached sulfate or SBS paperboard), has a basis weight that can vary to suit different requirements. The basis weight can be within a broad range, for instance, from 50 lbs. / 3msf to 400 lbs. / 3msf. However, for most applications, a more typical range may be from 90 lbs. / 3msf to 300 lbs. / 3msf. For some specific uses where a balance of strength and flexibility is desired, the paperboard may have a basis weight in the range of 99 lbs. / 3msf to 233 lbs. / 3msf. These ranges allow for flexibility in choosing the appropriate cellulosic board based on factors such as the intended contents of the pouch and the environmental conditions it might be exposed to.

[0044] The cellulosic board, or paperboard (for example, SBS paperboard), has a caliper thickness that can be tailored to specific requirements. The caliper thickness of the paperboard can range widely, potentially spanning from 3 point (pt) to 30 pt. However, a more commonly utilized range might be between 7 pt and 24 pt, which offers a good balance of strength, flexibility, and cost-effectiveness for a variety of applications. In certain scenarios where specific physical properties are desired, the paperboard might have a narrower caliper range, such as between 14 pt and 20 pt. Such a range might be beneficial for applications that require a particular degree of rigidity and durability without substantial increase in weight or material cost. Specific examples of cellulosic board that would be suitable are 16 pt and 18 pt PrintKote, which is a brand name for a type of coated, solid bleached paperboard (SBS) that is produced by WestRock. PrintKote has exceptional printability and high stiffness-to- weight ratio.

[0045] The innermost heat seal layer of the first and second laminated structures function to seal around the cavity. By applying heat to the innermost heat seal layers, these layers can bemade to adhere to each other, creating a secure bond that helps to prevent leakage, contamination, or premature exposure of the pouch’s contents.

[0046] The composition of the innermost heat seal layer can be selected according to different requirements. Often, this layer is made up of thermoplastic materials, such as polyolefins and polyolefin based copolymers. These materials are characterized by their thermal behavior, softening or melting at a specific temperature and solidifying once cooled. Notably, the heat seal layer could include materials from the olefin family, including Low-Density Polyethylene (LDPE), High-Density Polyethylene (HDPE), Linear Low-Density Polyethylene (LLDPE), Ethyl Methyl Acrylate (EMA), or a copolymer of polyolefin.

[0047] The thickness of the heat seal layer can be tailored to address varying requirements. A thicker heat seal layer, while potentially providing a more robust seal, could result in increased material costs and potentially elongate the heat-sealing process. On the other hand, a thinner heat seal layer might be a more cost-effective option and enable quicker sealing, although it could decrease the strength. Therefore, the selection of the heat seal layer’s thickness should strike a balance between performance, cost, and manufacturing efficiency. The thickness of the heat seal layer can range widely, for instance, from 0.1 mil to 2 mils. However, a thickness in the range of 0.4 mil to 1 mil may be used for a balance of properties.

[0048] According to the present description, an intermediate polymer film coated with a barrier material is positioned between the cellulosic substrate and the innermost heat seal layer in the first and second laminated structures. The barrier material applied on the intermediate polymer film serves to provide resistance against moisture, oxygen, and other environmental factors that could compromise the quality or safety of the product within the pouch or that could comprise the integrity of the cellulosic substrate.

[0049] The polymer film may be composed of a variety of polymers based on the specific requirements of the pouch. Some potential polymers include, but are not limited to, polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), different types of polyesters, polyolefins, or eco-friendlier biopolymers derived from renewable resources. Each of these polymers comes with its own set of properties, such as strength, flexibility, and transparency, which influence their suitability for different applications. Exemplary polymer films includepolyethylene terephthalate (PET) and biaxially-oriented polypropylene (BOPP). PET has excellent strength, thermal stability, and barrier properties against gases like oxygen, carbon dioxide, and volatile organic compounds. BOPP, on the other hand, provides excellent clarity, good tensile strength, and superior moisture barrier properties. An exemplary material is Biaxially Oriented Polypropylene (BOPP) film, which demonstrates excellent heat-sealing capabilities and robust barrier properties. BOPP film is manufactured by stretching a polypropylene film in both longitudinal and lateral directions, a process that increases its strength, clarity, and dimensional stability. One of the advantages of BOPP film is that it can be pre-fitted with a heat seal layer, simplifying the manufacturing process.

[0050] The thickness of the polymer film can be customized to address specific needs. The selection of the thickness is influenced by a variety of factors, including the required strength, flexibility, and cost-effectiveness. For instance, polymer film thickness can fall within a range, such as from 0.1 mils to 10 mils. This range provides flexibility in meeting diverse packaging requirements. However, for most typical applications, a more common range might be from 0.25 to 5 mils. This offers a good balance of pouch strength, flexibility, and barrier properties for a wide array of products, while also considering material cost and processing efficiency. A thick film, for example in the range of 3 to 5 mils, could offer improved physical strength and superior barrier properties against gases, moisture, and light, thus better preserving the product’s quality and extending its shelf life. However, this could lead to an increase in material costs and possibly the time required for sealing processes. Conversely, a thinner film, for example in the range of 0.25 to 1 mil, could be more cost-effective, more flexible, and quicker to seal, which might be advantageous for high-speed, high-volume production lines. However, it might not provide the same level of strength or barrier performance as thicker films, making it more suitable for less demanding applications or products with shorter intended shelf life. In some instances, specific thicknesses may be chosen, such as 0.5 or 0.75 mil, based on precise application requirements and trade-offs between strength, barrier properties, cost, and process efficiency.

