U.S. patent application number 11/076638 was filed with the patent office on 2005-09-15 for package enclosure with fabric-line outer layer.
Invention is credited to Hausmann, Karlheinz, Schenck, Heiko E., Schloezer, Ruediger, Tillmanns, Claudia, Trouilhet, Yves M..
Application Number | 20050202743 11/076638 |
Document ID | / |
Family ID | 34965707 |
Filed Date | 2005-09-15 |
United States Patent
Application |
20050202743 |
Kind Code |
A1 |
Hausmann, Karlheinz ; et
al. |
September 15, 2005 |
Package enclosure with fabric-line outer layer
Abstract
A package and a packaging material have a fabric-like appearance
and/or texture. The packaging material is a layered structure that
comprises an underlayer selected from paper, card stock, polymer
films, and the like, and an outer layer including one or more of a
woven fabric, a non-woven fabric, and fibers. The underlayer and
the outer layer are adjacent and adhere to each other. At least one
surface internal or external to the packaging material is printed
or treated, or is rendered opaque by pigmentation, or has a pattern
or other marking that is visible from outside the package.
Inventors: |
Hausmann, Karlheinz;
(Auvernier, CH) ; Schenck, Heiko E.; (Eppstein,
DE) ; Tillmanns, Claudia; (Riedstadt-Erfelden,
DE) ; Schloezer, Ruediger; (Senden, DE) ;
Trouilhet, Yves M.; (Vesenaz, CH) |
Correspondence
Address: |
E I DU PONT DE NEMOURS AND COMPANY
LEGAL PATENT RECORDS CENTER
BARLEY MILL PLAZA 25/1128
4417 LANCASTER PIKE
WILMINGTON
DE
19805
US
|
Family ID: |
34965707 |
Appl. No.: |
11/076638 |
Filed: |
March 9, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60551591 |
Mar 9, 2004 |
|
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Current U.S.
Class: |
442/334 |
Current CPC
Class: |
B32B 2323/04 20130101;
B32B 2329/04 20130101; B32B 2439/00 20130101; B32B 27/302 20130101;
B32B 27/34 20130101; B32B 2439/70 20130101; B32B 2323/10 20130101;
B32B 27/306 20130101; B32B 2325/00 20130101; B32B 27/12 20130101;
B32B 2377/00 20130101; B32B 2317/12 20130101; Y10T 442/608
20150401; B32B 5/24 20130101; B32B 27/08 20130101; B32B 27/32
20130101; B32B 7/12 20130101; B32B 29/02 20130101 |
Class at
Publication: |
442/334 |
International
Class: |
D04H 001/00 |
Claims
1. A packaging material comprising: (a) an underlayer comprising
paper, card stock or a polymer film, wherein the underlayer has an
upper surface that is internal to the packaging material and a
lower surface that is external to the packaging material; and,
adjacent to the upper surface of the underlayer, (b) an outer layer
comprising a woven fabric, a nonwoven fabric, or fibers, wherein
the outer layer has an upper surface that is external to the
packaging material and a lower surface that is internal to the
packaging material; wherein the underlayer is firmly adhered to the
outer layer, and wherein at least one surface internal or external
to the packaging material is printed such that the printing is
visible when the upper surface of the outer layer is viewed from
the exterior of the packaging material.
2. The packaging material of claim 1, wherein the lower surface of
the outer layer adjoins the upper surface of the underlayer.
3. The packaging material of claim 1, further comprising an
intermediate layer, wherein the intermediate layer has at least an
upper surface and a lower surface, and wherein the upper surface of
the intermediate layer is adjacent to the outer layer and the lower
surface of the intermediate layer is adjacent to the
underlayer.
4. The packaging material of claim 3, wherein the intermediate
layer is an adhesive layer.
5. The packaging material of claim 4, wherein the underlayer is
paper or card stock, wherein a surface of the paper or card stock
is printed surface, and wherein the intermediate layer is a single
synthetic film adhering by its opposite faces to the underlayer and
to the outer layer.
6. The packaging material of claim 3, wherein the intermediate
layer is a multilayered structure comprising two or more layers
selected independently from the group consisting of one or more tie
layers, one or more adhesive layers, one or more barrier layers,
and one or more structural polymer layers.
7. The packaging material of claim 6, wherein the one or more
adhesive layers are selected from the group consisting of
polyurethanes and copolymers of ethylene and at least one comonomer
selected from the group consisting of vinyl acetate, alpha olefins
containing between 3 and 8 carbon atoms, alkyl acrylates, and
carboxylic acids that may optionally be neutralized to form
ionomers; the one or more barrier layers are selected from the
group consisting of polyethylene vinyl alcohol, liquid crystalline
polymers, and polyamides; and the one or more structural polymer
layers are selected from the group consisting of polyethylenes,
polypropylenes, polystyrenes, and polyamides.
8. The packaging material of claim 1, wherein the outer layer
comprises a nonwoven fabric.
9. The packaging material of claim 8, wherein a surface of the
outer layer is printed.
10. The packaging material of claim 9, wherein the exterior surface
of the outer layer is printed.
11. The packaging material of claim 1, wherein the underlayer
comprises a polymer film, and wherein the polymer film comprises a
copolymer of ethylene and at least one comonomer selected from the
group consisting of vinyl acetate, alpha olefins containing between
3 and 8 carbon atoms, alkyl acrylates, and carboxylic acids that
may optionally be neutralized to form ionomers
12. The packaging material of claim 11 wherein the outer layer
comprises a spunlaced fabric or a fabric made of a combination of
spunbonded and meltblown fibers.
