U.S. patent application number 09/837399 was filed with the patent office on 2002-10-24 for flexible package with audio tract.
Invention is credited to Gendreau, Steven C., Mallik, Donald W..
Application Number | 20020153273 09/837399 |
Document ID | / |
Family ID | 25274333 |
Filed Date | 2002-10-24 |
United States Patent
Application |
20020153273 |
Kind Code |
A1 |
Mallik, Donald W. ; et
al. |
October 24, 2002 |
Flexible package with audio tract
Abstract
A flexible container comprising an audio tract. The audio tract
is incorporated into the container as the container is made. The
audio tract produces an audible sound when a stylus is moved across
the surface of the tract. A method of producing a flexible
container comprising forming an audio tract on a sheet of flexible
packaging material.
Inventors: |
Mallik, Donald W.; (Atlanta,
GA) ; Gendreau, Steven C.; (Acworth, GA) |
Correspondence
Address: |
SUTHERLAND ASBILL & BRENNAN LLP
999 PEACHTREE STREET, N.E.
ATLANTA
GA
30309
US
|
Family ID: |
25274333 |
Appl. No.: |
09/837399 |
Filed: |
April 18, 2001 |
Current U.S.
Class: |
206/459.1 ;
206/459.5; 383/63 |
Current CPC
Class: |
B65D 75/12 20130101;
B65D 33/255 20130101; B65D 75/54 20130101; B65D 33/00 20130101 |
Class at
Publication: |
206/459.1 ;
206/459.5; 383/63 |
International
Class: |
B65D 085/00; B65D
033/16 |
Claims
What we claim:
1. A flexible container comprising: an enclosure formed of flexible
sheet material; a closure for sealing the enclosure; and an audio
tract on the flexible sheet material comprising a series of grooves
for producing an audible sound when a stylus is moved across the
surface of the grooves.
2. The flexible container of claim 1, wherein the audio tract is
located on or adjacent the closure.
3. The flexible container of claim 2, wherein the closure is a
seam, zipper, snap closure, slide closure, lap seal or fin
seal.
4. The flexible container of claim 3, wherein the closure is a
seam.
5. The flexible container of claim 2, wherein the enclosure has a
top, a side and a bottom and the closure is located on the top,
side or bottom of the enclosure.
6. The flexible container of claim 1, wherein the flexible sheet
material is a thermoplastic film.
7. The flexible container of claim 6, wherein the flexible sheet
material is a polyester, polyethylene or polypropylene film.
8. The flexible container of claim 1, wherein the audible sound is
in the form of musical notes or spoken words.
9. The flexible container of claim 1, wherein the audio tract is
incorporated into the flexible sheet material as the enclosure is
formed.
10. The flexible container of claim 1, wherein the closure is a
zipper including a zipper slider for opening and closing the zipper
and a stylus connected to the zipper slider such that the stylus
moves across the audio tract when the zipper slider is moved.
11. A method of producing a flexible container comprising: forming
flexible sheet material into an enclosure; sealing the enclosure
with at least one closure; and forming an audio tract on the
flexible sheet material, the audio tract comprising a series of
grooves for producing an audible sound when a stylus is moved
across the surface of the grooves.
12. The method of claim 11, wherein the step of forming the audio
tract comprises embossing the audio tract onto the flexible sheet
material.
13. The method of claim 11, wherein the audio tract is formed on
the flexible sheet material so that the audio tract is located on
the at least one closure.
14. The method of claim 12, wherein the enclosure has a top, a side
and a bottom and the at least one closure is located on the top,
side or bottom of the enclosure.
15. The method claim 13, wherein the at least one closure is a
seam, zipper, snap closure, slide closure, lap seal, or fin
seal.
16. The method claim 13, wherein the at least one closure is a
seam.
17. The method of claim 16, wherein the audio tract and seam are
formed simultaneously, and the audio tract is part of the seam.
18. The method of claim 11, wherein the flexible sheet material is
a thermoplastic film.
19. The method of claim 18, wherein the flexible sheet material is
a polyester, polyethylene or polypropylene film.
20. The method of claim 11, wherein the method is continuous.
21. The method of claim 11, wherein the audio tract is formed by:
applying a softened thermoplastic polymer to the flexible sheet
material; and embossing the audio tract into the thermoplastic
polymer with an engraved disc.
22. The method of claim 21, wherein the thermoplastic resin is
polyolefin, nylon, vinyl, EVA copolymer, styrene butadiene block
copolymer, or wax.
