Enhanced sealing for flexile packaging

Abstract

A packaging material and packages made therefrom are shown and described herein. The packaging material comprises a sealing configuration comprising a combination of sealable materials. In embodiments, the sealable materials may be selected from a heat sealable film, a heat seal coating material, and / or a cold seal coating material. The combination of the sealable materials provides enhanced sealing that allows for sealing at high line speeds during packaging.

Description

PATENT APPLICATION Docket No.: 55334-00027 IR9712ENHANCED SEALING FOR FLEXILE PACKAGINGFIELD OF INVENTION

[0001] The present technology relates to packaging material and packages or components for a package comprising such packaging material. In particular, the present technology relates to packaging material comprising a sealing configuration comprising a plurality7of seal materials. The plurality of seal materials provides enhanced sealing outcomes when forming a package or a component for a packaging material (e.g., a cover, lid, etc.) from a flexible packaging material.BACKGROUND

[0002] Packaging materials formed from polymeric and sometimes paper-based materials are employed to form flexible packages for housing or storing a variety of products include both food and non-food products. The ability to form a suitable seal in the formation of the package, and particularly to achieve effective sealing in high speed production, can be a challenge. Additionally, recyclable materials, and particularly those employing paper, face sealing challenges due to the insulative properties of paper.SUMMARY

[0003] The following presents a summary7of this disclosure to provide a basic understanding of some aspects. This summary is intended to neither identify key or critical elements nor define any limitations of embodiments or claims. Furthermore, this summary may provide a simplified overview of some aspects that may be described in greater detail in other portions of this disclosure.

[0004] In one aspect, provided is a packaging material configured to provide enhanced sealing when forming the package. The packaging material comprises a combination of sealable materials. In embodiments, the sealable materials may be selected from a heat sealable film, a heat seal coating material, and / or a cold seal coating material. The combination of the137604174.1sealable materials provides enhanced sealing that allows for sealing at high line speeds during packaging. Additionally, the enhanced sealing may be particularly useful in applications for packaging products requiring or employing a modified atmosphere within the package (e.g., nitrogen filled head space). The enhanced sealing may allow for faster lines speeds and quicker sealing to ensure or provide that hermeticity' required in such applications.

[0005] In one aspect, provided is a packaging material comprising: a structural film and a sealing configuration comprising sealing materials selected from at least two of a heat seal film, a heat seal coating, and a cold seal coating.

[0006] In one embodiment, the structural film is a heat seal film and is part of the sealing configuration.

[0007] In one embodiment, the sealing configuration comprises a heat seal coating disposed on a lower surface of the heat seal film.

[0008] In one embodiment, the sealing configuration comprises a cold seal coating disposed on a lower surface of the heat seal film.

[0009] In one embodiment, the sealing configuration comprises a heat seal coating disposed on a lower surface of the heat seal film, and a cold seal coating disposed on the heat seal coating.

[0010] In one embodiment, the structural film comprises an inner film and an outer film, wherein the inner film is a heat seal film and is part of the sealing configuration.

[0011] In one embodiment, the wherein the sealing configuration comprises a heat seal coating disposed on a lower surface of the heat seal film.

[0012] In one embodiment, the sealing configuration comprises a cold seal coating disposed on a lower surface of the heat seal film.

[0013] In one embodiment, the sealing configuration comprises a heat seal coating disposed on a lower surface of the heat seal film, and a cold seal coating disposed on the heat seal coating.

[0014] In one embodiment, the outer film is selected from a polymeric film.

[0015] In one embodiment, the outer film is a paper-based film.

[0016] In one embodiment, the structural film comprises a film that is not heat sealable, and the sealing configuration comprises a heat seal coating and a cold seal coating.

[0017] In one embodiment, the structural film comprises an inner film and an outer film, and the heat seal coating is disposed on a lower surface of the inner film, and the cold seal coating is disposed on the heat seal coating.

[0018] In one embodiment, the inner film is a polymeric film.237604174.1

[0019] In one embodiment, the outer film is a polymeric film.

[0020] In one embodiment, the outer film is a paper-based film.

[0021] In another aspect, provided is a package comprising the packaging material of any of the previous aspects or embodiments.

[0022] In one embodiment, the package is formed from the packaging material.

[0023] In one embodiment, the package comprises a container having an lower end and an upper end distal to the lower end. a container wall disposed between the upper end and the lower end and defining an container interior, and a lid disposed over the upper end of the container, wherein the lid comprises the packaging material.

