EP3684709A1

EP3684709A1 - Composite structure having reclosable and reusable surfaces for packaging articles

Info

Publication number: EP3684709A1
Application number: EP18859409.7A
Authority: EP
Inventors: Christopher R. Tilton
Original assignee: Smart Planet Technologies Inc; SMART PLANET Tech Inc
Current assignee: Smart Planet Technologies Inc; SMART PLANET Tech Inc
Priority date: 2017-09-22
Filing date: 2018-09-24
Publication date: 2020-07-29
Also published as: EP3684709A4; WO2019060832A1

Abstract

Disclosed herein are storage enclosures, comprising: a primary enclosure having an opening region comprising an aperture, wherein at least a portion of the primary enclosure comprises a composite material, the composite material comprising a fiber-containing layer and a mineral-containing layer, wherein the mineral-containing layer comprises a binding polymer and a mineral, wherein the mineral is present in the mineral-containing layer at up to 65% by weight; and a closure sheet comprising a first edge and a second edge that opposes the first edge, wherein the first edge is coupled to or contiguous with an edge of the aperture, wherein the closure sheet is dimensioned to span the aperture.

Description

COMPOSITE STRUCTURE HAVING RECLOSABLE AND REUSABLE SURFACES FOR

PACKAGING ARTICLES

[0001] This application claims priority to U.S. Provisional application with serial number 62/562,322, filed on September 22, 2017, which is incorporated by reference herein in its entirety.

Field of the Invention

[0002] The field of the invention is composite structures, particularly those used to fabricate storage articles and consumer packaging, such as folding cartons and boxes and related methods of manufacturing such articles.

Background

[0003] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0004] All publications and patent applications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

[0005] Packaging materials for product retail and shipping purposes are typically sufficiently durable during manufacture and use to allow reliable structural performance. However, considerations in the composition and design of such materials include their ability to have a machine-able structure. Further, for some needs, it is an advantage of packaging to be opened and then re-closed for multiple uses. It is also desirable that packages and packaging materials are inexpensive to manufacture, can use existing equipment, and be attractive in appearance. [0006] Packaging having a re-ciosable and/or re-useable closure is frequently used for shipping and storage of foodstuffs. This feature is generally achieved by methods that require minimal modifications to a base carton, flexible package, or box. A variety of food and non-food packages using flexible and rigid materials, or combinations of both, are primarily formed from laminations or gluing of one or more polymer-containing films, paper, metal, foil, and similar laminar structures. In many instances (e.g. food packaging) such re-ciosable packaging is used for shipping and/or storage of products that are consumed over time. Such products are frequently susceptible to being damaged by exposure to the environment after the package is opened for the first time. Typically, re-closability is achieved by using combinations of additional layers of material, such as pressure sensitive and/or permanent adhesives. Frequently, additional materials and added processing costs are imposed on the structure to achieve the re- closing feature. For example, re-closability can be achieved using or adding pressure sensitive adhesive labels or flaps that are attached to the exterior of the package adjacent the location where the package is to be opened. Such labels are typically formed separately from the packaging structure itself and can add significant costs. Further, it often requires a separate manufacturing step (with associated costs) to send rolls of packing sheets to a converter to add such labels before forming and printing the packaging structure. In addition the use of added labels often requires a release liner, thereby adding costs.

[0007] Thus, there is still a need for attractive re-closable packaging that is effective and economical to manufacture.

Summary of the Invention

[0008] The inventive subject matter is directed to various storage enclosures having reclosable and reusable surfaces for packaging articles. In one particularly preferred aspect,

[0009] In another aspect of the inventive subject matter, disclosed herein is a storage enclosure, comprising: a primary enclosure having an opening region comprising an aperture, wherein at least a portion of the primary enclosure comprises a composite material, the composite material comprising a fiber-containing layer and a mineral-containing layer, wherein the mineral- containing layer comprises a binding polymer and a mineral, wherein the mineral is present in the mineral-containing layer at up to 65% by weight, and a closure sheet comprising a first edge and a second edge that opposes the first edge, wherein the first edge is coupled to or contiguous with an edge of the aperture, wherein the closure sheet is dimensioned to span the aperture. The closure sheet comprises an adhesive, which may be a reusable adhesive. The primary enclosure may comprise a first coupling mechanism and the closure sheet comprises a second coupling mechanism, wherein the first coupling mechanism and the second coupling mechanism are configured to mate to form a seal. In some embodiments, the seal may be a pressure sensitive adhesive sealing mechanism. In one embodiment, the closure sheet is first pushed inward to break free the pressure sensitive adhesive, and then pulled out. In some embodiments, the seal may be a zipper mechanism or an interlocking projection and groove mechanism .

[0010] The fiber containing layer may comprise natural and/or synthetic fibers. The closure sheet may comprises a composite material, the composite material comprising a polymer- containing layer and a mineral-containing layer, wherein the mineral-containing layer comprises a binding polymer and a mineral, wherein the mineral is present in the mineral-containing layer at up to 65% by weight. The storage enclosure may be manufactured by extrusion of the mineral- containing layer onto the fiber-containing layer. The binding polymer disclosed herein may comprise a polyethylene copolymer, a polypropylene copolymer, copolymers of ethylene and propylene, or combinations thereof. The mineral containing layer may comprise about 20% to about 40% mineralized, with a structure that is about 20% to about 60%> amorphous and about 20% to about 55% crystalline. The primary enclosure and/or the closure sheet may further comprise a printable surface.

[0011] Various embodiments disclosed herein also comprise a method of making a container from a sheet of a composite packaging structure comprising cutting the sheet into desired shape, folding the sheet to form a three-dimensional shape, and heat sealing abutting surfaces to secure the abutting surfaces to one another, wherein the sheet of composite packaging structure compri ses a fiber-containing layer and a polymer containing layer, and wherein the heat sealing is performed under the following conditions: a dwell time in the range from about 0.30 seconds to about 15 seconds, a temperature range from about 1 15 °C to about 240 °C, and a seal pressure at or below about 0.80 MPa. The container may comprise a lid, wherein one side of the lid is coupled to or contiguous with an edge of an aperture in the container, while the other side of the lid attaches to the aperture of the container by an adhesive sealing mechanism. In one embodiment, one side of the lid is first pushed inward to break the pressure sensitive adhesive, and then pulled out to open the lid.

[0012] Embodiments of the present disclosure further comprise a storage box enclosure comprising: a composite material and a transparent plastic sheet material, wherein the transparent plastic sheet material forms part of an opening region comprising an aperture, wherein the transparent plastic sheet material is attached to the composite material with a permanent adhesive and a pressure sensitive resealable adhesive, and wherein the permanent adhesive bonds to the composite material on the inside of the box, and the pressure sensitive resealable adhesive bonds to the composite material on the outside of the box. The plastic material may be on top of the box providing a window. The composite material may comprise a fiber-containing layer and a mineral-containing layer, wherein the mineral-containing layer comprises a binding polymer and a mineral, wherein the mineral is present in the mineral- containing layer at up to 65% by weight. In some embodiments, the permanent adhesive may be optimized to bind to the mineral containing layer and the pressure sensitive resealable adhesive is optimized to bind to the fiber containing layer. In other embodiments, the permanent adhesive may optimized to bind to the fiber containing layer and the pressure sensitive resealable adhesive is optimized to bind to the mineral containing layer. The storage box enclosure may further comprise a detachable perforation line that follows the shape of the aperture and/or opening region. It may also comprise a bendable hinge on one side of the aperture and/or opening region. In some embodiments, the permanent adhesive is on the inside of the score line, while the pressure sensitive resealable adhesive is on the outside of the perforation line.

[0013] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

Brief Description of the Drawings

[0014] Figure 1 illustrates, in accordance with embodiments herein, a schematic side cross- sectional view of a multilayer packaging composite material [[00001155]] FFiigguurree 22 iilllluussttrraatteess,, iinn aaccccoorrddaannccee wwiitthh eemmbbooddiimmeennttss hheerreeiinn,, aa sscchheemmaattiicc ttoopp vviieeww ooff tthhee rreecclloossaabbllee ttaabb ssttrruuccttuurree..

