( 12 ) United States Patent
`Wang
`
`US 10,889,093 B2
`( 10 ) Patent No .:
`( 45 ) Date of Patent :
`Jan. 12 , 2021
`
`US010889093B2
`
`( 54 ) DIMENSIONALLY STABLE RECYCLABLE
`PLASTIC PACKAGE
`( 71 ) Applicant : Colgate - Palmolive Company , New
`York , NY ( US )
`( 72 ) Inventor : Jun Wang , Fort Washington , PA ( US )
`( 73 ) Assignee : Colgate - Palmolive Company , New
`York , NY ( US )
`Subject to any disclaimer , the term of this
`patent is extended or adjusted under 35
`U.S.C. 154 ( b ) by 0 days .
`( 21 ) Appl . No .: 16 / 721,472
`( 22 ) Filed :
`Dec. 19 , 2019
`( 65 )
`Prior Publication Data
`Nov. 12 , 2020
`US 2020/0353731 A1
`Related U.S. Application Data
`Provisional application No. 62 / 843,691 , filed on May
`6 , 2019 .
`( 51 ) Int . Ci .
`B32B 27132
`B32B 27/08
`B32B 7035
`B32B 27/30
`( 52 ) U.S. CI .
`???
`
`( * ) Notice :
`
`( 60 )
`
`( 2006.01 )
`( 2006.01 )
`( 2019.01 )
`( 2006.01 )
`B32B 27/32 ( 2013.01 ) ; B32B 27/08
`( 2013.01 ) ; B32B 27/306 ( 2013.01 ) ; B32B
`2250/24 ( 2013.01 ) ; B32B 2270/00 ( 2013.01 ) ;
`B32B 2323/043 ( 2013.01 ) ; B32B 2323/046
`( 2013.01 ) ; B32B 2439/70 ( 2013.01 )
`( 58 ) Field of Classification Search
`B32B
`B32B 271
`B32B 27/306 ;
`CPC
`B32B 2250/24 ; B32B 2270/00 ; B32B
`
`2323/043 ; B32B 2323/046 ; B32B
`2439/70 ; B29L 2009/00 ; B29L 2023/001 ;
`B29L 2023/22 ; B29K 2995/0053 ; B29C
`35/041 ; B29C 35/06 ; B29C 53/10 ; B29C
`55/28 ; B29B 13/024
`See application file for complete search history .
`References Cited
`U.S. PATENT DOCUMENTS
`
`( 56 )
`
`2010/0015423 A1
`2010/0279046 Al
`2016/0339663 A1 *
`2018/0354241 A1
`
`1/2010 Schaefer et al .
`11/2010 Ashman
`11/2016 Clare
`12/2018 Gilbert
`
`B32B 1/02
`
`FOREIGN PATENT DOCUMENTS
`2014/005214
`1/2014
`4/2018
`2018/070945
`2018/202479
`11/2018
`2019/172932
`9/2019
`
`WO
`WO
`WO
`WO
`
`OTHER PUBLICATIONS
`International Search Report and the Written Opinion of the Inter
`national Searching Authority issued in International Application
`PCT / US2020 / 070023 dated Oct. 7 , 2020 .
`* cited by examiner
`Primary Examiner — Yan Lan
`ABSTRACT
`( 57 )
`Described herein is a sheet comprising : a multi - layer struc
`ture comprising : a plurality of layers including an uppermost
`layer and a lowermost layer , each of the plurality of layers
`having a molecular orientation that results in a stress value
`for each layer ; wherein the stress value of at least two of the
`plurality of layers are non - zero and different from one
`another ; and wherein the multi - layer structure has a net
`stress value that is less than the greater stress value of the
`plurality of layers .
`10 Claims , 18 Drawing Sheets
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`17-11
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`EPL LIMITED EX1001
`U.S. Patent No. 10,889,093
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`0001
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`

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`U.S. Patent
`U.S. Patent
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`Jan. 12, 2021
`Jan. 12 , 2021
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`Sheet 1 of 18
`Sheet 1 of 18
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`US 10,889,093 B2
`US 10,889,093 B2
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`