[0024] The following description and the drawings disclose various illustrative aspects. Some improvements and novel aspects may be expressly identified, while others may be apparent from the description and drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings illustrate various systems, apparatuses, devices and related methods, in which like reference characters refer to like parts throughout, and in which:

[0026] FIGURE 1 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology;

[0027] FIGURE 2 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology;

[0028] FIGURE 3 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology;

[0029] FIGURE 4 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology;

[0030] FIGURE 5 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology7;

[0031] FIGURE 6 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology;

[0032] FIGURE 7 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology;

[0033] FIGURE 8 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology;337604174.1

[0034] FIGURE 9 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology;

[0035] FIGURE 10 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology;

[0036] FIGURE 11 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology;

[0037] FIGURE 12 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology;

[0038] FIGURE 13 is a cross-sectional view of an embodiment of a packaging material in accordance with aspects of the present technology.DETAILED DESCRIPTION

[0039] Reference will now be made to exemplary embodiments, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made. Moreover, features of the various embodiments may be combined or altered. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments. In this disclosure, numerous specific details provide a thorough understanding of the subject disclosure. It should be understood that aspects of this disclosure may be practiced with other embodiments not necessarily including all aspects described herein, etc.

[0040] As used herein, the words “example” and “exemplary” means an instance, or illustration. The words “example” or “exemplary” do not indicate a key or preferred aspect or embodiment. The word “or” is intended to be inclusive rather than exclusive, unless context suggests otherwise. As an example, the phrase “A employs B or C,” includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C). As another matter, the articles “a” and “an” are generally intended to mean “one or more” unless context suggest otherwise.

[0041] As used herein, “recyclable” refers to a material that is acceptable into a recycling program. The recyclable material may be a polymeric material or a paper-based material. A recyclable paper-based product that is acceptable into a paper recycling program. As used herein, “repulpable” refers to a product that can be reused or remade into paper. As used herein, a paper-based packaging material in accordance with the present technology is considered to be recyclable if it meets the standard for recyclability according to the "Voluntary 437604174.1Standard for Repulping and Recyling Corrugated Fiberboard Treated to Improve its Performance in the Presence of Water and Water Vapor” (Revised August 16, 2013). which is incorporated herein by reference in its entirety.

[0042] Provided is a packaging material and packages comprising such packaging material. The packaging material may be employed to form all or part of a package, e.g., a flexible package. The packaging material may be employed to form the entirety of the package or it may be employed to form a portion of a package such as. for example, a cover, a lid, or the like.

[0043] The packaging material comprises a combination of sealable materials. The combination of different sealable materials has been found to provide enhanced sealing of a flexible packaging film. In accordance with aspects of the present technology, the packaging film comprises a combination of sealable materials, wherein the sealable materials are selected from at least two of a heat sealable film, a heat seal coating, and a cold seal coating. In one embodiment, the packaging material comprises a heat sealable film and a heat seal coating. In one embodiment, the packaging material comprises a heat sealable film and a cold seal coating. In one embodiment, the packaging material comprises a heat sealable film, a heat seal coating, and a cold seal coating. In one embodiment, the packaging material comprises a heat seal coating and a cold seal coating.

[0044] In embodiments, the packaging material comprises a film layer that functions as a heat sealable film. In such embodiments, the heat sealable film forms a part of the base film of the packaging material. In one embodiment, the packaging material may be a single film construction comprising the heat sealable film as the base film, and the sealing configuration further comprises a heat seal coating and / or a cold seal coating disposed on the heat seal film.

[0045] In still other embodiments, the packaging material comprises a heat sealable film and one or more additional structural layers. Such multi-layered configurations still comprise a sealing configuration that includes a heat seal coating and / or a cold seal coating disposed on the heat sealable film. The additional structural layers may be selected from, for example, polymeric film layers, paper layers, or a combination of film layers and paper layers. The packaging material may include other materials such as adhesives to join adjacent film or structural layers. The packaging material may also include print layers, protective coatings (e.g., overprint varnishes, lacquers, etc.), barrier layers, and the like.537604174.1

[0046] Referring to the figures, various non-limiting embodiments of flexible packaging materials comprising the improved sealing configurations are shown. FIGURES 1-8 show embodiments of a packaging material comprising a heat seal film layer.

[0047] FIGURES 1 and 2 show an embodiment of a single film construction comprising a heat seal film as the base film of the packaging material. In FIGURE 1, the packaging material includes a single film construction 100 comprising a heat seal film 110 as the base film and a heat seal coating 120 disposed on a lower surface of the heat seal film 110. In FIGURE 1, the heat seal coating is provided as a continuous coating disposed substantially over the entire surface of the heat seal film 110.

[0048] In FIGURE 2, the packaging material 100’ comprises the heat seal film 110 and a heat seal coating 120’ disposed on a lower surface of the heat sealable film. The heat seal coating 120’ is disposed as a discontinuous or patterned coating that does not cover the entire surface of the heat seal film 110. The discontinuous or patterned coating can be provided over selected or discrete regions or areas of the heat seal film configured to be sealed in the sealing operation.

[0049] In embodiments, the packaging material may be printed with an ink layer 130 to provide desired indicia or markings on the film such as branding, product information, etc. A protective layer such as a lacquer or overprint varnish 140 may be provide over the print / ink layer 130.

