U.S. patent application number 12/408172 was filed with the patent office on 2010-03-18 for dispensing package.
This patent application is currently assigned to THE TAPEMARK COMPANY. Invention is credited to Craig D. Bakken, Thomas J. Dombroski, Donavon Nelson, William Weernink.
Application Number | 20100065582 12/408172 |
Document ID | / |
Family ID | 46332283 |
Filed Date | 2010-03-18 |
United States Patent
Application |
20100065582 |
Kind Code |
A1 |
Nelson; Donavon ; et
al. |
March 18, 2010 |
DISPENSING PACKAGE
Abstract
A package for carrying and dispensing contents through at least
one metered opening includes a plastic backing having a first
elastic limit and a shear modulus sufficient to maintain the
package in a substantially flat configuration; a first score
extending at least partially into the first side of the plastic
backing; a coating formed on a second side of the plastic backing
having a second elastic limit that is greater than the first
elastic limit; a pouch formed on the second side of the plastic
backing that is adapted to carry the contents of the package.
Flexure of the plastic backing by a first amount is sufficient to
cause the plastic backing to exceed the first elastic limit and
break along the first score while flexure to a folded position is
insufficient to cause the coating to exceed the second elastic
limit.
Inventors: |
Nelson; Donavon; (Lake Elmo,
MN) ; Dombroski; Thomas J.; (Newport Coast, CA)
; Weernink; William; (Savage, MN) ; Bakken; Craig
D.; (Littleton, CO) |
Correspondence
Address: |
PAULY, DEVRIES SMITH & DEFFNER, L.L.C.
Plaza VII-Suite 3000, 45 South Seventh Street
MINNEAPOLIS
MN
55402-1630
US
|
Assignee: |
THE TAPEMARK COMPANY
West St. Paul
MN
|
Family ID: |
46332283 |
Appl. No.: |
12/408172 |
Filed: |
March 20, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11380533 |
Apr 27, 2006 |
7506762 |
|
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12408172 |
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11004573 |
Dec 2, 2004 |
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11380533 |
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60526690 |
Dec 2, 2003 |
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Current U.S.
Class: |
222/107 ;
206/459.5; 206/484; 220/266 |
Current CPC
Class: |
B65D 85/00 20130101;
B65B 61/02 20130101; B65D 73/00 20130101; B65D 75/5855 20130101;
B65D 75/585 20130101; A45D 2200/1018 20130101; B65D 51/00 20130101;
B65B 61/18 20130101; A45D 34/04 20130101; A45D 40/0087 20130101;
A45D 37/00 20130101; B65D 35/02 20130101 |
Class at
Publication: |
222/107 ;
206/459.5; 206/484; 220/266 |
International
Class: |
B65D 35/02 20060101
B65D035/02; B65D 85/00 20060101 B65D085/00; B65D 73/00 20060101
B65D073/00; B65D 51/00 20060101 B65D051/00 |
Claims
1. A package for carrying and dispensing contents through at least
one metered opening comprising: a plastic backing having a first
elastic limit and a shear modulus sufficient to maintain the
package in a substantially flat configuration; a label attached to
a first side of the plastic backing; a first score formed through
the label and extending at least partially into the first side of
the plastic backing; a coating formed on a second side of the
plastic backing having a second elastic limit that is greater than
the first elastic limit; a pouch formed on the second side of the
plastic backing that is adapted to carry the contents of the
package; and at least one second score extending from an interior
portion of the pouch and at least partially into the second side of
the plastic backing, the at least one second score substantially
aligned with the first score on the plastic backing so that flexure
of the plastic backing by a first amount is sufficient to cause the
plastic backing to exceed the first elastic limit and break along
the first score while flexure to a folded position is insufficient
to cause the coating to exceed the second elastic limit.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/380,533, now issued as U.S. Pat. No.
7,506,762, which is a continuation-in-part of U.S. patent
application Ser. No. 11/004,573 filed Dec. 2, 2004, which claims
priority to U.S. Provisional Patent Application 60/526,690 filed
Dec. 2, 2003, and also claims the benefit of U.S. Provisional
Patent Application 60/725,083, filed Oct. 7, 2005, the entireties
of which are hereby incorporated by reference. This application
also claims the benefit of U.S. Provisional Patent Application
60/725,083, filed Oct. 7, 2005.
BACKGROUND OF THE INVENTION
[0002] a. Field of the Invention
[0003] The present invention generally pertains to packaging and
more specifically pertains to dispensing packages.
