SYSTEMS AND METHODS FOR MAKING A PAPER POUCH OR CONTAINER

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Application No. 63/634,862, filed on April 16, 2024, and entitled “Systems and Methods for Making a Paper Pouch or Container,” the entire contents of which is incorporated by reference herein in its entirety.

REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable

SEQUENTIAL LISTING

[0003] Not applicable

BACKGROUND OF THE DISCLOSURE

1. Field of the Invention

[0004] The present disclosure generally relates to systems and methods for making a pouch or container made partially or entirely of repulpable and/or recyclable paper, and more particularly to pouches and containers with sealing structures that are also or alternatively made of repulpable and/or recyclable paper.

2. Description of the Background of the Invention

[0005] Historically, re-closeable pouches and containers (collectively “bags”) that are used in food and household storage and packaging comprise one or more of a folded web of elastomeric material, a web formed of blown, cast, monolayer, or co-extruded films, or a silicone-based mixture that may be liquid injection molded, all of which generally have two side walls that are connected along the bottom and opposing sides. The bags typically include a re-closable fastener or closure system at a top of the bag, such as, for example, an adhesive, a wire tie, or zipper. While thermoplastic and elastomeric bags have a variety of benefits, including reduced cost and ease of manufacture, efficient packaging and transport, and desirable sealing capabilities for end use, such bags are not recyclable or repulpable, and given consumer trends related to recyclable and repulpable packaging, new and improved food packaging bags are desired that maintain the benefits associated with prior art bags.

[0006] It is therefore desirable to maintain or enhance the benefits of prior art bags through the use of materials that are configured to be recycled or repulped, i.e., by using one or more sustainable materials. It is further desirable to optimize sealing structures used with such repuplable and/or recyclable bags, pouches, or containers, including by having a simple sealing structure that is capable of providing an optimized seal for the intended use of each particular bag and that can be used in various rigorous applications.

[0007] Furthermore, the current state of the art in paper bags or products focuses on the repulpability of the product rather than the recyclability. Creating a recyclable paper bag or product would address the consumer desire for a more sustainable product.

SUMMARY OF THE DISCLOSURE

[0008] According to some embodiments of the present disclosure, a pouch made of plant-based cellulose materials includes a body defining a left side, a right side, a bottom side, and a mouth at an upper end thereof that provides access into a cavity of the pouch, and a sealing structure that is configured to allow access into the cavity of the pouch in an open configuration and to prevent access into the cavity of the pouch in a closed configuration. The body of the pouch consists of at least 90% plant-based cellulose material, and a remaining percentage of the pouch consists of a binder that includes a water-soluble polymer.

[0009] In some embodiments the plant-based cellulose material includes an organic material selected from the group consisting of wood pulp, paper fibers, cotton, linen, silk, wool, wheat straw, sugar cane waste, flax, bamboo, wood, linen rags, esparto, manilla, jute, palm fiber, mulberry, coconut husk, agave, reed grass, and hemp. In some embodiments, the binder consists of one or more of alkali-soluble polymers, thermoplastic polymers, hydrophilic copolymers, ionic polymers, alkali-soluble polyvinyl acetate copolymers, ethylene-maleic anhydride copolymers, polyacrylates, polyethers, polyvinyl alcohol, ethylene vinyl alcohol, polyvinyl pyrrolidone, styrene-maleic anhydride, water-soluble cellulosic ethers, hydroxyethylcellulose, methycellulose, sodium carboxymethylcellulose, or combinations thereof. In some embodiments, the plant-based cellulose material is blended with the water-soluble polymer. In some embodiments, the plant-based cellulose material is coated with the water-soluble polymer.

[0010] In some embodiments, the sealing structure consists of at least 90% plant-based cellulose material. In some embodiments, the sealing structure includes interlocking elements. The interlocking elements may include a male portion and a female portion. In some embodiments, the sealing structure includes a clasp, button, tape, drawstring, or over loop. The clasp may include one or more of string, paper, metal, plastic, or fluted paper board, or combinations thereof. The sealing structure may also include a sealing strip. The sealing strip may include one or more of an adhesive, a thermoplastic, a pressure sensitive sealing, or combinations thereof. In some embodiments, the body of the pouch is coated with wax, silicone, polyurethane, cellulose, polylactic acid, or combinations thereof.

[0011] Another aspect of the disclosure includes a method for making a body for a pouch. The method includes blending up to 10% of binder that includes a water-soluble polymer combined with at least 90% of one or more plant-based cellulose materials.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 is a schematic view of a recyclable and/or repulpable pouch with a first sealing structure shown in an open configuration, as disclosed herein;

[0013]FIG. 2 is a schematic view of the pouch of FIG. 1 with the first sealing structure shown in a closed configuration;

[0014]FIG. 3 is a side cross-sectional view of a second sealing structure including a male portion and a female portion shown in an open configuration;

[0015]FIG. 4 is a side cross-sectional view of a third sealing structure including a male portion and a female portion shown in an open configuration;

[0016]FIG. 5 is a side cross-sectional view of the third sealing structure shown in a closed configuration;

[0017]FIG. 6 is a side-cross-sectional view of a fourth sealing structure having interlocking portions on opposing sides thereof;

[0018]FIG. 7 is a perspective view of a fifth sealing structure that includes a clasp shown in a partially open configuration;

[0019]FIG. 8 is a side view of the fifth sealing structure shown in a partially closed configuration;

[0020]FIG. 9 is a front view (A) and side view (B) of the fifth sealing structure shown in a closed configuration;

[0021]FIG. 10 is a side cross-sectional view of a sixth sealing structure shown in an open configuration;

[0022]FIG. 11 is a side cross-sectional view of the sixth sealing structure shown in a closed configuration;

[0023]FIG. 12 is a side cross-sectional view of a seventh sealing structure shown in an open configuration;

[0024]FIG. 13 is a side cross-sectional view of the seventh sealing structure shown in a closed configuration;

[0025]FIG. 14 is a top view of an eighth sealing structure shown in an open configuration with phantom lines showing a closed configuration;

[0026]FIG. 15 is a front view of a ninth sealing structure shown in an open configuration;

[0027]FIG. 16 is a cross-sectional, schematic view of the ninth sealing structure shown in a partially open configuration;

[0028]FIG. 17 is a schematic, cross-sectional view of a tenth sealing structure shown in an open configuration;

[0029]FIG. 18 is a schematic, cross-sectional view of the tenth sealing structure shown in a closed configuration;

[0030]FIG. 19 is a front view of an eleventh sealing structure shown in an open configuration;

[0031]FIG. 20 is a perspective view of the eleventh sealing structure including a clasp shown in a partially closed configuration;

[0032]FIG. 21 is a front view of the eleventh sealing structure including the clasp shown in a closed configuration;

[0033]FIG. 22 is a front schematic view of a twelfth sealing structure having a breathable seal;

[0034]FIG. 23 is a front view of a thirteenth sealing structure having various score lines or folds;

[0035]FIG. 24 is a front schematic view of a fourteenth sealing structure having various perforations therealong;

[0036]FIG. 25 is a front view of a fifteenth sealing structure having opposing ears that are configured to seal the pouch;

[0037]FIG. 26 is a side view of the fifteenth sealing structure;

[0038]FIG. 27 is a top view of a pouch that is configured to collapse to surround contents therein, shown in an open configuration;

[0039]FIG. 28 is a top view of the pouch of FIG. 27, shown in a closed configuration; and

[0040]FIG. 29 is a front schematic view of a pouch that may be used with any of the sealing structures noted above, which includes a coating that provides increased breathability.

