U.S. patent application number 10/156455 was filed with the patent office on 2003-12-04 for package with pocket and method for making the same.
Invention is credited to Knoerzer, Anthony Robert, Kohl, Garrett William, Tucker, Steven Kenneth.
Application Number | 20030223653 10/156455 |
Document ID | / |
Family ID | 29582268 |
Filed Date | 2003-12-04 |
United States Patent
Application |
20030223653 |
Kind Code |
A1 |
Knoerzer, Anthony Robert ;
et al. |
December 4, 2003 |
Package with pocket and method for making the same
Abstract
A flexible package and method for making the same provides for a
package that has a pocket formed adjacent to a portion of a
package. Thereby, the package, such as a snack food package, can be
filled with one product in the main compartment of the package and
can be filled with a separate product in the pocket. To realize
this, the package is formed with an extra length of film extended
adjacent to the main portion of the tube of the package. First and
second longitudinal seals are provided to form a pocket over a
portion of the tube of the package. The package can then be filled
with a first product in the main portion of the package and a
second product in the separate and distinct pocket.
Inventors: |
Knoerzer, Anthony Robert;
(Plano, TX) ; Kohl, Garrett William; (Allen,
TX) ; Tucker, Steven Kenneth; (Hurst, TX) |
Correspondence
Address: |
CARSTENS YEE & CAHOON, LLP
P O BOX 802334
DALLAS
TX
75380
|
Family ID: |
29582268 |
Appl. No.: |
10/156455 |
Filed: |
May 28, 2002 |
Current U.S.
Class: |
383/40 ;
383/127 |
Current CPC
Class: |
B65D 33/004 20130101;
B65D 75/46 20130101; B65D 31/12 20130101 |
Class at
Publication: |
383/40 ;
383/127 |
International
Class: |
B65D 030/22 |
Claims
What is claimed is:
1. A flexible package, comprising: a film body formed as a discrete
package for containing a first product; and a pocket for containing
a second product from a main body of the package containing the
first product wherein the film body and the pocket are produced
from a continuous segment of film.
2. The flexible package of claim 1 wherein the package is formed
from a loop of the continuous segment of film having the first and
second products placed within the package prior to sealing both
terminal ends of the loop.
3. The flexible package of claim 1 wherein a back seal is formed
axially along the package to form the main body.
4. The flexible package of claim 3 wherein the pocket is formed
from overlapped film body positioned adjacent to a portion of the
main body.
5. The flexible package of claim 4 wherein the pocket begins at a
first back seal and extends axially to at least a second back
seal.
6. The flexible package of claim 5 wherein terminal ends of the
pocket are sealed to portions of terminal ends of the package.
7. The flexible package of claim 5 wherein one or more additional
back seals are provided to form one or more additional pockets.
8. The flexible package of claim 1 wherein the second product is a
printed graphic or food product.
9. The flexible package of claim 1 wherein the second product is
air.
10. A method for forming a package with a pocket, comprising:
forming a sheet of film into a tube with an overlapped segment of
film extending adjacent to the tube to form a the pocket; providing
at least two seals longitudinally along the pocket; and sealing
transversely both terminal ends of the tube and the pocket to form
a flexible package with pocket.
11. The method for forming the package of claim 10 further
comprising placing product within the package prior to sealing the
package at both terminal ends of the tube.
12. The method for forming the package of claim 10 wherein the
pocket is formed by extending the film outwardly and over the main
body of the tube to a predetermined length.
13. The method for forming the package of claim 10 wherein the
pocket is formed along a back portion of the tube.
14. The method for forming the flexible package of claim 10 further
comprising positioning a printed graphic or food product within the
pocket prior to forming the transverse seals at the terminal
ends.
15. The method for forming the flexible package of claim 10 wherein
at least one additional seal is formed longitudinally between the
at least two longitudinal seals to form at least two pockets over
the main body of the tube.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a flexible package, and the
method for making same. More particularly, the present invention
relates to a flexible package, and the method for making the same
that contains a pocket. The invention allows for the production of
a flexible package with a pocket that can be filled with material
such that the material in the pocket is integral to the package and
easily accessible yet separated from a main portion of the
package.
