DESIGN

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No.

62/868,273, filed on June 28, 2019, the entire disclosure of which is hereby incorporated by reference.

TECHNICAL FIELD

[0002] Embodiments of the present disclosure generally relate to flexible product packaging. More specifically, embodiments of the present disclosure relate to flexible packages comprising an energy absorbing seal design to lessen packaging rupture when dropped.

BACKGROUND

[0003] A variety of liquid foodstuffs and other consumer goods are packaged for storage or transport in sealed flexible packaging. However, the sealed flexible packages must undergo a series of validation tests so as to verify that the packaging will be able to withstand transport to and usage by the end consumer. Specifically, many pouched articles are tested with a drop height impact test where the package is dropped from a defined height onto a hard surface to verify that the package structure and seals will withstand a similar fall or impact during transport and/or storage. However, failure of the packaging seals and/or the packaging structure proximate the seal is common during such testing. Failure of traditional packaging occurs because the liquid within the sealed flexible packaging applies a force to the interior of the packaging upon contact with the hard surface and may rupture the packaging.

[0004] Previous solutions to overcome this problem have included increased strength throughout the packaging structure to reinforce the areas that traditional experience failure. Specifically, the thickness of the material forming the sealed flexible packaging is increased throughout the package to ensure that the point of the seals/packaging receiving the highest forces during a drop event are capable of withstanding impact. This leads to utilization of unnecessary material volume and waste. [0005] Accordingly, there remains a need for a sealed flexible packaging that is capable of withstanding a drop event without bulking the thickness of the packaging material uniformly throughout the sealed flexible packaging.

SUMMARY

[0006] Embodiments of the present disclosure are directed to flexible containers, such as a stand-up pouch or a pillow pouch, with a new sealing geometry to lessen packaging rupture when dropped.

[0007] In accordance with one embodiment, a flexible container is provided. The flexible container comprises a package body formed from a plurality of flexible panels jointed with a plurality of seals, thereby enclosing an interior of the container. The plurality of flexible panels are formed from a flexible film. Further, at least a portion of at least one of the plurality of seals comprises a crenellated geometry formed from a continuous base seal and a plurality of aligned sealing projections oriented toward an interior of the package body. Additionally, the flexible film comprises a sealant layer and a substrate layer. The substrate layer may comprise a monolayer or multilayer film.

[0008] These and additional features provided by the embodiments of the present disclosure will be more fully understood in view of the following detailed description, in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the drawings enclosed herewith.

[0010] FIG. 1 is a schematic view of a pouch according to one or more embodiments of the present disclosure.

[0011] FIG. 2A is a schematic view of a pouch according to one or more embodiments of the present disclosure.

[0012] FIG. 2B is an exploded view of the pouch according to FIG. 2A. [0013] FIG. 3 is a schematic view of a seal according to one or more embodiments of the present disclosure.

[0014] FIG. 4 is a schematic view of a seal according to one or more embodiments of the present disclosure.

[0015] FIG. 5A is a schematic view of a seal according to one or more embodiments of the present disclosure.

[0016] FIG. 5B is a schematic view of a seal according to one or more embodiments of the present disclosure.

[0017] FIG. 6A is a graph of stress-strain curves for high speed testing of comparative and inventive seals according to one or more embodiments of the present disclosure.

[0018] FIG. 6B is a graph of stress-strain curves for high speed testing of comparative and inventive seals according to one or more embodiments of the present disclosure.

[0019] FIG. 6C is a graph of stress-strain curves for high speed testing of comparative and inventive seals according to one or more embodiments of the present disclosure.

[0020] FIG. 7A is a graph of stress-strain curves for low speed testing of inventive seals according to one or more embodiments of the present disclosure.

[0021] FIG. 7B is a graph of stress-strain curves for low speed testing of inventive seals according to one or more embodiments of the present disclosure.

[0022] FIG. 7C is a graph of stress-strain curves for low speed testing of inventive seals according to one or more embodiments of the present disclosure.

[0023] The embodiments set forth in the drawings are illustrative in nature and not intended to be limiting to the claims. Moreover, individual features of the drawings will be more fully apparent and understood in view of the detailed description.