[0041] Other aspects and advantages of the present disclosure will become apparent upon consideration of the following detailed description, wherein similar structures have similar reference numerals.

DETAILED DESCRIPTION

[0042] The present disclosure is directed to containers or pouches (collectively “bags”), and the associated sealing structures for the pouches that are made either entirely or partially from repulpable and/or recyclable materials, such as paper. More specifically, the present disclosure is directed to a repulpable and/or recyclable, re-closeable pouch, a repulpable body for a pouch, a repulpable sealing structure for a re-closeable pouch, and a method of making a repulpable and/or recyclable pouch and sealing structure therefor. While the systems and methods disclosed herein may be embodied in many different forms, several specific embodiments are discussed herein with the understanding that the embodiments described in the present disclosure are to be considered only exemplifications of the principles described herein, and the disclosure is not intended to be limited to the embodiments illustrated.

[0043] Throughout the disclosure, the terms “about” and “approximate” mean plus or minus 5% of the number or value that each term precedes. As used herein, the phrase “leak resistant seal” refers to a seal that resists leakage of liquids and solids from the container during storage and transport without the aid of an external structure to maintain the seal. Finally, the term “closure element” is defined herein to mean one part of a closure system that is configured to close a pouch. The closure system may comprise a sealing structure used to seal the pouch, wherein the sealing structure comprises one or more closure elements. For example, on a zipper sealing structure, a closure element is one profile or the other of the zipper, e.g., a rib profile or a groove profile.

[0044] The pouches and sealing structures disclosed herein may be entirely or partially repulpable and/or recyclable. The pouches may take varying forms, and representative examples are provided in FIGS. 1-29. As used herein, the term “repulpable” refers to a cellulose material whose fibers can be broken down and returned to the pulp state and suspended in a liquid such as water, i.e., material that can undergo the operation of re-wetting and fiberizing for subsequent sheet formation. The dissociated fibers can then be re-used (e.g., re-combined) to make a new cellulose material. Examples of repulpable materials include various papers, cardboards, and other plant-based cellulose materials. The sealing structures disclosed herein enable production of fully repulpable and/or recyclable flexible packages that can be opened and re-closed by a consumer. In some embodiments, the sealing structure may include a repuplable pressure sensitive adhesive.

[0045] As further used herein, “recyclable” material means “used material that is capable of being processed into new paper or paperboard.” A paper product that is recyclable must be repulpable, but a paper product that is repulpable is not always recyclable. Repulpability may be tested through a method of blending paper material with water into a pulp, filtering the pulp, and determining how much fiber can be recovered. Recyclability may be tested by pulping the paper product and converting it into a new sheet that is then put through a series of quality tests to validate both properties and appearance. In some embodiments, the lignin is removed from the repulpable, plant-based material (or “pulp”) entirely.

[0046] The advantages of the repulpable and/or recyclable pouches disclosed herein are: 1) improved environmental performance; 2) waste is eliminated since the leftover pouches do not have to be disposed of and less material is wasted in the mixing process, and 3) material utilization is improved since all of the material in the pouch ends up in the mixer and none otherwise enters into the environment. The paper comprising the pouches may include kraft paper, twisted paper, greaseproof paper, recycled paper, coated paper, cotton, offset paper, paperboard, duplex paper, or combinations thereof. In some embodiments, repulpable tape may be included, which may comprise water soluble modified acrylic adhesive, coated on a repulpable paper carrier, such that the repulpable tape’s backing and glue can be dissolved in water. In some embodiments, recyclable tape may be utilized.

[0047] The body and, in some embodiments, the sealing structure of the pouch may include at least one plant-based cellulose material. In some embodiments, more than 10%, or more than 20%, or more than 30%, or more than 40%, or more than 60%, or more than 70%, or more than 80%, or more than 85%, or more than 90%, or more than 95% of the body may include at least one plant-based cellulose material. In further embodiments, the sealing structure of the pouch also includes at least one plant-based cellulose material. In some embodiments, more than 10%, or more than 20%, or more than 30%, or more than 40%, or more than 60%, or more than 70%, or more than 80%, or more than 85%, or more than 90%, or more than 95% of the sealing structure may include at least one plant-based cellulose material.

[0048] As noted above, the pouches, bodies, and sealing structures of the present disclosure are made of paper or paper-like materials, and in some embodiments are made using a pulp/binder mixture. In some embodiments, the sealing structure is a zipper that includes a male profile and a female profile. The details of the sealing structure and body of the pouch may be modified based on a user’s intended use and are not limited to the embodiments disclosed herein. While the ratio of the pulp/binder mixture may be modified based on intended use, in some embodiments more than 50% of the mixture comprises pulp or a similar substance, e.g., potato fibers, vegetable fibers, or other organic fibrous material that can be mixed with a binder. In some embodiments, more than 20%, or more than 30%, or more than 40%, or more than 60%, or more than 70%, or more than 80%, or more than 90%, or more than 95% of the body of the pouch may include the pulp or similar substance. In further embodiments, the sealing structure of the pouch also comprises the pulp. In some embodiments, more than 20%, or more than 30%, or more than 40%, or more than 60%, or more than 70%, or more than 80%, or more than 90%, or more than 95% of the sealing structure of the pouch may include the pulp or similar substance.

[0049] The pulp may comprise one or more different types of organic materials that may be made from cellulose, tannin, cutin, and/or lignin. The organic materials may come from various plants, including cotton, wheat straw, sugar cane waste, flax, bamboo, wood, linen rags, esparto, manilla, jute, palm fiber, mulberry, coconut husk, agave, reed grass, and/or hemp. In some embodiments, the end pulp/binder mixture is configured to be heat resistant up to 451°F (232°C), freezer capable, and oven and microwave resistant. Preferably, the pulp/binder mixture in its end form is water and oil resistant. In some embodiments, the binder is entirely made from or includes RTU silicone. In some embodiments, the zipper profile is separately combined with and/or joined to a paper pouch to make a fully recyclable paper pouch product. In some embodiments, the pouch and/or the sealing structure may be repulpable, recyclable, or repulpable and recyclable. Further, one or more adhesives may be used along the pouch and/or the sealing profile, which may also be repulpable, recyclable, or repulpable and recyclable. In some embodiments, the pouch may be customized by printing one or more indicia on one or both of the first and second opposing walls at predetermined intervals. Indicia may include, e.g., logos, writable surfaces, volumetric fill lines or other indicators, etc. Indicia may be applied at various stages during the manufacturing process. In still another aspect, indicia may not be applied to the pouch. In yet another aspect, customizing may include adding sliders, stickers, embossing, scoring, or other decorative and/or functional attributes to the pouch.

