US20100155357A1 - Liner Material - Google Patents

Abstract

Provided is container and container closure with a liner material that includes a substrate layer, an active material absorbed into or overlying the substrate layer, and a first protective layer overlying the active material on the top surface of said substrate layer. Optionally, a second protective layer underlies the bottom surface of the substrate layer. The protective layers are impermeable to the active material and are water-soluble. The protective layer precludes release of the active material from the substrate layer so long as the protective layers are intact and undissolved.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This patent application is a continuation-in-part of copending U.S. patent application Ser. No. 11/423,504, filed Jun. 12, 2006.
BACKGROUND OF THE INVENTION
• 1. Field of the Invention
• This invention relates to liner materials, and more specifically to fragranced liner materials used for container closure seals.
• 2. Description of the Related Art
• Liner materials have had many applications in use with consumer products. In one example, liner material was used to produce container closure liquid seals well known to those or ordinary skill in the art. Typically in the prior art, liner materials were supplied in flat sheets and container closure seals, sized to fit inside a cylindrically shaped container closure, sometimes referred to as a bottle cap, were die-cut from the liner material sheet to form a thin disk. This closure seal was inserted into the plastic or metal container closure adjacent the inside surface of the top of the container closure before the container closure was secured on the container neck, sometimes referred to as a container spout. Typically, the container closure was secured to the container neck by means of a threaded connection or a snap-fit interference connection. The closure seal operated as a gasket to form a liquid tight seal between the container neck lip and the inside surface of the top of the container closure thus containing any liquid material inside the container whenever the container closure was firmly secured to the container neck. As the container closure was secured to the container neck, by, for example twisting of a threaded container closure about a threaded container neck, the inside surface of the top of the container closure and the upper lip of the container neck compressed the closure seal therebetween. As the closure seated to the neck lip, a liquid tight seal was formed and liquid leakage around the connection of the container closure and the container neck was precluded.
• Another means to form a liquid tight seal at a container neck included so-called induction seals. Induction seals are also thin disks sized, however, somewhat larger than the lip of the container neck. In one prior art example, an induction seal was formed of electrically conductive seal material such as aluminum foil. The conductive seal material was secured to the container neck lip by means of a thermoset adhesive. The thermoset adhesive securing the inductive seal to the container neck lip was activated by heat generated in the seal by an alternating electrical inductive field. The closure seal and the thermoset adhesive formed a liquid tight seal about the container neck lip to contain liquid within the container. Induction seals were typically intended as an additional temporary seal for use in container transit and storage. A consumer typically punctured or removed the inductive seal before the first use of the liquid product contained in the container.
• It was often desirable to include a fragrance material absorbed within or sprayed on the closure seal surface. Fragranced liner material was supplied to closure seal converters to form fragranced closure seals. Closure seals containing a fragrance component would exude the fragrance material into the headspace of the container between the liquid level surface and the top of the container. Fragranced closure seals were marketed to provide scents in products so that when a consumer opened the container, a “whiff” of fragrance was noticed.
• Fragranced closure seals were particularly advantageous when the liquid product contained in the container was incompatible with or destructive of the desired fragrance material. For example, sodium hypochlorite solutions, such as common household laundry bleach, are particularly destructive of most fragrance materials by oxidation of the fragrance. Most consumer pleasing fragrances are not amenable to direct mixing with these hypochlorite solutions.
• However, historically there were problems in converting fragrance liner material. One particular disadvantage of using fragranced liner material to form closure seals was the emanation of the fragrance material from the liner stock to the manufacturing floor during conversion of the liner stock to closure seals. High concentration of the fragrance built up in the workplace and become a hazard or nuisance to workers. The converting facility took on the aroma of the fragrance that could potentially harm employees who may have been sensitive to the fragrance. Use of prior art fragranced liner materials was rarely adopted to fabricate closure seals due to the issues of controlling fragrance release. Further, closure seals once die-cut from the liner material stock continued to emanate absorbed or coated fragrance material causing similar exposure concerns at downstream converting and bottling facilities.
• There remained a need in the prior art to supply liner materials suitable for fabrication into fragranced closure seals and other articles of manufacture and that avoided the disadvantage of uncontrolled fragrance release.
