Abstract:
Packaging containers for liquids, such as beverages, comprise at least one sidewall comprising an abuse layer comprising a frangible flap; a zoned release coating on an inner surface of the abuse layer over an area that includes the frangible flap; and an inner layer; wherein upon peeling the frangible flap, a portion of the inner layer is exposed intact. A sanitary surface is provided for receiving a straw. Because there is not a pre-formed opening for the straw, the receipt by the inner layer of a straw conforms exactly to the straw, which fits snugly with the container during use.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates to packaging containers for liquids such as pouches and boxes that provide sanitary surfaces for receiving straws. The containers comprise a frangible flap in an outer abuse layer that when peeled away exposes a portion of an inner layer intact for receiving the straw. The portion of the inner layer that is intact may further have a pressure sensitive adhesive for resealing of the frangible flap. A tab may extend from the flap for ease of handling. 
       BACKGROUND 
       [0002]    Stand-up bags and pouches that use a straw are in the art of beverage containers. In CA1116130, a multilayered beverage container is constructed with an insertion opening through outside layers up to an inner layer and a tear-off closure strip covering the insertion opening, where in use, the strip tears the inner layer to expose the insertion opening in its entirety. U.S. Pat. No. 5,425,583, which is directed to a stand-up bag, sought to eliminate the tear-off strip of CA1116130 by providing a piercing opening for the straw that is through all layers of the bag material and a sealing foil or strip that is affixed to an inner side of the material around the piercing opening. Thus, the sealing foil or film is outwardly exposed but there is not a tear-off tab that needs disposing. The sealing film, however has the potential to be exposed to unsanitary conditions prior to being punctured by the straw. 
         [0003]    In U.S. Patent Appln. Pub. No. 2013/0101239, a packing container with a pull tab built into the packing material is disclosed, where a closure film is provided in the area of the pull tab, and only a connection area of the pull tab that is connected to the closure film makes an opening in the closure film for the straw 
         [0004]    There is an on-going need to provide liquid packaging containers such as pouches or boxes that provide excellent protection to and sanitary conditions for beverages such as juice, while at the same time are economical and customizable to consumer&#39;s needs. 
       SUMMARY 
       [0005]    In order to provide sanitary conditions for receiving a straw and for providing a resealable container—a pouch or box, for example, having at least one sidewall—provided are frangible flaps formed in an exterior or abuse layer of the container that may be resealed as needed. A tab that is also frangible may extend from the flap for ease of handling. Upon peeling of the frangible flap and optional tab, a portion of an inner layer of the sidewall is exposed intact. That is, no ripping of the inner layer occurs. By exposing the inner layer of the sidewall and not an additional secondary film, there are no extra material handling or manufacturing steps. Also, a sanitary surface—one that has not been exposed to the environment during handling—is provided for receiving a straw. Because there is not a pre-formed opening for the straw, the receipt by the inner layer of a straw conforms exactly to the straw being used and the straw fits snugly with the container during use. When a pressure sensitive adhesive is provided on the portion of the inner layer that is intact, the flap may be resealed. 
         [0006]    In an aspect, therefore, provided are packaging containers for liquids, such as beverages, the containers comprising: at least one sidewall comprising an abuse layer comprising a frangible flap; a zoned release coating on an inner surface of the abuse layer over an area that includes the frangible flap; and an inner layer; wherein upon peeling the frangible flap, a portion of the inner layer is exposed intact. 
         [0007]    Other features that may be used individually or in combination with respect to any aspect of the invention are as follows. 
         [0008]    The packaging containers may further comprise: a first adhesive coating on the inner surface of the abuse layer excluding the zoned release coating and contacting a first surface of the inner layer; a second adhesive coating on a second surface of the inner layer; and a sealant layer affixed to the inner layer by the second adhesive coating. 
         [0009]    The packaging containers may further comprise: a pressure sensitive adhesive on at least a part of the portion of the inner layer that is exposed intact. In this way, the frangible flap may be resealed to the inner layer. 
