Foil free tabbed seal

Abstract

Various forms of tabbed sealing members are described along with the laminates from which the sealing members are formed. In some forms, the tabbed sealing members may generally be formed from materials that may be processed using a single recycling stream. In one form, the tabbed seals do not include any metal foils, such as would traditionally be included in induction heated seals. Instead, the seals may be applied in other manners, such as using ultrasonic sealing, conduction heating, high frequency sealing/welding, pressure sensitive adhesives, and the like.

Description

FIELD

The disclosure relates to pull-tab sealing members for sealing the mouth of a container, and more particularly, to pull-tab sealing members that are free from foil and other metal materials.

BACKGROUND

It is often desirable to seal the opening of a container using a removable or peelable seal, sealing member, or inner seal. Often a cap or other closure is then screwed or placed over the container opening capturing the sealing member therein. In use, a consumer typically removes the cap or other closure to gain access to the sealing member and then removes or otherwise peels the seal from the container in order to dispense or gain access to its contents.

Initial attempts at sealing a container opening utilized an induction- or conduction-type inner seal covering the container's opening where the seal generally conformed to the shape of the opening such that a circular container opening was sealed with a round disk approximately the same size as the opening. These prior seals commonly had a lower heat activated sealing layer to secure a periphery of the seal to a rim or other upper surface surrounding the container's opening. Upon exposing the seal to heat, the lower layer bonded to the container's rim. In many cases, these seals included a foil layer capable of forming induction heat to activate the lower heat seal layer. These prior seals tended to provide good sealing, but were often difficult for a consumer to remove because there was nothing for the consumer to grab onto in order to remove the seal. Often, the consumer needed to pick at the seal's edge with a fingernail because there was little or no seal material to grasp.

Other types of seals for containers include a side tab or other flange that extended outwardly from a peripheral edge of the seal. These side tabs are generally not secured to the container rim and provide a grasping surface for a consumer to hold and peel off the seal. These side tabs, however, extend over the side of the container rim and often protrude into a threaded portion of the closure. If the side tab is too large, this configuration may negatively affect the ability of the seal to form a good heat seal. The side tabs (and often the seal itself) can be deformed or wrinkled when the closure or other cap is placed on the container due to contact between the closure (and threads thereof) and tabbed part of the seal. To minimize these concerns, the side tabs are often very small; thus, providing little surface area or material for a consumer to grasp in order to remove the seal.

Yet other types of seals include a sealing member having a tab defined on the top of the seal. One approach of these prior seals includes a partial layer of coated pressure sensitive adhesive to secure the tab to a layer of metal foil. The tab was formed by a full layer extending across the entire surface of the sealing member, but the full layer was only bonded to half of the seal to form the tab. This type of top-tabbed seal offered the advantage of a larger tab, which provided more grasping area for the consumer to hold and peel off the seal, but required a full additional layer of material in order to form the tab. In other approaches, the seal may include a tab formed from the additional full layer of film combined with an additional full layer of adhesive utilizing a part paper or part polymer layer, called a tab stock, to form the tab. This part layer is inserted between the additional full layer of adhesive and lower seal portions to prevent the tab from sticking to the layers below, which formed the tab.

However, oftentimes such tabs are induction sealed to the container, thereby requiring an induction heating layer, such as a metal foil. Such metal foils complicate recycling efforts as the metal foil would need to be separated from the sealing member. Further, in some instances, a portion of the metal foil may remain on the container, thereby complicating recycling the container itself.

In this regard, such tabbed sealing members and the containers may be problematic, such as in Germany according to the “Duales System.” The components would be considered composite materials, containing both plastics and metal foil. Such materials cannot be processed as a “mixed plastic film” such as by wind sifting according to the Duales System. Other countries are considering similar recycling systems and requirements such that the overall components used in a sealing member must be considered.

Therefore, it may be desirable to provide tabbed sealing members that are more suited for recycling according to different recycling systems and programs.

SUMMARY

Various forms of tabbed sealing members are described along with the laminates from which the sealing members are formed. In some forms, the tabbed sealing members may generally be formed from materials that may be processed using a single recycling stream. In one form, the tabbed seals do not include any metal foils, such as would traditionally be included in induction heated seals. Instead, the seals may be applied in other manners, such as using ultrasonic sealing, high frequency sealing, conduction heating, pressure sensitive adhesives, and the like.

According to one form, a tabbed sealing member for sealing to a rim surrounding a container opening is provided. The sealing member includes a multi-layer laminate including an upper laminate portion partially bonded to a lower laminate portion forming a gripping tab defined wholly within a perimeter of the sealing member. The gripping tab is configured for removing the sealing member from the container opening. The lower laminate portion is positioned below the gripping tab and includes at least a sealant layer for bonding to the container rim. The upper laminate portion includes a support layer. The tabbed sealing member is free of a metal foil layer.