23. The method of claim 11, wherein the audio tract is formed by:
applying a curable resin to a first side of the flexible sheet
material; embossing the audio tract into the resin with an engraved
roller; and curing the resin so that the audio tract is adhered to
the packaging material.
24. The method of claim 23, wherein the resin is cured while it is
in contact with the engraved roller.
25. The method of claim 23, wherein the resin is cured with
ultraviolet radiation.
26. The method of claim 12, wherein the embossing step comprises
bringing a heated engraved disk into rolling contact with the
flexible sheet material.
27. The method of claim 12, wherein the embossing step comprises
bringing an embossing die into contact with the flexible sheet
material.
28. The method of claim 27, the embossing die simultaneously forms
the audio tract and closure, and wherein the audio tract is part of
the closure.
29. The method of claim 11, wherein the step of forming the
enclosure comprises: forming the flexible sheet material into a
flexible pouch comprising at least two layers, a top edge, two side
edges, and a bottom edge; and forming a first closure at the bottom
edge, a second closure at the first side edge, and a third closure
at the second side edge.
30. The method of claim 29, further comprising forming a fourth
closure at the top edge.
31. The method of claim 30, wherein the audio tract is formed on
the flexible sheet material so that the audio tract is located on
the first, second, third or fourth closure.
32. The method of claim 31, wherein the closure comprising the
audio tract is a seam, zipper, snap closure, slide closure, lap
seal or fin seal.
33. The method of claim 32, wherein the audio tract and the closure
are formed simultaneously, and the audio tract is part of the
closure.
34. The method of claim 29, further comprising folding the sheet of
flexible material to form a bottom folded edge and the at least two
layers.
35. The method of claim 34, wherein the first closure is formed by
the bottom folded edge.
36. The method of claim 34, further comprising: prior to forming
the structure, forming the second and third closure on the flexible
material wherein the closures are spaced apart and are
perpendicular to the bottom folded edge.
37. The method of claim 29, wherein the audio tract is formed by:
applying a softened thermoplastic polymer to the flexible sheet
material; and embossing the audio tract into the thermoplastic
polymer with an engraved disc.
38. The method of claim 29, wherein the audio tract is formed by:
applying a curable resin to a first side of the flexible sheet
material; embossing the audio tract into the resin with an engraved
roller; and curing the resin so that the audio tract is adhered to
the packaging material.
39. The method of claim 29, wherein the audio tract is formed by
embossing the audio tract into the flexible sheet material with a
heated engraved disk.
40. The method of claim 29, wherein the audio tract is formed by
bringing an embossing die into contact with the flexible sheet
material wherein the audio tract is embossed into the flexible
sheet material.
41. The method of claim 40, the embossing die simultaneously forms
the audio tract and closure, and wherein the audio tract is part of
the closure.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to the packaging industry, and
more particularly to a flexible container comprising an audio
tract, as well as a method for making the same.
BACKGROUND OF THE INVENTION
[0002] The production of sound from manually operated audio tract
strips is well known in the prior art. Typically, a recorded audio
tract is placed on a strip of material and an audible sound is
produced when a fingernail or other stylus is moved against the
audio tract. These "talking strips" are useful for education,
entertainment and advertising purposes. For example, the audio
tracts may be attached to book pages for assisting young children
in reading, or the audio strips may be located on greeting cards
for the purpose of delivering an audible message to the card
recipient.
[0003] Typically, items comprising audio strips are produced by
preforming the audio tract and subsequently attaching it to the
item or engraving the audio tract into the surface of the item.
Depending on the shape and material of the object, the step of
attaching or engraving the audio strip onto the object can be
difficult and time consuming. Therefore, there is a need for an
improved method of incorporating an audio tract into an item.
SUMMARY OF THE INVENTION
[0004] The present invention provides a flexible container
comprising an audio tract, wherein the audio tract is incorporated
into the container as the container is formed. The flexible
container comprises an enclosure formed of flexible sheet material
so as to have a closure for sealing the enclosure. An audio tract
is located on the flexible sheet material and the audio tract
comprises a series of grooves for producing an audible sound when a
stylus is moved across the surface of the grooves.
[0005] Suitable closures include a seam, zipper, snap or slide
closure. According to one embodiment, the audio tract is located on
the closure. Suitable flexible sheet material includes
thermoplastic film such as a polyester, polyethylene or
polypropylene film.