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`U.S. Patent
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`Jan. 12 , 2021
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`Sheet 2 of 18
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`US 10,889,093 B2
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`CREATE FIRST WEB
`USING BLOWN FILM
`EXTRUSION OR CAST
`FILM PROCESS
`
`CREATE SECOND WEB
`USING BLOWN FILM
`EXTRUSION OR CAST
`FILM PROCESS
`
`LAMINATE TOGETHER
`THE FIRST WEB AND
`SECOND WEB TO
`FORM A SHEET
`
`CUT SHEET INTO
`PACKAGING
`SHAPE AND FORM
`PACKAGING
`
`FIG . 2
`
`0003
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`

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`U.S. Patent
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`Jan. 12 , 2021
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`Sheet 3 of 18
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`US 10,889,093 B2
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`Sheet 4 of 18
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`U.S. Patent
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`Jan. 12 , 2021
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`Sheet 5 of 18
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`US 10,889,093 B2
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`Jan. 12 , 2021
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`Sheet 6 of 18
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`US 10,889,093 B2
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`

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`Jan. 12 , 2021
`Jan. 12, 2021
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`Sheet 7 of 18
`Sheet 7 of 18
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`US 10,889,093 B2
`US 10,889,093 B2
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`U.S. Patent
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`U.S. Patent
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`Jan. 12 , 2021
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`Sheet 8 of 18
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`US 10,889,093 B2
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`282a
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`

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`U.S. Patent
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`Jan. 12 , 2021
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`Sheet 9 of 18
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`US 10,889,093 B2
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`

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`U.S. Patent
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`Jan. 12 , 2021
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`Sheet 10 of 18
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`US 10,889,093 B2
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`

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`U.S. Patent
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`Jan. 12 , 2021
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`Sheet 11 of 18
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`US 10,889,093 B2
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`

`

`U.S. Patent
`U.S. Patent
`
`Jan. 12 , 2021
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`US 10,889,093 B2
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`U.S. Patent
`U.S. Patent
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`Jan. 12, 2021
`Jan. 12 , 2021
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`Sheet 13 of 18
`Sheet 13 of 18
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`US 10,889,093 B2
`US 10,889,093 B2
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`U.S. Patent
`U.S. Patent
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`Jan. 12, 2021
`Jan. 12 , 2021
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`Sheet 14 of 18
`Sheet 14 of 18
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`US 10,889,093 B2
`US 10,889,093 B2
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`U.S. Patent
`U.S. Patent
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`Jan. 12, 2021
`Jan. 12 , 2021
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`Sheet 15 of 18
`Sheet 15 of 18
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`US 10,889,093 B2
`US 10,889,093 B2
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`U.S. Patent
`U.S. Patent
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`Jan. 12, 2021
`Jan. 12 , 2021
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`Sheet 16 of 18
`Sheet 16 of 18
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`US 10,889,093 B2
`US 10,889,093 B2
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`U.S. Patent
`U.S. Patent
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`Jan. 12, 2021
`Jan. 12 , 2021
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`Sheet 17 of 18
`Sheet 17 of 18
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`US 10,889,093 B2
`US 10,889,093 B2
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`U.S. Patent
`U.S. Patent
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`Jan. 12 , 2021
`Jan. 12, 2021
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`Sheet 18 of 18
`Sheet 18 of 18
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`US 10,889,093 B2
`US 10,889,093 B2
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`