[0050] FIGURE 3 shows a packaging material 100” that is a single film construction comprising a heat seal film 110 as the base film, a heat seal coating 120 disposed on a lower surface of the heat seal film 110, and a cold seal adhesive 150 disposed on the heat seal coating. In FIGURE 3, the heat seal coating and cold seal adhesive are provided as a continuous coating disposed substantially over the entire surface of the heat seal film 110. It will be appreciated that either or both the heat seal coating and / or the cold seal adhesive may be provided as a discontinuous coating.

[0051] FIGURE 4 is a packaging material 100’” that is a single film construction comprising a heat seal film 110 as the base film and a cold seal adhesive 160 disposed on a lower surface of the heat seal film 110. In FIGURE 4, the cold seal adhesive 160 is provided as a continuous coating disposed substantially over the entire surface of the heat seal film 110. It will be appreciated that the cold seal adhesive could be provided as a discontinuous coating.

[0052] FIGURE 5 illustrates an embodiment of a packaging material 200 comprising a multi-film construction. A multi-film construction may comprise two or more film layers adhered to or otherwise bonded to one another. In FIGURE 5, packaging material 200637604174.1comprises a heat sealable film layer 210 and an outer film 230 joined together via an adhesive layer 240. The packaging material comprises a heat seal coating 220 disposed on a lower surface of the heat sealable film 210. In the packaging material 200, the upper surface of the outer film may be printed with an ink 250 and include a lacquer or overprint varnish 260 over the print layer. The heat seal coating is shown as a discontinuous or patterned coating, but it will be appreciated that the heat seal coating may be provided as a continuous coating.

[0053] It will also be appreciated that the laminated film may be reverse printed such that the lower surface of the outer film is printed with the desired markings or indicia.

[0054] FIGURE 6 illustrates an embodiment of a packaging material 300 comprising a multi-layer laminate / construction. In FIGURE 6, packaging material 300 comprises a heat sealable film layer 310 and a paper layer 330 joined together via an adhesive layer 340. The packaging material comprises a heat seal coating 320 disposed on a lower surface of the heat sealable film 310. In the packaging material 300, the upper surface of the paper layer 330 may be printed with an ink 350 and include a lacquer or overprint varnish 360 over the print layer. The heat seal coating 320 in FIGURE 6 is shown as a continuous coating, but may be provided as a discontinuous or patterned coating. It will be appreciated that the packaging material of FIGURE 6 could include one more additional film layers between the heat sealable film and the paper layer and / or one or more additional film above the paper layer.

[0055] FIGURE 7 is a packaging material 400 that is a multi-film construction that comprises a cold seal adhesive in combination with a heat sealable film. The packaging material 400 includes a heat sealable film 410, an outer film 430, and a cold seal adhesive layer 420 disposed on a lower surface of the heat seal film. The cold seal film 420 is shown as being discontinuous or patterned but could optionally be a continuous coating. The packaging material 400 is shown as a reverse printed construction where the outer film is printed with an ink 450 on a lower surface of the outer film. The outer film is adhered to the heat sealable film layer via an adhesive or extrudate 440.

[0056] FIGURE 8 illustrates an embodiment of a packaging material 500 comprising a multi-film construction. In FIGURE 8, packaging material 500 comprises a heat sealable film layer 510 and an outer film 530 joined together via an adhesive layer 540. The packaging material comprises a cold seal coating 520 disposed on a lower surface of the heat sealable film 510. In the packaging material 500, the upper surface of the outer film may be printed w ith an ink 550 and include a lacquer or overprint varnish 560 over the print layer. The cold seal coating is shown as a discontinuous or patterned coating, but it will be appreciated that the cold seal coating may be provided as a continuous coating.737604174.1

[0057] FIGURE 9 is a packaging material 600 that is a multi-film construction that comprises a heat seal coating and a cold seal adhesive in combination with a heat sealable film. The packaging material 600 includes a heat sealable film 610, an outer film 640, a heat seal coating 620 disposed on a lower surface of the heat sealable film 610, and a cold seal adhesive 630 disposed on the heat seal coating. The cold seal adhesive 630 and heat seal coating are each shown as being discontinuous or patterned but either could optionally be provided as a continuous coating. The packaging material 600 is shown as a reverse printed construction where the outer film 640 is printed with an ink 660 on a lower surface of the outer film. The outer film is adhered to the heat sealable film layer via an adhesive or extrudate 650.

[0058] FIGURE 10 illustrates an embodiment of a packaging material 700 comprising a multi-film construction that comprises a heat seal coating and a cold seal adhesive in combination with aheat sealable film. In FIGURE 10, packaging material 700 comprises aheat sealable film layer 710 and an outer film 740 joined together via an adhesive layer 750. The packaging material comprises a heat seal coating 720 disposed on a lower surface of the heat sealable film 710, and a cold seal coating 730 disposed on the heat seal coating. In the packaging material 700, the upper surface of the outer film may be printed with an ink 760 and include a lacquer or overprint varnish 770 over the print layer. The heat seal coating and the cold seal coating are shown as a discontinuous or patterned coating, but it will be appreciated that either may be provided as a continuous coating.

