U.S. patent application number 12/429855 was filed with the patent office on 2009-10-29 for flexible package having an automatic closure feature.
This patent application is currently assigned to Kraft Foods Global Brand LLC. Invention is credited to Robert C. Jones, Paul Anthony Zerfas.
Application Number | 20090266036 12/429855 |
Document ID | / |
Family ID | 42561099 |
Filed Date | 2009-10-29 |
United States Patent
Application |
20090266036 |
Kind Code |
A1 |
Zerfas; Paul Anthony ; et
al. |
October 29, 2009 |
FLEXIBLE PACKAGE HAVING AN AUTOMATIC CLOSURE FEATURE
Abstract
A reclosable flexible package is suitable for retail sale of
food products and is comprised of a film material. The reclosable
flexible packages are suitable for mass production on high-speed
form-fill-seal equipment. The flexible package includes a pair of
semi-rigid strips attached to the walls of the flexible pouch and
positioned parallel to the package opening. The semi-rigid strips
are configured and arranged to nest together and bias toward one
another. Upon opening of the package, the semi-rigid strips are
moveable between a closed position and an open position. Further,
the semi-rigid strips are configured such that they automatically
reclose the package when the strips are released from the open
position.
Inventors: |
Zerfas; Paul Anthony;
(Verona, WI) ; Jones; Robert C.; (Aurora,
IL) |
Correspondence
Address: |
FITCH EVEN TABIN & FLANNERY
120 SOUTH LASALLE STREET, SUITE 1600
CHICAGO
IL
60603-3406
US
|
Assignee: |
Kraft Foods Global Brand
LLC
Northfield
IL
|
Family ID: |
42561099 |
Appl. No.: |
12/429855 |
Filed: |
April 24, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12247903 |
Oct 8, 2008 |
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12429855 |
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12347374 |
Dec 31, 2008 |
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12247903 |
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61047695 |
Apr 24, 2008 |
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Current U.S.
Class: |
53/469 |
Current CPC
Class: |
B65B 47/04 20130101;
B65B 9/087 20130101; B65B 9/213 20130101; B65B 2220/08 20130101;
B65B 9/042 20130101; B65D 33/007 20130101; B65B 9/20 20130101; B65B
9/207 20130101; B65B 61/02 20130101; B65B 61/18 20130101; B65B
61/188 20130101; B65B 7/164 20130101; B65D 33/30 20130101; B65B
9/093 20130101; B65D 75/5805 20130101 |
Class at
Publication: |
53/469 |
International
Class: |
B65B 61/04 20060101
B65B061/04 |
Claims
1. A method of mass producing a packaged food product in high-speed
form-fill-seal equipment comprising: forming a series of disposable
pouches having front and back panels made of film material, each of
the disposable pouches defining a cavity therein; filling the
cavity of the disposable pouches with a food product; hermetically
sealing the disposable pouches; attaching a first semi-rigid strip
to the front panel and a second semi-rigid strip to the back panel
with each of the semi-rigid strips having a profile aligned with
the profile of the adjacent semi-rigid strip such that the strips
align, the first and second semi-rigid strips being biased toward
one another; and separating the disposable pouches from one
another.
2. The method of claim 1 further comprising forming a removable top
portion in the disposable pouches defined by an area of
weakness.
3. The method of claim 1 wherein the first and second semi-rigid
strips are attached to inside surfaces of the front and the back
panels.
4. The method of claim 1 wherein the first and second semi-rigid
strips are attached to outside surfaces of the front and back
panels.
5. The method of claim 1 wherein the first and second semi-rigid
strips are pre-cut.
6. The method of claim 1 wherein strip material from which the
first and second semi-rigid strips are produced dispensed from a
reel.
7. The method of claim 6 wherein the strip material is wound on the
reel in flat form such that the profile of the first and second
semi-rigid strips is imparted by a thermal forming tool when the
material is unwound from the reel.
8. The method of claim 1 wherein attaching the first and second
semi-rigid strips comprises at least one of: heat sealing the first
and second semi-rigid strips to the inside surface of the front and
back panels; heat sealing the first and second semi-rigid strips to
the outside surface of the front and back panels; adhesive bonding
the first and second semi-rigid strips to the inside surface of the
front and back panels; adhesive bonding the first and second
semi-rigid strips to the outside surface of the front and back
panels.
9. The method of claim 1 wherein heat sealing the first and second
semi-rigid strips comprises having an external heat seal layer
compatible on the first and second semi-rigid strips that is
compatible with a sealant on the front and back panels.
10. The method of claim 1 wherein the first and second semi-rigid
strips are attached in an orientation parallel to the machine
direction.
11. The method of claim 1 wherein the first and second semi-rigid
strips are attached in an orientation perpendicular to the machine
direction via a strip applicator module configured and arranged to
cut and heat-seal the first and second semi-rigid strips to the
disposable pouch.
12. A method for mass producing a packaged food product in a
horizontal thermoform-fill-seal equipment comprising: thermoforming
a series product cavities from a thermoformable flexible plastic
bottom film; filling the thermoformed series of product cavities;
securing the first semi-rigid strip to the bottom film; securing
the second semi-rigid strip to a flexible top film; heat sealing
the flexible top film to the bottom film, the films defining a
pouch wherein the first and second semi-rigid strips significantly
overlap one another and the first and second semi-rigid strips have
profiles that align in the same direction such that the strips nest
together in a closed position.
13. The method of claim 12 wherein securing the first semi-rigid
strip to the bottom film comprises heat sealing.
14. The method of claim 12 wherein securing the first semi-rigid
strip to the bottom film comprises adhesive bonding.
15. The method of claim 12 wherein the first and second semi-rigid
strips are attached to inside surfaces of the front and the back
panels.
16. The method of claim 12 wherein the first and second semi-rigid
strips are attached to outside surfaces of the front and the back
panels.
