Multi-Layer Products

Abstract

A multi-layer product such as a seal for use with a container for storing and dispensing consumer products is described. The seal includes a first layer having pre-formed lines of separation defining one or more first portions and a second layer having pre-formed lines of separation defining one or more second portions. An adhesive layer is provided between the first and second layers. A release layer is provided between the second layer and the adhesive layer. At least part of each first portion is fixedly secured to a respective one of the one or more second portions at one or more securing locations, e.g., by ultrasonic welding or by an area of the release layer that is absent, modified or coated so that each second portion is directly adhered to the adhesive layer or by means of the interposing release layer.

Claims

1. A multi-layer product comprising: a first layer having pre-formed lines of separation defining one or more first portions; a second layer having pre-formed lines of separation defining one or more second portions; and an adhesive layer between the first and second layers; wherein a release layer is provided between the second layer and the adhesive layer; and wherein at least part of each second portion is fixedly secured to a respective one of the one or more first portions at one or more securing locations.

2. The multi-layer product of claim 1, wherein the first and second portions are fixedly secured by welding at the one or more securing locations.

3. The multi-layer product of claim 1, wherein the release layer is absent, modified or coated at the one or more securing locations so that the first and second portions are fixedly secured by the adhesive layer.

4. The multi-layer product of claim 1, wherein each pre-formed line of separation in the first layer is formed by a pre-scored or pre-perforated tear line, a cut line, or a combination thereof.

5. The multi-layer product of claim 1, wherein each pre-formed line of separation in the second layer is formed by a pre-scored or pre-perforated tear line, a cut line, or a combination thereof.

6. The multi-layer product of claim 1, wherein the first layer is a metal foil, a metallized polymeric film or paper sheet, a plastics film of single or multiple layer construction, or any combination thereof.

7. The multi-layer product of claim 1, wherein the second layer is a metal foil, a metallized polymeric film or paper sheet, a plastics film of single or multiple layer construction, or any combination thereof.

8. The multi-layer product of claim 1, being a self-adhesive label or a seal for use with a container for storing and dispensing consumer products.

9. A seal for sealing a container for storing and dispensing consumer products, the seal comprising: a cover film having pre-formed lines of separation defining one or more releasable portions; a barrier film secured to the cover film, the barrier film having pre-formed lines of separation defining a barrier patch per releasable portion; and an adhesive layer between the cover film and the barrier film; wherein a release layer is provided between the barrier film and the adhesive layer; and wherein at least part of each barrier patch is fixedly secured to a respective one of the one or more releasable portions at one or more securing locations.

10. The seal of claim 9, wherein each barrier patch is fixedly secured to the associated releasable portion by welding at the one or more securing locations.

11. The seal of claim 9, wherein the release layer is absent, modified or coated at the one or more securing locations so that each barrier patch is fixedly secured to the associated releasable portion by the adhesive layer.

12. The seal of claim 9, wherein each releasable portion of the cover film includes a tab.

13. The seal of claim 12, wherein the tab is part of each releasable portion.

14. The seal of claim 12, wherein the tab is fixedly adhered or lamination to each releasable portion.

15. A container for storing and dispensing consumer products, comprising: a tray having a generally planar top surface into which has been formed one or more discrete cavities for receiving the consumer products; and a seal comprising a cover film secured to the generally planar top surface of the tray by an adhesive layer to seal the one or more cavities to retain the consumer products in the one or more cavities, the cover film having pre-formed lines of separation defining a releasable portion per cavity; and a barrier patch per releasable portion; wherein a release layer is provided between each barrier patch and the adhesive layer; and wherein at least part of each barrier patch is fixedly secured to a respective one of the one or more releasable portions at one or more securing locations.

16. The container of claim 15, wherein each barrier patch is fixedly secured to the associated releasable portion by welding at the one or more securing locations.

17. The container of claim 15, wherein the release layer is absent, modified or coated at the one or more securing locations so that each barrier patch is fixedly secured to the associated releasable portion by the adhesive layer.

18. The container of claim 15, wherein each releasable portion of the cover film includes a tab.

19. The container of claim 18, wherein the tab is part of each releasable portion.

20. The container of claim 18, wherein the tab is fixedly adhered or lamination to each releasable portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0063] The present invention can be even more fully understood with the reference to the accompanying drawings which are intended to illustrate, not limit, the present invention.