[0004] b. Description of the Background
[0005] Various techniques have been used in the past for providing
packaging of various types of materials. Prior devices, however,
have generally been unable to provide packages that are capable of
dispensing liquids, gels, creams, pastes and other types of fluid
and semi-fluid materials in a controlled fashion using a low cost,
easy to use package. In addition, many packages require the use of
two hands to open a package. Further, many packages require
application of fine dexterity or the use of fingernails to peel off
coverings to access the contents of the package. Opening these
types of packages may require additional time, and may require
skills not possessed by certain segments of the population, such as
young children, elderly individuals, handicapped persons, etc.
[0006] Exemplary packaging dispensers that can be opened with one
hand are shown and described in DeVries U.S. Pat. No. 4,140,409;
Kaufman U.S. Pat. No. 4,430,013; and Koptis U.S. Pat. No. 6,007,264
all incorporated herein by reference in their entireties. The '409
patent discloses a disposable liquid applicator including a
pre-scored container such that a liquid within the applicator is
dispensed into an absorbent material positioned on the exterior of
the applicator at a point where the applicator snaps open when two
opposing ends are bent away from the pre-scored portion. The '409
patent discloses two opposing large raised portions that contain
the liquid and are interconnected by a pair of narrow raised
channels. The applicator is then pre-scored along the portion of
the package having the narrow raised channels. By using two narrow
channels to join the opposing large raised portions, the volume of
the liquid contained in the applicator is substantially contained
in the large raised portions. Because of this, these applicators
have irregular shapes with varying vertical thicknesses causing
packaging and shipping problems. In addition, these applicators
create problems for users because they are bulky to store and
transport and the large raised portions are vulnerable to puncture
whereby the liquid can leak out of the applicator. Thus, there
exists a need for a dispensing package that provides controlled
dispensing and application of a substance in the package while
providing uniform dimensions for ease and safety in packaging,
transporting and using the package without the risk of puncturing
the package such that the contents leaks.
[0007] The '013 patent discloses an applicator package with a foam
applicator attached to a backing member having at least one
reservoir formed of a flat sheet material for containing a material
to be applied. The flat sheet material has a slit or weakened
portion under the foam applicator so that, when the distal ends of
the package are forced toward one another, the package ruptures
along the slit or weakened portion thereby dispensing the material
into the foam applicator. In addition to this embodiment, the '013
patent discloses several embodiments of the package designed for
controlled dispensing and application of the material, including
foam contained within the reservoir, a "Band Aid" style opening,
scrubbing bristles attached to the exterior of the package, and
neck-down receptacles (similar to the design of the '409 patent).
Despite the modifications proposed in the '013 patent, there still
exists a need for a dispensing package that provides controlled
dispensing and application of a wide variety of substances with
varying viscosities while providing durability and uniformity in
shape and size of the packages.
[0008] The '264 patent to Koptis discloses a pouch-like container
for dispensing ingredients via built-in outwardly pivoting flaps.
In order to dispense the material within the container, the user
must break apart the flaps. The pouch-like container is created and
remains in a folded position. The '264 patent discloses filling the
container with a needle filler, as is known in the art. Problems
associated with needle fillers include delivering imprecise volumes
of material within the container, creating an additional puncture
point in the container and being limited to materials with certain
viscosities. Additionally, these containers suffer from a very high
moisture vapor transmission (MVT) rate thereby allowing product to
evaporate and dry out. Accordingly, there is a need for an
efficient and cost-effective method of creating and filling
dispensing packages with a variety of materials having varying
viscosities, where the package size can be easily varied and the
risk of moisture vapor transmission reduced.
[0009] For these reasons, a simple and easy to use, low cost
package is needed that allows the user to open a package with one
hand and dispense the contents of the package in a controlled
manner.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention overcomes the disadvantages and
limitations of the prior art by providing a low cost, simple and
easy to use package that allows the user to dispense the contents
of the package in a controlled manner. It is an object of the
present invention to provide a dispensing package with uniform
vertical thickness. It is a second object of the present invention
to provide a dispensing package adaptable to contain materials with
varying viscosities. It is a third object of the present invention
to provide a method for creating and filling a dispensing package
with a variety of materials, in a variety of sizes and with reduced
MVT.