In accordance with one form, a tabbed sealing member for sealing to a rim surrounding a container opening is provided. The sealing member includes a multi-layer laminate including an upper laminate portion partially bonded to a lower laminate portion forming a gripping tab defined wholly within a perimeter of the sealing member. The gripping tab is configured for removing the sealing member from the container opening. The lower laminate portion is positioned below the gripping tab and includes at least a sealant layer for bonding to the container rim. The sealant layer includes a polyolefin. The sealant layer may also comprise a polyester, such as polyethylene terephthalate. In some forms, other materials such as EVA, acrylics, and EMA materials may also be included in the sealant layer. The upper laminate portion including a polyolefin support layer. The tabbed sealing member is free of a metal foil layer.

In one form, a laminate for forming a tabbed sealing member is provided. The laminate includes an upper laminate portion and a lower laminate portion. The upper laminate portion includes a support layer. The lower laminate portion includes at least a sealant layer for bonding to the container rim. The upper laminate portion is partially bonded to a lower laminate portion and configured to form a gripping tab when the laminate is formed into the sealing member. The laminate is free of a metal foil layer.

According to one form, the support layer and the sealant layer each include a polyolefin.

In accordance with one form, the sealant layer is a pressure sensitive adhesive.

In one form, the upper laminate portion includes a tab layer.

According to one form, the tab layer is a printed layer.

In accordance with one form, the upper laminate portion includes a release layer.

In one form, the release layer is a lacquer layer.

According to one form, the sealant layer is a relatively low density and low melting point material compared to the support layer.

In accordance with one form, the support layer and the sealant layer each comprise polypropylene, polyethylene, or a combination thereof.

In one form, at least one of the support layer and the sealant layer comprises polyester.

According to one form, the support layer and the sealant layer each comprise polyester.

These and other aspects may be understood more readily from the following description and the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of one form of a tabbed sealing member that does not include a metal foil layer;

FIG. 2 is a cross-sectional view of another form of a tabbed sealing member that does not include a metal foil layer;

FIG. 3 is a cross-sectional view of another form of a tabbed sealing member that does not include a metal foil layer;

FIG. 4 is a cross-sectional view of one form of a tabbed sealing member having a two-piece construction;

FIG. 5 is a cross-sectional view of one form of a tabbed sealing member;

FIG. 6 is a bottom view of one form of a tabbed sealing member showing a heat seal that has been applied in registration with the sealing member;

FIG. 7 is a side view of one form of a tabbed sealing member installed on a container; and

FIG. 8 is a perspective view of one form of assembling a laminate used to form a tabbed sealing member.

DETAILED DESCRIPTION

For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated.

A pull tab sealing member for a container is described herein containing an upper laminate having a pull tab bonded to a lower laminate capable of being sealed to a container's mouth or opening. Generally, the sealing member is free from metal foil, such as aluminum foil, that would typically be used to induction seal to a container. Instead, many of the forms described herein may use alternative sealing technology, such as conduction heating, ultrasonic sealing, high frequency sealing, pressure sensitive adhesives, and the like.

For simplicity, this disclosure generally may refer to a container or bottle, but the sealing members herein may be applied to any type of container, bottle, package or other apparatus having a rim or mouth surrounding an access opening to an internal cavity. In this disclosure, reference to upper and lower surfaces and layers of the components of the sealing member refers to an orientation of the components as generally depicted in figures and when the sealing member is in use with a container in an upright position and having an opening at the top of the container. Different approaches to the sealing member will first be generally described, and then more specifics of the various constructions and materials will be explained thereafter. It will be appreciated that the sealing members described herein, in some cases, function in both a one-piece or two-piece sealing member configuration. A one-piece sealing member generally includes just the sealing member bonded to a container rim. A cap or closure may be also used therewith. A two-piece sealing member includes the sealing member temporarily bonded to a liner. In this construction, the sealing member is bonded to a container's rim, and the liner is configured to separate from the sealing member during heating to be retained in a cap or other closure used on the container. Alternatively, the bond between the liner and the sealing member may be frangible such that it separates when the lid is removed from the container by a user. In a two-piece construction, a wax layer, for example, may be used to temporarily bond the sealing member to a liner. Other types of releasable layers may also be used to provide a temporary bond between the seal and liner.

As discussed above, tabbed seals can suffer from problems associated with the use of metal foils in the tabbed sealing member. This can result in a combination of metal and polymer in the removed sealing member as well as remnant metal and polymer on the container once the sealing member is removed. These combinations of materials can lead to difficulties for recycling.

One form of a foil free tabbed sealing member is shown in FIG. 1. More specifically, FIG. 1 is a cross-section of tabbed sealing member 20 which is a multi-layer laminate. The tabbed sealing member 20 includes a lower laminate portion 22 partially bonded to an upper laminate portion 24 as shown at the arrow. A tab 27 is thereby formed for a user to grasp. The lower laminate portion 22 includes a sealant layer 26 for bonding to a container rim and, in some forms, may include one or more polymer layers. The upper laminate portion 24 includes at least one polymer layer, such as polymer layer 28 and polymer layer 30. The upper laminate portion 24 also includes an optional tab layer 32 and a release layer 34.