[0059] A packaging film can be provided that does not include a heat sealable film as part of the film construction. Polymeric films that are not heat sealable may be employed in place of the heat sealable film. In such embodiments, the film will employ a heat sealable coating in combination with a cold seal adhesive.

[0060] FIGURE 11 shows an embodiment of a packaging material 800 comprising a polymeric film 810, aheat seal coating 820 disposed on a lower (inner) surface of the polymeric film 810, and a cold seal adhesive 830 disposed on the heat seal coating 820. The polymeric film 810 is a film that is not a heat sealable film. The packaging material may be provided w ith a print layer 850 and a protective layer 840 such as, for example, a lacquer or overprint varnish.

[0061] FIGURE 12 is a packaging material 900 that is a multi-film construction that comprises that comprises a plurality of polymeric films and does not include a heat sealable film and employs a combination of a heat seal coating and a cold seal adhesive. The packaging material 900 includes an inner film 910, an outer film 940, a heat seal coating 920 disposed on a lower surface of the inner film 910, and a cold seal adhesive 930 disposed on the heat seal coating. The cold seal film 930 and heat seal coating 920 are each show n as being discontinuous 837604174.1or patterned but either could optionally be provided as a continuous coating. The packaging material 900 is shown as a reverse printed construction where the outer film 940 is printed with an ink 950 on a lower surface of the outer film. The outer film is adhered to the inner film layer via an adhesive or extrudate 960.

[0062] FIGURE 13 illustrates an embodiment of a packaging material 1000 comprising a multi-film construction that comprises polymeric films other than a heat seal film, and employs a sealing configuration comprising a heat seal coating in combination with a cold seal adhesive. In FIGURE 13, packaging material 1000 comprises an inner film layer 1010 and an outer film 1040 joined together via an adhesive layer 1050. The packaging material comprises a heat seal coating 1020 disposed on a lower surface of the inner film 1010, and a cold seal coating 1030 disposed on the heat seal coating. In the packaging material 1000, the upper surface of the outer film may be printed with an ink 1060 and include a lacquer or overprint varnish 1070 over the print layer. The heat seal coating and the cold seal coating are shown as a discontinuous or patterned coating, but it will be appreciated that either may be provided as a continuous coating.

[0063] Heat Sealable Film

[0064] In accordance with the present technology, the sealing configuration for the packaging material may comprise a heat sealable film. The heat sealable film is a polymeric material that is capable of forming a seal to itself or a surface under the application of heat. The heat sealable film generally has the properties of softening of the polymeric material upon heating without melting the other layers in the film or the material to which it is being attached.

[0065] The heat sealable film may be designed to meet different conditions of expected use and various heat seal formulations are known in the art and may be employed with the present invention. The heat sealable film is heat sealable to itself, but may be sealable to other objects, films, layers, or materials, e.g. to a tray when used as a lidding film, or to an outer layer in a lap seal or in certain tray overwrap embodiments. In embodiments, the heat sealable cavitated film may have a seal initiation temperature that is above about 30 °C. In embodiments the seal initiation temperature of the cavitated heat sealable film is from above about 30 °C to about 130 °C.

[0066] The composition and construction of the heat sealable film may be selected as desired. Examples of suitable materials that can be used for the heat sealable film include, but are not limited to polyolefins, polyesters, ionomer films, ethylene / unsaturated ester copolymers, and the like.937604174.1

[0067] Examples of suitable polyolefin resins that may be used in the heat sealable film include, but are not limited to, homopolymers and copolymers of olefins having 2-8 carbon atoms, and copolymers of olefins having 2-8 carbon atoms with monomer(s). Examples of such olefin resins include, but are not limited to, high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density' polyethylene resin, and other such polyethylene, polypropylene, polyisobutylene, poly (1 -butene), poly-4-methylpentene, polyvinylcyclohexane, polystyrene, poly(p-methylstyrene), poly(a-methyl styrene), ethylene / propylene block copolymers, ethylene / propylene random copolymers, ethylene / butene-1 copolymers, ethylene / 4-methy 1-1 -pentene copolymers, ethylene / hexene copolymers, and other such a-olefin copolymers, ethylene / vinyl acetate copolymers, ethylene / aery lie acid copolymers, ethylene / methyl methacrylate copolymers, ethylene / vinyl acetate / methyl methacrylate copolymers, ionomer resins, and so forth may be cited. Moreover, it is also possible use chlorinated polyolefins obtained by chlorination of any of these polyolefins.

[0068] Particularly suitable olefin resins include low density’ polyethylene (hereinafter may be abbreviated as “LDPE”), polypropylene (PP) and polyethylene obtained by polymerization in the presence of a metallocene catalyst (hereinafter may be abbreviated as “M-LLDPE”). Further, in case where a resin material has a higher melting point higher than a desired seal initiation temperature, the melting point may be adjusted to the above defined range by blending the other resin thereinto to depress the melting point. Examples of LLDPE include, but are not limited to, LLDPE (commercial products). Unipole (by Union Carbide, Corporation), Dowlex (by Dow Chemical Company), Screar (by DuPont Canada), Marlex (by Philips), Neozex and Ultzex (by Mitsui Chemicals, Inc.), Nisseki Linirex (by Nippon Oil Corporation) and Stamirex (by DSM) are mentioned.