13. A package comprising the packaging material of claim 1.
14. The package of claim 13 being a box.
15. The package of claim 13 being a pouch or bag.
16. The package of claim 13 being a polygonal, prismatic,
cylindrical, or rectangular overpack.
17. The package of claim 13 being a primary package.
18. The package of claim 13 being a secondary package.
19. A method of fabricating the packaging material of claim 3,
comprising extrusion laminating the outer layer to an adhesive
layer and bonding the adhesive layer to the underlayer.
20. The method of claim 19 wherein the underlayer is paper or card
stock.
21. The method of claim 19 wherein the adhesive layer is bonded to
the underlayer by heat lamination.
22. A method of fabricating the packaging material of claim 3,
comprising laminating the outer layer, the intermediate layer and
the underlayer together by co-extrusion.
23. The method of claim 10 wherein the outer layer comprises a
nonwoven fabric.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. .sctn. 119
(e) to U.S. Provisional Application Ser. No. 60/551,591, filed on
Mar. 9, 2004, the disclosure of which is incorporated herein by
reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to packages and packaging materials
and, in particular, to packages and packaging materials with an
outer surface that provides a fabric-like appearance or texture, or
both. These packages and packaging materials are well suited as
primary or secondary containers for products such as food,
cosmetics and personal care products.
BACKGROUND OF THE INVENTION
[0003] Several patents and publications are cited in this
description in order to more fully describe the state of the art to
which this invention pertains. The entire disclosure of each of
these patents and publications is incorporated by reference
herein.
[0004] Packages that can be found on the market are usually
optimized for sealing, barrier properties and cost, whereas
technical features relating to the tactile and visual aspects of
the package are typically given less consideration. It is, however,
the tactile and visual aspects that in many cases determine the
appeal to the consumer and strongly influence the decision to
purchase the packaged product. In particular, the appearance and
texture of fabrics connotes warmth and luxury to many consumers.
This invention, therefore, incorporates desirable fabric-like
tactile and visual aspects into packages and packaging materials
through the use of fibers and/or nonwoven fabrics.
[0005] Nonwoven fabrics are well known and have been widely used
for many applications such as protective apparel and surgical
applications. Various prior art documents describe the use of
nonwoven fabrics in packaging applications in which the nonwoven
usually fills a precise technical function.
[0006] For example, European Patent No. EP-A-0 499 476 and
corresponding U.S. Pat. No. 5,096,722 describe a package for
microwave cooking of food with a grease-absorbing pad that has a
porous spunbonded polyester outer fabric bonded to a needle-punched
nonwoven polyester staple-fiber core layer. The pad provides
absorption and retention of liquid fat and grease generated during
microwave cooking.
[0007] Also, German Patent No. DE 4000143 describes a packaging
material to protect packed contents from moisture, such as
foodstuffs or tobacco products, using a non-woven material with a
high water absorption character which is enclosed in a layer of
material which is impermeable to steam, and a further non-woven
material in contact with the packaging atmosphere to compensate for
loss of humidity within the packaging and maintain a preset
moisture balance.
[0008] Japanese Patent No. JP 07-040514 describes a nonwoven fabric
to which a coating solution based on a polyester resin is applied
on a single surface. The coated nonwoven fabric is dried to provide
a printing layer.
[0009] U.S. Pat. No. 6,286,872 describes a label intended to be
applied to a package. The label comprises a printed substrate and a
film of non-woven material placed on the printed side of the
substrate, so that the printing can be seen through the film.
[0010] International Publn. No. WO 2004/007590 describes certain
liquid crystalline polymers that may be used as barrier layers for
containers of multilayer structure, where the barrier layer can be
laminated to a substrate such as foil, paper, paperboard or
nonwoven fibrous material, and the coated multilayer structure can
be formed into a shaped article by folding to provide a rigid
container such as a box or carton.
[0011] In summary, many consumer decisions are influenced by the
sensory appeal of a product's packaging, and in particular by
packaging that connotes warmth and luxury. Consequently, it will be
appreciated that an ongoing need exists for packages and packaging
materials with the appealing texture and appearance of
textiles.
SUMMARY OF THE INVENTION
[0012] Accordingly, the present invention provides a packaging
material comprising an underlayer. The underlayer may comprise
paper, card stock or a polymer film, and it has an upper surface
that is internal to the packaging material and a lower surface that
is external to the packaging material. Adjacent to the upper
surface of the underlayer is an outer layer. The outer layer may
comprise a woven fabric, a nonwoven fabric, or fibers, and it has
an upper surface that is external to the packaging material and a
lower surface that is internal to the packaging material. The
underlayer is firmly adhered to the outer layer, and at least one
surface internal or external to the packaging material is printed.
The printing is visible when the upper surface of the outer layer
is viewed from the exterior of the packaging material.
[0013] Also provided is a package comprising the packaging material
of the invention and a method of manufacturing the packaging
material. The method comprises steps of extrusion laminating the
outer layer and the intermediate layer(s) to form a laminated sheet
and laminating this sheet to the underlayer. An alternative method
includes steps of extrusion laminating the outer layer, the
intermediate layer and the underlayer together.