The sealant layer 26 may take a variety of forms. For example, sealant layer 26 may be a polyolefin film including, but not limited to, polypropylene, polyethylene, high density polyethylene, low density polyethylene, metallocene, polybutylene, and the like. In some forms, the sealant layer may comprise polyester materials. For example, the sealant layer may include a polyethylene terephthalate (PET) material, such as a PET heatseal lacquer. The material may be a co-polyester resin.

In some forms, the sealant layer may be applied to another layer, such as a support layer in the lower laminate portion. In some forms, the sealant layer may be modified such that it is suitable for use with certain types of materials. For example, when used with polyester containers, such as PET, the sealant may comprise polyester, such as PET. In other forms, the sealant layer may be used with polyolefin containers, such as polypropylene and/or polyethylene. In these forms, it may be more suitable that the sealant layer contains polypropylene and/or polyethylene to form a desirable bond.

In one form, the sealant layer 26 may have a relatively lower melting point, such as below about 110° C., below about 90° C., below about 80° C. The sealant layer 26 may also have a relative low density such as about 0.9 g/cm³ to about 1.4 g/cm³. In some forms, the sealant layer may have a thickness of about 1 μm to about 100 μm. In some forms, the sealant layer may be peelable (soft and/or hard). The sealant layer may also be forgiving and suitable for use with an oversealing device.

Further, the sealant layer 26 may be especially suited to other forms of sealing besides induction sealing since the tabbed sealing member does not include a foil layer. For example, the sealant layer 26 may be configured for ultrasonic sealing, conduction sealing, high frequency sealing, and the like.

In some forms, the sealant layer may be configured as a pressure sensitive adhesive. Such pressure sensitive adhesives may include about 0.2 to about a 0.5 mil (or less) adhesive, such as a coated ethylene vinyl acetate (EVA), polyolefins, 2-component polyurethane, ethylene acrylic acid copolymers, curable two part urethane adhesives, epoxy adhesives, ethylene methacrylate copolymers, and the like bonding materials.

The polymer layers, such as polymer layers 28 and 30, may take a variety of forms and perform a variety of different functions. For instance, in some forms, at least one of the polymer layers 28,30 may function as a support layer to provide structural stability. In some forms, at least one of the polymer layers 28,30 may function as an adhesive layer between the upper laminate portion 24 and lower laminate portion 22, such as indicated at the arrow in FIG. 1.

A variety of different materials can be used in polymer layers 28,30. For instance, polymer layer 28 may include polyolefin film, such as polypropylene, polyethylene, combinations thereof, and the like. In some forms, the material may be in the form as a monofilm or a coextruded film.

Polymer layer 30 may also include a variety of different materials. For instance, polymer layer 30 may include polyolefin film, such as polypropylene, polyethylene, HDPE, LLDPE, MDPE, LDPE, metallocene, polybutylene, combinations thereof, and the like. Further, the material may be a monofilm or coextruded film.

Polymer layers 28,30 may also take other forms, such as comprising polyester. For example, at least one of polymer layers 28,30 may comprise polyester terephthalate (PET). These materials can include plain PET films, PET coextruded films, heat sealable PET films, amorphous PET films, PET films having varying crystallinity, and the like. For instance, PET films having up to about 50% crystallinity may be used in some forms. In some forms, when provided in the lower laminate portion, the upper of the polymer layers may provide support and/or heat insulation while the lower polymer layer may provide compressibility and flexibility and a substrate for the sealant coating.

In one form, the polymer layers 28,30 in the upper laminate portion 24 are relatively higher melting point and/or higher density than polymers used in the lower laminate portion 22. For instance, the polymer layers 28,30 may have a melting point of about 115° C. to about 270° C. The polymer layers 28,30 may also have a density of about 0.90 g/cm³ to about 1.4 g/cm³. In some forms, polypropylene may be used, such as having a melting point of about 145° C. to about 170° C. and a density of about 0.90 g/cm³ to about 0.93 g/cm³.

The polymer layers may also be transparent, such as when forming one or more of the upper laminate. In this form, the transparent polymer layer in the upper laminate may permit other portions of the sealing member to be seen, such as when printing or other features are included.

The tab layer 32 may also take a variety of different forms and provide different properties, as desired. In one form, the tab layer can be a print layer. In general, the print layer can be applied to another layer, such as in the form of printing. Printing inks may be used including, but not limited to, nitrocellulose, PVD (physical vapor deposition) pigments, acrylic, polyurethane, polyvinyl butyral, (PVB) and the like. In some forms, the print layer is applied to one of the polymer layers 28,30. In other forms, the print layer 32 may be applied to a different layer, such as a polymer layer, which is then combined with one or more of the polymer layers 28,30.

