WO2025054139A1

WO2025054139A1 - Container holding an air-activated material

Info

Publication number: WO2025054139A1
Application number: PCT/US2024/045080
Authority: WO
Inventors: Darko MARQUEZ
Original assignee: Rbce Tech LLC
Current assignee: Rbce Tech LLC
Priority date: 2023-09-05
Filing date: 2024-09-04
Publication date: 2025-03-13
Anticipated expiration: 2026-03-05

Abstract

A container for an air-activated material includes a base film layer, an internal film layer and a removable film layer. The internal film layer, which is permeable to air, is sealed to the base film layer at a first perimeter seal surrounding the air-activated material with the air-activated material disposed between the base film layer and the internal film layer. The removable film layer is sealed to the internal film layer at a second perimeter seal surrounding the air-activated material. The second perimeter seal has a seal strength less than that of the first perimeter seal to allow for removal of the removable film layer from the internal film layer to open the container without removing portions of the internal film layer within the first perimeter seal nor the internal film layer from the base film layer.

Description

CONTAINER HOLDING AN AIR-ACTIVATED MATERIAL

BACKGROUND

[0001] US 9,278,796 B2 discloses a container 10, which is shown in FIG. 1 , including a first web 20 and a second web 30 sealed to the first web 20 to form a compartment 40 therebetween, and an air-activated material 50 disposed within the compartment 40. The first web 20 is a laminate made up of a first film layer 22 adhered to a second film layer 24 using a pressure-sensitive adhesive 26. The second film layer 24 is precision scored (e.g., kiss or die cut) to define plugs 60; however, the plugs 60 are maintained within the second film layer 24 so as to avoid creating holes in the second film layer 24 where air may prematurely enter the compartment 40 and react with the air-activated material 50 held within the compartment 40. The plugs 60 are configured to be separated and displaced from the second film layer 24 upon peeling away of the respective portion of the first film layer 22 to create openings 65 in the second film layer 24. With reference to FIG. 2, a third web 70 can be heat sealed to the first web 20 and/or the second web 30 to provide an enclosed holding space 80 for holding contents 15 to be heated.

[0002] Precision scoring the second film layer 24 to define the plugs 60 can be difficult and relatively expensive to manufacture. In practice, the first film layer 22 is adhered via the pressure-sensitive adhesive 26 to the second film layer 24 and then the side of the second film layer 24 opposite the first film layer 22 is kiss cut to form the plugs 60 while care is taken not to cut into the first film layer 22. Because of the kiss cut operation to form the plugs 60, the plugs 60 are spaced inwardly from the edges of the second film layer 24, e.g., the left and right edges shown in FIGS. 1 and 2. This results in more openings 65 near the center of the second film layer 24 as compared to around the edges, which can reduce air flow into the air-activated material 50 around the edges of the container 10.

SUMMARY

[0003] In view of the foregoing, an article of manufacture includes a container defining an internal compartment and an air-activated material disposed in the internal compartment. The container prior to opening is configured to allow ingress of oxygen into the internal compartment at a rate less than 10 cc per 645 cm² per 24 hrs. at 23° C. The container includes a base film layer, an internal film layer and a removable film layer. The internal film layer, which is permeable to air, is sealed to the base film layer at a first perimeter seal surrounding the air-activated material with the air-activated material disposed between the base film layer and the internal film layer. The removable film layer is sealed to the internal film layer at a second perimeter seal surrounding the air-activated material. The second perimeter seal has a seal strength less than that of the first perimeter seal to allow for removal of the removable film layer from the internal film layer to open the container without removing portions of the internal film layer within the first perimeter seal nor the internal film layer from the base film layer. This allows the air-activated material to remain disposed between the base film layer and the internal film layer.