[0006] The present invention also relates to a method of producing
a flexible container comprising the steps of forming flexible sheet
material into an enclosure and sealing the enclosure with at least
one closure. An audio tract is formed on the flexible sheet
material wherein the audio tract comprises a series of grooves for
producing an audible sound when a stylus is moved across the
surface of the grooves.
[0007] One suitable method for incorporating the audio tract is
embossing the tract onto the flexible sheet material. The audio
tract may be formed on the flexible sheet material so that the
audio tract is located on the at least one closure. Desirably, the
audio tract and closure are produced simultaneously and the method
of forming the flexible container is continuous.
[0008] According to one embodiment, the audio tract is formed by
delivering a softened thermoplastic polymer to the flexible sheet
material. An engraved disc is brought in rolling contact with the
flexible sheet material so that the audio tract is embossed into
the thermoplastic polymer. Alternatively, the audio tract is formed
by applying a curable resin to a first side of the flexible sheet
material, and bringing an engraved roller in rolling contact with
the flexible sheet material so that the audio tract is embossed
into the resin. The resin is cured in order to harden and adhere
the audio tract to the flexible sheet material.
[0009] In a further embodiment, a heated engraved disk is brought
in rolling contact with the flexible sheet material so that the
audio tract is embossed into the flexible sheet material. The audio
tract may also be embossed into the flexible sheet material by
bringing an embossing die into contact with the flexible sheet
material. The embossing die may be used to simultaneously form the
audio tract and the closure when the audio tract is part of the
closure.
[0010] Other objects, features, and advantages to this invention
will be apparent from the following detailed description of
embodiments of the invention, claims, and drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0011] FIGS. 1a-1d are plan views of flexible containers made in
accordance with an embodiment of this invention.
[0012] FIG. 2 is a plan view of a flexible container made in
accordance with another embodiment of this invention.
[0013] FIG. 3 is a perspective view of a flexible container made in
accordance with an alternative embodiment of this invention.
[0014] FIG. 4 is a partial perspective view of an apparatus for
applying an audio tract in accordance with the invention.
[0015] FIG. 5 is a side view of an alternative apparatus for
applying an audio tract in accordance with an embodiment of the
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring to FIGS. 1a-1d, shown is a flexible container or
pouch 10 comprising an enclosure 11 having a first side 12 and a
second side 14. The enclosure 11 is formed of flexible sheet
material and comprises at least one closure 16. An audio tract 18
is located on the flexible sheet material and produces an audible
sound when a stylus is moved across the audio tract. As indicated,
the enclosure 11 may comprise additional closures 16 which seal the
edges of the enclosure about the periphery of the enclosure. The
audio tract may be located on or adjacent the at least one closure
16 or on or adjacent one or more of the additional closures.
[0017] The enclosure 11 may be formed from any flexible sheet
material including, but not limited to thermoplastic material such
as polyesters, polyethylenes, and polypropylene, cellophanes,
paper, foil and combinations thereof. Desirably, the flexible sheet
material is heat-sealable.
[0018] The audio tract 18 comprises a series of sound grooves
whereby an audible sound is heard when a stylus is moved across the
surface of the grooves down the length of the audio tract. The
audio tract 18 may be designed to produce any type of registered or
unregistered audible sound such as, phrases, musical notes, or
animal sounds, for example. Preferably, the audible sound is in the
form of a musical or spoken message which can be used for
advertising purposes including sweepstakes, contests, collector's
items, or novelties.
[0019] Various types of closures 16 may be utilized in the flexible
container 10 of the present invention. Examples of suitable
closures include, but are not limited to a seam, zipper, snap or
slide closure, lap seal or fin seal. Preferably, the closure 16 is
a seam.
[0020] In the preferred embodiment, the closure 16 comprising the
audio tract 18 is located on the top, side or bottom of the
enclosure 11 as illustrated in FIGS. 1a-1d. However, this closure
16 may be located anywhere on the flexible container enclosure
11.
[0021] The audio tract 18 may be embossed on the flexible sheet
material so that the tract forms an integral part of the closure
16. For example, the audio tract 18 may be embossed into one side
of the closure 16. Alternatively, as illustrated in FIG. 2, the
audio tract 18 may be embossed into a zipper as the zipper is
attached to the enclosure 11. If the audio tract 18 is formed on a
zipper closure 16, the audio tract can be placed adjacent the
zipper slider 19 so that when the slider is moved to open the
container the slider engages the audio tract and acts as a stylus
to generate sound from the audio tract. The slider 19 can include a
protrusion which acts as a stylus.