17. The method of claim 12 wherein the first and second semi-rigid
strips are pre-cut.
18. The method of claim 12 wherein strip material from which the
first and second semi-rigid strips are dispensed from wound on a
reel.
19. The method of claim 18 wherein the strip material is wound on
the reel in flat form such that the profile of the first and second
semi-rigid strips is imparted by a thermal forming tool when the
material is unwound from the reel.
20. The method of claim 12 wherein the first and second semi-rigid
strips are attached in an orientation parallel to the machine
direction.
21. The method of claim 12 wherein the first and second semi-rigid
strips are attached in an orientation perpendicular to the machine
direction via a strip applicator module configured and arranged to
cut and heat-seal the first and second semi-rigid strips to the
disposable pouch.
22. A method for mass producing a packaged food product in a
vertical form-fill-seal equipment comprising: forming a flexible
plastic tube from a roll of flexible plastic film, the plastic tube
having a sealed edge and having a pair of semi-rigid strips secured
to the flexible film wherein the pair of semi-rigid strips
significantly overlap one another once the semi-rigid strips are
secured to the flexible film; forming a first side seal in the
plastic tube to create a flexible pouch from the flexible plastic
tube; filling the flexible pouch with a food product; forming a
second side seal in the flexible pouch to seal the food product
within the flexible pouch; and separating a filled flexible pouch
from the plastic tube.
23. The method of claim 22 wherein the semi-rigid strips have
formed profiles that align in the same direction such that the
semi-rigid strips nest together when the flexible pouch is in a
closed position.
24. The method of claim 22 wherein forming a flexible plastic tube
from a roll of flexible plastic film further includes forming the
flexible film over a forming collar to create the plastic tube.
25. The method of claim 22 wherein the plastic tube having a sealed
edge and securing a pair of semi-rigid strips to the flexible film
includes forming a top seal in the flexible film having a front and
a back panels, the front and back panels each having one of the
pair of semi-rigid strips attached thereto.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
application No. 61/047,695, filed Apr. 24, 2008, which is
incorporated by reference in its entirety herein. This application
is a continuation-in-part of U.S. patent application Ser. No.
12/247,903, filed Oct. 8, 2008, and is a Continuation-in-Part of
U.S. patent application Ser. No. 12/347,374, filed Dec. 31, 2008,
both of which claim the benefit of U.S. Provisional Application No.
61/047,695, and all of which are incorporated by reference in their
entirety herein.
TECHNICAL FIELD
[0002] This invention relates generally to packaging, and more
particularly to a disposable food packaging comprising a pouch made
of a film material with an automatic closure feature.
BACKGROUND
[0003] Flexible film packages are well known in the art and
typically comprise disposable pouches commercially produced on
high-speed form-fill-seal machines from rolls of plastic film
material. The flexible film packages have cavities within which
pluralities of contents, such as food products, are stored.
Consumers often consume only a portion of the package's contents. A
package reclosability feature allows the user to discharge a
portion of the contents through the package opening and then seal
the opening to reclose the flexible package.
[0004] Numerous reclosable flexible packages are well known in the
art. By one approach, reclosable flexible packages have
press-to-close zipper closures. Press-to-close zippers require
alignment of two profiles located on opposing package walls to
interlock the closure and reclose the package. This alignment may
be cumbersome and/or time consuming for consumers, especially
younger or older consumers who may have limited manual dexterity.
In addition, if a particulate food product, like shredded cheese or
bread crumbs, is stored within the flexible package, the
particulate may interfere with the alignment of the zipper
profiles, which often have narrow channels or tracks.
[0005] In another approach, the reclosable flexible packages
include a slider zipper closure. The slider closures on these
flexible packages assist with the alignment of the two profiles
located on the package walls; however, these slider closures
require additional plastic material and manufacturing that come
with additional costs. While the sliders allow the users to more
easily align the package wall profiles, the slider closures create
a slight opening between the slider and the side seal when the
package is in the closed configuration. Further, the zipper slider
remains on the slider tracks when the package is in the open
position and the slider extends into the opening, thereby slightly
reducing the size of the pouch opening.
[0006] In addition, typical recloseable flexible packages do not
automatically reclose themselves. These reclosable flexible
packages typically require affirmative manual action to reclose.
Thus, the user must remember to close the package and accurately
press-to-seal the closure or pull the zipper slider to the closed
configuration between each usage. Further, if one of these
reclosable flexible packages is inadvertently dropped, while open,
the contents may be permitted to spill out. The consumer must
remember or have sufficient time to reclose the package to avoid
possible spilling or spoilage of the package contents.
SUMMARY
[0007] The package described herein comprises a flexible pouch made
of film material and a pair of semi-rigid strips attached to the
walls of the flexible pouch positioned such that the semi-rigid
strips align and bias toward one another. Upon removal of the top
portion, the semi-rigid strips are moveable between a closed
position and an open position. Further, the semi-rigid strips are
configured such that they automatically reclose the package when
the strips are released from the open position. The strips may
extend along the entire width of the flexible pouch or may extend
between the side seals of the pouch.