[0051] The barrier material coated to the polymer film serves to provide resistance against environmental factors. This can include moisture, oxygen, light, or even specific gases that could compromise the quality or safety of the product within the pouch, or that could affect the integrity of the cellulosic substrate.

[0052] The barrier material can be composed of a multitude of substances. One prominent example is a metallization layer, such as an aluminum metallized polyethylene terephthalate (PET) film or a metallized biaxially oriented polypropylene (BOPP) film. Metallized films incorporate a thin layer of metal (commonly aluminum) that is vapor-deposited onto the surface of a polymer film. This metallization process significantly enhances the barrier properties of the film, providing improved protection against environmental factors such as moisture, gases, light, and aroma. Aluminum metallized PET films are often favored due to their high barrier characteristics, combined with the strength and flexibility of the PET substrate. Another notable example is a ceramic coated plastic film, which may include metal oxides such as aluminum oxide (AlOx) and silicon dioxide (SiCh) coated onto a PET or PP substrate. Ceramic coated films utilize a deposition process to create an extremely thin, transparent ceramic layer on the surface of a polymer film. This ceramic layer provides excellent barrier. Both of these types of barrier materials (metallized polymer films and ceramic coated polymer films) offer robust protection for the contents of the pouch, while also supporting the overall structural integrity of the pouch. The choice between these and other types of barrier materials depends on the specific requirements of the product being packaged, including its sensitivity to environmental factors, the intended shelf-life, and aesthetic or marketing considerations.

[0053] Incorporating an intermediate polymer film coated with a barrier material into the design of the laminated structures comes with numerous advantages. This film, situated between the cellulosic substrate and the innermost heat seal layer, can improve the overall performance of the disposable pouch. The barrier material on the polymer film can serve as a barrier against environmental elements blocking moisture, oxygen, light, or other gases, thus extending the shelf life of the product enclosed in the pouch and maintaining its freshness, taste, aroma, and nutritional content. The polymer film can add to the structural integrity of the pouch, imparting extra strength, flexibility, and durability, thereby reducing the likelihood of the pouch getting punctured, torn, or damaged during transport, handling, or retail display. The pouch may also withstand more rigorous conditions, such as changes in temperature or pressure. The polymer films can avoid traditional materials like metal foils. The pouch may also withstand more rigorous conditions, such as changes in temperature or pressure. The polymer films can also be tailored to fit specific needs regarding thickness, barrier performance, and other characteristics allowing for a more optimized design of the pouch. The intermediate polymer film can be readilyintegrated into various manufacturing processes, such as extrusion lamination and adhesive lamination. Additionally, the intermediate polymer film coated with a barrier material can maintain barrier properties even after folding of the laminated structure, formation of the preformed weaknesses, or embossing, thus enabling for an improved overall design of the disposable pouch.

[0054] The first and second laminated structures may further include a first tie layer between the cellulosic substrate and the intermediate polymer film coated with the barrier material. The first tie layer serves as an adhesive intermediary, bridging the cellulosic substrate and the intermediate polymer film to ensure a strong and durable bond.

[0055] This tie layer is generally composed of thermoplastic polymers, which possess excellent adhesive properties. Suitable materials for the tie layer may be derived from the olefin family, including Low-Density Polyethylene (LDPE), High-Density Polyethylene (HDPE), and Ethyl Methyl Acrylate (EMA) or their blends and co-ex structure. Olefins are ideal due to their inherent adhesion capabilities, their compatibility with other materials in the laminated structure, and their ability to withstand the heat-sealing process without degrading or causing structural defects. They also exhibit good chemical resistance, ensuring they will not react adversely with the product contained within the pouch.

[0056] In terms of thickness, the tic layer can, for example, range from as thin as 0.05 mils to as thick as 1.0 mils. The optimal thickness depends on various factors, such as the specific materials used for the cellulosic substrate and the polymer film, the pouch’s size and intended use, and the desired balance between performance, cost, and manufacturing efficiency. A thicker tie layer can offer stronger adhesion and better durability, which may be beneficial in cases where the pouch needs to accommodate heavier or more abrasive products, or where it may be subjected to rigorous handling or harsh environmental conditions. However, a thicker tie layer may increase the material costs and could potentially impact the heat-sealing process, leading to longer sealing times or the need for higher sealing temperatures. On the other hand, a thinner tie layer can provide sufficient adhesion for many applications, while reducing material costs and potentially improving the speed and efficiency of the heat-sealing process. This might be the preferred option for products with a shorter intended shelf life or those that require high-speed,high-volume production. Overall, the inclusion of the first tie layer between the cellulosic substrate and the intermediate polymer film in the laminated structures adds an additional level of integrity to the disposable pouch, helping to ensure the security and longevity of the packaged product.

