Article and Method for Forming an Integrated Liner Seal, Dispensing Aperture and Spout

CROSS-REFERENCE TO RELATED APPLICATION

[0001]This application claims priority to a U.S. Provisional Application No. 63/745,493, filed on Jan. 15, 2025, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

[0002]The present invention relates to the field of liner seals for sealing to the rim of a container and protecting a product stored in the container prior to use, the liner seal according to the present invention providing an integrated dispensing aperture and spout for controlled dispensing of the product from the container.

BACKGROUND OF THE INVENTION

[0003]Liners or seals have been used on containers for many years to prevent leakage or contamination and to increase the shelf life of the product held within the container. For example, liners are used on containers for cosmetics, foods, drinks, medicines and other items in the form of liquids, creams, gels, particulates, powders and other substances. Liners for this purpose are typically placed over the opening on the container or, in some instances, within the cap on the container before placing the combined cap and liner over the opening (mouth) of the container.

[0004]It is common practice to attach the liner to the rim (surrounding the opening) of the container by the process of induction heat sealing. This requires that a metal foil layer be present in the liner structure to transfer heat to a lowermost heat sealant layer for bonding the liner to the container rim. The bonding is temporary, allowing the customer (user) to remove the liner by peeling it off the rim of the container. The liner thus serves multiple purposes, providing a tamper-proof seal, as well as preventing leakage, contamination, or spoilage of the product in the container.

[0005]To form and apply a liner, the liner is typically punched from a multi-layer sheet of heat seal liner material, inserted into a closure, the closure is screwed onto the neck of a previously filled container, and the closure is then passed under a heat sealer that bonds (via induction heating) the liner to the rim of the container. Another type of liner, known as a two-element liner, is punched from a multi-layer sheet of material that combines both the heat seal liner layers and backing liner layers, inserted into a closure, the closure is screwed onto the container, and the closure is passed under a heat sealer that both induction heat seals the heat-sealable liner to the rim and melts a layer (e.g., wax) between the heat seal liner and backing liner so that when the user removes the closure, the backing liner remains in the closure. With a two-element liner, the backing liner remains in the cap to provide a secondary tightness (barrier to the exterior) after the heat seal liner has been partly or fully removed.

[0006]Another desirable liner element is a pull tab, extending from the perimeter of the liner, or as one or more tabs extending from the top of the liner (within the perimeter), that can be more easily grasped by the user to assist in removing the liner from the rim. However, the addition of a pull tab increases the complexity and expense of the design and may lead to delamination of the layers during the process of removal from the container rim.

[0007]Once the liner is removed, dispensing the product through the container opening in a controlled manner can be difficult. Tilting the container to allow gravity to cause the flow of material out the top opening may result in too much, or not enough flow for a desired application. This problem occurs whether the product is a liquid, a powder, a tablet or a paste. The prior art solution is to provide a separate spout, that is attached to the opening of the container once the liner is removed, to facilitate a more controlled dispensing of product. However, providing a separate spout adds greatly to the complexity of manufacture and use, and to the cost and generation of multiple articles after use, many of which may not be properly disposed of (e.g., in a recycling stream).

[0008]It would be desirable to provide a liner construction that can be easily and inexpensively manufactured, is easy to remove, will not interfere with liner insertion or heat sealing, and provides the necessary barrier functionality and strength, e.g., to resist delamination or rupture of the liner or pull tab while separating the liner from the container rim.

[0009]It would also be desirable to provide a liner with a product orifice that is smaller (more restricted) than the opening provided by the rim (open mouth) of the container, for dispensing a product through the restricted orifice.

[0010]It would also be desirable to provide a liner with an integrated dispensing orifice and spout to facilitate controlled dispensing of a product through the orifice and spout.

SUMMARY OF THE INVENTION

[0011]The present invention is a liner seal for sealing to the rim of a container opening and protecting a product stored in the container prior to use, the liner seal according to the present invention also providing a restricted product opening that is smaller than the mouth of the container and an integrated dispensing spout for controlled dispensing of the product from the liner opening and spout.