[0069] Another category of polymer resin suitable for a heat sealable film includes polyester materials. An example of a suitable polyester is ethylene / unsaturated ester copolymers. An ethylene / unsaturated ester copolymer may comprise any ethylene / unsaturated ester copolymer or derivative thereof. For example, the ethylene / unsaturated ester copolymer or derivative thereof may comprise one or more of ethylene / methyl acrylate copolymer, ethylene / methyl methacrylate copolymer, ethylene / ethyl acrylate copolymer, ethylene / ethyl methacrylate copolymer, ethylene / butyl acrylate copolymer, ethylene / 2-ethylhexyl methacrylate copolymer, ethylene / vinyl acetate copolymer, and blends thereof, and more particularly an ethylene / vinyl acetate copolymer or blends thereof.1037604174.1

[0070] Other examples of suitable polyesters suitable for a heat sealable film include homopolymers and copolymers of alkyl-aromatic esters. For example, the heat-seal film may comprise polyethylene terephthalate (PET), amorphous polyethylene terephthalate (APET), crystalline polyethylene terephthalate (CPET), glycol-modified polyethylene terephthalate (PETG), and polybutylene terephthalate. In some aspects, the heat-seal layer may comprise copolymers of terephthalate and isophthalate, such as, for example, polyethylene terephthalate / isophthalate copolymer. In some aspects, the heat-seal layer may comprise homopolymers and copolymers of aliphatic esters such as, for example, polylactic acid (PL A) and polyhydroxyalkonates, such as, for example, but not limited to, polyhydroxypropionate, poly(3-hydroxybutyrate) (PH3B), poly(3-hydroxyvalerate) (PH3V), poly(4-hydroxybutyrate) (PH4B), poly(4-hydroxyvalerate) (PH4V). poly(5-hydroxyvalerate) (PH5V), poly(6-hydroxydodecanoate) (PH6D), and blends thereof.

[0071] The heat sealable film may be a single layer film or may be a multi-layer film. Multi-layer films comprise two or more layers formed from selected polymeric materials. The polymeric materials that form the various layers of a multi-layer film may be the same or different from one another. Multi-layer films may be formed in any suitable manner such as, for example, co-extrusion of the polymeric materials to form the film.

[0072] The heat sealable film may be unoriented or may be an oriented film. The oriented films may be uniaxially or biaxially oriented.

[0073] In one embodiment, the heat seal film may be a cavitated film. Cavitated films comprise fillers configured to create voids within the film when the film is stretched. Cavitated films have lower densities than non-cavitated films and can be employed to reduce the weight of the film and packaging material.

[0074] The thickness of the heat seal film may generally be from about 10 pm to about 200 pm, from about 20 pm to about 175 pm, from about 25 pm to about 150 pm, from about 40 pm to about 125 pm, from about 50 pm to about 100 pm, or from about 75 pm to about 90 pm.

[0075] Heat Seal Coating (Adhesive)

[0076] Heat seal coatings are thermoplastic materials that can be coated onto a substrate, dried, and then reactivated by heat and pressure. Upon drying, they form a coating that can be heat-activated and bonded to other substrates. They are non-tacky materials at ambient temperature and become molten liquids upon heat activation during the product assembly process. The term “heat seal coating” and “heat seal adhesive” may be used interchangeably.1137604174.1

[0077] The heat seal coating may be chosen from any material suitable as a heat seal coating. The heat seal coating may be a solvent-based or water-based coating composition. Example of suitable classes of materials include, but are not limited to, ethylene vinyl acetate, polyolefins such as polyethylene, polypropylene, or the like, polyamides, polyvinyl chloride, and the like.

[0078] The heat seal coating may be applied to provide a dry coating weight in the range of about 2 to about 25 g / m2, about 5 g / m2to about 20 g / m2, about 8 g / m2to about 18 g / m2, or about 15 g / m2to about 15 g / m2.

[0079] Cold Seal Coating (Adhesive)

[0080] The cold seal coating can be any suitable material useful for sealing / adhering materials at temperatures between 0° C. and 30° C. Examples of suitable cold seal adhesive materials include, but are not limited to, natural or synthetic rubber or “latex’’.

[0081] An example of a suitable cold seal adhesive is a composition based on mixtures of natural or synthetic latex dispersions and one or more dispersions selected from an aqueous polyacrylic dispersion, a poly(meth)acrylate dispersion, an acrylate and / or methacrylate based co-polymer dispersion. An example is a cold seal adhesive composition containing 40-65% by weight of a natural latex emulsion, preferably with an ammonia content giving pH values of approximately 10, 20-50% by weight of a st rene-acr late emulsion, and small amounts (e.g., 1-5% by weight) of wetting agents, latex stabilizers, antioxidants, biocides, thickeners, and optionally tackifiers.