The release layer 34 can generally be included to permit a part of the lower and upper laminate portions 22,24 to be separate or otherwise separate from one another by a user. The release layer 34 can take a variety of forms such as films, coatings, and the like. In one form, the release layer can be a silicon coating. According to one form, the release layer 34 can be a lacquer layer. The release layer 34 may also include polyamide coatings, nitrocellulose/polyamide blends, polyurethane resin coatings, acrylic resins, and the like. In some forms, the release layer is a physical separation as opposed to an anti-sticking layer, such as with silicon. In this regard, a physical non-melting layer may be suitable as a release layer.

Another form of tabbed sealing member is shown in FIG. 2. Tabbed sealing member 120 generally includes similar features as described above. However, in this form, the tabbed sealing member 120 does not include printed layer 32. In some forms, the release layer 34 can be made thicker or thinner as desired and to provide a suitable grasping surface for a user.

FIG. 3 provides an illustration of tabbed sealing member 220. This form is similar to the form found in FIG. 1. However, tabbed sealing member 220 includes a single polymer layer 30. In this form, polymer layer 30 can function at least as a support layer providing sufficient strength for a user to grasp the tab 27 and remove at least a portion of the tabbed sealing member 220.

A two-piece configuration is shown in FIG. 4. Generally, this form can include any of the different combination of features described herein along with a liner portion 40. More specifically, tabbed sealing member 320 includes a liner portion 40 that comprises a backing layer 42 and a temporary bonding layer 44. The temporary bonding layer 44 can take a variety of forms and provide temporary bonding to the upper laminate portion 24 in a variety of manners. In one form, the temporary bonding layer 44 may take the form of a wax that can be absorbed into one of the backing layer 42 and the upper laminate portion 24. For example, backing layer 42 may be a paper or pulp layer such that when tabbed sealing member 320 is heated and installed onto a container, the wax can melt and be absorbed. In another form, the temporary bonding layer can simply provide a frangible bond that can be easily broken, such as when a closure is removed from the container.

FIG. 5 illustrates another form of a sealing member 420. This form is similar to a number of the embodiments described above. FIG. 5 differs in that various polymer layers are included in the lower laminate portion 22. More specifically, lower laminate includes sealant layer 26 along with polymer layer 50, and polymer layer 52. A partial adhesive layer 54 is positioned to form a partial bond, providing tab portion 27. The upper laminate includes polymer layer 28.

One exemplary form for the features of FIG. 5 will now be described. In some forms, each of the layers in the sealing member may comprises a common type of material. For example, each of the layers may comprise a form of polyester, such as PET. In some forms, the sealant layer 26 may be a PET heat seal lacquer. The PET heat seal lacquer can be applied to various PET containing materials in the polymer layer 50. For instance, polymer layer 50 may be a PET film that is chemically treated, such as an acrylic treatment. Other treatments may include, but are not limited to, corona treatment, co-polyester treatment, and the like. Further, polymer layer 52 may comprise a polyester material, such as an amorphous PET material.

Amorphous PET may be especially useful in certain seals as it may provide compressibility, replacing some of the function of foams that are traditionally used in sealing members. Further, PET materials, may have a pigment to protect the contents of the container from light. PET materials are generally fairly stiff, but amorphous PET may be used to provide some compression and flexibility in the sealing member.

While not shown in FIG. 5, an adhesive, such as a two-part polyurethane adhesive may be used between polymer layers 50 and 52. Similarly, partial adhesive layer 54 may be a two-part polyurethane adhesive. Finally, the polymer layer 28 may be a transparent PET film.

FIG. 6 illustrates another form of sealing member 520. As shown in FIG. 6, a sealant layer 526 is applied in registration with the size and shape of the sealing member 520. In this form, the sealant layer 526 is applied in the area of the sealing member that will contact and seal to the rim of a container when installed. As such, when viewed from the bottom, the sealant layer 526 is shown towards the edge of the sealing member 520 while layers above the sealant layer are shown in areas which generally are not positioned above the rim of the container. For example, in a configuration similar to FIG. 5, polymer layer 50 is visible from the bottom of the sealing member. When preparing such a sealing member, the sealant layer 526 can be applied only in specific areas on the polymer layer 50, when in the form of a laminate or sheet. Then, when the laminate or sheet is cut, the cuts are made in registration with the location of the sealant layer 526. This provides for sealant layer 526 being generally just positioned towards an outer edge of the sealing member 520 in locations where the sealing member would contact and seal the container. It should be appreciated that this application of sealant layer in registration with the sealing member may be used and applied to any of the embodiments described above.

In some forms, it should be understood that many and/or all of the layers in the sealing members comprise a common form of material. For example, the layers may generally comprise polyolefins. In some forms the layers may generally comprise polyesters, such as PET. In some forms, the layers, with the exception of the sealant layer, may comprise a common form of material. For instance, the polymer layers of the sealing member may comprise polyesters, such as PET while the sealing member may comprise polyolefin, such as polypropylene and/or polyethylene. In this form, a majority of the sealing member may be considered as a mono-material, from the same type of material, with the exception of the sealant layer.