[0022] Another embodiment is illustrated in FIG. 3 wherein a film
of pre-embossed audio tract 18 is attached to the outside of the
flexible container 10. A form, fill and seal machine may be used to
seal the audio tract 18 to the top closure 16 and bottom closure
16.
[0023] The flexible container 10 can be formed in a variety of
shapes or configurations. For example, the container 10 my comprise
a single pouch, multiple pouches, or side or bottom gusset.
Preferably, the flexible container 10 is substantially rectangular
in shape.
[0024] The present invention also relates to a method of producing
a flexible container 10 including an audio tract 18. As shown in
FIG. 4, the audio tract 18 is formed on flexible sheet material 20
as the container 10 is being produced. The flexible sheet material
20 is formed into an enclosure 11 and the enclosure is sealed with
at least one closure 16. An audio tract 18 is formed on the
flexible sheet material 20, wherein the audio tract comprises a
series of grooves for producing an audible sound when a stylus is
moved across the surface of the grooves. Preferably, the method of
producing the flexible container is continuous.
[0025] Further, the audio tract 18 may be formed on the flexible
sheet material 20 so that the audio tract is located on the at
least one closure 16. The enclosure 11 may be formed to have a top,
a side and a bottom wherein the closure 16 comprising the audio
tract 18 is located on the top, side or bottom of the
enclosure.
[0026] The enclosure 11 may be sealed with any type of closure 16
including but not limited to a seam, zipper, snap or slide closure,
lap seal or fin seal.
[0027] A standard "Form, Fill and Seal" (f/f/s) machine is
typically used to produce the flexible container 10. However, it is
not necessary that the filling step and sealing step be performed
at the same time as the forming operation. The audio tract 18 is
formed on the top edge of the flexible container 10 as produced on
a horizontal f/f/s machine. This is the parallel to the web
direction of the flexible sheet material 20 from which the
container 10 is formed.
[0028] In a standard horizontal f/f/s machine (not illustrated), a
sheet of flexible sheet material 20 from a roll is fed to a plow
assembly which folds the sheet in half. A plurality of closures 16
are formed in the flexible sheet material 20 wherein the closures
are spaced apart and are perpendicular to the fold. The folded edge
may function as the closure 16 at the bottom edge of the enclosure
11, or if desired, a seam may be formed along the folded edge. The
flexible sheet material 20 is cut to form a plurality of enclosures
11 comprising at least two layers, an open top edge, two sealed
side edges and a bottom folded or sealed edge. The enclosure 11 is
filled and then a closure 16 is formed on the flexible sheet
material 20. Preferably, the audio tract 18 is located on a closure
16 at the top edge, side edge or bottom of the enclosure 11.
[0029] In a standard vertical f/f/s machine, flexible sheet
material 20 from a roll is fed through a series of rollers. A
bag-forming collar receives the sheet from the rollers and changes
the sheet travel from a flat plane and shapes it around a bag
forming tube. As the flexible sheet material 20 moves down around
the tube, the overlapped edges of the sheet are sealed with a
vertical seal bar, thereby forming the flexible sheet material into
a tube. The length of the flexible container 10 will be equal to
the extent of the flexible sheet material 20 hanging down from the
bottom of the tube. A filling tube is used to fill the container
10. A cross seal consisting of a front and rear cross-sealing jaw
seals the container 10. Each cross sealing jaw comprises a top
sealing section and a bottom sealing section with a container
cutoff device in between. The top sealing section seals the bottom
of an empty container 10 suspended down from the forming tube, and
the bottom portion seals the top of a filled container 10. The
cutoff device, which can be a knife or a hot wire, operates during
the jaw closing/sealing operation. Thus, when the jaws open, the
filled container 10 is released from the machine.
[0030] The audio strip 18 is formed or embossed onto the flexible
packaging material 20 prior to the formation of the closure 16, or
the audio tract is embossed on or beside the closure after the
closure is formed. Alternatively, the audio tract 18 and closure 16
are formed simultaneously so that the audio tract is part of the
closure.
[0031] Any method of embossing the audio tract 18 onto the flexible
sheet material 20 may be employed. The audio tract 18 may be
embossed into any width flexible sheet material 20 or coating on
the material, using heat and/or pressure. The following are
possible methods of embossing the audio tract 18, but do not
constitute all possibilities.