[0011] The present invention may therefore comprise a package for
carrying and dispensing contents through at least one metered
opening comprising: a plastic backing having a first elastic limit
and a shear modulus sufficient to maintain the package in a
substantially flat configuration; a label attached to a first side
of the plastic backing; a first score formed through the label and
extending at least partially into the first side of the plastic
backing; a coating formed on a second side of the plastic backing
having a second elastic limit that is greater than the first
elastic limit; a pouch formed on the second side of the plastic
backing that is adapted to carry the contents of the package; and
at least one second score extending from an interior portion of the
pouch and at least partially into the second side of the plastic
backing, the at least one second score substantially aligned with
the first score on the plastic backing so that flexure of the
plastic backing by a first amount is sufficient to cause the
plastic backing to exceed the first elastic limit and break along
the first score while flexure to a folded position is insufficient
to cause the coating to exceed the second elastic limit.
[0012] The present invention may further comprise a method of
making a dispensing package for dispensing contents through at
least one metered opening comprising: providing a plastic backing
having a first sheer modulus sufficient to maintain the package in
a substantially flat configuration and having a first elastic
limit, the plastic backing having a coating formed on a second side
of the plastic backing, the coating having a second elastic limit
that is greater than the first elastic limit; placing a label on a
first side of the plastic backing; placing a first score in the
label and the plastic backing that penetrates the label and the
plastic backing; placing at least a second score in the coating and
the second side of the plastic backing; placing a pouch on the
second side of the plastic backing over the coating, the pouch
adapted to carry the contents.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In the drawings,
[0014] FIG. 1 is a top perspective view of one embodiment of the
dispensing package of the present invention.
[0015] FIG. 1A is a top perspective view of an alternative
embodiment of the dispensing package depicted in FIG. 1.
[0016] FIG. 2 is a side perspective view of the dispensing package
of FIG. 1.
[0017] FIG. 3 is a bottom perspective view of the device of FIG.
1.
[0018] FIG. 3A is a bottom perspective view of an alternate
embodiment of the dispensing package of FIG. 1.
[0019] FIG. 3B is a bottom perspective view of an alternate
embodiment of the dispensing package depicted in FIG. 1.
[0020] FIG. 4A is a side view illustrating the manner in which the
dispensing package can be grasped for opening.
[0021] FIG. 4B is a side view illustrating the manner in which the
dispensing package is flexed for opening.
[0022] FIG. 4C is a side view illustrating additional flexure of
the dispensing package and the further dispensing of fluid.
[0023] FIG. 4D is a perspective view of one embodiment of the
invention illustrating the rapid dispensing of fluid.
[0024] FIG. 4E is a perspective view illustrating controlled
dispensing of fluid from an alternative embodiment of the present
invention.
[0025] FIG. 4F is a perspective view illustrating controlled
dispensing of fluid from an alternative embodiment of the present
invention.
[0026] FIG. 4G is a side view illustrating controlled dispensing of
fluid from an alternative embodiment of the present invention.
[0027] FIG. 4H is a side view illustrating controlled dispensing of
fluid from an alternative embodiment of the present invention.
[0028] FIG. 4I is a perspective view illustrating controlled
dispensing and application of fluid from the dispensing package of
FIG. 4G.
[0029] FIG. 4J is a perspective view illustrating controlled
dispensing and application of fluid from the dispensing package of
FIG. 4H.
[0030] FIG. 4K is a perspective view illustrating controlled
dispensing and application of fluid from an alternate embodiment of
the invention.
[0031] FIG. 5A is a cutaway side view of an alternate embodiment of
the invention.
[0032] FIG. 5B is a cutaway side view of an alternate embodiment of
the invention.
[0033] FIG. 5C is a cutaway side view of the dispensing package of
FIG. 3B.
[0034] FIG. 5D is a cutaway side view of the dispensing package of
FIG. 3A.
[0035] FIG. 5E is a cutaway side view of an alternate embodiment of
the invention.
[0036] FIG. 5F is a cutaway side view of an alternate embodiment of
the invention.
[0037] FIG. 6 is a close-up perspective view of an alternate
embodiment of the invention.
[0038] FIG. 7 is a perspective view of the embodiment of FIG. 6
showing an opened dispensing package.
[0039] FIG. 7A is a perspective view of the embodiment of FIG. 4F
showing an opened dispensing package.
[0040] FIG. 7B is a perspective view of the embodiment of FIG. 4H
showing an opened dispensing package.
[0041] FIG. 7C is a perspective view of the embodiment of FIG. 4G
showing an opened dispensing package.
[0042] FIG. 8 is a top perspective view of an alternate embodiment
of the invention.
[0043] FIG. 9 is a close-up perspective view of the embodiment of
FIG. 8.
[0044] FIG. 10 is a perspective view of the embodiment of FIG. 8
showing an opened dispensing package.