[0050] The present disclosure provides a sustainable solution for the sealing structure and body of the pouches or containers used for food packaging by utilizing cellulose as a biodegradable, recyclable, and versatile material. By replacing traditional synthetic adhesives or plastic coatings, sealing structures and bodies of the pouch or containers comprising cellulose improve the recyclability, support environmentally friendly practices, and can help reduce the carbon footprint of food packaging. With continued innovation and development in cellulose processing, this technology could play a significant role in the future of sustainable food packaging.

[0051] Plant-based cellulose pouches are biodegradable and can break down naturally in the environment. They are also compostable, making them an eco-friendly option compared to plastic pouches, which persist in landfills for centuries. Cellulose is derived from plants, making it a renewable resource. This contrasts with fossil fuel-based plastic, which is non-renewable. The treatment of paper or plant-based cellulose material with coatings or dyes, can often be recycled in paper recycling streams which helps reduce the overall environmental impact. Cellulose fibers, especially when processed well (such as in kraft paper or other strong fibers), can be durable and lightweight. They can hold moderate amounts of weight depending on their thickness and treatment. Cellulose materials can be made into a variety of textures, designs, and strengths. Another positive about plant-based cellulose materials for food packaging is that cellulose pouches can be made food-safe, making them suitable for food storage or packaging needs. These plant-based cellulose materials can be made of materials including kraft paper, known for its strength and recyclability, cellulose films, bio-based films made from cellulose and that are biodegradable, fibers (like hemp or cotton), and recycled paper. While cellulose- based materials can be prone to tearing, reinforcement with strong fibers and binders can increase the strength of the pouch and provide more durability without sacrificing recyclability.

[0052] In some embodiments, the pouch may include a fold top closure, a slider sealer, a hook-and-loop-type sealer, or an adhesive to at least partially seal a mouth of the pouch. In some embodiments, a tab disposed adjacent the mouth may assist in opening the pouch. Additionally, as would be appreciated by those of ordinary skill in the pertinent art, the subject technology is applicable to any type of bag, pouch, package, and various other storage containers, e.g., snack, sandwich, quart, and gallon size bags. The subject technology is also adaptable to pouches having a double zipper, multiple zippers, or other type of closure mechanisms.

[0053] In some embodiments, the ratio of fiber to another material may be 85% fiber compared with 15% of a different material, which achieves a repulpable material. In some embodiments, more than 90% fiber may be utilized, which renders the pouch recyclable. A repulpable formulation for the pouches disclosed herein may include a blend of a water-soluble polymer and plant-based cellulose materials. In some embodiments, the water-soluble polymer material acts as a binder of the plant-based cellulosic material to maintain structural integrity of the zipper closure during use, and further enables the repulpability and recyclability of the packaging structure. As noted above, a formulation range of 15% or less of the water-soluble polymer enables ease of repulpability and maintains recyclability with current recycling streams, which require 85% recovered repulpability. However, use of more than 90% plant-based cellulose material increases recyclability and composability of the product, due to the higher ratio of fiber content to polymer.

[0054] The closure elements disclosed herein can include any suitable water-soluble polymer that dissolves in water or aqueous liquids. When present, the closure element can be formed using the same water-soluble polymer as the remainder of the pouch or can be formed using a different water-soluble polymer. Suitable repulpable materials include plant-based cellulose materials, including wood pulp, paper fibers, cotton, linen, silk, wool, combinations thereof, and/or any of the plant-based materials listed above. While other (e.g., non-cellulose) materials may qualify as repulpable, the plant-based cellulose materials, combined with suitable amounts of water-soluble polymer, contribute mechanical and structural properties that are helpful in some embodiments to maintain the structural integrity of the closure element.

[0055] To that end, the materials used to form the pouches, bodies, and sealing structures may fall into the same two categories. The first category includes water-soluble flexible polymers that dissolve in water, and possibly other liquids, releasing the contents of the package. Historically, these types of packages have been used for packaging dry, granulated soaps such as laundry and dishwasher soaps, chemical additives, industrial cleaners, paint mixing, and in other uses where pre-measured quantities of a substance are advantageous. The second category includes repulpable and recyclable materials, such as plant-based cellulose materials that are intended to replace disposable non-repulpable/recyclable plastic packages. The pouches disclosed herein can include between about 5% and about 95% by weight of a water-soluble polymer and between about 5% and about 95% by weight of a repulpable and/or recyclable material. In some embodiments, the pouches, bodies, and/or sealing structures can include between about 10% and about 90% by weight of a water-soluble polymer and between about 10% and about 90% by weight of a repulpable and/or recyclable material, or between about 15% and about 85% by weight of a water-soluble polymer and between about 15% and about 85% by weight of a repulpable and/or recyclable material. In embodiments that include a repulpable zipper, the zipper is movable between a first open position that disengages the at least one interlocking element adapted for connection to the front wall from the at least one interlocking element adapted for connection to the second wall and a second closed position that engages the at least one interlocking element adapted for connection to the front wall to the at least one interlocking element adapted for connection to the second wall.

[0056] The water-soluble polymers may include any polymer combinations that are useful, including alkali-soluble polymers, thermoplastic polymers, hydrophilic copolymers, ionic polymers, alkali-soluble polyvinyl acetate copolymers, ethylene-maleic anhydride copolymers, polyacrylates, polyethers, polyvinyl alcohol, ethylene vinyl alcohol, polyvinyl pyrrolidone, styrene-maleic anhydride, water-soluble cellulosic ethers, hydroxyethylcellulose, methycellulose, sodium carboxymethylcellulose, and combinations thereof. In some embodiments, the water-soluble polymer used to form the body of the pouch (i.e., the front wall and the back wall thereof) can be the same water-soluble polymer or polymer combination used to form the one or more sealing structures or can be a different water-soluble polymer or polymer combination. In some embodiments, the plant-based cellulose material is blended with the water-soluble polymer. In some embodiments, the plant-based cellulose material is coated with the water-soluble polymer.

[0057] Alkali-soluble polymers refer to polymers that become soluble in alkaline solutions, often due to the presence of functional groups that ionize under basic conditions. These polymers typically contain ionic or polar groups such as carboxylate (–COO⁻) groups that facilitate solubility in alkaline environments.