[0016] The following description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0017] A purpose of the present disclosure is to provide new and improved composite structures for containers for food and other products such as cookies and the like of which the container provides adequate protection for the contents thereof while concurrently facilitating opening of the container closure and resealing the container to protect the contents thereof until the contents are fully consumed. An additional purpose of the present disclosure is to provide a container which can be manufactured using methods other than those used in prior food containers having resealable openings. A further purpose of the present disclosure is to use alternative materials for a container for food product.

[0018] In one embodiment, the instant disclosure provides a storage enclosure, comprising: a primary enclosure having an opening region comprising an aperture, wherein at least a portion of the primary enclosure comprises a composite material, the composite material comprising a fiber-containing layer and a mineral-containing layer, wherein the mineral-containing layer comprises a binding polymer and a mineral, wherein the mineral is present in the mineral- containing layer at up to 65% by weight; and a closure sheet comprising a first edge and a second edge that opposes the first edge, wherein the first edge is coupled to or contiguous with an edge of the aperture, wherein the closure sheet is dimensioned to span the aperture.

[0019] The composite material (s) used to form a closure having single or multiple reclosable and resealable features that can be universally used, including cartons and trays made of a paperboard including boxes of corrugated or fluted in structure, substantially comprised of synthetic or natural fibers, or any suitable material used as part of or primarily used as a sealing panel or sealing surface present of a box or carton structure that can be cut, scored, folded, glued, erected, filled with product, and securely sealed. The carton and box structures also comprising polymer content for any use but particularly for windows, adhesion, barrier or structural reinforcement. Carton and box designs include but not limited to Double Wall Brightwood, Shadow Box, Frame View box, Glued Sleeves, Glued Sleeves with Chime Locks, Butterly Locked Sleeves, Double Anchor Lock, Stripper Lock Tray, Hinged Stripper Lock Tray, Four Corner Brightwood, Six Corner Brightwood, Pinch Lock Tray, Walker Lock Tray, Arthur Lock Tray, Foot Lock Double Wall, Simplex a.k.a. Kwikset, Simple Glued Gussets, Rigidwall Tray, Fiiploek Tray, Standard Straight Tuck, Airplane Style Straight, Mailer Lock, Tuck and Tongue, Bellows or Gusset Tuck, Reverse Tuck Dust Flaps, Rectangular Sleeve, Standard Reverse Tuck, French Reverse Tuck, Edge Lock, 1-2-3 Houghland, Auto Bottom, Quad Lock Bottom, Full Overlap Seal End, Partial Overalap Seal End, Economy Overlap Seal End, Himes Lock, Full Flap Auto Bottom, Infold Auto Bottom, Tuck and Seal end carton. Simplex Tray, Four Comers Beers Tray, Infold/Outfold tray, Four Corners Beers Tuck, Six Corners Beers, Bliss Boxes, Telescope boxes, Gaylord Containers, single wall box, multiple wall box. Mailer Box, folders, Bin Boxes, Slide Boxes, RSC, HSC, CSSC, Self Locking Trays, Tray -Form Boxes, Display Trays, Multi-Use boxes, Slotted Trays and any combinations thereof.

[0020] The film layer of the instant disclosure may comprise of a polymer containing layer, metal layer, paper layer or similar other layer. The film layer is adhered to the fiber containing layer, forming part(s) of a packaging structure. The film layer may have an inside surface adhered to a fiber surface. The inside film surface would be adhered to the fiber surface using heat seal, locking tabs, or combinations of permanent and re-usable adhesives, include pressure sensitive adhesives, which in turn forms temporary reclosable, reusable, and/or permanent seal areas between the layers. The fiber and film layers having inner and outer surfaces are capable of being printed or designed in ways known to those in the art. The fiber layer is contemplated to have score lines or perforation lines. These lines allow the packaging structure or storage enclosure to be severed in a certain linear shape, the package opened along the score or cut lines, and thus allowing the user to gain access to the products inside the package and then reclosing the package. Used in a similar fashion, the film iayer(s) may also have score lines that provide reclosable and reopenable features to the storage enclosure. [0021] The package structure could include corrugated liners and medium. The fiber and film layers disclosed herein form a frame structure defining the shape of the container, for example a container has a top, bottom, and sides that can be connected at the top, sides, and bottom. Single or multiple layers of polymer containing films can be adhered to one or more surface areas of the frame and could also comprise a part of the frame and therefore have contacting surfaces on the top, sides, or bottom of the container. The container can have an opening or closure sufficiently large enough to provide access to substantially all the food or other product contained within the fiber containing frame.

[0022] The closure sheet or sealing layer is adhesively sealed to the top and the one side around the opening. The closure sheet or sealing layer is resealable when the starter tab is pulled in a direction away from the side to which the closure sheet or sealing layer is sealed to in turn pull and thereby release at least a portion of the closure sheet or sealing layer to provide access to the top opening. The closure sheet or sealing layer is resealable against the top and side to seal the opening when the closure sheet or sealing layer is laid back against the top. The container can be of any shape including polygonal, such as square or rectangular, cylindrical or in the shape of a tub. The tray portion of the package may have sides which extend upwardly from the bottom of the tray and terminate at their ends or the sides which may include flanges which extend either inwardly or outwardly relative to the interior of the tray.

[0023] In one embodiment, a packaging composite structure is formed when combinations of a single layer film are adhered to a fiber containing layer. The composite comprising a 2-iayer packaging material that can be formed and printed into a package structure, the stmcture having optional score and perforation lines on the fiber and film layers or both. When used as part of a packaging structure, the score and perforation lines can provide a fiber layer tear-off opening tabs, employed as part of a reusable closure. The packaging structure can have one or more of these tabs.

[0024] The fiber and film layers are bonded together using a multitude of permanent, pressure sensitive or reusable adhesive options or heat sealing methods, alone or in combination. The inner composite surface can include bonded, glued, or heat-sealed polymer containing areas that can be continuous across the surface of the fiber layer or dis-continuous (separated) layers, therefore, the packaging composite structure can contain multiple, individual, or separated film areas adhered to the inner si de of the fiber contai ning layer, each fi lm layer having the attributes described, the inner film layers facing towards the exterior of the package. The inner side of the fiber containing layer facing the inside of the packaging structure. When portions of the outer fiber containing layer with adjoined inner polymer layer are pulled upward via a tab, score, or perforation lines, the inner film surface of the package is now above the above the outside of the package or above the outer facing fiber containing layer package surface; thus making the previously inner facing film surface now available for application to the outer side of the package as a resealable or reusable closure surface, the previously inner facing film area now able to make contact with the outer side of the fiber layer.

[0025] Also, the inner facing side of the film layer making contact with the inner side of the fiber layer, also faces upward toward the outside of the package. Therefore, this is possible when the outer fiber layer is removed via methods previously described while making contact with an exposed inner film surface of an adjacent, but not connected, film surface located on the fiber containing layer reusable adhesives available as the outside package. The newly exposed adhesives can now provide a contact surface for adjacent or overlapping reusable and reclosable tabs.

[0026] The inner side of an adjacent locking tab can be comprised of film or fiber, the adjacent tab can join the outer side of the same films, when film areas are the bottom part of a raised locking tab. Also, a fiber tab can be removed solely for the function of exposing its inner film side, this film side with reusable adhesive facing upward. The reusable adhesive making contact with the outer film side when the adjacent locking tab that is lowered back into position on to adjacent exposed outer film side.

[0027] When used as the i nner side of a rai sed locking tab, the outer side of the film layer can make contact with an inner film side of an adjacent film layer. The film surfaces make contact as the locking tab i s with to now outer film layer is lowered back into place. The two film areas are now bonded by a reusable adhesive surface found on a now exposed inner side of the adjacent film layer. After breaking the score line, the tabbed portion of 2-layer composite is pulled upward with the inner film side now facing downward towards to outer side of the package. When the tab is lowered back into position, the film layer extends past the score lines and is now overlapping and extending on to the adjacent outer side of the package. When the tab is fully lowered the overlapping film side extends and adheres to the outer film side of the adjacent, but separate exposed inner side of the adjacent film layer, this facing film side have reusable adhesives or locking mechanism in adjoining fiber layer.

