Seal Bar and Process for Using Same

Abstract

The present disclosure provides a seal bar. In an embodiment, the seal bar comprises a base member having a flat front surface and a flat recessed surface a distance (d) behind the front surface. The front surface defines an x-axis, X. The flat recessed surface has a first endpoint (A1), wherein an axis that is perpendicular to the flat recessed surface at the first endpoint (A1) defines a first y-axis (Y1). The seal bar has a concave surface extending the distance (d) between the first endpoint (A1) and a point (B1) on the flat front surface. The concave surface defines a quadrant arc segment of an ellipse between the first endpoint (A1) and the point (B1).

1 - 8 . (canceled) 
     
     
         9 . A process comprising:
 A. providing a seal bar apparatus, the seal bar apparatus having a first heated seal bar and a second heated seal bar opposing the first heated seal bar,   each heated seal bar having a flat front surface and a flat recessed surface a distance (d) behind the flat front surface, and the flat front surface of the first seal bar faces the flat front surface of the second seal bar;   B. providing a fitment with a base and placing the base between two opposing multilayer films, each multilayer film having a respective seal layer comprising an olefin-based polymer and forming a film/base/film sandwich;   C. positioning the film/base/film sandwich between the opposing first heated seal bar and the second heated seal bar; and   D. sealing the base to each multilayer film with the opposing heated seal bars.   
     
     
         10 . The process of  claim 9  wherein the sealing comprises flattening the base with the opposing flat recessed surfaces of the first and second heat deal bars. 
     
     
         11 . The process of  claim 10  comprising
 forming opposing flattened ends of the base; and 
 forming seal joints at each flattened end of the base. 
 
     
     
         12 . The process of  claim 11  wherein the base comprises an ethylene/α-olefin multi-block copolymer, the process comprising
 forming, with the flattening, a caulk, the caulk comprising a material selected from the group consisting of melted olefin-based polymer from the seal layer, melted ethylene/α-olefin multi-block copolymer from the base, and combinations thereof. 
 
     
     
         13 . The process of  claim 12  comprising solidifying the caulk; and
 forming in situ winglets composed of the solidified caulk. 
 
     
     
         14 . The process of  claim 13  comprising forming with the in situ winglets, a seal between the films and the fitment at each flattened end of the base. 
     
     
         15 . The process of  claim 9  wherein providing the seal bar apparatus comprises
 providing a flat recessed surface having a first endpoint (A 1 ), wherein an axis that is perpendicular to the flat recessed surface at the first endpoint (A 1 ) defines a first y-axis (Y 1 ); 
 a concave surface extending the distance (d) between the first endpoint (A 1 ) and a point (B 1 ) on the flat front surface, the concave surface defining a quadrant arc segment of an ellipse between the first endpoint (A 1 ) and the point (B 1 ). 
 
     
     
         16 . The process of  claim 15  comprising
 providing a concave surface defining a quadrant arc segment of an ellipse defined by Equation ( 1 ) 
 
       
         
           
             
               
                 
                   
                     
                       
                         
                           
                             x 
                             1 
                             2 
                           
                           
                             
                               ( 
                               
                                 
                                   R 
                                   1 
                                 
                                  
                                 d 
                               
                               ) 
                             
                             2 
                           
                         
                         + 
                         
                           
                             y 
                             1 
                             2 
                           
                           
                             
                               ( 
                               d 
                               ) 
                             
                             2 
                           
                         
                       
                       = 
                       1 
                     
                     , 
                   
                 
                 
                   
                     Equation 
                      
                     
                         
                     
                      
                     
                       ( 
                       1 
                       ) 
                     
                   
                 
               
             
           
         
       
       wherein
 a center of the ellipse C 1  is the intersection of the x-axis (X) and the first y-axis, (Y 1 ); 
 d is from 0.3 mm to 2.0 mm; 
 x 1  is the ellipse semi-major axis having a length from 0.1 mm to 12.0 mm; 
 y 1  is the ellipse semi-minor axis having the length (d); and 
 R 1  is the ratio of the semi-major axis (x 1 ) divided by the semi-minor axis (y 1 ) and R 1  is from 0.6 to 3.0. 
 
     
     
         17 . The process of  claim 16  wherein providing the seal bar apparatus comprises providing a flat recessed surface comprising a second endpoint A 2  on an end opposite of the first endpoint (A 1 );
 an axis that is perpendicular to the flat recessed surface at the second endpoint (A 2 ) defining a second y-axis (Y 2 ); 
 a second concave surface extending the distance (d) between the second endpoint (A 2 ) and a point (B 2 ) on the flat front surface, the second concave surface defining a second quadrant arc segment of a second ellipse between the second endpoint (A 2 ) and the point (B 2 ). 
 
     
     
         18 . The process of  claim 17  comprising
 providing a seal bar wherein the second concave surface defines a second quadrant arc segment of the second ellipse defined by Equation (2) 
 
       
         
           
             
               
                 
                   
                     
                       
                         
                           
                             x 
                             2 
                             2 
                           
                           
                             
                               ( 
                               
                                 
                                   R 
                                   2 
                                 
                                  
                                 d 
                               
                               ) 
                             
                             2 
                           
                         
                         + 
                         
                           
                             y 
                             2 
                             2 
                           
                           
                             
                               ( 
                               d 
                               ) 
                             
                             2 
                           
                         
                       
                       = 
                       1 
                     
                     , 
                   
                 
                 
                   
                     Equation 
                      
                     
                         
                     
                      
                     
                       ( 
                       2 
                       ) 
                     
                   
                 
               
             
           
         
       
       wherein
 a center of the second ellipse (C 2 ) is the intersection of the x-axis (X) and the second y-axis, (Y 1 ); 
 d is from 0.3 mm to 2.0 mm; 
 x 2  is the second ellipse semi-major axis having a length from 0.1 mm to 12.0 mm; 
 y 2  is the second ellipse semi-minor axis having the length (d); and 
 R 2  is the ratio of the semi-major axis (x 1 ) divided by the semi-minor axis (y 1 ) and R 1  is from 0.6 to 3.0.