[0058] Thermoplastic polymers refer to polymers that become soft and moldable when heated and return to a solid state upon cooling. These polymers can be processed into films, fibers, or molded products and are water-soluble under certain conditions.

[0059] Hydrophilic copolymers refer to copolymers that contain hydrophilic (water-attracting) monomer units, which enable them to dissolve or swell in water. These copolymers often form gels or semi-solid materials when exposed to water.

[0060] Ionic polymers refer to polymers that contain ionic groups (such as sulfonate, carboxylate, or ammonium) within their structure, making them soluble in water and allowing them to interact with other charged species in aqueous environments.

[0061] Alkali-soluble polyvinyl acetate copolymers refer to copolymers of polyvinyl acetate (PVAc) that are modified to become soluble in alkaline solutions. These modified polyvinyl acetate copolymers have increased solubility in alkaline solutions. They may be used in adhesives, coatings, and paints. Since alkali-soluble PVAc copolymers can be modified to dissolve under specific conditions, they might be used to create packaging that is more easily processed or removed after use. For example, an alkali-soluble packaging film could be designed to dissolve in a specific solution, reducing waste and making disposal more sustainable. Alkali-soluble polyvinyl acetate copolymers can also be used in food packaging materials to create barriers that prevent the loss of moisture, oxygen, or other contaminants.

[0062] Ethylene-maleic anhydride copolymers refer to a group of copolymers that combine ethylene and maleic anhydride. These polymers can be used in coatings, adhesives, and as impact modifiers in plastics. These polymers can also be grafted ethylene-maleic anhydride copolymers which can be used for improving adhesion of the polymer coating to other substrates.

[0063] Polyacrylates refer to a group of polymers derived from acrylic acid or acrylate esters. These monomers often include compounds like methyl acrylate, ethyl acrylate, butyl acrylate, and other acrylate esters. Polyacrylates are commonly used in applications requiring flexibility, adhesion, and water resistance.

[0064] Polyethers refer to polymers characterized by repeating ether linkages (–O–) in their main chain. These polymers can be formed through the polymerization of monomers containing ether groups, such as ethylene oxide or tetrahydrofuran (THF). These polymers can also be blended with other polymers including polyurethane to create flexible foams or block copolymers.

[0065] Polyvinyl alcohol (PVA) refers to a water-soluble synthetic polymer made from the hydrolysis of polyvinyl acetate. PVA can be used in a variety of applications, including as a film former, in adhesives, and in food packaging due to its film-forming and adhesive properties, as well as its biodegradability.

[0066] Ethylene vinyl alcohol (EVOH) refers to a copolymer of ethylene and a vinyl alcohol, known for its gas barrier properties. EVOH can be used in packaging applications to preserve food and prevent the diffusion of gases and can be blended with other polymers like polyethylene to improve processability and barrier characteristics.

[0067] Polyvinyl pyrrolidone (PVP) refers to a polymer made from the polymerization of vinyl pyrrolidone, a monomer derived from the compound 2-pyrrolidone. PVP is a water-soluble polymer with a variety of molecular weights. In food packaging, PVP can be used for creating coatings and biodegradable packaging. Its ability to stabilize and form protective barriers can assist in maintaining food quality.

[0068] Styrene-maleic anhydride refers to copolymers made from the polymerization of styrene and maleic anhydride. These polymers can be used in applications requiring good solubility in water and the formation of stable dispersions, such as in coatings and emulsifiers. Styrene-maleic anhydride copolymers can be further modified with glycol or amide for improved use in blends, coatings, adhesives, and emulsion formulations.

[0069] Water-soluble cellulosic ether polymers refer to cellulose derivatives that have been chemically modified with ether groups to make them soluble in water. These include materials like hydroxyethylcellulose and methylcellulose and can be used as thickeners, binders, and stabilizers.

[0070] Hydroxyethylcellulose refers to a water-soluble derivative of cellulose that is used as a thickener in personal care, pharmaceutical, and food products. Methylcellulose is another cellulose derivative used as a thickening agent or emulsifier. Sodium Carboxymethylcellulose (CMC) is another cellulose derivative used as a thickener, stabilizer, and binder. Similarly, methylcellulose refers to a water-soluble cellulose ether where some of the hydroxyl groups of cellulose are substituted with methyl groups. Sodium carboxymethylcellulose refers to a water-soluble derivative of cellulose that has been modified with carboxymethyl groups and sodium to enhance solubility in water.

[0071] With reference to FIGS. 1 and 2, one particular embodiment of a pouch 100 is illustrated, which includes a closure system 102 in the form of an origami over center hinge that defines a first sealing structure 104. While it is contemplated that the closure systems disclosed herein may be applied to any of a bag, a pouch, or a container, for ease of reference only the pouch 100 is discussed hereinafter. Further, any of the closure systems of the embodiments discussed herein may be applied to or made integrally with the pouch 100 shown in FIGS. 1 and 2. In some embodiments, the pouch 100 may or may not include a closure system having one or more closure elements 106. In some embodiments, a repulpable and/or recyclable pouch includes the following elements: a repulpable front wall 108 and a repulpable back wall 110, each of which defines a first side 112 (i.e., left edge), a second side 114 (i.e., right edge), a top 116, and a bottom 118.

[0072]The front wall 108 and the back wall 110 are joined together at the respective first sides 112, second sides 114, and bottoms 118. Each of the respective joinders can be a fold (if the front and back walls are continuous), or a heat seal, or any suitable joint that is essentially permanent and cannot be opened and re-closed. A re-closeable mouth 120 is defined by the top 116 of the front wall 108 and the top 116 of the back wall 110. In some embodiments, the pouch 100 may be a zippered pouch, a slider pouch, a drawstring pouch, or any other type of pouch that is unsealable, sealable, and/or resealable. Further, pouches may broadly encompass any type of component made from a repulpable and/or recyclable material for use by a consumer or industrial user. Various embodiments of pouches and closure systems are depicted herein; however, one of ordinary skill will understand that the presently disclosed system and method may encompass other containers and pouches as noted herein, and that various embodiments may be combined with other embodiments to achieve an optimal or desired solution.

[0073]Still referring to FIGS. 1 and 2, the re-closable pouch 100 is shown to include a body made up of the front wall 108 and the back wall 110, which are joined together at the respective first side 112, second side 114, and bottom 118, and the closure system 102, as disclosed herein. The pouch 100 in pouch form may be entirely made of one or more repulpable and/or recyclable materials, as described above. When the pouch 100 as a pouch is formed as a unitary component, leak paths along edges of the pouch 100, e.g., the left edge 112, the right edge 114, and the bottom edge 118, are minimized or eliminated since no additional sealing is required along the various edges or sides of the pouch 100, in contrast to some prior art pouches.