[0057] The first and second laminated structures may further include a second tie layer between the intermediate polymer film coated with the barrier material and the innermost heat seal layer. Its primary function is to further enhance the adhesion between the intermediate polymer film coated with the barrier material and the innermost heat seal layer, creating a stronger and more robust structure.

[0058] The second tie layer, like the first, can be made from thermoplastic polymers derived from the olefin family, including Low-Density Polyethylene (LDPE) and Ethyl Methyl Acrylate (EMA) or their blends or co-ex structure. These polymers are known for their outstanding adhesive qualities, their ability to withstand heat sealing processes, and their compatibility with other materials in the laminated structure. In addition, they exhibit good chemical resistance, thereby avoiding adverse reactions with the product contained in the pouch.

[0059] The thickness of this second tie layer can range between 0.05 mils and 1.0 mils. The selection of the specific thickness should be determined based on several factors, such as the materials used for the polymer film and the heat seal layer, the size and intended use of the pouch, and the desired balance between performance, cost, and manufacturing efficiency.

[0060] A thicker second tie layer may offer superior bonding strength and durability, which could be advantageous for pouches that need to hold heavier or more abrasive products, or for pouches that are expected to endure more rigorous handling or harsher conditions. However, a thicker layer could also increase material costs and may affect the heat-sealing process, possibly requiring longer sealing times or higher sealing temperatures.

[0061] Conversely, a thinner second tie layer could suffice in terms of providing adequate adhesion for many applications. It may also help reduce material costs and improve the efficiency of the heat-sealing process. This could be a more suitable choice for products with a shorter shelf life or for those that need to be produced at a high speed and in large volumes.

[0062] The presence of the second tie layer may be particularly preferred when laminating preformed heat seal layers to the barrier material coated polymer films. Alternatively, the second tic layer may be omitted, particularly in the case where the innermost heat seal layers are applied as a coating to the barrier material coated polymer films.

[0063] The first and second laminated structures may be engineered to be more readily recyclable due to barrier coating on only one side of the paperboard and have paperboard content (wt. basis) greater 85% based on type of board, barrier film and seal layer thickness used.

[0064] The first and second laminated structures may be formed in any suitable manner. For example, the laminated structures may be created by extrusion lamination or adhesive lamination processes. In one specific example, a paperboard may be laminated with Al metallized or with Ceramic coated plastic film such as such AlOx PET and a heat seal layer or layers may be applied using extrusion process. In another example, Al metallized, or Ceramic coated plastic film can be adhesive laminated to paperboard and heat seal layer or layers can be applied using extrusion or aqueous coating process.

[0065] The first and second laminated structures can have an Oxygen Transmission Rate (OTR) of 50 cc / mA2.day@23C / 0%RH or less. Preferably, the first and the second laminated structures have an Oxygen Transmission Rate (OTR) of 20 cc / mA2.day@23C / 0%RH or less. Preferably, the first and the second laminated structures have an Oxygen Transmission Rate (OTR) of 5 cc / mA2.day@23C / 0%RH or less. The first and the second laminated structures can have a Water Vapor Transmission Rate (WVTR) of 5 g / mA2.day@38C / 90%RH or less. Preferably, the first and the second laminated structures have a Water Vapor Transmission Rate (WVTR) of 2 g / mA2.day@38C / 90%RH or less. Preferably, the first and the second laminated structures have a Water Vapor Transmission Rate (WVTR) of 0.5 g / mA2.day@38C / 90%RH or less.

[0066] The first and second laminated structures can maintain or show minimum deterioration in water vapor and oxygen barrier after creasing, embossing and / or folding, which can be helpful in converting them into a package required for high barrier application. The first and the second laminated structures can have an Oxygen Transmission Rate (OTR) of 50 cc / mA2.day@23C / 0%RH or less. Preferably, the first and the second laminated structures havean Oxygen Transmission Rate (OTR) of 20 cc / mA2.day@23C / 0%RH or less. Preferably, the first and the second laminated structures have an Oxygen Transmission Rate (OTR) of 5 cc / mA2.day@23C / 0%RH or less. The first and the second laminated structures can have a Water Vapor Transmission Rate (WVTR) of 5 g / mA2.day@38C / 90%RH or less. Preferably, the first and the second laminated structures have a Water Vapor Transmission Rate (WVTR) of 2 g / mA2.day@38C / 90%RH or less. Preferably, the first and the second laminated structures have a Water Vapor Transmission Rate (WVTR) of 0.5 g / mA2.day@38C / 90%RH or less.

