WO2017124049A1

WO2017124049A1 - Materials and package configurations for use in packaging closed by permeable membranes

Info

Publication number: WO2017124049A1
Application number: PCT/US2017/013597
Authority: WO
Inventors: Nicholas D. Mckay; Bao Trong Do; Eric Mehnert
Original assignee: Enviroscent, Inc.
Priority date: 2016-01-15
Filing date: 2017-01-14
Publication date: 2017-07-20

Abstract

The present disclosure generally relates to produce packages and materials used for product packaging. The materials and packages disclosed herein may form a receptacle for holding a product. In some embodiments, the materials and packages may include a gas impermeable layer configured to seal off the receptacle to prevent the product held therein from interacting with the surrounding air. The gas impermeable layer of the material and package may be configured to be peelable by a user to expose a gas permeable layer. The gas permeable layer may allow for gas exchange between the product and the surrounding environment. Certain embodiments may be particularly useful for sealing a product including a volatile substances, such as, but not limited to, fragrance carriers and/or deodorizers.

Description

MATERIALS AND PACKAGE CONFIGURATIONS FOR USE IN PACKAGING CLOSED BY PERMEABLE MEMBRANES

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Patent Application

62/279,323, entitled "Materials and Package Configurations for Use in Product Packaging" and filed January 15, 2016, the contents of which are incorporated herein by reference in its entirety.

BACKGROUND

[0002] The present disclosure generally relates to produce packages and materials used for product packaging. The materials and packages disclosed herein may form a receptacle for holding a product. In some embodiments, the materials and packages may include a gas impermeable layer configured to seal off the receptacle to prevent the product held therein from interacting with the surrounding air. The gas impermeable layer of the material and package may be configured to be peelable by a user to expose a gas permeable layer. The gas permeable layer may allow for gas exchange between the product and the surrounding environment.

Certain embodiments may be particularly useful for sealing a product including a volatile substances, such as, but not limited to, fragrance carriers and/or deodorizers.

[0003] Some traditional product packages may include bags formed out of film material or blister packs with pop-through films. However, when storing products having volatile substances or that undergo chemical reactions when exposed to the open atmosphere (e.g., exothermic oxidation reactions), special considerations may be needed. Accordingly, further improvements may be desired.

SUMMARY

[0004] Embodiments described herein are generally related to materials used for product packaging. Exemplary embodiments may be particularly useful for packaging products which include volatile substances or products activated upon exposure to the open atmosphere (e.g., oxygen activated or the like). For example, in some embodiments, a product may include a volatile fragrance. In other embodiments, a product may include an oxygen activated compound. In still further embodiments, the product may be a drug, aromatherapeutic agent, or moisture delivery device such as a hydrogel product. When products include or are configured to diffuse a volatile substance, the materials used for packaging the material may inadvertently interact with and damage the packaging materials. Even relatively small chemical interactions between the product and the packaging can be problematic if products are not sold or used over the course of longer periods of time (e.g., months, years, etc.). Over time, these relatively minor chemical interactions may also lead to significant damage to the product packaging. In some situations, volatile substances may cause delamination of packaging material and/or may interact with and damage seals meant to contain the volatile substance within the package. If the layers are delaminated or the seals are breached inadvertently, the product held therein may become prematurely depleted prior to consumer use. In other situations, the volatile substances may undesirably discolor the packaging material which may adversely affect product sales or marketing. Further, some chemical interactions between volatile substances and product packaging may put off an odor or may alter the odor of the volatile substance. This may be particularly problematic when the product is a fragrance delivery device. Accordingly, there is a need for packaging materials which are configured to package products which include volatile chemical substances. In many embodiments, it may be desirable if the packaging material does not chemically interact with the product held therein. Additionally, certain embodiments may provide for product packages that are particularly well suited for minimizing undesirable interactions with the product and which provide a longer shelf life. Some embodiments may also include a peelable barrier film that exposes permeable layer. The permeable layer may provide a physical barrier that holds the product within the receptacle, but may also provide gas exchange so that the volatile substance of the product may be diffused into the surrounding air. In some embodiments, the permeable layer may prevent direct contact of the product with other surfaces. This may help reduce interaction of the volatile substance with surfaces in which the permeable layer rests on.

[0005] In some aspects of the present disclosure, a package is provided. The package may include a barrier layer defining a receptacle for receiving and storing a product. The receptacle may include an opening for receiving the product. A permeable layer may be provided and coupled with the barrier layer. A portion of the permeable layer may be configured to cover the opening of the barrier layer receptacle. A peelable barrier film may be releasably coupled with the permeable layer. A portion of the peelable barrier film may be configured to cover the portion of the permeable layer covering the opening of the barrier layer receptacle. The peelable barrier film may be configured to be peelable from the permeable layer so as to expose the portion of the permeable layer covering the opening of the barrier layer receptacle.

[0006] In some embodiments, a package may be provided. The package may include a barrier layer defining a receptacle for storing a product. The receptacle may include an opening for receiving the product. A permeable layer may be coupled with the barrier layer. A portion of the permeable layer may be configured to cover the opening of the barrier layer receptacle. A peelable barrier film may be releasably coupled with the permeable layer. A portion of the peelable barrier film may be configured to cover the portion of the permeable layer covering the opening of the barrier layer receptacle. The peelable barrier film may be configured to be peelable from the permeable layer so as to expose the portion of the permeable layer covering the opening of the barrier layer receptacle.

