Abstract:
A heat resistant multi-layer structure configured to form a food or beverage container. The multi-layer structure includes a core layer connected to an external multi-layer side and an internal multi-layer side. The external multi-layer side includes an external multi-layer polymer film and a first bonding layer. The internal multi-layer side includes an internal multi-layer polymer film, a second bonding layer and a barrier layer.

Description:
RELATED APPLICATIONS 
       [0001]    This application relates to, claims priority from, and incorporates herein by reference, as if fully set forth, U.S. Provisional Patent Application Ser. No. 60/925,929, filed on Apr. 24, 2007 and entitled “LAMINATE STRUCTURE FOR HOT AND COLD FILL FOOD AND BEVERAGE PACKAGING.” 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to composite laminates, and in particular to composite laminate material that is recyclable and has heat resistance characteristics. 
         [0004]    2. Background Information 
         [0005]    In product packaging today, it is important that materials used for packaging products be recyclable. Many packaging products for liquids and dairy products require the product to first be cooled as the recyclable containers do not withstand filling with hot pasteurized liquids. This adds cost and delays in shipping the products. Some of the costs involved are cooling, storage space required, supervision, etc. 
       SUMMARY OF THE INVENTION 
       [0006]    One aspect of the invention provides a heat resistant multi-layer structure configured to form a food or beverage container. The multi-layer structure includes a core layer connected to an external multi-layer side and an internal multi-layer side. The external multi-layer side includes an external multi-layer polymer film and a first bonding layer. The internal multi-layer side includes an internal multi-layer polymer film, a second bonding layer and a barrier layer. 
         [0007]    Another aspect of the invention provides a laminate structure. The laminate structure comprising: a core layer coupled to a first multi-layer side and a second multi-layer side. The first multi-layer side comprising: a first multi-layer polymer sealable film, a print layer, and a first bonding layer. The second multi-layer side comprising: a second multi-layer polymer sealable film, a second bonding layer, a barrier layer, and a third bonding layer. 
         [0008]    Yet another aspect provides a method of forming a recyclable heat resistant multi-layer structure configured for forming food and beverage containers. The method comprising: welding a first side of a core layer to a first multi-layer side and welding a second side of the core layer to a second multi-layer side. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    For a fuller understanding of the nature and advantages of the invention, as well as a preferred mode of use, reference should be made to the following detailed description read in conjunction with the accompanying drawings, in which: 
           [0010]      FIG. 1  illustrates a first embodiment of a laminate structure; 
           [0011]      FIG. 2  illustrates another embodiment of a laminate structure; 
           [0012]      FIG. 3  illustrates yet another embodiment of a laminate structure; and 
           [0013]      FIG. 4  illustrates still another embodiment of a laminate structure. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0014]    The following description is made for the purpose of illustrating the general principles of the invention and is not meant to limit the inventive concepts claimed herein. Further, particular features described herein can be used in combination with other described features in each of the various possible combinations and permutations. Unless otherwise specifically defined herein, all terms are to be given their broadest possible interpretation including meanings implied from the specification as well as meanings understood by those skilled in the art and/or as defined in dictionaries, treatises, etc. 
         [0015]      FIG. 1  illustrates a laminate structure according to an embodiment of the invention. The laminate structure  100  is heat resistant and recyclable. The laminate structure  100  is formed into containers for holding food or beverages and can be hot-filled. As illustrated, the laminate structure  100  includes an external outer layer  101  comprising a multi-layer polymer film. In one embodiment of the invention outer layer  101  is extruded either by blown film extrusion or by cast film extrusion. In another embodiment of the invention outer layer  101  is a single layer. In one embodiment of the invention outer layer  101  protects the surface and bonds to an internal layer by use of heat welding at certain portions of the outer layer  101 . In one embodiment the outer layer  101  is made of a polyolefin base material and in other embodiments include a polyamide (PA), ethylene vinyl alcohol copolymer (EVOH) or similar materials having high barrier properties that are “sandwiched” in between layers to increase barrier properties. External outer layer  101  forms a clear but anti-contamination barrier and liquid seal, which prevents external material and atmospheric penetration. External outer layer  101  also prevents contamination from penetrating and provides see through functionality. 
         [0016]    In one embodiment of the invention, external outer layer  101  is clear. In another embodiment of the invention the laminate structure  100  includes a print layer  102 . In one embodiment of the invention the print layer  102  is printed in reverse to protect the printed design from scratches and prevents the ink from coming into contact with food or body parts of users. In this embodiment of the invention, print layer  102  includes a reverse printed label, which can include technical and presentational information in relation to the contents which will be held within a formed container from the laminate material. 
         [0017]    In one embodiment, the laminate structure  100  includes a bonding layer  103 . In one embodiment the bonding layer  103  is a liquid adhesive coated on a laminating machine. In another embodiment bonding layer  103  is a film layer placed between outer layer  101  and print layer  102  and the metalized layer  104  and or core layer  106  to amalgamate to one another. In one embodiment of the invention, bonding layer  103  secures the print layer  102  and external outer layer  101  on a film layer  104 . In one embodiment of the invention, to laminate different layers liquid glue is used to amalgamate the layers. In another embodiment of the invention an adhesive film is used for laminating, and placed between layers and pressed by heat to bond one to the other. In one embodiment of the invention, film layer  104  is a metalized layer. In another embodiment, film layer  104  is a non-metalized film. 
