Method for Preparing a Scored Flexible Structure, and Method for Making a Flexible Packaging Structure Having A Built-In Open and Reclose Feature

A method for preparing a scored flexible structure, comprising the steps of:

• (i) providing a structure comprising a web of flexible material;
• (ii) enhancing a thickness of the structure in a discrete region thereof by applying a substantially all-solids electron-beam-curable polymer material in fluid form onto the discrete region, the discrete region occupying a minor percentage of a total surface area of the structure;
• (iii) curing the polymer material by irradiating the polymer material with an electron beam, thereby forming an EB-cured polymer region;
• and
• (iv) forming a score line through a thickness of the EB-cured polymer region and through the thickness of the structure.

A flexible packaging structure having a built-in open and reclose feature, comprising:

• a laminate comprising a first structure adhesively laminated to a second structure, the first structure comprising a web of flexible material and the second structure comprising a web of flexible material;
• an EB-cured polymer region formed on the first structure for enhancing a thickness of the first structure in a discrete region thereof, the discrete region occupying a minor percentage of a total surface area of the first structure and corresponding to a desired location of the built-in open and reclose feature to be formed, the EB-cured polymer region being formed by applying a substantially all-solids electron-beam-curable polymer material in fluid form onto the discrete region and curing the polymer material by irradiating the polymer material with an electron beam;
• a first score line formed through a thickness of the EB-cured polymer region and through the thickness of the first structure so as to create a first flap in the first structure, the first flap being movable out of a plane of the first structure to create an opening through the first structure;
• a second score line formed in the second structure so as to create a second flap in the second structure, the second flap being movable out of a plane of the second structure to create an opening through the second structure, the second flap having a smaller footprint than the first flap;
• wherein the first and second flaps are placed in registration and adhesively joined together so that a marginal region of the first flap extends beyond a periphery of the second flap, and wherein the adhesive includes at least a pressure-sensitive adhesive that is positioned to adhere the marginal region of the first flap to an underlying surface of the second structure.