[0082] Another example of a suitable cold seal coating is a natural rubber comprising more than 50% but less than 90% natural latex in the formulation composition and one or more of the following components: acrylic polymer or copolymers; styrene acrylic polymer or copolymer where the monomers are mainly but not exclusively butyl acrylate, methyl methacrylate, and ethyl hexyl acrylate; styrene copolymer; and, vinyl acetate ethylene copolymer. The total synthetic polymer proportion of the cold-seal formulation my be from about 10% and 50% of the final composition.

[0083] The cold seal adhesive layer may completely or only partially be disposed on the reverse side of the second web of the multi-layer material or tag. A partially disposure is particularly advantageous to reduce cost or to avoid contact of the cold seal layer to the object in the final application. Preferably the cold seal layer is applied in stripes, most preferably in the web direction of both flexible webs. Nevertheless, any useful pattern of the cold seal adhesive may be chosen depending on the application. As the cold seal adhesive1237604174.1is only used in the areas which are contacted to each other in the final application only these areas need to have the adhesive.

[0084] The cold seal adhesive layer typically has a dry coating weight in the range of about 2 to about 25 g / m2, about 5 g / m2to about 20 g / m2, about 8 g / m2to about 18 g / m2, or about 15 g / m2to about 15 g / m2.

[0085] The packaging material may comprise structural layers such as one or more polymeric film layers (other than a heat sealable film), one or more paper layers, or a combination thereof. As discussed above, embodiments of the packaging material may include a heat sealable film. In embodiments comprising a heat sealable film, the heat sealable film will generally be provided as the inner most film or structural layer of the packaging material. In embodiments not comprising a heat sealable film, the polymeric film layer may be positioned as one of the lower layers that will be positioned toward the interior of the package formed from the packaging material.

[0086] Polymeric materials suitable for forming the structural layers may be chosen as desired for a particular purpose or intended application. The packaging material can be made to be recyclable or non-recyclable by selection of the polymenc materials for the structural layers. Examples of suitable polymers for forming the polymeric film layer include, but are not limited to, a polyolefin, a polyester, a polyamide, and the like. Examples of suitable polyolefins include, but are not limited to polyethylene, polypropylene, polybutylene, and the like. In one embodiment, the polyolefin is selected from polyethylene. The polyethylene is not particularly limited and can be selected from various types of polyethylene include, for example, a high density polyethylene, a medium density polyethylene, or a low density polyethylene. It will be appreciated that the polymer film layer can be formed from a blend of polymers, e.g., a blend of different polyolefins, a blend of a particular polyolefin (e.g., a blend of different polyethylenes), and the like.

[0087] Examples of suitable polyester materials include, but are not limited to, polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polyethylene isophthalate (PEI), poly cycloterephthalate (PCT), polytriethylene terephthalate (PT), and the like.

[0088] The polymeric materials may be oriented or non-oriented polymer films. Additionally, the polymeric materials can be single layer or multi-layer films.

[0089] The packaging material may comprise one or more paper layers. The recyclable flexible packaging film may comprise a recyclable paper, for example, a commercial fiber paper that is highly calendared.1337604174.1

[0090] The paper material may be modified or have incorporated therein various fillers (e.g., inorganic fillers) or other materials to provide or impart certain properties to the paper material. In embodiments, the paper material may have a polymer material incorporated in the material. The polymer material incorporated in the paper material should generally be provided to allow for the paper to still be recyclable if desired. Polymers that may be included in the paper material may include those described herein with respect to the optional polymeric film layers.

[0091] The thickness of the structural layers may be selected as desired for a particular purpose or intended application. In embodiments, structural layers formed from polymeric films may have a thickness of from about 4 pm to about 30 pm, from about 7 pm to about 25 pm, or from about 9 pm to about 20 pm.

[0092] The paper can have a weight as desired for a particular purpose or intended application. In embodiments employing paper as a structural layer in the packaging material, the paper can have a weight of from about 20 gsm to about 500 gsm, from about 50 gsm to about 250 gsm, or from about 100 gsm to about 200 gsm. In embodiments, the paper is a food grade paper. Food grade papers can be uncoated, single coated, double coated. The paper can be natural colored or include one or more pigments.

[0093] The packaging material may optionally include other layers to provide particular characteristics or properties to the packaging material. In embodiments the packaging material may include one or more barrier layers. The barrier layer can be configured as a gas barrier layer, a moisture layer, or as both a gas and moisture barrier layer.

[0094] Gas barrier layers may be, for example, oxygen barrier layers configured to have a selected oxygen transmission rate and low oxygen permeability if such is desired for a particular package application. Non-limiting examples of gas barrier layers include those comprising EVOH, poly vinylidene chloride, polyamide, polyester, poly alkylene carbonate, polyacrylonitrile, nanocomposite, a metallized film such as aluminum vapor deposited on a polyolefin, etc.