`

`US 10,889,093 B2
`
`1
`DIMENSIONALLY STABLE RECYCLABLE
`PLASTIC PACKAGE
`
`2
`olefin layer comprising high - density polyethylene ; a third
`polyolefin layer comprising high - density polyethylene ; a
`fourth polyolefin layer comprising high - density polyethyl
`ene ; a first barrier tie layer ; a barrier layer ; a second barrier
`BACKGROUND
`5 tie layer ; a fifth polyolefin layer comprising high - density
`polyethylene ; and a sixth polyolefin layer comprising linear
`Recycling is a way to prevent waste material from being
`deposited in a landfill . Currently , rigid packaging , such as
`low - density polyethylene .
`polyethylene terephthalate ( PET ) bottles and high - density
`In other embodiments , the present invention includes a
`polyethylene ( HDPE ) bottles , may be recycled . However ,
`multi - layer structure which consists of : a first polyolefin
`flexible packaging , such as ( e.g. , toothpaste ) tubes , may not 10 layer comprising high - density polyethylene ; a second poly
`be recycled due to the tubes being made from multiple
`olefin layer comprising high - density polyethylene and tita
`different plastics , such as low - density polyethylene ( LDPE ) ,
`nium dioxide ; a third polyolefin layer comprising high
`linear low - density polyethylene ( LLDPE ) , HDPE , polypro
`density polyethylene and titanium dioxide ;
`a fourth
`pylene ( PP ) , ethylene vinyl alcohol ( EVOH ) , aluminum foil ,
`and mixtures of these materials are not recyclable . Further- 15 polyolefin layer comprising high - density polyethylene ; a
`first barrier tie layer ; a barrier layer ; a second barrier tie
`more , other flexible materials that may be recyclable may
`layer , a fifth polyolefin layer comprising high - density poly
`not be suitable as a packaging material because such flexible
`ethylene ; and a sixth polyolefin layer comprising linear
`material exhibit poor dimensional stability , which causes
`low - density polyethylene .
`such material to curl onto itself making it unsuitable as a
`packaging material . Therefore , a need exists for a recyclable 20
`Other embodiments of the present invention include a
`packaging material that is not only flexible but also exhibits
`multi - layer structure comprising : a first polyolefin layer
`comprising high - density polyethylene ; a second polyolefin
`dimensional stability .
`layer comprising high - density polyethylene ; a third poly
`olefin layer comprising high - density polyethylene ; a fourth
`BRIEF SUMMARY
`25 polyolefin layer comprising high - density polyethylene ; a
`fifth polyolefin layer comprising high - density polyethylene ;
`Some embodiments of the present invention include a
`sheet comprising : a multi - layer structure comprising : a
`a sixth polyolefin layer comprising high - density polyethyl
`plurality of layers including an uppermost layer and a
`ene ; a seventh polyolefin layer comprising high - density
`lowermost layer , each of the plurality of layers having a
`polyethylene ; an eighth polyolefin layer comprising high
`molecular orientation that results in a stress value for each 30 density polyethylene ; a first barrier tie layer ; a barrier layer ;
`layer ; wherein the stress value of at least two of the plurality
`a second barrier tie layer ; a ninth polyolefin layer compris
`of layers are non - zero and different from one another ; and
`ing high - density polyethylene ; and a tenth polyolefin layer
`wherein the multi - layer structure has a net stress value that
`comprising linear low - density polyethylene .
`is less than the greater stress value of the plurality of layers .
`Other embodiments of the present invention include a
`In other embodiments , the present invention includes a 35