SUMMARY OF THE INVENTION
• In accordance with the principles of the present invention, a liner material is provided that contains an active material, such as a fragrance material, absorbed on a substrate layer, coated on the surfaces of the substrate layer, or both. In one embodiment, the fragrance material may be added to the substrate layer in an enclosure to control nuisance odors in the liner material manufacturing facility.
• In one embodiment of the present invention, a water-soluble material that is impermeable to the active material is next applied to the top and bottom surfaces of the substrate layer to form overlying, impermeable protective layers that preclude emanation or volatilization of the active material from the substrate layer.
• In one embodiment of the present invention, a container comprises a container having a container neck; a container cap attached to the container neck; a liner material within the container cap comprising; a substrate layer comprising, a first protective layer on the top surface of the substrate layer adjacent to the container cap, and a second protective layer on the bottom surface of the substrate layer wherein the second protective layer is water soluble, and an active material within the substrate layer.
• In one embodiment of the present invention, container comprises a container body having a container neck and filled with a water containing liquid; a container closure having a closure liner inserted therein wherein the closure liner has a first layer containing an active material and a protective layer on the bottom surface of the first layer wherein the protective layer is exposed the water containing liquid and the protective layer is water soluble.
• In one embodiment of the present invention, fragrance release container comprises a container having a container neck; a container closure having a closure inner surface and a closure outer surface and adapted to fit the container neck; and a closure seal liner material within the container closure and having a top surface and a bottom surface and comprising a substrate layer, a fragrance within the substrate layer, a first protective layer on the top surface of the substrate layer adjacent to the closure inner surface, and a second protective layer on the bottom surface of the substrate layer, wherein the liner material is configured such that the liner material is adapted to cooperate with the container closure to form a seal between the container closure and the container, and wherein the second protective layer is water soluble.
• With the active material, for example a fragrance material, so enclosed, no fragrance material from the substrate layer enters the workplace at converting and bottling facilities. The fragrance material is of a type that does not permeate through nor dissolve the impermeable protective layers overlying the top and bottom surfaces of the absorbent substrate layer. The fragrance material does not volatilize and emanate from the substrate layer until the protective coating is dissolved and removed.
• For use with liquid containing containers, the liner material is next converted into closure seals and placed into container closures. After the closures are connected to the container necks of liquid-containing containers, fragrance may be released into the headspace of the containers. Any water contained in the container liquid produces water vapor at saturation partial pressure in the headspace of the container. The water vapor acts to dissolves the impermeable, water-soluble protective layer overlying the absorbent substrate layer forming the closure seal. Alternatively, water-containing liquid may splash on the closure seal during container transit to likewise dissolve the impermeable water-soluble protective layer. In another embodiment, the container is intentionally inverted after closure placement to assure liquid contact with the soluble protective layer. The fragrance material absorbed on the substrate layer is thus released so that when a consumer opens the container a pleasant fragrance is noticed. Significant reductions in the required amount of fragrance material for the closure seals may be realized over prior art fragranced closure seals.
• In another embodiment, the liner material need not be absorbent. In this embodiment, fragrance is coated as a fragrance layer on one or more non-absorbent substrate layer surfaces and then overlain with one or more respective impermeable water-soluble protective layers. Alternatively, the protective layers may be separately formed and next laminated to the fragrance layer on the surface of the substrate layer.
• In yet another embodiment, the protective layer and the fragranced substrate layer may be co-extruded in a manner well known to those of ordinary skill in the art. Other means for fabricating encapsulated fragranced liner material in accordance with the principles of the present invention would be apparent to those skilled artisans.
• Liner materials containing a water-soluble protective layer encapsulating active materials other than fragrance material are also possible. For example, water-soluble, impermeable protective layers may encapsulate a substrate layer having an antibacterial or disinfecting agent layer thereon. The disinfecting material is released upon contact of the impermeable, water-soluble protective layer with, for example, food juices or waste liquids. In one example, the liner material of the present invention is placed at the bottom of a cat litter pan to advantageously release odor maskants, fragrances or disinfectants as waste liquids contact the liner.