[0014] These and various other advantages and features that
characterize the invention are pointed out with particularity in
the claims annexed hereto and forming a part hereof. However, for a
better understanding of the invention, its advantages, and the
objects obtained by its use, reference should be made to the
drawings which form a further part hereof, and to the accompanying
descriptive matter, in which there is illustrated and described a
preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a fragmentary side view of a first embodiment of
the packaging material according to the invention.
[0016] FIG. 2 is a fragmentary side view of a second embodiment of
the packaging material according to the invention.
[0017] FIG. 3 is a fragmentary side view of a third embodiment of
the packaging material according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The definitions herein apply to the terms as used throughout
this specification, unless otherwise limited in specific
instances.
[0019] The term "package", as used herein, is synonymous with
"packaging enclosure" and refers to a wrapper, container, or other
receptacle for holding a material. Packages may be sealed or
unsealed. Portions of packages, such as lids, caps, cups, trays,
and bags, are also included in the term "package", provided that
they serve a structural function.
[0020] The term "packaging material", as used herein, refers to a
material that can be fabricated into a package, provided that the
packaging material serves a structural function.
[0021] The term "label", as used herein, refers to a film that is
applied to the surface of a package to impart information or
decoration without having a structural function. A label may have
one or more layers.
[0022] The term "structural function", as used herein, refers to
the property of imparting integrity to a package. Examples of
structural functions include, without limitation, providing
rigidity, providing containment, providing adhesion between
portions of a package, and the like.
[0023] The term "to print", as used herein, means "to impress with
a mark, design, lettering, or pattern". The mark, design lettering,
or pattern may be colored or uncolored; thus, "printing" includes
visibly marking and also embossing, treating, rendering opaque by
pigmentation, and the like.
[0024] The term "about" means that amounts, sizes, formulations,
parameters, and other quantities and characteristics are not and
need not be exact, but may be approximate and/or larger or smaller,
as desired, reflecting tolerances, conversion factors, rounding
off, measurement error and the like, and other factors known to
those of skill in the art. In general, an amount, size,
formulation, parameter or other quantity or characteristic is
"about" or "approximate" whether or not expressly stated to be
such.
[0025] Referring now to the drawings, wherein like reference
numerals designate corresponding structure throughout the views,
and referring in particular to FIG. 1, provided is a packaging
material 100 that comprises an underlayer 10 and an outer layer
20.
[0026] The underlayer 10 has an upper surface that is internal to
the packaging material and a lower surface that is external to the
packaging material. Underlayer 10 may be selected from materials
such as paper, card stock, or a polymer film. Suitable polymers for
the polymer film include, without limitation, polyethylene;
polypropylene; polyester; copolymers of ethylene with one or more
.alpha.,.beta.-unsaturated carboxylic acids or esters (preferably
alkyl esters) of .alpha.,.beta.-unsaturated carboxylic acids
optionally neutralized to form ionomers; polylactic acid;
copolymers of ethylene with other alpha olefins; copolymers of
ethylene with vinyl acetate and/or vinyl alcohol; blends of any two
or more of these polymers; and like polymers and blends. The
polymer film may be unoriented, oriented, or biaxially
oriented.
[0027] Examples of suitable materials for polymer films are those
available under the Trademarks SURLYN.RTM., ELVALOY.RTM.,
BYNEL.RTM., APPEEL.RTM. and NUCREL.RTM. of E.I. du Pont de Nemours
and Company of Wilmington, Del. ("DuPont").
[0028] Still referring to FIG. 1, the outer layer 20 forms the
exterior of the packaging materials and packages of the invention,
and also provides a fabric-like texture or appearance. The outer
layer 20 has an upper surface that is external to the packaging
material and a lower surface that is internal to the packaging
material. The outer layer 20 may thus be formed of any material
that provides the desired tactile and visual characteristics.
Notable materials are nonwoven fabrics, woven fabrics, and
fibers.
[0029] Nonwoven fabrics are manufactured sheets of directionally or
randomly oriented fibers, bonded by friction, and/or cohesion,
and/or adhesion, possibly with the application of heat and
pressure, but excluding paper. Woven fabrics can be woven, knitted
or tufted.
[0030] The package outer layer 20 is advantageously a non-woven
fabric made of at least one of polyesters such as poly(ethylene
terephthalate) and poly(trimethylene terephthalate), polypropylene,
polyethylene, rayon, acrylic, nylon, wood pulp and cotton fibers or
mixtures thereof. Preferably, the outer layer 20 is a spunlaced
fabric or a fabric made of a combination of spunbonded and
meltblown fibers.
[0031] The term "spunlaced fabric" as used herein refers to a
nonwoven fabric that is produced by entangling fibers in the web to
provide a strong fabric that is free of binders. For example, a
spunlaced fabric can be prepared by supporting a nonwoven web of
fibers on a porous support such as a mesh screen and passing the
supported web underneath water jets, such as in a hydraulic
needling process. The fibers can be entangled in a repeating
pattern. Spunlaced fabrics, sometimes referred to as
"hydroentangled", are described for example in U.S. Pat. Nos.
3,485,706, 4,635,628, 5,093,190, 5,240,764 and 5,320,898.
[0032] Spunbonded nonwovens (sometimes called "spunlaid") are
produced by extruding a molten polymer through spinnerets.
Spunbonded nonwovens are relatively strong.
[0033] Meltblown nonwovens are produced by extruding low viscosity
polymers into a high velocity airstream.