[0028] The polymer containing layer may have a shear rate from about 1 to about 10,000 at temperatures from about 180 °C to about 410 °C. The outer layer may provide hot tack operating ranges from about 25 °C to about 225 °C having from about 1.0 N/mm to about 6.0 N/mm seal strengths. The polymer bonding agent may comprise a polyethylene copolymer, and the outer layer may provide hot tack operating ranges from about 80 °C to about 220 °C having from about 2.5 N/mm to about 15 N/mm seal strengths. The outer layer may be about 20% to about 40% mineralized, with a structure that is about 20% to about 60% amorphous and about 20% to about 55% crystalline. The outer layer may have a density from about 1 .20 g/cm³ to about 1 .35 g/cnr.

[0029] Certain of the present embodiments comprise method of making a container from a sheet of a composite packaging structure. The sheet includes a fiber-containing l ayer and a polymer containing layer. The method comprises cutting the sheet into a desired shape, folding the sheet to form a three-dimensional shape, and heat sealing abutting surfaces of the container to secure the abutting surfaces to one another. The heat sealing is performed under the following conditions: a dwell time in the range from about 0.30 seconds to about 15 seconds, a temperature range from about 1 15 °C to about 240 °C, and a seal pressure at or below about 0,80 MPa. The folding may be performed manually or by machine. The three-dimensional shape may comprise a box having a bottom wall, one or more side walls, and a lid portion. The three-dimensional shape may comprise a container liner. The three dimensional shape may comprise an envelope. The peel strengths between the heat sealed abutting surfaces may range from about 1 J/m to about 45 J/m².

[0030] Certain of the present embodiments comprise a composite packaging structure. The composite packaging structure comprises a fiber-containing layer, and an outer layer bonded to the fiber-containing layer the outer layer has a density from about ,88 g/cm3 to about 1 .65 g/cm3 and a basis weight from about 2.5 lbs/3msf to about 50 lbs/3msf. The polymer containing layer of the outer layer has a basis weight from about I lbs/3 msf to about 20 lbs/3msf The outer layer may be extruded. The outer layer may have a basis weight from about 7 lbs/3msfto about 21 ibs/3msf, and the polymer containing layer of the outer layer may have a basis weight from about 2,45 lbs/3msf to about 16.8 lbs/3msf. The polymer containing lay er of the outer layer may comprise polypropylene. The outer layer may comprise about 40% by weight of the calcium carbonate particles. The polymer containing layer or polymer container layer may have an isotactic run length from about 1 to about 40. The polymer containing layer may have a shear rate from about 1 to about 10,000 at temperatures from about 180 °C to about 410 °C, The outer layer may provide hot tack operating ranges from about 25 °C to about 225 °C having from about 1 ,0 N/mm to about 6.0 N/mm seal strengths. The polymer bonding agent may comprise a polyethylene copolymer, and the outer layer may provide hot tack operating ranges from about 80 °C to about 220 °C having from about 2.5 N/mm to about 15 N/mm seal strengths. The outer layer may be about 20% to about 40% mineralized, with a structure that may be about 20% to about 60% amorphous and about 20%> to about 55% crystalline. The outer layer may have a density from about 1.20 g/cm³ to about 1.35 g/ m³.

[0031] Certain of the present embodiments comprise a method of making a container from a sheet of a composite packaging structure. The sheet includes a fiber-containing layer and a mineral-containing layer. The method comprises cutting the sheet into a desired shape, folding the sheet to form a three-dimensional shape, and heat sealing a surface of the fiber-containing layer to a surface of the mineral-containing layer. The heat sealing is performed in a temperature range from about 25 °C to about 225°C, with a dwell time from about 0.01 seconds to about 6.0 seconds, and produces seal strengths from about 1.0 N/mm to about 6.0 N/mm. The folding maybe performed manually or by machine. The three-dimensional shape may comprise a box having a bottom wall, one or more side walls, and a lid portion. The three-dimensional shape may comprise a container liner. The three-dimensional shape may comprise an envelope.

[0032] Figure 1 is a schematic side cross-sectional view of a multilayer packaging composite material according to the present embodiments. This configuration can be found in multiple locations throughout the packaging structure. The illustrated embodiment includes a first outer facing fiber containing package surface 101 which can contain various tab or pull away perforations as known in the art. The tab is first pushed inward breaking free the pressure sensitive adhesive 104 and the pulled out past the outer fiber layer 101. Then, the tab is realigned such that outer fiber layer surface 101 is again flat. Outer fiber layer 101 surface is substantially adhered to the outer facing film layer 109 by permanent adhesive location 102 and location 103. Outer facing film layer 109 is not bonded to fiber containing layer 101 in area 111 and area 112, Permanent adhesive layer 103 is bonding the outer facing film layer 109 to the inner facing outer fiber layer 101 adjacent to pressure sensitive reusable adhesive or no adhesive surface 104. Fiber containing layer 101 has scoring, perforation, or combinations of both scores and perforation lines 108 and 110. Outer fiber container layer 101 is broken free and lifted forward past the outer facing package surface 107. Outer fiber containing surface 101 tab is then placed back into its original position. Once outer fiber containing surface 101 is back in place and aligned, inner film surface 105 makes contact with outer fiber containing surface area 106 and provides a resalable and reusable package closure.

[0033] Figure 2 is a schematic top view of the reclosable tab structure, which is part of the package outer fiber layer 212. The tab shape 201 is outlined with a detachable perforation or score line 209 that follows the shape of the tab around both sides until intersecting bendable hinge score line 210. Just on the inside of the score line 201, 209 is permanent adhesive 205, which makes contact and bonds outer fiber layer 212 and inner film layer 206. On the inside area of tab 212, the inner film layer 206 is a single window layer not making contact with the outer fiber layer. Adjacent on outside of score line 201 is pressure sensitive reusable adhesive 203 making contact with the outer side of inner film layer 206 and bonding to the inner side of the outer fiber layer. The permanent adhesive 205 continues the detachable line 201. The permanent adhesive line 205 which bonds the film layer 206 to the outer fiber layer.

[0034] In one embodiment, the instant disclosure comprises a storage box enclosure comprising a composite material and a transparent plastic sheet material, wherein the transparent plastic sheet material forms part of an opening region comprising an aperture, wherein the transparent plastic sheet material is attached to the composite material with a permanent adhesive 205 and a pressure sensitive resealable adhesive 203, and wherein the permanent adhesive 205 bonds to the composite material on the inside of the box, and the pressure sensitive resealable adhesive 203 bonds to the composite material on the outside of the box. A top view of one embodiment of this storage box enclosure is illustrated in Figure 2. The storage box enclosure is contemplated to have a window comprising of a transparent plastic material is on top of the box. As illustrated throughout the disclosure, the composite material comprises a fiber-containing layer and a mineral-containing layer, wherein the mineral-containing layer comprises a binding polymer and a mineral, wherein the mineral is present in the mineral-containing layer at up to 65% by weight. In one embodiment, the permanent adhesive 205 may be optimized to bind to the mineral containing layer and the pressure sensitive resealable adhesive 203 is optimized to bind to the fiber containing layer. In another embodiment, the permanent adhesive 205 is optimized to bind to the fiber containing layer and the pressure sensitive resealable adhesive 203 is optimized to bind to the mineral containing layer. The box disclosed herein may comprise a detachable perforation or score line 209 that follows the shape of the aperture and/or opening region. The storage box disclosed herein may comprise a bendable hinge 210 on one side of the aperture and/or opening region. The permanent adhesive is contemplated to be on the inside of the perforation or score line 209, while the pressure sensitive resealable adhesive is contemplated to be on the outside of the perforation or score line 209.

[0035] Typically, heat seal coatings as well as polyolefin coatings are applied to a fiber- containing or heat scalable layer such that the layer can be sealed to the thermoplastic surface, forming the packaging article. However, unique properties of the mineral-containing layer can be used to reduce or eliminate the need for polymer content in the finished packaging structures, or the coatings used to facilitate heat seals between surfaces. Examples of these include, but are not limited to Aquaseal 2277 and Aquaseal 2105, both by Paramelt Company. The coatings are often applied on the paper or other surfaces during the converting process and before or after printing. The active ingredients are typically delivered through aqueous and emulsion solutions and mixtures, using an organic vehicle, for example, an alcohol or aromatic hydrocarbon such as xylene or a mixture thereof.

