Recycle-ready laminate structure for optimal barrier in a folded package configuration

Abstract

An improved configuration for a multilayer recycle-ready film laminate for use in a polyolefin-based package having a folded portion in an assembly. The recycle-ready laminate includes a first layer, a second layer having a barrier layer positioned on the second layer opposed to the first layer, and a third layer. The first and third layers are outer layers of the laminate with the first layer having a first major surface aligned with an exterior of the package and the third layer having a second major surface aligned with an interior of the package. The third layer is a sealing layer. Positioning the barrier layer adjacent to the sealing layer maintains and improves the barrier properties of the laminate when folded and compared to traditional and standard recycle-ready laminates for packaging subjected to retort processing

Description

[0001] RECYCLE-READY LAMINATE STRUCTURE FOR OPTIMAL BARRIER IN A FOLDED PACKAGE CONFIGURATION

[0002] TECHNICAL FIELD

[0003]

[0001] This disclosure is related to an improved configuration for a multilayer recycle-ready film for use in a package having a folded portion in an assembly. More particularly. this disclosure is related to multilayer recycleready films having a barrier layer position selected to minimize the action of compressive forces on the barrier layer when utilized in packaging requiring a folded assembly.

[0004] BACKGROUND

[0005]

[0002] It has become increasingly desirable to design flexible packaging structures that are more sustainable, increased sustainability may be in the form of using raw materials that are renewably resourced, such as paper or starch-based polymers. Increased sustainability may also be in the form of an end-of-life solution that is something other than waste, such as recyclable options. For flexible packaging that is used for extended shelf-life food products, it can be difficult to match the required performance properties to any of these more sustainable options.

[0006] [0031 in addition to the packaging design challenges, flexible packages that hold moisture-rich food products must have sufficient oxygen and water vapor transmission barrier properties to maintain the integrity of the package and the contents within the interior of the package during use. Typically, these packages require a shelf-life from 3 to 18 months, in certain packaging styles, such as, but not limited to a stand-up pouch (“SUP”), a barrier layer is positioned as a sandwiched layer between a pair of oriented film layers. In this configuration, the barrier layer is protected by the pair of stable oriented webs which are less prone to shrinkage or deformation as deformation or shrinkage of materials adjacent to the barrier layer can cause a fracture or small cracks to develop within the barrier affecting the barrier capability of the barrier layer.

[0007]

[0004] in addition to the normal demands of a flexible film laminate when used in a typical package, the stand-up pouch requires a fold or a crease during assembly to generally form a gusset. This folding of the flexible laminate creates a compressive force on each of the various layers of the laminate, including a barrier layer placed within the assembly. When this barrier layer comprises an inorganic barrier layer, such as an aluminum oxide (“AIOx") or silicon oxide (“SiOx"), the inherent brittle nature of these coatings is especially susceptible to compressive cracks resulting in the potential of barrier failure.

[0008]

[0005] Accordingly, to compensate for the brittle nature of these inorganic barrier coatings when utilized in recycle-ready flexible laminates for package assemblies requiring a fold, improvements are necessary to prevent cracking and degradation of the barrier component within these flexible laminates during use.

[0009] SUMMARY

[0010]

[0006] The developments described herein include multilayer film structures having specific layers within the multilayer film structure in a designated position relative to the use of the multilayer film structure in a package configuration that includes a fold. This folded area, often in the form of a gusset within a package, is particularly susceptible to a degradation of the barrier properties of the multilayer film due to the inherent compression and stress placed on sensitive barrier layer materials when subject to being arranged in this folded position When package configurations having a fold are used for items that are subjected to retort processing, protection of the sensitive barrier layer is increased due to the harsh conditions of high humidity, temperatures, and pressures associated with the typical retort process

[0011]

[0007] In addition to improved barrier properties associated with folded package assemblies, the multilayer film structures described herein are comprised of a combination of materials that enable the package to be considered recyclable or recycle-ready. Accordingly, the materials comprising the multilayer film structure are comprised of similar polyolefins, wherein they may be considered to comprise mono-polyolefins, such as, but not limited to, a mono-polyprcpylene structure. This combination of similar materials allows the multilayer film comprising the package to be recycled within a dedicate recycling stream, such as, but not limited to, a polypropylene-based or recycling stream.

[0012]

[0008] The recyclable and / or recycle-ready multilayer film laminates of the present disclosure are configured for use in specific package types having a fold or gusset within their assembly with the package generally defining an interior package space. The laminate of the multilayer film includes a first layer of a polyolefin, a second layer, and a third layer. The second layer is adjacent to this first layer with the second layer comprising a polyolefin of the same type of polyolefin of the first layer. This second layer includes a barrier layer with this barrier layer positioned on the second layer in a position opposed the adjacency of the first layer. A third layer is positioned adjacent the barrier layer and forms a sealing layer comprising a polyolefin of the same type as the polyolefin of the first layer and the second layer with the position of this third layer placed in an alignment with the package interior. The position of the first layer, the second layer, the barrier layer, and the third layer relative to each other and the package interior space is specifically selected to prevent a loss of barrier properties when the iaminate is placed in a folded position in packages requiring a fold in package assembly.