[0067] Fig. 1 illustrates a potential structure for the first and second laminated structures. The laminated structure 1 of Fig. 1 comprises a paperboard layer 10, a first tie layer 20, a barrier film 30, a second tie layer 40, and a heat seal layer 50. An exemplary paperboard layer 10, may be coated board which can have basis weight in range of 124 lbs. / 3msf to 233 lbs. / 3msf. An exemplary first tie layer 20 can be from family of olefin such as LDPE, HD PE or olefin copolymer such as EMA, and can have thickness in range of 0.05 mil to 1.0 mils. An exemplary barrier film 30 can be metallized or metal oxide coated film from family of polyesters or polyolefins having thickness in range of 0.25 to 5 mils. An exemplary second tie layer 40 can be from family of olefin such as Low Density Polyethylene (LDPE) or olefin copolymer such as Ethyl methyl Acrylate (EMA), and can have thickness in range of 0.05 mil to 1.0 mils. An exemplary heat seal layer 50 can be from family of olefins such as LDPE, HDPE, LLDPE, Ethyl methyl acrylate (EMA) or copolymer of polyolefin.

[0068] Table 1 lists exemplary laminated paperboard structures that may be employed as laminated structures for the disposable pouch of the present description.TA B L E 1

[0069] Fig. 2 shows Oxygen Transmission Rate (OTR) and Water Vapor Transmission Rate (WVTR) properties for flat laminated sheets produced from the exemplary laminated paperboard structures of Table 1. As per Fig. 2, AlOx Laminates showed improved WVTR and OTR vs. metallized laminates.

[0070] Figs. 3 and 4 show Oxygen Transmission Rate (OTR) and Water Vapor Transmission Rate (WVTR) properties for flat, creased, embossed, and folded laminated sheets produced from examples 0405-4 and 0405-6 of Table 1. Creasing was created using a ruler to the depth of 0.2 mm beyond thickness of laminate which is considered as deep crease. Emboss condition was 45- degree angle and 5 mm depth. Fold was 180 degree towards the bander side of the laminate. Figs.3 and 4 show good barrier properties in creased, embossed folded conditions.

[0071] Table 2 shows repulpability properties of exemplary first and second laminated structures. Table 2 shows that structures can be designed in a way that they can achieve repulpability results of more than 80% and that the laminated structure can be engineered to have paperboard content (wt. basis) greater than 85%.TA B L E 2

[0072] Table 3 shows additional examples of first and second laminated structures according to the present description, comparing various barrier materials. The mark indicates that the metallized biaxially oriented polypropylene film included preformed heat seal layer. The mark “**” indicates a specialty sealant resin described as ionomer of ethylene acrylic acid copolymer, which can provide good sealing and improved chemical compatibility.TA B L E 3

[0073] Table 4 lists exemplary laminated structures including metallized BOPP layers. Table 4 shows the impact of the BOPP film on paperboard content. As per Table 4, lower basis weight of polypropylene (PP) film due to low density vs. polyethylene terephthalate (PET) film can be favorable to achieve high paperboard content, thus helping with repulpability and recyclability.TA B L E 4

[0074] Table 5 shows the barrier properties of the exemplary laminated structures of Table 4.As per Table 5, the metallized BOPP layers provide good barrier properties.TA B L E 5

[0075] Fig. 5 illustrates an exemplary pouch 500 comprises a first laminated structure 510, a second laminated structure 520, and a cavity 530 between the first and second laminated structures. The innermost heat seal layers of the first laminated structure 510 and second laminated structure 520 are heat sealed together at peripheral portions of the first and second laminated structures at edges of the cavity except for the opening as illustrated. The heat sealing of the innermost heat seal layers define the edge of the cavity and binds the first and second laminated structures together.

[0076] Fig. 6 illustrates first and second laminated structure 600 for a disposable pouch having lines of preformed weakness 610, 620, 630, which may be formed by creasing. A disposable pouch may be formed as illustrated in Fig. 5 from the first and second laminated structure 600 of Fig. 6. The preformed weaknesses are formed prior to heat sealing the first laminated structure to the second laminated structure, preferably at the time of a die-cutting of the laminated structure to form the overall desired shape. The one or more preformed weaknesses facilitate loading of a product into the cavity, and particularly an automated loading of a product into the cavity by ensuring a consistent shape of the opened cavity.

[0077] Fig. 7 illustrates a single laminated structure 700 including a fold line 710. The single laminated structure 700 may be folded along the fold line 710 to define a first laminated structure 720 and a second laminated structure 730. The first laminated structure and the second laminated structure may be heat sealed together at peripheral portions 740 of the first and second laminatedstructures to form the disposable pouch 800 illustrated in Fig. 8 having the cavity 830 between the first laminated structure 720 and the second laminated structure 730.

[0078] Figs. 9A and 9B illustrate a disposable pouch 900 comprising a first laminated structure 910 having a central embossed portion 920. The second laminated structure (not shown) of the disposable pouch 900 may also be similarly embossed. To form the disposed pouch 900, the innermost heat seal layers of the first laminated structure and second laminated structure are heat sealed together at peripheral portions of the first and second laminated structures at edges of the cavity except for the opening 930 as illustrated. As shown in Fig. 9B, the disposable pouch 900 can incorporate an access feature 940, which is illustrated as a perforated tear line in Fig. 9B. This tear line provides a simple and direct method for accessing the contents within the pouch post-sealing. By way of embossing the first and second laminated structures, the resulting disposable pouch has an increased volume of the cavity increasing the capacity for loading a product into the disposable pouch.