DETAILED DESCRIPTION

[0024] A flexible container in accordance with the present disclosure includes a package body formed from a plurality of flexible panels jointed with a plurality of seals. The plurality of flexible panels and seals form an enclosed interior of the flexible container. The flexible panels are formed from at least one flexible film which comprises a sealant layer and a substrate layer. The substrate layer may comprise a monolayer or multilayer film. The plurality of seals joining the flexible panels comprise at least a portion having a crenellated geometry formed from a continuous base seal and a plurality of aligned sealing projections oriented toward an interior of the package body.

[0025] Referring to FIGS. 1 and 2, one or more embodiments of a flexible container 1 are shown. The depicted flexible container 1 is rectangular; however, various additional sizes and shapes are contemplated herein and within the scope of this disclosure. As stated above, the flexible container 1 could be a pillow pouch or a stand-up pouch.

[0026] With reference to FIG 1, in one or more embodiments, the flexible panels 10 forming the flexible container 1 include a front wall 12 and a rear wall 14. The front wall 12 has a first end 16 and a second end 18 and the rear wall 14 has a first end 17 and a second end 19. Further, side edges 20 connect the first ends 16, 17 and the second end 18, 19. The rear wall 14 is adhered to the front wall 12 at corresponding first ends 16, 17 to form a first end seal 24. The rear wall 14 is adhered to the front wall 12 at corresponding second ends 18, 19 to form a second end seal 28. Additionally, the rear wall 14 is adhered to the front wall 12 at corresponding side edges 20 to form side seals 26.

[0027] With reference to FIG 2, in one or more embodiments, the flexible panels 10 forming the flexible container 1 include a front wall 12, a rear wall 14, a first side panel 32, and a second side panel 34. The first side panel 32 and the second side panel 34 are laterally opposed in the structure of the flexible container 1. The front wall 12 has a first end 16 and a second end 18, the rear wall 14 has a first end 17 and a second end 19, the first side panel has a first end 16 and a second end 18, the rear wall 14 has a first end 17 and a second end 19, the first side panel 32 has a first end 36 and a second end 38, and the second side panel 34 has a first end 37 and a second end 39. Further, side edges 20 connect the first ends 16, 17, 36, 37 and the second end 18, 19, 38, 39. The front wall 12 and the rear wall 14 are adhered to the first side panel 32 and the second side panel 34 at corresponding first ends 16, 17, 36, 37 to form a first end seal 24.

The front wall 12 and the rear wall 14 are adhered to the first side panel 32 and the second side panel 34 at corresponding second ends 18, 19, 38, 39 to form a second end seal 28. Additionally, the rear wall 14 and the front wall 12 are adhered to the first side panel 32 and the second side panel 34 at corresponding side edges 20 to form a plurality of side seals 26. In one or more embodiments, the rear wall 14, the front wall 12, the first side panel 32, and the second side panel 34 may form a seal around a pouring spout 60.

[0028] The flexible panels 10 forming the flexible container 1 are formed from a flexible film. The flexible film includes a sealant layer and a substrate layer. The sealant layer is configured to form a heat sealable seal upon application of heat and optionally pressure. It will be appreciated that the sealant layer may be activated by any form of heat induction in processes such as conductive sealing, high frequency (HF) sealing, radio frequency (RF) sealing, ultrasonic (US) sealing, inductive sealing, hot air sealing, or flame sealing techniques. The substrate layer is a flexible film configured to provide the structural aspects of the flexible container 1 and many be a monolayer or a multilayer film. Specifically, the flexible film comprises the sealant layer to form a seal with adj oining media and the substrate layer to provide desired structural, environmental, or other material properties.

[0029] As heat sealable seals, the first end seal 24, the second end seal 28, and the side seals 26 are generally formed by applying heat to the flexible film. Application of the heat causes heat to transfer through the substrate layer(s) and melt and fuse the sealant layer to form a seal. As such, while the sealant layer is melted to form a seal, the substrate layer or layers melt at a greater melting point or points than the set point to form the seal. Subsequently, the flexible film is cooled to room temperature and the sealant layer solidifies to form the completed seal.

[0030] In one or more embodiments, the first end seal 24, the second end seal 28, and the side seals 26 may hermetically seal the interior volume of the flexible container 1.