[0020]In one embodiment, the basewall (22) is an integral disc-shaped body of multi-layer construction having opposing top and bottom surfaces (TS, BS) with a transverse thickness (t) defined between the top and bottom surfaces.

[0021]In one embodiment, the basewall perimeter (23) is disc-shaped, the opposing tear lines are parallel to one another, and each of the tabs is half-moon shaped and extends from a respective tear line toward the basewall perimeter.

[0022]In one embodiment, the multilayer basewall (22) includes a metal layer and an indictive heat sealant on the bottom surface for inductive heat sealing to a container rim (11).

[0023]In one embodiment, the basewall (22) includes a heat sealant on the bottom surface for convection heat sealing to a container rim (11).

[0024]In one embodiment, the liner seal (20) is configured to fit between a container rim (11) and a closure cap (16).

[0025]In one embodiment, the liner seal (20) comprises a lidding for sealing an opening (10) of a container (4).

[0026]In one embodiment, the multi-layer construction of the basewall (22) includes one or more of: a polymer material layer, a paper material layer, a hybrid paper and polymer material layer, a metal layer, and a heat sealant layer.

[0027]In one embodiment, a top layer of the multi-layer construction of the basewall (22) includes the tabs, detached from the side portions, and a central area attached to the central portion.

[0028]In one embodiment, the multi-layer construction of the basewall (22) includes: a top polymer layer that forms the tabs and the central portion, a middle layer of metal for inductive heating, and a bottom layer of an inductive heat sealant.

[0029]In one embodiment, the top layer is of multi-layer construction and includes: an uppermost layer that forms the tabs (40A, 40B) and uppermost layer of the central portion (26), a lowermost layer of solid or foam polymer material, and a middle bonding layer between the uppermost layer of the central portion and lowermost layer.

[0030]In one embodiment, the liner seal (20) is die cut or punched from a web of sheet material of the multi-layer construction.

[0031]In one embodiment, the sheet material includes the tear lines (44A, 44B) extending entirely or partially through the thickness of the multi-layer construction.

[0032]In one embodiment, the top layer includes in serial order an upper cover layer, a middle tab layer attached to the upper cover layer by a bonding material, and a lower layer of solid or foam polymer material, wherein the tab layer includes the central portion (26) bonded to the lower layer and the pair of spaced apart tabs (40A, 40B) not bonded to the lower layer.

[0047]In one embodiment, the basewall (122) is an integral disc-shaped body of multi-layer construction having opposing top and bottom surfaces (TS, BS) with a transverse thickness (t) defined between the top and bottom surfaces.

[0048]In one embodiment, the basewall perimeter (123) is disc-shaped, the opposing tear lines are angled with respect to one another forming a trapezoid shaped central portion, with the first end section and tab being a narrower end of the trapezoid compared to the opposing second end section.

[0049]In one embodiment, the multilayer construction of the basewall (123) includes a metal layer and an inductive heat sealant on the bottom surface for inductive heat sealing to a container rim (11).

[0050]In one embodiment, the basewall (123) includes a heat sealant on the bottom surface for convection heat sealing to a container rim (11).

[0051]In one embodiment, the liner seal (120) is configured to fit between a container rim (11) and a closure cap (16).

[0052]In one embodiment, the liner seal (120) comprises a lidding for sealing an opening (10) of a container (4).

[0053]In one embodiment, the multi-layer construction of the basewall (122) includes one or more of: a polymer material layer, a paper material layer, a hybrid paper and polymer material layer, a metal layer, and a heat seal layer.

[0054]In one embodiment, the multi-layer construction of the basewall (122) includes: a top polymer layer, a middle layer of metal for inductive heating, and a bottom layer of an inductive heat sealant.

[0055]In one embodiment, a top layer is of multi-layer construction and includes: an uppermost layer of polymer material or a hybrid of polymer and paper material, a lowermost layer of solid or foam polymer material, and a middle bonding layer between the uppermost and lowermost layers.

[0056]In one embodiment, the liner seal (120) is die cut or punched from a web of sheet material of the multi-layer construction.