[0004] The base film layer can include an internal surface configured to be heat sealable to the internal film layer. The internal film layer can include a first surface and a second surface opposite to the first surface, each of which can be configured to be heat sealable. The first surface of the internal film layer can be heat sealed to the internal surface of the base film layer at the first perimeter seal. The removable film layer can include an inner surface configured to be heat sealable. The inner surface of the removable film layer can be heat sealed to the second surface of the internal film layer at the second perimeter seal.

[0005] The internal film layer can include openings extending through the internal film layer, and at least one opening can disposed outside of the first perimeter seal. Also, the first perimeter seal can be coincident with the second perimeter seal. A portion of a perimeter of the removable film layer and the internal film layer can be unbonded to allow for the removable film layer to be at least partially peeled or otherwise separated from the internal film layer. If desired, the removable film layer can extend farther from the second seal than the internal film layer.

[0006] The article of manufacture can include a second internal compartment that prior to removing the removable film layer is configured to allow ingress of oxygen into the second internal compartment at a rate less than 10 cc per 645 cm² per 24 hrs. at 23° C. A second air-activated material can be disposed in the second internal compartment. The internal film layer is sealed to the base film layer at another first perimeter seal surrounding the second air-activated material with the second airactivated material disposed between the base film layer and the internal film layer. The removable film layer is sealed to the internal film layer at another second perimeter seal surrounding the second air-activated material. The other second perimeter seal a seal strength less than that of the first perimeter seals to allow for removal of the removable film layer from the internal film layer to open the container without removing portions of the internal film layer within the first perimeter seals nor the internal film layer from the base film layer such that the air-activated materials remain disposed between the base film layer and the internal film layer.

[0007] A method of manufacturing an article includes placing an air-activated material on a base film, sealing the base film to an internal film to form a first perimeter seal surrounding the air-activated material, and sealing a removable film to the internal film to form a second perimeter seal surrounding the air-activated material where the second perimeter seal has a seal strength less than that of the first perimeter seal. The internal film is permeable to air and the base film and the removable film are impermeable to air.

[0008] In the method described above, sealing the base film to the internal film and sealing the removable film to the internal film can occur simultaneously. Also in the method described above, sealing the removable film to the internal film can include leaving a portion of a perimeter of the removable film layer and the internal film layer unbonded. Further, in any of the methods described previously sealing the removable film to the internal film can result in a container defining an internal compartment. The container prior to opening allows ingress of oxygen into the internal compartment at a rate less than 10 cc per 645 cm² per 24 hrs. at 23° C with the air-activated material disposed in the internal compartment. The methods described previously can also include providing a roll of the base film; providing a roll of the internal film having the plurality of openings provided therein; and providing a roll of the removable film.

[0009] The methods described above can further include placing another airactivated material on the base film, sealing the base film to the internal film to form another first perimeter seal surrounding the other air-activated material, sealing the removable film to the internal film to form another second perimeter seal surrounding the other air-activated material where the other second perimeter seal has a seal strength less than that of the first perimeter seals, and cutting through the removable film, the internal film and the base film while leaving the removable film and the base film intact between the first perimeter seal and the other first perimeter seal and leaving the removable film and the internal film intact between the second perimeter seal and the other second perimeter seal. Such a configuration can provide a relatively long strip of heater or oxygen scavenger with a single activation by way of removing only one removable film for multiple sealed air-activated materials.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a cross-sectional view of a container prior to peeling away of a first film layer in accordance with the prior art.

[0011] FIG. 2 is a cross-sectional view of the container of FIG. 1 after peeling away of the first film layer.

[0012] FIG. 3 is a perspective view of a container holding an air-activated material in accordance aspects of the present disclosure.

[0013] FIG. 4 is a cross-sectional view (not to scale) of the container of FIG. 3 prior to peeling away of a removable film layer.

[0014] FIG. 5 is a perspective view of the container of FIG. 3 while peeling away of the removable film layer.

[0015] FIG. 6 is an exploded view of the container and the air-activated material shown in FIG. 3.

[0016] FIG. 7 is a schematic depiction of a method of manufacturing the container and the air-activated material shown in FIG. 3.