[0031] With reference to FIGS. 3 and 4, at least one of the plurality of seals comprises a crenellated geometry formed from a continuous base seal 40 and a plurality of aligned sealing projections 50 oriented toward an interior of the flexible container 1. The crenellated geometry forms a seal with a profile reminiscent of a comb with a solid handle represented by the continuous base seal 40 and a series of teeth represented by aligned sealing projections 50.

[0032] The aligned sealing projections 50 implement the mechanical principles of energy absorption into the seal geometry. Specifically, the aligned sealing projections 50 interrupt fluid dynamic wave energy and impact progression of fluids within the flexible container 1. The energy of the sloshing fluid within the flexible container 1 is dissipated as the fluid is passed between the aligned sealing projections 50 such that the continuous base seal 40 can withstand the remaining fluid energy when the fluid impacts the continuous base seal 40. As the fluid passes between the aligned sealing projections 50, the flexible film is able to stretch or bulge to dissipate energy in the fluid before contacting the continuous base seal 40. Specifically, the thermoplastic behavior of the yield strength and tensile strength of the flexible film as expressed in stress-strain curves is exploited to diminish the fluid energy through stretching of the flexible film while not ultimately breaking the flexible film. Further, the aligned sealing projections 50 induce entropic impact dissipation in the form of turbulent flow from a tip 52 of the aligned sealing projections 50 to the continuous base seal 40, thereby resulting in an energy absorbing system.

[0033] With reference to FIG. 3, in one or more embodiments the aligned sealing projections 50 comprise a substantially rectangular profile. The rectangular profile for the aligned sealing projections 50 provides a consistent distance between sequential aligned sealing projections 50 along the entire length of the aligned sealing projections 50.

[0034] With reference to FIG. 4, in one or more embodiments the aligned sealing projections 50 comprise a substantially trapezoidal profile. The trapezoidal profile for the aligned sealing projections 50 provides a diminishing distance between sequential aligned sealing projections 50 along the length of the aligned sealing projections 50 from the tip 52 to connection with the continuous base seal 40. Diminishing the distance between sequential aligned sealing projections 50 along the length of the aligned sealing projections 50 provides for increased restriction of the fluid traversing the gap as the fluid nears the continuous base seal 40.

[0035] The terminus of each aligned sealing projections 50 comprises the tip 52. The tip 52 is oriented toward the interior volume of the flexible container 1 and is the initial point of impact of energetic fluids within the flexible container 1. The tip 52 may comprise a rounded profile or an angular profile. In various embodiments, the rounded profile at the tip 52 may comprise a semicircle, a parabolic arc, or an arched profile to deflect and divert the energetic fluid into the spaces between the aligned sealing projections 50. In various embodiments, the angular profile at the tip 52 may comprise a triangular point with an acute or obtuse leading angle, a faceted profile with three or more faces, or a squared profile, in each case to deflect and divert the energetic fluid into the spaces between the aligned sealing projections 50. [0036] In one or more embodiments, a distance between each aligned sealing projection 50 is a least twice as large as a width of each aligned sealing projection 50 measured at the same distance from the continuous base seal 40. The distance between each aligned sealing projection 50 determines the volume of fluid which may dissipate energy for each unit length of the aligned sealing projections 50. In various embodiments, the distance between each aligned sealing projection 50 is a least two and one-half times, three times, four times, or five times as large as the width of each aligned sealing projection 50. With reference to FIGS. 3 and 4, such arrangement is synonymous with D > 2d, 2.5d, 3d, 4d, or 5d where“D” represents the distance between aligned sealing projections 50 and“d” represents the width of each aligned sealing projection 50. It will be appreciated that in some embodiments the distance between each aligned sealing projection 50 is two to ten times, two to five times, two to four times, or two to three times as large as the width of each aligned sealing projection 50.

[0037] The length of each aligned sealing projection 50 also affects the area for turbulent flow between the aligned sealing projections 50 for energy dissipation from the fluid present in the flexible container 1. In various embodiments, a length of each aligned sealing projection 50 is at least three times, at least five time, at least ten times, or at least fifteen times as large as a distance between each aligned sealing projection 50 measured at a midpoint of the length of the aligned sealing projection 50. It will be appreciated that in some embodiments the length of each aligned sealing projection 50 is three to twenty-five, five to twenty, or ten to fifteen times the distance between each aligned sealing projection 50 measured at a midpoint of the length of the aligned sealing projection 50. With reference to FIGS. 3 and 4, such arrangement is synonymous with b > 3D, 5D, 10D, or 15D where“D” represents the distance between aligned sealing projections 50 and“b” represents the length of each aligned sealing projection 50.

