Patent Description:
Packages can be used to store various types of products. In some cases, for example, a flexible laminate structure can be used to form a package, such as a bag or a pouch, for holding a product that may, over time, generate gas (e.g., outgas). For example, freshly roasted coffee may have a tendency to outgas carbon dioxide. Other products may also undergo a reaction over time within the package that results in the generation of gas.

At the same time, the products stored in the package may need to be isolated and protected from the ingress of oxygen and/or moisture to promote freshness and shelf-life and to maintain the quality of the contents for as long as possible.

<CIT> describes a re-closable pouch which includes first and second film layers disposed on a first pouch sidewall. The first film layer is attached to the second film layer by first and second intermittent spot seals disposed across respective first and second edges of the first film layer. The second film layer is sealed to the sidewall by third and fourth intermittent spot seals disposed across respective third and fourth edges of the second film layer. Offset first and second apertures extend through the first and second film layers, respectively, wherein one of the first and second apertures communicates with a pouch interior and the other of the first and second apertures communicates with a pouch exterior. A fifth intermittent spot seal is disposed between the first and second film layers, the fifth intermittent spot seal surrounding a region including the first and second apertures.

<CIT> describes a new process for the production of polylaminate film for packaging, and the reel obtained by said process, comprising the phases of unwinding of an inner film and an outer film, application of adhesive substance on the bonding surface of said inner film and/or of said outer film, with the exception of localised areas; bonding of said outer film with said inner film so that the respective said localised areas are opposite each other, creation of one or more holes on said inner film and on said outer film, in each of said localised areas and wherein said holes of said inner film do not overlap said holes of said outer film; rewinding of said polylaminate composite film on a reel.

<CIT> describes a packaging container having a foil laminate comprising at least two layers in which openings are formed. The two layers are joined together over their entire surface area, except for in a striplike channel. A valve strip is disposed in the channel and in valvelike fashion covers the openings of the inner layer. If there is an overpressure in the packaging container, resultant gas can escape through the openings and the valve strip acts like an overpressure valve. As a result of the specialised disposition and embodiment of the valve strip and of the openings, a reliable escape of gas produced is achieved.

<CIT> describes a multilayered flexible laminate comprising a first lamina having an inlet channel; a second lamina having an outlet channel; the first and second laminas joined to one another about an unbonded valve region having open and closed orientations; wherein the first and outlet channels are in gaseous communication when the valve region is in the open orientation.

Embodiments of the invention described herein provide improved packages for storing products and associated methods for forming such packages, where the packages are designed to allow gas generated within the package to escape to the external environment (e.g., to minimize or prevent ballooning or other distortions of the package that may be caused by increasing gas pressure within the package) while at the same time minimizing the amount of oxygen and/or moisture that is allowed to enter the package.

According to the present invention, a flexible laminate structure for a package is provided that includes an integrated one-way valve feature, according to claim <NUM>. The flexible laminate structure comprises a first film layer and a second film layer laminated to the first film layer via a permanent adhesive that is pattern-applied to at least one of the first or second film layers. The first film layer includes a first cut line and the second film layer includes a second cut line offset from the first cut line. A valve area is defined in the laminate, where the valve area includes the first and second cut lines and is devoid of the permanent adhesive. In addition, the valve area comprises a viscous medium, such as oil, that is pattern-applied to at least one of the first or second film layers and is disposed between the first and second film layers so as to occupy at least a portion of the valve area. An opposing surface of at least one of the first or second film layers further includes a surface coating treatment configured to decrease an amount of surface energy between the first and second film layers in the valve area.

In some cases, the surface coating treatment may comprise a printed ink. The surface treatment of the first or second film layers may be located only in the valve area. Additionally or alternatively, at least one of the first or second film layers may comprise two or more sub-layers. For example, one of the first or second film layers may comprise polyethylene terapthalate (PET) and/or oriented polypropylene (OPP).