[0079] Still referring to Figs. 9A and 9B, the shape and size of the central embossed portion 920 may be varied depending on the specifics of the product filling process and the nature of the product. Figs. 10A and 10B illustrate two examples of a female die of the embossing mold. In one example, as shown in Fig. 10A, the depth of the emboss DA may be uniformly about 3mm. In another example, the depth of the emboss DA may be uniformly at least 0.5 mm. In another example, the depth of the emboss DA may be uniformly at least 1 mm. In another example, the depth of the emboss DA may be uniformly at least 1.5 mm. In another example, the depth of the emboss DA may be uniformly at least 2 mm.

[0080] In another example, as shown in Fig. 10B, the depths of the emboss, DBI and DB2 may be about 1.5 mm to about 3 mm, depending on the location of the emboss. In another example, the emboss may have a variable depth of at least 0.1 mm. In another example, the emboss may have a variable depth of at least 0.2 mm. In another example, the emboss may have a variable depth of at least 0.3 mm. In another example, the emboss may have a variable depth of at least 0.5 mm. In another example, the emboss may have a variable depth of at least 0.7 mm. In another example, the emboss may have a variable depth of at least 1 mm. In another example, theemboss may have a variable depth of at least 1 .5 mm. In another example, the emboss may have a variable depth of at least 2 mm.

[0081] Referring to Fig. 11A, the access feature 1140 may be located on the opposite side of the opening 1130, unlike the example in Fig. 9. The first and the second laminated structures may be heat sealed together along the peripheral portions for the first heat sealing 1110, 1111, 1112 forming a disposable pouch 1100 with an opening on the bottom. The second heat sealing 1120 may enclose the cavity after loading of a product. In other words, the product filling may be done through the bottom of the disposable pouch. In this approach, the preformed weaknesses 1170, 1171, 1172, which facilitate loading of a product into the cavity, do not need to extend to the access feature 1140, thereby potentially avoiding interference with the access feature 1140.

[0082] Some access features 1140 including, but not limited to, notches, creases, and partial cut tear lines may be place on both the first and second laminated structures before they arc heat sealed together forming the disposable pouch 1100. Fig. 1 IB illustrates a close-up view of the access feature 1140 of Fig. 11 A. In the current example, the access feature involves both notches 1150 and a tear line 1160. While Fig. 11 A only shows the first laminated structure, the second laminated structure may also have identical features as the first laminated or alternating perforations on each laminated structure. These double-sided features may provide better tearing guidance.

[0083] Referring to Figs. 12A, 12B and 12C, one iteration of an access feature 1200 may be a combination of notches 1210 and creases 1230, 1231, 1232, 1233, 1234, 1235. These creases may provide bending and tearing guidance to consumers. Many different configurations are possible depending on the number of creases. Referring to Fig. 12A, one example of the access feature 1200 may involve notches 1210 and a crease 1230. As shown in Fig. 12B, the access feature 1200 may involve notches 1210 and at two creases 1231, 1232. As shown in Fig 12C, the access feature 1200 may involve notches 1210 and at least three creases 1233, 1234, 1235.

[0084] Referring to Figs. 13A, 13B and 13C, another iteration of an access feature 1300 may be a combination of notches 1310 and partial cuts 1330, 1331, 1332, 1333, 1334, 1335. These cuts may be made before the first heat sealing 1110 of the first and second laminated structures forming a disposable pouch 1100. The partial cuts 1330, 1331, 1332, 1333, 1334, 1335 mayprovide better tear guidance than the simple creases 1230, 1231 , 1232, 1233, 1234, 1235 in Figs. 12A, 12B and 12C because partial cuts 1330, 1331, 1332, 1333, 1334, 1335 involve actual physical separation in the cellulosic substrate layer. Even though deeper partial cuts 1330, 1331, 1332, 1333, 1334, 1335 may provide better guidance in tearing, they may affect the performance of the disclosed disposable pouch near the partial cuts 1330, 1331, 1332, 1333, 1334, 1335. Referring to Fig. 13A, one example of the access feature 1300 may involve notches 1310 and a solid partial cut 1330. As shown in Fig. 13B, the access feature 1300 may involve notches 1310 and two solid partial cuts 1331, 1332. As shown in Fig 13C, the access feature 1300 may involve notches 1310 and at least three solid partial cuts 1333, 1334, 1335.