[0038] In one or more embodiments, the aligned sealing projections 50 have a consistent length with each aligned sealing projection 50 comprising the same length. A consistent length of the aligned sealing projections 50 results in uniform energy dissipation across the entire energy absorbing seal.

[0039] In one or more embodiments, the aligned sealing projections 50 vary in length across the energy absorbing seal and/or between different seals. As the aligned sealing projections 50 extend into the inner volume of the flexible container 1 they also reduce the storage capacity of the flexible container 1. As such, only having the aligned sealing projections 50 comprise a length as necessary to provide sufficient energy dissipation is desirable to maximize the interior volume of the flexible container 1. In some embodiments, the length of the aligned sealing projections 50 may reduce in length in a step-wise manner along the length of the energy absorbing seal with a plurality of aligned sealing projections 50 at a first length followed by a plurality of aligned sealing projections 50 at a second length and optionally a plurality of aligned sealing projections 50 at a third or higher order length. In further, embodiments, , the length of the aligned sealing projections 50 may reduce in length in a gradient along the length of the energy absorbing seal with the length of sequential aligned sealing projections 50 smoothly reducing along the length of the seal.

[0040] Without wishing to be bound by theory, it is believed that the width of each aligned sealing projection 50 should be minimized so as to allow the aligned sealing projection 50 to elongate at the tip 52. Specifically, stretching of the aligned sealing projections 50 into the third dimension representative of the direction of seal separation utilizes the elongation of the flexible film and the sealant layer to dissipate energy from the turbulent fluid. In various embodiments, a width of each aligned sealing projection 50 measured at a midpoint of the length of the aligned sealing projection 50 is less than ten times, five times, or three times a thickness of the sealant layer. The thickness of the sealant layer is represented by the gauge of the sealant layer. For example, with a 20 micron sealant layer, the width of each aligned sealing projection 50 may be less than 200 microns, less than 100 microns, or less than 60 microns. The width of the aligned sealing projections 50 are only limited by the physical constraints of seal bar machining, but it will be appreciated that a smaller width of the aligned sealing projections 50 allows for less force required to elongate the aligned sealing projections 50 in the third dimension.

[0041] With reference to FIGS. 3 and 4, the aligned sealing projections 50 may be continuous. Specifically, the aligned sealing projections may form a continuous structure from the continuous base seal 40 to the tip 52 of each aligned sealing projection 50. The continuous form of the aligned sealing projections 50 forms closed channels which may serve to form turbulent flow within the liquid and dissipate energy.

[0042] With reference to FIGS 5 A and 5B, the aligned sealing projections 50 may be discontinuous with each aligned sealing projection 50 formed from a series of aligned discrete seals. The aligned sealing projections 50 may substantially replicate the continuous aligned sealing projections 50 with unsealed sections 54 along the length of each aligned sealing projection 50 as illustrated in FIG. 5 A. The unsealed sections 54 may be aligned or may be staggered in various embodiments. The aligned sealing projections 50 may also be formed from a series of aligned dot seals as illustrated in FIG. 5B.

[0043] The seals with the crenellated geometry formed from the continuous base seal 40 and the plurality of aligned sealing projections 50 may be positioned in the areas of the flexible container 1 expected to experience the greatest stress when the flexible container 1 is dropped. Limiting the energy absorbing seal design to the areas expected to experience the greatest stress allows for maximal interior volume of the flexible container 1 while sustaining sufficient seal strength in the areas of greatest stress to avoid rupture upon dropping the flexible package 1. In further embodiments, the energy absorbing seal design may be extended to all seals joining the flexible panels.