[0017] FIG. 8 is an exploded view of an alternative container similar to FIG. 3.

[0018] FIG. 9 is a cross-sectional view similar to FIG. 4 with multiple sealed airactivated materials.

[0019] FIG. 10 is a perspective view of another alternative container. DETAILED DESCRIPTION

[0020] FIGS. 3 and 4 depict an article 120 of manufacture including a container 122 defining an internal compartment 124. The container 122 prior to opening is generally air impermeable in that the container 122 is configured to allow ingress of oxygen into the internal compartment 124 at a rate less than 10 cc per 645 cm² per 24 hrs. at 23° C. The container 122 prior to opening is generally impermeable to water vapor in that the container 122 is configured to allow ingress of water vapor into the internal compartment 124 at a rate less than 1 g H2O per 645cm² per 24 hrs at 23° C. FIG. 5 depicts the container 122 being opened. An air-activated material 126 is disposed in the internal compartment 124.

[0021] With reference to FIGS. 4 and 6, the container 122 includes a base film layer 130, an internal film layer 132 and a removable film layer 134. The internal film layer 132 is permeable to air and is sealed to the base film layer 130 at a first perimeter seal 136. The air-activated material 126 is disposed between the base film layer 130 and the internal film layer 132. The removable film layer 134 is sealed to the internal film layer 132 at a second perimeter seal 138 that has a seal strength less than that of the first perimeter seal 136. This allows for removal of the removable film layer 134 from the internal film layer 132 to open the container 122 without removing the internal film layer 132 from the base film layer 130. This results in the air-activated material 126 remaining disposed between the base film layer 130 and the internal film layer 132, which is shown in FIG. 3, when the removable film layer 134 is removed from the internal film layer 132. Different than the prior art container 10 described above, removal of the removable film layer 134 from the internal film layer 132 to open the container 122 does not remove any portion of the internal film layer 132 because the first seal 136 is intended to be permanent in that the internal film layer 132 is not intended to be remove from the base film layer 130 by a person in a typical peeling operation.

[0022] The base film layer 130 can serve as the base of the container 122. The base film layer 130 is an air impermeable (as described above) multi-layer laminate. An internal side 150 of the base film layer 130 is heat sealable, such as, but not limited to, a heat sealable oriented polypropylene. The base film layer 130 can also be metallized to improve hermeticity. For example, the base film layer 130 can be a laminate including film layers such as Lumirror ® PA10 film and Torayfan ® MH5C film available from Toray Plastics (America), Inc.

[0023] With reference to FIG. 6, the air-activated material 126 is placed onto the internal (heat sealable) side 150 of the base film layer 130 without covering the entire surface, more specifically, leaving a perimeter 152 clear of any air-activated material 126. The air-activated material 126 can be adhered or heat sealed to the base film layer 130. The area of the perimeter 152 will be enough to make a heat seal to other layers 132, 134. The air-activated material 126 can be the heater more particularly described in US 2014/0109890 A1. The air-activated material 126 may also be a loose agglomerate of the materials such as iron powder, water, salt, activated charcoal and vermiculite, which are typical in packages of hand warmer pouches and similar heating products.

[0024] The internal film layer 132 of the container 122 is air permeable and heat sealable on each side. A first side 154 of the internal film layer 132 will have what is intended to be a permanent bond after heat sealing while the second, opposite, side 156 will have a peelable bond after heat sealing. The first side 154 of the internal film layer 132 is heat sealed to the internal side 150 of the base film layer 130, surrounding the air-activated material 126 and forming the first perimeter seal 136 (FIG. 4). The perimeter 158 of the internal film layer 132 is heat sealed to the base film layer 130 around the perimeter 152 of the base film layer 130 where there is no air-activated material 126. The internal film layer 132 can have one or more openings 160. These openings 160 may be formed via hot or cold needle aperture, laser aperture, mechanical dies or any other means of creating openings in a film. The size, amount, and placement of the openings 160 will determine how much oxygen gets to the airactivated material 126, and therefore, when using an exothermic heater, how much heat output there is. The internal film layer 132, for example, can be made from CP423BXPW film available from Copol International Ltd.