`multi - layer structure which consists of : a first polyolefin
`sheet comprising : a first web comprising at least one layer
`layer comprising high - density polyethylene ; a second poly
`formed of high - density polyethylene ; a sheet intermediate
`olefin layer comprising high - density polyethylene ; a third
`layer having a first major surface opposite a second major
`polyolefin layer comprising high - density polyethylene ; a
`surface ; a second web comprising at least one layer formed
`of high - density polyethylene and a barrier layer ; and the first 40 fourth polyolefin layer comprising high - density polyethyl
`web laminated to the first major surface of the sheet inter-
`ene ; a fifth polyolefin layer comprising high - density poly
`mediate layer and the second web laminated to the second
`ethylene ; a sixth polyolefin layer comprising high - density
`polyethylene ; a seventh polyolefin layer comprising high
`major surface of the sheet intermediate layer .
`In other embodiments , the present invention includes an
`density polyethylene ; an eighth polyolefin layer comprising
`oral care packaging comprising a flexible tube formed from 45 high - density polyethylene ; a first barrier tie layer ; a barrier
`layer ; a second barrier tie layer ; a ninth polyolefin layer
`one of the aforementioned sheets .
`In other embodiments , the present invention includes a
`comprising high - density polyethylene ; and a tenth poly
`method of forming a sheet comprising : a ) forming a first
`olefin layer comprising linear low - density polyethylene .
`multi - layer web by a first blown - film process or a first cast
`Other embodiments of the present invention include an
`film process and a second multi - layer web by a second 50 oral care packaging comprising a flexible tube having a wall
`blown - film process or a second cast film process , and b )
`formed of a multi - layer structure comprising at least two
`laminating together the first multi - layer web , an intermedi-
`polyolefin layers and a barrier layer , the multi - layer structure
`ate layer formed of polyolefin , and the second multi - layer
`having a density ranging from about 0.950 g / cm² to about
`0.965 g / cm3 .
`web to form the sheet .
`In other embodiments , the present invention includes a 55
`Other embodiments of the present invention include an
`multi - layer structure comprising : a first polyolefin layer
`oral care packaging comprising a flexible tube having a wall
`comprising high - density polyethylene ; a second polyolefin
`formed of a multi - layer structure comprising at least two
`layer comprising high - density polyethylene ; a third poly-
`polyolefin layers and a barrier layer , the multi - layer structure
`olefin layer comprising high - density polyethylene ; a fourth
`having a melt flow index ranging from about 0.7 g / 10 min
`polyolefin layer comprising high - density polyethylene ; a 60 to about 1.1 g / 10 min .
`first barrier tie layer ; a barrier layer ; a second barrier tie
`Further areas of applicability of the present invention will
`layer ; a fifth polyolefin layer comprising high - density poly-
`become apparent from the detailed description provided
`ethylene ; and a sixth polyolefin layer comprising linear
`hereinafter . It should be understood that the detailed descrip
`low - density polyethylene .
`tion and specific examples , while indicating the preferred
`In other embodiments , the present invention includes a 65 embodiment of the invention , are intended for purposes of
`multi - layer structure which consists of : a first polyolefin
`illustration only and are not intended to limit the scope of the
`layer comprising high - density polyethylene ; a second poly-
`invention .
`
`0020
`
`