[0008] To commercially produce the self-closing flexible package
having the semi-rigid strips, high-speed form-fill-seal equipment
having a vertical or horizontal configuration may be employed. In
one embodiment, cavities are formed out of film material in an
in-line operation such that the strips may be added to the inside
or outside surfaces of the film material. The semi-rigid strips may
be secured to the front and back panels by heat sealing or adhesive
bonding.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The above needs are at least partially met through provision
of the flexible pouch having an automatic closure feature described
in the following detailed description, particularly when studied in
conjunction with the drawings, wherein:
[0010] FIG. 1 comprises a front elevational view of a flexible
package as configured in accordance with various embodiments of the
invention;
[0011] FIG. 2 comprises a cross sectional view of the flexible
package of FIG. 1 along line 2-2;
[0012] FIG. 3 comprises an isometric cross sectional view of the
flexible package of FIG. 1 in the open configuration;
[0013] FIG. 4 comprises a cross sectional view of the flexible
package of FIG. 1 in the open configuration;
[0014] FIG. 5 comprises a perspective view of the flexible package
of FIG. 1 in the open configuration;
[0015] FIG. 6 comprises a front elevational view of another
embodiment of a flexible package;
[0016] FIG. 7 comprises a cross sectional view of the flexible
package of FIG. 6 along line 7-7;
[0017] FIG. 8 comprises a rear elevational view of another
embodiment of a flexible package;
[0018] FIG. 9 comprises a cross sectional view of the flexible
package of FIG. 8 along line 9-9;
[0019] FIG. 10 comprises a cross sectional view of another
embodiment of a flexible package;
[0020] FIG. 11 comprises a perspective view of the flexible package
of FIG. 10 in the open configuration;
[0021] FIG. 12 comprises a partial perspective view illustrating an
apparatus as configured in accordance with an embodiment of the
invention;
[0022] FIG. 13A comprises a partial perspective view illustrating
an apparatus configured in accordance with an embodiment of the
invention;
[0023] FIG. 13B comprises a partial perspective view illustrating
an apparatus as configured in accordance with an embodiment of the
invention;
[0024] FIG. 14 comprises a partial perspective view illustrating an
apparatus as configured in accordance with an embodiment of the
invention;
[0025] FIG. 15 comprises a perspective view of a of another
embodiment of a flexible package;
[0026] FIG. 16 comprises a cross sectional view of the flexible
package of FIG. 15;
[0027] FIG. 17 comprises a perspective view of the flexible package
of FIG. 15 in the open configuration;
[0028] FIG. 18 comprises a perspective view of another embodiment
of a flexible package;
[0029] FIG. 19 comprises a cross sectional view of the flexible
package of FIG. 18; and
[0030] FIG. 20 comprises a partial perspective view illustrating an
apparatus as configured in accordance with an embodiment of the
invention.
[0031] Skilled artisans will appreciate that elements in the
figures are illustrated for simplicity and clarity and have not
necessarily been drawn to scale. For example, the dimensions and/or
relative positioning of some of the elements in the figures may be
exaggerated relative to other elements to help to improve
understanding of various embodiments of the present invention.
Also, common but well-understood elements that are useful or
necessary in a commercially feasible embodiment are often not
depicted in order to facilitate a less obstructed view of these
various embodiments of the present invention. It will further be
appreciated that certain actions and/or steps may be described or
depicted in a particular order of occurrence while those skilled in
the art will understand that such specificity with respect to
sequence is not actually required. It will also be understood that
the terms and expressions used herein have the ordinary technical
meaning as is accorded to such terms and expressions by persons
skilled in the technical field as set forth above except where
different specific meanings have otherwise been set forth
herein.
DETAILED DESCRIPTION
[0032] Generally speaking, pursuant to these various embodiments, a
flexible package or pouch with an automatic closure feature is
illustrated in FIGS. 1-11. The flexible pouch 10, as shown in FIGS.
1-5, may be used for packaging food products 12, such as
particulate food products including shredded cheese, cereal, and
trail mix, to note but a few. The flexible pouch 10 has a pair of
curved semi-rigid strips 14, 16 that run parallel to the pouch
opening. The curved, semi-rigid strips 14, 16 are configured and
arranged to nest together and bias toward one another. The first
and second semi-rigid strips 14, 16 are secured to the opposed
front and back panels 18, 20 of the flexible pouch 10 and the
biasing of the strips 14, 16 biases the panels 18, 20 to the closed
configuration. The flexible pouch 10 may be comprised of a flexible
film material that is formed using high-speed form-fill-seal
equipment. The flexible pouch may have a variety of seals, folds,
and other features as determined by a variety of considerations,
such as the products stored in the pouch and the method of
manufacturing the pouch, to note but a few.
[0033] In one illustrative embodiment, as depicted in FIG. 1, the
flexible pouch 10 includes front and back panels 18, 20 that have a
side seals 22, a top seal 24, and a bottom fold 26. To facilitate
access to the product, the flexible pouch 10 includes a removable
top portion 28. A distance below the removable top portion 28, the
front and back panels 18, 20 have curved semi-rigid strips 14, 16
located thereon. Upon removal of the top portion, the curved
semi-rigid strips 14, 16 are movable between an open position
permitting dispensing of the food product and a closed position
that limits or prevents egress of the food product.
[0034] As shown in FIG. 1, the side seals 22 extend along the
outside edges of the panels 18, 20 to create the pouch 10. The side
seals 22, top seal 24 and similar seals discussed herein may be
conventional heat-seals. Such conventional heat seals may be
created by reciprocating heat sealing bars or other suitable
sealing apparatus and are well known to those skilled in the
art.
[0035] In addition, the flexible pouch 10 includes an area of
weakness 30 that assist the user with separating the removable top
portion 28 from the flexible pouch 10. The area of weakness 30 may
be a mechanical or laser score line. This line may be linear or
non-linear. If the area of weakness is non-linear, the flange at
the top of the package (discussed below) may not extend entirely
across the package width. In addition to a laser score line, the
area of weakness 30 may include perforations. The score line or
perforations may be extended along the entire width of the flexible
pouch 1O. Instead, or in addition to a score line, the area of
weakness 30 may include a tear initiation feature 32 along only a
portion of the pouch, such as, for example, a small V-notch or slit
on one edge of the package. For example, as shown in FIG. 1, the
area of weakness 30 may include a tear initiation feature 32
aligned with a score line.