[0057]In one embodiment, the sheet material includes the tear lines (144A, 144B) extending entirely or partially through the thickness of the multi-layer construction.

[0058]In one embodiment, the sheet material includes the tear lines (144A, 144B) extending through the multi-layer construction and the fold lines.

BRIEF DESCRIPTION OF THE DRAWINGS

[0066]For a better understanding of the invention, and to show how the same may be carried into effect in various embodiments, reference will now be made, by way of example to the accompanying drawings, in which:

[0067]FIGS. 1-4 illustrate an article and a series of method steps according to a first embodiment of the invention, the article comprising an integrated liner seal, dispensing aperture and spout for sealing and controlled dispensing of a product through the liner aperture and spout, wherein FIG. 1 is a top perspective view showing a starting liner seal having a basewall with a basewall perimeter sealed to the container rim, the basewall having a central portion defined by an opposing pair of tear lines and an associated pair of movable tabs that together with the central basewall portion are configured to form the integrated dispensing aperture and spout, FIG. 2 is a top perspective view of the liner seal of FIG. 1 after pulling the tabs and central portion upwardly to detach a first end section of the basewall perimeter from the rim and continued pulling and tearing away of the central portion along the tear lines to separate the central portion and tabs from the basewall, thus forming a central dispensing aperture in the liner and leaving a remaining second end section of the basewall perimeter attached to the rim, FIG. 3 is a top perspective view showing the next step of rotating the tabs to form the dispensing spout, and FIG. 4 is a top perspective view showing the next step of positioning the dispensing spout and container to allow a product to flow through the central dispensing aperture and along the dispensing spout in a controlled manner from the container;

[0068]FIGS. 5-9 illustrate an article and a series of method steps according to a second embodiment of the invention, the article comprising an integrated liner seal, dispensing aperture and spout for sealing and controlled dispensing of a product through the liner aperture and spout, wherein FIG. 5 is a top perspective view showing a starting liner seal having a basewall with a basewall perimeter sealed to the container rim and a pull tab extending outside the container rim, the basewall having a central portion defined by an opposing pair of tear lines and fold lines for forming foldable wall sections that together with the central basewall portion and pull tab are configured to form the integrated dispensing aperture and spout, FIG. 6 being a top perspective view of the liner seal of FIG. 5 after pulling the tab and central portion upwardly to detach a first end section of the basewall perimeter from the rim and continued pulling of the central portion along the tear lines to separate the foldable wall sections and central portion from the basewall, thus forming a restricted central opening in the liner and leaving a remaining second end section of the basewall perimeter attached to the rim, FIG. 7 is a top perspective view showing the next step of moving the foldable wall sections toward one another to form the dispensing spout, and FIG. 8 is a top perspective view showing the next step of positioning the dispensing spout and container to allow a product to flow through the central aperture and along the dispensing spout in a controlled manner from the container, while FIG. 9 is a top perspective view similar to FIG. 8 but at a different angle perspective showing the container and spout in position for controlled dispensing;

[0069]FIG. 10 is a flow diagram of one method embodiment of the invention in accordance with the article and steps shown in FIGS. 1-4;

[0070]FIG. 11 is a flow diagram of a second method embodiment of the invention in accordance with the article and steps shown in FIGS. 5-9;

[0071]FIG. 12 is a perspective view of a liner, container and closure assembly according to one embodiment of the invention; and

[0072]FIG. 13 is a perspective view of the assembly of FIG. 12 with the liner sealed to the container rim;

[0073]FIGS. 14A-14F are perspective (FIG. 14A) and cross-sectional (FIGS. 14B-14C) views of one example of the first liner embodiment; and perspective (FIG. 14D) and cross-sectional (FIGS. 14E-14F) views of another example of the first liner embodiment;

[0074]FIGS. 15A-15B are top perspective views of two examples of a web of multi-layer material for forming the integrated liner seal according to the embodiments of FIGS. 14A-14F, FIG. 15A showing a single punch process, and FIG. 15B a double punch process;

[0075]FIGS. 16A-16C are cross-sectional views of one example of the second liner embodiment (tab not shown), FIGS. 16A and 16B showing two different layer embodiments with four and three layers respectively, and FIG. 16C showing the four layer embodiment;

[0076]FIGS. 17A-17B are top and bottom perspective views (FIGS. 17A and 17B respectively) of a web of multi-layer material for forming the integrated liner seal according to the second embodiment of the invention, the bottom view of FIG. 17B showing the tear lines and fold lines as well as the side pull tab.