Mono-material sealing members may be especially suitable for recycling purposes. Further, a mono-material system may be utilized with common polymer layers used for different types of seals where only the sealant layer is modified. One such example may include a polyester mono-material sealing member where each of the polymer layers comprise a form of PET. In the case where the mono-material system is used on PET containers, the sealant layer may also comprise PET. In the case where the mono-material system is used with polypropylene, the polymer layers would still comprise the same PET materials, but the sealant layer would comprise polypropylene instead of PET. This system may be useful where the same polymer layers are used for different types of seals, only having to modify the sealant layer, as needed. Other types of mono-material systems may be configured in a similar manner, such as polyolefin mono-material systems with varying sealant layers.

When used in mono-material sealing systems, the sealant layer may be applied in registration with the sealing member, as described above, to minimize the amount of any alien materials. For example, in a PET mono-material sealing system, a polypropylene sealant layer may be applied in registration, as described above, to minimize the amount of any non-PET materials. This can increase the use as a recyclable stream.

It should be appreciated that various adhesives may be included in the layer described above for the various embodiments. For example, adhesives and/or adhesive layers may be provided between the various polymer layers, as needed.

A tabbed sealing member 100 is shown as installed on a container 101. Tabbed sealing member 100 can include any of the embodiments described above as well as combinations of features from the embodiments. As shown in FIG. 7, a tab 102 is being lifted away from a lower laminate portion 104 that is sealed on the container 101. A user can grasp the tab 102 to remove at least a portion of the tabbed sealing member 100 from the container 101.

One form of assembling tabbed sealing members is shown in FIG. 6. In this form, the upper laminate portion 24 is joined to the lower laminate portion 22 with the printed layer 32 therebetween. It should be appreciated that the release layer 34 can also or alternatively be positioned therebetween. In some forms, the upper laminate portion can be pre-formed, such as using higher density, higher melting point materials adhered to one another in a separate bonding process. This pre-formed material can then be adhered to the lower laminate portion using a heat lamination process using heated rollers and/or using a separate adhesive.

The layers may also be assembled in other manners. For example, in addition to heat lamination, other adhesives or lamination materials may be used. Polyurethane adhesive lamination may be used between one or more layers and may also include a strip of such material that is applied, such as on or adjacent the release lacquer. Similarly, partial application of polyurethane adhesive may be used between one or more layers. Other partial applications may also be used with other materials such as hot melt adhesives, low melt co-polyesters, and the like.

In some forms, the tabbed sealing members described herein may be more suitable for recycling. For instance, the tabbed sealing members are free from metal foils that may otherwise contaminate or complicate the recycling process of the tabbed sealing member and/or container. In some traditional sealing members, at least a portion of the foil layer may remain on the container and/or with the seal when the seal is removed. The metal foil typically cannot be recycled with the polymer layers such that it must be removed or the overall material cannot be recycled. Further, in some forms, the tabbed sealing member may be made substantially from the same type of polymer material such that the seal can be recycled in a single process or otherwise easily separated into the component layers. For example, the layers can include polyolefins and similar materials that can be recycled.

According to one form, the sealant layer is a low density, low melting point material that does not require significant heat to adhere to a container. Such materials may include, but are not limited to, co-extruded polypropylene and a random copolymer. Other layers in the tabbed sealing member may be relatively higher density and higher melting point such that they do not melt during the heating process for applying the sealing member to a container.

The tabbed sealing members described herein, in some forms, may be prepared such that they do not require a specific tab layer, such as a PET layer, as used in many traditional tabbed seals. This can lower costs and/or provide for thinner laminates.

Similarly, in some forms, PET layers can be eliminated from the upper laminate portion, as desired. Instead, PET layers in the upper laminate portion can be replaced with other materials, such as co-extruded polypropylene. This can also help improve the recyclability of the tabbed sealing member. As noted above, substantially the entire tabbed sealing member can include polyolefin layers, such as polypropylene and/or polyethylene.

It should be appreciated that layers described herein may be a combination of two or more materials, such as a co-extrusion of multiple materials whereby a first material is an adhesive and a second material may provide extra support and/or strength.

By eliminating the metal foil layer from the tabbed sealing member, it may be possible to provide a seal whereby the internal contents of the container are visible when the tab is lifted.

In some forms, since the lower laminate portion 22 does not include an induction heating layer, the lower laminate may or may not provide sufficient barrier properties. Such barrier properties include, but are not limited to, oxygen barrier, moisture barrier, and the like. However, in some forms it may be desirable to increase these properties without adding a metal foil layer. In such forms, barrier films and/or coatings may be used. Such materials include, but are not limited to SiOx, AlOx, EVOH, and combinations thereof.