[0013]

[0009] in an alternate embodiment of the recyclable multilayer film laminate of the present disclosure an adhesive is placed between the first layer and the second layer and between the barrier layer and the third layer

[0014]

[0010] In another embodiment of the recyclable multilayer film laminate according to the present disclosure and previous alternate embodiment, the polyolefin of the first layer is polypropylene Accordingly, to the keep the multilayer film recyclable and comprised of a mono-material structure, the selection of the first layer being a polypropylene requires the second layer and the sealing layer to be comprised of polypropylene as well.

[0015]

[0011] in some embodiments, the barrier layer is selected to comprise an inorganic coating.

[0016]

[0012] in another aspect which may be combined with any other embodiment or aspect, the inorganic coating is selected to comprise a coating of aluminum oxide (AIOx) or silicon oxide (SiOx).

[0013] In another aspect, which may be combined with any other embodiment or aspect, the first layer and the second layer comprise an orientation, wherein the first iayer and the second layer comprise oriented layers.

[0017]

[0014] In yet another aspect, which may be combined with any other aspect or embodiment, the multilayer laminate has an has an oxygen transmission rate of about less than i .0 cm3 / m2 / day measured according to ASTM Fl 927 using conditions of 1 atmosphere, 23’C and 50% RH in the folded area after retort at 127”C for period of 50 minutes.

[0018]

[0015] In one aspect, which may be combined with any other aspect or embodiment, the disclosure provides a recycle-ready laminate with a layered composition selected to optimize the integrity of the barrier properties when using the laminate in packages requiring a fold. The laminate includes a first layer of an oriented polyolefin having a first side and a second side opposed the first side with the first side being an outer side and first major surface. A second iayer being an oriented polyolefin of the same type as the first iayer is positioned adjacent to the second side of the first layer. The second iayer includes an inorganic barrier layer positioned opposite the first layer. A third layer forming a sealing layer and comprising a polyolefin of the same type as the first layer and second layer is positioned adjacent to the inorganic barrier layer, wherein the positioning of the third layer relative to the barrier layer is specifically selected to prevent the loss of barrier properties of the barrier layer by reducing tension upon the barrier layer when the laminate is folded during package assembly,

[0019] [016j in another aspect, which may be combined with any other aspect or embodiment, the disclosure provides a recyclable stand-up package and / or pouch having a folded portion or gusset with the folded portion or gusset of the stand-up package comprising a multilayer film. The stand-up package is constructed from a multilayer film comprising a first layer of an oriented polyolefin having an outer surface being aligned with an exterior of the standup package A second layer comprising an oriented polyolefin of the same type as the first layer is positioned adjacent the first layer opposed to the outer surface. An inorganic barrier layer is positioned on the second layer opposed to the first layer with a sealing layer comprising a polyolefin of the same type as the first layer and the second layer positioned adjacent to the inorganic barrier layer opposed to the second Sayer. The sealing layer has an inner surface positioned opposed to the inorganic barrier layer with the inner surface being aligned with an interior of the package. The position of the inorganic barrier layer in adjacency to the sealing layer and towards the package interior relative to the first layer and the second layer is specifically selected to prevent the loss of barrier properties of the film when the film is manipulated to form a folded or a gusset portion during assembly of the stand-up package.

[0020] BRIEF DESCRIPTION OF THE DRAWINGS

[0021] [017j The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings, in which:

[0022]

[0018] FIG. 1 is a cross-sectional view of a first embodiment of a recyde- ready laminate having an optimal barrier position for use in packaging requiring a fold:

[0023] [0191 FIG. 2 is a cross-sectional view of another embodiment of a recycleready laminate having an optimal barrier position for use in packaging requiring a fold;

[0024]

[0020] FIG. 3 is a cross-sectional view of the first embodiment of a recycleready laminate having an optimal barrier position for use in packaging requiring a fold with the laminate in a folded position: and

[0025]

[0021] FIG. 4 is a cross-sectional view of a package having a fold and comprising a recycle-ready laminate having an optimal barrier position.

[0026]

[0022] The drawings show some but not ail embodiments. The elements depicted in the drawings are illustrative and not necessarily to scale, and the same (or similar) reference numbers denote the same (or similar) features throughout the drawings

[0027] DETAILED DESCRIPTION

[0028]

[0023] The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments, which are also referred to herein as “examples,” are described in enough detail to enable those skilled in the art to practice the invention. The embodiments may be combined, other embodiments may be utilized, or structural, and logical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be token in a limiting sense. Before the present invention is described in such detail, however, it is to be understood that this invention is not limited to particular variations set forth and may, of course, vary.

[0029] Definitions

[0030]

[0024] The following terms are used throughout as defined below.

[0031]

[0025] As used herein and in the appended claims, singular articles such as “a” and “an” and “the" and similar referents in the context of describing the elements (especially in the context of the following claims) are io be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. Ail methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and al! examples, or exemplary language (e.g. , “such as”) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the claims unless otherwise stated. No language in the specification should be construed as indicating any non-claimed element as essential.