[0034] Some suitable nonwoven fabrics and fibers are commercially
available from DuPont under the trademarks Sontara.RTM. and
Sorona.RTM..
[0035] The outer layer of non-woven (or less preferably woven)
fabric that provides the fabric-like tactility and appearance
usually has a thickness corresponding to 5-150 g/m.sup.2,
preferably from 10-30 g/m.sup.2 where a see-through effect is
wanted.
[0036] The underlayer and the intermediate layer(s) of the layered
structure are preferably co-extensive with the entire package
enclosure and the outer layer of woven or non-woven fabric is also
preferably co-extensive with the entire package enclosure, but
alternatively it only partly covers the package enclosure.
[0037] When underlayer 10 and upper layer 20 are adjacent to each
other, they may adhere to each other directly, or alternatively
through one or more intermediate layers 40, as is the case in
packaging material 200, depicted in FIG. 2. When underlayer 10 and
upper layer 20 adjoin each other, and thus are adhered directly to
each other, the adhesion may result from any physical mechanism
that provides sufficient stability to the packaging material 100,
depicted in FIG. 1.
[0038] One suitable physical mechanism for adhering underlayer 10
and upper layer 20 is mechanical entanglement. One favorable
condition for mechanical entanglement is selecting an underlayer 10
whose melt flow index (MFI) is of sufficient value, e.g., equal to
or greater than 5 g/10 min at 190.degree. C. under a 2.16 kg
weight. Another favorable condition for mechanical entanglement is
the result of pairing materials of like polarity. Specifically,
when underlayer 10 comprises a polar material, such as a copolymer
of ethylene and a polar monomer, mechanical entanglement is favored
when upper layer 20 comprises a polar fabric or fibers, such as a
polyester, for example. Conversely, when upper layer 20 comprises a
nonpolar fabric or fibers, such as polypropylene, mechanical
entanglement is favored by the choice of an underlayer 10
comprising a nonpolar material, such as polyethylene, e.g.
[0039] Still referring to FIG. 1, the packaging material of the
invention also includes printing that is visible when the upper
surface of the outer layer 20 is viewed from the exterior of the
packaging material 100. Stated alternatively, the printing is
visible when the packaging material 100 is viewed along line a-a.
Thus, if underlayer 10 is transparent, printing may be included at
one or more of positions 30, 35, and 37. Likewise, when underlayer
10 is opaque such that printing at position 37 cannot be viewed
along line a-a, then printing is included at one or both of
positions 30 and 35.
[0040] In more complicated embodiments of the invention, such as
packaging materials 200 and 300, depicted in FIGS. 2 and 3,
respectively, there are more possible positions for printing. For
clarity, only positions 30 and 35 are shown. Those of skill in the
art, however, are capable of determining optimal positions for
printing based on the materials to be used in the packaging
material and on the desired visual effects. For example, in
general, when the printing is at position 30, it will appear to be
clearer and sharper than when it is viewed through one or more
layers, as it is at position 35 or 37. Also, printing may interfere
with the performance of intermediate layer 40. In this case,
printing at position 35 is inadvisable.
[0041] Those of skill in the art also understand how to order the
formation of the various layers and the conversion steps necessary
to achieve printing at any suitable position within the packaging
material. For example, referring again to FIG. 1, a film comprising
underlayer 10 and upper layer 20 may be printed on one or both of
its exterior surfaces, that is, at positions 30 and/or 37. If
printing at position 35 is desired, however, then the upper surface
of underlayer 10 or the lower surface of upper layer 20 may be
printed before the underlayer 10 and the upper layer 20 are
adhered.
[0042] The printing may be accomplished by any suitable means known
in the art, including embossing, flexography, rotogravure, and
lithographic printing. The choice of ink and printing technique may
be made by one of skill in the art according to established
criteria such as economic factors, compatibility of ink with
substrate, level of detail of the design to be printed, and the
like.
[0043] Referring now to FIG. 2, which depicts packaging material
200, one or more other layers may optionally be included in the
packaging material. For example, in certain embodiments, it may be
desirable to include an intermediate layer 40. The intermediate
layer 40 has an upper surface and a lower surface. The upper
surface of intermediate layer 40 is adjacent to the outer layer 20
and the lower surface is adjacent to the underlayer 10. Preferably,
the upper surface of intermediate layer 40 adjoins the outer layer
20 and the lower surface adjoins the underlayer 10, but for any
printing that may intervene, such as printing at position 35, for
example.
[0044] In some preferred embodiments, the intermediate layer 40 is
an adhesive layer. Suitable polymers forming the adhesive layer are
typically thermoplastic polymers or thermosetting polymers.
Suitable thermoplastic polymers include copolymers of ethylene and
at least one comonomer selected from alpha olefins containing
between 3 and 8 carbon atoms, alkyl acrylates (e.g., methyl
acrylate, ethyl acrylate or butyl acrylate), saturated or
unsaturated ethylene carboxylic acid copolymers, optionally
neutralized to form ionomers, or ethylene vinyl acetate copolymers.
Suitable thermosetting polymers include, for example, those based
on polyurethane chemistry.
[0045] When the underlayer 10 is paper or card with a printed
surface, the intermediate layer 40 is preferably a single synthetic
film adhering by its opposite faces to the underlayer and to the
outer layer.