DETAILED DESCRIPTION

Overview and Summary of Reference Numbers

[0086]Various embodiments of the invention, including both articles and methods of the invention are disclosed in the accompanying figures The following reference numbers identify various elements of each article and method in the disclosed embodiments:

Product, Container and Closure ( 2 - 16 Series of Reference Numbers; FIGS. 1 - 9 and 12 - 15 )

First Embodiment ( 20 - 63 Series of Reference Numbers, FIGS. 1 - 4 , 10 , 12 - 13 , 14 - 15 )

Second Embodiment ( 120 - 163 Series of Reference Numbers (FIGS. 5 - 9 , 11 , 16 - 17 )

First Embodiment, Article and Method of FIGS. 1 - 4 and 10

[0134]In accordance with the first embodiment, FIG. 1 is a top perspective view showing a starting liner seal 20 comprising an integral disc-shaped multi-layer basewall 22 having a basewall perimeter 23, and with opposing top and bottom surfaces and a transverse thickness defined between the top and bottom surfaces. The basewall is sealed to a container rim 11 by a heat seal coating along the bottom surface at the perimeter, and the basewall 22 has a central portion 26 defined by a pair of opposing parallel and spaced apart tear lines 44A, 44B and adjacent tabs 40A, 40B that together with the central basewall portion 26 are configured to form the integrated dispensing aperture 50 and spout 60.

[0135]FIG. 2 is a top perspective view of the liner seal of FIG. 1 after pulling the tabs 40A, 40B and central basewall portion 26 upwardly to detach a first end section 24 of the basewall perimeter 23 from the rim 11 and continued pulling and tearing away of the central basewall portion 26 along the tear lines to form a detached central portion 61 and tabs 40A, 40B from the starting basewall 22, thus forming a restricted central opening 50 in the liner and leaving a remaining second end section 25 of the basewall perimeter attached to the rim 11.

[0136]FIG. 3 is a top perspective view showing the next step of rotating the tabs 40A, 40B along the tear lines (first outwardly away form one another, and then in the opposite direction toward one another) to form a pair of opposing sidewalls 63A, 63B that lie along the detached central portion 61 and together form the dispensing spout 60.

[0137]FIG. 4 is a top perspective view showing the next step of positioning the dispensing spout 60 and container 4 (e.g., tiling the container sideways) to allow a product 2 to flow through the central dispensing aperture 50 of the liner and along the dispensing spout 60 in a controlled manner from the restricted central aperture 50.

[0138]In the embodiment shown in FIGS. 1-4 and 12-13, and without limiting the invention to the specific configurations and structures shown therein, the liner 20 has a disc-shaped basewall perimeter that is sized to completely seal a similarly shaped and sized circular rim 11 surrounding a circular opening 10 at a top end of the container 4. The container may be configured to store any of various types of products 2, such as food, beverage, pharmaceutical, health care, cosmetic, cleaning, automotive or other product, including various product forms such as a liquid, solid (e.g., powder or granular), paste or composite material. The container 4 itself may be made of various materials (e.g., plastic or glass) and take various forms. In one embodiment a plastic container 4 is provided (see FIGS. 12-13) having a hollow container body 5 that defines a cavity 6 for holding a product 2, the container body including a bottom wall 7, sidewall 8, and reduced diameter threaded neck finish 9 at the top end for receiving a threaded closure or cap. The neck finish defines the opening 10 at the top end of the container for dispensing the product, the neck finish 9 having an uppermost rim 11 to which the liner seal 20 is first attached for protecting the product disposed in the container cavity 6.