[0036] Homogeneous blends of solid olefin polymers with varying densities and melt indexes can be used for the polymer container layer, either interspersed or non-interspersed through coextrusion. The mineral-containing composite layer can be applied and bonded substantially and continuously on at least a fiber-containing layer using extrusion or extrusion lamination, including blown film, cast, or extrusion coating methods. Polymer content can be used as a tie layer for interspersed and non-interspersed constructions as well as particle bonding agents within each individual layer. These bonding agents or tie layers can include individually, or in mixtures, polymers of monoolefins and diolefms, e.g. polypropylene, polyisobutylene, polybut- 1-ene, poly-4- methylpent- 1-ene, polyvinyl cyclohexane, polyisoprene or poiybutadiene, homogeneous mettallocene copolymers, and polymers of cycloolefins, e.g. cyclopentene or norbomene, polyethylene, cross-linked polyethylene, ethylene oxide and high density

polyethylene, medium molecular weight high density polyethylene, ultra heavy weight high density polyethylene, low density polyethylene, very low density polyethylene, ultra low density polytheylene; copolymers of monoloefins and diolefms with one another or with other vinyl monomers, e.g. ethylene/propylene copolymers, linear low density polyethylene, and blends thereof with low density polyethylene, propylene but-l-ene, copolymers ethylene,

propyl ene/isobutylene copolymers, ethylene/but-l-ene copolymers, ethyl ene/hexene

copolymers, ethyiene/octene copolymers, ethylene/methylepentene copolymers,

ethyiene/octene copolymers, ethylene/vinyelcyclohexane copolymers, ethylene/cycloolefin copolymers, COC,ethylene/I-olefin copolymers, the i-olefin being produced in situ;

propyiene/butadiene copolymers, isobutylene/isoprene copolymers, ethyl ene/vinylcyclohexene copolymers, ethylene vinyl acetate copolymers, ethylene/alkyl methacrylate copolymers, ethylene/aciylic acid copolymers or ethyelene/acrylic acid copolymers and salts thereof

(ionomers) and terapolymers of ethylene with propylene and diene, such as, for example, hexadiene, dicyclopentadiene or ethylidenenorbomene; homopolymers and copolymers that may have any desired three dimensional structure (stereo-structure), such as, for example, syndiotactic, isotactic, hemiisotactic or atactic stereoblock polymers are also possible;

polystyrene, polymethylstyrene, poly alph-methystyrene, aromatic homopolymers and copolymers derived from vinylaromatic monomers, including styrene, alpha-methylstyrene, all isomers of vinyl toluene, in particular p-vinyletoluene, all isomers of ethylstyrene, propyl styrene, vinylbiphenyl, vinyl naphthalene and blends thereof, homopolymers and copolymers of may have any desired three dimensional structure, including syndiotactic, isotatic, hemiisotactic or atactic, stereoblock polymers, copolymers, including the above mentioned vinylaromatic monomers and comonomers selected from ethylene, propylene, dienes, nitriles, acids, maleic anhydrides, vinyl acetates and vinyl chlorides or acryloyl derivatives and mixtures thereof, for example styren/butadiene, styrene/acrylonitrile, styrene/ethyiene (interpolymers) styrene/alkymethacrylate, styrene/butadiene/aikyi acrylate, styrene/butadiene/alkyl methacrylate, styrene/maleic anhydride, styrene copolymers; hydrogen saturated aromatic polymers derived from by saturation of said polymers, including polycyclohexylethylene; polymers derived from alpha or beta-unsaturated acids and derivatives: unsaturated monomers such as

acrylonitrile/butadiene copolymers acrylate copolymers, halide copolymers and amines from acyl derivatives or acetals; copolymers with olefins, homopoiymers and copolymers of cyclic ethers; poly amides and copolyamides derived from diamines and dicarboxylic acids and or from aminocarboxylicacides and corresponding lactams; polyesters and polyesters derived from dicarboxylic acids and diols and from hydroxycarboxylic acids or the corresponding lactones; blocked copolyetheresters derived from hydroxyl terminated polyethers; polyketones, polysulfones, polyethersufones, and polyetherketones; cross-linked polymers derived from aldehydes such as phenols, ureas, and melamines such as phenol/formaldehyde resins and cross- linked acrylic resins derived from substantial acrylates, e.g. epoxyacrylates, urethaneacryiates or polyesteracrylates and starch; polymers and copolymers of such materials as polylactic acids and its copolymers, cellulose, polyhdyroxy alcanoates, poiycaprolactone, polybutylene succinate, polymers and copolymers of N-vinylpyrroolidone such as polyvinylpyrrrolidone, and crosslinked polyvinylpyrrolidone, and ethyl vinyl alcohol. Additional examples of thermoplastic polymers suitable for the mineral-containing composite include polypropylene, high density polyethylene combined with MS0825 Nanoreinforced POSS polypropylene, thermoplastic elastomers, thermoplastic vulcinates, polyvinylchloride, polylactic acid, virgin and recycled polyesters, cellulosics, polyamides, polycarbonate, polybutylene tereaphthylate, polyester elastomers, thermoplastic polyurethane, cyclic olefin copolymer, biodegradable polymers such as Cereplast- Polylactic acid, Purac-Lactide PLA, Nee Corp PLA, Mitsubishi Chemical Corp GS PLS resins, Natureworks LLC PLA, Cereplast Biopropropylene, Spartech PLA Rejuven 8, resins made from starch, cellulose, polyhydroxy alcanoates, poiycaprolactone, polybutylene succinate or combinations thereof, such as Ecoflex FBX 7011 and Ecovio L Resins from BASF,

polyvinylchloride and recycled and reclaimed polyester such as Nodax biodegradable polyester by P & G.

[0037] The polymer-containing layer can include coupling agents from about 0.05% to about 15% of the weight of the mineral-containing layer. The agents aid in the mixing and the filling of the mineral into the polymer matrix. Functional coupling groups include (Pyro-) phosphate. Benzene sulfonyl and ethylene diamine. These can be added to thermoplastics including polyethylene, polypropylene, polyester, and ethyl vinyl alcohol, aluminate, siloxane, silane, amino, malice anhydride, vinyl and methacryl . The results of these combinations improve adhesion to fibers, heat seal strength, heat seal activation temperatures, surface energy, opacity, and cosmetic effect. Mineral content can include, but is not limited to, wollanstonite, hydrated and non-hydrated, magnesium silicate, barium sulfate, barium ferrite, magnesium hydroxide, magnesium carbonate, aluminum trihy dioxide, magnesium carbonate, aluminum trihydroxide, natural silica or sand, cristobalite, diaonite, novaculite, quartz tripoli clay calcined, muscovite, nepheliner-syenite, feldspar, calcium suphate-gypsum, terra alba, selenite, cristobalite, domite, silton mica, hydratized aluminum silicates, coke, montmorillonite (MMT), attapulgite (AT), carbon black, pecan nut flour, cellulose particles, wood flour, fly ash, starch, TiO? and other pigments, barium carbonate, terra alba, selenite, nepheline-syenite, muscavite, pectolite, chrysotile, borates, sulfacates, nano-particles of the above from 0.01 to 0.25 micron particle size, and precipitated and ground calcium carbonate,

[0038] Among, but not limited, procedures generally involving the use of polymerization initiators of catalysts for the polymerization of butene monomer to polymers of high molecular weight, preferably catalytic systems used in such procedures are the reaction products of metal alkyl compounds such as aluminum tri ethyl, and a heavy metal compound, such as the trihalides of Groups IV- VI metal s of the periodic table, e.g. titanium, vanadium, chromium, zirconium, molybdenum, and tungsten. The polymers thus formed can exhibit substantial isotactic properties as a result of variations in the molecular weight and the nature of the polymerization catalyst, co- reactants, and reaction conditions, Isotatic poiybutylenes are relatively rigid at normal temperatures but flow readily when heated, and they most preferably, should show good flow when heated, expressed in melt flow. Applicable isotatic poiybutylenes should show a melt flow of from 0.1 to 500, preferably 0.2 to 300, more preferably from 0.4 to 40, most preferably from 1 to 4. Other polymers expressed within the contents of the present specification should also be considered within these parameters.