[0032]

[0026] As used herein, “about” will be understood by persons of ordinary skill in the art and will vary to some extent depending upon the context in which it is used, if there are uses of the term which are not clear to persons of ordinary skill in the art, given the context in which it is used, “about” will mean up to pius or minus 10% of ths particular term - for example, “about 10 wt.%” would be understood to mean "9 wt.% to 11 wt.%.” It is to be understood that when “about” precedes a term, the term is to be construed as disclosing “about” the term as well as the term without modification by “about” - for example, "about 10 wt.%” discloses “9 wt.% to 1 1 wt.%” as well as disclosing “10 wt / A”

[0033]

[0027] The phrase “and / or” as used in the present disclosure will be understood to mean any one of the recited members individually or a combination of any two or more thereof - for example, “A, 8, and / or C” would mean “A, B, C, A and B, A and C. B and C, or the combination of A, B, and

[0034]

[0028] The term “polyolefin”, as used herein, refers to homopolymers or copolymers, including, for example, bipolymers, terpolymers, etc., having a methylene linkage between monomer units which may be formed by any method known to those having skill in the art. Non-limiting examples include low density polyethylene (LDPE), high density polyethylene (HDPE), ethylene alpha-olefin copolymers (EAO) preferably utilizing butene-1 , hexene-1 , or octene- 1 comonomer with a predominate ethylene comonomer portion and including, e g , linear low density polyethylene (LL.DPE), very low density polyethylene (VLDPE), metaliocene-catalyzed linear low density polyethylene (mLLDPE), plastomers, and elastomers, copolymers of ethylene and polar groups such as vinyl acetate (VA), methyl acrylate (MA), or acrylic acid (AA), e g., ethylene vinyl acetate copolymer (EVA) or ethylene methyl acrylate copolymer (EMA) or ethylene acrylic acid copolymer (EAA), ionomers, functional group-modified polymers including, e.g., anhydride-modified polyolefins Propylene and butene-1 homopolymers including polypropylene and polybutene-1 as well as copolymers of varying proportions of ethylene, propylene and butene-1 are useful.

[0035]

[0029] As used throughout this application, the term "polypropylene” or "PR” refers to a elastomer, homopolymer or copolymer having at least one propylene monomer linkage within the repeating backbone of the polymer. The propylene linkage may be represented by the general formula: [CH2CH(CH3)]n. Such polypropylene may be a polypropylene impact copolymer, a polypropylene random copolymer, ora polypropylene homopolymer, may be syndiotactic or isotactic, or may or may not be clarified,

[0036]

[0030] As used herein, a “laminate11is a film that may be built from an unlimited number of films and / or layers, the films and / or layers being bonded together by any known process such as, but not limited to, coextrusion, coating or laminating, to form a composite article.

[0037]

[0031] The term “layer1*, as used herein, refers to a building block of a film that is a structure of a single material type or a homogeneous blend of materials. A layer may be a single polymer, a blend of materials within a single polymer type or a blend of various polymers, may contain metallic materials and may have additives. Layers may be continuous with the film or may be discontinuous or patterned. A layer has an insignificant thickness (z direction) as compared to the length and width (x-y direction), and therefore is defined to have two major surfaces, the area of which are defined by the length and width of the layer. An outer layer is one that is connected to another layer at only one of the major surfaces. In other words, one major surface of an outer layer is exposed. An inner layer is one that is connected to another layer at both major surfaces. In other words, an inner layer is between two other layers. A layer may have sub-layers.

[0038]

[0032] As used throughout this application, the term “package” refers to any component or combination of components used to wholly or partially surround a product. A package may take many, various forms. For example, the term “package” may include pouches that wholly surround a product (or products) to be packaged, such as a stand-up pouch: the term “package” may also include films, sheets, etc. that partially surround a product (or products) to be packaged and, when used in conjunction with another film, sheet, etc. wholly surround a product (or products).

[0039] [0331 As used herein, the term “adjacent" means that the items, such as layers of a film, are near each other, with or without intervening material, such as adhesive. As used herein, the term “directly adjacent* or “in direct contact with” means that the items are in contact with each other, without intervening material.

[0040]

[0034] As used herein, a “retort packaging fiSm” or “retort packaging” is a film, or package made from the film, that can be filled with product, seated, and remain hermetically sealed after being exposed to a typical retort sterilization process. Typical retort sterilization is a batch process that uses temperatures from about 100’C to about 150”C, over-pressure up to about 70psi (483 kPa), and may have a duration from a few minutes up to several hours. Common retort processes used for products packaged in flexible films include steam or water immersion. Food or other products packaged in retort packaging film and retort sterilized can be stored at ambient conditions for extended periods of time (i.e., are shelf-stable), retaining sterility. Because the retort process is incredibly abusive, very specialized flexible packaging films have been designed to survive the process.