[0139]The disc-shaped liner 20 has a basewall 22 with a circular basewall perimeter 23 that substantially matches the circular perimeter of the rim 11 so as to effectively seal the same completely around the circular rim, such that it does not interfere with attachment of a closure cap 16 that is then threaded over the composite neck finish 9 and liner 20. The basewall includes a roughly rectangular central portion or area 26 defined by 4-sides, namely two opposing curved first and second end sections 24, 25 of the basewall perimeter 23, and two opposing spaced-apart and generally parallel tear lines 44A, 44B that extend between the opposing end sections 24, 25 of the basewall perimeter to form a generally rectangular central portion 26.

[0140]The liner 20 includes first and second tabs 40A, 40B, that together with the central basewall portion 26 and first and second tear lines 44A, 44B, are used to transform the starting liner seal from a simple seal that closes and seals the top opening of the container (to protect the sealed product contained therein), to a final configuration of the liner seal having a restricted central liner opening 50 and dispensing spout 60 for controlled dispensing of the product from the container. As shown in the article and method steps illustrated in FIGS. 1-4 and FIG. 10, the starting liner 20 (shown in FIG. 1) has a pair of spaced apart tabs 40A, 40B each having a first end integral with the central portion and extending outwardly toward the perimeter 23 from an opposing one of the tear lines 44A, 44B, each of the tabs having a second end detached from and lying above a respective one of the opposing side portions 28A, 28B of the basewall.

[0141]The tabs 40A, 40B are respectively positionable to lie over the opposing left and right side portions 28A, 28B of the basewall, when the starting seal is attached to the container rim and the liner is disposed beneath a closure cap. Once the closure cap is removed, the tabs can be grasped by the user and moved upwardly and toward one another (in the direction of a central transverse axis through the thickness of the liner), forming an easily grasped pair of wings that a user can then use to grab and pull the liner upwardly away from the rim, in order to form the restricted central opening 50 in the liner and dispensing spout 60, as described below.

[0142]After pulling together and grasping the tabs, the user pulls the tabs upwardly and away from the rim to detach either the first end section 24 or second end section 25 of the basewall perimeter from the rim. The user then continues to pull upwardly on the tabs, which cases rupture or tearing along the tear lines 44A, 44B, until reaching the opposite end section (25 or 24 respectively) of the basewall perimeter which remains attached to the rim (as shown in FIG. 2). By rupturing along the opposing tear lines, a first end of the central portion of the basewall becomes detached from the opposing side portions 28A, 28B of the basewall (the latter still being attached to the rim) to form the restricted central opening or aperture 50 in the liner.

[0143]Next, as shown in FIG. 3, the user rotates the tabs (first outwardly and then inwardly with respect to the central bottom wall portion 26, about 180 degrees total) to form the dispensing spout. The tabs are readily rotated along the tear lines and then folded back along either side of the detached central portion to form (as shown in FIG. 3) a dispensing spout adjacent the remaining attached section 25 of the basewall perimeter (see FIG. 4). More specifically, the central portion of the basewall now forms a bottom wall or channel 61 of the spout, and the tabs form two opposing left and right sidewalls 63A, 63B along either side of the channel 61 to direct the product as it exits the restricted central opening in the liner and down the bottom wall (channel) of the spout. The restricted central aperture 50 and three-sided spout 60 (bottom wall 61 and opposing sidewalls 63A, 63B) thus forms a controlled path for product dispensing.

Second Embodiment, Article and Method of FIGS. 5 - 9 and 11

[0151]FIGS. 5-9 illustrate a second embodiment of an article and a series of method steps for producing the article, the article 120 comprising an integrated liner seal, dispensing aperture and spout for sealing and controlled dispensing of a product 2 through an opening 10 of a container 4. The article and method of the second embodiment are similar to the first embodiment in multiple aspects, with corresponding reference numbers and part names, the reference numbers for the second embodiment being labeled with a 100 series of numbers. The second embodiment differs primarily from the first by: providing a tab extending beyond the basewall perimeter (instead of a pair of movable tabs on the top surface), and providing a pair of fold lines in the central section to define foldable wall sections in the central portion, the foldable wall sections then forming the opposing sidewalls of the dispensing spout (instead of forming the opposing sidewalls of the dispensing spout from the pair of movable tabs).