[0039] Regarding the polymer and fiber containing composite layers, upon substantially and continuously or discontinuous surface converage on the composite, polymer layer bonding to the fiber-containing using extrusion coating or extrusion lamination techniques, the layer of which can then be used to form a laminated structure of which the layers can be used as a peel coat onto a desired backing material. The best peel seal, for example, to the polymer containing layer of the composite, may be selected from poly-4-methyl pentene, nylon, high density polyethylene "HDPE," aluminum foil, polycarbonate polystyrene, polyurethane, polyvinyl chloride, polyester, polyacrylonitrile, polypropylene "PP," and paper. An example extrusion process can be accomplished with a screw or pneumatic tube. In some embodiments the mineralized polymers can be combined with such materials as plasticizers lubricants, stabilizers, and colorants by means of Banbury mixers. The resulting mix is then extruded through rod shaped dies and chipped into pellets. Pelletized mineralized polymer can then enhance the mineral and other content by "letting down" the resin pellet mix with inline or offline mixing capability before being fed into the end of a, for example, screw -type extruder, heated, and mixed into a viscous fluid or semi-fluid in the extruder barrel for further processing to the die. Further, when properly dispersed the interaction between the mineral particles and the polymer content without covalent bonding, results in improved van der Waals forces that provide attraction between the materials. This interaction results in some adhesion in the composite during extrusion, resulting in an absorbed polymer layer on the filler surface.

[0040] Heat sealing from fiber to polymer layer, from polymer layer to polymer layer, and heated polymer layers making contact with fiber layers during extaision coating, are the most commonly used techniques for constructing packaging materials that are then heat sealed during package forming. Packages are formed after extrusion coating using different heat sealing technologies, such as ultrasonic welding, hot air welding, chemical adhesives, bar heat sealing, and impulse heat sealing. The molecular process that occurs during the heat sealing under compression or extrusion coating of a polymer layer to fibers, having semi-crystalline polymer content, is the interface between the polymer curtain or layer and fiber surface. Here, van der Waals forces arise in the contact area of the materials. These considerations combined with the unique attributes of the mineral content dispersed within the polymeric matrix of both monolayer and multilayer mineral composite layers impact the application of heat that initiates the melting of semi-crystalline polymers, causing the polymer molecules to better diffuse across the interface. Given sufficient time, the diffused polymer molecules and mineral content will become entangled with each other. The heat capacity of the layer is generally about the same as a neat polyolefm layer, accelerating fiber bonding at sufficient temperatures, particularly at very short dwell intervals with high heat levels, for example, using hot air sealing from about 0.23 second dwell and above and heat ranges from about 925 °C to about 1, 100 °C. Heat seal pressure requirements are generally less, but in the same range as, neat polyolefms from about 20 psi to about 80 psi.

[0041] Molecular weight ranges of the polymer bonding agent content of the mineral-containing layer from about Mw 10,000 D to about 100,000 D. Further, having, but not limited to, a minimum of about 10%-70% of the polymer content having branching index (g') of about 0.99 or less measured at the Z-average molecular (Mz) of the polymer. Some, part, or all of the mineral- containing layer polymer bonding agent is preferred but not required to a have an isotactic run length from about 1 to about 40. Further, the mineral containing layer polymer bonding content shear rate range is from about 1-10,000 at temperatures from about 80 °C to about 410 °C. The mineral-containing composite layer, having mineral content from about 20% to about 65% (but not limited to), can generally provide hot tack operating ranges from about 25 °C to about 225 °C having from about 1.0 N/mm to about 6.0 N/mm seal strengths. Using polyethylene copolymers, with temperatures from about 80 °C to about 220 °C and having hot tack strength from about 2.5 N/mm to about 15 N/mm with optimal strength in the range of about 120 °C to about 160 °C. Additionally, mineral-containing dispersed and non-interspersed polymer layer peel strengths having ranges represented in J/m2 from about 1 to about 45, having sealing (dwell) times in the range from about 0.30 seconds to about 15 seconds, in temperature ranges from about 115 °C to about 240 °C with corresponding seal pressures at or below about 0.80 MPa.

[0042] When applying the polymer layer to the fiber layer, the ability of an adhesive or polymer coating layer to resist creep of the seal while it is still warm or in a molten state is called hot tack. Hot tack includes two components, the melt strength of the seal layer at the temperature of the seal, and the interfacial adhesion of the sealant layer. Table 1 , below, illustrates the heat seal tack improvement of mineralized resins according to the present embodiments (Film A) vs. neat polyolefms (Film B).

Table 1 : Hot Tack Performance FILM A: 20%-40%Mineralized, 20%-60%Amorphous, 20%-55% Crystalline Structure

Observations - N/25 mm (5⁾ 250 MS

Note; Mineralized resin density is 1.20 to 1 .35 g/cm^~

FILM B 100% Neat, No Mineral Load

Interface Observations - N/25 mm © 250 MS MeanN Std. Dev. N rature

[0043] Heat sealing of a polymer is a combination of mass and heat transfer processes. Heat flow to the polymer films, the melting of the polymer, and the inter-diffusion of molten polymer chains are time relevant. In order to form a strong, intact seal, an adequate dwell time, or the duration of time when the films make contact together during sealing, must be given to allow the mass and heat transfer processes to proceed until the target end conditions are reached, e.g., complete melting of crystalline fraction to obtain crystal fusion using, for example, random copolymers with densities at or above 0.88 g/cm " and adequate inter-diffusion of molten polymers to form a continuum interface. Potential, but not limited to, copolymer isotacticity index from about 20% to about 85% measured by the DSC method can be used, and as such mineral-containing layers with mineral by weight concentrations up to about 75% having a melt flow index "MFI" from about 190 g/1 0 minutes to about 1.0 g/10 minutes measured by the NF T 51-620 standard can be obtained. The addition of poly olefin plastomers and elastomers having the densities per ASTM D 792 from about 0.86 to about 0.891 g/cm' with DSC melting peaks from about 59 °C to about 10 °C can be considered having a 2% secant modulus, and MPa from about 15 to about 120. The optimal dwell time interacts strongly with temperature, the application of higher temperatures reduces the time required for polymer layers and vice versa. Mineralization alters the specific heat of the mineralized polymer layer, thermal diffusion, and heat conductivity. Therefore, upon heat capacity apex, dwell time and pressure requirements can significantly diminish. At the same time, a high performance bond takes place along the fiber- containing layer contact surface. For example, increasing the dwell time from 0,3 to 1.4 sat a 130 °C temperature during heat sealing 12 lbs/3 msf layer of PE increased seal strength by only 10%. However, a 25% to 65% mineralized poly olefin layer increased peel strength from about 20-30% with dwell times of about 0.4 to 0.9 seconds with a 9 lbs/3 msf layer weight. Therefore, dwell time during heat seal can contract, however, it is still considered to be a secondary factor compared to temperature. High temperature sealing methods can be employed such as hot air with seal temperatures from about 650 °C to about 1200 ^C'C having nominal seal pressures below about 30 psi and dwell times of below about 2 seconds. Molecular contact between two surfaces is necessary in order to allow the diffusion of polymer chains across the seal or contact interface. Pressure applied to mineral -containing layers during the sealing process can be from about 5 psi to about 90 psi. This contact can be established by compressing the polymer films together or to fiber surfaces, under compression pressure. The applied pressure helps to remove surface irregularities and to increase the actual contact area between the sealed surface interface, thereby increasing heat flow. However, the mineralized layer can provide greater heat flow efficiencies, thus reducing dependence on pressure. The plateau initiation temperature is when the interface temperature is high enough to melt the crystalline region of the polymer completely. Other than pressure required to accomplish efficient surface area contact between the sealing surfaces, the effect of pressure on heat sealing can be considered a less important variable when using mineralized layers vs. pofyofefin layers. Mineralization improves the critical inter-diffusion process of polymer molecules.

[0044] The peeling failure mode is generally correlated with low heat seal strength due to low entanglement density in the sealing areas, while tearing mode or fiber tear is associated with the highest seal strength. In the latter failure mode, the strength of the seal is higher than the cohesive strength of the polymer indicating production of an ideal seal and adhesion. The heat seal failure mode is dependent on the material type, laminate structure, and the surface properties of the seal substrate. For instance, two failure modes during heat sealing is an example, namely fractures in the seal and at the edge of the seal, and necking behavior at the edge of the seal related to the peeling failure mode. Corona discharge treatment, which is commonly applied to increase surface activity of poly mer films to improve printability, can create cross-links on the film surface that reduce the inter-diffusion of polymer chains, thereby changing the failure mode of the material. The observed difference due to the reduction in entanglement density in the sealing area is caused by the corona discharge treatment. However, particle mineralization of the polyofefin can reduce or mitigate the adverse effect of corona treat to the surface of the mineral- containing layer.