[0044] The adhesion strength between individual flexible panels 10 may be adjusted by adjusting the temperature, pressure, or dwell time of the sealing bar configured to form the seals in the desired locations. For example, increasing the pressure applied by the sealing bar during a sealing operation generally results in a seal with an increased adhesion strength. Similarly, increasing the temperature of the fusing nip also generally results in an increased adhesion strength until such an elevated temperature is reached that the integrity of the film structure is damaged. For example, a lock-up (or non-peelable) seal may be expected to form with a fusing nip pressure of 5 bars (0.5 N/mm ² ) and a temperature in excess of 130 °C for ½ a second. The particular materials and structure of the films determine the specific seal strength profile for varying temperatures and/or pressures. Besides temperature and pressure, the sealing bar geometry may influence seal strength.

[0045] In various embodiments, the substrate layer may be a monolayer or may be formed of a plurality of layers to input desired physical and chemical properties to the flexible film. For example, the substrate layer may provide tearing or stretching strength, oxygen barrier properties, opacity, or other desirable material properties to the flexible film based on the formulation of the substrate layer.

[0046] In one or more embodiments, the substrate layer of the flexible film may include polyolefins, such as high-density polyethylene (HDPE), polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyamides (PA). The flexible film may be biaxially oriented (i.e., stretched) and may include, for example, biaxially oriented polyethylene terephthalate (BOPET), or biaxially oriented polypropylene (BOPP), biaxially oriented polyamide (BOP A), or other materials used in flexible packaging. It will be appreciated that the energy absorbing seal design through inclusion of the plurality of aligned sealing projections is not limited to application with these specifically disclosed flexible film compositions, and is instead believed applicable across all flexible films regardless of the particular formulation. For example, future developed polymer compositions for packaging film application would benefit from the disclosed energy absorbing seal design of the present application and are intended to be captured by the present disclosure.

[0047] In one or more embodiments, the sealant layer of the flexible film may include a blend of a propylene based plastomer or elastomer, and at least one of a polyethylene or ethylene co-polymer or ionomer based polymer. Non-limiting examples of the polymer forming the sealant layer include ELITE™ AT 6410, ELITE™ 5401 GS, AFFINITY™ PL 1881,

VERSIFY™ 2200, NUCREL™ 0903, and SURLYN™ 1605, each commercially available from The Dow Chemical Company (Midland, MI).

[0048] It will be appreciated that the flexible film utilized in each of the plurality of flexible panels may differ. Specifically, the flexible panel forming one face of the flexible container 1 may be formed from a flexible film selected for different physical properties than the flexible panel forming a second face of the flexible container 1. For example, the flexible panel forming a front face of the flexible container 1 and an integrated pouring spout may be formed from a different flexible film than the flexible panel forming a back face of the flexible container 1 which does not include a pouring spout.

[0049] The thickness or gauge of the flexible film may vary based on the desired film properties. The total thickness of the flexible film is determined by the sum of the thickness or gauge of the sealant layer and the thickness or gauge of the substrate layer. In various embodiments, the sealant layer may comprise a thickness of 5 to 60 microns, 10 to 40 microns, 15 to 30 microns, or approximately 20 microns. In various embodiments, the substrate layer may comprise a thickness of 10 to 250 microns, 30 to 200 microns, 40 to 100 microns, or approximately 50 microns. [0050] It should be understood that the flexible film may contain various additives.

Examples of such additives include antioxidants, ultraviolet light stabilizers, thermal stabilizers, slip agents, antiblock pigments or colorants, processing aids (such as fluoropolymers), crosslinking catalyst, flame retardants, pigments, fillers, foaming agents, and combinations thereof.

[0051] In one or more embodiments, the flexible container 1 comprises indicia. Non-limiting examples of the indicia include printing to indicate the contents of the flexible container 1, instructions for opening the flexible container 1, and marketing slogans and graphics.

[0052] It will be appreciated that he energy absorbing seal may be produced independent of the flexible container 1 and may be applied to seals in other products.

[0053] EXAMPLES

[0054] Test sample of sealed flexible films were prepared to demonstrate the improved performance of seals prepared in accordance with the present disclosure. Seal integrity testing is measured in laboratory method with a tensile test of a sealed strip to determine the force until breakage. Such testing also allow for determination regarding if the seal itself fails or if the surrounding film fails with the seal proper remaining intact. Test strips of flexible film were cut to a width of 15 millimeters (mm) and sealed together with a single seal across the 15 mm sample.