[0074]Referring specifically to FIG. 1, a schematic view is shown of the recyclable and/or repulpable pouch with the closure system 102 shown in an open configuration, as disclosed herein. The pouch 100 may include a blend of a water-soluble non-polymer and plant based cellulose material, as discussed above. The water-soluble non-polymer material may act as a binder of the plant-based cellulosic material to maintain structural integrity of the zipper closure during use, and further enables the repulpability and/or recyclability of the packaging structure. As noted above, in some embodiments, the formulation may include a range of between 10% and 90% by weight of water-soluble non-polymer and between 10% and 90% plant based cellulose material. As noted above, use of more than 90% plant-based cellulose material increases recyclability and compostability of the product, due to the higher ratio of fiber content to polymer. In some embodiments, adhesives and/or cohesives used may be selected from mucilage adhesives, cement adhesives (i.e,. contact cement and rubber-based adhesives, including both natural and synthetic rubber), biopolymer-based adhesives (i.e., itaconic acid), soy protein adhesives, casein adhesives, hot melt adhesives (i.e., thermoplastic adhesives that are applied using heat), pressure sensitive adhesives (i.e., adhesives that are bonded using pressure), thermoset adhesives, glycoprotein adhesives, multipart adhesives, UV curing adhesives, cyanoacrylate adhesives (i.e., super glue), synthetic adhesives (i.e., PVA, PVAc, VAE, etc.), and combinations thereof.

[0075] The non-polymer coating may comprise gelatin, pectin, dextrin, sucrose, urea, glucose, fructose, glycerin, citric acid, hyaluronic acid, sodium alginate, and combinations thereof. In some embodiments, non-polymer coatings used may be selected from protein-based, lipid-based, and steric acid-based coatings. The respective tops 116 of the front wall 108 and back wall 110 define the mouth 120, which can be opened and closed using a repulpable sealing structure 104, which may be a zipper that is defined by interlocking elements that are connected to and/or adjacent to the tops 116 of the respective front and back walls. As shown in FIG. 3 for example, the repulpable zipper 124 includes at least one (or more than one) first interlocking element 126 connected to the front wall 108 and at least one (or more than one) second interlocking element 128 connected to the back wall (not shown) of the repulpable, re-closeable flexible pouch 100. In such an embodiment, the repulpable zipper 124 is movable between a first open position that disengages each of the first interlocking elements 126 from each of the second interlocking elements 128 and a second closed position that engages each of the first interlocking elements 126 to each of the respective second interlocking elements 128. In some embodiments, the interlocking elements include a male portion and a female portion.

[0076] Referring again to FIG. 2, a schematic view is shown of the pouch of FIG. 1 with the first sealing structure 104 shown in a closed configuration. In the present embodiment, the first sealing structure 104 includes a first flap 130 (see FIG. 1) that is configured to be folded over a fold line 132 (see FIG. 1) to achieve the folded configuration shown in FIG. 2. Additional features, such as an adhesive (not shown) may be applied to the first flap 130, which may aid in retaining the first flap 130 to the body of the pouch 100. In some embodiments, multiple flaps may be provided, which may further aid in sealing the pouch 100 to achieve the sealed configuration shown in FIG. 2 to enclose an interior volume thereof. In some embodiments, the pouch 100 is leakproof, and in other embodiments, the pouch 100 is not leakproof. In some embodiments, adhesives and cohesives used in the sealing structure may be selected from mucilage adhesives, cement adhesives (i.e. contact cement and rubber-based adhesives, including both natural and synthetic rubber), biopolymer-based adhesives (i.e. itaconic acid), soy protein adhesives, casein adhesives, hot melt adhesives (i.e. thermoplastic adhesives that are applied using heat), pressure sensitive adhesives (i.e. adhesives that are bonded using pressure), thermoset adhesives, glycoprotein adhesives, multipart adhesives, UV curing adhesives, cyanoacrylate adhesives (i.e. super glue), synthetic adhesives (i.e. PVA, PVAc, VAE, etc.), and combinations thereof. The non-polymer coating may comprise gelatin, pectin, dextrin, sucrose, urea, glucose, fructose, glycerin, citric acid, hyaluronic acid, sodium alginate, and combinations thereof. In some embodiments, non-polymer coatings used may be selected from protein-based, lipid-based, and steric acid-based coatings.

[0077] Referring now to FIG. 3, a side cross-sectional view is shown of a second sealing structure 134 including a first or male portion 136 and a second or female portion 138 shown in an open configuration. The male portion 136 includes a stem 140 from which a head 142 extends, the head 142 defining a generally triangular configuration. The female portion 138 comprises a base portion 144, a first or upper arm 146, and a second or lower arm 148 that are spaced apart from one another and extend toward one another from the base portion 144. The female portion 138 further defines a cavity 150 with rounded inner fillets 152 and a bulbous innermost area 154, which is configured to receive the male portion 136. The female portion 138 is symmetric about a longitudinal center plane or centerline 156; however, alternative a-symmetric embodiments are contemplated. The upper arm 146 and the lower arm 148 are integral with the base 144 and extend therefrom. The upper arm 146 and the lower arm 148 define an opening into the cavity 150, into which the head 142 of the male portion 136 is inserted to seal the pouch 100. The opening of the cavity 150 is defined between distal ends of the upper arm 146 and the lower arm 148. The upper arm 146 and the lower arm 148 are capable of deflecting inward or outward when the head 142 of the male portion 136 is inserted into or removed from the cavity 150.

[0078] Still referring to FIG. 3, the female portion 138 further defines a height 158 and a thickness 160, the cavity 150 defines a height 162 and a thickness 164, and the opening of the cavity 150 defines a height 166. The base portion 144 includes an inner portion 168 and an outer portion 170. The inner portion 168 is defined by a vertical line or plane that extends perpendicularly through the longitudinal centerline 172 and through an innermost point 174 along the surface defining the cavity 150. As such, the inner portion 168 includes the entire cavity 150, while the outer portion 170 does not include any portion of the cavity 150. The inner portion 168 further defines a thickness 176 which is measured in a direction parallel with respect to the centerline 172, and the outer portion 170 defines a thickness 178 measured in a direction parallel with respect to the centerline 172.

[0079] The male portion 136 of the second closure system 134 is also shown in FIG. 3, which includes the stem portion 140 that extends outward from a base portion 180 and joins the head 142. The head 142 defines an outer corner 182 and inner rounds 184 that are disposed in a triangular configuration. The head portion 142 and the stem 140 are unitary components with the male base portion 180. The base portion 180 of the male portion 136 defines a height 186 and a thickness 188, and the male portion 136 defines a thickness 190. The cavity 150 of the female portion 138 is defined by an inner surface 192. The male profile 136 is defined by an outer surface 194 that corresponds to its profile. As shown in FIG. 3, the outer surface 194 of the male portion 136 does not follow a profile of the inner surface 192 of the female portion 138. In the present embodiments, surfaces that do not follow a corresponding profile portion can be considered to have different shapes or curvatures defining the respective surfaces, i.e., they do not mirror one another or have profiles that substantially conform with one another. Non-identical profiles may be selected to provide performance benefits, such as improved vacuum sealing. In other embodiments, the surfaces may follow a corresponding profile portion having identical or substantially conforming profiles. In some embodiments, the male portion 136 and the female portion 138 combine to define a sealing structure that is a zipper having a water-soluble polymer component, that may be coupled with the pouch 100 or made as an integral component thereof. In some embodiments, the male portion 136 and the female portion 138 are positioned at the top of the front wall 108 and the top of the back wall 110. The second sealing structure 134 is movable between a first open position that disengages the male portion 136 from the female portion 138, and a closed position.