`

`US 10,889,093 B2
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`4
`3
`The description of illustrative embodiments according to
`BRIEF DESCRIPTION OF THE DRAWINGS
`principles of the present invention is intended to be read in
`connection with the accompanying drawings , which are to
`The present invention will become more fully understood
`be considered part of the entire written description . In the
`from the detailed description and the accompanying draw-
`5 description of embodiments of the invention disclosed
`ings , wherein :
`herein , any reference to direction or orientation is merely
`FIG . 1 is a perspective view of a sheet according to the
`intended for convenience of description and is not intended
`present invention ;
`in any way to limit the scope of the present invention .
`FIG . 2 is a block - diagram of a method of forming the
`Relative terms such as “ lower , " “ upper , ” “ horizontal , ” “ ver
`sheet as well as a packaging from the sheet according to the
`10 tical , ” “ above , " " below , " " up , " " down , ” “ top , ” and “ bottom ”
`present invention ;
`as well as derivatives thereof ( e.g. , “ horizontally , " " down
`FIG . 3 is a cross - sectional representation of how the sheet
`wardly , " " upwardly , ” etc. ) should be construed to refer to the
`of the present invention is formed according to some
`orientation as then described or as shown in the drawing
`embodiments of the present invention ;
`under discussion . These relative terms are for convenience
`FIG . 4 is a cross - sectional view of a web that forms part 15 of description only and do not require that the apparatus be
`of the sheet of the present invention ;
`constructed or operated in a particular orientation unless
`FIG . 5 is a cross - sectional view of the web of FIG . 4 being
`explicitly indicated as such .
`processes according to the method of the present invention ;
`Terms such as " attached , "
`" affixed , "
`" connected , "
`FIG . 6 is a cross - sectional representation of how a sheet
`“ coupled , ” “ interconnected , ” and similar refer to a relation
`according to some embodiments of the present invention are 20 ship wherein structures are secured or attached to one
`another either directly or indirectly through intervening
`formed using the web of FIGS . 4 and 5 ;
`FIG . 7 is a cross - section view of the sheet of FIG . 6 taken
`structures , as well as both movable or rigid attachments or
`relationships , unless expressly described otherwise . More
`along lines X - X of FIG . 1 ;
`FIG . 8 is a cross - section view of a web that forms part of
`over , the features and benefits of the invention are illustrated
`the sheet according to another embodiment of the present 25 by reference to the exemplified embodiments . Accordingly ,
`the invention expressly should not be limited to such exem
`invention ;
`FIG . 9 is a cross - section view of a sheet taken along lines
`plary embodiments illustrating some possible non - limiting
`X - X of FIG . 1 according to another embodiment of the
`combination of features that may exist alone or in other
`combinations of features ; the scope of the invention being
`present invention that comprises the web of FIG . 8 ;
`FIG . 10 is a cross - section view of a web that forms part 30 defined by the claims appended hereto .
`of the sheet according to another embodiment of the present
`Unless otherwise specified , all percentages and amounts
`expressed herein and elsewhere in the specification should
`invention ;
`FIG . 11 is a cross - section view of a sheet taken along lines
`be understood to refer to percentages by weight . The
`X - X of FIG . 1 according to another embodiment of the
`amounts given are based on the active weight of the mate
`present invention that comprises the web of FIG . 10 ;
`35 rial . According to the present application , the term “ about "
`FIG . 12 is a blown - film processing apparatus according to
`means +/- 5 % of the reference value . According to the pres
`ent application , the term “ substantially free ” less than about
`some embodiments of the present invention ;
`FIG . 13 is a web of the present invention after leaving the
`0.1 wt . % based on the total of the referenced value .
`blown - film processing apparatus ;
`Referring now to FIGS . 1 and 16 , the present invention is
`FIG . 14 is a processing apparatus further showing how the 40 directed to a sheet 10 and a container 1 ( also referred as
`“ packaging " ) comprising a sleeve 3 that may be formed at
`sheet of the present invention may be formed ;
`FIG . 15 is an open - tube formed from the sheet according
`least in part from the sheet 10. The sheet 10 of the present
`invention may be flexible — i.e . , capable of being non
`to some embodiments of the present invention ;
`FIG . 16 is an packaging formed from the open - tube of
`permanently deformed without fracture . The sheet 10 of the
`FIG . 15 according to some embodiments of the present 45 present invention may be recyclable — i.e . , capable of being
`recycled . As discussed in greater detail herein , the container
`invention ;
`FIG . 17 is a cross - sectional view of the container along
`1 may be a container suitable for containing an oral care
`composition - e.g . , toothpaste .
`lines XX - XX of FIG . 16 ; and
`FIG . 18 is a close - up view of the region V in FIG . 17 .
`The term “ flexible ” refers to the ability of a material to
`50 non - permanently deform under an applied stress , whereby
`the material returns to its original shape after the applied
`DETAILED DESCRIPTION
`stress is removed .
`Referring now to FIGS . 1 and 3 , the sheet 10 may
`The following description of the preferred embodiment ( s )
`comprise a first exposed major surface 11 opposite a second
`is merely exemplary in nature and is in no way intended to
`limit the invention , its application , or uses .
`55 exposed major surface 12. The sheet may further comprise
`As used throughout , ranges are used as shorthand for
`an exposed side surface 13 extending between the first and
`describing each and every value that is within the range . Any
`second major exposed surfaces 11 , 12. The sheet may have
`value within the range can be selected as the terminus of the
`a sheet thickness to as measured between the first exposed
`range . In addition , all references cited herein are hereby
`major surface 11 opposite a second exposed major surface
`incorporated by referenced in their entireties . In the event of 60 12 — the sheet thickness ts ranging from about 20 um to
`a conflict in a definition in the present disclosure and that of
`about 550 um — including all thickness and sub - ranges there
`a cited reference , the present disclosure controls .
`between . In a preferred embodiment , the sheet thickness ts
`Unless otherwise specified , all percentages and amounts
`may range from about 120 um to about 380 um — including
`expressed herein and elsewhere in the specification should
`all thickness and sub - ranges there between .
`be understood to refer to percentages by weight . The 65
`Referring now to FIG . 7 , the sheet 10 may comprise a
`amounts given are based on the active weight of the mate-
`multi - layer structure 50 comprising a plurality of layers . As
`discussed in greater detail herein , each of the layers may be
`rial .
`
`0021
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`

