AU2008203792A1 - Packaging Roll Stock with Windows - Google Patents

Packaging Roll Stock with Windows Download PDF

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Publication number
AU2008203792A1
AU2008203792A1 AU2008203792A AU2008203792A AU2008203792A1 AU 2008203792 A1 AU2008203792 A1 AU 2008203792A1 AU 2008203792 A AU2008203792 A AU 2008203792A AU 2008203792 A AU2008203792 A AU 2008203792A AU 2008203792 A1 AU2008203792 A1 AU 2008203792A1
Authority
AU
Australia
Prior art keywords
layer
package
windows
laminate
heat
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
AU2008203792A
Inventor
David A Coutts
Donald B Hilder
Andrew G Pattenden
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
GENPAK LP
Original Assignee
GENPAK LP
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by GENPAK LP filed Critical GENPAK LP
Priority to AU2008203792A priority Critical patent/AU2008203792A1/en
Publication of AU2008203792A1 publication Critical patent/AU2008203792A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B32B2038/042—Punching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/31—Heat sealable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/41—Opaque
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/412—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B32B2439/02—Open containers
    • B32B2439/06—Bags, sacks, sachets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B32B2439/70—Food packaging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B32B2439/80—Medical packaging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state

Landscapes

  • Wrappers (AREA)
  • Laminated Bodies (AREA)