[0041]

[0035] “Inorganic coating layer as used herein refers to a layer that comprises a metal layer or an oxide coating layer. These layers function for barrier purposes. The inorganic coating layer may be vacuum deposited (i.e., vacuum coated, vapor coated, vacuum metaiized) directly on the surface of the buffer layer. Alternatively, the inorganic coating layer may be deposited by wet chemistry methods, such as solution coating. Accordingly, the inorganic coating layer may comprise silicon oxide (SiOx) or aluminum oxide (AIOx).

[0042]

[0036] As used herein, “recyclable” refers to packaging that passes the standards for collection, sorting, and recycling as it currently exists in a specific region.

[0043]

[0037] As used herein “recycle-ready” is used to refer to packaging that is intentionally designed and produced to enable recycling in certain streams based on material choices and global guidance, such as, but not limited to a polypropylene-based recycling stream.

[0044]

[0038] As described herein, a layer and / or film may be oriented. Orientation may be the result of monoaxially oriented (machine direction or transverse direction). or biaxially oriented (machine direction and transverse direction) stretching of the film, increasing the machine direction and / or transverse direction dimension and subsequently decreasing the thickness of the materia!. Biaxial orientation may be imparted to the film simultaneously or successively. Stretching in either or both directions is subjected to the film in ths at a temperature just below the melt temperature of the polymers in the film In this manner, the stretching causes the polymer chains to “orient” , changing the physical properties of the film. At the same time, the stretching thins the film. The resulting oriented films are thinner and can have significant changes in mechanical properties such as toughness, heat resistance, stiffness, tear strength and barrier. Orientation is typically accomplished by a double- or triple-bubble process, by a tenter-frame process or an MDO process using heated roils. A typical blown film process does impart some stretching of the film, but not enough to be considered oriented as described herein. An oriented film may be heat set (i.e., annealed) after orientation, such that it is relatively dimensionally stable under elevated temperature conditions that might be experienced during conversion of the retort film laminate (i.e., printing or laminating) or during the use of the laminate (i.e., heat sealing or retort sterilization).

[0045]

[0039] As used herein, the term "adhesive layer," or “tie layer," refers to a layer or material placed on one or more layers or films to promote the adhesion of that layer or film to another surface. For example, tie layers may be positioned between two layers of a multilayer film to maintain the two layers in position relative to each other and prevent undesirable delamination. In another example, adhesive layers may be positioned between two films of a laminate to maintain the two layers in position relative to each other and prevent undesirable delamination.

[0046]

[0040] As used herein, “barrier” or “barrier film” or “barrier layer” or “barrier material” or “barrier coating” refers to providing for reduced transmission to gases such as oxygen (i.e., containing an oxygen barrier material). The barrier material may provide reduced transmission to moisture (i.e., containing a moisture barrier material) The barrier characteristic may be provided by one or more, or a blend, of multiple barrier materials. The barrier layer may provide the specific barrier required to preserve the product within a package throughout an extended shelf-life which may be several months or even more than one year.

[0047]

[0041] As used herein, the term “fold” or “folded” means to bend over on to itself and the bend of the fold may have a sharp or rounded edge. This bent over shape may be described as being "V-shaped,” wherein the fold has an apex at a convergence of the bent over surfaces. Accordingly, the V-shape can alternately be described as generally having a narrow portion and a wide portion with the apex being the narrow-most point of the narrow portion. The term “dead fold” refers to fold that is not capable of unfolding spontaneously, such as a fold in a soft foil material.

[0048]

[0042] As used herein, the term “gusset” refers to a folded portion of a flexible pouch, such as a stand-up pouch, which includes at least three folds in the flexible film defining one or more a central folds that extend inwardly toward the interior of the product volume and two folds disposed on opposite sides of the central fold, the two folds extending outwardly away from the central fold. Gussets are also variously known as tucks, pleats, joints, couplings, and gatherings. Gussets can be arranged to provide stability in a flexible pouch, for example, by creating a face for the flexible pouch to rest on. Gussets can also be used to increase the volume of the flexible pouch, for example by creating a three-dimensional shape rather than a two-dimensional shape from a flexible material. A flexible pouch can include one or more gussets disposed at any portion of the flexible pouch, such as the botom, top, and / or one or more sides of the flexible pouch.

[0049]

[0043] The term ’’outer layer” as used herein refers to one or more layers of a film that are on either major surface of the film , i.e. , the layers that are not between two other layers of that film. A film has an exterior surface that becomes the exterior of a package in which the film is used When formed into a package, the exterior surface of the film is exposed to the environment. A film has an interior surface that becomes the interior of a package in which the film is used. When formed into a package, the interior surface is used for forming seals and is exposed to the packaged product.

[0050]

[0044] As used herein, a “sealing layer” is a layer comprising a composition configured to affix the film to another structure or itself, such as a surface of a package or packaging film, via fusion bonding or chemical bonding, such as adhesion. For example, the sealing layer may comprise a heat sealable polymeric composition The sealing layer forms one of the two major surfaces of the film.