[0159]FIG. 5 is a top perspective view showing a starting liner seal 120 having an integrated basewall 122 with a basewall perimeter 123 sealed to the container rim 11 and a pull tab 129 extending outside (radially beyond) the container rim 11. The basewall has a central portion 126 disposed between opposing left and right side portions 128A, 128B, and an opposing pair of tear lines 144A, 144B extending between first and second end sections 124, 125 on the basewall perimeter that define the boundaries between each respective one of the side portions and the central portion. The central portion 126 has a pull tab 129 located at and extending beyond the first end section 124 of the basewall perimeter, and a pair of fold lines 141A, 141B each spaced apart from a respective one of the tear lines and each fold line extending between the first and second end sections 124, 125 to form a pair of foldable wall sections 140A, 140B in the central portion 126 along each respective tear line.

[0160]The basewall is an integral disc-shaped body of multi-layer construction having opposing top and bottom surfaces with a transverse thickness defined between the top and bottom surfaces. The basewall perimeter is disc-shaped, the opposing tear lines 144A, 144B are angled with respect to one another forming a trapezoid shaped central portion 126, with the first end section 124 (with tab 129) of the basewall perimeter forming a narrower end of the trapezoid compared to the opposing second end section 125 of the basewall perimeter.

[0161]FIG. 6 is a top perspective view of the liner seal of FIG. 5 after pulling the tab 129 and central portion 126 (including the foldable wall sections 140A, 140B) upwardly to detach the first end section 124 of the basewall perimeter from the rim 11 and continued pulling of the central portion 126 (with foldable wall sections 140A, 140B) along the tear lines 144A. 144B to form a detached central portion 126 (from the remaining basewall side portions 128A, 128B that remain attached to the rim at the basewall perimeter), thus forming a restricted central opening or aperture 150 in the liner and leaving a remaining second end section 125 of the detached central portion attached to the rim 11.

[0162]FIG. 7 is a top perspective view showing the next step of folding the foldable wall sections 140A, 140B (on opposing sides of the detached central portion 126) along respective fold lines 141A, 141B toward one another to form the dispensing spout 160. Here the foldable wall sections are moved inwardly (toward one another) to form opposing sidewalls 163A, 163B of the spout, while the detached central basewall portion between the foldable wall sections forms the bottom wall 161 of the spout.

[0163]FIG. 8 is a top perspective view showing the next step of positioning the dispensing spout and container (e.g., tilting the container sideways) to allow a product to flow through the restricted central aperture 150 and along the bottom wall 161 of the spout and opposing left and right sidewalls 163A, 163B of the spout in a controlled manner.

[0164]FIG. 9 is a top perspective view similar to FIG. 8, but at a different angle perspective, showing the container neck finish 9 and final liner seal with integrated dispensing aperture and spout in position for controlled dispensing.

Alternative Embodiments, Structures and Materials (FIGS. 12 - 17 )

[0172]Referring to FIGS. 12-15, there is shown an integrated liner seal 20 in accordance with the first embodiment of the present invention configured to be sealed over an opening 10 to an internal cavity 6 of a container 4 holding a product 2. A removable closure or cap 16 (here a threaded cap) is then applied over the liner and removably attached to the container.

[0173]The integrated liner seal 20 has an integral one-piece multi-layer construction (as shown in FIGS. 14-15) and is die cut or punched from a web of such multi-layer material (see FIG. 15). The liner 20 is a generally disc-shaped (circular) article having a diameter D, with parallel and opposing top TS and bottom BS planar surfaces each with a matching circular circumference 20c, and a transverse liner thickness 20t which is relatively thin compared to the diameter D (note in FIGS. 14-15 the liner thickness, layer thicknesses and diameter are not shown to scale, as the liner thickness 20t would more typically be on the order of 0.2 to 2% of the liner diameter D). In one embodiment, the total liner thickness 20t is in a range of 3 mil (0.003 inch/0.076 mm) to 30 mil (0.030 inch/0.76 mm) and the liner disk diameter D in the range of 28 mm (1.10 inch) to 150 mm (5.90 inch). A mil is a unit of length equal to one thousandth of an inch (0.0254 millimeter).