[0064] FIG. 1 is a top view of a moulded tray of a known multiple-compartment dispensing container.

[0065] FIG. 2 is a top view of a cover film.

[0066] FIG. 3 is a top view of a barrier film to be used in conjunction with the cover film of FIG. 2 to form a seal according to the present invention.

[0067] FIG. 4 is a top view of a seal according to the present invention where the cover film of FIG. 2 has been secured to the barrier film of FIG. 3.

[0068] FIG. 5 is a cross section of part of the seal of FIG. 4.

[0069] FIG. 6 is a top view of part of a seal according to the present invention where each barrier patch is fixedly secured to the overlying releasable portion by a weld.

[0070] FIG. 7 is a cross section of part of the seal of FIG. 6.

[0071] FIG. 8 is a top view of a barrier film and applied release layer forming part of a seal according to the present invention where each barrier patch is fixedly secured to the overlying releasable portion by the adhesive layer because part of the release layer is absent.

[0072] FIG. 9 is a cross section of part of the seal of FIG. 8.

[0073] FIG. 10 is a top view of a barrier film and alternative applied release layer forming part of a seal according to the present invention where each barrier patch is fixedly secured to the overlying releasable portion by the adhesive layer because part of the release layer is absent.

[0074] FIG. 11 is a cross section of part of the seal of FIG. 10.

[0075] FIG. 12 is a top view of a barrier film and alternative applied release layer forming part of a seal according to the present invention where each barrier patch is fixedly secured to the overlying releasable portion by the adhesive layer and the release layer because part of the release layer has modified properties.

[0076] FIG. 13 is a cross section of part of the seal of FIG. 12.

[0077] FIG. 14 is a top view of a barrier film and alternative applied release layer forming part of a seal according to the present invention where each barrier patch is fixedly secured to the overlying releasable portion by the adhesive layer and the release layer because part of the release layer is coated.

[0078] FIG. 15 is a cross section of part of the seal of FIG. 14.

[0079] FIGS. 16A to 16F are top and cross section views of different tab constructions for a seal according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0080] Although the following description relates to a seal for use with a container, it will be readily understood that the same features can be applied to other multi-layer products such as self-adhesive labels, for example.

[0081] A container for storing and dispensing consumer products is shown in FIGS. 1 to 5 and includes a tray 1 having a generally planar top surface 2 into which has been formed an array of discrete cavities 3 for receiving the consumer products. A cover film 10 is adhered to the generally planar top surface of the tray 1 by a layer of adhesive 28 to seal the cavities 3 to retain the consumer products in the cavities. The cover film 10 has pre-formed lines of separation 13 defining a releasable portion 12 per cavity to retain the consumer products in that cavity until it is removed. The cover film 10 therefore has a corresponding array of releasable portions 12. Each line of separation 13 can be a tear line (e.g., a score line or perforation line) that must be torn or broken to release the releasable portion, or a cut line extending completely through the material of the cover film 10. Each releasable portion 12 of the cover film 10 has low vapour transmission properties in the area which in use overlies the associated cavity, those low vapour transmission properties being created by a barrier patch 24 with high vapour barrier properties shaped and sized to overlie the associated cavity. Each barrier patch 24 is adhered to the underside of the cover film 10 by the same layer of adhesive 28 as that which adheres the cover film to the top surface of the tray 1.

[0082] The array of barrier patches 24 can be created from a single sheet of barrier film 20 as follows. A single sheet of barrier film 20 is secured to the underside of the cover film 10 by the adhesive layer 28 to form a seal. The barrier film 20 has pre-formed lines of separation 23 (e.g., tear lines such as score lines or perforation lines, or cut lines) defining the periphery of each vapour-resistant barrier patch 24 so that peeling away the majority of the barrier film 20 from the cover film 10 immediately prior to application of the cover film to secure it to the generally planar top surface of the tray 1 exposes the adhesive 28 in areas necessary for adhesion to the tray. If the lines of separation 23 are tear lines they will tear when the barrier film 20 is removed to leave a barrier patch 24 attached to the underside of each releasable portion 12 of the cover film.