[0007] Optionally, the package is gas impermeable when the peelable barrier film covers the portion of the permeable layer covering the opening of the barrier layer receptacle. The package may be gas permeable when the peelable barrier film is peeled to expose the portion of the permeable layer covering the opening of the barrier layer receptacle.

[0008] The permeable layer may be a non-woven fabric. The permeable layer may be a polyester material. In some embodiments, the permeable layer may be 100% non-woven polyester. The peelable barrier film may be an ethylene vinyl alcohol (EVOH) layer.

[0009] Optionally, the peelable barrier film may be a peelable sealant layer configured to releasably couple the EVOH layer to the permeable layer. The peelable sealant layer may be a low density polyethylene (LDPE). In some embodiments, the peelable barrier film may further include a tie layer configured to couple the peelable sealant layer with the EVOH layer. The peelable barrier film may further include a foil. The EVOH layer may be disposed between the foil layer and the permeable layer.

[0010] In some embodiments, the peelable barrier film may further include a tie layer disposed between the EVOH layer and the foil layer. The peelable barrier film may further include a sealant layer disposed between the tie layer and the foil layer. The peelable barrier film may further include an ethyl acetoacetate (EAA) layer disposed between the sealant layer and the foil layer. The peelable barrier film may further include a paper layer in some embodiments. The foil layer may be disposed between the paper layer and the EVOH layer. Optionally, a sealant layer may couple the foil layer to the paper layer. In certain embodiments, the paper layer may be a bleached or unbleached craft paper.

[0011] In some embodiments, the peeiable barrier film may further include a

polyethylene terephthalate (PET) layer. The EVOH layer may be disposed between the PET layer and the permeable layer. The peeiable barrier film may further include a tie layer disposed between the EVOH layer and the PET layer. An LDPE layer may couple the tie layer to the PET layer.

[0012] In some embodiments, the receptacle is vacuum sealed. Optionally, the receptacle is sealed with an inert gas environment that is sealed in the receptacle by the peelabie barrier film. The inert gas environment may be a nitrogen gas environment.

[0013] In some embodiments, the product may be oxygen activated. Optionally, the product includes a fragrance and a fragrance carrier.

[0014] The peeiable barrier layer, the permeable layer, and the barrier layer may be heat sealed with one another in some embodiments. The peeiable barrier layer may include a sealant layer configured to couple the peeiable barrier layer with the permeable layer. The sealant layer may be configured to melt, protrude through holes of the permeable layer, and form a seal with the permeable layer (e.g., after cooling and solidifying). The permeable layer may be configured to melt during heat sealing. .

[0015] In further aspects, a packaging material may be provided that includes a first sealant layer, a second sealant layer, an ethylene vinyl alcohol (EVOH) layer sandwiched between the first sealant layer and the second sealant layer, a first tie layer disposed between the first sealant layer and the EVOH layer, the first tie layer configured to tie the first sealant layer with the EVOH layer, and/or a second tie layer disposed between the second sealant layer and the EVOH layer. The second tie layer may be configured to tie the second sealant layer with the EVOH layer.

[0016] The first sealant layer, the second sealant layer, the first tie layer, and the second tie layer may form a moisture barrier on both sides of the EVOH layer to extend EVOH barrier effectiveness against gas permeation. The first sealant layer and the second sealant lay er may be low density polyethylene layers

[0017] In some embodiments, the packaging material may further include a polyethylene terephthalate (PET) layer coupled with the first sealant layer such that the first sealant layer is positioned between the PET layer and the EVOH layer. Optionally, the packaging material may further include a foil layer coupled with a first side of an ethyl acetoacetate (EAA) layer. A second side of the EAA layer may be coupled with the first sealant lay er. The first side of the EAA layer may be opposite the first side of the EAA layer. In still further embodiments, the packaging material may further include a paper layer coupled with the foil layer. A third sealant layer may be disposed between the paper layer and the foil layer.

[0018] The packaging material may further include a permeable layer coupled with the second sealant layer. The permeable layer may be heat sealed with the second sealant layer. The permeable layer may be a polymer material configured to melt during heat sealing so as to form an air tight seal with the second sealant layer. The heat seal formed between the permeable layer and the second sealant layer may be configured to allow the second sealant layer to be peeled from the permeable layer.

[0019] In still further aspects of the disclosure, a package may be provided that includes a non-permeable layer coupled with the permeable layer of the packaging material disclosed herein to form a receptacle for holding a product. The non-permeable layer may couple with the packaging material with an air tight seal. The second sealant layer may be configured to be peelable from the permeable layer of the packaging material to allow gas transfer into and out of the receptacle through the permeable layer.

[0020] The permeable layer may optionally be a nonwoven material. The nonwoven material may be a polyester material. The polyester material may include a first plurality of parallel strands overlapping a second plurality of parallel strands. The first plurality of parallel strands may be transverse to the second plurality of parallel strands. Optionally, the first plurality of parallel strands may be melted to the second plurality of parallel strands.