[0045] FIG. 11 is an alternate embodiment in accordance with the
present invention.
[0046] FIG. 12 is a close-up perspective view of the embodiment of
FIG. 11.
[0047] FIG. 13 is a perspective view of the embodiment of FIG. 11
showing an opened dispensing package.
[0048] FIG. 14 is a perspective view of an alternate embodiment in
accordance with the present invention.
[0049] FIGS. 15-29 illustrate a press that can be used to make
various embodiments of the dispensing package in accordance with
the present invention.
[0050] FIG. 30 is a block diagram illustrating exemplary components
of the press of the present invention in communication with a
controller.
[0051] FIG. 31 is a block diagram of the exemplary components of
the controller used in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0052] FIG. 1 is a perspective view of one embodiment of a
dispensing package 100 in accordance with the present invention.
Dispensing package 100 may take on any shape whatsoever such as
square, round, rectilinear, triangular, etc. Dispensing package 100
has a plastic backing 102 made of thin plastic materials such as
polystyrene, polyethylene, polypropylene or other polymeric or
plastic type of material. Plastic backing 102 has a sufficient
thickness and stiffness to hold dispensing package 100 in a
substantially flat configuration. Located on the top surface of
dispensing package 100 is a label 104. Label 104 can comprise any
desired type of label including clear plastic labels, printed
labels, etc. Label 104 can be attached to plastic backing 102 using
a pressure sensitive adhesive, a heat curing adhesive or any other
desired type of adhesive. Those in the art will appreciate that
pressure sensitive layer 102 and label 104 may be eliminated
entirely and printing can be done directly on plastic backing 102.
According to FIG. 1, a score 106 is made through label 104 and into
plastic backing 102. Upon flexure of dispensing package 100,
plastic backing 102 breaks along score 106. A pouch 108 on the
under side of dispensing package 100 contains a fluid material such
as a liquid or gel that is dispensed through the broken plastic
backing 102.
[0053] Referring now to FIG. 1A, there is shown an alternate
embodiment in accordance with the present invention. Dispensing
package 100 of this embodiment includes plastic backing 102, label
104 and score 106. This embodiment additionally includes removable
film 105 located on the top surface of label 104. Film 105 may
comprise any desired type of film 105 including polyethylene,
Barex.RTM. (BP Chemicals, Inc., Naperville, Ill., USA), foils,
nylon, other co-extruded films, and the like. Film 105 may be
attached to label 104 using pressure sensitive adhesives, heat
curing adhesives or any other desired type of adhesives. Adhesive
may be omitted from a portion of one end or one corner of film 105
in order to provide a peel tab 107 whereby a user can grasp film
105 and peel it off label 104. In this embodiment score 106 is made
only through label 104 and into plastic backing 102 while film 105
remains unscored as for example when it is desired to have a
protective covering if the dispensing package 100 is going to
travel in luggage or handbags. Alternatively, it may provide for a
child-resistant seal. Still further, unscored film 105 may create
additional billboard space if printing is done directly on film
105. Upon removal of film 105 and flexure of dispensing package
100, plastic backing 102 breaks along score 106 so that the
contents of pouch 108 on the under side of dispensing package 100
is dispensed through the broken plastic backing 102. In an
alternative embodiment, film 105 can also be scored.
[0054] As disclosed in more detail below, a metering hole is formed
by a second score that extends through the interior portion of the
package into plastic backing 102 so that the contents of dispensing
package 100 is dispersed only over a portion of score 106.
[0055] FIG. 2 is a side perspective view of dispensing package 100
of FIG. 1. As shown in FIG. 2, plastic backing 102 has a thickness
that provides sufficient structural integrity to hold dispensing
package 100 in a substantially flat configuration. Label 104 is
placed on the outer (upper) surface of plastic backing 102. Score
106 is formed through label 104 and into plastic backing 102. As
can also be seen in FIG. 2, a pouch 108 is attached to the
underside of plastic backing 102 and contains the contents of the
package, which normally includes a liquid, lotion, gel, paste or
other such materials but can also include pharmaceuticals or
medicines in pill form.
[0056] FIG. 3 is a perspective view of the underside of dispensing
package 100. As shown in FIG. 3, plastic backing 102 has a score
106 that extends the entire width of plastic backing 102 as
indicated above. An additional score, or metered slit 110 is formed
underneath pouch 108 on the interior portion of dispensing package
100, which is the backside (or underside) of plastic backing 102.