[0046] Referring now to FIG. 3, which depicts packaging material
300, the intermediate layer may be a multilayered structure. For
example, when the package enclosure protects the contents notably
against the ingress of gases such as air, packaging material 300
advantageously comprises a layer 50 between first and second
synthetic films 40 and 45.
[0047] Layer 50 may, for example, be a flexible transparent barrier
layer. The flexible transparent barrier layer 50 may include
materials such as polyethylene vinyl alcohol (EVOH), liquid
crystalline polymers (LCP), or polyamides (PA), and the like.
Examples of suitable liquid crystalline polymers (LCP) are given in
the above-mentioned publication WO 2004/007590.
[0048] Alternatively, layer 50 may be a structural polymer layer
that provides stiffness to packaging material 300 or to a package
comprising packaging material 300. Appropriate levels of stiffness
can be achieved by selecting stiff polymers such as certain
polyethylenes, polypropylenes, polystyrenes, and polyamides. The
stiffness of packaging material 300 may also be varied
systematically by varying the thickness of layer 50.
[0049] In either case, first and second synthetic films 40 and 45,
which may be the same or different, are tie layers that provide
adhesion between the flexible transparent barrier layer 50 and the
outer layer 20 and underlayer 10, respectively.
[0050] It is apparent that layer 50 may itself be a multilayered
structure, for example, when the particular packaging application
requires a combination of several functions. In this case, layer 50
and synthetic films 40 and 45, taken together, include two or more
layers selected independently from the group consisting of one or
more tie layers, one or more adhesive layers, one or more barrier
layers, one or more structural polymer layers, and the like. Those
of skill in the art know how to formulate and fabricate such
multilayered laminated structures 50, and how to select appropriate
tie layers 40 and 45 to ensure the physical integrity of the
packaging material 300.
[0051] The invention also provides a method of manufacturing the
packaging material, which comprises steps of extrusion laminating
the outer layer and the intermediate layer(s) to form a laminated
sheet and laminating this sheet to the underlayer. An alternative
method includes steps of laminating the outer layer, the
intermediate layer and the underlayer together by coextrusion.
[0052] The layers of the layered structure are preferably bonded by
heat lamination. The barrier layer and the sealant/adhesive layer
can be coextruded through blown and cast film or extrusion coating
techniques. An extra adhesive/bonding agent can be used if
needed.
[0053] The packaging material may be converted into packages by any
suitable method that is known in the art, for example, one or more
of die cutting, folding, sealing, and the like.
[0054] The package may be a flexible pouch or bag. The pouch or bag
may be sealed, unsealed, or partially sealed. Alternatively, the
package enclosure may be a generally polygonal, prismatic,
cylindrical, or rectangular overpack, open or closed at its ends,
for example with a printed card or paper underlayer. Such overpacks
are generally formed by cutting and, optionally, scoring a portion
of the packaging material. The portion is then folded or bent into
the desired shape. Other examples are folded boxes, cans, bottles
and tubes, and lids.
[0055] Moreover, the packages according to the invention may be
primary or secondary packages. The term "primary package" as used
herein refers to a package that is in direct contact with its
contents. For example, a jar containing a cosmetic is a primary
package. The term "secondary package" as used herein refers to a
package that contains one or more other packages. For example, a
box that encloses the jar containing the cosmetic is a secondary
package, as is a film that wraps the box.
[0056] The package according to the invention is suitable for
numerous packaging applications where a good "textile feel" and
appearance is important combined with excellent strength where
required, good visibility of printing or decoration allowing
multiple possibilities of decorating or displaying printed matter
on the package, a wide choice of the materials that can be used for
different applications, possibilities for including functional
layers for instance to increase sealing or strength, the
possibility to form the layered structure into many different types
of packages of different shapes, and ease of manufacture. The
mentioned "textile feel" and appearance and the printing/marking
can if desired be provided for the entire package surface and are
already produced during the package manufacture, without the need
to separately manufacture labels and apply the labels to the
packaging.
[0057] Two preferred embodiments of the invention will now be
described in detail, the first type having a card or paper
underlayer, and the second type having a polymer sealant
underlayer.
First Embodiment
Nonwoven/Adhesive Layer/Card or Paper
[0058] A first example of the inventive package enclosure has a
layered structure made of a card or paper underlayer, which is
usually printed, an intermediate layer made of a single usual
transparent synthetic film forming an adhesive layer, and a
nonwoven outer layer which is usually translucent (to allow
visibility of printing on the paper/card) or can have a printed
surface.
[0059] Nonwoven fabrics on rigid or semi-rigid container packages
of paper/card are predominantly intended for cosmetic applications,
but are also useful in food applications where separate means are
used for sealing of the food content.
[0060] The nonwoven outerlayer can be spunlaced nonwoven based on
PP, PE, PET, PA, Polyaramid, LCP, Nomex.RTM., or Rayon in pure
form, in blends of two or more polymers, or in blends of one or
more polymers with wood pulp or cotton. An advantage of
incorporating wood pulp or cotton is sustainability/use of
renewable resources.
[0061] Spunlaced nonwoven fabric is preferred as this gives a
three-dimensional touch and excellent tactile feeling. Preferred
spunlaced fabrics are available from DuPont under the trademark
SONTARA.RTM.. These spunlaced fabrics provide good
through-visibility (transparency) for viewing printing on the
underlayer, and are also printable.
[0062] Alternatively, spunbonded or spun flashed or blown
fiber-based nonwovens can be used. Suitable spunbonded nonwovens
are available from DuPont under the trademarks TYVEK.RTM. and
TYPAR.RTM..