[0080] In some embodiments, the sealing structures disclosed herein include between about 1% and about 99% by weight, or between about 3% and about 97% by weight, or between about 6% and about 94% by weight, or between about 9% and about 91% by weight, or between about 12% and about 88% by weight, or between about 15% and about 85% by weight, or between about 20% and about 80% by weight, or between about 25% and about 75% by weight, or between about 30% and about 70% by weight of a water-soluble polymer and between about 1% and about 99% by weight, or between about 3% and about 97% by weight, or between about 6% and about 94% by weight, or between about 9% and about 91% by weight, or between about 12% and about 88% by weight, or between about 15% and about 85% by weight, or between about 20% and about 80% by weight, or between about 25% and about 75% by weight, or between about 30% and about 70% by weight of a plant-based cellulose material.

[0081] In some embodiments, the bodies of the pouches disclosed herein include between about 1% and about 99% by weight, or between about 1% and about 97% by weight, or between about 6% and about 94% by weight, or between about 9% and about 91% by weight, or between about 12% and about 88% by weight, or between about 15% and about 85% by weight, or between about 20% and about 80% by weight, or between about 25% and about 75% by weight, or between about 30% and about 70% by weight of a water-soluble polymer and between about 1% and about 99% by weight, or between about 3% and about 97% by weight, or between about 6% and about 94% by weight, or between about 9% and about 91% by weight, or between about 12% and about 88% by weight, or between about 15% and about 85% by weight, or between about 20% and about 80% by weight, or between about 25% and about 75% by weight, or between about 30% and about 70% by weight of a plant-based cellulose material. In some embodiments, more than 10%, or more than 20%, or more than 25%, or more than 30%, or more than 40%, or more than 50%, or more than 60%, or more than 70%, or more than 75%, or more than 80%, or more than 85%, or more than 90%, or more than 95% of the body of the pouch includes plant-based cellulose materials. In further embodiments, more than 10%, or more than 20%, or more than 25%, or more than 30%, or more than 40%, or more than 50%, or more than 60%, or more than 70%, or more than 75%, or more than 80%, or more than 85%, or more than 90% of the sealing structure of the pouch includes plant-based cellulose materials.

[0082] In some embodiments, the pouches 100 disclosed herein include between about 1% and about 99% by weight, or between about 3% and about 97% by weight, or between about 6% and about 94% by weight, or between about 9% and about 91% by weight, or between about 12% and about 88% by weight, or between about 15% and about 85% by weight, or between about 20% and about 80% by weight, or between about 25% and about 75% by weight, or between about 30% and about 70% by weight of a water-soluble polymer and between about 1% and about 99% by weight, or between about 3% and about 97% by weight, or between about 6% and about 94% by weight, or between about 9% and about 91% by weight, or between about 12% and about 88% by weight, or between about 15% and about 85% by weight, or between about 20% and about 80% by weight, or between about 25% and about 75% by weight, or between about 30% and about 70% by weight of a plant-based cellulose material.

[0083] In some embodiments, more than 0.1%, or more than 0.2%, or more than 0.3%, or more than 0.4%, or more than 0.5%, or more than 0.6%, or more than 0.7%, or more than 0.8%, or more than 0.9%, or more than 1%, or more than 2%, or more than 3%, or more than 4%, or more than 5%, or more than 6%, or more than 7%, or more than 8%, or more than 9%, or up to 10% of the body of the pouch may include the water-soluble polymer. In some embodiments, more than 0.1%, or more than 0.2%, or more than 0.3%, or more than 0.4%, or more than 0.5%, or more than 0.6%, or more than 0.7%, or more than 0.8%, or more than 0.9%, or more than 1%, or more than 2%, or more than 3%, or more than 4%, or more than 5%, or more than 6%, or more than 7%, or more than 8%, or more than 9%, or up to 10% of the sealing structure of the pouch may include the water-soluble polymer.

[0084] Referring now to the embodiment depicted in FIGS. 4 and 5, side cross-sectional views of a third sealing structure 200 are shown, which includes a male portion 202 and a female portion 204 shown in open and closed configurations, respectively. As a result, the third sealing structure 200 is an interlocking closure with portions on opposing walls 108, 110 that, when closed, create a torturous paper path that is sealed through one or both walls. The closure elements are disposed on the outside of the pouch enabling the tortuous path when the closures are interlocked or otherwise sealingly interdigitated, such as by, for example, an interference fit. This also ensures no pouch content interaction with the closure elements. The male portion 202 includes a first interlocking element 206 that is disposed on an outer surface 208 of the front wall 108 of the pouch 100. While the first interlocking element 206 is shown having a square or rectangular shape in cross-section, other shapes are contemplated for the cross-sectional profile. The female portion 204 includes a second interlocking element 210 and a third interlocking element 212 that is spaced from and disposed below the second interlocking element 210, thereby defining an interlocking gap 214.

[0085] Still referring to FIGS. 4 and 5, the second interlocking element 210 and the third interlocking element 212 also have square or rectangular shapes in cross-section, although other shapes are contemplated for the cross-sectional profile. The second interlocking element 210 and the third interlocking element 212 are also disposed on the outer surface 208 of the back wall 110 of the pouch 100. When the male portion 202 is inserted into the female portion 204, the first interlocking element 206 is pressed between the second interlocking element 210 and the third interlocking element 212 to close the top 116 of the pouch 100. In some embodiments, the gap 214 defines a thickness that is similar to or the same as a thickness of the first interlocking element 206, and as a result, an interference fit is created between the first interlocking element 206, and the second interlocking element 210 and third interlocking element 212. Depending on the specific structure of the repulpable zipper, the engagement and disengagement of the first and second interlocking elements can be accomplished using manual pressure, in which the consumer uses his or her hands to press the interlocking elements into engagement or separate them into disengagement. In some embodiments, a slider (not shown) may be included, which may have an opening end and a closing end. The slider may also be repulpable and/or recyclable, and can be movable between a first position that opens the mouth 120 and a second position that closes the mouth 120 of the pouch 100.