[0036] Where the flexible pouch 10 is used for food products 12, a
hermetic seal 34 is desirable to ensure product freshness. The
hermetic seal 34 may have a pealably openable characteristic. In
the illustrative embodiment of FIG. 1, the pealable hermetic seal
34 is positioned below the curved semi-rigid strips 14, 16. In
another embodiment, the hermetic seal 34 may be created by the top
seal 24 if the area of weakness 30 takes the form of a score line
as opposed to perforations, which would interfere with the hermetic
seal 34 created by the top seal 24. In addition, the flexible pouch
10 may have a tamper evidence feature.
[0037] Below the area of weakness 30, the front and back panels 18,
20 each have a curved semi-rigid strip 14, 16 secured thereon. The
curved semi-rigid strips 14, 16 have a slight arc and are
positioned on the panels 18, 20 such that the curved strips nest
tightly together. More particularly, the curvature of the first
curved semi-rigid strip 14 aligns in the same direction as the
curvature of the second curved semi-rigid strip 16 as illustrated
in FIG. 2. The radius of curvature of the curved semi-rigid strips
14, 16 may be larger or smaller than that illustrated in FIG.
2.
[0038] The curved semi-rigid strips 14, 16 may have a variety of
dimensions. For example, the strips 14, 16 may have a radius of
curvature from 0.125 to 6.0 inches, a thickness of 0.007 to 0.050
inches, a height of 0.125 to 2.5 inches, and a length of 0.75 to 20
inches. In one illustrative embodiment, the curved semi-rigid
strips 14, 16 are about 1.25 inches in height, 5.75 inches in
length, with a radius of curvature of 1.25 inches, and a thickness
of about 0.015 inches. Depending on the dimensions and features of
the flexible pouch 10, the curved semi-rigid strips 14, 16 may
extend the entire width of the package, as shown in FIG. 1, or may
extend in between the side seals 22 such that the strips 14, 16
terminate at the inside margin of the side seal 22. Other
embodiments are contemplated, such as, for example, an embodiment
having curved semi-rigid strips 14, 16 that terminate in the middle
of the side seals 22.
[0039] As suggested, the curved semi-rigid strips 14, 16 bias
toward one another to automatically close the flexible pouch 10
upon release from the open position. The curved semi-rigid strips
14, 16 are in their stable resting configuration when they are
extended to their full length. When the curved semi-rigid strips
14, 16 are separated and moved to a fully open position, as shown
in FIGS. 3 and 4, lengthwise tension is induced in the strips 14,
16 such that when the strips are released from that position, they
automatically move to the fully extended position which brings the
strips 14, 16 together tightly and closes the flexible pouch 10.
Further, in addition to the curved semi-rigid strips 14, 16
imparting an automatic closure feature to the flexible pouch 10,
the strips 14, 16 create an audible snap when the flexible package
recloses. The audible snap assures the consumer that the package is
securely closed and the unused portion of the contents will remain
fresh.
[0040] As shown in FIG. 1, the curved semi-rigid strips 14, 16 are
positioned parallel to the opening created at the top of the pouch
10 upon the removal of the top portion 28. In addition, the curved
semi-rigid strips 14, 16 are positioned a distance form the area of
weakness 30. In one embodiment, the strips 14, 16 are positioned
about 0.75 inches from the top film edge. This distance may vary
and a desired distance may be between 0.125 and 2.0 inches.
[0041] The curved semi-rigid strips 14, 16 may be comprised of a
variety of materials including a relatively heat resistant polymer
such as polyethylene terephthalate (PET), high impact polystyrene
(HIPS), polypropylene (PP), high density polyethylene (HDPE),
another of a variety of relatively stiff polymers, or a thin strip
of resilient metal such as a thin strip of steel. The curved
semi-rigid strips 14, 16 may be secured to the panels 18, 20 in a
variety of manners such as, for example, by heat sealing or
adhesive bonding. Further, the strips 14, 16 may be attached to the
inside or outside surfaces of the panels 18, 20. By one approach,
the first and second curved semi rigid strips 14, 16 have an
external heat seal layer compatible with a sealant on the
respective front and back panels 18, 20.
[0042] The semi-rigid spring-loaded strips 14, 16 may be produced
in a variety of manners such as by stamping, injection molding,
thermoforming, extrusion, or by a combination of two or more of
these processes. For example, the strips may be stretched and
rapidly quenched after profile extrusion. In addition, the curved
semi-rigid strips 14, 16 may be produced either as separate
elements, pairs, or as a continuous ribbon of strip material wound
onto a reel. In one embodiment, the curved semi-rigid strips 14, 16
may be brought to the line in pre-cut strips. In another
manufacturing process, the curved semi-rigid strips 14, 16 may be
formed in-line. For example, in one embodiment, the material from
which the curved semi-rigid strips 14, 16 is formed is wound on a
reel in a flat form such that the curvature of the semi-rigid
strips 14, 16 is imparted by a forming process such as a
thermoforming tool when the material is unwound from the reel.
[0043] Turning now to FIGS. 3 and 5, the flexible pouch 10 is
illustrated in the open configuration. Above the curved semi-rigid
strips 14, 16 and below the area of weakness 30, a portion of film
material extends, which comprises the panel flanges 36, 38. Thus,
when the removable portion 28 has been separated from the flexible
pouch 10, the panel flanges 36, 38 extend above the curved
semi-rigid strips 14, 16 and may be grasped by the user. In one
illustrative embodiment, the strips 14, 16 are positioned between
0.5 and 1.0 inches from the top edge of the film material. Thus, in
one illustrative embodiment, the panel flanges 36, 38 may be
between 0.25 and 0.8 inches in height. Such panel flanges 36, 38
provide loose film for easy grasping, which assists with the
opening of the pouch 10.