[0178]FIGS. 14D-14E show another example, similar to FIGS. 14A-14C, wherein the top layer includes in serial order an upper cover layer a middle tab layer attached to the upper cover layer by a bonding material, and a lower layer of solid or foam polymer material, wherein the tab layer includes the central portion (26) bonded to the lower layer and the pair of spaced apart tabs (40A, 40B) not bonded to the lower layer.

[0179]FIGS. 15A-15B illustrate two examples of a web or sheet 220 of bulk liner material from which a plurality of individual liners 20 of the first embodiment are cut or punched. FIG. 15A shows a web with a single row of liners (single punch process) and FIG. 15B shows a web with two parallel rows of liners (double punch process). As shown the plurality of die cut liners formed from the web each include a central portion 26 that lies between opposing left and right side portions 28A, 28B having the movable tabs 40A, 40B, with opposing tear lines 44A, 44B at the boundaries between the central portion and side portions, for forming a liner according to the first embodiment. Web 220 is assembled as a one-piece, multi-layer sheet prior to partially punching the liners 20 from the web sheet. The web 220 is made from a plurality of individual sheets (layers) stacked one atop the other in the transverse thickness direction to form an integral liner sheet material 220. Alternately, if desired, liners can be made from strips of multi-layered materials, mounted on reels that are fed through a punching machine to die cut or punch the seal.

[0184]FIGS. 17A-17B illustrate (top and bottom views in FIGS. 17A and 17B respectively) one example of a web or sheet 320 of bulk liner material from which a plurality of individual liners 120 of the second embodiment are cut or punched. Web 320 is assembled as a one-piece, multi-layer sheet prior to partially punching the liners 120 from the web sheet. The web 320 is made from a plurality of individual sheets (layers) stacked one atop the other in the transverse thickness direction to form an integral liner sheet material 320. Alternately, if desired, liners can be made from strips of multi-layered materials, mounted on reels that are fed through a punching machine to die cut or punch the seal. The die cut liners 120 (shown in position across the web) each include a side tab 129 at the first end section of the perimeter 124, the opposing second end perimeter section 125, and both tear lines 144A, 144B and fold lines 141A, 141B extending from the first end section 124 toward the second end section 125 for forming a liner according to the second embodiment. The tear liners may extend entirely or partially through the thickness of the web and liners. Similarly, the fold lines may extend only partially through the thickness, or across the entire thickness.

[0185]In various embodiments, the integrated liner seal 20, 120 may be used on a variety of containers for holding various food, cosmetic, confectionery, household, automotive and other products in the form of liquid, solid, gel or paste (semi-solid) substances 2. The container 4 is typically made of plastic, but may be glass, molded fiber/pulp, or metal (e.g., aluminum).

[0186]The container 4 is filled with a product 2 through the opening 10 (or through another orifice of the container that communicates with the cavity 6) and the liner 20, 120 is sealed around the opening rim 11, allowing the customer to remove the cap 16 and peel off the liner 20, 120 to form the restricted central liner opening 50 and spout 60 for controlled dispensing of the product. The liner 20, 120 can be used with different types of containers 4 and different types of closures or caps 16, such as a threaded cap (see FIGS. 12, 13, 16), a snap-closed or flip-top cap, or other types of caps known in the industry. In the embodiment of FIGS. 12-13, the liner 20 is heat-seal bonded at the perimeter 23 of its lower-most (bottom) surface BS to an annular (circumferential) rim 11 of the container 4 surrounding the opening 10, and the cap 16 is closed (threaded) thereover.

[0187]The container 4 may be composed of any material capable of providing a tamper evident, removable induction heat seal or convection heat seal secured to the container rim and that are suitable for storage of the substance being sold. It may also provide barrier properties as desired. The container 4 may be composed of a polymer material, for example of polyethylene PE, polypropylene PP, polyethylene terephthalate PET or polyvinyl chloride PVC. In another embodiment, the container 4 is glass, molded fiber/pulp, or metal (e.g., aluminum).