A method of manufacturing a flexible laminate structure for a package is provided that includes an integrated one-way valve feature is disclosed in claim <NUM>. The method includes laminating a first film layer to a second film layer via a pattern-printed permanent adhesive that is applied to at least one of the first or second film layers; defining a first cut line in the first film layer; and defining a second cut line in the second film layer, where the first and second cut lines are offset with respect to each other. In addition, the method includes leaving an area of the laminate devoid of the permanent adhesive so as to define a valve area, the valve area including the first and second cut lines. Moreover, a viscous medium, such as oil, is pattern-applied to at least one of the first or second film layers in the area of the laminate devoid of the permanent adhesive, and a surface coating treatment is effected with respect to at least one of the first or second film layers, where the surface treatment is configured to decrease an amount of surface energy between the first and second film layers in the valve area.

The step of effecting a surface coating with respect to at least one of the first or second film layers may comprise using a printed ink. In some cases, effecting a surface treatment with respect to at least one of the first or second film layers may include effecting the surface treatment with respect to at least one of the first or second film layers only in the valve area.

At least one of the first or second film layers may comprise two or more sub-layers. For example, one of the first or second film layers may comprise polyethylene terapthalate (PET). Additionally or alternatively, one of the first or second film layers may comprise oriented polypropylene (OPP).

In some cases, at least one of the steps of defining a first cut line in the first film layer or defining a second cut line in the second film layer may comprise defining the cut line using a laser. Moreover, at least one of the steps of defining a first cut line in the first film layer or defining a second cut line in the second film layer may comprise defining the cut line using mechanical scoring.

The present invention now will be described more fully hereinafter with reference to the accompanying drawings in which some but not all embodiments of the invention are shown. The invention should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

Packages can be used to hold a variety of products, including food products and other products that may undergo a reaction over time that generates gas. As an example, fresh roasted coffee has a tendency to outgas (generate carbon dioxide). Other products may release gas over time, as the product ages or is exposed to even minimal levels of oxygen or moisture as may enter the sealed package.

When such products are stored in a sealed container, there is a danger that the gas produced inside the package will build up. As a result, the package can become inflated and bulge outwardly, which may be unsightly and/or deter a customer from purchasing the package. Furthermore, as more and more gas accumulates within the package, the pressure inside the package may rise to the level of bursting the package or affecting one or more of the seals of the package (e.g., before a consumer wishes to open the package).

At the same time, maintaining a good seal on the package is important to protect the contents of the package from the external environment, such as to prevent the ingress of atmospheric gas (e.g., oxygen and water vapor). The goals of allowing gas to escape from the package while at the same time also preventing the unwanted ingress of gas/water vapor into the package are, thus, seemingly diametrically opposed.

Conventional solutions for venting gas produced within an enclosed package include the use of button valves or pressure sensitive valves that are formed separately from the package and are affixed to the package at the time the package is filled. Such solutions, however, are expensive to implement and add complexity to the filling operation to accommodate application of the valves to the packages.

Accordingly, embodiments of the present invention provide a flexible laminate structure for a package that includes an integrated one-way valve feature configured to allow gas generated within the package (e.g., carbon dioxide outgas) to be released to the external environment, while at the same time maintaining the integrity of the package contents by preventing environmental elements from entering the package. Because the valve is integral to the flexible laminate structure (e.g., defined by the layers that form the flexible laminate, as opposed to being a separate structure that is adhered to or otherwise combined with the flexible laminate), the cost of forming a separate valve and modifying the flexible laminate to accommodate attachment of the valve to the package is avoided, thereby reducing the overall cost and complexity of manufacturing and/or filling a package with a one-way valve. Moreover, as the valve is integrated with the flexible laminate, seams and/or attachment locations of the package can be minimized or eliminated, thereby also reducing the potential for leaks.

With reference to <FIG>, for example, a package <NUM> (e.g., a gusseted bag, pouch, or other flexible package) is shown that is designed to hold a product that is prone to off-gassing, such as freshly roasted coffee. The package <NUM> may have a first end <NUM>, upon which the package might rest when placed on a surface, and a second end <NUM> opposite the first end. In some cases, the product contained within the package <NUM> may only occupy a portion of the volume of the package, such that part of the inner volume of the package closest to the second end <NUM> may be empty. The first end <NUM> of the package <NUM> may be gusseted to accommodate a greater volume of product within the package and/or to provide a more stable base on which the package can rest. The second end <NUM> of the package <NUM> may, in some cases, include a seal <NUM>, such as a heat seal that is applied to maintain the package contents inside the package and prevent atmospheric gas from entering the package prior to opening of the package.