[0003] 2. Description of Related Art
[0004] Vertical form, fill, and seal packaging machines are
commonly used in the snack food industry for forming, filling, and
sealing bags of chips and other like products. Such packaging
machines take a packaging film from a sheet roll and forms the film
into a vertical tube around a product delivery cylinder. The
vertical tube is vertically sealed along its length to form a back
seal. The machine applies a pair of heat-sealing jaws or facings
against the tube to form a transverse seal. This transverse seal
acts as the top seal on the bag below and the bottom seal on the
package being filled and formed above. The product to be packaged,
such as potato chips, is dropped through the product delivery
cylinder and formed tube and is held within the tube above the
bottom transverse seal. After the package has been filled, the film
tube is pushed downward to draw out another package length. A
transverse seal is formed above the product, thus sealing it within
the film tube and forming a package of product. The package below
said transverse seal is separated from the rest of the film tube by
cutting across the sealed area.
[0005] The packaging film used in such process is typically a
composite polymer material produced by a film converter. For
example, one prior art composite film used for packaging potato
chips and like products is illustrated in FIG. 1a, which is a
schematic of a cross-section of the film illustrating each
individual substantive layer. FIG. 1a shows an inside, or product
side, layer 16 which typically comprises metalized oriented
polypropylene ("OPP") or metalized polyethylene terephtalate
("PET"). This is followed by a laminate layer 14, typically a
polyethylene extrusion, and an ink or graphics layer 12. The ink
layer 12 is typically used for the presentation of graphics that
can be viewed through a transparent outside layer 10, which layer
10 is typically OPP or PET.
[0006] The prior art film composition shown in FIG. 1a is ideally
suited for use on vertical form and fill machines for the packaging
of food products. The metalized inside layer 16, which is usually
metalized with a thin layer of aluminum, provides excellent barrier
properties. The use of OPP or PET for the outside layer 10 and the
inside layer 16 further makes it possible to heat seal any surface
of the film to any other surface in forming either the transverse
seals or back seal of a package.
[0007] Typical back seals formed using the film composition shown
in FIG. 1a are illustrated in FIGS. 2 and 3. FIG. 2 is a schematic
of a "lap seal" embodiment of a back seal being formed on a tube of
film. FIG. 3 illustrates a "fin seal" embodiment of a back seal
being formed on a tube of film.
[0008] With reference to FIG. 2, a portion of the inside metalized
layer 26 is mated with a portion of the outside layer 20 in the
area indicated by the arrows to form a lap seal. The seal in this
area is accomplished by applying heat and pressure to the film in
such area. The lap seal design shown in FIG. 2 insures that the
product to be placed inside the formed package will be protected
from the ink layer by the metalized inside layer 26.
[0009] The fin seal variation shown in FIG. 3 also provides that
the product to be placed in the formed package will be protected
from the ink layer by the metalized inside layer 36. Again, the
outside layer 30 does not contact any product. In the embodiment
shown in FIG. 3, however, the inside layer 36 is folded over and
then sealed on itself in the area indicated by the arrows. Again,
this seal is accomplished by the application of heat and pressure
to the film in the area illustrated.
[0010] As noted, a benefit of both the prior art fin seal and lap
seal design is the containment of the product in the package by a
barrier layer (the metalized inside layer) that keeps ink and
solvent levels in the package to a minimum. Ink and solvent levels
in fatty food packages are frequently regulated to insure product
safety. It may be desirable, however, to provide a graphics
capability inside a package. This would allow for promotional
information or coupons to be maintained inside the package and only
accessible after the consumer has opened the package. For example,
a promotional prize campaign could be offered with the prize
announcements being maintained inside the package. Likewise,
coupons offering product rebate rewards, promotional prize points,
or discounts on products could be maintained within the sealed
package.
[0011] One prior art method used to provide a graphics capability
inside the package involves the use of a paper insert dropped with
the product into the package during filling. When the consumer
opens the package, the paper insert can be removed for viewing and
use. This method has several drawbacks, however. The reliability of
placing a single paper insert in each bag (by dropping the paper
with a weighed amount of product) is a major consideration,
particularly in small packages. A capacity issue is raised by the
need to rent inserters to be used during the filling process.
Foreign matter detectors are also frequently set off by the
detection of the paper insert within the bag. The insertion of a
piece of paper can raise the solvent level in the package beyond
acceptable levels. All of the above greatly adds to the expense of
each single package.