[0085] Fig. 14 illustrates a potential structure for the first and second laminated structures with a partial cut 1430. The partial cut 1430 is made on a paper board layer 1410 of the laminated structure 1400. Those skilled in the art may choose the right depth that strikes a balance between consumer convenience and performance. In one example, the depth of the partial cuts DCUT may be at least 5 percent of the thickness of the paperboard layer TPB. In another example, the depth of the partial cuts DCUT may be at least 10 percent of the thickness of the paperboard layer TPB. In another example, the depth of the partial cuts DCUT may be at least 15 percent of the thickness of the paperboard layer TPB. In another example, the depth of the partial cuts DCUT may be at least 20 percent of the thickness of the paperboard layer TPB. In another example, the depth of the partial cuts DCUT may be at least 25 percent of the thickness of the paperboard layer TPB. In another example, the depth of the partial cuts DCUT may be at least 30 percent of the thickness of the paperboard layer TPB. In another example, the depth of the partial cuts DCUT may be at least 40 percent of the thickness of the paperboard layer TPB. In another example, the depth of the partial cuts DCUT may be at least 50 percent of the thickness of the paperboard layer TPB. In another example, the depth of the partial cuts DCUT may be at least 60 percent of the thickness of the paperboard layer TPB. In another example, the depth of the partial cuts DCUT may be at least 70 percent of the thickness of the paperboard layer TPB.

[0086] Referring to Figs. 15 A, 15B, 15C, 15D and 15E, there may be various partial cut patterns that may be used. As shown in Fig. 15A, one example may involve a scallop pattern 1510, such as a 15 mm x 2.5 mm scallop pattern 1510. As shown in Fig. 15B, another example may involve a single wave pattern 1520, such as a 15 mm single wave pattern 1520. As shown inFig. 15C, another example may involve a perforated pattern 1530, such as a 15mm perforated pattern 1530. As shown in Fig. 15D, another example may involve a staggered pattern 1540, such as a 15mm staggered pattern 1540. As shown in Fig 15E, another example may involve an S Rule pattern 1550, such as a 15mm S Rule pattern 1550. The exact specification of each pattern may be determined by those skilled in the art based on the application.

[0087] Fig. 16 illustrates one example of the disclosed disposable pouch with a length L of 120 mm and a height H of 200 mm. Those skilled in the art will appreciate that various lengths L and heights H may be used, depending on application, among other things. The disposable pouch 1600 may be formed by the first heat sealing 1610 the first and second laminated structures, which include the central embossed portion 1650, on three peripheral portions of the pouch 1600. The second heat sealing 1620 portion is left open until a product is loaded into the pouch 1600. In this example, the location of the central embossed portions LE is 32mm from the top edge of the laminated structures. The distance between the top of the central embossed portion 1650 and the tear line LTE may be set to 5-8 mm, for example, to ensure that the tearing does not deviate into the central embossed portion 1650, which can disrupt the whole tearing process. The distance between the tear line and the edge of the top heat sealing LT may be as little as 1 mm.

[0088] Still referring to Fig. 16, thicknesses of the heat sealings Ti, To, T3 may vary depending on the specific applications. The thicker the sealing portion, the stronger the pouch, but the smaller the cavity for a product. Those skilled in the art may choose appropriate thicknesses for the heat sealings Ti, T2, T3. In one example, the thicknesses of the heat sealing for the sides Tl are at least 7 mm while the thickness of the heat sealing for the top T2 and the bottom T3 are at least 9 mm. In another example, thicknesses of the heat sealings Ti, T2, T3 may be at least 1 mm. In another example, thicknesses of the heat sealings Ti, T2, T3 may be at least 3 mm. In another example, thicknesses of the heat sealings Ti, T2, T3 may be at least 5 mm. In another example, thicknesses of the heat sealings Ti, T2, T3 may be at least 7 mm. In another example, thicknesses of the heat sealings Ti, T2, T3 may be at least 10 mm. In another example, thicknesses of the heat sealings Ti, T2, T3 may be at least 20 mm.

[0089] Fig. 17 illustrates one example of a microscopic view of a grain direction 1710 in relation to an access feature, including a notch 1730 and a tear line 1750. The orientation of thegrain direction 1710 may affect the tearing performance. The more parallel the grain is oriented with the tearing direction, the better the performance of the tearing, without deviating from the predetermined direction of the tear line 1750. In the current example, the grain direction is substantially parallel to the tear line 1750, which may result in a better tearing experience. In another example, the grain direction may be substantially perpendicular to the tear line 1750 which may negatively affect the tearing performance.

[0090] Further, the disclosure comprises examples according to the following clauses:

[0091] Clause 1. A disposable pouch, comprising: a first laminated structure having: a cellulosic substrate; an innermost heat seal layer; and an intermediate polymer film coated with a barrier material disposed between the cellulosic substrate and the innermost heat seal layer; a second laminated structure having: a cellulosic substrate; an innermost heat seal layer; and an intermediate polymer film coated with a barrier material disposed between the cellulosic substrate and the innermost heat seal layer; and a cavity between the first laminated structure and the second laminated structure for positioning a product therein, wherein the innermost heat seal layers of the first and second laminated structures are heat sealed together at peripheral portions of the first and second laminated structures at edges of the cavity.

[0092] Clause 2. The disposable pouch of Clause 1 , wherein the first and the second laminated structures have an Oxygen Transmission Rate (OTR) of 50 cc / mA2.day@23C / 0%RH or less.