[0083] In a preferred arrangement, the barrier patches 24 are larger than the associated releasable portions 12 of the cover film 10 and are adhered to an overlapping region of the cover film between the pre-formed line of separation in the cover film and the periphery of the associated barrier patch. The barrier patches 24 are not adhered to the generally planar surface of the tray 1, but only to the cover film.

[0084] The barrier film 20 can have a further pre-defined tear line 25 (or cut line) close to one edge thereof to define a tear-off strip 26 which when removed exposes a location anchorage area of the adhesive on the underside of the cover film 10, for adhering an edge portion of the cover film 10 to an edge portion 4 of the tray 1 before peeling away the majority of the barrier film 20 and adhering the cover film over the cavities. To assist in the process of adhering the cover film 10 to the top surface of the tray, the tray 1 can have upstanding cover film location means 5. The cover film 10 can have cooperating means 11 for accurate location of the cover film over the tray 1 with the one or more cavities 3 and associated tear-off portions 12 in register before adhering the cover film to the tray.

[0085] The cover film 10 is secured to the tray 1 by the same layer of adhesive 28 that is used to secure the cover film to the barrier film 20. After the majority of the barrier film 20 has been peeled away from the cover film 10 to expose the adhesive, the cover film can be secured to the top surface of the tray 1.

[0086] In one arrangement, each releasable portion 12a is attached to the remainder of the cover film 10 by a bridge region 16 defined by a gap in the associated pre-formed line of separation. (Although in FIG. 2 only one releasable portion 12a of this type is shown, it will be readily appreciated that in practice all of the releasable portions would include a similar bridge region if the seal has this particular letterbox construction.) This means that the line of separation 13a defining each releasable portion 12a in the cover film does not extend completely around the periphery of the associated cavity to form a closed loop. The ends of the line of separation 13a are separated by the bridge region 16. The releasable portion 12a will remain attached to the cover film 10 by means of the bridge region 16 when it separates along the associated line of separation 13a to define a flap that overlies the cavity. This might be considered to be more environmentally friendly than if the lines of separation extend completely around the periphery of the or each cavity because the individual releasable portions do not become fully detached from the cover film and do not need to be discarded each time the contents of a cavity are dispensed.

[0087] To dispense the contents of a particular cavity, the user simply presses down on the overlying releasable portion 12. If the line of separation 13 is a tear line (e.g., a score line or a perforation line) the application of a sufficient amount of force will cause it to tear such that the releasable portion 12 is fully released from the remainder of the cover film 10 or partially released apart from in the bridge region 16. The bridge region 16 acts as a hinge to allow the attached releasable portion 12a (or flap) to bend downwardly into the cavity or upwardly to allow the contents of the cavity to be dispensed through the opening created in the cover film 10. Most of the barrier patch 24 adhered to the releasable portion will be peeled away from the overlapping region of the cover film 10 that surrounds the opening. However, a small portion of the barrier patch 24 that lies underneath the bridge region 16 may remain partially or loosely adhered to the cover film 10.

[0088] The preferred arrangement incorporates tamper evident properties because once a releasable portion 12 of the cover film 10 has been released, it cannot be easily repositioned over the associated cavity. This is because the barrier patch 24 is slightly larger than the releasable portion 12 such that the overlapping region 14 of the cover film 10 surrounding the opening (i.e., the part of the cover film from which the barrier patch 24 is peeled away when the releasable portion 12 is released from the cover film) will tend to adhere to the generally planar top surface of the tray once the adhesive is exposed. This makes it very difficult to slide the peripheral edge of the barrier patch 24 back between the cover film 10 and the top surface of the tray. Tamper evident properties are especially important if the container is used to store and dispense food and medication such as pills, tablets and capsules.

[0089] FIG. 5 shows how a release layer or coating 29 is applied to the top surface 27 of the barrier film 20 to allow the majority of it to be easily and cleanly peeled away from the cover film 10. Any suitable release coating can be used. (It will be readily understood that in FIGS. 5, 7, 9 and 11 the layers of the seal are shown exaggerated and spaced slightly apart for improved clarity. In a practical seal, each of the respective layers will have a suitable thickness and adjacent layers will be in contact with each other.)