`

`US 10,889,093 B2
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`6
`and different from one another . In some embodiments , the
`independently formed from a polymeric material . In some
`stress values of at least three of the plurality of layers may
`embodiments , each of the layers independently may consist
`be non - zero values and different from one another . In some
`essentially of polymeric material . In some embodiments of
`embodiments , the stress values of at least four of the
`the present invention , each of the layers independently may
`consist of polymeric material .
`plurality of layers may be non - zero values and different from
`Polymeric material is comprised of macromolecule
`one another .
`chains . Within each layer of the multi - layer structure 50 that
`According to the present invention , it has been discovered
`is formed from a polymeric material , the corresponding
`that the resulting multi - layer structure 50 may comprise such
`macromolecule chains ( i.e. , polymer chains ) may exhibit a
`layers having such non - zero stress values that are different
`specific molecular orientation .
`from one another , yet the overall multi - layer structure 50 has
`For the purpose of the present application , each layer may
`a net stress value that is less than the greater stress value for
`exhibit a molecular orientation — which corresponds to the
`the individual layers within the multi - layer structure 50 .
`molecular orientation of the polymeric chains contained
`may
`Stated otherwise , the multi - layer structure 50
`exhibit a
`within the layer . Depending on the molecular orientation for
`a given layer , the counterbalancing forces of the polymer 15 non - zero stress value , yet the net stress value of the multi
`layer structure 50 will still be less than the greatest stress
`chains within that given layer may not be at equilibrium ,
`value for an individual layer within that multi - layer structure
`thereby causing that layer to be in a state of internal stress .
`50 — thereby resulting in the multi - layer structure 50 exhib
`The internal stress of the given layer may manifest in the
`given layer deforming ( e.g. , curling ) from a substantially flat
`iting less curl as compared the layer having the greatest
`state ( i.e. , the major surfaces of the layer are substantially 20 individual stress value .
`planar and parallel to each other ) to a non - flat state ( e.g. ,
`Thus , while the stress patterns of each individual layer
`curled or wavy configuration ) when no external forces are
`may be a non - zero value and are different from each
`applied to that given layer . Stated otherwise , each layer of
`other — the summation of all stress patterns may at least
`the multi - layer structure 50 that is formed of polymeric
`partially counterbalance each other , thereby putting the
`material may exhibit a stress pattern . The layer's respective 25 multi - layer structure 50 closer to equilibrium and reducing
`change in shape may be the result of the counterbalancing
`the amount of deformation ( e.g. , curling ) within the multi
`forces of all polymer chains returning to a state of equilib-
`layer structure 50. The result is
`multi - layer structure 50
`that will deform less and be less likely to transition from a
`rium .
`The internal stress of each layer in the flat state that is
`flat state ( i.e. , non - curled ) to a non - flat state ( i.e. , curled ) in
`caused by the molecular orientation may form a stress 30 the absence of an external force applied to that multi - layer
`pattern having a corresponding stress value . The stress
`structure 50 even when those individual layers that make up
`pattern refers to the distribution of forces within each
`the multi - layer structure 50 , when observed individually ,
`referenced layer and the corresponding stress value is a
`may deform from a flat state to a non - flat state in the absence
`value assigned to the referenced layer that indicates whether
`of an external force applied to that given layer .
`the layer is at equilibrium or not at equilibrium . The stress 35
`In some embodiments , it has been discovered that the
`value is a measure of magnitude of stress therefore , the
`resulting multi - layer structure 50 may comprise such layers
`stress value is an absolute value ( i.e. , positive value ) irre-
`having such non - zero stress values that are different from
`spective of whether the molecular orientation within each
`one another , yet the overall multi - layer structure 50 may
`layer produces positive and / or negative when the stress
`have a net stress value that is substantially zero .
`pattern . As an example , a first layer have a first stress value 40
`The counterbalancing stress patterns of the multi - layer
`that is zero refers to the internal stress caused by the
`structure 50 of the present invention result in a sheet 10 that
`molecular orientation of the polymer chains within that first
`may remain substantially flat even when the layers con
`layer being at equilibrium ; a second layer having a non - zero
`tained therein may exhibit an internal stress due to different
`stress value refers to the internal stress caused by the
`relative molecular orientations . Such discovery provides an
`molecular orientation of the polymer chains within that 45 advantage as it allows for rapid production of sheet 10
`second layer not being at equilibrium . As an example , a first
`material that is highly suitable for the container 1 .
`layer have a first stress value that is a non - zero value and a
`Referring now to FIG . 3 , the multi - layer structure 50 of
`second layer having a non - zero stress value , whereby the
`the sheet 10 may comprise a first web 100. The multi - layer
`first stress value is greater than the second stress value ,
`structure 50 of the sheet 10 may also comprise a second web
`refers to the first layer having a greater internal stress caused 50 200. The multi - layer structure 50 of the sheet 10 may
`by the molecular orientation of the polymer chains within
`comprise an intermediate sheet layer 300. The intermediate
`the first layer , as compared to the second layer , which has a
`sheet layer 300 may function as a tie layer for two adjacent
`lower internal stress caused by the molecular orientation of
`layers having non - functionalized polyolefin surfaces .
`polymer chains within that second layer .
`The first web 100 may be a single layer web 100. In other
`In some embodiments , the stress value of a given layer 55 embodiments , the first web 100 may be a multi - layer web
`may be a non - zero value — meaning that the given layer may
`( also referred to as a “ first multi - layer web ” ) . The first web
`deform from a flat state to a non - flat state when no external
`100 may have a first major surface 101 opposite a second
`force is applied to that given layer . In other embodiments ,
`major surface 102 and a side surface 103 extending there
`the stress value of a given layer may substantially zero .
`between . The first web 100 may have a first thickness twi
`According to the present application , a substantially zero 60 ( also referred to as a “ first web thickness ” ) as measured
`stress value refers to that given layer not deforming from a
`between the first and second major surfaces 101 , 102 of the
`flat state to a non - flat state in the absence of an external force
`first web 100 .
`applied to that given layer .
`The second web 200 may be a multi - layer web ( also
`Each layer of the multi - layer structure 50 of the present
`referred to as a “ second multi - layer web ” ) . The second web
`invention may have a molecular orientation resulting in a 65 200 may have a first major surface 201 opposite a second
`stress value for that respective layer . The stress values of at
`major surface 202 and a side surface 203 extending there
`least two of the plurality of layers may be non - zero values
`between . The second web 200 may have a second thickness
`
`0022
`
`