[0051]

[0045] As used herein, the term “interior is used to describe a film, layer or surface that is located in a position such that it is at or near the packaged product when the film is used in a packaging application. This layer is aligned towards the product and is located such that when a product is placed in the package, it becomes possible for the product to contact this layer.

[0052]

[0046] There is a need for improved barrier properties associated with packaging configurations having a fold and being subjected to retort processing. Further, this need for improved barrier properties is particularly needed for structures that can be considered recyclabie or recycle-ready. The solutions presented herein tackle this issue through the formation of a laminate having a specific positioning of a barrier layer in adjacency to a sealing layer that is aligned with an interior space of a package assembly utilizing or requiring a told. Generally, when subjected to folds in package assembly, the barrier layer of a laminate may become compromised due to the compressive nature and stress placed on barrier materials when folded. Accordingly, by utilizing the positioning of the barrier layer to be more aligned with the interior package space when folded, this compressive stress is reduced, and barrier integrity is maintained

[0053]

[0047] The recycle-ready laminate disclosed herein includes a first layer, a second layer including a barrier layer, and a third layer, as will be detailed and discussed below. An embodiment of a recycle-ready laminate 10 is shown as FIG. 1 , wherein the laminate includes a first layer 191 , a second layer 102 adjacent the first layer 101 and including a barrier layer 103, and a third layer 104 adjacent the barrier layer 103. Accordingly, the barrier layer 103 is 105 between the first layer 101 and the second layer 102. In some embodiments, ths adhesive layer 105 is positioned between the barrier layer 103 and the third layer 104. in some embodiments, a pair of adhesive layers 105 are positioned between both the first layer 101 and the second layer 102 and between the barrier layer 103 and the third layer 104. The adhesive 105 may be solvent-based, solvent-free or water-based. Commercially available adhesives may have base reactive chemistry of isocyanate Alternatively, the films and / or layers of the laminate 10 may be connected to one another by other means such as extrusion lamination, using an extruded polymer for bonding, coextrusion or thermal lamination.

[0054]

[0051] The first layer 101 being an outer layer of the laminate 10 is positioned as the exterior surface of a package 300 having a told 301 (FIG. 4) when the laminate 10 is formed into the package 300. The first layer 101 , while being the exterior surface the package 300. is aligned with an interior-most position of ths fold, as is shown in FIG. 3 which generally illustrates the relative position of the multilayers (101 , 102, 103, 104) of the laminate 10 in a package having a gusset. In this position, the first layer 101 is under compressive stress along with the rest of the layers of the laminate 10.

[0055] However, as shown (FIG. 3), the interior-most positioning of the first layer 101 relative to the fold results in more compressive stress when compared to the other layers, including the barrier layer 103. Accordingly, as a result of the positioning of the barrier layer 103 relative to the fold, the barrier layer 103 is placed under tension as opposed to the compression experienced by the first layer 101.

[0056]

[0052] The second layer 102 is a polyolefin of the same type as the first layer 101 and is positioned as an inner layer between the first layer 101 and the barrier layer 103. The second layer 102 is adjacent the first layer 101 and includes the barrier layer 103 positioned on the second layer 102 opposed to the first layer 101.

[0057] [0531 The barrier layer 103 is a barrier coating generally utilized to provide barrier properties to the laminate 10 by reducing the transmission of moisture and / or oxygen. The barrier layer 103 may be a metaiized layer. The barrier layer 103 may be an inorganic deposition that is liquid coated or deposited for forming the barrier layer, such as, but not limited to oxides of silicon (SiOx) or aluminum (AIOx). This barrier layer 103 may be a vacuum deposited barrier layer. The barrier layer 103 may be deposited by way of an atmospheric atomic layer deposition.

[0058]

[0054] The third layer 104 is positioned adjacent the barrier layer 103 and is comprised of the same polyolefin as the first layer 181 and the second layer

[0059] 102. The third layer 104 is a sealing layer and is positioned as an outer layer of the laminate 10 including a second major surface 140 in alignment with an interior space 302 of the package 300 The third layer 104 in reference to the fold 301 of the package 300, is aligned with an exterior-most position of the fold at the apex, as is shown in FIG. 3. In this position, the third layer 104 is under the least amount of compressive stress relative to the fold when compared to the other layers and is considered, along with the barrier layer

[0060] 103, to be under tension as opposed to compression

[0061]

[0055] in embodiments of the multilayer laminate 10 the first layer 101 may comprise orientation, wherein the first layer 101 is an oriented layer. In embodiments the second layer 102 may comprise orientation, wherein the second layer 102 is an oriented layer. In further embodiments, the first layer 101 and the second layer 102 may both comprise orientation, wherein the first layer 101 and the second layer 102 are oriented layers.

[0062]

[0056] To ensure adequate barrier properties, in embodiments, the recycleready laminate 10 has an oxygen transmission rate of about less than 1 .0 cm3 / m2 / day measured according to ASTM Fl 927 using conditions of 1 atmosphere, 23’C and 50% RH in the folded area after retort at 127°C for period of 50 minutes.