[0063] Monocomponent fibers can be used for the nonwoven fabric,
but in order to produce special effects bicomponent fibers can be
used produced according to Advanced Composite Technology (ACT)
employing nonwoven fabrics combining spunbonded and meltblown
fibers to combine strength with fine structure, for instance as
described in U.S. Pat. No. 5,240,764, U.S. Pat. No. 5,885,909, U.S.
Pat. No. 6,548,431, WO 0109425, WO 0229145, and U.S.
2002/0025748.
[0064] Thicknesses of 5-100 or 150 g/m.sup.2 of nonwovens can be
used, preferably in the range of 10-30 g/m.sup.2. Ideally, in order
to facilitate reading through the nonwoven to better identify
printing underneath the nonwoven, the nonwoven can be specifically
hydroentangled in order to make it appear more open in
structure.
[0065] The adhesive layer can be a monolayer film based on a
polyethylene or ethylene copolymer, but it can also be made up of
more than one layer, and can be made of ethylene homopolymers and
copolymers of ethylene with at least one comonomer, selected from
the group of alpha olefins containing between 3-8 C atoms,
vinylacetate, alkylacrylate ester (methylacrylate, ethylacrylate or
butylacrylate), saturated or unsaturated carboxylic acids (acrylic
acid or methacrylic acid), optionally neutralized between 0.05-95%
with metal ions (Zn, Na, Li, Mg, K or others). Alternatively,
thermosetting adhesive layers common for adhesive laminations can
be used, for example based on polyurethane chemistry.
[0066] Optionally a barrier layer can be incorporated in the
adhesive layers as well as any required tie layers to adhere this
barrier layer to the adhesive layer and to adhere to both carton or
paper and nonwovens. The barrier layer, like the adhesive layer(s),
can be transparent when needed, or can be pigmented/opaque in the
case where an outer spunlaced nonwoven fabric is printed.
[0067] The adhesive layer can be extrusion coated on the nonwoven
or on the paper/board substrate and subsequently laminated to
either the paper/board or the nonwoven substrate. Alternatively the
Nonwoven/Adhesive/Paper-Board structure can be extrusion laminated
in one step.
[0068] For paper or board substrates, conventional materials of any
suitable thicknesses can be used, and these materials may be coated
with a surface treatment or a printing layer depending on the final
application.
[0069] The full structure can then be folded to form a rigid or
semi-rigid package. This could be a folded one-part or two-part
box, or an open-ended folded card package.
Second Embodiment
Spunlaced Nonwoven/Adhesive/Barrier/Adhesive/Sealant Layer
[0070] A second example of the inventive package enclosure has a
layered structure made of a polymer sealant underlayer, which is
possibly printed, a first adhesive film, a barrier layer, a second
adhesive film, and a spunlaced, nonwoven outer layer which is
usually translucent (to allow visibility of printing on the sealant
layer through the adhesive layers and barrier layer, which in this
case are all transparent) or can have a printed surface. This type
of layered structure is intended principally for food or nonfood
packaging applications where the packaging has to seal the content.
In this case the nonwoven will be preferably be spunlaced or ACT
technology, as defined above.
[0071] The adhesive and the sealant layer can be as defined as for
the first embodiment, but can also be polypropylene (PP). The
flexible, transparent barrier material should be either EVOH,
(polyethylenevinylalcohol) or LCP (Liquid Crystal Polymer) or
polyamide. Examples of suitable liquid crystalline polymers (LCP)
are given in the above-mentioned publication WO 2004/007590. In
addition, the intermediate layer of the package optionally further
includes a structural layer (e.g. PP or PE) to enhance the strength
of the package. The structural layer will usually be sandwiched
between two adhesive layers.
[0072] This second type of packaging enclosure can typically be
embodied in a sealed flexible pouch or bag, or could be a
semi-rigid package. Such packages can be closed by heat sealing
edges together.
[0073] In another preferred embodiment, the underlayer comprises a
synthetic polymer sealant layer which for example comprises or
consists essentially of a copolymer of ethylene and at least one
comonomer selected from alpha olefins containing between 3 and 8
carbon atoms, alkyl acrylates (methylacrylate, ethylacrylate or
butylacrylate), saturated or unsaturated ethylene carboxylic acid
copolymers, optionally neutralized to form ionomers, or ethylene
vinyl acetate copolymers, and in this case the outer layer is
preferably a spunlaced fabric or a fabric made of a combination of
spunbonded and meltblown fibers.
[0074] Also of note are the following embodiments of the
invention:
Embodiment 1
[0075] A package enclosure for containing products in particular
food and cosmetics, said package enclosure being a layered
structure that is shaped or shapeable to fit over and to surround a
product or products, the layered structure comprising:
[0076] (a) an underlayer, selected from paper, card and synthetic
polymer sealant layer(s);
[0077] (b) an outer layer made of a woven or non-woven fabric that
provides the outer surface of the package enclosure with a
fabric-like tactile feel and visual appearance; and
[0078] (c) at least one intermediate layer that provides adherence
between the underlayer and the outer layer, and that
[0079] is a single synthetic film adhering by its opposite faces to
the underlayer and to the outer layer, or
[0080] includes a first synthetic film adhering by an inner face to
the underlayer and a second synthetic film adhering by an outer
face to the outer layer, the first and second synthetic films
adhering together or being separated by one or more further
intermediate layers, in particular a barrier layer,
[0081] wherein the underlayer and/or at least one intermediate
layer has at least one printed or treated surface, or is rendered
opaque by pigmentation or has a pattern, that is visible from
outside the package enclosure through the woven or non-woven fabric
of the outer layer, and/or the outer layer has a visible printed
surface.