As described above, the upper and lower laminate portions may include a variety of layers. The layers may include different polymer materials, such as films, foams, papers, combinations thereof, and the like. The layers could be built using various backings, various HDPE foams at a variety of different densities. Other paper or fibrous materials could also be used in the upper laminate for insulation since fracture strength is no longer an issue compared to the lower laminate portion.

Further general details of the tabbed seals and layers are provided below.

Additional layers may be included in the upper and/or lower laminate such as polyethylene terephthalate (PET), nylon, or other structural polymer layer and may be, in some approaches, about 0.5 to about 1 mil thick. In some approaches, additional layers may be included in the lower laminate. It should be appreciated that the lower seal laminate may include any number of other layers, such as polymer layers, adhesives, polymer films, polymer foams and the like.

The lower sealant or heat seal layer may be composed of any material suitable for bonding to the rim of a container, such as, but not limited to, induction, conduction, or direct bonding methods. Suitable adhesives, hot melt adhesives, or sealants for the heat sealable layer include, but are not limited to, polyesters, polyolefins, ethylene vinyl acetate, ethylene-acrylic acid copolymers, surlyn, and other suitable materials. By one approach, the heat sealable layer may be a single layer or a multi-layer structure of such materials about 0.2 to about 3 mils thick. By some approaches, the heat seal layer is selected to have a composition similar to and/or include the same polymer type as the composition of the container. For instance, if the container includes polyethylene, then the heat seal layer would also contain polyethylene. If the container includes polypropylene, then the heat seal layer would also contain polypropylene. Other similar materials and combinations are also possible.

The polymer layers used in the upper and/or lower laminates may take a variety of forms such as coatings, films, foams, and the like. Suitable polymers include but are not limited to, polyethylene, polypropylene, polyester, ethylene-propylene copolymers, blends thereof as well as copolymers or blends with higher alpha-olefins. By one approach, one or more of the polymer layers may be a blend of polyolefin materials, such as a blend of one or more high density polyolefin components combined with one or more lower density polyolefin components. In one form, one polymer layer may be a polyethylene film while another polymer layer may be a PET film. According to one form, the polyethylene film may have a thickness of about 5 to about 20 microns while the PET film may have a thickness of about 5 to about 20 microns.

A support layer may be optional in the laminate. If included, it may be polyethylene terephthalate (PET), nylon, or other structural polymer layer and may be, in some approaches, about 0.5 to about 1 mil thick.

In some forms, the seals may include an insulation layer or a heat-redistribution layer. In one form, the insulation layer may be a foamed polymer layer. Suitable foamed polymers include foamed polyolefin, foamed polypropylene, foamed polyethylene, polyester foams, amorphous polyesters, and the like. In some forms, these foams generally have an internal rupture strength of about 2000 to about 3500 g/in. In some approaches, the foamed polymer layer 106 may also have a density less than 0.6 g/cc and, in some cases, about 0.4 to less than about 0.6 g/cc. In other approaches, the density may be from about 0.4 g/cc to about 0.9 g/cc. The foamed polymer layer may be about 1 to about 5 mils thick.

In other approaches, a non-foam heat distributing or heat redistributing layer may be included. In such approach, the non-foam heat distributing film layer is a blend of polyolefin materials, such as a blend of one or more high density polyolefin components combined with one or more lower density polyolefin components. Suitable polymers include but are not limited to, polyethylene, polypropylene, ethylene-propylene copolymers, blends thereof as well as copolymers or blends with higher alpha-olefins. By one approach, the non-foam heat distributing polyolefin film layer is a blend of about 50 to about 70 percent of one or more high density polyolefin materials with the remainder being one or more lower density polyolefin materials. The blend is selected to achieve effective densities to provide both heat sealing to the container as well as separation of the liner from the seal in one piece.

The heat-activated bonding layer may include any polymer materials that are heat activated or heated to achieve its bonding characteristics or application to the seal. By one approach, the heat-activated bonding layer may have a density of about 0.9 to about 1.0 g/cc and a peak melting point of about 145° F. to about 155° F. A melt index of the bonding layer 120 may be about 20 to about 30 g/10 min. (ASTM D1238). Suitable examples include ethylene vinyl acetate (EVA), polyolefin, 2-component polyurethane, ethylene acrylic acid copolymers, curable two-part urethane adhesives, epoxy adhesives, ethylene methacrylate copolymers, polybutylene, combinations thereof, and the like bonding materials.

The adhesives useful for any of the adhesive or tie layers described herein include, for example, ethylene vinyl acetate (EVA), polyolefins, 2-component polyurethane, ethylene acrylic acid copolymers, curable two-part urethane adhesives, epoxy adhesives, ethylene methacrylate copolymers, polybutylene, copolyesters, combinations thereof, and the like bonding materials. Other suitable materials may include low density polyethylene, ethylene-acrylic acid copolymers, and ethylene methacrylate copolymers. By one approach, any optional adhesive layers may be a coated polyolefin adhesive layer. If needed, such adhesive layers may be a coating of about 0.2 to about a 0.5 mil (or less) adhesive, such as coated ethylene vinyl acetate (EVA), polyolefins, 2-component polyurethane, ethylene acrylic acid copolymers, curable two-part urethane adhesives, epoxy adhesives, ethylene methacrylate copolymers, copolyesters, and the like bonding materials.