[0021] In still further embodiments, a plurality of packages may be provided. A first package may include a barrier layer defining a cavity for storing a product. The cavity may include an opening for receiving the product. A permeable layer may be coupled with the barrier layer. A portion of the permeable layer may be configured to cover the opening of the barrier layer cavity. The permeable lay er may include a plurality of strands at a first density. A peelable barrier film may be releasably coupled with the permeable lay er. A portion of the peelable barrier film may be configured to cover the portion of the permeable layer covering the opening of the barrier layer cavity. The peelable barrier film may be configured to be peelable from the permeable layer so as to expose the portion of the permeable layer covering the opening of the barrier layer cavity . A second package may be provided that includes a barrier layer defining a receptacle for storing a product. The receptacle may include an opening for receiving the product. A permeable layer may be coupled with the barrier lay er. A portion of the permeable layer may be configured to cover the opening of the barrier layer receptacle. The permeable layer may include a plurality of strands at a second density. The peelable barrier film may be reieasably coupled with the permeable layer. A portion of the peelable barrier film may be configured to cover the portion of the permeable layer covering the opening of the barrier layer receptacle. The peelable barrier film may be configured to be peelable from the permeable layer so as to expose the portion of the permeable layer covering the opening of the barrier layer receptacle. The first density of strands may be less than the second density of strands in some embodiments. The first package may be rated for a faster delivery of a volatile substance relative to the second package.

[0022] Embodiments of the disclosure covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed

Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.

[0023] The disclosure will be better understood on reading the following description and examining the figures that accompany it. These figures are provided by way of illustration only and are in no way limiting on the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 illustrates an exemplar}' product package according to some

embodiments of the disclosure;

[0025] Figure 2A illustrates an exemplary cross-section of the product package illustrated in Figure 1 ;

[0026] Figure 2B illustrates an exemplar}' cross-section of another product package according to some embodiments of the disclosure; [0027] Figure 2C illustrates an exemplar}' cross-section of yet another product package according to some embodiments of the disclosure;

[0028] Figure 3 illustrates a back side of the exemplary product package illustrated in

Figure 1;

[0029] Figure 4 illustrates the back side of the exemplary product package illustrated in

Figure 1 with an exemplary impermeable layer removed;

[0030] Figure 5 illustrates an exemplar}' configuration of the peelable barrier film illustrated in Figure 2A-2C;

[0031] Figure 6 illustrates another exemplary configuration of the peelable barrier film illustrated in Figure 2A-2C;

[0032] Figure 7 illustrates an exemplar}' configuration of the permeable layer illustrated in Figure 2A-2C;

[0033] Figure 8 illustrates an exemplary cross-section of the permeable layer illustrated in Figure 7; and

[0034] Figure 9 illustrates an exemplary configuration of the barrier layer illustrated in

Figure 2A-2C,

DETAILED DESCRIPTION

[0035] Figure 1 illustrates an exemplary product package 10 according to some embodiments of the disclosure. The exemplary product package 10 may be configured to store a product 11. Product 11 may be a fragranced stick. The fragranced stick may include a carrier material configured to provide a controlled release of a fragrant substance. The fragrant substance may be a volatile substance. Product package 10 may be configured to limit chemical interactions between components of the product package 10 with the volatile substance of the product 11. Accordingly, product package 10 may be configured to limit adverse chemical reactions between a product (e.g., product 11) and product package 10 and may thereby provide for long term storage of the product.

[0036] The product package 10 may include a front layer 12 coupled with a back layer

14. The front layer 12 and the back layer 14 may cooperate to define a receptacle 16 for receiving and storing the product 11. [0037] The front layer 12 may form an air tight seal around the product 11 with back layer 14. In some embodiments, the front layer 12 may be heat sealed or melted together with back layer 4 to provide the air tight seal around the product 11. This may be advantageous when the packaged product (e.g., product 1 1) includes a volatile substance as the volatile substance may interact chemically with many types of packaging adhesives. In some situations, the product 11 may not include a volatile substance. In such cases, the front layer 12 may be adhered (e.g., chemically using adhesives) to the back layer 14 to provide the air tight seal around the product 11.

[0038] In some embodiments, the front layer 12 and the back layer 14 may comprise two or more layers coupled with one another. For example, Figure 2A shows exemplary details of the front layer 12 and the back layer 14. As can be seen in Figure 2 A, back layer 14 may include a peelable barrier layer 26 coupled with a back side 27 of permeable layer 28. The peelable barrier layer 26 may be configured to be gas impermeable. Exemplary configurations of peelable barrier layer 26 are described in further detail below. The permeable layer 28 may be configured to be gas permeable. As mentioned above, products including volatile substances may chemically interact with adhesives. Accordingly, in package embodiments where the product includes volatiles substances, the peelable barrier layer 26 may be removably heat sealed or melted with the back side 27 of permeable layer 28 along at least a portion of the peelable barrier layer 26. Thus, when the peelable barrier layer 26 is coupled with the back side 27 of permeable layer 28 to form the back layer 14, the back layer 14 is gas impermeable. When the product 11 does not include volatile materials, adhesives may be used to couple the peelable barrier layer 26 with the back side 27 of permeable layer 28.