[0086] Referring now to FIG. 6, a side-cross-sectional view is shown of a fourth sealing structure 218 having first and second interlocking portions 220, 222 on opposing sides thereof. The first and second interlocking portions 220, 222 extend from opposing tops 116 of the front wall 108 and the back wall 110 of the pouch 100. The first and second interlocking portions 220, 222, may be integral with the pouch 100, and may include portions that are more rigid than surrounding portions of the pouch 100 such that the interlocking portions 220, 222 are relatively more rigid than adjacent portions of the pouch 100. In some embodiments, the interlocking portions 220, 222 increase in thickness from a distal end 224 thereof to a fold line 226 where the interlocking portions 220, 222 meet the walls 108, 110 of the pouch 100. A wall thickness of the walls 108, 110 may also vary in a region adjacent the fold line 226. The fourth sealing structure 218 is movable between a first open position that disengages the first interlocking element 220 connected to the first wall from the second interlocking element 222 connected to the second wall and a second closed position that engages the first interlocking element 220 to the second interlocking element 222.

[0087] Now referring to FIGS. 7-9, a fifth sealing structure 230 is shown that includes a clasp provided in a partially open configuration, a partially closed configuration, and a closed configuration, respectively. The fifth sealing structure 230 is configured to create a tortuous path and includes a clasp 232 that may comprise one or more of cotton, string, paper, metal, plastic, or fluted paper board. The clasp 232 may additionally or alternatively include a button, tape, drawstring, or over loop. In the present embodiment, the clasp 232 includes a first leg 234 that is foldably connected with a second leg 236, which is further foldably connected with the body of the pouch 100. In the present embodiment, a rigid member 238, which is shown as dotted line, is attached to a portion of the first leg 234 that is foldably connected to the second leg 236 which is further foldably connected with the body of the pouch 100. The first leg 234 is configured for retention within a retention cavity 240, which is defined by a cavity strip 242 that extends from an upper end of the front wall 108 of the pouch. The cavity 240 is configured to receive the first leg 234 of the fifth sealing structure 230. The first leg 234 is generally rectangular and includes parallel sides that are configured to align with inner sides of the retention cavity 240 when the first leg 234 is inserted therein. The rigid member 238 includes a cutout portion 244, which may be included to reduce material or to provide enhanced sealing.

[0088] Referring specifically to FIG. 7, the fifth sealing structure 230 is shown in a partially open configuration, where the rigid member 238 is beginning to be inserted into the cavity 240. FIG. 8 illustrates the fifth sealing structure 230 in a partially closed configuration such that the rigid member 238 has been partially inserted into the cavity 240, but a portion of the first leg 234 remains out of the cavity 240. Finally, FIG. 9A is a front view of the fifth sealing structure 230 shown in a closed configuration such that the entire rigid member 238 has been inserted into the cavity 240 and the pouch 100 is in a closed configuration, FIG. 9B. As noted above, the clasp 232 could additionally or alternatively include one or more of cotton, spring, paper, metal, or plastic, and additional sealing structures may be provided in addition to the rigid member 238.

[0089] Now referring to FIGS. 10 and 11, side, cross-sectional schematic views are shown of a sixth sealing structure 248, which is shown in an open configuration and a closed configuration, respectively. Referring specifically to FIG. 10, a closure element 250 of the sixth sealing structure 248 includes a wedge element 252 on a left side, which is coupled or integral with the first wall 108 of the pouch 100, and further includes an opening 254 that is configured to receive at least a portion of the wedge element 252 on the back wall 110 of the pouch 100. The wedge element 252 is in a triangular configuration as shown in FIG. 10 and includes an upper wedge portion 256 and a lower wedge portion 258 that are separated by a frangible portion 260 that is disposed along a lower leg of the wedge portion 252. As shown in FIG. 11, the lower wedge portion 258 may be removable or break off from the upper wedge portion 256 at the frangible portion 260, which provides for a “fishhook” type fastening mechanism. To that end, the sixth sealing structure 248 is closed by inserting the wedge portion 252 into the opening and is re-opened by squeezing a tip 262 of the wedge portion 252 to cause the upper wedge portion 256 and the frangible portion 260 to come together so the portions are condensed enough to be re-inserted back through the opening. While only a single wedge element 252 and opening 254 are shown in the figures, it is contemplated that the sixth sealing structure 248 may include any number of wedge elements 252 and openings 254.

[0090] Referring now to FIGS. 12 and 13, a seventh sealing structure 266 is depicted in an open configuration and a closed configuration, respectively, which is similar to the sixth sealing structure 248 in that a closure element 268 also includes a wedge element 270 that is coupled or integral with the first wall 108 of the pouch 100, and further includes an opening 272 that is configured to receive at least a portion of the wedge element 270 on the back wall 110 of the pouch 100. As with the sixth sealing structure 248, the wedge element 270 of the seventh sealing structure 266 is in a triangular configuration, although the present embodiment does not include different portions separated by a frangible portion. Instead, and as shown in FIG. 13, the wedge element 270 includes an upper wedge portion 274 and a lower wedge portion 276, which are separated at a vertex 278 of the wedge element. As shown in FIG. 13, the wedge element 270 may be inserted through the opening 272, e.g., by squeezing the upper wedge portion 274 and the lower wedge portion 276 together and through the opening, and the widened wedge element 270 retains the pouch 100 in a closed configuration.

[0091] Referring now to FIG. 14, an eighth sealing structure 282 is shown in an open configuration with phantom lines showing a closed configuration, which is similar to the sixth sealing structure 248 and the seventh sealing structure 266 in that the eighth sealing structure 282 includes a wedge element 284, which is a unitary component without a gap between upper and lower portions thereof. To that end, the wedge element 284 of the present embodiment is coupled or integral with the first wall 108 of the pouch 100, and opposing wedge structures 286 are provided on the back wall 110 of the pouch 100 with a wedge gap 288 therebetween that is configured to receive the wedge element 284 (i.e., as shown in broken lines). The wedge element 284 is therefore configured to be inserted into the wedge gap 288 formed between opposing wedge structures 286. In some embodiments, a height of the wedge element 284 is substantially the same as a height of the wedge structures 286.

[0092] Referring now to FIGS. 15 and 16, a ninth sealing structure 292 is shown, which includes a closure element 294 that includes parallel edges on opposing sides to create a frictional seal across the top of the pouch 100. As a result, the wedge element configuration of FIG. 14 differs from the ninth sealing structure 292 in that opposing sides of the wedge element 284 are non-parallel, and angled toward one another while the sides of the present embodiment are parallel with respect to one another. Referring specifically to FIG. 15, a particular embodiment of the ninth sealing structure 292 is shown, which includes various circular elements 296 that are linearly arranged along the front wall 108 of the pouch 100 and that are configured to be inserted into circular openings 298 provided along a sealing strip 300 that extends from the back wall 110 of the pouch 100. FIG. 16 is a schematic representation illustrating how the circular elements 296 are inserted into the circular openings 298, i.e., by aligning the circular elements 296 with the circular openings 298 therein.