[0032] As shown in FIG. 4, the audio tract 18 can be engraved into
the edge of the disk or a previously engraved audio tract may be
attached to the edge of a disk to produce an engraved disk 21. The
engraved disk 21 may be any size, and is preferably about 3.0
inches in diameter and less than about 1.0 inch wide.
[0033] In one embodiment, the audio tract 18 is formed from a
thermoplastic polymer 22 that is melted and delivered as a small
bead or thin layer to the area of flexible sheet material 20 where
the audio tract 18 will be formed. Examples of suitable
thermoplastic polymers include, but are not limited to polyolefin,
nylon, vinyl, EVA copolymers, SBR-styrene butadiene block
copolymers, and wax. While the polymer bead or layer is still
relatively soft, the engraved disk 21, which is in rolling contact
with the flexible sheet material 20, embosses the audio tract 18
into the thermoplastic material 22. The embossment of the audio
tract 18 may also function to simultaneously form the container
closure 16. Alternatively, a separate strip of material is attached
to the flexible sheet material 20 and the strip is embossed with
the audio tract 18. The engraved disk 21 is maintained in register
to the flexible sheet material 20 so that the audio tract 18 is
always in the proper position on the finished container 10.
[0034] If desired, a smooth disk 24 is brought in rolling contact
with the opposite side of the flexible sheet material 20, wherein
the engraved disk 21 presses against the smooth disk thereby
allowing sufficient pressure to emboss the audio tract 18. The
smoother disk 24 may be any size, and is preferably about 3.0
inches in diameter and less than about 1.0 inch wide.
[0035] Alternatively, a heated engraved disk 21 similar to that
described above can emboss the audio tract 18 directly into the
flexible sheet material 20 without the use of the melted
thermoplastic polymer 22. In another embodiment, the flexible sheet
material 20 is heated and the audio tract 18 is embossed with a
heated or unheated engraved disk 21.
[0036] Furthermore, it is possible to form the audio tract 18 on
the packaging material 20 by utilizing a curing process as opposed
to thermal embossing. This process is illustrated in FIG. 5. One
example of this technique is to coat a curable resin 26 on one side
of the flexible sheet material 20. The curable resin 26 may be
applied through the use of rollers 28. An engraved roller or drum
30, the surface of which is engraved with the audio tract 18 is
brought into rolling contact with the flexible sheet material 20 to
emboss the audio tract into the uncured resin coating 26. The resin
coating 26 is then cured with heat or ultraviolet radiation from a
heat source or ultraviolet radiation source 31. The resin coating
26 may be cured while it is in contact with the engraved roller or
drum 30. If the resin coating 26 is cured with ultraviolet
radiation, the radiation may be directed through the flexible sheet
material 20 while the coating is being engraved. If desired, a
smoother roller or drum (not shown) is brought into rolling contact
with the opposite side of the flexible sheet material 20, so that
the engraved roller 30 presses against the smoother roller thereby
providing sufficient pressure to emboss the audio tract 18. Upon
removal of the flexible sheet material 20, the cured pattern of the
audio tract 18 is adhered to the flexible sheet material with the
audio tract surface exposed.
[0037] In another embodiment (not illustrated), a flat embossing
die is used instead of a circular engraved disk. The embossing die
is brought into contact with the flexible sheet material and the
audio tract is embossed through a reciprocating motion of two die
bars. The embossing die may be used to form the audio tract at the
same time as the container closure wherein the audio tract is an
integral part of the closure.
[0038] It is also possible to print the audio tract onto the
packaging material via a wax printer.
[0039] The above-described methods may further be used to emboss
the audio tract 18 into a separate strip of material, followed by
attaching the strip to the packaging material 20 with an adhesive
as the container 10 is formed.
[0040] The audio tract 10 itself may be produced by several
techniques. One example is generating and recording the desired
sound as an audio wave file on a computer. The wave file can then
be manipulated to produce the desired sound effect. It can then be
transposed into a machine language used by an appropriate engraving
machine. The audio tract is then engraved into the surface of a
plate, cylinder, or the edge of a disk. The plate, cylinder, or
disk may become the actual embossing device, or it may be
replicated into another surface by electroforming or casting. The
replicated surface may then be configured as the embossing device,
or be used in turn to make the actual embossing device.
[0041] It should be understood that the foregoing relates to
particular embodiments of the present invention, and that numerous
changes may be made therein without departing from the scope of the
invention as defined by the following claims.
* * * * *