• Further features and advantages of the present invention will become apparent to those of ordinary skill in the art in view of the detailed description of embodiments below.
BRIEF DESCRIPTION OF THE DRAWINGS
• Reference will now be made to the drawings wherein like numerals refer to like parts throughout. As used herein, positional terms, such as “bottom” and “top” and the like, and directional terms, such as “up” and “down” and the like, are employed for ease of description in conjunction with the drawings. These terms are not meant to indicate that the components of the present invention must have a specific orientation except when specifically set forth below.
• FIG. 1 shows a side sectional view of a liner material in accordance with the principles of the present invention having an absorbent substrate layer and an active material absorbed within the substrate layer, a first protective layer on the top surface of the substrate layer, and a second protective layer on the bottom surface of the substrate layer;
• FIG. 2 shows a side sectional view of a liner material in accordance with the principles of the present invention having substrate layer that is a partially absorbent; and
• FIG. 3 shows a side sectional view of a liner material in accordance with the principles of the present invention having a non-absorbent substrate layer.
• FIG. 4 shows a cross-sectional view of a container body and closure in accordance with the principles of the present invention.
• FIG. 5 shows a cross-sectional view of another container body and closure in accordance with the principles of the present invention.
DETAILED DESCRIPTION
• As shown in side cross-section inFIG. 1, in one embodiment, aliner material100 includes asubstrate layer10 that is absorbent. Absorbed withinsubstrate layer10 is anactive material12 as indicated in dotted line withinsubstrate layer10. In the embodiment ofFIG. 1,substrate layer10 is sufficiently absorbent such that all ofactive material12 absorbs intosubstrate layer10. Overlyingactive material12 at the top surface ofsubstrate layer10 is a firstprotective layer14. Underlyingsubstrate layer10 at the bottom surface ofsubstrate layer10 is a secondprotective layer16. Firstprotective layer14 and secondprotective layer16 are impermeable toactive material12. Further, active material is in a state that it does not dissolve firstprotective layer14 and secondprotective layer16.
• When it is said herein that a layer is impermeable to a material it is meant that the layer sufficiently precludes the transmission of the material across the layer so that any material that is transmitted is so small that operation of the present invention is not frustrated. In one example,protective layers14 and16 are impermeable toactive material12 if the amount ofactive material12, such as a fragrance material, that transmits acrossprotective layers14 and16 is such that the concentration of theactive material12 emanated fromsubstrate layer10 does not cause adverse health or safety effects in a converting facility. In one embodiment, firstprotective layer14 and secondprotective layer16 are water-soluble. In another embodiment, firstprotective layer14 and secondprotective layer16 are solvent-soluble such thatprotective layers14 and16 dissolve in a solvent liquid that contains no water.
• When it is said herein that an active material is in a state that the active material does not dissolve a protective layer it is meant the active material is in a state such or has properties such that it does not dissolve the protective layer to the point where the protective layer is ineffective. For example, a fragrance material dissolved in water may be applied to a substrate layer and subsequently dried to the point the dried active material does not dissolve a water-soluble protective layer.
• Afterliner material100 is fabricated as described above, emanation ofactive material12 fromsubstrate layer10 is precluded so long asprotective layers14 and16 are intact and undissolved. Said another way,substrate layer10 and, more particularly,active material12 absorbed therein, is encapsulated by firstprotective layer14 and secondprotective layer16.
• In another embodiment,FIG. 2 shows a side sectional view of aliner material200 in accordance with the principles of the present invention havingsubstrate layer20 that is a partially absorbent. Overlying,substrate layer20 at the top surface of thesubstrate layer20 is anactive material layer22. An active material such as a fragrance or disinfectant is applied as a powder or as a liquid in a spray or wash that subsequently dries to formactive material layer22. Sincesubstrate layer20 is partially absorbent, only a portion of the active material applied tosubstrate layer20 absorbs intosubstrate layer20 while the remaining portion of the active material deposits on the top surface ofsubstrate layer20 as a distinctactive material layer22.Active material layer22 may also be pre-formed as a separate layer by means well known in the art and subsequently coupled to the top surface ofsubstrate layer20. For example, coupling ofactive material layer22 withsubstrate layer20 may be accomplished by means of co-extrusion, adhesive bonding, thermal bonding, static bonding, or other means.
• Similar to the embodiment described above with reference toFIG. 1, overlyingactive material layer22 at the top surface ofsubstrate layer20 is a firstprotective layer24. Optionally, a secondprotective layer26 at the bottom surface ofsubstrate layer20 underliessubstrate layer20. In some embodiments, the amount of active material absorbed withinsubstrate layer20 and making upactive material layer22 that migrates to the bottom surface ofsubstrate layer30 is sufficiently small that no protective layer is required on the bottom surface ofsubstrate layer20.