         [0010]    The abuse layer may comprise a polyester, for example an oriented polyethylene terephthalate (OPET). The abuse layer may be reverse-printed with indicia. Specifically, the frangible flap may comprise indicia, which could provide, for example, a coupon or a game for consumer use. 
         [0011]    The inner layer may comprise a barrier layer, which may be an ethylene-vinyl alcohol (“EVOH”) copolymer film or a foil film. 
         [0012]    The sealant layer may comprise a polyolefin, a polyester, a polyamide, a polystyrene, and blends thereof. 
         [0013]    One specific combination is: the abuse layer comprises an oriented polyethylene terephthalate (OPET), the inner layer comprises a foil film, and the sealant layer comprises a polyethylene. 
         [0014]    The packing containers may comprising two or more sidewalls formed into a pouch. The portion of the inner layer that is exposed intact may be effective to retain a straw upon puncturing of the inner layer by the straw. The flap may further comprise a tab. 
         [0015]    In another aspect, provided is a method of making a packaging container for a liquid, the method comprising forming at least one sidewall by: extruding a first polymer resin through a die thereby forming an abuse layer; applying a laser to the abuse layer to form a frangible flap; applying a zoned release coating on an inner surface of the abuse layer over an area that includes the frangible flap; extruding a second polymer resin through a die or obtaining a foil film thereby forming an inner layer; extruding a third polymer resin through a die or obtaining a polymeric film thereby forming a sealant layer; applying a first adhesive coating on the inner surface of the abuse layer excluding the zoned release coating and affixing a first surface of the inner layer thereto; applying a second adhesive coating on a second surface of the inner layer and affixing the sealant layer thereto; and adhering the at least one sidewall to itself or a plurality of sidewalls to each other to create a seam thereby forming a liquid container. 
         [0016]    An additional aspect is a method of delivering a liquid product in a packaging container, the method comprising: obtaining any packing container disclosed herein packaging the liquid product in the packaging container; peeling the frangible flap; and inserting a straw into the portion of the inner layer that is exposed intact. The method may further comprise resealing the frangible flap to the inner layer. 
         [0017]    These and other aspects of the invention are described in the detailed description below. In no event should the above summary be construed as a limitation on the claimed subject matter. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings, in which: 
           [0019]      FIGS. 1A and 1B  show a schematic view of an exemplary liquid packaging container in the shape of a pouch; 
           [0020]      FIG. 2  is a schematic view of the inner surface of an abuse layer; 
           [0021]      FIG. 3  is a cross-section view of the sidewall of  FIG. 1A  taken along line  3 - 3 . 
       
    
    
       [0022]    The figures are not necessarily to scale. Like numbers used in the figures refer to like components. It will be understood, however, that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number. 
       DETAILED DESCRIPTION 
       [0023]    Provided are packaging containers for liquids formed from at least one sidewall, the sidewall has at least an abuse layer and an inner layer. There is a frangible flap in the abuse layer and a zoned release coating on an inner surface of the abuse layer over an area that includes the frangible flap. Upon peeling of the frangible flap, a portion of the inner layer is exposed intact. 
         [0024]    Reference to “exposed intact” means that no ripping by a layer being removed occurs to the layer that is so exposed. The layer being removed is therefore not adhered or is only weakly adhered to the layer being exposed. 
         [0025]    Reference to “frangible” means easily broken. 
         [0026]    A “layer” as used herein refers to a building block of sidewalls that is a structure of a single polymer-type or a blend of polymers or that may be an additive. 
         [0027]    Reference to “abuse layer” or “outer layer” as used herein refers to the portion of the container that located outermost of all the layers and is subject to handling and the environment. The abuse layer is exposed to varying conditions at any given time, some of which may be unsanitary. 
         [0028]    Reference to an “inner surface” means the surface of a layer away from the outer layer and towards the interior where the liquid is packaged. 