[0045] Seal integrity can be defined as a seal that is continuous and consistent without having any discontinuities, such as micro-leaks, or any other defects such as wrinkles, abrasions, dents, blisters, and delamination. Seal integrity is important in food packaging to ensure that the product is protected from unwanted factors from the atmosphere, such water vapor, that are deleterious to sensitive components in food. Seal integrity and seal strength are the main parameters that determine the quality of a heat seal. Seal integrity is defined as a seal continuum in which there is a complete fusion of the polymer with no discontinuities. The maximum seal strength can be defined as the maximum force per unit width of seal required to progressively separate the seal, under some specific test conditions. In many food packaging applications, adequate seal strength is critical during product distribution to ensure that the package can withstand mechanical stresses because of handling. Accordingly, seal strength is often used as one of the process control parameters to ensure that adequate seal integrity is achieved. The dominant process variables that dictate seal strength are jaw temperature, jaw configuration, and dwell time (the time spent in the seal cycle when polymer films are held together by the seal). Higher peel seal strength was reported using linear low density polypropylene (LLDPE) samples of less branched and higher molecular weight. Also, reported seal strength of a semi -crystalline polyolefin was closely related to the melting temperature. Upon polyolefin mineralization, the melt temperature of the polymer content remains the same. However, the mineral content improves the performance of less crystalline stractures through more efficient heat conductivity and diffusion characteristics.

[0046] Seal strength properties can also be affected by surface treatment and modification of polymer films. In general, homopolymers require less contact time to achieve the maximum seal strength than polymers containing structurally different (heterogeneous) copolymers.

Mineralization from about 20% to about 65% altered those dynamics due to the changed thermal properties of the matrix, particularly entanglement at the interface layer. For example, samples sealed at the jaw temperatures (150 °C and 165 °C) at 1.5 seconds dwell time found that mineralization decreased dwell time. Also, slightly increasing jaw temperature further improved dwell times and significantly improved seal peel strength from about 10% to about 30%. Under this high-temperature long seal time seal condition, interface temperatures ranged from about 130 °C to about 150 °C. These results suggest that long contact time results can be improved when sealing at higher jaw temperatures to prevent excessive squeeze out of polymer melt, and possible material degradation, whereas at lower jaw temperatures, the dwell time is still sufficient to allow for the melting of crystallites and diffusion of polymer chains across the interface to form a strong seal. Exemplar mineral containing layer weights are from about 7.5 ibs/3msf to about 60 lbs/3msf, having heat seal strengths from about 1.25 lbs/in and to about 6.45 lbs/in, and terminal hot tack strength from about 2.10 to about 8.55 N/in. Heat seal initiation temperatures from about 59 °C to about 76 °C and hot tack initiation temperatures from about 57 °C to about 99 °C. Pressure during dwell from about 10 psi to about 80 psi and dwell times from about 0.30 seconds to about 1.75 seconds.

[0047] Further, low temperature seals from about 340 °C to about 425 °C at dwell time intervals of about 0.50 to about 6.25 seconds with seal pressures from about 20 psi to about 85 psi have average peel force from about 0,50 to about 4.0 lbs lbs/inch. Heat seal process methods that can used also include tray sealers, transverse form-fill-seal, platen die, and rotary 4-side machines. [0048] Most pure inorganic matter, including salts, has very high surface energy as measured by surface tension, e.g. up to and over 200 dynes/cm, due to the imbalance of bonding forces at the surface. High surface-free-energy materials are generally hydrophilic and absorb water from hydrogas of the atmosphere, corresponding reducing the energy level based on the rule that ail matter tends to assume its lowest energy, most stable state. Observed surface tensions on all high surface energy mineralized layers between 95% and 0.6% relative humidity are found to be pre-treatment levels from about 34 dyne/cm to about 45 dyne/cm, respectively. In comparison, unfilled (neat) LDPE has an approximate 32 dynes/cm. As particle size decreases, surface activity increases. Small to very small particles have little mass, low bulk densities, and are affected by forces of agglomeration. The forces may be mechanically effective over great distances relative to molecular dimensions. These forces greatly improve adhesion to fibers of the composite during extrusion coating production. Also, the enhanced surface energy levels strength than polymers containing structurally different (heterogeneous) copolymers.

Mineralization from about 20% to about 65% altered those dynamics due to the changed thermal properties of the matrix, particularly entanglement at the interface layer. For example, samples sealed at the jaw temperatures (150 °C and 165 °C) at 1.5 seconds dwell time found that mineralization decreased dwell time. Also, slightly increasing jaw temperature further improved dwell times and significantly improved seal peel strength from about 10% to about 30%. Under this high-temperature long seal time seal condition, interface temperatures ranged from about 130 ^C'C to about 150 ^C'C. These results suggest that long contact time results can be improved when sealing at higher jaw temperatures to prevent excessive squeeze out of polymer melt, and possible material degradation, whereas at lower jaw temperatures, the dwell time is still sufficient to allow for the melting of crystallites and diffusion of polymer chains across the interface to form a strong seal. Exemplary mineral containing layer weights are from about 7.5 lbs/3msf to about 60 lbs/3msf, having heat seal strengths from about 1.25 lbs/in and to about 6.45 lbs/in, and terminal hot tack strength from about 2.10 to about 8.55 N/in. Heat seal initiation temperatures from about 59 °C to about 76 °C and hot tack initiation temperatures from about 57 °C to about 99 °C can be used. Pressure during dwell from about 10 psi to about 80 psi and dwell times from about 0.30 seconds to about 1.75 seconds can be used.

[0049] Further, low temperature seals from about 340 °C to about 425 °C at dwell time intervals of about 0.50 to about 6,25 seconds with seal pressures from about 20 psi to about 85 psi have average peel force from about 0.50 to about 4.0 lbs lbs/inch. Heat seal process methods that can used also include tray sealers, transverse form-fill-seal, platen die, and rotary 4-side machines.

[0050] Most pure inorganic matter, including salts, has very high surface energy as measured by surface tension, e.g. up to and over 200 dynes/cm, due to the imbalance of bonding forces at the surface. High surface-free-energy materials are generally hydrophilic and absorb water from hydrogas of the atmosphere, corresponding reducing the energy level based on the rale that all matter tends to assume its lowest energy, most stable state. Observed surface tensions on all high surface energy mineralized layers between 95% and 0.6% relative humidity are found to be pre-treatment levels from about 34 dyne/cm to about 45 dyne/cm, respectively. In comparison, unfilled (neat) LDPE has an approximate 32 dynes/cm. As particle size decreases, surface activity increases. Small to very small particles have little mass, low bulk densities, and are affected by forces of agglomeration. The forces may be mechanically effective over great distances relative to molecular dimensions. These forces greatly improve adhesion to fibers of the composite during extrusion coating production. Also, the enhanced surface energy levels (dyne) greatly improve surface performance for ink and mineral-containing layer composite surface adhesive applications.