The flexible laminate that forms the package <NUM> defines a valve area <NUM>. For example, the valve area <NUM> may be disposed proximate the second end <NUM> of the package <NUM>, such as in the empty region of the package. In this way, the risk that the package contents will interfere with the operation of the valve <NUM> can be minimized.

<FIG> shows a close-up view of the valve area <NUM> of the package <NUM>. The valve area <NUM> includes a first cut line <NUM> defined in a first film layer <NUM> of the laminate and a second cut line <NUM> defined in a second film layer <NUM> of the laminate. In the view shown in <FIG>, for example, the first film layer <NUM> forms the outer layer of the flexible laminate forming the package <NUM>, whereas the second film layer <NUM> forms an inner layer of the flexible laminate and is thus underneath the first film layer.

Accordingly, the flexible laminate structure comprises a first film layer <NUM> and a second film layer <NUM>. The second film layer <NUM> is laminated to the first film layer via a permanent adhesive <NUM> (shown in <FIG>) that is pattern-applied to at least one of the first or second film layers. The first film layer <NUM> thus includes the first cut line <NUM>, and the second film layer <NUM> may include the second cut line <NUM>, which is offset from the first cut line <NUM> (e.g., is not aligned with the first cut line, but rather is spaced from the first cut line).

A cross-section of the valve area <NUM> is shown in <FIG> in a closed position and in <FIG> in an open position. With reference to <FIG>, the valve area <NUM> includes the first and second cut lines <NUM>, <NUM>, such that the first and second cut lines are contained within a perimeter <NUM> of the valve area <NUM> (shown in <FIG>). The valve area <NUM> is an area of the flexible laminate that is devoid of the permanent adhesive <NUM> adhering the first and second film layers <NUM>, <NUM> to each other. In this way, the perimeter <NUM> of the valve area <NUM> may be the interface between an area including permanent adhesive <NUM> and an area devoid of permanent adhesive.

The valve area <NUM> comprises a viscous medium, such as oil <NUM>, that is pattern-applied to at least one of the first or second film layers <NUM>, <NUM> and is disposed between the first and second film layers so as to occupy at least a portion of the valve area. The oil <NUM> may, for example, be silicone oil in some cases. The presence of the oil <NUM> may encourage the opposing surfaces of the first and second film layers <NUM>, <NUM> (e.g., the surface of each film layer that is adjacent to or most proximate the other film layer) to maintain contact with each other (with the oil disposed therebetween) by virtue of the viscosity and/or surface tension of the oil, such that the integrated valve is biased towards the closed position shown in <FIG> when the pressure inside the package is below a certain threshold pressure. For example, in some embodiments, the volume of oil <NUM> disposed between the first and second film layers <NUM>, <NUM> is selected such that the valve opens when the pressure inside the package just exceeds the atmospheric pressure outside the package. An example of a desirable range of pressures inside the package for moving the first layer <NUM> towards the open position shown in <FIG> is approximately <NUM> psi to approximately <NUM> psi.

In addition, when the atmospheric pressure outside the package is still slightly above the pressure inside the package, the valve should be configured to move from the open position to the closed position shown in <FIG> so as to seal and prevent gas and/or moisture from entering the package. In some embodiments, the valve is configured such that a desirable range of atmospheric pressures outside the package for moving the first layer <NUM> towards the closed position shown in <FIG> is approximately <NUM> psi to approximately <NUM> psi, but in any case is less than the pressure required inside the package to open the valve.