[0039] Front layer 12 may be a barrier layer 30. Barrier layer 30 may also include multiple component layers that provide a prolonged gas impermeability as will be described in further detail below. Barrier layer 30, permeable layer 28, and peelable barrier layer 26 form the receptacle 16 for receiving and storing the product 1 1. In some embodiments barrier layer 30 and permeable layer 28 are heat sealed together and are not configured to be peelable from one another by a consumer. Peelable barrier layer 26 and barrier layer 30 may form a gas impermeable enclosure to prevent gas exchange between the receptacle 16 and an outside atmosphere. This may be advantageous with a product 11 that includes a volatile substance to limit the ability of the volatile substance from prematurely escaping from the package 10 and depleting the product 1 prior to consumer use.

|0040] The peelable barrier layer 26 may be configured to be peeled from the permeable layer 28. When the peelable barrier layer 26 is peeled away from the permeable layer 28, the back layer 14 of product package 10 becomes gas permeable. Accordingly, a consumer may elect when to allow the product 11 to diffuse the volatile substance (e.g., a fragrance) into the surrounding air by peeling away the peelable barrier layer 26.

[0041] While Figure 2A illustrates back layer 14 as generally planar and front layer 12 as curved, forming a pocket or otherwise forming a majority of the receptacle 16, it should be understood that other configurations are possible where front layer 12 and back layer 14 are each curved, forming the pocket, and equally form receptacle 16. In certain embodiments, front layer 12 may be generally planar and back layer 14 may be curved, forming the pocket, or otherwise forming a majority of the receptacle 16, as illustrated in Figure 2B to provide package 0b. Accordingly, when peelable barrier layer 26 is peeled from package 10b, a larger area of permeable layer 28 may be exposed compared to the area of permeable layer 28 exposed when peelable barrier layer 26 is peeled from package 10 shown in Figure 2 A. This may allow for increased gas exchange between the interior of package 10b shown in Figure 2B and the surrounding atmosphere relative to package 10 shown in Figure 2A.

[0042] In still further embodiments, back layer 14 may be configured to form an apex 13 of receptacle 16, as illustrated in Figure 2C to provide package 1 Oc. The increased height or distance of back layer 14 from front layer 12 at the apex 13 of back layer 14 may increase airflow through receptacle 16 when the peelable barrier layer 30 is peeled from package 10c. A hanging mechanism may also be provided at the apex 13 of the back layer 14. In certain embodiments, package 10c may be configured to house a plurality of products 11. In still further embodiments, the package 10c may also house a composition configured to undergo an exothermic chemical reaction when exposed to the outside atmosphere. For example, the composition configured to undergo an exothermic chemical reaction when exposed to the outside air may be a mixture of one or more of iron, water, cellulose, vermiculite, activated carbon and salt. When the iron in the warmer is exposed to oxygen in the air, it oxidizes. In the process of doing so, heat is created. The salt may act as a catalyst and the carbon may help disperse the heat. The vermiculite may act as an insulator, keeping the heat from dissipating too rapidly, while the polypropylene may help the air to mix with the ingredients while holding in moisture. The chemical reaction may occurs slowly enough to allow the source to last for hours (1-4 hours). In some embodiments, where product 1 1 comprises a volatile composition reservoir (e.g., a fragrance carrier or the like), the exothermic reaction of the composition may facilitate or otherwise increase a rate of volatile composition (e.g., fragrance) release from the reservoir. U.S. provisional patent application 62/279,374 filed on January 15, 2016 and entitled

"Modulated Release of Volatile Compositions with Application of Low Energy," the contents of which are incorporated herein by reference, describes various sources of low energy (e.g., electric heater, solar, chemical, etc.) that may be used for modulating the release of a volatile composition from an associated reservoir. Accordingly, embodiments of the present disclosure may also include product packages used in combination with the sources of low energy described in U.S. provisional patent application 62/279,374.

[0043] In some embodiments, the front layer 12 may further comprise a peelable barrier layer 15 and a layer 17. The layer 17 may include the composition that is configured to undergo an exothermic chemical reaction when exposed to air. Layer 7 may be disposed between peelable barrier layer 5 and the barrier layer 30. With such a package configuration 10c, the peelable barrier layer 15 may be peeled away to expose the layer 17 to air. When layer 17 comprises the composition, this action initiates the exothermic chemical reaction. Thereafter, heat generated by the reaction may be conducted through barrier layer 30 and may heat product 1 1. Heating of product 1 1 may increase a rate of volatile composition release from product 11 in certain embodiments.

[0044] While package 10c is described as being configured to enclose a plurality of products 1 1 and/or a composition configured to undergo an exothermic chemical reaction when exposed to air, it should be understood that any package embodiments described herein may also enclose a plurality of products and/or a composition configured to undergo an exothermic chemical reaction when exposed to air.

[0045] In additional embodiments, layer 17 may additionally or alternatively comprise an adhesive. When layer 17 comprises an adhesive material, the peelable barrier layer 1 5 may be peeled to expose the adhesive material and the package 10c may then be adhered to a surface (e.g., wail or the like) via the exposed layer of adhesive. While the configuration of front layer 12 including peelable barrier layer 15 and layer 17 comprising an adhesive is described primarily with respect to package 0c, it should be understood that any package embodiments described herein may also benefit from such a configuration of front layer 12 (e.g., package 10, package 10b, etc).