[0055] A first cohort of seals was prepared using a standard flat seal bar to form the seal as comparative examples. The comparative flat seals were formed at a pressure of 0.5 Newton per square millimeter (N/mm ² ) and a sealing bar temperature of 160°C for 2 seconds to form a bar seal with a width of 10 mm across the entire 15 mm edge of the test sample.

[0056] A second cohort of seals was prepared in accordance with the present disclosure with a crenellated geometry formed from a continuous base seal and a plurality of aligned sealing projections as inventive examples. The continuous base seal was formed with a width of 10 mm across the entire 15 mm edge. The aligned sealing projections were formed having a length of 10 mm, a width of 90 microns, and a spacing of 550 microns. The seal was produced using a sealing bar having the inventive geometry at a pressure of 0.5 N/mm ² and a sealing bar temperature of 160°C for 2 seconds. [0057] The first and second cohorts of seals were prepared using three different flexible film structures. A first set of examples were prepared with the substrate layer comprised of a multilayer film formed with a 15 microns outside skin made from a Polyamide, a 10 microns adhesive layer from a maleic-anhydride-grafted Polyethylene named Amplify™ TY 1353 and a 115 microns bulk layer made from an Innate™ ST-50 precision polyethylene-based resin commercially available from The Dow Chemical Company and the sealant layer comprised of a 20 micron layer formed from Affinity™ PL 1881 polyolefin plastomer (POP) commercially available from The Dow Chemical Company. The crenulated seal is designated Inventive Example 1 and the flat bar seal is designated Comparative Example 2. A second set of examples were prepared with the flexible film substrate layer comprised of a multilayer film formed with a 13 microns outside skin made from a Polyamide from UBE PA 5034B, a 8 microns adhesive layer from a maleic-anhydride-grafted Polyethylene named Amplify™ 1353 and a 125 microns bulk layer made from an Innate™ ST-50 precision polyethylene-based resin commercially available from The Dow Chemical Company and the sealant layer comprised of a 15 microns layer formed from Elite™ AT 6410 enhanced polyethylene resin commercially available from The Dow Chemical Company. The crenulated seal is designated Inventive Example 3 and the flat bar seal is designated Comparative Example 4. Finally, a third set of examples were prepared with a flexible film substrate layer comprised of a multilayer film formed with a 13 microns outside skin made from a Polyamide from UBE PA 5034B, a 8 microns adhesive layer from a maleic-anhydride-grafted Polyethylene named Amplify™ 1353 a gas barrier block consisting of a 9 microns EYOH polymer EYAL F171B from Kuraray sandwiched in-between 12 microns each side of a Polyamide layer from UBE PA 5034B and in total 65 microns of bulk layer made from an Innate™ ST-50 precision polyethylene-based resin commercially available from The Dow Chemical Company and the sealant layer comprised of a 36 microns layer formed from ELITE 5401 GS, an enhanced polyethylene resin commercially available from The Dow Chemical Company. The crenulated seal is designated Inventive Example 5 and the flat bar seal is designated Comparative Example 6. The structure of each flexible film test sample is detailed in Table 1.

[0058] Each of Inventive/Comparative Examples 1 -6 were pulled apart through constant strain rate high speed tensile testing to develop stress-stain plots for each flexible multilayer film and seal combination. This testing is representative of the quick impulse of force provided to the seals when the flexible container is dropped. With reference to FIG. 6A which illustrates the stress-strain plots for Inventive Example 1 and Comparative Example 2 pulled at 1 meter/second (m/sec), 0.1 m/sec, and 0.01 m/sec, the increased overall strain at failure of the test specimen is illustrated. Specifically, the Inventive Example 1 demonstrates an increased overall strain at failure of 100 to 150% strain when compared to the corresponding Comparative Example 2 test. For example, Inventive Example 1 at 0.01 m/sec demonstrates failure at approximately 460% strain in comparison to failure of Comparative Example 2 at approximately 310% strain. With reference to FIG. 6B which illustrates the stress-strain plots for Inventive Example 3 and Comparative Example 4 pulled at 1 m/sec, 0.1 m/sec, and 0.01 m/sec, similar increases overall strain at failure of 100 to 150% are demonstrated. Finally, with reference to FIG. 6C which illustrates the stress-strain plots for Inventive Example 51 and Comparative Example 6 pulled at 1 m/sec, 0.1 m/sec, and 0.01 m/sec, similar increases overall strain at failure of 100 to 150% are demonstrated. The increased percent strain at failure for the Inventive Examples demonstrates the ability of the energy absorbing seal design and the aligned sealing projections to elongate and dissipate energy through elongation before reaching the continuous base seal. As such it will be appreciated that in various embodiments of the present disclosure, the percent strain at failure of the seal comprising a crenellated geometry is at least 75 percent, at least 100 percent, at least 125 percent, or at least 150 percent strain greater than the percent strain at failure for a conventional bar seal matching the dimensions of the continuous base seal when measured at a pull speed of greater than 0.01 m/sec, greater than 0.1 m/sec, or from approximately 0.01 m/sec to m/sec.