[0095] In embodiments, the packaging material may comprise a moisture barrier layer having a moisture permeability sufficiently low to protect the contents of the package from deteriorating or losing freshness or crispness. Non-limiting examples of moisture barrier layers include, but are not limited to, aluminum foil, PVDC, or polyolefins such as LDPE or LLDPE.

[0096] The thickness of the barrier layer(s) may be selected to provide the desired barrier performance. In embodiments, a barrier layer may have a thickness of from about 1 pm to about 5 pm, from about 2 pm to about 4 pm, or from about 1 pm to about 3 pm.1437604174.1

[0097] It will be appreciated that the packaging material can comprise one or more adhesive layers to adhere adjacent layers of the packaging material together. The adhesive is not particularly limited and can be selected by those skilled in the art for adhering adjacent layers of selected materials. Examples of suitable adhesives include, but are not limited to, acrylic adhesives, polyolefins, natural rubber, synthetic rubber, styrenic polymers, silicones, polyurethanes, and the like. Some examples include, but are not limited to, modified polyolefins, which are mostly based on LDPE or LLDPE co-polymers or. graft co-polymers with functional-group containing monomer units, such as carboxylic or glycidyl functional groups, e.g. (meth)acrylic acid monomers or maleic anhydride (MAH) monomers, (i.e. ethylene acrylic acid copolymer (EAA) or ethylene methacrylic acid copolymer (EMAA)), ethylene-glycidyl(meth)acrylate copolymer (EG(M)A) or MAH-grafted polyethylene (MAH-g-PE). When the packaging material is to be used for food packaging, the adhesives are generally selected from food-grade materials.

[0098] The packaging material can be formed in any suitable manner. The various structural layers (e.g., heat seal film, polymeric film layer, and / or paper layer) may be formed by adhesively laminating the respective layers to one another. The heat seal coating and / or the cold seal adhesive may be applied to the inner most structural layer (e.g., a polymeric film or heat seal film) via any suitable coating techniques such as, but not limited to, roller coating, meyer bar, die systems, or rotogravure. For the partial coating, the die system or rotogravure technique is preferred. The upper surface of the laminate can be subjected to a printing process (e.g., but not limited to, rotogravure printing, flexographic, digital printing, or the like) to apply graphics or indicia to the package. This can be done to the outermost paper layer prior or subsequent to formation of the bulk laminate (in a construction with multiple paper layers and / or polymeric film layers). The outer surface of the upper most paper layer may optionally be treated prior to printing to render the surface more receptive to the inks. Such treatments include corona discharge or flame treatment. Alternatively, the outer structural layer of the film can be reverse printed prior to lamination to an inner layer of the packaging material.

[0099] The upper surface of the laminate can be subjected to a printing process (e.g., but not limited to. rotogravure printing, flexographic, digital printing, or the like) to apply graphics or indicia to the package. This can be done to the outermost paper layer prior or subsequent to formation of the bulk laminate (in a construction with multiple paper layers and / or polymeric film layers). The outer surface of the upper most paper layer may optionally be treated prior to printing to render the surface more receptive to the inks. Such treatments include corona discharge or flame treatment.1537604174.1

[0100] The present packaging materials are provided for use in a package configured for housing or storing a product, e.g., a food item. The packaging material may be employed to form all of or a portion of a package for housing one or more items.

[0101] In embodiments, the packaging material may be used to form a flexible package (e.g., a pouch, bag, wrapper, or the like). The packaging can be formed from any suitable now known or later discovered packaging method. Examples of suitable methods for forming packaging include, but are not limited to. vertical form / fill / seal (VFFS), horizontal form / fill / seal (HFFS), thermoforming / lidstock, and continuous horizontal packaging. It will be appreciated that those skilled in the art will be capable of employing the present packaging fdm to provide the necessary conditions to form the shape of the packaging and effect sealing. In one embodiment of a flow wrapping process, the heat sealing jaws that compress sides of the packaging material to form the end seals may be configured such that the sealing jaws will penetrate into the packaging material to a selected depth. This may allow for increased efficiency in transfer of heat to particular layers such as, for example, where the packaging material comprises paper layer(s). In one embodiment, the packaging film can be employed to form a bag, pouch, or sachet. Such configurations are generally formed from multiple sheets of packaging film brought together to form the w alls of the package. A pouch or bag may be sealed in a fin seal or lap seal configuration. A sachet may have side seals and end seals. Fitments or other closures may be sealed to any part of the recyclable film.

[0102] In one embodiment, the packaging film is employed as a cover or lid for a container. The container may be, for example, a tray, cup, or the like. The container material is not particularly limited and can be selected as desired. The container material may be, for example, flexible, semi-rigid, or rigid. Examples of suitable materials for a container include, but are not limited to, polyester, polyolefin (e.g., polyethylene, polypropylene, etc.), polystyrene, polyvinyl chloride, paper, metal, glass, ceramic, and the like. The container will typically have an upper surface, and the package film is sealed to the upper surface of the container. The package film is sealed to the container such that the package film can be peeled away from the container body to expose the contents of the container. The cover or lid that is sealed to a container body by application of heat and pressure.