[0093] Clause 3. The disposable pouch of Clause 1, wherein the first and the second laminated structures have an Oxygen Transmission Rate (OTR) of 20 cc / mA2.day @23C / 0%RH or less.

[0094] Clause 4. The disposable pouch of Clause 1, wherein the first and the second laminated structures have an Oxygen Transmission Rate (OTR) of 5 cc / mA2.day@23C / 0%RH or less.

[0095] Clause 5. The disposable pouch of Clause 1, wherein the first and the second laminated structures have a Water Vapor Transmission Rate (WVTR) of 5 g / mA2.day @38C / 90%RH or less.

[0096] Clause 6. The disposable pouch of Clause 1 , wherein the first and the second laminated structures have a Water Vapor Transmission Rate (WVTR) of 2 g / mA2.day @38C / 90%RH or less.

[0097] Clause 7. The disposable pouch of Clause 1, wherein the first and the second laminated structures have a Water Vapor Transmission Rate (WVTR) of 0.5 g / mA2.day@38C / 90%RH or less.

[0098] Clause 8. The disposable pouch of Clause 1, wherein the cellulosic substrate has a grain direction that is substantially parallel to a tear line.

[0099] Clause 9. The disposable pouch of Clause 1, wherein the cellulosic substrate has a grain direction that is substantially perpendicular to a tear line.

[0100] Clause 10. The disposable pouch of Clause 1, wherein the first laminated structure and the second laminated structure are folded portions of a single laminated structure connected by a fold line.

[0101] Clause 11. The disposable pouch of Clause 10, wherein the innermost heat seal layers of the first and second laminated structures are not heat sealed together at the fold line.

[0102] Clause 12. The disposable pouch of Clause 1, wherein the first laminated structure and the second laminated structure are separate laminated structures.

[0103] Clause 13. The disposable pouch of Clause 1, wherein an unsealed peripheral portion of the first and second laminated structures provides an opening for product loading to the cavity.

[0104] Clause 14. The disposable pouch of Clause 1, having a product in the cavity and wherein the cavity is completely sealed.

[0105] Clause 15. The disposable pouch of Clause 1, wherein at least one of the first laminated structure and the second laminated structure include one or more preformed weaknesses about which the laminated structure may be bent.

[0106] Clause 16. The disposable pouch of Clause 1 , wherein at least one of the first laminated structure and the second laminated structure arc embossed to increase a volume of the cavity.

[0107] Clause 17. The disposable pouch of Clause 1, wherein the innermost heat seal layer of at least one of the first and second laminated structures comprises a polyolefin or a copolymer of polyolefin.

[0108] Clause 18. The disposable pouch of Clause 1, wherein the intermediate polymer film coated with a barrier material of at least one of the first and second laminated structures comprises a metallized or metal oxide coated film from the family of polyesters or polyolefins.

[0109] Clause 19. The disposable pouch of Clause 1, wherein at least one of the first and second laminated structures further comprises a first tie layer between the cellulosic substrate and the intermediate polymer film coated with a barrier material.

[0110] Clause 20. The disposable pouch of Clause 19, wherein the first tie layer comprises a polyolefin.

[0111] Clause 21. The disposable pouch of Clause 1, wherein at least one of the first and second laminated structures further comprises a second tie layer between the intermediate polymer film coated with a barrier material and the innermost heat seal layer.

[0112] Clause 22. The disposable pouch of Clause 21, wherein the second tie layer comprises a polyolefin or functional copolymers of polyolefins.

[0113] Clause 23. The disposable pouch of Clause 1, further comprising an access feature.

[0114] Clause 24. The disposable pouch of Clause 23, wherein the access feature comprises a notch and a tear line.

[0115] Clause 25. The disposable pouch of Clause 24, wherein the tear line comprises a crease.

[0116] Clause 26. The disposable pouch of Clause 24, wherein the tear line comprises a partial cut having a depth of at least 10 percent of a thickness of the cellulosic substrate.

[0117] Clause 27. The disposable pouch of Clause 24, wherein the tear line comprises a partial cut having a depth of at least 20 percent of a thickness of the cellulosic substrate.

[0118] Clause 28. The disposable pouch of Clause 24, wherein the tear line comprises a partial cut having a depth of at least 30 percent of a thickness of the cellulosic substrate.

[0119] Clause 29. The disposable pouch of Clause 1, wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion has a uniform depth of at least 1 mm.

[0120] Clause 30. The disposable pouch of Clause 1, wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion has a uniform depth of at least 2 mm.

[0121] Clause 31. The disposable pouch of Clause 1, wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion has a uniform depth of at least 3 mm.

[0122] Clause 32. The disposable pouch of Clause 1, wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion has a variable depth of at least 1.5 mm.

[0123] Clause 33. The disposable pouch of Clause 1, wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion has a variable depth of at least 3 mm.

[0124] Clause 34. The disposable pouch of Clause 1, wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion is located at least 2 mm away from a tear line.

[0125] Clause 35. The disposable pouch of Clause 1, wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion is located at least 4 mm away from a tear line.