• Firstprotective layer24 and secondprotective layer26 are impermeable to the active material making upactive material layer22. Firstprotective layer24 precludes emanation and desorption of the active material fromsubstrate layer20 and fromactive material layer22 while firstprotective layer24 is intact and undissolved. Secondprotective layer26 precludes emanation of the portion of the active material that absorbed and diffused to the bottom surface of partiallyabsorbent substrate layer20 while secondprotective layer26 is intact and undissolved.
• Examples of priorart liner materials100 suitable for converting into container closure seals include pulp/paper laminations, foamed polyolefin co-extrusions (i.e. foamed polyethylene, foamed polypropylene), solid polyolefins, pressure sensitive foamed olefins, foam backed induction heat seals, one piece induction heat seals, other foamed and solid plastic films, and other compressible sheet materials or laminates and co-extruded combinations of these materials. Polyvinyl alcohols, gelatins, and other materials and combinations of materials that are soluble in water.
• are examples of materials suitable for use in forming water-soluble protective layers to overlie fragranced substrate layers of the liner materials of the present invention. Active materials suitable for use with the present invention include fragrance oils, antimicrobials, and disinfectants.
• In yet another embodiment,FIG. 3 shows a side sectional view of aliner material300 in accordance with the principles of the present invention having anon-absorbent substrate layer30. Overlying,substrate layer30 at the top surface of thesubstrate layer30 is anactive material layer32. An active material such as a fragrance or disinfectant is applied as a powder or liquid in a spray or wash that subsequently dries to formactive material layer32. Sincesubstrate layer30 is non-absorbent all of the active material deposits on the top surface ofsubstrate layer20 as a distinctactive material layer32. As with the embodiment described above with reference toFIG. 2,active material layer32 may also be pre-formed as a separate layer by means well known in the art and subsequently coupled to the top surface ofsubstrate layer30.
• Overlyingactive material layer32 at the top surface ofsubstrate layer30 is aprotective layer34. In this embodiment, no protective layer is needed at the bottom surface ofsubstrate layer30 sincesubstrate layer30 is nonabsorbent. Thus, none of the active material making upactive material layer32 migrates to the bottom surface ofsubstrate layer30. In one embodiment,protective layer34 is impermeable toactive material layer32 and is water-soluble.Protective layer34 precludes emanation of the active material fromactive material layer32 while firstprotective layer24 is intact and undissolved.
• Liner material300 is particularly adapted to applications where a hardsurface substrate layer30 is required, such as on cutting board liners use to protect, for example, pull-out wooden food cutting boards commonly found in kitchens.Substrate layer30 may be made from a non-absorbent material such as polypropylene, high-density polyethylene, polystyrene, crystalline polyethylene terephthalate, amorphous polyethylene terephthalate, polyvinyl chloride, and polycarbonate. These types of material are not easily cut through and thus offer protection to a wooden cutting board. In one embodiment,active material layer32 on the top surface ofsubstrate layer20 may include antimicrobial or disinfecting material to protect against contamination of food cut on the liner. Food juices dissolveprotective layer34 to release the antimicrobial active material when needed.
• Now referring toFIG. 4, thecontainer400 comprises acontainer body402 having acontainer neck404 and filled with a liquid406. Acontainer closure408 is adapted to fit thecontainer neck404 with a threadedconnection410. Thecontainer closure408 has acontainer liner412 comprising a topfirst layer414 adjacent to the closureinner surface416 and a bottomprotective layer418 in contact with vapors from the liquid406. In one embodiment the topfirst layer414 contains an active material, for example a fragrance. In another embodiment the bottomprotective layer418 contains an active material, for example a fragrance. The bottomprotective layer418 may be water soluble or water dispersible.
• Now referring toFIG. 5, thecontainer500 comprises acontainer body502 having acontainer neck504 and filled with a liquid506. Acontainer closure508 is adapted to fit thecontainer neck504 with a threaded connection510. Thecontainer closure508 has acontainer liner512 comprising a top firstprotective layer514 adjacent to the closureinner surface516, asubstrate layer520, and a bottom secondprotective layer518 in contact with vapors from the liquid506. In one embodiment thesubstrate layer520 contains an active material, for example a fragrance. The bottomprotective layer518 may be water soluble or water dispersible.
• This invention has been described herein in considerable detail to provide those skilled in the art with information relevant to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by different equipment, materials and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself For example, the liner material of the present invention may be uses in diapers to release an active material when wetted. As such, these changes and modifications are properly, equitably, and intended to be, within the full range of equivalence of the following claims.