[0025] The difference between the openings 160 formed in the internal film layer 132 and the kiss or die cut plugs 60 in the prior art is that the openings 160 are formed entirely through the internal film layer 132 obviating the need for the kiss or die cut and retention of the plugs 60 in the openings formed in the internal film layer 132. Also, a large roll of material having the openings 160 already formed in the film that makes up the internal film layer 132 can be provided when manufacturing the container 122, which does not require as much registration as compared to manufacturing the prior art container in which the first web 20 is a laminate made up of the first film layer 22 adhered to the second film layer 24 using the pressuresensitive adhesive 26. The openings 160 formed in the internal film layer 132 can extend to the edges of the internal film layer 132, which is not possible with the kiss or die cut plugs 60 in the prior art design.

[0026] The removable film layer 134 is an air impermeable (as described above) multi-layer laminate and can be made from the same laminate from which the base film layer 130 is made. An inner side 164 of the removable film layer 134 is heat sealable, such as, but not limited to, a heat sealable oriented polypropylene. Like the base film layer 130, the removable film layer 134 can also be metallized to improve hermeticity. The inner side 164 of the removable film layer 134 is heat sealed to the second side 156 of the internal film layer 132. The perimeter 166 of the removable film layer 134 is heat sealed to the internal film layer 132 around the perimeter 158 to form the second perimeter seal 138.

[0027] The perimeter seals 136, 138 will hold the hermiticity of the container 122. The removable film layer 134 is removed, and thus the container 122 is opened, by peeling the removable film layer 134 off the internal film layer 132 and exposing the openings 160 of the internal film layer 132 to the environment and the heating, for example, can begin.

[0028] A method of manufacturing the article 120 depicted in FIG. 3 will be described in more detail with reference to FIG. 7. A roll 230 of a base film, which will make up the base film layer 130, a roll 232 of an internal film, which will make up the internal film layer 132, and a roll 234 of a removable film, which will removable film layer 134 are each provided. The internal film on the roll 232 may already have a plurality of openings 160 (see FIG. 3) provided in the internal film through which air can pass, but the removable film on the roll 234 need not be adhered to the internal film and no kiss cutting is required to make the openings. [0029] The air-activated material 126 is placed on the base film rolling out from the roll 230. Next, the base film from the roll 230 is sealed to the internal film from the roll 232 to form the first perimeter seal 136 (FIG. 4) surrounding the air-activated material 126, and the removable film from the roll 234 is sealed to the internal film from the roll 232 to form the second perimeter seal 138 (FIG. 4) surrounding the air-activated material 126. As mentioned above, the second perimeter seal 138 has a seal strength less than that of the first perimeter seal 136. To form the perimeter seals 136, 138 a heat sealing machine 236 presses the base film from the roll 230, the internal film from the roll 232 and the removable film from the roll 234 together and heats them to the appropriate temperature to make the perimeter seals 136, 138. As such, both seals 136 and 138 can be formed simultaneously. Different than the prior art container 10, for the container 122, and with reference to FIG. 6, only the perimeter 166 of the removable film layer 134 is sealed to the perimeter 158 of the internal film layer 132 such that the area of the removable film layer 134 within the perimeter 166 is movable away from and with respect to the internal film layer 132 without opening the container 122. Also, as seen in FIG. 3, a portion of a perimeter 166 of the removable film layer 134 and the internal film layer 132 may be unbonded to allow for the removable film layer 134 to be at least partially peeled or otherwise separated from the internal film layer 132. A guillotine 240, or similar cutting device, can be used to cut through the removable film layer 134, the internal film layer 132 and the base film layer 130 to form separate articles 120.