[0044] To open the flexible pouch 10, the user may manually grasp
and pull the front and back panel flanges 36, 38 apart from one
another. Pulling the panel flanges 36, 38 with a mild force causes
the package to move to a fully open configuration. Once opened, the
flexible pouch 10 may be held in the fully open configuration by
applying longitudinal compression to the sides of the flexible
pouch 10 where the curved semi-rigid strips 14, 16 terminate.
Continuous application of such longitudinal compression retains the
flexible pouch 10 in the fully open configuration, as shown in
FIGS. 3 -5. The fully open configuration allows significant access
to the food products stored within the flexible pouch 10. In one
embodiment the flexible package is sized to allow one-hand manual
application of the longitudinal compression.
[0045] Upon release of the longitudinal compression, the
spring-tension of the curved semi-rigid strips 14, 16 causes them
to snap back to the closed position thereby automatically closing
pouch 10. As mentioned, the closing action may be rapid and
accompanied by an audible snap sound. After returning to the closed
position, the matching curvature of the curved semi-rigid strips
14, 16 is forced tightly together creating a secure closure at the
top of the flexible pouch 10.
[0046] Turning now to FIGS. 6 and 7, there is illustrate another
embodiment of a flexible pouch. In this and subsequent embodiments,
similar flexible pouches are illustrated having slightly different
features. For convenience, features of the various embodiments that
correspond to features already discussed with respect to previously
discussed embodiments are identified using the same reference
numeral in combination with a prefix (such as `1`) to distinguish
the different embodiment. For example, flexible pouch 110
corresponds to previously described flexible pouch 10.
[0047] As shown in FIG. 6, flexible pouch 110 includes side seals
122, a top seal 124 and a bottom seal 142. This embodiment may be
produced out of two rolls of film material that are heat sealed
together. In this example, the curved semi-rigid strips 114, 116
extend to the outside edges of the side seals 122. As shown in FIG.
7, the flexible pouch 100 comprises a front panel 120 that is
generally vertical and a back panel 118 within which a bulge is
created to accommodate a plurality of food product 112.
[0048] Turning now to FIGS. 8 and 9, there is illustrated another
embodiment of a flexible pouch 210. The flexible pouch 210 includes
a bottom seal 242, side folds 244, and a lap or fin seal 246 along
the back of the flexible pouch 210. The fin seal 246, like side
seals 22, may be conventional heat seals. As shown in the
illustrative embodiment of FIG. 9, the curved semi-rigid strips
214, 216 are secured to the outside surfaces of the front and back
panels 218, 220.
[0049] In yet another illustrative embodiment, depicted in FIGS. 10
and 11, a flexible pouch 310 is illustrated. The flexible pouch 310
is similar to the flexible pouch 10 described above except that
flexible pouch 310 has only one curved semi-rigid strip 314 secured
to one of either the front or back panels 318, 320. Such an
embodiment functions similarly to the previously discussed
embodiments, except that the closure may not be as air-tight as the
previous embodiments but the flexible pouch 310 uses less strip
material and thus has a cost savings.
[0050] As mentioned above, the method of manufacturing the flexible
pouches may affect the particular seals, folds, and various other
features of particular flexible pouches. A variety of manufacturing
methods are available to commercially produce the flexible pouches
and a few examples will be discussed herein and illustrated in
FIGS. 12-14. The flexible pouches may be made in a high-speed
form-fill-seal (FFS) operation that produces up to 800 packages per
minute. The FFS operation may be on a vertical FFS machines as
illustrated in FIG. 12 or also may be on a horizontal FFS machine
as illustrated in FIGS. 13A and 13B or on a horizontal
thermoform-fill-seal (HTFFS) machine as shown in FIG. 14. The
curved semi-rigid strips may also be secured to the pouches in a
variety manners, such as by heat sealing or adhesive bonding via an
add-on equipment module designed to work in harmony with the
pouch-making machines of the FFS operation.
[0051] In one illustrative embodiment shown in FIG. 12, the
flexible pouches are made in a vertical FFS or bagging line. A
series of flexible pouches is formed from a roll of film 48, such
that the front and back panels of the film material define a
cavity. By one approach, a web of the rolled film material is fed
over a folding shoulder 50 such as a forming collar and mandrel to
provide it with a tubular shape. Opposite longitudinal edges of the
film are brought together around the fill tube 49. The longitudinal
edges are sealed, such as by a seal tool 52 to form a fin seal, or
overlapped to form a lap seal. In one illustrative embodiment, the
curved semi-rigid strips are wound on reels 54. The strips are
brought into alignment with a reciprocating seal tool 56 for
attachment to the walls of the flexible pouch. A bottom seal for
the pouch is also formed by the reciprocating sealing tool 56,
which may include a pair of reciprocating sealing bars. The
reciprocating sealing bars are heat sealing bars maintained at a
desired temperature to apply heat and pressure to the front and
rear walls. Further, the heat seal bars are brought together on
opposite sides of the tubular web so that heat is conductively
transferred to the film from both sides while pressure is applied.
The sealing bars may be used in an intermittent or continuous
operation. In an intermittent operation, the film is stopped while
the sealing bars engage the film. In a continuous operation, the
sealing bars may move vertically at the machine speed as they
engage the film. During operation, sealing tool 56 attaches the
curved semi-rigid strips and creates a top seal in a lower pouch
and creates a bottom seal in an upper pouch at roughly the same
time. In addition, sealing tool 56 may contain a reciprocating
knife which acts to separate the bottom pouch from the upper pouch.
Once the operation is complete and the upper pouch has been filled
with food product, the upper pouch advances downward and becomes
the bottom pouch to which curved semi-rigid strips are attached. In
addition to attaching the strips and sealing the pouches, the
sealing tool 56 may also be used to impart the curvature to the
curved semi-rigid strips and/or to create the area of weakness. By
one approach, the sealing tool 56 has a cutting device associated
therewith to create a perforation across the top of the package or
a notch at the edge of the package to aid in tear initiation. By
another approach, the area of weakness in the pouch is not
perforated at the package line but is pre-scored (mechanically or
with a laser) at the film manufacturer.
