OVENABLE FLEXIBLE PACKAGING STRUCTURES
A laminated web having a machine direction and a transverse direction extending in a direction perpendicular to the machine direction is provided, and includes outer and inner plies. The outer ply is formed of a paper material having a cutout defining a window region disposed at a predetermined location on the outer ply. The inner ply is formed of a heat sealable, ovenable polymer film having a perforation region disposed at a predetermined location on the inner ply. An adhesive layer is disposed intermediate the outer and inner plies and bonds the outer and inner plies together wherein the outer ply and the inner ply are in registration with each other such that the perforation region is substantially overlapping with the window region. In further aspects, packaging articles, methods for making the laminated web, and method for making the packaging articles are provided.
1 . A laminated web of material having a machine direction and a transverse direction which extends in a direction perpendicular to the machine direction, the laminated web comprising:
an outer ply comprising a paper material having a cutout defining a window region disposed at a predetermined location on the outer ply;
an inner ply comprising a heat sealable, ovenable polymer film having a perforation region wherein the perforation region is disposed at a predetermined location on the inner ply; and
an adhesive layer disposed intermediate the outer ply and the inner ply, the adhesive layer bonding the outer ply to the inner ply;
wherein, in the laminated web, the outer ply and the inner ply are in registration with each other such that the perforation region is substantially overlapping with the window region.
2 . The laminated web of claim 1 , wherein the perforation region defines a discrete region that does not form a continuous strip in the machine direction.
3 . The laminated web of claim 1 , wherein the perforation region is bounded entirely within the window region.
4 . The laminated web of claim 1 , further comprising one of:
the perforation region and the window region are substantially coextensive; and
the perforation region is smaller in area than the window region.
5 . The laminated web of claim 1 , further comprising one or both of:
the adhesive layer is defined by first and second adhesive strips extending in the machine direction, wherein the first and second adhesive strips are disposed on opposing transverse sides of the window region; and
the adhesive layer comprises one or more adhesive free regions wherein adhesive is absent from the adhesive layer, the one or more adhesive free regions being disposed upstream of the window region in the machine direction, downstream of the window region in the machine direction, or both.
6 . (canceled)
7 . The laminated web of claim 5 , further comprising:
a varnish layer disposed on an outward facing surface of the outer ply.
8 . The laminated web of claim 7 , wherein the varnish layer is in registration with the one or more adhesive free regions.
9 . The laminated web of claim 5 , wherein the adhesive layer comprises:
a first adhesive free region wherein adhesive is absent from the adhesive layer, the first adhesive free region being disposed upstream of the window region in the machine direction; and
a second adhesive free region wherein adhesive is absent from the adhesive layer, the second adhesive free region being disposed downstream of the window region in the machine direction.
10 . The laminated web of claim 1 , wherein the adhesive layer forms a substantially continuous layer surrounding the window region, and wherein the window region is substantially free of adhesive.
11 . The laminated web of claim 1 , further comprising:
a varnish layer disposed on an outward facing surface of the outer ply; optionally wherein the varnish layer comprises an ultraviolet (UV) curable, heat-resistant varnish.
12 . The laminated web of claim 11 , further comprising:
a printed ink layer disposed between the varnish layer and the outward facing surface of the outer ply, optionally wherein the printed ink layer comprises an ultraviolet (UV) curable ink.
13 . (canceled)
14 . (canceled)
15 . The laminated web of claim 1 , wherein the outer ply comprises a paper material selected from the group consisting of a natural kraft paper, a bleached kraft paper, a white kraft paper, a coated paper, a recycled paper, a grease resistant paper, and a paper having a basis weight in the range of from about 35 grams per square meter (gsm) to about 130 gsm.
16 . (canceled)
17 . The laminated web of claim 1 , wherein the inner ply comprises one or both of:
a polymer material configured to provide a sealing initiation temperature (SIT) in the range of from about 80° C. to about 160° C. when sealed under a sealing pressure of 40 psi for a dwell time of 0.5 seconds; and
an ovenable polymer film is configured to provide a seal strength in the range of from 200 g/inch to 4000 g/inch.
18 . The laminated web of claim 1 , wherein the inner ply comprises a polymer material selected from the group consisting of a heat sealable polyolefin-based polymer material, a heat sealable polyamide-based polymer material, a heat sealable polyester-based polymer material, and a heat sealable regenerated cellulose-based polymer material.
19 . The laminated web of claim 18 , wherein the polymer material is selected from the group consisting of low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), metallocene polyethylene (mPE), cast polypropylene (CPP), copolymers derived from ethylene and propylene, copolymers derived from ethylene, propylene, and one or more additional comonomers, polyethylene-polypropylene blends, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), blends of PET and PBT, biaxially oriented polyethylene terephthalate (BOPET), nylon 6, nylon 6,6, polyamide copolymers, polyamide blends, regenerated cellulose, cellophane, and regenerated cellulose modified with one or more heat seal promoting additives.
20 . (canceled)
21 . The laminated web of claim 1 , wherein the heat sealable polymer layer has a thickness in the range of from about 12 microns to about 30 microns.
22 . A packaging article formed of the laminated web of claim 1 , optionally wherein the packaging article is selected from the group consisting of a bag and a pouch.
23 . (canceled)
24 . A method of making a laminated web, comprising:
providing an outer ply comprising a paper substrate, the outer ply having a first major surface and a second major surface opposite the first major surface;
forming a cutout defining a window in the outer ply;
providing an inner ply comprising a heat sealable polymer film, the inner ply having a first major surface facing the second major surface of the outer ply, the inner ply having a second major surface opposite the first major surface of the inner ply;
forming a perforation region comprising a plurality of perforations bounded within the perforation region on the inner ply;
applying an adhesive to one or both of the second major surface of the outer ply and the first major surface of the inner ply; and
forming a laminate by bringing the outer ply and the inner ply into contact, wherein, in the laminated web, the outer ply and the inner ply are in registration with each other such that the perforation region is substantially overlapping with the window region.
25 . The method of claim 24 , further comprising one or both of:
forming a printed ink layer disposed on at least a portion of the first major surface of the outer ply; and
forming a varnish layer disposed on at least a portion of the first major surface of the outer ply.
26 . The method of claim 24 , further comprising folding, sealing, and/or manipulating the laminated web to thereby form a packaging article.