In one aspect, the tab may be formed by a full layer or partial layer of material combined with a partial width composite adhesive structure that includes a polyester core with upper and lower adhesives on opposite sides thereof. This partial composite adhesive structure bonds the upper laminate to the lower laminate to form the gripping tab.

In other aspects of this disclosure, the upper laminate of the seal does not extend the full width of the sealing member in order to define the gripping tab. To this end, the pull tab sealing members herein may also combine the advantages of a tabbed sealing member with a large gripping tab defined completely within the perimeter of the seal, but achieve such functionality with less material (in view of the part layers of the upper laminate) and permit such a tab structure to be formed on many different types of pre-formed lower laminates. The partial upper laminate structure is advantageous, in some approaches, for use with a seal configured for large or wide mouth containers, such as containers with an opening from about 30 to about 100 mm (in other approaches, about 60 to about 100 mm). These seals may also be used with 38 mm or 83 mm container openings, or can be used with any sized container.

In further aspects of this disclosure, the sealing members herein may include a pull or grip tab defined in the upper laminate portion wholly within a perimeter or circumference of the sealing member wherein an upper surface of the sealing member is partially defined by the upper laminate portion and partially defined by the lower laminate portion. In one approach of this aspect, the top surface of the sealing member is provided by a minor portion of the upper laminate and a major portion of the lower laminate. In other approaches of this aspect, the lower laminate is partially exposed at a top surface of the seal with about 50 percent to about 75 percent (or more) of the lower laminate exposed at the top surface of the entire seal. The seals of this aspect allow consumers to remove the sealing member using the tab (as in a conventional pull tab seal) and/or puncture the sealing member by piercing the exposed lower laminate portion to provide push/pull functionality depending on the preference of the consumer.

In the various embodiments, the seals of the present disclosure defining a tab wholly within a perimeter or circumference of the seal (formed by a full or partial layer) also provide an improved ability for the tabbed sealing member to function in a two-piece seal and liner combination. In a two-piece seal and liner combination, the tabbed sealing member is temporarily adhered across its top surface to a liner. After container opening and removal of a cap or closure, the sealing member stays adhered to the container mouth and the liner separates and remains in the container's cap.

In some prior versions of two-piece seal and linear assemblies, the bottom layer of the sealing member is a heat seal layer that is activated by heating, such as by induction or conduction heating, in order to adhere or bond an outer periphery of the sealing member to a rim surrounding the mouth of a container. In the two-piece seal and liner combination, an upper surface of the sealing member is temporarily adhered to a lower surface of the liner by a release layer, which is often a heat-activated release layer, such as an intervening wax layer. During heating to bond the sealing member to the container, heat not only activates the lower heat seal layer, but also travels upwardly through the seal to melt the intervening wax across the entire surface of the sealing member to separate the liner from the sealing member. Often, the melted wax is absorbed by the liner in order to permit easy liner separation from the sealing member. As can be appreciated, for this sealing member and liner combination to function properly, the intervening wax layer needs to be melted across the entire surface of the sealing member. If the wax is not melted evenly all the way across the sealing member upper surface, the liner may not properly separate from the lower seal portion.

The various layers of the sealing member are assembled via coating adhesives, applying films, and/or a heat lamination process forming a sheet of the described layers. Extrusion lamination may also be used. The resulting laminate sheet of the sealing members can be cut into appropriate sized disks or other shapes as needed to form a vessel closing assembly or tabbed sealing member. The cut sealing member is inserted into a cap or other closure which, in turn, is applied to the neck of a container to be sealed. The screw cap can be screwed onto the open neck of the container, thus sandwiching the sealing member between the open neck of the container and the top of the cap. The sealing layer may be a pressure sensitive adhesive, the force of attaching the closure to the container can activate the adhesive.

EXAMPLES

One form of a mono-material sealing member system may be formed from polyester materials, such as PET materials. In the lower laminate portion, a 12 micron PET film that has been acryl treated has a 3 gsm PET heat seal lacquer applied on the treated side of the film. On the opposite side of the PET film is a two-part polyurethane adhesive that secures a 250 micron amorphous PET layer. A partial adhesive layer comprising two-part polyurethane is used to secure a 36 micron PET transparent film to the amorphous PET layer, thereby forming the tab portion therebetween.