Claims (16)

1. A container comprising:

a container having a container neck;

a container cap attached to the container neck;

a liner material within the container cap comprising;

a substrate layer comprising, a first protective layer on the top surface of the substrate layer adjacent to the container cap, and a second protective layer on the bottom surface of the substrate layer wherein the second protective layer is water soluble, and

an active material within the substrate layer.

2. The container ofclaim 1, wherein the active material is a fragrance.

3. The container ofclaim 1, wherein one of layers of the substrate layer comprises a material selected from the group consisting of paper, foamed polyethylene, pulp/paper laminations, foamed polyolefin co-extrusions, foamed polyethylene, foamed polypropylene, solid polyolefins, pressure sensitive foamed polyolefins, foam backed induction heat seals, one piece induction heat seals, and laminates and co-extruded combinations thereof.

4. The container ofclaim 1, wherein the active material is selected form the group consisting of fragrance oils, disinfectants, antimicrobials and combinations thereof.

5. The container ofclaim 1, wherein the first protective layer and the second protective layer are impermeable to said active material.

6. The container ofclaim 1, wherein the second protective layer comprises a material selected from the group consisting of polyvinyl alcohols, gelatins, and combinations thereof.

7. A container comprising:

a container body having a container neck and filled with a water containing liquid;

a container closure having a closure liner inserted therein wherein the closure liner has a first layer containing an active material and a protective layer on the bottom surface of the first layer wherein the protective layer is exposed the water containing liquid and the protective layer is water soluble.

8. The container ofclaim 7, wherein the active material is a fragrance.

9. The container ofclaim 7, wherein the active material is selected form the group consisting of fragrance oils, disinfectants, antimicrobials and combinations thereof.

10. The container ofclaim 7, wherein the protective layer comprises a material selected from the group consisting of polyvinyl alcohols, gelatins, and combinations thereof.

11. The container ofclaim 7, wherein the protective layer is impermeable to the active material.

12. A fragrance release container comprising:

a container having a container neck;

a container closure having a closure inner surface and a closure outer surface and adapted to fit the container neck; and

a closure seal liner material within the container closure and having a top surface and a bottom surface and comprising a substrate layer, a fragrance within the substrate layer, a first protective layer on the top surface of the substrate layer adjacent to the closure inner surface, and a second protective layer on the bottom surface of the substrate layer,

wherein the liner material is configured such that the liner material is adapted to cooperate with the container closure to form a seal between the container closure and the container, and

wherein the second protective layer is water soluble.

13. The container ofclaim 12, wherein the closure seal liner is configured as a thin disk inserted into the container closure adjacent the inside surface of the top of the container closure before the container closure is secured on the container.

14. The container ofclaim 12, wherein the container is inverted after the container is filled with a liquid and after the container closure is secured on the container.

15. The container ofclaim 12, wherein the second protective layer comprises a material selected from the group consisting of polyvinyl alcohols, gelatins, and combinations thereof.

16. The container ofclaim 12, wherein the first protective layer comprises a material selected from the group consisting of paper, foamed polyethylene, pulp/paper laminations, foamed polyolefin co-extrusions, foamed polyethylene, foamed polypropylene, solid polyolefins, pressure sensitive foamed polyolefins, foam backed induction heat seals, one piece induction heat seals, and laminates and co-extruded combinations thereof.

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