Embodiment 2
[0082] The package enclosure of embodiment 1, wherein the
underlayer and the intermediate layer(s) of the layered structure
are co-extensive with the entire package enclosure and the outer
layer of woven or non-woven fabric is co-extensive with the entire
package enclosure or partly covers the package enclosure.
Embodiment 3
[0083] The package enclosure of embodiment 1 or 2 wherein the outer
layer is a non-woven fabric made of at least one of polyester,
polypropylene, polyethylene, rayon, acrylic, nylon, woodpulp and
cotton fibers, which is a spunlaced fabric or a fabric made of a
combination of spunbonded and meltblown fibers.
Embodiment 4
[0084] The package enclosure of embodiment 1, 2 or 3, wherein the
underlayer is paper or card with a printed surface, and the
intermediate layer is preferably a single synthetic film adhering
by its opposite faces to the underlayer and to the outer layer.
Embodiment 5
[0085] The package enclosure of any preceding embodiment, wherein
the underlayer comprises a synthetic polymer sealant layer which is
a copolymer of ethylene and at least one comonomer selected from
alpha olefins containing between 3 and 8 C atoms, vinyl acetate,
alkyl acrylates (methyl-, ethyl- or butyl-acrylate), saturated or
unsaturated carboxylic acid (in particular methacrylic or acrylic
acid), which can optionally be neutralized between 0.05 and 95%
with metal ions selected from Na, Zn, Mg, K, or Li to form an
ionomer, and the outer layer is preferably a spunlaced fabric or a
fabric made of a combination of spunbonded and meltblown
fibers.
Embodiment 6
[0086] The package enclosure of any preceding embodiment, wherein
the intermediate layer comprises a flexible transparent barrier
layer between first and second synthetic films.
Embodiment 7
[0087] The package enclosure of embodiment 6, wherein the barrier
layer is selected from polyethylenevinylalcohol (EVOH), liquid
crystalline polymers (LCP) and polyamides (PA).
Embodiment 8
[0088] The package enclosure of any preceding embodiment, wherein
the synthetic film(s) forming, the adhesive layer are typically
thermoplastic polymers or thermosetting polymers.
Embodiment 9
[0089] The package enclosure of embodiment 8, wherein said
thermoplastic, polymers are copolymers of ethylene and at least one
comonomer selected from alpha olefins containing between 3 and 8 C
atoms, vinyl acetate, alkyl acrylates (methyl-, ethyl- or
butyl-acrylate), saturated or unsaturated carboxylic acid (in
particular methacrylic or acrylic acid), which can optionally be
neutralized between 0.05 and 95% with metal ions selected from Na,
Zn, Mg, K, or Li to form an ionomer, and the outer layer is
preferably a spunlaced fabric or a fabric made of a combination of
spunbonded and meltblown fibers.
Embodiment 10
[0090] The package enclosure of any preceding embodiment, wherein
the layers of the layered structure are bonded by heat
lamination.
Embodiment 11
[0091] The package enclosure of any preceding embodiment, wherein
the outer layer of woven or non-woven fabric has a thickness
corresponding to a fabric weight of 5-100 g/m.sup.2, preferably
from 10-30 g/m.sup.2.
Embodiment 12
[0092] The package enclosure of any preceding embodiment which is a
sealed enclosure.
Embodiment 13
[0093] The package enclosure of embodiment 12 which is a closed
flexible pouch or bag.
Embodiment 14
[0094] The package enclosure of any of embodiments 1 to 11 which is
a generally polygonal, prismatic or rectangular folded overpack,
open at its ends.
Embodiment 15
[0095] The package enclosure of any of embodiments 1 to 11 which is
a folded box.
Embodiment 16
[0096] The package enclosure of any of embodiments 1 to 11 which is
a can, bottle or tube.
Embodiment 17
[0097] A method of manufacturing a package enclosure according to
any preceding embodiment, which comprises extrusion laminating the
outer layer and the intermediate layer(s) to form a laminated sheet
and laminating this sheet to the underlayer.
Embodiment 18
[0098] A method of manufacturing a package enclosure according to
any one of embodiments 1 to 16, which comprises extrusion
laminating the outer layer, the intermediate layer and the
underlayer together.
Embodiment 19
[0099] A layered structure of a package enclosure according to any
one of embodiments 1 to 11, the layered structure being a laminated
sheet that is shapeable to form a package enclosure that fits over
and surrounds a product or products.
[0100] The following examples are provided to describe the
invention in further detail. These examples, which set forth a
preferred mode presently contemplated for carrying out the
invention, are intended to illustrate and not to limit the
invention.
EXAMPLES
[0101] Using a commercial extrusion coating line with a 3 layer (45
mm) extruder set up, available from Egan Davis-Standard Extrusion
Coating Systems of Somerville, N.J., a three layer polymer film was
extruded onto a substrate of Sontara.RTM. 8010.