[0090] FIGS. 6 and 7 show how each barrier patch 24 is fixedly secured to the overlying releasable portion 12 of the cover film 10 by welding. In FIG. 6 the line of separation 23 defining the periphery of one of the barrier patches 24 is shown as if it were visible through the cover filmwhich is possible in practice if the seal layers, including the adhesive and release layers, are transparent or translucent. Ultrasonic spot welding can be used, for example. The weld 30 extends through the adhesive layer 28 and the release layer 29 to physically secure each barrier patch 24 to the overlying releasable portion 12. The weld 30 represents a securing location. Although only one weld 30 is shown, it will be readily appreciated that each barrier patch 24 can be welded to the overlying releasable portion 12 at two or more spaced securing locations if appropriate.

[0091] FIG. 8 shows part of the release layer 29. The overlying adhesive layer and the cover film have been omitted for improved clarity. The line of separation 23 defining the periphery of one of the barrier patches 24 is shown as if it were visible through the release layer 29. It will be readily appreciated that the overlying releasable portion 12 of the cover film is smaller than the barrier patch 24.

[0092] The release layer 29 includes a securing location 31. A similar securing location 31 is provided in the release layer 29 for each barrier patch 24. The securing location 31 is shown to be located generally in the centre of the barrier patch 24 but it can be provided anywhere within the periphery of the overlying releasable portion 12 (not shown in FIG. 8). Although only one securing location 31 is shown, it will be readily appreciated that each barrier patch 24 can be fixedly secured to the overlying releasable portion 12 at two or more spaced securing locations if appropriate.

[0093] Each securing location 31 is formed by selectively applying the release layer 29 to just certain parts of the top surface 27 of the barrier film 20, or by applying the release layer over substantially the whole of the top surface 27 of the barrier film 20 and then selectively removing it, e.g., by selectively applying a chemical to the release layer to remove or disperse part of the release layer. In each case, the release layer 29 is absent in those parts that define each securing location 31. Each barrier patch 24 is therefore effectively adhered to the adhesive layer 28 at each securing location 31 and cannot be easily released from it because there is no interposing release layer. Such adhesion between the barrier patch and the adhesive layer 28 is sufficient to prevent the barrier patch from becoming detached from the releasable portion during normal usage of the seal, e.g., if the releasable portion and barrier patch are fully detached when the contents of a particular cavity are dispensed, or in the case of a letterbox construction, if the releasable portion 12a remains attached to the remainder of the cover film 10 by a bridge region 16 defined by a gap in the associated pre-formed line of separation 13a.

[0094] As shown in FIGS. 8 and 9, the release layer 29 can be absent in one or more small areas within the periphery of each barrier patch 24 so that each barrier patch is effectively adhered to the adhesive layer at one or more spaced securing locations. Alternatively, the release layer 29 can be absent over substantially all of the area within the periphery of each releasable portion 12 so that each underlying barrier patch 24 is effectively firmly adhered to the adhesive layer across the substantially the whole of its surface area apart from the peripheral region that is released from an overlapping region of the cover film 10. This is shown in FIGS. 10 and 11 where the release layer 29 has been removed over a large area to define a larger securing location 32. The securing location 32 extends substantially to the periphery of the overlying releasable portion 12. The release layer 29 is still present in a peripheral region 33 of the barrier patch 24 which is released from an overlapping region of the cover film 12 that surrounds the overlying releasable portion 12. FIG. 11 shows how almost the whole of the barrier patch 24 is effectively firmly adhered to the adhesive layer 28 with only its peripheral region 33 being in contact with the release layer 29.

[0095] FIG. 12 shows part of the release layer 29. The overlying adhesive layer and the cover film have been omitted for improved clarity. The line of separation 23 defining the periphery of one of the barrier patches 24 is shown as if it were visible through the release layer 29. It will be readily appreciated that the overlying releasable portion 12 of the cover film is smaller than the barrier patch 24.

[0096] The release layer 29 includes a securing location 34. A similar securing location 34 is provided in the release layer 29 for each barrier patch 24. The securing location 34 is shown to be located generally in the centre of the barrier patch 24 but it can be provided anywhere within the periphery of the overlying releasable portion 12 (not shown in FIG. 12). Although only one securing location 34 is shown, it will be readily appreciated that each barrier patch 24 can be fixedly secured to the overlying releasable portion 12 at two or more spaced securing locations if appropriate.