[0059] The force required to pull a seal apart is called the seal strength. The seal strength can be measured in accordance with ISO 527. ISO 527 testing utilizes a 100 millimeter per minute (mm/min) pull speed with the sample specimens clamped 35 mm from seal. The Inventive Examples 1, 3, and 5 were tested in accordance with ISO 527 to plot the low speed stress-strain curves for each seal. With reference to FIGS. 7A, 7B, and 7C representing low speed stress strain curves for Inventive Examples 1, 3, and 5 respectively, an intermediate yield point at low extension may be observed followed by a strong increase to the plateau and final maximum force. Each Inventive Example was repeatedly tested to provide a sample size of five for each specimen type. The intermediate yield point at low extension is representative of the effect of the aligned sealing projections.

[0060] Demonstration of the improvement afforded by the inventive seal geometry with aligned sealing projections was also completed with drop testing of sealed vessels. A 5 liter vessel with dimensions and construction in accordance with a pacXPERT™ bottle from The Dow Chemical Company was produced with standard bar seals in a first specimen as Comparative Example 8 and the addition of the aligned sealing projections of the inventive seals along portions of the package seals in a second specimen as Inventive Example 7. The pacXPERT™ bottle was of the style illustrated in FIG. 2. The aligned sealing projections in Inventive Example 7 were prepared with a width of 80-95 microns, a length of 10 mm, and a spacing of 550 microns. The seals in all cases were generated with a sealing pressure of 0.5 N/mm ² , a temperature of 160 °C, and a sealing time of 2 seconds. The Inventive Example 7 consists of a commercially available industrial filling good packed into a pacXPERT™ bottle with a multilayered film of very similar characteristics and same sealant layer as in above mentioned Comparative Example 1. Comparative Example 8 is the same pacXPERT™ bottle used as in Inventive Example 7, but with the original flat seal. This Example demonstrated failure of seal integrity with a drop from a height of 80 cm. Inventive Example 7 demonstrated improvements with the test specimen 5 liter package retaining seal integrity until drops from a height as great as 180 cm. At a drop height of 180 cm, the Inventive Example 7 package exhibited stresses at the aligned sealing projections but no bursting of the packaging. Additional testing of further packaging designs for commercially available pacXPERT™ bottles have demonstrated an improvement of drop height resistance from 50 to over 100 percent which equates to a minimum double of the drop height before seal failure for a package.

[0061] It is noted that there is an inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. Further it is understood that there is a degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. For conciseness, the terms“about”,“substantially” and the like are omit from disclosed values, measurements, or other representations, but are implicitly include within the intended meaning and scope to cover these stated situations.

[0062] The singular forms“a”,“an” and“the” include plural referents, unless the context clearly dictates otherwise.

[0063] It is further noted that terms like“preferably,” "generally,"“commonly,” and “typically” are not utilized herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present disclosure. [0064] Throughout this disclosure ranges are provided. It is envisioned that each discrete value encompassed by the ranges are also included. Additionally, the ranges which may be formed by each discrete value encompassed by the explicitly disclosed ranges are equally envisioned.

[0065] As used in this disclosure and in the appended claims, the words“comprise,”“has,” and“include” and all grammatical variations thereof are each intended to have an open, non limiting meaning that does not exclude additional elements or steps.

[0066] While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.