[0012] Another approach to providing graphics within the bag would
involve the application of the graphics directly to the inside
metalized layer 16 shown in FIG. 1a. The application of such
graphics can be accomplished using an inkjet printer. However, this
method likewise raises a capacity issue, since present technology
converters produce packaging film at a speed of 1500 to 2000 feet
per minute, while the capacity of present inkjet printer heads is
approximately 300 feet per minute. Additional modification to
converters must be made in order to keep the inkjet printing in
register with the graphics formed by the ink layer 12. All of the
above considerations again add to the cost of the package. In
addition, the United States Food & Drug Administration does not
presently allow for the use of an ink-carrying layer that comes
into contact with a fatty food.
[0013] Another prior art approach to this issue is illustrated in
FIG. 1b, which is again a schematic cross-section of a packaging
film. As with the embodiment shown in FIG. 1a, the embodiment shown
in FIG. 1b comprises an outside OPP layer 10 followed by an ink
layer 12, a laminate layer 14, and a metalized OPP or PET layer 16.
However, an additional laminate layer 14' is applied to the
metalized layer 16 so that an additional ink layer 12' and OPP or
PET layer 10' can be used as the new inside layer 10'. The use of
the ink layers 12, 12' as the second to last layer on both the
outside and inside of the package allows for a full graphics
capability on both the outside and the inside of the film. The
additional film, however, adds approximately sixty percent (60%) to
the cost of the material when compared with the embodiment shown in
FIG. 1a. Overall capacity is also cut in half, since the film must
be run through a typical converter twice. Further, since the
material is 60% thicker, it cannot be run on a vertical form and
fill machine at speeds as high as that used to make packages out of
the embodiment shown in FIG. 1a. This is because longer dwell times
must be used to form all the seals involved. As with the inkjet
printer solution, the embodiment shown in FIG. 2a also requires
additional efforts to keep the inside graphics and outside graphics
in registration. Importantly, the embodiment shown in FIG. 1b again
places ink inside a functional barrier layer, the metalized layer
16, which is not presently permitted for direct contact with many
foods by the United States Food & Drug Administration.
[0014] In addition to ink and solvent concerns with package
construction, packages, particularly with snack foods, benefit from
marketing. With current packaging, inserts or other graphics, such
as coupons and game pieces, are separately packaged and deposited
into snack food packages or are temporally adhered to the exterior
of the packages. With the former, inserts are hidden from consumers
hindering the effectiveness of the promotion. With the latter,
graphic materials adhered to package exteriors can be dislodged and
lost. Consequently, a need exists for a package construction and
method that allows for a package to self-contain inserts, graphic
materials, and other products separated from the main compartment
of the package. Thereby, flexible package constructions would
benefit have a separate compartment for placement of materials with
graphics so as to avoid or, at least minimize, ink and solvent
contact with food in addition to marketing benefits.
SUMMARY OF THE INVENTION
[0015] The proposed invention involves producing a package made
from flexible film having a film body formed as a discrete package.
A pocket for containing materials separate from a main portion of
the package is formed on and along a portion of the package. To
achieve this, the pocket is formed from a continuous segment of
film laid against the main portion of the package. Thereby, the
package can be filled with a first product such as snack chips
while the pocket is filled with a printed material or other food
product for example. Advantageously, the first product is kept
separate from the second product placed in the pocket. This avoids
any product-to-product contamination.
[0016] One method for forming a package with a pocket comprises
forming a sheet of film into a tube with an overlapped segment of
film extending out and over the tube to form the pocket.
Thereafter, at least two seals are formed longitudinally along the
overlapped segment of film forming the pocket. Sealing both
terminal ends of the tube and the pocket finishes the package.
Optionally, a multiple pockets can be formed along the exterior of
the package by providing more than two longitudinal seals.
[0017] The above as well as additional features and advantages of
the present invention will become apparent in the following written
detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The novel features believed characteristic of the invention
are set forth in the appended claims. The invention itself,
however, as well as a preferred mode of use, further objectives and
advantages thereof, will be best understood by reference to the
following detailed description of illustrative embodiments when
read in conjunction with the accompanying drawings, wherein:
[0019] FIGS. 1a and 1b are schematic cross-section views of prior
art packaging films;
[0020] FIG. 2 is a schematic cross-section view of a tube of
packaging film illustrating the formation of a prior art lap
seal;
[0021] FIG. 3 is a schematic cross-section of a tube of packaging
film illustrating the formation of a prior art fin seal;
[0022] FIG. 4 is a cross-sectional view of a package having a
pocket made in accordance with an embodiment of the invention;
and
[0023] FIG. 5 is a top perspective view of the package in FIG. 4
showing an article contained within the pocket.
