Flexible packaging with internal release
The invention comprises a package for reactive materials comprising a panel defining a first end, a second end opposite the first end, and at least two side edges. The panel comprises at least one film layer, an adhesive adjacent the film layer, wherein the adhesive is pattern applied such that it is disposed within an interior region of the film layer and wherein a perimeter of the film layer is adhesive-free adjacent each of the first end, second end, and side edges, and a release liner comprising a substrate layer and a cured silicone layer. The release liner is adhered to the film layer via the adhesive, the substrate layer of the release liner is disposed adjacent the film layer, and a perimeter of the release liner is smaller than the perimeter of the film structure. In an embodiment, the panel comprises a tubular body and the side edges are sealed together to form a fin seal, the first end is sealed closed to form an end seal, and the second end is sealed closed to form an end seal.
1. A method of manufacturing a blank for a package comprising:
providing a film layer;
providing a release liner comprising a substrate layer and a cured silicone layer;
pattern applying an adhesive onto the film layer or the substrate layer of the release liner such that a perimeter region of the film layer remains adhesive-free;
adhesively joining the film layer to the substrate layer of the release liner to form a laminate;
advancing the laminate to a scoring station at which an inner score line is formed through the thickness of the release liner but does not extend into the film layer, wherein the inner score line is disposed interior of the perimeter region, and wherein an outer score line is formed through the thickness of the laminate; and
removing a skeleton of the release liner, wherein the skeleton comprises the portion of the release liner exterior the inner score line, wherein after removal of the skeleton, a region between the inner score line and the outer score line comprises a seal region in which the film layer is exposed.
2. The method of claim 1 , wherein the seal region is adhesive-free on its inner surface.
3. The method of claim 1 , comprising forming the blank into a package by sealing the seal region to form a fin seal and two end seals.
4. The method of claim 3 , wherein one or more reactive materials is filled into the package after formation of the fin seal and one of the end seals, but prior to sealing of the second end seal.
5. The method of claim 1 , wherein the step of providing a film layer comprises coextruding an outer layer, a permanent adhesive, and a printable sealant.
6. The method of claim 1 , wherein the seal region comprises the perimeter region of the film layer.
7. The method of claim 1 wherein the substrate layer comprises polyethylene terephthalate.
8. The method of claim 1 wherein the at least one film layer comprises an outer layer adhered to a printable sealant.
9. The method of claim 8 comprising coextruding the outer layer and printable sealant.
10. The method of claim 8 wherein the outer layer comprises biaxially oriented nylon.
11. The method of claim 8 wherein the printable sealant is print receptive.
12. The method of claim 8 wherein the printable sealant comprises polyethylene.
13. The method of claim 8 wherein the printable sealant is coextensive with the outer layer.
14. The method of claim 1 wherein a perimeter of the release liner is substantially aligned with an outer perimeter of the adhesive.
15. A method of manufacturing a package comprising:
providing a film layer;
providing a release liner comprising a substrate layer and a cured silicone layer;
pattern applying an adhesive onto the film layer or the substrate layer of the release liner such that a perimeter region of the film layer remains adhesive-free;
adhesively joining the film layer to the substrate layer of the release liner to form a laminate;
advancing the laminate to a scoring station at which an inner score line is formed through the thickness of the release liner but does not extend into the film layer, wherein the inner score line is disposed interior of the perimeter region, and wherein an outer score line is formed through the thickness of the laminate;
removing a skeleton of the release liner, wherein the skeleton comprises the portion of the release liner exterior the inner score line, wherein after removal of the skeleton, a region between the inner score line and the outer score line comprises a seal region in which the film layer is exposed; and
forming the laminate into a package for reactive materials having a first end, a second end opposite the first end, and at least two side edges.
16. The method of claim 15 comprising forming the laminate into a tubular body by sealing the side edges together to form a fin seal, closing the first end to form an end seal, and closing the second end to form an end seal.
17. The method of claim 16 , wherein one or more reactive materials is filled into the package after formation of the fin seal and the first end seal, but prior to forming the second end seal.
18. The method of claim 15 wherein the cured silicone layer faces an interior of the package.