Description

P/00/011 Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT ORIGINAL TO BE COMPLETED BY APPLICANT Name of Applicant: Genpak LP Actual Inventor(s): David A. Coutts, Donald B. Hilder, Andrew G. Pattenden Address for Service: A.P.T. Patent and Trade Mark Attorneys PO Box 222, Mitcham, SA 5062 Invention Title: Packaging roll stock with windows The following statement is a full description of this invention, including the best method of performing it known to me/us:- PACKAGING ROLL STOCK WITH WINDOWS FIELD OF THE INVENTION [0001] The invention relates to materials used for packaging, processes for the manufacture thereof and packages produced thereby. BACKGROUND OF THE INVENTION [0002] Combinations containing films are commonly used for packages product such as foodstuffs, medical and pharmaceutical products, electronic products and others. These combinations generally comprise at least one layer of non-transparent material such as aluminum foil, metalized polymer film, paper or the like. These combinations often also comprise films of polyethylene, polypropylene, polyester or the like, layered on one or both sides of the non-transparent material. [0003] One popular packaging combination consists of a layer of paper having adhesive-laminated thereto a clear heat-sealable plastic layer. The paper portion of the laminate is die-cut prior to lamination, to provide windows to view the contents of packages formed therewith. When forming a bag with this material, it is usually necessary to apply a hot melt or other adhesive on the paper/plastic back seam, and on the paper/plastic interface at the bottom of the bag. 2 [0004] Due to the manufacturing complexity associated with the application of adhesive on the bag back seam and bottom, it is conventional to sell pre-made bags to processors, for subsequent filling and closure. The use of pre-made bags is relatively expensive. Also, the use of adhesive lamination can result in gaps between the layers of the finished material, which gaps render the material prone to delamination, loss of barrier and insect infestation. Voids are also prone to occur where the window meets the paper. Yet further, these bags are typically not hermetically sealed. [0005] Another popular material comprises a layer of non-transparent, heat-sealable material. Materials of this type can be used in form-fill-seal machines, of the type for producing stand-up pouches and other packages, which is advantageous to processors in terms of cost. Also advantageous, these packages are generally hermetically sealed. However, these packages suffer in terms of consumer acceptance, as consumers cannot view the contents thereof. SUMMARY OF THE INVENTION [0006] A process for manufacturing a laminate forms one aspect of the invention. The laminate is for forming a package having one or more windows for viewing the contents of said package. This process comprises the step of extrusion laminating, onto a first material perforated by a hole for and defining each of said windows, a heat-sealable second material. 3 [0007] A laminate for forming a package forms another aspect of the invention. The package has one or more windows for viewing the contents of said package. This laminate comprises a layer of a first material, a layer of a second material and a layer of thermoplastic. The layer of first material has formed therein a hole for and defining each of said one or more windows. The layer of second heat-sealable plastic material is spaced from the layer of first material. The layer of thermoplastic has been deposited by extrusion between the layer of first material and the layer of second material in a manner such that the windows are hermetically sealed by plastic through which the contents of a package produced from the laminate can be viewed. [0008] A heat-sealed package forms another aspect of the invention. This package comprises an outer layer, an inner layer and an intermediate layer of thermoplastic. The outer layer is of a first material, and has formed therein one or more holes. The inner layer is of heat-sealable second plastic material and is spaced from the outer layer. The intermediate layer of thermoplastic has been deposited by extrusion between the inner and outer layers such that the holes are hermetically sealed by plastic through which the contents of the package can be viewed. 4 [0009] Other advantages, features and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying drawing, the latter being briefly described hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS [0010] Figure 1 is a schematic of a process for manufacturing laminate according to a preferred embodiment of the invention; [0011] Figure 2 is a perspective view of a package formed with the laminate formed by the process of Figure 1; and [0012] Figure 3 is a schematic cross-sectional view of the laminate formed by the process of Figure 1. DETAILED DESCRIPTION [0013] Reference is made first to Figure 3 which depicts schematically a laminate 46 forming one preferred embodiment of the invention. This laminate 46 includes a first material 22, namely, 65 gsm (gram per square metre) coated bleached glossy paper, having a print-bearing face 28 and an opposing face 30. The print, deposited by Flexography, is indicated 5 schematically by thin layer 23. Material 22 is perforated by a hole indicated with general reference numeral 70. The print 23 comprises synchronization marks (not shown). This laminate 46 also includes a second material 36. This second material 36 comprises a 110 gauge (26 micron) transparent barrier 37 film sold by Exxon Mobil as product 110AXT under the trade-mark BICOR, which has been laminated, by a solvent-based adhesive, to a 1 mm transparent sealant film 39 sold by Pliant Corporation as product 1029. The sealant film 39 is orientated to present away from paper 22, so as to render the second material 36 heat-sealable. This laminate 46 also includes an intermediate layer of LDPE 20. [0014] Attention is now directed to a process for manufacturing this laminate, which process forms another preferred embodiment of the invention and is depicted schematically in Figure 1. [0015] In this process, the first material 22 is released from a secondary unwind roller 24 and passed through a die cutting unit 26. [0016] In the die cutting unit 26, the synchronization marks are detected by an optical sensor (not shown). Detection of a synchronization mark initiates a punching operation in the die cutting unit 26, such that holes 70 are formed in the first layer material 22 in predetermined locations relative to the synchronization marks, to produce a perforated material 32. The manner in which such detection and die cutting is carried out is well known to persons of ordinary skill in the art, and as such, is not described in detail herein. 6 [0017] The perforated material 32 advances next to a laminating section 34, along with the second material 36 that has been released from a primary unwind roller 38. [0018] In the laminating section 34, an extruder 40 applies a 11.5 gsm layer of an extrudant 20 onto the barrier film 37 portion of the second material 36 before the barrier film portion 37 of the second material 36 is overlaid upon the opposing face 30 of the first material 22 and laminated thereto by passage through a nip-roller 42, to produce laminate 46. The laminant extrudate 20 in this process is LDPE applied at a curtain temperature of 300 0 C, and forms intermediate layer 20 shown in Figure 3. [0019] In this process, the laminator 34 includes a chill roll 44 bearing a mirror pocket finish (not shown), so as to facilitate smooth release of the laminate 46 therefrom. [0020] This laminate 46 is then advanced to rewind roller 48, and spooled for subsequent use. [0021] Figure 2 shows such a subsequent use, namely, a hermetically sealed bag or pouch 90 made from laminate 46 by a conventional vertical form-fill-seal machine. As illustrated, the pouch or package 90 has a window 100 for viewing its contents. This window 100 is not fully transparent, but rather is slightly translucent, owing to the chill roll 44 texture. The degree of opacity/translucence of window 100 is such that the contents of the package can be viewed through the window 100, so as to 7 permit potential consumers to readily inspect the contents, while at the same time facilitating smooth release of the laminate 46 from the chill roll 44. It is noted that, in this bag, the paper first material 22 forms the bag outer layer, whereas the second material 36 forms the inner layer. [0022] The specific package 90 described hereinbefore is known to be useful for the packaging of tortilla chips, but could be used for other purposes. [0023] Whereas a specific process, laminate and package produced thereby are herein described, it should be understood that various changes to the process, laminate and package produced thereby can be made. [0024] Firstly, whereas a 65 gsm paper is herein described to be utilized, paper stocks of other weights can be utilized. For example, weights of the type normally utilized in packaging, to wit, between 20 gsm and 120 gsm, are known to be useful. As well, whereas a bleached, glossy finish paper is described, natural and other papers can be used, as can matte and other finishes. Additionally, materials other than paper, such as plastics, metal foils or laminates thereof can be utilized. [0025] Further, whereas a print deposited by Flexography is herein described, other printing processes, such as rotogravure, lithography and others can readily be employed. 8 [0026] Moreover, the print could be deposited on the first layer material either prior to forming the holes or subsequent thereto. A print could also be omitted. [0027] As well, whereas the laminate extrudate in the described process is LDPE, other thermoplastics, including but not limited to PE, LLDPE, MDPE, EVA, EMA, EAA and HDPE could be utilized. As is readily understood by persons of ordinary skill in the packaging arts, modification of the extrudate composition may compel alteration of the curtain temperature, so as to ensure that the extrudate both flows and bonds properly to the first and second layer materials. Whereas a 11.5 gsm layer of extrudate is hereinbefore described, this may be modified, to, inter alia, meet the specific performance requirements of the product to be packaged. Weights between 3 and 40 gsm are known to be useful. [0028] Additionally, whereas a specific laminated transparent film is described as forming the second material, other heat-sealable films may be employed. For example, barrier properties may, in some cases, not be required. Other weights and compositions could also be employed. Of course, barrier films other than AXT, and sealant films other than 1029, could readily be utilized. As well, lamination techniques other than solvent based could be utilized, and monolithic films (i.e. non-laminated films) could be employed as the second material. [0029] Further, whereas the print is indicated to include synchronization marks for the purposes of window positioning, these synchronization marks, 9 or other syncronization marks, can be used at a later processing stage for cutting the packaging materials in appropriate places to form unit packages. [0030] Further still, whereas die cutting is taught, other cutting apparatus, such as laser cutting or water jet cutting, could be employed. [0031] Additionally, whereas the bag illustrated was formed by a vertical form-fill-seal machine, laminates constructed according to the invention can be utilized in horizontal form-fill-seal machines as well. [0032] Finally, whereas a textured chill roll is described, which facilitates removal of the laminate from the nip roller, untextured i.e. smooth-finished rollers can also be utilized, to produce laminate with substantially transparent windows, although this may have deleterious impacts on lamination throughput. [0033] Accordingly, it should be understood that the invention is to be limited only by the claims appended hereto, purposively construed. 10