[0046] In some embodiments, to facilitate peeling of the peeiable barrier layer 26, a portion 32 of the peeiable barrier layer 26 may be left uncoupled with the permeable layer 28, as can be seen in Figure 3. At the uncoupled portion 32 of the peeiable barrier layer 26, a flap is provided to a user to facilitate the gripping and peeling of the remainder of the peeiable barrier layer 26 from the permeable layer 28. Additionally or alternatively, the product package 10 may include a perforation or cut 20 that extends through the front layer 12 and/or the back layer 14 from the front side 22 of product package 10 to the back side 24 of product package 10. In the exemplary embodiment, the perforation or cut 20 may have a U-shape or C-shape. Additionally, the perforation or cut 20 may facilitate hanging the product package 10 by allowing a user to feed a hook, for example, through the perforation or cut 20 to hang the product package 10 using the hook. Alternative embodiments of product package 10 may include a through-hole where a portion of the front layer 12 and the back layer 1 are cut out.

[0047] Figure 4 illustrates the back side 24 of the exemplary product package 10 illustrated in Figure 1 with the exemplar}' impermeable layer 26 removed. Once the peeiable barrier layer 26 is removed, only the permeable layer 28 and the barrier layer 30 enclose the product 11. Gas exchange between the interior of the package 10 and the surrounding atmosphere may then occur.

[0048] Figure 5 illustrates an exemplary configuration 36 of the peeiable barrier film 26 illustrated in Figure 2A-2C. The exemplary configuration 36 includes an ethylene vinyl alcohol (EVOH) layer 38. The EVOH layer 38 may provide the gas impermeable barrier for peeiable barrier film 26. The EVOH layer 38 may be coupled with a first sealant layer 40 on a first side of the EVOH layer 38 and a second sealant layer 42 on a second side of the EVOH layer 38. The first sealant layer 40 may be configured to couple with the permeable layer 28. The second sealant layer 42 may be configured to couple an outer portion 44 of barrier film 26 which will be described in further detail below.

[0049] The first and/or second sealant layers 40, 42 may be a low density polyethylene layer (LDPE) in some embodiments. In some embodiments, first and/or second sealant layers 40, 42 may be a polypropylene (PP) layer. Optionally, the first and/or second sealant layers 40, 42 may be a LLDPE. A first tie layer 46 may be provided between the EVOH layer 38 and the first LDPE layer 40 to facilitate coupling between the EVOH layer 38 and the first LDPE layer 40. Additionally, a second tie layer 48 may be provided between the EVOH layer 38 and the second LDPE layer 42 to facilitate coupling between the EVOH layer 38 and the second LDPE layer 42. The tie layers 46, 48 and/or the sealant layers 40, 42 sandwiching the EVOH layer 38 may protect the EVOH layer 38 from exposure to moisture. Moisture contact with the EVOH layer 38 may reduce the ability of the EVOH layer 38 to prevent gas exchange across the EVOH layer 38.

[0050] The outer portion 44 may include a foil layer 50. An ethyl acetoacetate (EAA) layer 52 may be sandwiched between the foil layer 50 and the second sealant layer 42. In some embodiments, the EAA layer 52 may provide bonding to the foil layer 50. In some situations, an EAA layer 52 may be sensitive to our volatile substances such as fragrances and may become de- bonded from the foil 50 after prolonged exposure to the volatile substance. In some

embodiments, the EVOH laminate may protect the EAA layer 52 from undesired chemical reaction with the volatile substances. The outer portion 44 may further include a paper layer 54. The paper layer 54 may be a white bleached craft paper, unbleached craft paper, etc. In some embodiments, the foil 50 and/ or the paper 54 may be a cellophane, PET, LDPE, PE, or any other film material. A sealant layer 56 may be disposed between the paper layer 54 and the foil layer 50 to couple the paper layer 54 with the foil layer 50. The sealant layer 56 may be an LDPE layer or PP layer. In some embodiments, LLDPE, EAA or adhesives may be used as an alternative to a LDPE or PP layer for sealant layer 56.

[0051] According to some aspects, a paper layer 54 and foil layer 50 may be used in "pop through" packaging embodiments. In such embodiments, the user has the option of "popping" the product through both the permeable layer and EVOH/f oil/paper layer and removing it from the package entirely or may elect to use the product in the packaging with the permeable layer acting as a barrier against direct contact between the product and a supporting surface while still allowing for gas permeability.

[0052] The configuration 36 of peelable barrier layer 26 may provide a gas impermeable layer (EVOH layer 38) to prevent or otherwise limit volatile substances from escaping from the receptacle 16. Additionally, the gas impermeable layer may also prevent or otherwise limit interactions between the volatile substances and layers of the peelable barrier layer 26 that are on an opposite side of the gas impermeable layer (e.g., such as the EAA layer 52). As discussed above, moisture may reduce the ability of an EVOH layer 38 to prevent or limit gas permeation through the layer. Accordingly, configuration 36 includes moisture barriers (e.g., tie layers 46, 48) to protect the EVOH layer 38 and to prolong the functionality of the EVOH layer 38.

Further, the use of sealant layer 40 to couple with the permeable layer 28 may be desirable when the product 11 includes a volatile substance. Many volatile substances interact with adhesives which could lead to package discoloration, breaches in the air tight seal, and/or the emission of off-odors. By heat sealing the sealant layer 40 with the permeable layer 28, the two layers may- melt together to form the seal. Additionally, the sealant layer 40 may also be configured to be peeiable from the permeable layer 28 as discussed above.

