Reclosable Package Seal Using Ionomer Resin and PSA
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Solution Overview
Problem
Existing easy-open and reclosable food packaging solutions require die cuts for easy-openability and reclosability, increasing manufacturing costs and limiting the number of reopen/reclose cycles, especially for smaller packages where frequent use is not necessary.
Innovation Solution
A package design featuring a tray with a sealant layer comprising at least 80% ionomer resin and a laminated lidstock with a substrate film and coextruded film, including a polymeric oxygen barrier and pressure-sensitive adhesive, allowing for manual opening and reclosing without die cuts, while maintaining hermeticity and supporting multiple reopen/reclose cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If die cuts are installed in the lidstock to provide easy-openability and reclosability, then the package can be easily opened and reclosed multiple times, but manufacturing costs increase and the package structure becomes more complex
Solution Approach 1:
The patent removes the die-cut feature from the lidstock structure entirely. Instead of incorporating opening mechanisms into the lidstock, the invention uses the natural seal between the lidstock and tray flange that can be manually broken and reclosed without requiring any special die-cut openings or complex structural modifications.
Solution Approach 2:
The package structure utilizes the existing sealant layer and adhesive properties of the lidstock materials to enable easy opening and reclosing. The seal itself serves the dual function of both sealing and providing the opening mechanism, eliminating the need for separate die-cut features.
2Ease of operation
If die cuts are installed in the lidstock to enable easy opening and reclosing, then manual opening without tools is achieved, but manufacturing costs increase due to additional die-cut installation
Solution Approach 1:
The invention extracts and eliminates the die-cut component from the packaging system. The lidstock is manufactured as a continuous sheet without any die-cut openings, and the easy-open functionality is achieved through the sealant layer properties rather than physical openings.
Solution Approach 2:
The patent modifies the material properties of the sealant layer (composition, thickness, adhesive characteristics) to enable manual opening without tools. By changing the parameters of the sealing interface rather than the lidstock structure, the invention achieves tool-free opening while avoiding die-cut manufacturing costs.
3Reliability
If a hermetic seal is maintained throughout multiple reopen/reclose cycles, then package integrity and hermeticity are preserved, but the ease of repeated opening and reclosing becomes more difficult to achieve
Solution Approach 1:
The patent applies different functional properties to different regions of the seal interface. The sealant layer has localized adhesive properties that allow it to bond hermetically when closed but can be manually separated and re-bonded. This local differentiation enables both hermetic sealing and easy reclosing functionality.
Solution Approach 2:
The invention uses a composite sealant layer structure combining materials with complementary properties: one component provides strong adhesion for hermetic sealing, while another component allows manual separation. This composite material approach enables the seal to function both as a hermetic barrier and an easy-open/reclose mechanism.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables easy manual opening and reclosing of packages without tools, reduces manufacturing costs by eliminating die cuts, and allows for multiple usage cycles while maintaining package integrity and hermeticity.
Implementation Method 1
a second layer comprising a pressure sensitive adhesive; wherein the first layer of the coextruded film is sealed to the tray liner; the coextruded film is adhered to the inner surface of the substrate film
Implementation Method 2
a second layer comprising a polymeric oxygen barrier having an oxygen permeability, of the barrier material, less than 50 cm3 O2/m2·day·atmosphere
Implementation Method 3
the tray liner comprises a sealant layer comprising at least 80%, by weight of the sealant layer, of ionomer resin; the first layer of the coextruded film is sealed to the tray liner
Data Source
AI summary
An easy-open, reclosable package includes a tray with tray liner; a product; and a lidstock, including a substrate including a first layer of high modulus thermoplastic material, and a second layer including an oxygen barrier; and a coextruded film including a first layer including a blend of from 80% to 88% ionomer resin, and from 12% to 20% olefinic polymer, a second layer including a pressure sensitive adhesive, and optionally a third layer including a polymeric adhesive; wherein the first layer of the coextruded film is sealed to the tray liner; the coextruded film is adhered to an inner surface of the substrate film; and after the package is opened, and the pressure sensitive adhesive is exposed, the package can be reclosed by adhering the adhesive to a portion of the first layer of the coextruded film that remained sealed to the tray liner when the package was opened.