[0126] Clause 36. The disposable pouch of Clause 1 , wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion is located at least 6 mm away from a tear line.

[0127] Clause 37. The disposable pouch of Clause 1, wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion is located at least 8 mm away from a tear line.

[0128] Clause 38. The disposable pouch of Clause 1, wherein at least one of the first and second laminated structures are at least one of folded and embossed or include one or more preformed weaknesses.

[0129] Clause 39. The disposable pouch of Clause 38, wherein the first and the second laminated structures have an Oxygen Transmission Rate (OTR) of 50 cc / mA2.day@23C / 0%RH or less.

[0130] Clause 40. The disposable pouch of Clause 38, wherein the first and the second laminated structures have an Oxygen Transmission Rate (OTR) of 20 cc / mA2.day@23C / 0%RH or less.

[0131] Clause 41. The disposable pouch of Clause 38, wherein the first and the second laminated structures have an Oxygen Transmission Rate (OTR) of 5 cc / mA2.day@23C / 0%RH or less.

[0132] Clause 42. The disposable pouch of Clause 38, wherein the first and the second laminated structures have a Water Vapor Transmission Rate (WVTR) of 5 g / rnA2.day @38C / 9O%RH or less.

[0133] Clause 43. The disposable pouch of Clause 38, wherein the first and the second laminated structures have a Water Vapor Transmission Rate (WVTR) of 2 g / mA2.day@38C / 90%RH or less.

[0134] Clause 44. The disposable pouch of Clause 38, wherein the first and the second laminated structures have a Water Vapor Transmission Rate (WVTR) of 0.5 g / mA2.day@38C / 90%RH or less.

[0135] Although various examples of the disclosed disposable pouch have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

Claims

What is claimed is:

1. A disposable pouch, comprising: a first laminated structure having: a cellulosic substrate; an innermost heat seal layer; and an intermediate polymer film coated with a barrier material disposed between the cellulosic substrate and the innermost heat seal layer; a second laminated structure having: a cellulosic substrate; an innermost heat seal layer; and an intermediate polymer film coated with a barrier material disposed between the cellulosic substrate and the innermost heat seal layer; and a cavity between the first laminated structure and the second laminated structure for positioning a product therein, wherein the innermost heat seal layers of the first and second laminated structures are heat sealed together at peripheral portions of the first and second laminated structures at edges of the cavity.

2. The disposable pouch of Claim 1, wherein the first and the second laminated structures have an Oxygen Transmission Rate (OTR) of 50 cc / mA2.day@23C / 0%RH or less.

3. The disposable pouch of Claim 1, wherein the first and the second laminated structures have a Water Vapor Transmission Rate (WVTR) of 5 g / mA2.day @38C / 90%RH or less.

4. The disposable pouch of Claim 1, wherein the cellulosic substrate has a grain direction that is substantially parallel to a tear line.

5. The disposable pouch of Claim 1, wherein the first laminated structure and the second laminated structure are folded portions of a single laminated structure connected by a fold line.

6. The disposable pouch of Claim 1 , wherein the first laminated structure and the second laminated structure arc separate laminated structures.

7. The disposable pouch of Claim 1, wherein an unsealed peripheral portion of the first and second laminated structures provides an opening for product loading to the cavity.

8. The disposable pouch of Claim 1, having a product in the cavity and wherein the cavity is completely sealed.

9. The disposable pouch of Claim 1, wherein at least one of the first laminated structure and the second laminated structure include one or more preformed weaknesses about which the laminated structure may be bent.

10. The disposable pouch of Claim 1, wherein at least one of the first laminated structure and the second laminated structure are embossed to increase a volume of the cavity.

11. The disposable pouch of Claim 1, wherein the innermost heat seal layer of at least one of the first and second laminated structures comprises a polyolefin or a copolymer of polyolefin.

12. The disposable pouch of Claim 1, wherein the intermediate polymer film coated with a barrier material of at least one of the first and second laminated structures comprises a metallized or metal oxide coated film from the family of polyesters or polyolefins.

13. The disposable pouch of Claim 1, wherein at least one of the first and second laminated structures further comprises a first tie layer between the cellulosic substrate and the intermediate polymer film coated with a barrier material.

14. The disposable pouch of Claim 1, wherein at least one of the first and second laminated structures further comprises a second tie layer between the intermediate polymer film coated with a barrier material and the innermost heat seal layer.

15. The disposable pouch of Claim 1 , further comprising an access feature.

16. The disposable pouch of Claim 15, wherein the access feature comprises a notch and a tear line.

17. The disposable pouch of Claim 1, wherein at least one of the first and second laminated structures are at least one of folded and embossed or include one or more preformed weaknesses.

18. The disposable pouch of Claim 1, wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion has a uniform depth of at least 1 mm.

19. The disposable pouch of Claim 1, wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion has a variable depth of at least 1.5 mm.

20. The disposable pouch of Claim 1, wherein at least one of the first laminated structure and the second laminated structure comprises an embossed portion, and wherein the embossed portion is located at least 2 mm away from a tear line.

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