`

`US 10,889,093 B2
`
`7
`8
`tw2 ( also referred to as a “ second web thickness ” ) as mea-
`The second web thickness tw2 of the second web 200 may
`sured between the first and second major surfaces 201 , 202
`range from about 60 um to about 200 um — including all
`thickness and sub - ranges there - between . In a preferred
`of the second web 200 .
`In some embodiments , the first web 100 may be joined to
`embodiment , the second web thickness tw2 of the second
`the second web 200. In some embodiments , the first web 100 5 web 200 may range from about 30 um to about 150
`may be joined directly to the second web 200. The first
`um — including all thickness and sub - ranges there - between .
`In a preferred embodiment , the second web thickness tw2 of
`major surface 201 of the second web 200 may face the
`the second web 200 may be about 105 um .
`second major surface 102 of the first web 100 .
`The intermediate layer thickness t of the intermediate
`In some embodiments , the intermediate sheet layer 300
`may be located between the first web 100 and the second 10 sheet layer 300 may range from about 10 um to about 50
`um — including all thickness and sub - ranges there - between .
`web 200. The intermediate sheet layer 300 may be a single
`In a preferred embodiment , the intermediate layer thickness
`layer . In other embodiments , the intermediate sheet layer
`tz of the intermediate sheet layer 300 may be about 25 um .
`300 may comprise a plurality of layers . The intermediate
`The first web 100 may have a first overall density ranging
`sheet layer 300 may have a first major surface 301 opposite 15 from about 0.94 g / cm3 to about 0.99 g / cm² — including all
`a second major surface 302 and a side surface 303 extending
`densities and sub - ranges there - between . The second web
`there - between .
`200 may