[0052] As mentioned, the strips are attached to flexible pouches
such that the curvature of the first curved semi-rigid strip aligns
with the curvature of the second curved semi-rigid strip. The
strips may be attached to the vertical FFS pouch in a variety of
manners, e.g., hot melt adhesive, pressure sensitive adhesive, and
heat sealing, to note but a few options. As mentioned above, the
curved semi-rigid strips may be applied to the outside surfaces of
the walls. In one vertical FFS process, the curved semi-rigid
strips have an external heal seal layer compatible with a sealant
on the outside surface of the package walls. In one such vertical
FFS operation, the curved semi-rigid strips are secured to the
front and back panels in a direction perpendicular to the machine
direction on the outside surface of the panels.
[0053] After a bottom seal is formed in the flexible pouch, the
partially formed flexible pouch is then filled with food product,
which is introduced into the pouch via the fill tube 49. In one
embodiment, an area of weakness is formed in the flexible pouches
to define a removable top portion. By one approach, a notch, score
line, or other feature to facilitate removal of the top portion of
the package may then be formed near the top of the pouch. A
hermetic seal may also be created in the disposable pouch. The
sealing tool 56 may perform a variety of functions simultaneously,
including: creating the bottom seal of the pouch that is about to
be filled with product; attaching the semi-rigid strips to the
upper portion of the front and back panels and creating a peelable
heat seal just below the strips on the pouch that was just filled;
and having a reciprocating knife or cutting tool which separates
the pouch that was just filled from the following one which is
about to be filled. The reciprocating cutting tool may also create
an area of weakness such as a perforation across the top of the
package or a notch at the package edge. By another approach, the
area of weakness in the pouch is not perforated at the package line
but is pre-scored (mechanically or with a laser) at the film
manufacturer such that the scored area of weakness is built into
the film as it arrives from the manufacturer. If such an approach
is taken, the film should be positioned on the packaging machine
via optical registration so that the previously imparted score line
is in the correct position when the flexible pouch is formed.
[0054] There are a variety of alternative steps to those described
in this vertical FFS operation. Also, high speed techniques may be
employed instead of application of heat and pressure by heat seal
bars as described above. For example, RF energy, ultrasonic energy
or other techniques may be employed.
[0055] In another example, shown in FIG. 13A, flexible pouches are
manufactured in a horizontal FFS or a flow-form wrapper. Like the
vertical process described above, a series of flexible pouches is
formed and the film material defines a cavity having front and back
panels. FIG. 13A illustrates a single roll of film 148 being folded
at a folding apparatus 150 and then sealed with a sealing die 152
to form pouch cavities in series with one another. After the film
is formed into cavities, the cavities are filled with food product.
The strip-alignment roller 158 is set at an angle to cause the
strips to turn after unwinding and to be redirected so that they
are aligned in the proper orientation for attachment to the
flexible pouches. As shown in FIG. 13A, a double roll of strips
154a is located on the reel. As the strips are positioned and
sealed to the pouches and the pouches are advanced in the machine
direction, the strips are continuously unwound from the roll 154a
and advanced in the machine direction along with the pouches. As
the double layer of continuous strips 154a is unwound, the strips
are dispensed from the roll and positioned between the two front
and back panels of the film material. In this embodiment, the
strips are sealed to the inside surface of the front and back
panels. As shown in FIG. 13A, the seal bars 156 seal the flexible
pouch and strips from both sides of the pouch. By one approach,
having the strips on the inside of the pouch material makes the
sealing process easier because the sealing bars 156 are configured
to transfer heat through the pouch material, which is thinner than
the semi-rigid strips. Whereas, the strips may be of a thicker
material and thus, may require more, heat, pressure, or time, to be
affected by the heat seal process. The sealing bars 156 may also
create an area of weakness in the package such as by a cutting
device associated therewith. By another approach, a separate
mechanical or laser score tool (not shown) may be employed in-line
to create the score line in the formed packages. By yet another
approach, the area of weakness such as the score line is already
formed in the film when the film arrives from the manufacturer.
[0056] In another embodiment such as that shown in FIG. 13B, the
flexible pouches are made in a horizontal FFS or a flow-wrapper
line similar to the example shown in FIG. 13A. A series of flexible
pouches is formed from a single roll of film 148 that is folded at
a folding apparatus 150, such as a folding plow as shown in FIG.
13B, and then sealed with a sealing die 152 to form pouch cavities
in series with one another. After the film is formed into cavities,
the cavities are filled with food product. In the illustrative
embodiment of FIG. 13B, the horizontal FFS process has two separate
reels 154b with curved semi-rigid strips, instead of the single
roll of double layer strips 154a shown in FIG. 13A. A continuous
ribbon of curved semi-rigid material is dispensed to the line from
the reel and then secured to the pouch cavities at sealing die 156.
It is also contemplated that pre-cut strips may be brought in-line
and secured to the flexible film pouches. The sealing die 156 also
imparts a top seal to the flexible pouch and may also create a
peelable seal, if desired. The filled cavities are then separated
from one another, such as by a reciprocating knife, not shown.
[0057] In yet another embodiment, illustrated in FIG. 14, the
flexible pouches are made on horizontal thermoform-fill-seal
equipment (TFFS). As shown, such a process may employ two rolls of
film material 248a, 248b. A series of product cavities are
thermoformed from a flexible plastic bottom film 248b, which can
then be filled with a food product. The forming of the bottom film
248b occurs at thermoforming station 260. After the lower cavities
are filled with a product, the curved semi-rigid strips are
introduced at the proper position between the top and bottom films.