Another form of mono-material sealing member may be formed generally from polypropylene materials. The upper laminate includes 50 micron coextruded three layer oriented polypropylene (OPP) that is partially adhered to the lower laminate portion through a two-part polyurethane that is partially applied to create the tab layer. The lower laminate portion includes a 75 micron cast polypropylene (CPP) that can be a monolayer and also may have a color, such as white. This layer may be used to provide compressibility. Below that, a 40 micron two-part polyurethane adhesive can be used to adhere to a coextruded three layer cast polypropylene (CPP) with a co-polymer blend in the heat seat. A further polypropylene layer may also be included, such as a 16 micron polypropylene that is coated with aluminum oxide. This layer can be included in the lower laminate portion and can provide for oxygen and water barrier properties. The aluminum oxide layer is typically very thin, such as in the angstrom range and is not visible.

The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of Applicant's contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.

Claims

1. A tabbed sealing member for sealing to a rim surrounding a container opening, the sealing member comprising: a multi-layer laminate including an upper laminate portion partially bonded to a lower laminate portion forming a gripping tab, the gripping tab configured for removing the sealing member from the container opening,the lower laminate portion positioned below the gripping tab and including at least a sealant layer for bonding to the container rim,the upper laminate portion including a support layer, andthe tabbed sealing member being free of a metal foil layer,wherein the sealing member is mono-material with each of the layers in the sealing member, with the exception of the sealant layer, being made from the same type of material.

2. The tabbed sealing member of claim 1, wherein the support layer and the sealant layer each comprise a polyolefin.

3. A tabbed sealing member for sealing to a rim surrounding a container opening, the sealing member comprising: a multi-layer laminate including an upper laminate portion partially bonded to a lower laminate portion forming a gripping tab, the gripping tab configured graspable by a user for removing the sealing member from the container opening,the lower laminate portion positioned below the gripping tab and including at least a sealant layer for bonding to the container rim,the upper laminate portion including a support layer forming at least a portion of the gripping tab, andthe tabbed sealing member being free of a metal foil layer,wherein the support layer and the sealant layer each comprise a polyester such that at least a portion of the gripping tab is polyester.

4. The tabbed sealing member of claim 1, wherein the upper laminate portion includes a print layer.

5. The tabbed sealing member of claim 4, wherein the print layer is a tab layer.

6. The tabbed sealing member of claim 1, wherein the lower laminate portion includes a polymer layer.

7. The tabbed sealing member of claim 6, wherein polymer layer comprises an amorphous polyethylene terephthalate.

8. The tabbed sealing member of claim 6, wherein the polymer layer comprises a chemically treated polyethylene terephthalate.

9. The tabbed sealing member of claim 1, wherein the support layer and the sealant layer each comprise polypropylene, polyethylene, or a combination thereof.

10. The tabbed sealing member of claim 1, wherein the sealant layer is positioned at an outer periphery of the sealing member such that it is in registration with the rim of the container when installed.

11. A tabbed sealing member for sealing to a rim surrounding a container opening, the sealing member comprising: a multi-layer laminate including an upper laminate portion partially bonded to a lower laminate portion forming a gripping tab, the gripping tab configured for removing the sealing member from the container opening,the lower laminate portion positioned below the gripping tab and including at least a sealant layer for bonding to the container rim and at least one polymer layer, the polymer layer comprising polyester,the upper laminate including a support layer comprising polyester, andthe tabbed sealing member being free of a metal foil layer,wherein the sealing member is mono-material with each of the layers in the sealing member, with the exception of the sealant layer, being made from the same type of material.

12. The tabbed sealing member of claim 11, wherein the sealant layer comprises polyester.

13. The tabbed sealing member of claim 11, wherein the sealant layer comprises polyolefin.

14. The tabbed sealing member of claim 11, wherein the upper laminate portion includes a print layer.

15. The tabbed sealing member of claim 14, wherein the print layer is a tab layer.

16. The tabbed sealing member of claim 11, wherein polymer layer comprises an amorphous polyethylene terephthalate.

17. The tabbed sealing member of claim 11, wherein the lower laminate portion further includes a second polymer layer, the second polymer layer comprising a chemically treated polyethylene terephthalate.

18. The tabbed sealing member of claim 11, wherein the support layer in the upper laminate portion is a transparent polyester terephthalate film.

19. The tabbed sealing member of claim 11, wherein the sealant layer is positioned at an outer periphery of the sealing member such that it is in registration with the rim of the container when installed.

20. A laminate for forming a tabbed sealing member, the laminate comprising: an upper laminate portion including a support layer; anda lower laminate portion including a sealant layer for bonding to the container rim and at least one polymer layer,the upper laminate portion partially bonded to a lower laminate portion and configured to form a gripping tab when the laminate is formed into the sealing member, the laminate being free of a metal foil layer,wherein the laminate is mono-material with each of the layers in the laminate, with the exception of the sealant layer, being made from the same type of material.

21. The laminate of claim 20 wherein the support layer comprises polyester and the polymer layer comprises polyester.

22. The tabbed sealing member of claim 1, further comprising a partial adhesive layer positioned between the upper laminate portion and the lower laminate portion forming the gripping tab.

23. The tabbed sealing member of claim 1, wherein the sealant layer is a pressure sensitive adhesive.