[0053] The foil layer may also provide a gas impermeable layer. In other embodiments, other barriers besides EVOH may be used. For example, the gas impermeable layer may be a PVDC. While PVDC may discolor with prolonged contact with a fragrance, it may nevertheless be used in such embodiments or may be used in embodiments were volatile substances are not being packaged. As set forth above, the EVOH may help prevent the EAA from debonding from the foil layer. Sealant layer 40 can be made peel able with the use of a peeiable LDPE.

[0054] Figure 6 illustrates another exemplary configuration 58 of the peeiable barrier film 26 illustrated in Figure 2A-2C. The exemplary configuration 58 is similar to that of configuration 36, except that the outer portion 44 may be replaced with a polyester layer or cellophane layer 60. Other potential alternatives could be any dyed, textured, colored, or standard lamination film.

[0055] Configuration 58 may offer many of the benefits described above. In an alternative to an outer portion 44 having a foil layer 50 and paper layer 54, outer portion 44 may be configured with a poly ester layer or cellophane layer 60 which may provide additional strength to the outer portion 44. The added strength may reduce the chances of tearing the peeiable barrier layer 26 when peeling it from the permeable layer 28.

[0056] Figure 7 illustrates an exemplary configuration of the permeable layer 28 illustrated in Figure 2A-2C. The permeable layer 28 may a nonwoven material. The nonwoven material may be a nonwoven polyester. The nonwoven material may include a first plurality of parallel strands 61 at a first level and a second plurality of parallel strands 62 at a second level that extend in a direction transverse to the first plurality of parallel strands 61 and overlap with the first plurality of parallel strands 61. In the illustrated embodiment, the first plurality of parallel strands 61 are perpendicular relative to the second plurality of parallel strands 62. Figure 8 illustrates an exemplary cross-section 63 of the permeable layer 28 illustrated in Figure 7. In some embodiments, the first and/or second plurality of parallel strands 61 , 62 may have strands with diameters of about 10 ixm. Nonwovens can come is a variety of thickness/density/and laydown styles. Different nonwovens may be chosen for the properties needed for the specific application. Some may want as little impedance to release as possible, thereby resulting in a quicker or more rapid release. Some embodiments on the other hand may want a thicker material to provide a slower release of the substance. Accordingly, in some embodiments, a plurality of packages 10 may be provided where the density of the non- woven material is different. For example, a first package 10 may include a permeable layer having a first density of strands and a second package 10 may include a permeable layer having a second density of strands that is less than the first density of strands. The second package 10 may be rated for a quicker or larger release of the volatile substance whereas the first package 10 may be rated for a slower prolonged release or smaller release relative to the second package 10.

[0057] While the permeable layer 28 may allow gas exchange between the interior of the package 10 and the open atmosphere, permeable layer 28 may still act as a physical partition that prevents the product from physically contacting an adjacent surface. For example, it may be desirable to prevent the volatile substance carrier from making direct physical contact with other surfaces (e.g., table tops, drawers, floors, etc.) or objects (e.g., clothes, carpet, etc.). When in direct physical contact, the volatile substances may interact with the surface or objects and may tarnish, discolor, or otherwise ruin the surfaces or objects.

[0058] While permeable layer 28 is illustrated and described as a nonwoven material, it should be understood that other permeable layers 28 may be used depending on the product stored. For example, when the product does not include a volatile substance, the permeable layer may be a perforated (e.g., microperf) material (e.g., plastic, paper, etc.). Additionally, various woven or mesh materials may be used, such as cotton fabric, 65%/35% poly/cotton blend fabric, polyester (mesh and fabric), nylon (mesh and fabric), polyester nonwoven (higher density). In some circumstances, fabrics may be too tight and may limit adequate fragrance release, but such materials may be beneficial in other applications (e.g., oxygen activated products, hydrogel products, drug delivery products, moisturizing products, or the like). Accordingly, the tightness of the material and/or permeability may be selected based upon the particular application of the package 10.

[0059] Figure 9 illustrates an exemplar}' configuration 64 of the barrier layer 30 illustrated in Figure 2A-2C. The exemplary configuration 64 may be used to provide a gas impermeable barrier 30. The configuration 64 includes an EVOH layer 66. As mentioned above, the EVOH layer 66 may provide the gas impermeable barrier of barrier 30.

[0060] A first sealant layer 68 may be coupled with the EVOH layer 66. The first sealant layer 68 may be configured to couple with the permeable layer 28. A first tie layer 70 may be disposed between the first sealant layer 68 and the EVOH layer 66 to couple the first sealant layer 68 with the EVOH layer 66. The first sealant layer 68 may be an LDPE layer or a PP layer.

[0061] A second sealant layer 72 may be coupled with the EVOH layer 66 on a side opposite the first tie layer 70. The second sealant layer 72 may be configured to couple with a surface layer 74. The surface layer 74 may be a PET layer. A second tie layer 76 may be disposed between the second sealant layer 72 and the EVOH layer 66 to couple the second sealant layer 72 with the EVOH layer 66. The second sealant layer 72 may be an LDPE layer or a PP layer.