[0188]In one embodiment, shown in FIG. 14A-14C, the integrated liner seal includes in serial order from top to bottom: a top paperboard and/or polymer layer, a middle layer of metal foil (here aluminum foil) for inductive heating, and a bottom heat seal layer. In the case of first embodiment (FIGS. 1-4, 10), the tabs (40A and 40B) form an additional sub-layer of the top layer of the structure. In the case of the second embodiment (FIGS. 5-9, 11), the liner basewall includes a side tab 129 that extends from a first end section 124 of the basewall perimeter 123 (namely radially beyond the basewall perimeter), and the foldable wall sections 140A, 140B are part of the complete multi-layer construction of the central portion, i.e., the second embodiment does not require an additional sub-layer. It should be noted that more or fewer layers, or layers of other materials than listed herein, may be used without departing from the present invention. For example, adhesives, other bonding materials, and coatings may be provided between the layers. In one embodiment, a laminating adhesive layer is provided between the top paperboard and/or polymer layer, and the metal foil layer. Alternatively, one or more layers may include printed information or designs, e.g., in the form of a varnish or coating with inks or dyes. In one embodiment, a printed or informational layer is provided on the outermost top surface of the liner, above the top paperboard or polymer layer and facing the consumer when the closure cap is removed from the sealed container.

[0189]The integral liner seal of the present invention may be used as either: a closure liner seal (e.g., as shown in FIGS. 12-13) that is induction heat sealed to the container rim with a closure or cap placed over the liner sealed container to complete the package; or a lidding that is sealed to the container rim (e.g., by conduction heat sealing) to form the final closed package (without requiring a closure or cap).

[0190]In one embodiment, a top paperboard and/or polymer layer thickness and/or metal layer thickness of the liner eliminates any need for a further barrier layer, membrane or material to be laminated to the liner, while preventing access, leakage, and contamination through the liner.

[0191]In some embodiments the heat seal bond layer (bottom layer) may be limited to a perimeter area of the liner, as this is all that is required for sealing around the opening of the container. In other embodiments, the heat sealant bond layer may cover additional surface areas and/or the entire lowermost surface of the liner.

[0192]The barrier properties of the liner measured e.g., in terms of oxygen transmission rates (OTR) or moisture vapor transmission rates (MVTR)) can be controlled by adjusting (reducing or increasing) the materials and dimensions of the various layers in the liner. In one embodiment, the required barrier properties of the sealed container are maintained by the paper and/or polymer top layer and metal foil layer.

[0193]As used herein, the paper or paperboard layer may comprise a sheet of cellulose material, including those materials typically used in the liner industry and referred to as paper, paperboard, board and pulp. The sheet may comprise wood fiber or other cellulose fibers, and may further include fillers, binders, chemical treatment and surface coatings, and may be made of virgin or recycled materials.

[0194]The paperboard layer may be a sheet comprising a heterogeneous mixture of plant material such as cellulose, hemi-cellulose, lignin, etc. and filling material such as china clay, calcium carbonate, etc., chemical additives such as rosin, alum, starch, etc. depending on the grade of the paper. Typically, the paperboard layer is comprised of greater than 80% cellulosic fiber, together with one or more binders, optical brighteners, coatings and/or other chemicals.

[0195]In the first embodiment (FIGS. 1-4, 10), the thicknesses of the respective layers may comprise:

Top Layer

Middle Metal (e.g., Aluminum) Foil Layer

Bottom Heat Sealant Layer

[0201]In the second embodiment, the thickness of the respective layers may comprise:

Top Layer

Middle Metal (e.g., Aluminum) Foil Layer

Bottom Heat Sealant Layer

[0206]While the invention has been described and illustrated in various terms and embodiments, the scope of the invention is not intended limited thereby and other modifications or embodiments as may be suggested by the teachings herein are particularly reserved as they fall within the scope of the appended claims.