         [0029]    An “inner layer” as used herein refers to a layer is that is not exposed the environment. An exemplary inner layer is a barrier layer, which provides protection to the packaged liquid for freshness and/or a barrier to oxygen. The sealant layer is also an inner layer. An inner layer may be continuous throughout an overall sidewall structure, or it may be discontinuous—located only in the area of the frangible flap. 
         [0030]    A “sealant layer” is one that seals to itself to form a liquid-tight seal. That is, the sealant layer comprises a thermoplastic polymer or polymer mixture that softens when exposed to heat and returns to its original condition when cooled to room temperature. 
         [0031]    A “sidewall” is a discrete piece of polymer film or multi-layer laminate that is sealed to itself or another sidewall by, for example, welding or an adhesive, to form a pouch or a bag. 
       Materials  
       [0032]    The abuse layer may comprise any suitable polyester. An exemplary polyester is an oriented polyethylene terephthalate (OPET). 
         [0033]    In general, the sealant layer may comprise any suitable thermoplastic material including, but not limited too, synthetic polymers such as polyesters, polyamides, polyolefins, polystyrenes, and the like. Thermoplastic materials may also include any synthetic polymer that are cross-linked by either radiation or chemical reaction during a manufacturing or post-manufacturing process operation. Exemplary polyolefins include polyethylene (PE) and polypropylene (PP). 
         [0034]    A layer having an ethylene/vinyl alcohol “EVOH”) copolymer film provides oxygen barrier protection and may be suitable in an inner layer such as a barrier layer. A foil film, such as aluminum foil, also provides oxygen barrier protection and may be suitable alone or in combination with other films in an inner layer such as a barrier layer. 
         [0035]    Between any of the layers, an adhesive coating or layer may be provided to provide adhesion and continuity between the layers. Adhesive compositions invention may include, but are not limited to: modified and unmodified polyolefins, preferably polyethylene, most preferably, ethylene/α-olefin copolymer, modified and unmodified acrylate resin, preferably selected from the group consisting of ethylene/vinyl acrylate copolymer, ethylene/ethyl acrylate copolymer, ethylene/butyl acrylate copolymer, or blends thereof. EVA is an ethylene/vinyl acetate co-polymer, which may be used in particular to form a layer to facilitate bonding of polymerically dissimilar layers. 
         [0036]    Features 
         [0037]    The packaging containers such as pouches or boxes may be configured as needed to fit the needs of the juice-producer and/or consumer. Also, indicia of the container is tailored to convey information as desired by the juice-producer and/or consumer. The flap itself may provide product coupons or games for the consumer. 
         [0038]    The frangible flap and optional tab may be a die cut or laser cut region in the abuse or outer layer. When a release coating is used on an area on an inner surface of the abuse layer that is slightly larger than the frangible flap and optional tab, a portion of the inner layer remains intact when the frangible flap and optional tab is peeled. 
         [0039]    A straw is typically provided with these pouches and boxes. In use, the frangible flap and optional tab are peeled away to expose a portion of the inner layer intact, leaving a surface to receive the straw. The frangible flap may be resealable onto the inner layer by a pressure sensitive adhesive. Also, the frangible flap and optional tab may be formed into a loop that can help secure the straw to the pressure sensitive adhesive after a partial drinking of the beverage. 
         [0040]    Fabrication 
         [0041]    In general terms, to form the containers disclosed herein, the following steps are used. A desired sidewall is formed by making a multi-layered laminate that includes a frangible tab. To form the multi-layered laminate, techniques known in the art may be used in conjunction with design of a release coating in a desired area to account for the frangible flap and with a laser to form the frangible flap. In general terms, there is at least an abuse layer and an inner layer. In specific terms, there may be an abuse layer, an inner or barrier layer, and a sealant layer. 