[0103] The sealing configuration may form a hermetic seal and hermetically sealed package. The terms “hermetic seal” or “hermetically sealed”, as used herein, refer to a seal that is maintained against the flow of air or fluid, in other words, an airtight or liquid proof seal.

[0104] The package may also be provided with a modified atmosphere wherein the package comprises a gaseous material other than atmospheric gas. In particular, it may be 1637604174.1desirable to replace or lower the content of oxygen or other oxidative gases in a package. Such modified atmosphere packages may be provided to reduce or eliminate atmospheric gases or free oxygen or other oxidative gases from the package. The package atmosphere may be modified by flushing the package with gases such as, but not limited to, carbon dioxide, nitrogen, argon, kry pton, xenon, etc.

[0105] The packaging film can be used to package any type of product. Examples of suitable products include, but are not limited to, foods, beverages, pharmaceuticals, nutraceuticals, cosmetics, medical products, electronic devices and products, wipes, etc. Examples of food products that can be packaged using the packaging films include, but are not limited, dry foods, frozen foods, fresh foods, refrigerated foods, and the like. Examples of food products include but are not limited to, cereals, chips, pretzels, bars (e.g., candy bars, protein bars, granola bars, etc.), nuts, raisins, pizzas, tortillas, gum, popcorn, a grain, a seasoning, popsicles, a frozen bar, ready-to-bake dough, pet food, vegetables, fruits, meats, cheese, sugar and powders, candy, and the like.

[0106] It will be appreciated that the foregoing embodiments are exemplary embodiments of packaging materials, but packaging materials are not necessarily limited to such embodiments. For example, it will be appreciated that a packaging material may comprise two or more film layers; a configuration shown as reverse printed could be provided with printing on the outer / upper surface of the outermost film layer; a material shown as having printing on the upper surface of the outer film could instead be reverse printed; and the like. Additionally, the multi-film constructions could be provided as single film constructions.

[0107] What has been described above includes examples of the present specification. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the present specification, but one of ordinary skill in the art may recognize that many further combinations and permutations of the present specification are possible. Accordingly, the present specification is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.

[0108] The foregoing description identifies various, non-limiting embodiments of a packaging material. Modifications may occur to those skilled in the art and to those who may1737604174.1make and use the invention. The disclosed embodiments are merely for illustrative purposes and not intended to limit the scope of the invention or the subject matter set forth in the claims.1837604174.1

Claims

CLAIMSWhat is claimed is:

1. A packaging material comprising:a structural film and a sealing configuration comprising sealing materials selected from at least two of a heat seal film, a heat seal coating, and a cold seal coating.

2. The packaging material of claim 1 , wherein the structural film is a heat seal film and is part of the sealing configuration.

3. The packaging material of claim 2, wherein the sealing configuration comprises a heat seal coating disposed on a lower surface of the heat seal film.

4. The packaging material of claim 2, wherein the sealing configuration comprises a cold seal coating disposed on a lower surface of the heat seal film.

5. The packaging material of claim 2, wherein the sealing configuration comprises a heat seal coating disposed on a lower surface of the heat seal film, and a cold seal coating disposed on the heat seal coating.

6. The packaging material of claim 1, wherein the structural film comprises an inner film and an outer film, wherein the inner film is a heat seal film and is part of the sealing configuration.

7. The packaging material of claim 6, wherein the wherein the sealing configuration comprises a heat seal coating disposed on a lower surface of the heat seal film.

8. The packaging material of claim 6, wherein the sealing configuration comprises a cold seal coating disposed on a lower surface of the heat seal film.

9. The packaging material of claim 6, wherein the sealing configuration comprises a heat seal coating disposed on a lower surface of the heat seal film, and a cold seal coating disposed on the heat seal coating.1937604174.

110. The packaging material of any of claims 6-9, wherein the outer film is selected from a polymeric film.

11. The packaging material of any of claims 6-9, wherein the outer film is a paperbased film.

12. The packaging material of claim 1 , wherein the structural film comprises a film that is not heat sealable, and the sealing configuration comprises a heat seal coating and a cold seal coating.

13. The packaging material of claim 12, wherein the structural film comprises an inner film and an outer film, and the heat seal coating is disposed on a lower surface of the inner film, and the cold seal coating is disposed on the heat seal coating.

14. The packaging material of claim 13, wherein the inner film is a polymeric film.

15. The packaging material of claim 13 or 14, wherein the outer film is a polymeric film.

16. The packaging material of claim 13 or 14, wherein the outer film is a paperbased film.

17. A package comprising the packaging material of any of claims 1-16.

18. The package of claim 17, wherein the package is formed from the packaging material.

19. The package of claim 17. wherein the package comprises a container having an lower end and an upper end distal to the lower end, a container wall disposed between the upper end and the lower end and defining an container interior, and a lid disposed over the upper end of the container, wherein the lid comprises the packaging material.2037604174.1

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