[0062] The first tie layer 70 may be coupled with a first side of EVOH layer 66 and the second tie layer 76 may be coupled with a second side of EVOH layer 66. The tie layers 70, 76 may protect the EVOH layer 66 from moisture contact which may dimmish the abili ty of the EVOH layer 66 to prevent gas permeation through the barrier 30.

[0063] The barrier layer 30, the permeable layer 28, and the peelabie barrier layer 26 may be heat sealed together to form the package 10 and to enclose the product 11. The components of the barrier layer 30 and the peelabie barrier layer 26 may prevent gas permeation through the package 10. When a user is ready to unseal the product 11 to allow the product 11 to interact with the outside atmosphere, the user may readily peel the peelabie barrier layer 26 from the permeable layer 28 to expose the underlying permeable layer 28. Thereafter, the product 11 may- release the volatile substances into the surrounding area through the permeable layer 28.

[0064] While the permeable layer 28, peelabie barrier layer 26, and the barrier layer 30 are generally described in detail for packaging a fragranced carrier, it should be understood that other embodiments may utilize the permeable layer 28, peelabie barrier layer 26, and the barrier layer 30 to package other products. For example, when the product 11 does not include a volatile substance, other configurations of the permeable layer 28, peelable barrier layer 26, and the barrier layer 30 are available. In some embodiments (such as a moisture patch, drug delivery patch, or the like) the peelable barrier layer 26 may be peeled away from the permeable layer 28 to uncover an adhesive layer. The adhesive layer may allow a consumer or user to apply the package directly onto a surface, such as a patient's skin or the like. Additionally, packaged products may be oxygen activated. Accordingly, the peelable barrier layer 26 may be configured to prevent oxygen entry into the package. In such embodiments, the package may be sealed with an inert gas atmosphere (e.g., Nitrogen) or under vacuum. In some embodiments, the packaging may be used with a pest repellent product or the like or for use in OTC drug release (e.g., menthol or the like).

[0065] In some embodiments, a method of manufacturing may be provided. The method may include forming a cavity with a bottom barrier film, according to embodiments described herein. The product may be placed in the cavity and the gas permeable layer (e.g., nonwoven) may be placed on top to cover the opening of the cavity. The gas permeable layer may then be heat sealed to the barrier film, around the product. The third layer, according to embodiments described herein, may then be heat sealed to the gas permeable layer also around the product. In some embodiments, one end of the third layer may not be sealed as far as the first two layers so as to provide an area to grab and peel. The unit may then be diecut to the final shape.

Optionally, a hang hole is also diecut. As discussed above, the product may be a fragrance stick or the like.

[0066] The subject matter of embodiments of the present disclosure is described here with specificity, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.

[0067] Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combmations. Embodiments of the disclosure have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Additionally, it should be understood that the ranges and materials provided herein are exemplar and that the ultimate selection of sizes, materials, etc. may depend on the overall device design and application. Accordingly , the present disclosure is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.

Claims

CLAIMS What is claimed is:

1. A package comprising:

a barrier layer defining a receptacle for storing a product, the receptacle including an opening for receiving the product;

a permeable layer coupled with the barrier layer, a portion of the permeable layer configured to cover the opening of the barrier layer receptacle;

a peelable barrier film releasably coupled with the permeable layer, a portion of the peelable barrier film configured to cover the portion of the permeable layer covering the opening of the barrier layer receptacle, the peelable barrier film configured to be peelable from the permeable layer so as to expose the portion of the permeable layer covering the opening of the barrier layer receptacle,

2. The package of claim 1, wherein the package is gas impermeable when the peelable barrier film covers the portion of the permeable layer covering the opening of the barrier layer receptacle; and wherein the package is gas permeable when the peelable barrier film is peeled to expose the portion of the permeable layer covering the opening of the barrier layer receptacle.

3. The package of claim 1 , wherein the permeable layer comprises a non- woven fabric.

4. The package of claim 3, wherein the permeable layer comprises a polyester material.

5. The package of claim 4, wherein the permeable layer is 100% non-woven polyester.

6. The package of any of claims 1-5, wherein the peelable barrier film comprises an ethylene vinyl alcohol (EVOH) layer.

7. The package of claim 6, wherein the peelable barrier film comprises a peelable sealant layer configured to releasably couple the EVOH layer to the permeable layer.

8. The package of claim 7, wherein the peelable sealant layer comprises a low density polyethylene (LDPE).

9. The package of claim 7, wherein the peelable barrier film further comprises a tie layer configured to couple the peelable sealant layer with the EVOH layer.

10. The package of claim 6, wherein the peelable barrier film further comprises a foil, wherein the EVOH layer is disposed between the foil layer and the permeable layer.

1 1. The package of claim 10, wherein the peelable barrier film further comprises a tie lay er disposed between the EVOH layer and the foil layer.

12. The package of claim 1 1 , wherein the peelable barrier film further comprises a sealant layer disposed between the tie layer and the foil layer.

13. The package of claim 12, wherein the peelable barrier film further comprises an ethyl acetoacetate (EAA) layer disposed between the sealant layer and the foil layer.

14. The package of claim 0, wherein the peelable barrier film further comprises a paper layer, wherein the foil layer is disposed between the paper layer and the EVOH layer, and wherein a sealant layer couples the foil layer to the paper layer.

