Laminated metal foil packaging material and method of making

Abstract

A laminate including a flavorant useful for packaging cigarettes or other products such as food products. The laminate includes crosslinked polymer coatings adhered to at least two metal foils, and a volatile flavor component such as menthol is applied to one of the polymer-coated surfaces. The laminate minimizes loss of volatile and/or heat sensitive flavor components from the package during extended periods at elevated temperature which are often associated with long term storage and/or shipping.

What is claimed is:  
     
         1 . A laminate comprising: 
 a metal foil layer having opposed major surfaces;    a metal oxide layer on each of the major surfaces of the foil;    a crosslinked polymer coating adhered to the metal oxide layer on both sides of the metal foil; and    a flavor component applied to one side of the laminate.    
     
     
         2 . The laminate of  claim 1 , wherein the metal foil is aluminum foil or tin foil and/or the flavor component is applied to a paper layer adhered to the laminate.  
     
     
         3 . The laminate of  claim 1 , wherein the thickness of the metal foil is between approximately 1 and 25 mils.  
     
     
         4 . The laminate of  claim 1 , wherein the polymer coating is a polymer comprising acrylate subunits.  
     
     
         5 . The laminate of  claim 1 , wherein the thickness of the polymer coating is between approximately 0.25 and 5 mils.  
     
     
         6 . The laminate of  claim 1 , wherein the flavor component is menthol.  
     
     
         7 . The laminate of  claim 6 , wherein the menthol is applied to the laminate in the form of an alcohol/menthol solution.  
     
     
         8 . The laminate of  claim 6 , wherein the menthol is applied to the laminate in the form of a menthol-containing paper adhesively bonded to the laminate.  
     
     
         9 . The laminate of  claim 8 , wherein the amount of menthol in the paper is between about 2-65 weight percent, based on the dry weight of the paper.  
     
     
         10 . The laminate of  claim 8 , wherein the paper comprises 19 pound or heavier paper.  
     
     
         11 . A cigarette package comprising the laminate of  claim 1 .  
     
     
         12 . The cigarette package of  claim 11 , wherein the metal foil is aluminum foil or tin foil.  
     
     
         13 . The cigarette package of  claim 11 , wherein the thickness of the metal foil is between approximately 1 and 25 mils.  
     
     
         14 . The cigarette package of  claim 11 , wherein the polymer coating is a polymer comprising acrylate subunits.  
     
     
         15 . The cigarette package of  claim 11 , wherein the thickness of the polymer coating is between approximately 0.25 and 5 mils.  
     
     
         16 . The cigarette package of  claim 11 , wherein the flavor component is menthol.  
     
     
         17 . The cigarette package of  claim 11 , wherein the menthol is applied to the laminate in the form of an alcohol/menthol solution.  
     
     
         18 . The cigarette package of  claim 11 , wherein the menthol is applied to the laminate in the form of a menthol-containing paper adhesively bonded to the laminate.  
     
     
         19 . The cigarette package of  claim 18 , wherein the amount of menthol in the paper is between about 2-65 weight percent, based on the dry weight of the paper.  
     
     
         20 . The cigarette package of  claim 18 , wherein the paper comprises 19 pound or heaver paper.  
     
     
         21 . A method for forming a laminate containing a flavorant comprising: 
 a) feeding a first metal foil with a layer of metal oxide on both sides of the first metal foil and applying a layer of crosslinkable monomer to both sides of the first metal foil;    b) feeding a second metal foil with a layer of metal oxide on both sides of the second metal foil and applying a layer of crosslinkable monomer to both sides of the second metal foil;    c) forming a laminate by adhering the monomer coating on one side of the first metal foil to the monomer coating on one side of the second metal foil;    d) curing the monomer coatings; and    e) applying a flavor component to one side of the laminate.    
     
     
         22 . The method of  claim 21 , wherein the metal foil is aluminum foil or tin foil.  
     
     
         23 . The method of  claim 21 , wherein the thickness of the metal foil is between approximately 1 and 25 mils.  
     
     
         24 . The method of  claim 21 , wherein the coating is a polymer comprising acrylate subunits.  
     
     
         25 . The method of  claim 21 , wherein the thickness of the polymer coating is between approximately 0.25 and 5 mils.  
     
     
         26 . The method of  claim 21 , wherein the flavor component is menthol.  
     
     
         27 . The method of  claim 21 , wherein the menthol is applied to the laminate in the form of an alcohol/menthol solution.  
     
     
         28 . The method of  claim 21 , wherein the menthol is applied to the laminate in the form of a menthol-containing paper adhesively bonded to the laminate.  
     
     
         29 . The method of  claim 28 , wherein the amount of menthol in the paper is between about 2-65 weight percent, based on the dry weight of the paper.  
     
     
         30 . The method of  claim 28 , wherein the paper is Kraft paper or clay coat paper.  
     
     
         31 . The method of  claim 28 , wherein the monomer is applied to the metal foil in a composition which comprises a UV photoinitiator.  
     
     
         32 . The method of  claim 28 , further comprising forming a cigarette package by wrapping the laminate around a bundle of cigarettes.