DETAILED DESCRIPTION
[0024] FIG. 4 shows a cross sectional view of a flexible package 50
for containing snack food products. The composition of the package
material can be the same as used for prior art packaging as
described in relation to FIG. 1a or any other prior art film
composition used for the product application in the instant
invention.
[0025] A film 52 used in the present invention is fed into a
vertical or horizontal form, fill, and seal packaging machine
capable of manufacturing a package in accordance with the
invention. Thereby, package 50 is formed having a front 54 and a
back 56. Since film 52 is a flat film, film 52 is fed into the
packaging machine generally to form a cylinder. The leading end of
the film is sealed to a trailing end of the same film to form a
first back seal 62 rendering the cylinder independent. A second
back seal 64 is formed parallel to first back seal 62 with a
segment of film 52. In one embodiment, back seals 62, 64 are
simultaneously formed parallel to each other forming pocket 60,
which is separate from a main portion 58 of package 50. Pocket 60
is formed such that it is separate from inside portion 58 and can
retain separate product or contents. Once package 50 is complete, a
transverse end seal 68 can be formed at both ends of package
50.
[0026] Back seals 62, 64 are unlike prior art seals in that it is
not merely a thin seal of overlapped film. Here, film 52 is wrapped
to form pocket 60. More particularly, pocket 60 is formed, for
example, by allowing terminal ends from a sheet of film 52 to
extend over and above from the formed cylinder. Alternatively, film
52 can be wrapped to extend inward against the formed cylinder to
form a pocket (not shown). The portion of film 52 that is laid
above back 56 to form pocket 60 is external portion 61. Back seals
62, 64 can then be optionally formed longitudinally down the length
of the tube. Back seals 62, 64 can extend down from one terminal
end of package 50 to the other end to form pocket 60. However,
other embodiments are possible such as adding additional transverse
seals across the overlapped portion of film 52 to form an
abbreviated pocket or multiple pockets.
[0027] Generally, the terminal segments of external portion 61 are
sealed to transverse seals 68 of package 50 as shown in FIG. 5,
which is a top perspective view of package 50. This forms the top
and bottom seals of discreet package 50 wherein product may be
stored. The transverse seals of pocket 60 that coincide with
traverse seals 68 extend from the position where portion 61 extends
forth from first back seal 62 and end at second back seal 64.
Thereby, portion 61 is positioned above back 56. In another
embodiment, one or more additional seals (not shown) can be formed
between first and second back seals 62, 64. Thereby, pocket 60 can
be separated into two or more distinct pockets. This would be
advantageous if additional items need to be packaged separate from
each other and from the products in main portion 58.
[0028] As package 50 is comprised of a flexible material, portion
61 will generally lie flush against back 56 unless pocket 60 is
filled with product. As pocket 60 is filled with product, portion
61 will extend out and away from back 56. Even with product held in
pocket 60, portion 61 appears to be substantially flush or flat
when compared to the remaining exterior of package 50.
[0029] Shown in FIG. 5 is a printed material 66. Material 66 can
comprise items such as coupons, contest materials, or pamphlets.
With food products contained in the portion 58, having pocket 60 is
advantageous, as the printed materials would not come into with it
thereby avoiding any ink to food contact. This allows quick access
to any materials placed within pocket 60 without disturbing the
product within portion 58. An alternative advantage of pocket 60 is
that other food products can be kept separate from the main
contents of package 50 in portion 58. This allows separate food
samples, dips, or salsas to be stored in pocket 60 and accessed
separately when the consumer desires. Another alternative use for
pocket 60 is to fill it with air so that pocket 60 can form an
air-pillow. With an air-pillow, multiple packages can be placed on
top of each other such that the air-pillow separates each package
50. This deters any product breakage because of the cushioning
effect.
[0030] While the invention has been particularly shown and
described with reference to a preferred embodiment, it will be
understood by those skilled in the art that various changes in form
and detail may be made therein without departing from the spirit
and scope of the invention.
* * * * *