[0051] For this reason, polyolefins generally need to be surface-activated before the deposition of inks, paints, adhesives, metals, and coatings surface energy levels. These elevated levels (about 45-100 dynes/cm) provide for good fiber poly olefin adhesion and fiber tear during heat sealing, water based, and hot melt glue processes when the mineral-containing layer makes contact with opposing polymer or fiber-containing layers. Plasma treatment to the surface of polypropylene (PP), polyethylene (PE), high-density polyethylene (HDPE), EPDM, and other polyolefin-coated surfaces, is frequently used because of the low resident surface energy found on polyolefin coatings, often between 28-36 dynes/cm². For example, expressed in mN/m, the approximate surface energy levels of various materials are: PTFE-20, silicone-20, PP-30, PE- 32, PS-34, PC-34, ABS-34, XLPE-32, PUR-34, UV ink-up to 56, water-based coating up to 56, and UV-glue or water based glue up to 50, However, 40% to 60% mineralized layers before demonstrate up to 40% improved dyne levels. Generally, polyolefins with "low surface energy" or "non-polar surfaces" provide poor conditions for adhesives, gluing, or adhesion, thus resulting in poor quality ink wet-ability and graphics and very poor bond strength between the adhesive and its opposing surfaces. Ink wet-ability being defined as the surface tension or surface energy of the soli d substrate in relation to the surface tension of the liquid, the better the wet-abi lity, the smaller the contact angle. The problem is aggravated when using UV curing or water based adhesives, inks, and coatings. The strength of attraction between a material and a coating is determined by the relative surface energy and surface tension of the materials. The higher the solid's surface energy relative to the liquid's surface tension, the greater the molecular attraction. This draws the ink or adhesive closer for high bond strength. The lower the solid's surface energy relative to the liquid's surface tension, the weaker the attractive forces and the coating will be repelled. Plasma- and corona-treated on non-treated polymer-containing layers having mineral content from about 20% to about 70% can exceed the contacting liquid's surface energy from about 1-15 mN/m. The challenge faced when extrusion coating poly olefins and like polymers is to increase the surface energy (polarity) of the material to a level significantly higher than that of the opposing surface tension of the ink, coating, or adhesive, such that the surface provides favorable wetting and adhesion. Typically, the surface energy of the substrate needs to exceed the surface tension of the ink, paint, coating, or adhesive from about 10-15 dynes/cm².

[0052] There are several methods of increasing the surface energy and polarity of plastics. These include harsh, potentially environmentally harmful wet chemical treatments, high temperature flame torch treatments, high voltage corona treatment, and plasma surface activation. Plasma surface activation, which exposes low-surface-energy extrusion-coated polvoiefins to the highly active environment of either vacuum or atmospheric plasma, is a very effective and long lasting method of increasing their surface energy and polarity.

[0053] Corona treatment of plastic substrates involves high voltage and frequency electricity discharged from an electrode into an ionizing air gap (generally about 0.060"), where it passes through the substrate to an electrically grounded metal roll. This treatment increases the surface tension (measured in dynes/cm) of the substrate to at least 10 dynes/cm higher.

Table 2 - FiberLayer Characteristics

Fiber Aspect Ratio (Average) 5-100

Fiber Thickness (Softwood) 1.5-30 mm Fiber Thickness (Hardwood) 0.5-30 mm

Filled Fiber Content 1% to 30%

Fiber Density 0.3-0.7 g/cm³

Fiber Diameter 16-42 microns

Fiber Coarseness 16-42 mg/lOOm

Fiber Pulp Types Mechanical, Thermo-Mechanical, Cherni- (Single to Triple-Layered) Thermo- Mechanical, and Chemical

Permeability 0.1-1 10 niLx l OD

Hydrogen Ion Concentration 4.5-10

Tear Strength (Tappi 496, 402) 56-250

Tear Resistance (Tappi 414) m49-250

Moisture Content 2% to 18% by weight

The following resins are possible, but not limiting, ingredients for a polymer containing layer : carboxy- polyniethyeleiie, polyacrylic acid polymers and copolymers, hydroxypropylcelluiose, cellulose ethers, salts of poiy(methyi vinyl ether-co-maleic anhydride), amorphous nylon, polyvinylchrloride, polymethylpentene, methyl methacrylate-acrylonitrile-butadiene-styrene, acrylonitriie-styrene, polycarbonate, polystyrene, polymethylcrylate, polyvinyl pyrrolidone, poly(vinylpyrrolidone-co- vinyl acetate), polyesters, parylene, polyethylene napthalate, ethylene vinyl alcohol, and polylactic acids. In some embodiments a polymer containing layer can also contain from about 10% to 65% mineral content. Various mineral-containing layer polymer and mineral content can be determined based upon performance and content requirements. Branched, highly branched and linear polymer combinations are possible in ail composite layer constructions. Layer combinations depend on coextrusion die design, flow properties, and processing temperature allowing for coextrusion fusion layers and/or subsequently extruded lamination, or lamination of the layers into a final mineral-containing composition of which individual (non-interspersed) or total combination of layers having by weight mineral content of about 20-65%. Layers can be uniaxiaily or biaxialiy oriented (including stretching) from about 1.2 to about 7 times in the machine direction (MD) and from about 5 to about 10 times in the transverse direction, and stretched from about 10% to about 75% in both the (MD) and (CD) directions. Generally, although not limited to, polyolefin mineral content bonding agents have number average molecular weight distributions (Mn) of from about 5,500 D to about 13,000 D.

[0054] Methods currently used in consumer packaging structures relating to barrier performance include neat thermoplastic coatings applied in single and multiple layers contacting the fiber surface. Also, a variety of emulsion and waterborne polymer- and mineral -containing coatings can be applied with or without using thermoplastics and at room temperatures. However, these methods are either costly or do not provide desired levels of barrier performance, most particularly at the point of fracture or bending when cutting, shaping, and forming a packaging structure. Further, heat scalability and fiber adhesion are other critical aspects during the packaging manufacture and forming process. Finally, high quality printing surfaces are desirable, and existing methods do not provide sufficient cosmetics at desired cost levels.

[0055] The fiber-containing layers may include in their composition or surface, but are not limited to, mineral and polymeric sizings, surface treatments, coatings, and mineral fillers. Some advantages of the non-fiber content of the fiber-containing layer include improved fiber layer printability, ink hold out, dynamic water absorption, water resistance, sheet gloss, whiteness, delta gloss, pick strength, and surface smoothness.

[0056] Pressure sensitive surfaces found within the composite layers according to the present embodiments can be permanently or temporarily adhered or bonded during pre- or post- application (to the adhesion destination surface), with the chosen layer surfaces making contact directly to the chosen destination surface. Adhesive layers can make contact with one or more opposing surfaces of the composite layer. Further, one or more adhesives could make contact with the polymer or fiber containing layer and the outer surface of the stmcture on which adhesive is applied, and the fiber containing layer could comprise the outer surface of the structure with an adhesive backing on the polymer containing layer surface that is either permanently or temporarily directly bonded to the product or packaging surface in which the product is enclosed,

[0057] The polymer and fiber containing layer(s) in the present embodiments can make contact with thermoplastic or non-thermoplastic waterborne or emulsion-carried polymer starch- containing adhesives and glues currently used in the art. Adhesives can permanently or temporarily bond the present mineral-containing layer(s) to any of the outer or inner surfaces of the label structure itself, forming the label stmcture that may be applied with our without heat or pressure, but not limited to, label destination surfaces having metal, polymer, glass, woven, wood, cellulose, lignin, nano-treated surfaces, paper coatings, woven, or non-woven content. Further, the label itself may contain all or in part the same materials as the destination surface. Label structures might also include, for example, mineral-containing layers used as preprinted or non-preprinted layers that are subsequently adhered to corrugated liners and shaped to form corrugated structures.

[0058] The composite layer or layers make functiona contact with adhesives found in outer or inner label surfaces. The surfaces include label liner used for cold, wet, or dry strength label applications in calipers from about 0. 75 mil to about 10 mil. The finished labels can be used in both roll-to-roll or singly applied applications with basis weights from about 10 lbs/3 rnsf to about 400 lbs/3msf. The composite layer can be used as a layer or part of a pressure sensitive label having an MD-CD strength from about 4 to 9 lbs per inch to about 1 to 15 lbs per inch, MD-CD tear strengths from about 60 grams to about 64 grams, and with MD-CD tear strengths from about 2 lbs to about 15 lbs per sheet.

[0059] One example of label adhesive is emulsion acrylics contacting the mineral-containing layer with metals, polyesters, polymers, and glass-containing surfaces. The adhesive has loop tack from about 1.5 lbs to about 3.5 lbs and corresponding peel adhesion from about 0.5 to about 4.0 lbs. Surface application temperatures are from a minimum of about -22 °F with service temperatures from about - 70°F to about 220 °F. [0060] The present composite layer(s) can functionally contact one or more polymer or polyester containing layers within the surface structures, often but not limited to paper fiber roll stock across a web, with the layer having calipers from about 0.50 mil to about 2.5 mil and MD-CD tensile strengths from about 15,000 psi to about 60,000 psi and from about 16,000 to about 55,000 psi.