[0063]

[0057] in one aspect, which may be combined with any other aspect or embodiment, the disclosure provides for use of the recycle-ready laminate 10 with the layered composition and relative position of the layers (101 , 102, 103, 104) specifically selected to optimize the integrity of the above barrier properties when using the laminate 10 in packages requiring a fold.

[0064] [0581 Referring now to FIG. 4, in another aspect, which may be combined with any other aspect or embodiment, the package 300 is a recyclable standup package and / or pouch formed from recycle-ready laminate 10 having the folded portion 301 or gusset. As is generally shown, the position of the barrier layer in adjacency to the sealing layer second major surface 140 and towards

[0065] IS the package interior 302 relative to the folded portion 301 is specifically selected to prevent the loss of barrier properties of the film when the film is manipulated to form a folded or a gusset portion during assembly of the stand-up package and subjected to retort conditions. Accordingly, package 300 may be considered to be a retort package comprised of a retort packaging film.

[0066] EXAMPLES AND DATA

[0067]

[0059] A series of four laminates were tested to confirm the improved barrier properties of a recycle-ready retort package. Specific film structures and layer properties are shown in Table 1. These are adhesive laminations of the structure from package exterior to package interior as read left to right. For each barrier layer, a notation (*) is made to show which direction the barrier layer was facing

[0068]

[0060] Cl is a recycle-ready laminate for packages having a fold with the barrier positioned adjacent to the package exterior having the structure of a 25p oriented polypropylene outer film adhesively laminated to an inorganic barrier layer formed on a 19p oriented polypropylene film adhesively laminated to 60p cast polypropylene sealing film, in this laminate, the barrier layer is positioned adjacent to the outer layer aligned with the package exterior.

[0069]

[0061] Al is the inventive structure with optimized barrier layer placement in a laminate for packages having a fold. This structure is a recycle-ready laminate of a 25p oriented polypropylene outer film adhesively laminated to a 19p oriented polypropylene film with an inorganic barrier layer opposite the outer film adhesively laminated to a 60p cast polypropylene sealing film. In this laminate the barrier layer is positioned adjacent to the sealing layer and aligned with the package interior.

[0070]

[0062] C2 is two ply recycle-ready laminate for packages having a fold with the barrier positioned adjacent to the package exterior having the structure of a 19p oriented polypropylene film having an inorganic barrier layer adhesively laminated to a 60p cast polypropylene sealing film.

[0071]

[0063] C3 is conventional non-recyclable laminate for packages having a fold with the barrier positioned adjacent to the package exterior having the structure of a polyethy lene terephthalate (PET) outer film with inorganic barrier layer adhesively laminated to 15p oriented polyamide film adhesively laminated to a 60y cast polypropylene sealing film.

[0072] Table 1: Structures and Components of Tested Laminates

[0073]

[0064] The structures of Table 1 were subjected to laboratory testing for the determination of oxygen transmission rate according to ASTM Fl 927 using conditions of 1 atmosphere, 23OC and 50% RH in the folded area before and after retort at 127°C for period of 50 minutes. To simulate the presence of a fold in a padcage, sheets of the above laminates were folded over onto themselves in the machine direction with the sealing layer facing outward relative to the fold, as generally shown in FIG. 3. To further ensure consistency of the folding, a dead-fold crease at the apex of the fold was formed by compression in a controlled nip to simulate the forces present in packaging machine formation. Barner was then measured on the materials of Table 1 prior to retort The samples were then subjected to a steam retort process at 127°C for period of 50 minutes. To ensure that the representative folds stayed dosed to simulate a gusset, the folds were held dosed with paperclips in order to prevent the fold / simulated gusset from opening during the retort cycle Laminates were tested is both flat and folded positions before and after retort. Results of the testing are shown below in Table 2.

[0074] Table 2: Oxygen Barrier Properties of Tested Laminates OTR cc / m2 / d 23 ”C 50% RH - Retort 127°C, 50 min

[0075]

[0065] The OTR analysis and laboratory testing confirms the importance of the placement of the barrier layer relative to the fold. Laminates Cl and At are comprised of the same material and general structure with the exception of the positioning of the barrier layer on the second layer. Al has altered the position of the barrier layer relative to the fold. When comparing the results of testing for laminate Cl and Al , the data clearly indicates that this movement of the barrier in closer adjacency to the sealing layer improves oxygen transmission in folded areas. Since this folded area is generally the main point of barrier loss, it is confirmed that laminate Al has improved barrier properties due to the positioning of the barrier layer doser to the package interior and towards an exterior of the apex of the fold.

[0076] RECYCLE-READY LAMINATE AND PACKAGE EMBODIMENTS

[0077]

[0066] Embodiment A. A recycle-ready laminate for use in a package requiring a folded assembly to define an interior package space, the recycle-ready laminate comprising:

[0078] [0S7] a first layer, the first layer being a polyolefin:

[0079]

[0068] a second layer adjacent the first layer, the second layer being a polyolefin of the same type of polyolefin of the first layer, the second layer including a barrier layer, the barrier layer positioned on the second layer opposed the first layer:

[0080]

[0069] a third layer adjacent the barrier layer, the third layer forming a sealing layer and being a polyolefin of the same type of polyolefin as the first layer and the second layer, the third layer configured for positioning in an alignment with the interior package space:

[0081]

[0070] wherein the positioning of the barrier layer adjacent to the third layer and on the second layer opposed the first layer is selected to prevent a loss of barrier properties when the laminate is placed in a folded position in package assembly by placing the barrier layer closer to the interior space adjacent the third layer.

