Flexible pouch with post-consumer resin

1 . A flexible pouch comprising:

a first layer structure and a second layer structure, each layer structure comprising

(i) an inner liner that is a multilayer film and

(ii) an outer sheath,

the first layer structure superimposed on the second layer structure such that the inner liners oppose each other, the first layer structure and the second layer structure define a common peripheral edge;

each inner liner (i) composed of a flexible film composed of non-PCR polymeric material;

each outer sheath is a monolayer film (ii) consisting of a post-consumer resin (PCR) that is 100 wt % polyethylene-PCR selected from the group consisting of high density polyethylene PCR, linear low density polyethylene PCR, low density polyethylene PCR, and combinations thereof, the 100 wt % polyethylene-PCR having a GI200 value from greater than 50 to 10,000;

a peripheral heat seal along at least a portion of the common peripheral edge, the peripheral heat seal sealing the first layer structure to the second layer structure such that

(i) each outer sheath is directly sealed to its respective inner liner along the peripheral heat seal, and

(ii) the inner liners are directly sealed to each other along the peripheral heat seal;

an interface between the inner liner and its respective outer sheath, and

no adhesive contact occurs between the inner liner and its respective outer sheath except at the peripheral heat seal; and

a gap is present at the interface, except at the peripheral heat seal.

2 . The flexible pouch of claim 1 wherein the PCR has a GI200 value from 100 to 10,000.

3 . The flexible pouch of claim 1 wherein each layer structure comprises from greater than 50 vol % to 95 vol % of the outer sheath and from less than 50 vol % to 5 vol % of the inner liner.

4 . The flexible pouch of claim 3 wherein the peripheral heat seal comprises a layer configuration of first outer sheath, first liner, second liner, and second outer sheath from a cross-sectional view; and the peripheral heat seal comprises

the first outer sheath heat sealed to the first liner;

the first liner heat sealed to the second liner; and

the second liner heat sealed to the second sheath.

5 . The flexible pouch of claim 4 wherein each inner liner is a flexible multilayer film comprising at least three layers.

6 . The flexible pouch of claim 5 wherein each layer structure comprises a print film.

7 . The flexible pouch of claim 6 wherein the peripheral heat seal is the sole seal between the inner liner and its respective outer sheath.

8 . The flexible pouch of claim 5 wherein the inner liner is in direct contact with its respective outer sheath along an entirety of the interface.

9 . A flexible pouch comprising:

a first layer structure and a second layer structure, each layer structure comprising

(i) from less than 50 vol % to 5 vol % of an inner liner that is a multilayer film,

(ii) from greater than 50 vol % to 95 vol % of an outer sheath, and

(iii) an interface between the inner liner and the outer sheath;

the first layer structure superimposed on the second layer structure such that the inner liners oppose each other, the first layer structure and the second layer structure define a common peripheral edge;

each inner liner (i) composed of a flexible multilayer film composed of non-PCR polymeric material;

each outer sheath is a monolayer film (ii)) consisting of 100 wt % of a polyethylene post-consumer resin (polyethylene-PCR), the polyethylene-PCR selected from the group consisting of high density polyethylene PCR, linear low density polyethylene PCR, low density polyethylene PCR, and combinations thereof and having a GI200 value from greater than 50 to 10,000 and a density from 0.932 g/cc to 0.965 g/cc;

a peripheral heat seal along at least a portion of the common peripheral edge,

(1) the peripheral heat seal sealing the first layer structure to the second layer structure,

(2) no adhesive contact occurs between the inner liner and its respective outer sheath other than at the peripheral seal;

(3) the inner liner directly contacts the outer sheath along an entirety of the interface; and

(4) the inner liners are directly sealed to each other along the peripheral heat seal.

10 . The flexible pouch of claim 9 wherein a gap is present between the inner liner and its respective outer sheath along the interface except at the peripheral heat seal.

11 . The flexible pouch of claim 10 wherein each inner liner is a flexible multilayer film comprising at least three layers.

12 . The flexible pouch of claim 8 wherein the common peripheral edge defines a perimeter shape for the flexible pouch and the perimeter shape is selected from the group consisting of polygon and ellipse.

13 . The flexible pouch of claim 9 wherein the common peripheral edge defines a perimeter shape for the flexible pouch and the perimeter shape is selected from the group consisting of polygon and ellipse.

14 . The flexible pouch of claim 12 wherein the inner liner has an A/B/A layer structure having

sealant layers A composed of an ethylene-based polymer; and

an abuse layer B composed of an ethylene-based polymer different than sealant layers A.

15 . The flexible pouch of claim 12 wherein the inner liner has an A/B/C/B/A layer structure having

sealant layers A composed of an ethylene-based polymer;

tie layers B; and

a barrier layer C.

16 . The flexible pouch of claim 13 wherein the inner liner has an A/B/A layer structure having

sealant layers A composed of an ethylene-based polymer; and

an abuse layer B composed of an ethylene-based polymer different than sealant layers A.

17 . The flexible pouch of claim 13 wherein the inner liner has an A/B/C/B/A layer structure having

sealant layers A composed of an ethylene-based polymer;

tie layers B; and

a barrier layer C.

18 . A flexible pouch comprising:

a first layer structure and a second layer structure, each layer structure comprising

(i) an outermost layer that is a post-consumer resin (PCR)) that is 100 wt % polyethylene-PCR selected from the group consisting of high density polyethylene PCR, linear low density polyethylene PCR, low density polyethylene PCR, and combinations thereof, the 100 wt % polyethylene-PCR having a GI200 value from greater than 50 to less than 10,000,

(ii) an innermost layer that is a seal layer composed of non-PCR polymeric material, and

(iii) a foam layer disposed between the outermost layer (i) and the innermost layer (ii),

the first layer structure superimposed on the second layer structure such that the innermost layers oppose each other, the first layer structure and the second layer structure define a common peripheral edge, the common peripheral edge defining a perimeter shape;

a peripheral heat seal along at least a portion of the common peripheral edge;

the peripheral heat seal sealing the first layer structure to the second layer structure, and

the innermost layers are directly sealed to each other along the peripheral heat seal.

19 . The flexible pouch of claim 18 wherein the foam layer comprises a foamed PCR that is 100 wt % polyethylene-PCR selected from the group consisting of high density polyethylene PCR, linear low density polyethylene PCR, low density polyethylene PCR, and combinations thereof.

20 . The flexible pouch of claim 1 wherein the 100 wt % polyethylene-PCR is void of ethylene vinyl alcohol.