Embossed packaging laminate and method of making laminate

Details Embossed packaging laminate and method of making laminate Embossed packaging laminate and method of making laminate

2002-11-15

2004-08-31

Nolan, Sandra M. (Department: 1772)

Stock material or miscellaneous articles

Hollow or container type article

Paper containing

C428S069000, C428S072000, C428S101000, C428S116000

Reexamination Certificate

active

06783823

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a laminated multilayer structure intended for a packaging laminate with embossed appearance, as well as such packaging laminate, a method of producing the laminated multilayer structure, and a method of embossing such packaging laminates, as well as packaging containers produced from the packaging laminate according to the present invention.
BACKGROUND OF THE INVENTION
Packages of single-use disposable type have long been employed for packing and transporting liquid foods. Such so-called single-use packages are often produced from a flexible packaging laminate with a plurality of layers which each afford specific properties to the packaging laminate. For example, such packaging laminates normally include outer layers possessing superior thermosealing properties in order to make for reforming into packaging containers by fold formation and sealing of the outer layers against one another. Such thermosealable layers normally consist of thermoplastic which also functions as liquid and moisture barrier, on the one hand preventing moisture from the ambient surroundings from penetrating into the packaging wall and into the packed food product, and, on the other hand, preventing the liquid food from leaking out through the packaging wall into the surroundings. Such packaging laminates often also include a rigidifying core layer in order to impart to the finished packaging container strength and configurational stability, normally of paper or paperboard. Core layers of thicker, homogeneous or foamed plastic layers are also common.
For longer storage time of packed food products, such packaging laminates often include layers which act as barriers against gases and vapours, such as, for example, oxygen gas, in particular in the storage of the packed foods for a lengthy period of time, since oxygen gas has a negative effect on food products and their content of nutritive substances, vitamins, flavourings, etc. A very common type of gas barrier layer is thin foils or layers of metal or metal oxide, for example aluminium foil (Alifoil), but layers of polymer possessing superior gas barrier properties are also common, such as, for example, polyamide, ethyl vinyl alcohol copolymers, polyvinyl alcohol, and others.
Packaging containers are often produced in that a web of such a packaging laminate is reformed into a tube by the longitudinal edges of the web being united with one another, whereafter the tube is filled with the intended contents and sealed along narrow, transverse and spaced-apart sealing zones. The sealed sections of the tube containing the contents are thereafter separated from the tube by means of incisions in these sealing zones and can be formed by folding into a final geometric configuration which partly depends on how the sealing joints or seams have been oriented. It is also common to manufacture packaging containers by forming, from sheet-shaped packaging blanks, a container which is sealed in one end (the bottom or the top) and along the longitudinal joint, the container being filled the liquid food and thereafter sealed also in its other end (the top or bottom).
The composition of such packaging laminates is intended to impart to the packed product the best possible product protection properties, at the same time as making the package easy to produce and easy to handle. A very important property in a food package is moreover that it be aesthetically appealing, and can impart and added value to the packed food product, i.e. is attractive for customers to buy. Such added value may be attained in various ways depending upon the product which is packed and the customer group or age group which represents the target group. For example, fruit juices are often packed in packaging containers provided with fresh printed decorative artwork depicting fruit themes in bright, fresh colours. Glossy metal colours and artwork are often seen as being fresh and attractive. Such colours and artwork can be applied by means of known printing technology. Another method of providing packages with decorative artwork is to emboss, i.e. add figures and patterns to the packaging material by deforming the material by pressing and/or shearing it within certain regions according to a desired pattern. Such embossing according to known technology may suitably be put into effect on a core layer of paper or paperboard or a metal layer included in a packaging laminate if this is sufficiently thick. By such means, shadow effects in the surface of the packaging material will be obtained and the desired pattern clearly manifests itself.
One drawback in such patterned pressing or shearing is that it requires specifically manufactured mechanical tools, for example an embossing roller, like the creasing tools which are common today for providing a packaging material with fold indications. Such embossing tools are expensive to manufacture, in particular given that patterns and decorative artwork are subject to fickle fashion and are quite often replaced and renewed. Another drawback is that such mechanical methods always entail that a three-dimensional pattern or deformation is displayed on both sides of the packaging material, i.e. not only towards the outside of the packaging container, but also on its inside, which may involve problems in adhesion to surrounding layers on the inside along the depressed or raised surfaces seen from the inside of the packaging container. Further, conventional embossing places high demands on deformability and flexibility in the material which is to be embossed. Thin thermoplastic layers and thin metal layers and metal films of the type which are employed today to impart to the package superior oxygen gas barrier properties (or alternatively gloss metal appearance) are not suitable for mechanical embossing according to the known techniques. Employing thicker, flexible metal layers suitable for traditional embossing is not cost-effective, nor is it to be sought-for from the points of view of the environment and recycling, for which reason the only option is to emboss one of the other layers included in the packaging laminate, for example the core layer of paper or paperboard.
SUMMARY OF THE INVENTION
One object of the present invention is therefore to realise a novel, laminated multilayer structure which makes for the production of a packaging laminate with embossed appearance, without associated problems of the type inherent in the prior art technology.
Another object of the present invention is to realise a multilayer structure for a packaging laminate which may simply be given an embossed appearance without the employment of specially manufactured mechanical embossing tools.
A further object of the present invention is to realise a multilayer structure for producing a packaging laminate in which only the one side displays the pattern with embossed appearance.
These and other objects have been attained by means of a multilayer structure possessing the characterising feature as set forth in the characterising clause of appended Claim
1
.
Preferred embodiments of the multilayer structure according to the present invention have further been given the characterising features as set forth in appended subclaims
2
to
6
.
One object of the present invention is also to realise a packaging laminate with embossed appearance as defined in Claim
7
, comprising a multilayer structure according to the present invention in which the flexible, deformable layer is distanced from the base layer in those subregions where the two layers are not adhesively bonded to one another and by such means display a surface in relief along these regions according to the predetermined pattern.
According to one preferred embodiment of the present invention, a further object is to realise a multilayer structure and a packaging laminate whose one side displays a glossy metal and also embossed appearance.
This object is attained according to the present invention by means of the characterising feature as set forth in the characterising clause of appende

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