[0082]

[0071] Embodiment B. The recycle-ready laminate as embodiment A, wherein an adhesive is placed between the first layer and the second layer and between the barrier layer and the third layer.

[0072] Embodiment C. The recycle-ready laminate as in embodiments A or B, wherein the polyolefin of the first layer is polypropylene.

[0083]

[0073] Embodiment D. The recycle-ready laminate as in any of embodiments A to C, wherein the barrier layer comprises an inorganic barrier coating.

[0084]

[0074] Embodiment E. The recycle-ready laminate as in embodiment D, wherein the inorganic barrier coating comprises silicon oxide (SiOx) or aluminum oxide (AIOx).

[0085] [0751 Embodiment F. The recycle-ready iaminate of any embodiments A to E, wherein the first layer and the second layer are oriented.

[0086]

[0076] Embodiment G. The recycle-ready iaminate of any of embodiments A to F, wherein the laminate has an oxygen transmission rate of about less than 1.0 cm3 / m2 / day measured according to ASTM Fl 927 using conditions of 1 atmosphere, 23°C and 50% RH in the folded area after retort at 127°C for period of 50 minutes.

[0087]

[0077] Embodiment H. A recycle-ready laminate with a layered composition selected to optimize the integrity of barrier properties for a package having a fold, the recycle-ready laminate comprising:

[0088]

[0078] a first layer, the first layer being an oriented polyolefin film having a first side being an outer side and first major surface of the recycle-ready iaminate and in alignment with an exterior of the package having a fold;

[0089]

[0079] a second layer adjacent to the first layer, the second layer being an oriented polyolefin film of the same type as the first layer;

[0090]

[0080] an inorganic barrier layer, the inorganic barrier layer positioned on the second layer opposed to the first layer;

[0091]

[0081] a third layer, the third layer positioned adjacent to the inorganic barrier layer, the third layer forming a sealing layer and being a polyolefin of the same type as the first layer and the second layer, the third layer being an outer layer of the iaminate and having a second major surface, the second major surface in an alignment with an interior of the package requiring a fold:

[0092] [0821 wherein the positioning of the third layer adjacent to the inorganic barrier layer is selected to prevent the loss of barrier properties by reducing tension upon the barrier layer when the recycle-ready laminate is in a folded position during assembly of the package.

[0083] Embodiment I. The recycle-ready laminate as in embodiment H, wherein an adhesive is placed between the first layer and the second layer and between the barrier layer and the third layer.

[0093]

[0084] Embodiment J. The recycle-ready laminate as in embodiment H or I, wherein the polyolefin of the first layer is polypropylene.

[0094]

[0085] Embodiment K. The recyde-ready laminate as in any of embodiments H to J, wherein the inorganic barrier layer is a coating that comprises silicon oxide (SiOx) or aluminum oxide (AIOx).

[0095]

[0086] Embodiment L. The recycle-ready laminate of any of embodiments H to K, wherein the laminate has an oxygen transmission rate of about less than 1.0 cm3 / m2 / day measured according to ASTM Fl 927 using conditions of 1 atmosphere, 23!5C and 50% RH in the folded area after retort at 127*C for period of 50 minutes.

[0096]

[0087] Embodiment M. A stand-up package being recycle-ready and having a folded portion or a gusset portion, at least the folded portion or the gusset portion of the stand-up package comprising:

[0097]

[0088] a recycle-ready film, the recycle-ready film comprising:

[0098]

[0089] a first layer, the first layer comprising an oriented polyolefin, the first layer having a first major surface, the first major surface being an exterior of the stand-up package:

[0099]

[0090] a second layer, the second layer comprising an oriented polyolefin of the same type as the first layer, the second layer positioned adjacent the first layer opposed to the first major surface;

[0100]

[0091] an inorganic barrier layer, the inorganic barrier layer positioned on the second layer opposed to the first layer:

[0101]

[0092] a sealing layer, the sealing layer comprising a polyolefin of the same type as the first layer, the sealing layer positioned adjacent the inorganic barrier layer, the sealing layer having a second major surface, the second major surface opposed the barrier layer, the second major surface being an interior of the package; and

[0102]

[0093] wherein the position of the inorganic barrier layer adjacent the sealing layer and relative to the Interior of the package is selected to prevent the loss of barrier properties when the multilayer film is manipulated to form the folded portion necessary to form the stand-up package.