Moreover, an opposing surface of at least one of the first or second film layers <NUM>, <NUM> further includes a surface coating treatment configured to decrease an amount of surface energy between the first and second film layers in the valve area. The surface energy may be characterized as the amount of energy required to adhere the opposing surfaces of the first and second film layers <NUM>, <NUM> to each other. Thus, while the addition of the oil <NUM> in the valve area <NUM> between the opposing surfaces of the first and second film layers <NUM>, <NUM> serves to increase the surface energy of the interface between the opposing film surfaces, the resulting surface energy may be too great to allow the valve to open (<FIG>) at the desired pressure level of the package interior. The inclusion of the surface treatment for at least one of the opposing surfaces of the first and second film layers <NUM>, <NUM>, however, may counteract the increased adhesion force imparted by the oil <NUM>, thereby reducing the surface energy to a level that allows the valve to be moved from the closed configuration shown in <FIG> to the open configuration shown in <FIG> when a desired level of pressure is achieved within the package.

In some embodiments, for example, the surface coating treatment comprises a printed ink that is applied to one or both of the opposing surfaces of the first and second film layers <NUM>, <NUM>. The surface treatment may serve to create bumps or ridges <NUM> that extend from the surface of the respective film layer <NUM>, <NUM> that is treated toward the opposing surface of the other film layer. In the depicted example of <FIG>, for example, the surface treatment has been applied to the opposing surface of the first film layer <NUM>, such that the ridges <NUM> extend from the first film layer towards the second film layer <NUM>.

Accordingly, the surface energy of the interface between the first and second film layers <NUM>, <NUM> may be decreased due to the reduced contact area between the two film layers. For example, instead of substantially the entire opposing surface of the first film layer <NUM> in the valve area contacting substantially the entire opposing surface of the second film layer <NUM> in the valve area, in which case the surface energy would be at a maximum, the ridges <NUM> created by the surface treatment in some embodiments may reduce the contact area to the sum of the areas over which each of the ridges contacts the corresponding locations of the opposing surface of the respective film layer. The inventors have found that the smaller the contact area, the less energy is required to separate the first and second film layers <NUM>, <NUM>, and the less internal package pressure is needed to move the valve from the closed configuration of <FIG> to the open configuration of <FIG>. Accordingly, the type of surface treatment, the number of ridges <NUM> created, and/or the amount of inherent separation between the first and second film layers <NUM>, <NUM> caused by the extension of the ridges <NUM> may be selected to achieve a desired surface energy that results in the opening of the valve at the desired package pressure. In addition, the pattern of the ridges <NUM> may be selected to further tune the opening and closure of the valve, depending on the requirements of the package. In some cases, the thickness of the surface treatment (e.g., thickness of the coating used), the roughness imparted by the surface treatment (e.g., based on the chemical makeup of the surface treatment), and the location of the surface treatment may also affect the resulting surface energy.

In the depicted embodiments of <FIG>, the surface treatment of the first or second film layers is located only in the valve area <NUM>; however, in other embodiments, the surface treatment (e.g., the ridges <NUM>) may extend outside the valve area <NUM>. For example, in some cases, the surface treatment may extend along the entire film, or the surface treatment may be applied to an area that is larger than the valve area <NUM>. In this way, alignment of the valve area with the location of the surface treatment during lamination of the film layers <NUM>, <NUM> may be easier to achieve, such as during the manufacturing process.

The flexible laminate structure may include first and second film layers <NUM>, <NUM> made of various different materials, depending on the particular application (e.g., depending on the type of product stored in the package). The first and/or second film layers <NUM>, <NUM> may, for example, include a polymer. In some embodiments, for example, one of the first or second film layers <NUM>, <NUM> may comprise polyethylene terephthalate (PET). In other embodiments, one of the first or second film layers <NUM>, <NUM> may include oriented polypropylene (OPP). Other materials that may be used for the first or second film layers <NUM>, <NUM> may include Polyethylene (PE), metal foil (e.g., aluminum), metallized oriented polypropylene (mOPP), metallized polyethylene terephthalate (mPET), and co-polymer polypropylene (CPP), to name a few. Accordingly, typical laminate structures may include, for example, PET/Foil/PE, PET/Foil/PET/PE, PET/mPET/PE, PET/mOPP/PE, OPP/mOPP/PE, PET/PE, OPP/PE, OPP/OPP, OPP, mOPP, PET/CPP, and PET/Foil/CPP.