Claims (18)

1. A process for manufacturing a laminate for forming a package having one or more windows for viewing the contents of said package, said process comprising the step of extrusion laminating, onto a first material perforated by a hole for and defining each of said windows, a heat-sealable second material.
2. A process according to claim 1, wherein the heat-sealable second material is extrusion laminated to the first material by a laminator having a roll bearing a textured surface such that the windows are non-transparent.
3. A process according to claim 2, wherein the roll is a chill roll and the textured surface is a mirror pocket finish.
4. A process according to claim 1, wherein the first material is selected from the group consisting of paper, film, foil and a lamination containing paper, film or foil.
5. A process according to claim 4, wherein the first material has a weight of about 20 to about 120 gsm.
6. A process according to claim 1, wherein the heat-sealable second material comprises a thermoplastic. 11
7. A processing according to claim 1, wherein the heat-sealable second material comprises a polyolefin thermoplastic.
8. A process according to claim 1, wherein the laminant extrudant is a thermoplastic.
9. A process according to claim 8, wherein the heat-sealable second material comprises a thermoplastic.
10. A process according to claim 9, wherein the thermoplastic is selected from the group consisting of PE, LDPE, LLDPE, MDPE, EVA, EMA, EAA and HDPE.
11. A laminate for forming a package having one or more windows for viewing the contents of said package, said laminate comprising: a layer of a first material having formed therein a hole for and defining each of said one or more windows; a layer of a second heat-sealable plastic material spaced from the layer of first material; and a layer of thermoplastic deposited by extrusion between the layer of first material and the layer of second material in a manner such that the windows are hermetically sealed by plastic through which the contents of a package produced from the laminate can be viewed. 12
12. A laminate according to claim 11, wherein the layer of second material is extrusion laminated to the layer of first material by a laminator having a roll bearing a textured surface such that the windows are non-transparent.
13. A laminate according to claim 12, wherein the roll is a chill roll and the textured surface is a mirror pocket finish.
14. A laminate according to claim 11, wherein the first material is selected from the group consisting of paper, film, foil and a lamination containing paper, film or foil.
15. A heat-sealed package, said package comprising: an outer layer of a first material, said outer layer having formed therein one or more holes; an inner layer of heat-sealable second plastic material spaced from the outer layer; and an intermediate layer of thermoplastic deposited by extrusion between the inner and outer layers such that the holes are hermetically sealed by plastic through which the contents of the package can be viewed.
16. A package according to claim 15, wherein the windows are non transparent. 13
17. A package according to claim 15, wherein the first material is paper.
18. A package according to claim 15, wherein the heat-sealable plastic has barrier qualities. 14
AU2008203792A 2008-08-07 2008-08-07 Packaging Roll Stock with Windows Abandoned AU2008203792A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2008203792A AU2008203792A1 (en) 2008-08-07 2008-08-07 Packaging Roll Stock with Windows

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
AU2008203792A AU2008203792A1 (en) 2008-08-07 2008-08-07 Packaging Roll Stock with Windows

Publications (1)

Publication Number Publication Date
AU2008203792A1 true AU2008203792A1 (en) 2010-02-25

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Family Applications (1)

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AU2008203792A Abandoned AU2008203792A1 (en) 2008-08-07 2008-08-07 Packaging Roll Stock with Windows

Country Status (1)

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AU (1) AU2008203792A1 (en)

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