[0102] The film consists of HDPE and Elvaloy.RTM. 1224 AC, which is
a copolymer of ethylene methacrylate with a melt flow index (MFI)
of 2 at 190 C/2.16 kg measured according to ASTM 1268. The HDPE was
BOREALIS.TM. FL 5580 (1.2 Ml, 958 Kg/m.sup.3), available from
Borealis A/S of Copenhagen, Denmark. The film had the following
structure:
[0103] Sontara.RTM. 8010/Elvaloy.RTM. AC 1224/HDPE/Elvaloy.RTM. AC
1224
[0104] The thicknesses of the polymer layers were:
[0105] 60 microns/50 microns/60 microns.
[0106] The melt temperature settings of the 3 extruders were the
same, and are given below:
1 Zone 1 2 3 4 5 Flange Adaptor Pipe Die Temperature, .degree. C.
180 210 240 270 300 300 300 300 300
[0107] These settings resulted in an actual melt temperature of
290.degree. C.
[0108] This film three-layered polymer film was labeled as No. 1,
and it was coated onto the Sontara.RTM. 8010 using a line speed of
20 m/min.
[0109] In making Film No. 1, the inner surface of the Sontara.RTM.
may be printed before it is coated with the polymeric film.
Likewise, the outer surface of the Sontara.RTM. may be printed
before or after coating with the polymeric film. In addition, the
outer surface of the outer layer of Elvaloy.RTM. may be printed
before or after the polymeric film is coated onto the Sontara.RTM..
Moreover, the inner surface of the inner Elvaloy.RTM. layer may be
printed before or after the polymeric film is coated onto the
Sontara.RTM..
[0110] In a second trial the same three-layer polymer film was made
using the same temperature settings; however, the polymer film
portion was extruded onto the chill roll and hauled off without
extruding it onto a fabric or other substrate. This film was
labeled as No 2.
[0111] In a third trial, the following film was made using the same
temperature settings:
[0112] HDPE/Elvaloy.RTM. 1224AC
[0113] 110 micron/50 micron
[0114] This film was also extruded directly onto the chill roll of
the extrusion coating equipment and hauled off without extruding or
laminating it onto a fabric or other permanent substrate. This film
was labeled as No. 3.
[0115] Samples of each of these three films were fabricated into
pouches of dimensions 10 cm.times.10 cm. The pouches were prepared
and sealed with a commercial laboratory sealing equipment made by
Sentinel (150.degree. C., 0.5 MPa pressure, 1 sec dwell time). The
pouch seal was formed by cutting two samples (10 cm.times.10 cm)
from each film, and sealing the Elvaloy.RTM. 1224AC sides to each
other. The label numbers of the pouches are the same as those of
the corresponding films.
[0116] In a second series of experiments, Kraft paper board (250
g/m.sup.2) was used as a substrate. The paper board was
flame-treated to improve adhesion on the side to which the polymer
was applied.
[0117] The following temperature settings were applied to extrude
the Elvaloy.RTM. AC and the HDPE at a line speed of 100 m/min.
Different temperature settings are required because the processing
temperature of the HDPE should not exceed 300.degree. C.
2 Extruder zones 1 2 3 4 5 Temperature, .degree. C., for Elvaloy
.RTM. AC 200 230 260 290 320 Temperature, .degree. C., for HDPE 200
230 260 280 300
[0118] The structure of the laminate was:
[0119] BOARD/Elvaloy.RTM. AC 1224/HDPE/Elvaloy.RTM. AC 1224.
[0120] The thickness of each layer was: 250/20/20/20 microns.
[0121] In a fourth trial the substrate of Film No. 1 (Sontara.RTM.)
was replaced by the Kraft paper board described above, leaving all
the other components the same. The structure of this film, which
was labeled as No. 4, was:
[0122] BOARD/Elvaloy.RTM. AC 1224/HDPE/Elvaloy.RTM. AC1224.
[0123] In a fifth trial the same structure as in the fourth trial
was produced; however, Sontara.RTM. film was laminated onto the
outer Elvaloy.RTM. AC1224 layer to yield the following structure,
which was labeled as No. 5:
[0124] BOARD/ELVALOY1224AC/HDPE/Elvaloy.RTM. 1224AC/Sontara.
[0125] In a sixth trial, the film of trial 3 was extrusion coated
onto the board again under the same conditions so that eventually
the following structure was obtained and labeled as No. 6:
[0126] BOARD/Elvaloy.RTM. 1224AC/HDPE.
[0127] Samples of Film Nos. 4, 5, and 6 were converted by cutting
and folding into carton boxes of the dimensions 10 cm.times.10
cm.times.10 cm. The board side of the film was inside of the box.
The boxes were labeled with the same numbers as the corresponding
films.
[0128] The tactile properties of the flexible pouches and rigid
boxes were rated according to the following system:
[0129] A=feels soft, pleasant, warm
[0130] B=feels soft, sticky
[0131] C=feels hard, plastic-like
[0132] The results were as follows:
3 Pouch/Box No. 1 2 3 4 5 6 Touch Rating A B C B A C
[0133] These results demonstrate that packages and packaging
materials having an outer layer of Sontara.RTM. possess the
desirable tactile characteristics of fabrics.
[0134] While numerous characteristics and advantages of the present
invention have been set forth in the foregoing description,
together with details of the structure and function of the
invention, the disclosure is illustrative only, and changes may be
made in detail, especially in matters of shape, size and
arrangement of parts within the principles of the invention to the
full extent indicated by the broad general meaning of the terms in
which the appended claims are expressed.
* * * * *