The strips may arrive to the in-line process pre-cut or on a
continuous reel of semi-rigid spring strip material that may or may
not require further forming processing. In the illustrative
embodiment of FIG. 14, the curved semi-rigid strips are positioned
on two reels 254, mated together with one another at strip roller
guide 258, and brought in series to be attached to the flexible
pouch.
[0058] After alignment of the curved semi-rigid strips and the top
and bottom films, the films and the semi-rigid strips enter a
sealing station 256. This sealing station 256 is generally
contained within a vacuum chamber, especially when the food product
requires low oxygen vacuum packaging or modified atmosphere
packaging. Within the sealing station 256 are an upper moveable
heated seal bar 257a and an unheated moveable lower seal support
die 257b, which act together to apply heat and pressure to the
upper and/or lower films, accomplishing all of the necessary heat
seals to define the final package (such as the package shown in
FIGS. 6 and 7) including the side seals, the top and bottom seals,
the peelable seal below the semi-rigid strips, as well as sealing
the curved semi-rigid strips to the top and bottom films.
[0059] Upon leaving the sealing station 256, the formed flexible
pouches move in series to a trim station 262 where the pouches are
separated from one another. The trim station 262 may also create
the area of weakness in the pouches such as by a cutting device.
Alternatively, a separate mechanical or laser score tool (not
shown) may be employed in-line to create the score line in the film
as it is unwound from the roll, prior to forming the packages. By
another approach, the area of weakness is already formed in the
film when the film arrives from the manufacturer. However, if
pre-scored film is employed it should be registered on the
packaging machine so that the scored line is in the correct
position once the pouches have been formed.
[0060] By one horizontal TFFS process, the strips are sealed
between the top film 248a and the bottom film 248b such that they
are attached to the inside surfaces of the bottom film and the top
film. More particularly, the film may have a heat sealable layer on
the inside surface which seals to the resin material of the
semi-rigid strips. In yet another embodiment, the strips have an
external heat seal layer compatible with a sealant on the inside
surface of the film.
[0061] The film material or substrate of the flexible pouch may be
formed as a polymeric sheet of various plastic polymers,
copolymers, co-extrusions and/or laminations. Further, the film
material may be a monolayer polymeric film or a multilayer laminate
comprising an outer layer of durable material and one or more inner
barrier layers and sealant layers. The multilayer combination may
be comprised of polyolefin such as polyethylene (high, medium, low,
linear low, and/or ultra low density polymers including
metallocene), polypropylene (non-oriented, oriented, and/or
biaxially oriented); polybutylene; ethylene vinyl acetate (EVA);
polyamides (non-oriented, oriented, and/or biaxially oriented) such
as nylon; polyethylene terephthalate (non-oriented, oriented,
and/or biaxially oriented); polyvinyl chloride; ethylene vinyl
alcohol (EVOH); polyvinylidene chloride (PVDC); polyvinyl alcohol
(PVOH); polystyrene; or combinations thereof. In addition, adhesive
tie layers may also be used.
[0062] In addition to the curved, semi-rigid strips 14, 16
described above, it is also contemplated that the semi-rigid strips
may have alternative cross-sectional configurations. For example,
an illustrative embodiment in FIG. 15 includes a flexible package
400 having a pair of semi-rigid strips 414, 416 with a slight fold
therein such that the strips have a crease, angle, or v-shape
imparted thereto. The partially folded semi-rigid strips 414, 416
extend nearly the entire width of the package and are parallel to
the pouch opening. The partially folded, semi-rigid strips 414,
416, like previous strips, have matching profiles and are
configured to automatically close the package 400 once the
partially folded, semi-rigid strips 414, 416 are released from an
open position. More particularly, once released from the open
position, the strips and associated panels 418, 420 are forced
tightly together creating a secure closure at the top of the
flexible pouch 400.
[0063] As with curved, semi-rigid strips 14, 16, the
partially-folded semi-rigid strips 414, 416 are configured and
arranged to nest together and bias toward one another. The first
and second partially-folded, semi-rigid strips 414, 416 are secured
to the opposed front and back panels 418, 420 of the flexible pouch
400 such that the profiles of the strips align in the same
direction. Further, the biasing of the strips 414, 416 biases the
panels 418, 420 to the closed configuration. The pouch 400 may be
comprised of a thin, flexible film material such as that formed
using high-speed form-fill-seal equipment previously discussed.
While the package 400 includes a side seal 422, a top seal 424, and
a bottom seal 426, a variety of seals, folds, and other pouch
features are contemplated for use with the partially-folded,
semi-rigid strips 414, 416.
[0064] The pouch 400, illustrated in FIG. 15, includes an area of
weakness 430 that facilitates removal of the top portion 428. The
area of weakness 430, by one approach, is positioned a distance
below the top seal 424 and a distance above the partially-folded,
semi-rigid strips 414, 416 such that a portion of the front and
back panels 418, 420 comprises a flange 436, 438 that can be
manually grasped and separated to open the package 400 once the top
portion 428 has been removed. While flexible pouch 400 illustrates
the partially-folded, semi-rigid strips 414, 416 attached to inside
surfaces of the front and back panels 418, 420, as shown in FIG.
16, it is also contemplated that the strips 414, 416 may be affixed
to outside surfaces. To ensure freshness of the food product 412,
the flexible pouch 10 may include a hermetic seal. By one approach,
the hermetic seal may include the top seal 424. By another
approach, the hermetic seal may include a pealable hermetic seal
434.
[0065] Another illustrative flexible pouch 500, shown in FIGS. 18
and 19, includes planar semi-rigid strips 514, 516. By one
approach, the planar semi-rigid strips 514, 516 extend nearly the
entire width of the package and are parallel to the pouch opening.