         [0042]    An exemplary multi-layered laminate may be formed by extruding a first polymer resin through a die thereby forming an abuse layer; applying a release coating on an inner surface of the abuse layer that is zoned over an area that will include a frangible flap; extruding a second polymer resin through a die or obtaining a foil film thereby forming an inner layer; extruding a third polymer resin through a die or obtaining a polymeric film thereby forming a sealant layer; applying a first adhesive coating on the inner surface of the abuse layer excluding the release coating and affixing a first surface of the inner layer thereto; applying a second adhesive coating on a second surface of the inner layer and affixing the sealant layer thereto; and adhering the at least one sidewall to itself or a plurality of sidewalls to each other to create a seam thereby forming a liquid container. 
         [0043]    The frangible flap is formed by applying a laser to the abuse layer to form a laser cut. Application of the laser results in vaporization or delamination of a portion of abuse layer and optionally any adjacent adhesive layer and/or indicia ink while leaving the inner layer undamaged. An exemplary laser is a single beam refracted laser. A laser control system assists in controlling the shape of the flap and optional tab along with the depth of the cut. 
         [0044]    Before describing several exemplary embodiments of the invention, it is to be understood that the invention is not limited to the details of construction or process steps set forth in the following description. The invention is capable of other embodiments and of being practiced or being carded out in various ways. 
         [0045]    Turning to the figures,  FIGS. 1A and 1B  show a schematic view of an exemplary liquid packaging container  100  in the shape of a pouch. The liquid packaging container  100  comprises a sidewall  102  having a frangible flap  104  with an optional tab  106  both defined by a laser die cut  108 . In  FIG. 1A , the frangible flap  104  which is shown in the abuse layer  114  is unopened. Indicia  124   a  conveys the contents of the container as being “Juice” In  FIG. 1B , the frangible flap is in an open position showing the portion of the outer surface of the inner layer  112  that is intact and optional pressure sensitive adhesive  126 . There is no preformed hole in the inner layer. A “coupon” is indicia  124   b  on an inside surface of the flap. In use, straw  110  is inserted into the outer surface of the inner layer  112  that is intact and the straw is held in place without being loose. The frangible flap  104  may be resealable onto the inner layer by the pressure sensitive adhesive  126 . Also, the frangible flap  104  and optional tab  106  may be formed into a loop that can secure the straw  110  after puncture and a partial drinking of the as juice. 
         [0046]      FIG. 2  is a schematic view of the inner surface  116  of the abuse layer  114 . The underside of the frangible flap  104  is shown where there is an optional border  118  around the frangible flap  104 . There is a zoned release coating  120  on the underside of the frangible flap  104  and its optional border  118 . A first adhesive coating  122  is also on the inner surface  116  of the abuse layer  114  in this embodiment. 
         [0047]      FIG. 3  is a cross-section view of the sidewall of  FIG. 1A  taken along line  3 - 3 . In this embodiment, sidewall  102  has a frangible flap  104  defined by the laser die cut  108  in the abuse layer  114 . On the inner surface of the abuse layer  114  is a first adhesive coating  122  that attaches the abuse layer  114  to the inner layer  128 . Below the frangible flap  104  is a zoned release coating  120  that prevents the frangible flap  104  from sticking or adhering to the inner layer  128 . Thus, upon opening of the frangible flap  104 , the inner layer  128  is not ripped. An optional pressure sensitive adhesive  126  may be located below the frangible flap  104  as well. The inner layer  128  has a second adhesive coating  130  on the surface opposite where the first adhesive coating  122  is located. The second adhesive coating  130  attaches a sealant layer  132  to the inner layer  128 . 
         [0048]    Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. 
         [0049]    Reference throughout this specification to “one embodiment,” “certain embodiments,” “one or more embodiments” or “an embodiment” means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrases such as “in one or more embodiments,” “in certain embodiments,” “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily referring to the same embodiment of the invention. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments. 
         [0050]    Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It will be apparent to those skilled in the art that various modifications and variations can be made to the method and apparatus of the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention include modifications and variations that are within the scope of the appended claims and their equivalents.