15. The package of claim 14, wherein the paper layer comprises a bleached or unbleached craft paper.

16. The package of claim 6, wherein the peelable barrier film further comprises a polyethylene terephthalate (PET) layer, wherein the EVOH layer is disposed between the PET layer and the permeable layer, and wherein the peelable barrier film further comprises a tie layer disposed between the EVOH layer and the PET layer, and wherein an LDPE layer couples the tie layer to the PET layer.

17. The package of any of claims 1-5, wherein the receptacle is vacuum sealed.

18. The package of any of claims 1-5, wherein the receptacle is sealed with an inert gas environment that is sealed in the receptacle by the peelable barrier film.

19. The package of claim 18, wherein the inert gas environment comprises a nitrogen gas environment.

20. The package of claim 8, further comprising the product, and wherein the product is oxygen activated.

21. The package of any of claims 1-5, further comprising the product, and wherein the product includes a fragrance and a fragrance carrier.

22. The package of any of claims 1-5, wherein the peelable barrier layer, the permeable layer, and the barrier layer are heat sealed with one another.

23. The package of claim 22, wherein the peelable barrier layer includes a sealant layer configured to couple the peelable barrier layer with the permeable layer, the sealant layer configured to melt, protrude through holes of the permeable layer, and form a seal with the permeable layer.

24. The package of claim 22, wherein the permeable layer is configured to melt during heat sealing.

25. A packaging material comprising:

a first sealant layer;

a second sealant layer;

an ethylene vinyl alcohol (EVOH) layer sandwiched between the first sealant layer and the second sealant layer;

a first tie layer disposed between the first sealant layer and the EVOH layer, the first tie layer configured to tie the first sealant layer with the EVOH layer; and

a second tie layer disposed between the second sealant layer and the EVOH layer, the second tie layer configured to tie the second sealant layer with the EVOH layer.

26. The packaging material of claim 25, wherein the first sealant layer, the second sealant layer, the first tie layer, and the second tie layer form a moisture barrier on both sides of the EVOH layer to extend EVOH barrier effectiveness against gas permeation.

27. The packaging material of claim 25, wherein the first sealant layer and the second sealant layer comprise low density polyethylene layers

28. The packaging material of claim 25, further comprising a polyethylene terephthalate (PET) layer coupled with the first sealant layer such that the first sealant layer is positioned between the PET layer and the EVOH layer.

29. The packaging material of claim 25, further comprising a foil layer coupled with a first side of an ethyl acetoacetate (EAA) layer, wherein a second side of the EAA layer is coupled with the first sealant layer; wherein the first side of the EAA layer is opposite the first side of the EAA layer.

30. The packaging material of claim 29, further comprising a paper layer coupled with the foil layer, wherein a third sealant layer is disposed between the paper layer and the foil layer.

31. The packaging material of any of claims 25-30, further comprising a permeable layer coupled with the second sealant layer.

32. The packaging material of claim 3 , wherein the permeable layer is heat sealed with the second sealant layer.

33. The packaging material of claim 32, wherein the permeable layer comprises a polymer material configured to melt during heat sealing so as to form an air tight seal with the second sealant layer.

34. The packaging material of claim 33, wherein the heat seal formed between the permeable layer and the second sealant layer is configured to allow the second sealant layer to be peeled from the permeable layer.

35. A package comprising:

a non-permeable layer coupled with the permeable layer of the packaging material of claim 34 to form a receptacle for holding a product, wherein the non-permeable layer couples with the packaging material with an air tight seal, and wherein the second sealant layer is configured to be peelable from the permeable layer of the packaging material to allow gas transfer into and out of the receptacle through the permeable layer.

36. The packaging material of claim 31, wherein the permeable layer comprises a nonwoven material.

37. The packaging material of claim 36, wherein the nonwoven material comprises a polyester material.

38. The packaging material of claim 37, wherein the polyester material includes a first plurality of parallel strands overlapping a second plurality of parallel strands, the first plurality of parallel strands being transverse to the second plurality of parallel strands.

39. The packaging material of claim 38, wherein the first plurality of parallel strands are melted to the second plurality of parallel strands.

40. A plurality of packages comprising:

a first package comprising:

a barrier layer defining a cavity for storing a product, the cavity including an opening for receiving the product;

a permeable layer coupled with the barrier layer, a portion of the permeable layer configured to cover the opening of the barrier layer cavity, the permeable layer comprising a plurality of strands at a first density;

a peelable barrier film releasably coupled with the permeable layer, a portion of the peelable barrier film configured to cover the portion of the permeable layer covering the opening of the barrier layer cavity, the peelable barrier film configured to be peelable from the permeable layer so as to expose the portion of the permeable layer covering the opening of the barrier layer cavity;

a second package comprising:

a permeable layer coupled with the barrier layer, a portion of the permeable layer configured to cover the opening of the barrier layer receptacle, the permeable layer comprising a plurality of strands at a second density;

a peelable barrier film releasably coupled with the permeable layer, a portion of the peelable barrier film configured to cover the portion of the permeable layer covering the opening of the barrier layer receptacle, the peelable barrier film configured to be peelable from the permeable layer so as to expose the portion of the permeable layer covering the opening of the barrier layer receptacle;

wherein the first density of strands is less than the second density of strands; and wherem the first package is rated for a faster delivery of a volatile substance relative to the second package.