In this regard, in some cases, the flexible laminate structure described above may be made using a first or second film layer <NUM>, <NUM> (or both) that includes two or more sub-layers, as shown in <FIG>. One or both of the first and second film layers <NUM>, <NUM> may, for example, be a <NUM>-ply film, a <NUM>-ply film, a <NUM>-ply film, or include additional plies, depending on the particular application (e.g., depending on the type of product to be stored in the package), with some example structures as noted above. In <FIG>, for example, a flexible laminate structure showing the integrated valve in a closed configuration is illustrated that has a single-ply first film layer <NUM> and a <NUM>-ply second film layer <NUM>. Sub-layers having different characteristics (e.g., different thicknesses, different materials, etc.) may be used in some cases to achieve certain oxygen and/or moisture transmission rates, so as to promote the freshness and/or shelf life of the product stored in the package. For example, the first film layer <NUM> may be a single-ply layer of PET, whereas the second film layer <NUM> may be a <NUM>-ply film with sub-layers of foil/PET/PE.

Methods of manufacturing a flexible laminate structure for a package including an integrated one-way valve feature are also provided. According to embodiments of the methods, a first film layer may be laminated to a second film layer via a pattern-printed permanent adhesive that is applied to at least one of the first or second film layers, as described above. A first cut line may be defined in the first film layer, and a second cut line may be defined in the second film layer, where the first and second cut lines are offset with respect to each other. The cut lines may be defined in the flexible laminate after the first and second film layers have been laminated to each other, such as by using precision scoring techniques. In this way, the manufacture of the integrated valve is simplified as compared to conventional methods of providing a valve on packaging, in which a separately-formed valve must be attached to the flexible laminate at a predefined location.

In this regard, the first and/or second cut lines may be made in various ways, such as via a laser. As an alternative to the use of lasers for scoring the laminate, the cut lines can be formed in the laminate by mechanical scoring or cutting. For instance, a kiss roll and a backing roll may be used to form a nip through which the laminate is passed. The kiss roll may comprise a rotary cutting die defining a cutting edge that is configured to define the first and/or second cut lines.

As the first and second film layers are laminated to each other, an area of the laminate is left devoid of the permanent adhesive so as to define the valve area. As described above, the first and second cut lines are defined within the valve area, such that the valve area includes the first and second cut lines. In addition, oil is pattern-applied to at least one of the first or second film layers in the area of the laminate devoid of the permanent adhesive. A surface coating treatment is effected with respect to at least one of the first or second film layers, and the surface treatment is configured to decrease an amount of surface energy between the first and second film layers in the valve area, as described above.

In some cases, effecting a surface treatment with respect to at least one of the first or second film layers comprises using a printed ink. In some embodiments, ridges or bumps between opposing surfaces of the first and second film layers can be included.

The surface treatment may be effected with respect to at least one of the first or second film layers only in the valve area in some embodiments, whereas in other embodiments the surface treatment may extend outside of the valve area, such as in cases were the surface treatment is effected with respect to substantially the entire opposing surface of a respective film layer.

Claim 1:
A flexible laminate structure for a package (<NUM>) including an integrated one-way valve feature (<NUM>), said flexible laminate structure comprising:
a first film layer (<NUM>);
a second film layer (<NUM>) laminated to the first film layer via a permanent adhesive (<NUM>) that is pattern-applied to at least one of the first or second film layers, wherein the first film layer (<NUM>) includes a first cut line (<NUM>) and the second film layer (<NUM>) includes a second cut line (<NUM>) offset from the first cut line; and
a valve area (<NUM>) defined in the laminate, the valve area (<NUM>) including the first and second cut lines (<NUM>, <NUM>) and being devoid of the permanent adhesive (<NUM>), wherein the valve area (<NUM>) comprises a viscous medium (<NUM>) that is pattern-applied to at least one of the first or second film layers (<NUM>, <NUM>) and is disposed between the first and second film layers (<NUM>, <NUM>) so as to occupy at least a portion of the valve area (<NUM>),
wherein an opposing surface of at least one of the first or second film layers (<NUM>, <NUM>) further includes a surface coating treatment configured to decrease an amount of surface energy between the first and second film layers (<NUM>, <NUM>) in the valve area (<NUM>).