[0030] If desired and with reference to FIG. 8, a fourth layer 250 can be provided in between the base film layer 130 and the internal film layer 132. The fourth layer 250 can be an insulation layer, one non-limiting example being a spunbond polypropylene. Because the fourth layer 250 is positioned between the air-activated material 126 and the internal layer 132, the fourth layer 250 is also a breathable air permeable layer. The fourth layer 250 can be heat sealed around its perimeter 252 to the base film layer 130 and the internal film layer 132. If desired, the fourth layer 250 can be placed on the air-activated material 126 and positioned between the air-activated material 126 and the internal layer 132 without being heat sealed. In such an instance, first perimeter seal 136 (see FIG. 4) can retain the fourth layer 250 in place. [0031] If desired, another film layer that can have air throttling properties or water impermeability that the internal film layer 132 alone does not can be provided between the internal film layer 132 and the removable film layer 134. This other film layer can be removable from the internal film layer 132.

[0032] As discussed above, during manufacturing of the article 120 a cutting operation can be used to cut through the removable film layer 134, the internal film layer 132 and the base film layer 130 to form separate articles 120. FIG. 9 shows an area 260 that the guillotine 240, or similar cutting device, can cut through the removable film layer 134, the internal film layer 132 and the base film layer 130 to form separate articles 120. It may be desirable, however, not to cut through this area 260 between the adjacent heat seals 136, 138 and instead leave the removable film layer 134, the internal film layer 132 and the base film layer 130 intact in the area 260 between the adjacent heat seals 136, 138. By leaving the removable film layer 134, the internal film layer 132 and the base film layer 130 intact between the adjacent heat seals 136, 138, an operator can remove the removable film layer 134 from the internal film layer 132 to expose multiple pads (or similar separate elements) of air-activated material 126 to ambient oxygen via the openings 160 (see FIG. 6) in the internal film layer 132. The multiple pads (or similar separate elements) of air-activated material 126 would remain connected together via the internal film layer 132 and the base film layer 130 after the removable film layer 134 has been removed from the internal film layer 132. Even though FIG. 9 only shows two pads (or similar separate elements) of air-activated material 126 separated from one another by the area 260 and the adjacent heat seals 136, 138, a great number could be provided. For example, several pads (or similar separate elements) of air-activated material 126 separated from one another by multiple areas 260 and the adjacent heat seals 136, 138 could be connected prior to cutting through the removable film layer 134, the internal film layer 132 and the base film layer 130.

[0033] FIG. 10 discloses the removable film layer 134 extending farther from the heat seals 136, 138 than the base film layer 130 and the internal film layer 132. Such a configuration can be provided by a further cutting operation after the guillotine 240, or similar cutting device, passes through area 260 between the adjacent heat seals 136, 138 (FIG. 9). The removable film layer 134 extends farther from the heat seals 136, 138 on the left side per the orientation shown in FIG. 10; however, the removable film layer 134 could extend farther from the heat seals 136, 138 as compared to the base layer 130 and the internal film layer 132 on the right side too, or any other side. Providing such an extension or similarly extending tab can facilitate peeling the removable film layer 134 by providing more of it to grasp.

[0034] It will be appreciated that various of the above-disclosed embodiments and other features and functions, or alternatives or varieties thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Claims

CLAIMS:

1 . An article of manufacture comprising: a container defining an internal compartment, the container prior to opening being configured to allow ingress of oxygen into the internal compartment at a rate less than 10 cc per 645 cm² per 24 hrs. at 23° C; and an air-activated material disposed in the internal compartment, the container comprising: a base film layer; an internal film layer, which is permeable to air, sealed to the base film layer at a first perimeter seal surrounding the air-activated material with the airactivated material disposed between the base film layer and the internal film layer; and a removable film layer sealed to the internal film layer at a second perimeter seal surrounding the air-activated material, the second perimeter seal having a seal strength less than that of the first perimeter seal to allow for removal of the removable film layer from the internal film layer to open the container without removing portions of the internal film layer within the first perimeter seal nor the internal film layer from the base film layer such that the air-activated material remains disposed between the base film layer and the internal film layer.