As with previous strips, planar semi-rigid strips 514, 516 bias
toward one another such that the pouch automatically closes when
the strips 514, 516 and associated panels 518, 520 are forced
tightly together. The planar semi-rigid strips 514, 516 have a flat
profile and are secured to the front and back panels 518, 520 such
that the strips 514, 516 generally overlap. Thus, like previous
strips, planar strips 514, 516 nest together by overlapping or
having significant surface to surface contact. Additional
configurations for the semi-rigid strips are contemplated. Further,
the flexible pouch may have a variety of configurations with
differing seals, folds, and various other features.
[0066] In addition to the variety of manufacturing methods
discussed above, a number of alterations to the various methods
disclosed are contemplated without changing the overall operation
of the manufacturing method or the flexible packages produced. As
mentioned, high-speed form-fill-seal (FFS) operations may produce
significant quantities of flexible packages in a relatively short
period of time. The various processes described above including the
vertical manufacturing process of FIG. 12, the horizontal
manufacturing processes of FIGS. 13A-14, and the strip attachment
methods discussed herein may be modified or combined for particular
manufacturing requirements or limitations. For example, a packaging
system, shown in FIG. 20, employs a vertical FFS or bagging line
similar to that in FIG. 12 albeit with several modifications such
that flexible packages are produced having a top seal and two side
seals as shown produced in FIG. 13A and 13B. Further, the system of
FIG. 20 aligns the semi-rigid strips in a direction parallel to
machine direction or the movement of the series of pouches.
[0067] As shown in FIG. 20, flexible pouches are formed from a roll
of film 648, such that the front and back panels of the film
material define a cavity. By one approach, a web of rolled film
material is fed over a folding shoulder 650 to provide the film
with a tubular shape. Opposite longitudinal edges of the film 648
are brought together around the fill tube 649. The longitudinal
edges are sealed, such as by seal and attachment tool 652. By one
approach, the seal and attachment tool 652 forms a top seal that
will span the width of the package opening in between side seals
once the flexible package is formed. In addition, the seal and
attachment tool 652 may also attach semi-rigid strips to the film
648.
[0068] In one illustrative embodiment, the semi-rigid strips are
wound on reels 654 and brought into alignment with the film at the
seal and attachment tool 652 to be secured to the film. Attachment
to the film may be accomplished by a variety of mechanisms. By one
approach, heat sealing may be employed to secure the semi-rigid
strips to the film. By another approach, an adhesive may be used,
such as a hot melt adhesive or a pressure sensitive adhesive. The
semi-rigid strips may have an external heat seal layer compatible
with a sealant on the outside surface of the film comprising the
package walls. While the material wound on the reels 654 may have a
curvature or profile formed therein, by another approach, the
profile or curvature of the semi-rigid strip may be created at the
seal and attachment tool 652. In the example of FIG. 20, the
semi-rigid strips, being wound on reels 654, are secured to the
film as the series of semi-rigid strips from the reels 654 advances
in a direction parallel to the machine direction.
[0069] The seal and attachment tool 652 may also create an area of
weakness or a tear initiation feature such as a notch.
Alternatively, the area of weakness may be pre-scored in the film
by the film manufacturer. In such a case, the film 648 may need to
be loaded into the packaging system to ensure proper placement of
the area of weakness in the flexible pouch. In addition to the tool
652, the tear initiation feature may be created during other
operations as discussed below.
[0070] As shown in FIG. 20, side seals 622a, 622b of the flexible
package 610 may be formed by a reciprocating seal tool 656, which
may include a pair of reciprocating sealing bars. By one approach,
the reciprocating sealing bars are heat sealing bars maintained at
a desired temperature to apply heat and pressure to the tubular web
to create the flexible packages. In addition, the heat seal bars
656 illustrated in FIG. 20 are brought together on opposite sides
of the tubular web so that heat is conductively transferred to the
film from both sides while pressure is applied. The sealing bars
may be used in an intermittent or continuous operation. In an
intermittent operation, the film is stopped while the sealing bars
engage the film. In a continuous operation, the sealing bars may
move vertically at the machine speed as they engage the film.
During operation, sealing tool 656 seals the side seal 622b of a
lower pouch and creates another side seal 622a for another, upper
pouch, at substantially the same time. Thus, as a lower flexible
pouch is sealed at a second side seal 622b, thereby enclosing the
food within the flexible package, an upper flexible pouch has a
first side seal 622a created therein. After forming a side seal
622a into the upper flexible pouch, the upper flexible pouch may be
filled with food and lowered to form the second side seal sealed
622b therein. In addition to forming side seals, sealing tool 656
may create a tear initiation feature or tool 656 may contain a
reciprocating knife that is configured to separate the bottom or
lowered pouch from the upper pouch.
[0071] As mentioned, after the first side seal 622a has been
created in the flexible pouch, the pouch may then be filled with
product, which is introduced via the fill tube 649. Either before
or after the flexible pouch 610 has been filled with food, the
pouch may advance downward to become the lower or bottom pouch,
then, the second side seal 622b is created in the package thereby
enclosing the food product in the flexible pouch 610.
[0072] The sealing tools 652 and 656, similar to sealing tools
previously discussed, perform a variety of functions simultaneously
or in quick succession. For example, sealing and attachment tool
652 can create a top seal of the pouch and attach the semi-rigid
strips. In addition, tool 652 may also create a peelable heat seal
just below the semi-rigid strips and may impart the curvature or
formed profile of the semi-rigid strips. By one approach, seal tool
656 creates side seals on two different packages simultaneously and
may also separate these packages. In addition, seal tool 656 may
also include a cutting device to create a notch at the edge of the
package to aid in tear initiation or may create an area of weakness
in the film. The cutting device may also be used to separate the
packages as mentioned via reciprocating knife.
[0073] Those skilled in the art will recognize that a wide variety
of modifications, alterations, and combinations can be made with
respect to the above described embodiments without departing from
the spirit and scope of the invention, and that such modifications,
alterations, and combinations are to be viewed as being within the
ambit of the inventive concept.
* * * * *