[0093] Referring to FIGS. 17 and 18, a tenth sealing structure 304 is shown, which includes a closure element 306 that is defined by a first panel 308 and a second panel 310 that include a pivot 312 therebetween about which the panels 308, 310 are folded to close the pouch 100. Referring specifically to FIG. 17, the tenth sealing structure 304 is shown in an open configuration whereby the first panel 308 is coupled with the first wall 108 of the pouch 100 while the second panel 310 that is disposed on an opposing side of the pivot 312 is unsecured to any portion of the pouch 100, which allows the mouth 120 of the pouch 100 to remain in an open configuration. To close the pouch 100, the second panel 310 is folded about the pivot 312 and is secured to the back wall 110 of the pouch. As a result, a fold is formed that defines a tortuous path. In some embodiments, one or both of the first panel 308 and the second panel 310 are secured to the pouch 100 with an adhesive (not shown) or sticker (not shown).

[0094] Referring now to FIGS. 19-21, an eleventh sealing structure 316 is shown in an open configuration, a partially closed configuration, and a closed configuration, respectively. The eleventh sealing structure 316 includes a first sealing strip 318 that extends from the back wall 110 of the pouch 100 and is configured to fold over the mouth 120 of the pouch 100 at a hinge 320. In some embodiments, the eleventh sealing structure 316 includes string 322 in the form of an over loop that extends from a left tab 324 to a right tab 326, the string being configured to retain the first sealing strip 318 in a closed configuration. In some embodiments, the eleventh sealing structure 316 includes tape (see FIGS. 20 and 21), which may be used to retain the pouch 100 in a closed configuration. In a similar fashion as shown in FIGS. 17 and 18, in the present embodiment the sealing strip 318 is folded to create a tortuous path and a clasp is utilized to retain the sealing strip 318 in a closed configuration. The clasp may include string, paper, metal, plastic, or fluted paper board, and the clasp may be implemented through one or more of a button, tape, drawstring, or over loop. The sealing strip may include one or more of an adhesive, a thermoplastic, and a pressure sensitive sealing. The adhesive may include mucilage adhesives, cement adhesives, biopolymer-based adhesives, soy protein adhesives, casein adhesives, hot melt adhesives, pressure sensitive adhesives, thermoset adhesives, glycoprotein adhesives, multipart adhesives, UV curing adhesives, cyanoacrylate adhesives, synthetic adhesives, or combinations thereof.

[0095] Referring now to FIG. 22, a front schematic view of a twelfth sealing structure 330 is shown, which includes an intermittent seal 332. The intermittent seal 332 extends from the first edge 112 to the second edge 114 of the pouch 100.

[0096]FIG. 23 is a front view of a thirteenth sealing structure 334 having a plurality of folds 336 and a plurality of score lines 338. In the present embodiment, at least three folds 336 are included, defining a first sealing strip 340, a second sealing strip 342, and a third sealing strip 344 between the folds 336. When the first sealing strip 340, the second sealing strip 342, and the third sealing strip 344 are folded over one another, a tortuous path is created. The score lines 338 may separate the sealing strips 340, 342, 344 from perpendicular folds 346 that are configured to hold the pouch 100 in a closed configuration.

[0097] Referring now to FIG. 24, a fourteenth sealing structure 350 is shown, which has various perforations therealong between the first edge 112 and the second edge 114 of the pouch 100. The fourteenth sealing structure 350 is a hand seal (mechanical or with heat) with micro-perforations 352. During manufacturing, a continuous length of substrate that forms the pouch may be rolled and sold to consumers along with a tool that will create a perforation and/or a seal. In some embodiments, a manufacturer or the consumer can cut and seal their pouch to length of the contents therein, i.e., a width of the pouch 100 may be variable depending on an intended use thereof.

[0098]FIGS. 25 and 26 illustrate a fifteenth sealing structure 354 having opposing ears 356 that are configured to seal the pouch when closed over a first sealing strip 358. The ears 356 are depicted extending outwardly from the left side 112 and the right side 114 of the pouch 100. The ears 356 are configured to bend to retain the first sealing strip 358 in place while the pouch is in a closed configuration. The ears 356 may be integral with the pouch 100 or may be coupled thereto. The ears 356 disposed along the same side of the pouch 100 are configured to fold in opposite directions, or may be configured to fold in the same direction.

[0099]FIGS. 27 and 28 depict a pouch 360 that is configured to collapse to surround contents therein, shown in open and closed configurations, respectively. In particular, the pouch 360 defines an accordion-like sidewall 362 that is configured to collapse, as shown in FIG. 28. While the pouch 360 of FIGS. 27 and 28 is shown collapsing in a circular configuration, when looking down at the pouch, other shapes are contemplated, such as a triangle, a square, a rectangle, a pentagon, a hexagon, and an octagon. Further, while only a single accordion-like sidewall 362 is shown, it is contemplated that various discrete accordion-like sidewalls may be implemented.

[0100]FIG. 29 is a front schematic view of a pouch that may be used with any of the sealing structures noted above, which includes a coating that provides increased breathability. The coating 364 is disposed along various portions of the first wall 108 and the back wall 110 (shown in FIG.1) of the pouch 100. In some embodiments, the pouch 100 is coated in a specific pattern or section to create a breathability benefit by having differential moisture/oxygen barrier levels in the coating 364 compared with non-coated areas 366. Further, paper can be coated so that the inside surfaces of the walls have a coating on them to help facilitate forming/sealing the package as well as providing better surfaces to attach the zipper. The coating may include wax, silicone, polyurethane, cellulose, polylactic acid, or combinations thereof. A repulpable cellulose material can also be coated with minor amounts of a water-insoluble polymer such as an acrylic, provided that the overall zipper 124 is repulpable.

[0101] In some embodiments, a deforming apparatus may be used to provide discontinuities or other variations in the profile(s) 136, 138 that may affect closing characteristics such as actual or perceived closing sufficiency, amplitude of sound, type of sound, and texture or feel generated during closing of the zipper 124.

[0102] It is intended that the thin-thin-thin cross-hatching disclosed herein is inclusive of the materials disclosed herein, such as paper, repulpable materials, lignin, plant-based cellulose materials, polymers, binders, etc.

[0103] Additionally, as would be appreciated by those of ordinary skill in the pertinent art, the subject technology is applicable to any type of bag, pouch, package, and various other storage containers, e.g., snack, sandwich, quart, and gallon size pouches. The subject technology is also adaptable to bags having double zippers, or multiple zippers, or other type of closure mechanisms.

INDUSTRIAL APPLICABILITY

[0104] Numerous modifications will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention. The exclusive rights to all modifications which come within the scope of the application are reserved. All patents and publications are incorporated by reference herein in their entirety.