[0061] The composite layer(s) may be functionally bonded to internal and external surfaces and also have at least one of its surfaces applied to the outer surface of the destination package or product for the purpose of labeling. Non-limiting adhesives that can be used for bonding the mineral-containing layer to the destination product or package surface can include polyesters with crystallization rates of from about 40 to about 90 and for polycarbonates from about 45 to about 90, having low to high heat resistance and thermo- lasticity as measured at about 60 °C.

[0062] Other adhesive characteristics present on the composite surfaces within the packaging structure include inner bonding surface areas bonded to the destination surface, may include adhesives having, without limitation: a DOT-T Peel of 1 N or more on paper as measured by ASTM 1876, a heat of fusion of 1-70 Jig and molecular weight up to about 60,000, having one of more tackifiers including aliphatic hydrocarbon resins, aromatic modified aliphatic hydrocarbon resins, hydrongenated polycyclopentadiene resins, polycyclopntadiene resins, gum rosins, gum rosin esters, polyterpenes, aromatic modified polyterpenes, terpene phenolics, aromatic modified hydrogenated polycyclopentadiene resins, hydrogenated aliphatic resin, hydrogenated aliphatic aromatic resins, hydrogenated rosin esters, derivatives thereof, and/or combinations thereof.

[0063] Other adhesive characteristics between at least one side of a composite layer(s) and other surfaces within the structure or surface area bonded to the destination surface, may include, without limitation, adhesives having one or more waxes such as polar waxes, non-polar waxes, oxidized and non-oxidized Fischer- Tropsch waxes, hydroxy stearamide waxes, functionalized waxes, PP waxes, PE waxes, wax modifiers, and combinations thereof. The adhesive additives may include plasticizers oils, stabilizers, antioxidants, pigments, dyestuffs, polymeric additives, defoamers, preservatives, thickeners, rheology modifiers, humectants, fillers, and water. The adhesive may further containing as desired aliphatic oils, white oils, combinations thereof, and/or derivatives thereof. [0064] Additional functional bonding adhesive within the layers, or as an outer or inner surface area bonded to the destination surface, may include adhesives having, without limitation, polymeric additives including homo poly-alpha-olefins, copolymers of alph-olefins, copolymers and terpolymers of di olefins, elastomers, polyesters, block copolymers, ester copolymers, aery late polymers, aiky! aery late polymers, and vinyl acetate polymers.

[0065] Other functional bonding characteristics of adhesives between and other surfaces within the structure bonded to the destination surface, may include non-hot melt adhesives having, without limitation, pH levels from about 6.5 to about 8.8, boiling points for non-hot melt at approximately 212 °F, specific gravity from about 0.89 to about 1.61 g/cm', solids content from about 20% to about 85%, viscosities from about 70 mPa to about 150 mPa, and running temperatures up to 320 °F.

[0066] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. "such as") provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0067] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the tenns "comprises" and "comprising" should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C ....and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Claims

CLAIMS hat is claimed is:

1. A storage enclosure, comprising:

a primary enclosure having an opening region comprising an aperture, wherein at least a portion of the primary enclosure comprises a composite material, the composite material comprising a fiber-containing layer and a mineral -containing layer, wherein the mineral-containing layer comprises a binding polymer and a mineral, wherein the mineral is present in the mineral-containing layer at up to 65% by weight; and

a closure sheet comprising a first edge and a second edge that opposes the first edge, wherein the first edge is coupled to or contiguous with an edge of the aperture, wherein the closure sheet is dimensioned to span the aperture.

2. The storage enclosure of claim 1, wherein the closure sheet comprises an adhesive.

3. The storage enclosure of any of the preceding claims, wherein the adhesive is reusable.

4. The storage enclosure of any of the preceding claims, wherein the primary enclosure comprises a first coupling mechanism and the closure sheet comprises a second coupling mechanism, wherein the first coupling mechanism and the second coupling mechanism are configured to mate to form a seal.

5. The storage enclosure of claim 4, wherein the first coupling mechanism and the second coupling mechanism comprise a pressure sensitive adhesive sealing mechanism.

6. The storage enclosure of claim4, wherein the closure sheet is first pushed inward to break free the pressure sensitive adhesive, and then pulled out.

7. The storage enclosure of claim 4, wherein the first coupling mechanism and the second coupling mechanism comprise a zipper mechanism.

8. The storage enclosure of claim 4, wherein the first coupling mechanism and the second coupling mechanism comprise an interlocking projection and groove mechanism.

9. The storage enclosure of any of the preceding claims, wherein the fiber containing layer comprises natural and/or synthetic fibers.

10. The storage enclosure of any of the preceding claims, wherein the closure sheet

comprises a composite material, the composite material comprising a polymer-containin layer and a mineral-containing layer, wherein the mineral-containing layer comprises a binding polymer and a mineral, wherein the mineral is present in the mineral-containing layer at up to 65% by weight.

11. The storage enclosure of any of the preceding claims, wherein the primary enclosure is manufactured by extrusion of the mineral-containing layer onto the fiber-containing layer.

12. The storage enclosure of any of the preceding claims, wherein the binding polymer comprises a polyethylene copolymer, a polypropylene copolymer, copolymers of ethylene and propylene, or combinations thereof.

13. The storage enclosure of any of the preceding claims, wherein the mineral containing layer comprises about 20% to about 40% mineralized, with a structure that is about 20% to about 60% amorphous and about 20% to about 55% crystalline.

14. The storage enclosure of any of the preceding claims, wherein the primary enclosure comprises a printable surface.

15. The storage enclosure of any of the preceding claims, wherein the closure sheet

comprises a printable surface.

16. A method of making a container from a sheet of a composite packaging structure

comprising: cutting the sheet into desired shape, folding the sheet to form a three- dimensional shape, and heat sealing abutting surfaces to secure the abutting surfaces to one another, wherein the sheet of composite packaging structure comprises a fiber-containing layer and a polymer containing layer, and wherein the heat sealing is performed under the following conditions: a dwell time in the range from about 0.30 seconds to about 15 seconds, a temperature range from about 115 °C to about 240 °C, and a seal pressure at or below about 0.80 MPa.

17. The method of claim 16, wherein the container comprises a lid.

18. The method of claim 17, wherein one side of the lid is coupled to or contiguous with an edge of an aperture in the container.

19. The method of claim 17, wherein the lid attaches to the aperture of the container by a adhesive sealing mechanism.

20. The method of claim 17, wherein the one side of the lid is first pushed inward to break the pressure sensitive adhesive, and then pulled out to open the lid.

21. A storage box enclosure comprising:

a composite material and a transparent plastic sheet material, wherein the transparent plastic sheet material forms part of an opening region comprising an aperture, wherein the transparent plastic sheet material is attached to the composite material with a permanent adhesive and a pressure sensitive resealable adhesive, and

wherein the permanent adhesive bonds to the composite material on the inside of the box, and the pressure sensitive resealable adhesive bonds to the composite material on the outside of the box.

22. The storage box enclosure of claim 21, wherein the plastic material is on top of the box providing a window,

23. The storage box enclosure of claim 21 , wherein the composite material comprises a fiber- containing layer and a mineral-containing layer, wherein the mineral -containing layer comprises a binding polymer and a mineral, wherein the mineral is present in the mineral -containing layer at up to 65% by weight.

24. The storage box enclosure of claim 21, wherein the permanent adhesive is optimized to bind to the mineral containing layer and the pressure sensitive resealable adhesive is optimized to bind to the fiber containing layer.

25. The storage box enclosure of claim 21, wherein the permanent adhesive is optimized to bind to the fiber containing layer and the pressure sensitive resealable adhesive is optimized to bind to the mineral containing layer,

26. The storage box enclosure of claim 21, wherein the top view of the box is as shown in Figure 2.

27. The storage box enclosure of claim 21, wherein the box comprises a detachable

perforation line that follows the shape of the aperture and/or opening region.

28. The storage box enclosure of claim 21, wherein the box comprises a bendable hinge on one side of the aperture and/or opening region.

29. The storage box enclosure of claim 21, wherein the permanent adhesive is on the inside of the score line.

30. The storage box enclosure of claim 21, wherein the pressure sensitive resealable adhesive is on the outside of the perforation line.