         [0018]    In one embodiment of the invention, the laminate structure  100  includes bonding layer  105 . In one embodiment of the invention the bonding layer  105  is liquid glue or an adhesive film used to bond  2 ,  3 ,  4 , etc. layers to one another. In one embodiment of the invention, the lamination method used can be cold, hot, extrusion coating etc. In one embodiment of the invention bonding layer  105  secures film layer  104  on a core layer  106 . In this embodiment of the invention, core layer  106  is made of a polymeric compound material inclusive of mineral components. In one embodiment of the invention the core layer  106  is made of a compound comprising different plastic food grade materials compounded with natural food grade minerals and made in extrusion process. Core layer  106  provides the stiffness and rigidity required of the laminate when formed into a food or beverage container. In one embodiment of the invention core  106  forms a heat resistant and skeletal core on which a container shape is based around and which retains its structure and rigidity integrity when exposed to high temperature during hot food or beverage filling. In one embodiment of the invention the compounded material has heat resistance and dead folding characteristics similar to cardboard. The rigidity of the extruded material allows shaping different forms and shapes of containers. 
         [0019]    In one embodiment, the internal side of the laminate structure  100  includes a bonding layer  107 , which secures the core layer  106  to a barrier layer  108 . In one embodiment the barrier layer  108  is made of an aluminum foil layer, which prevents oxygen as well as a UV penetration to preventing penetration of degrading radiation and the minute amounts of Oxygen which may allow retained contents to deteriorate in potable quality. In another embodiment the barrier layer  108  is a polymeric film or coating having similar barrier properties of aluminum foil, namely barring the transmission of both oxygen and UV radiation. 
         [0020]    In one embodiment of the invention, the laminate structure  100  further includes a bonding layer  109  that secures the barrier layer  108  to an internal (i.e., to the contents in a container) multi-layer polymer film layer  110 . The multi-layer polymer film  110  forms a clear but anti-contamination and liquid impervious seal that forms the final and filled content contact surface. This layer also has seal through contamination properties. In another embodiment, the multi-layer polymer film  110  is colored for additional UV protection of food or beverages. 
         [0021]      FIG. 2  illustrates another embodiment of a laminate structure  200 . In this embodiment of the invention, bonding layer  103  is reversed with print layer  102  as compared with the embodiment illustrated in  FIG. 1 . In this embodiment of the invention, bonding layer  103  is a bonding agent that secures multi-layer polymer film  101  to the film layer  104 . On the external facing surface of the film layer  104  is a print layer  102  which will is printable, for example with technical and presentational information in relation to the contents which will be held within a formed container of laminate structure  200 . 
         [0022]      FIG. 3  illustrates another embodiment of a laminate structure  300 . In this embodiment, film layer  104  and bonding layer  105  are removed as compared to the embodiment illustrated in  FIG. 1 . 
         [0023]      FIG. 4  illustrates yet another embodiment of a laminate structure  400 . In this embodiment, print layer  102  and bonding layer  103  are reversed from the embodiment illustrated in  FIG. 3 . 
         [0024]    With the embodiments illustrated in  FIGS. 1-4 , the total combination of the production materials used within all the laminate layers are mechanically reducible into a regrind format of material that can be recycled and reused in other product configurations. Some of these embodiments include a clear outer barrier for non contact penetration of external materials or environments, that is used as a support layer for printed (e.g., a reverse printed) and protected message. Both the outer and inner multi-layer polymer films ( 101 ,  110 ) have seal through contamination properties. The core layer  106  is made from a polymeric compound material inclusive of mineral components that provides a rigid and stable structure. These embodiments reduce transmission of heat into and through the laminate structures, while preventing UV radiation and Oxygen from penetration. The clear internal sealing barrier forms an enclosure of liquid materials. 
         [0025]    Other embodiments of the laminate structure can also exist and retain matching properties to that of the above discussed embodiments. These other embodiments are structured such that the laminate layers can be added to, subtracted from, or base layer materials used in the initial structural layers changed to match either differing external environmental or final content containment criteria. 
         [0026]    In the description above, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. For example, well-known equivalent components and elements may be substituted in place of those described herein, and similarly, well-known equivalent techniques may be substituted in place of the particular techniques disclosed. In other instances, well-known structures and techniques have not been shown in detail to avoid obscuring the understanding of this description. 
         [0027]    Reference in the specification to “an embodiment,” “one embodiment,” “some embodiments,” or “other embodiments” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments. The various appearances of “an embodiment,” “one embodiment,” or “some embodiments” are not necessarily all referring to the same embodiments. If the specification states a component, feature, structure, or characteristic “may”, “might”, or “could” be included, that particular component, feature, structure, or characteristic is not required to be included. If the specification or claim refers to “a” or “an” element, that does not mean there is only one of the element. If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element. 
         [0028]    While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art.