[0097] Each securing location 34 is formed by selectively applying a chemical to modify the release properties of the release layer 29. This means that the release layer 29 is adhered to the adhesive layer 28 at each securing location 34. Each barrier patch 24 is therefore effectively adhered to the adhesive layer 28 at each securing location 34 by means of the release layer 29. Such adhesion between the barrier patch and the adhesive layer 28 is sufficient to prevent the barrier patch from becoming detached from the releasable portion during normal usage of the seal, e.g., if the releasable portion and barrier patch are fully detached when the contents of a particular cavity are dispensed, or in the case of a letterbox construction, if the releasable portion 12a remains attached to the remainder of the cover film 10 by a bridge region 16 defined by a gap in the associated pre-formed line of separation 13a.

[0098] FIG. 14 shows part of the release layer 29. The overlying adhesive layer and the cover film have been omitted for improved clarity. The line of separation 23 defining the periphery of one of the barrier patches 24 is shown as if it were visible through the release layer 29. It will be readily appreciated that the overlying releasable portion 12 of the cover film is smaller than the barrier patch 24.

[0099] The release layer 29 includes a securing location 35. A similar securing location 35 is provided in the release layer 29 for each barrier patch 24. The securing location 35 is shown to be located generally in the centre of the barrier patch 24 but it can be provided anywhere within the periphery of the overlying releasable portion 12 (not shown in FIG. 14). Although only one securing location 35 is shown, it will be readily appreciated that each barrier patch 24 can be fixedly secured to the overlying releasable portion 12 at two or more spaced securing locations if appropriate.

[0100] Each securing location 35 is formed by selectively applying a chemical to coat the release layer 29. The release layer 29 is adhered or bonded to the applied coating 36, which in turn is adhered to the adhesive layer 28 at each securing location 35. Each barrier patch 24 is therefore effectively adhered to the adhesive layer 28 at each securing location 35 by means of the coated release layer 29. Such adhesion between the barrier patch and the adhesive layer 28 is sufficient to prevent the barrier patch from becoming detached from the releasable portion during normal usage of the seal, e.g., if the releasable portion and barrier patch are fully detached when the contents of a particular cavity are dispensed, or in the case of a letterbox construction, if the releasable portion 12a remains attached to the remainder of the cover film 10 by a bridge region 16 defined by a gap in the associated pre-formed line of separation 13a.

[0101] FIGS. 16A to 16F show different tab constructions for the seal of the present invention. In each case, only a single barrier patch and overlying releasable portion are shown.

[0102] In the constructions shown in FIGS. 16A to 16D, the tab 37 is formed integrally as part of the releasable portion 12 of the cover film 10. The tab 37 extends upwardly away from the underlying barrier patch 24 so that it can be grasped easily by the user. The tab 37 can be made to upstand or bend upwardly when the seal is applied to the generally planar top surface 2 of the tray 1 by suitable pre-formed creases or folds 38 in the cover film 10.

[0103] In the constructions shown in FIGS. 16E and 16F, the tab is adhered to the releasable portion 12. In particular, the tab 37 is part of an additional tab portion 39 that is fixedly secured or laminated onto each releasable portion 12. The tab 37 can be made to upstand or bend upwardly when the seal is applied to the generally planar top surface 2 of the tray 1 by suitable pre-formed creases or folds 38 in the tab portion 39.

[0104] The present invention can include any combination of these various features or embodiments above and/or below as set-forth in sentences and/or paragraphs. Any combination of disclosed features herein is considered part of the present invention and no limitation is intended with respect to combinable features.

[0105] The entire contents of all references cited in this disclosure are incorporated herein in their entireties, by reference. Further, when an amount, concentration, or other value or parameter is given as either a range, preferred range, or a list of upper preferable values and lower preferable values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or preferred value and any lower range limit or preferred value, regardless of whether such ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the invention be limited to the specific values recited when defining a range.

[0106] Other embodiments of the present invention will be apparent to those skilled in the art from consideration of the present specification and practice of the present invention disclosed herein. It is intended that the present specification and examples be considered as exemplary only with a true scope and spirit of the invention being indicated by the following claims and equivalents thereof