2. The article of claim 1 , wherein the base film layer includes an internal surface configured to be heat sealable to the internal film layer.

3. The article of claim 2, wherein the internal film layer includes a first surface and a second surface opposite to the first surface, each of which are configured to be heat sealable, wherein the first surface of the internal film layer is heat sealed to the internal surface of the base film layer at the first perimeter seal.

4. The article of claim 3, wherein the removable film layer includes an inner surface configured to be heat sealable, wherein the inner surface of the removable film layer is heat sealed to the second surface of the internal film layer at the second perimeter seal.

5. The article of any of claims 1 - 4, wherein the internal film layer includes openings extending through the internal film layer, and at least one opening is disposed outside of the first perimeter seal.

6. The article of any of claims 1 - 4, wherein the first perimeter seal is coincident with the second perimeter seal.

7. The article of any of claims 1 - 4, wherein a portion of a perimeter of the removable film layer and the internal film layer is unbonded to allow for the removable film layer to be at least partially peeled or otherwise separated from the internal film layer.

8. The article of any of claims 1 - 4, wherein a portion of a perimeter of the removable film layer and the internal film layer is unbonded to allow for the removable film layer to be at least partially peeled or otherwise separated from the internal film layer, and the removable film layer extends farther from the second seal than the internal film layer.

9. The article of any of claims 1 - 4, further comprising: a second internal compartment that prior to removing the removable film layer is configured to allow ingress of oxygen into the second internal compartment at a rate less than 10 cc per 645 cm² per 24 hrs. at 23° C; and a second air-activated material disposed in the second internal compartment, wherein the internal film layer is sealed to the base film layer at another first perimeter seal surrounding the second air-activated material with the second airactivated material disposed between the base film layer and the internal film layer; and wherein the removable film layer is sealed to the internal film layer at another second perimeter seal surrounding the second air-activated material and having a seal strength less than that of the first perimeter seals to allow for removal of the removable film layer from the internal film layer to open the container without removing portions of the internal film layer within the first perimeter seals nor the internal film layer from the base film layer such that the air-activated materials remain disposed between the base film layer and the internal film layer.

10. A method of manufacturing an article comprising: placing an air-activated material on a base film, which is impermeable to air; sealing the base film to an internal film to form a first perimeter seal surrounding the air-activated material, the internal film being permeable to air; and sealing a removable film, which is impermeable to air, to the internal film to form a second perimeter seal surrounding the air-activated material where the second perimeter seal has a seal strength less than that of the first perimeter seal.

11 . The method of claim 10, wherein the method described above, sealing the base film to the internal film and sealing the removable film to the internal film occur simultaneously.

12. The method of claim 10, wherein sealing the removable film to the internal film includes leaving a portion of a perimeter of the removable film layer and the internal film layer unbonded.

13. The method of claim 10 or 12, wherein sealing the removable film to the internal film results in a container defining an internal compartment, the container prior to opening allowing ingress of oxygen into the internal compartment at a rate less than 10 cc per 645 cm² per 24 hrs. at 23° C with the air-activated material disposed in the internal compartment.

14. The method of claim 10, further comprising: providing a roll of the base film; providing a roll of the internal film having the plurality of openings provided therein; and providing a roll of the removable film.

15. The method of claim 10, further comprising: placing another air-activated material on the base film; sealing the base film to the internal film to form another first perimeter seal surrounding the other air-activated material; sealing the removable film to the internal film to form another second perimeter seal surrounding the other air-activated material where the other second perimeter seal has a seal strength less than that of the first perimeter seals; and cutting through the removable film, the internal film and the base film while leaving the air-activated material connected to the other air-activated material through the removable film, the internal film and the base film.