Claims

CLAIMSWhat is claimed is:1 . A recycle-ready laminate for use in a package requiring a folded assembly to define an interior package space, the recycle-ready laminate comprising: a first layer, the first layer being a polyolefin: a second layer adjacent the first layer, the second layer being a polyolefin of the same type of polyolefin of the first layer, the second layer including a barrier layer, the barrier layer positioned on the second layer opposed the first layer: a third layer adjacent the barrier layer, the third layer farming a sealing layer and being a polyolefin of the same type of polyolefin as the first layer and the second layer, the third layer configured for positioning in an alignment with the interior package space; wherein the positioning of the barrier layer adjacent to the third layer and on the second layer opposed the first layer is selected to prevent a loss of barrier properties when the laminate is placed in a folded position in package assembly by placing the barrier layer closer to the interior space adjacent the third layer,2, The recycle-ready laminate as in claim 1 , wherein an adhesive is placed between the first layer and the second layer and between the barrier layer and the third layer.

3. The recycle-ready laminate as in claim 1 or 2, wherein the polyolefin of the first layer is polypropylene,4, The recycle-ready laminate as in any of claims 1 to 3, wherein the barrier layer comprises an inorganic barrier coating.

5. The recycle-ready laminate as in claim 4, wherein the inorganic barrier coating comprises silicon oxide (SiOx) or aluminum oxide (AIOx).

6. The recycle-ready laminate of any of claims 1 to 5, wherein the first layer and the second layer are oriented.

7. The recycle-ready laminate of any of claims 1 to 6, wherein the laminate has an oxygen transmission rate of about less than 1 .0 cm3 / m2 / day measured according to ASTM Fl 927 using conditions of 1 atmosphere, 23’C and 50% RH in the folded area after retort at 127°C for period of 50 minutes.8 A recycle-ready laminate with a layered composition selected to optimize the integrity of barrier properties for a package having a fold, the recycle-ready laminate comprising: a first layer, the first layer being an oriented polyolefin film having a first side being an outer side and first major surface of the recycle-ready laminate and in alignment with an exterior of the package having a fold; a second layer adjacent to the first layer, the second layer being an oriented polyolefin film of the same type as the first layer; an inorganic barrier layer, the inorganic barrier layer positioned on the second layer opposed to the first layer: a third layer, the third layer positioned adjacent to the inorganic barrier layer, the third layer forming a sealing layer and being a polyolefin of the same type as the first layer and the second layer, the third layer being an outer layer of the laminate and having a second major surface, the second major surface in an alignment with an interior of the package requiring a fold:wherein the positioning of the third layer adjacent to the inorganic barrier layer is selected to prevent the loss of barrier properties by reducing tension upon the barrier layer when the recycle-ready laminate is in a folded position during assembly of the package.9 The recycle-ready laminate as in claim 8, wherein an adhesive is placed between the first iayer and the second layer and between the barrier iayer and the third layer.

10. The recycle-ready laminate as in claim 8 or 9, wherein the polyolefin of the first iayer is polypropylene.11 . The recycle-ready laminate as in any of claims 8 to 10. wherein the inorganic barrier iayer is a coating that comprises silicon oxide (SiOx) or aluminum oxide (AiOx).12 The recycle-ready laminate of any of claims 8 to 11 , wherein the laminate has an oxygen transmission rate of about less than 1 .0 cm3 / m2 / day measured according to ASTM Fl 927 using conditions of 1 atmosphere, 23*C and 50% RH in the folded area after retort at 127*C for period of 50 minutes13 A stand-up package being recycle-ready and having a folded portion or a gusset portion, at least the folded portion or the gusset portion of the stand-up package composing: a recycle-ready film, the recycie-ready film comprising: a first iayer, the first iayer comprising an oriented polyolefin, the first layer having a first major surface, the first major surface being an exterior of the stand-up package; a second iayer, the second layer comprising an oriented polyolefin ofthe same type as the first layer, the second layer positioned adjacent the first layer opposed to the first major surface; an inorganic barrier layer, the inorganic barrier layer positioned on the second layer opposed to the first layer; a sealing layer, the sealing layer comprising a polyolefin of the same type as the first layer, the sealing layer positioned adjacent the inorganic barrier layer, the sealing layer having a second major surface, the second major surface opposed the barrier layer, the second major surface being an interior of the package; and wherein the position of the inorganic barrier layer adjacent the sealing layer ano relative to the interior of the package is selected to prevent the loss of barrier properties when the multilayer Him is manipulated to form the folded portion necessary to form the stand-up package.

14. The stand-up package as in claim 13, wherein the multilayer layer film includes an adhesive between the first layer and the second layer and between the barrier layer and the sealing layer.15 The stand-up package as in claim 13 or 14, wherein the multilayer film first layer oriented polyolefin is polypropylene.16 The stand-up package as in any of claims 13 to 15, wherein the inorganic barrier layer comprises silicon oxide (SiOx) or aluminum oxide (AIOx).

17. The stand-up package as in any of claims 13 to 16, wherein the multilayer film has an oxygen transmission rate of about less than 1 .0 cm3 / m2 / day measuredaccording to ASTM Fl 927 using conditions of 1 atmosphere. 23°C and 50%RH in the folded area after retort at 127*0 for period of 50 minutes.

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