Score 110 is a short score and, as disclosed above, provides a
metering hole for dispensing the contents of dispensing package
100, as explained in more detail below.
[0057] FIG. 3A is a perspective view of an alternate embodiment of
the present invention. As depicted, the underside of dispensing
package 100 includes a first piece of material 109 positioned
laterally along one side of score 106 and a second piece of
material 111 positioned laterally along the other side of score
106. Alternately, material 109, 111 can be attached as one piece
and then scored when plastic backing 102 and label 104 are scored.
Material 109 may comprise any type of material including an
absorbent material such as a sponge, cloth, flock, foam or
non-absorbent, depending on its intended use, such as sand paper, a
hard plastic, or the like.
[0058] FIG. 3B is a perspective view of an alternate embodiment in
accordance with the present invention. According to this
embodiment, the underside of dispensing package 100 includes a
continuous piece of material 112, such as foam, flock, or sponge
that is positioned over score 106 and metered openings 114, 116,
118 made in the linear low density polyethylene to provide
controlled application of the contents of dispensing package 100.
Although three metered openings are depicted, those skilled in the
art can appreciate that there can be any number of metered openings
in a variety of different configurations to provide controlled
application of the contents of dispensing package 100 onto material
112.
[0059] FIG. 4A is a side view illustrating the manner in which
dispensing package 100 may be grasped by a user. As shown in FIG.
4A, the ends of dispensing package 100 are grasped between the
thumb and middle finger of the user. The index finger can then be
used to push on the pouch side of dispensing package 100. As shown
in FIG. 4B, dispensing package 100 flexes and breaks along score
106 to dispense contents 402.
[0060] As shown in FIG. 4C, continued folding of dispensing package
100 causes pouch 108 to further compress and squeeze more of
contents 402 from dispensing package 100. In this matter, the
amount and flow rate of the dispensing of contents 402 can be
controlled by the user.
[0061] FIG. 4D is another perspective view illustrating the manner
in which dispensing package 100 is opened. FIG. 4D illustrates the
embodiment of FIG. 1 in which score 106 extends across the entire
width of plastic backing 102. As shown in FIG. 4D, pouch 108
dispenses contents 402 along the center portion of score 106.
[0062] FIG. 4E is a perspective view of an alternate embodiment of
a dispensing package 400. As shown in FIG. 4E, a partial slit 404
is formed in plastic backing 406. This provides a more robust
dispensing package 400 since plastic backing 406 does not break
along the entire width of dispensing package 100. Hence, dispensing
package 400 is more difficult to "snap" and rather bends in a U
shape fashion. The user can better control the speed and volume for
dispensing of the contents and it prevents accidental dispensing
when package 400 is stored in luggage, purses, wallets, etc.
Alternatively, the more robust dispensing package 400 is ideal for
shipping because unwanted leakage is minimized.
[0063] FIG. 4F is perspective view illustrating the manner in which
an alternate embodiment of dispensing package 100 is opened. In
this embodiment, metered openings 106 extend across the plastic
backing 102. More than one metered opening is desirable depending
on the contents of the pouch and the application. With contents
such as lotions and gels several metered openings ensure that the
contents are not expressed from the package in one blob through a
center opening. A layer of pouch 108 adjacent plastic backing 102
is partially scored across the width of pouch 108. FIG. 4F depicts
three scores in pouch 108 such that contents 402 is dispensed via
three openings. Those skilled in the art can appreciate that pouch
108 can be scored more or less than three times and the scores can
be provided in various configurations depending on the contents of
dispensing package 100 in order to provide controlled dispensing
and application of contents 402.
[0064] FIG. 4G is another perspective view illustrating the manner
in which dispensing package 100 is opened. FIG. 4G illustrates the
embodiment of FIG. 3B in which score 106 extends across the entire
width of plastic backing 102 and continuous piece of absorbent
material 112 is positioned over score 106. As shown in FIG. 4G,
pouch 108 dispenses contents 402 along the center portion of score
106 and into absorbent material 112. Holding the two ends of
plastic backing 102, a user can apply contents 402 of dispensing
package 100 in a controlled manner as shown in FIG. 4I. For
example, applications for this embodiment include but are not
limited to applying a paint sample to a wall, applying a sterilizer
to a surface, applying a lotion or cosmetic, cleaning a surface,
and the like.
[0065] FIG. 4H is a perspective view illustrating the manner in
which an alternate embodiment of dispensing package 100 is opened.
FIG. 4H illustrates the embodiment of FIG. 3A in which score 106
extends across the entire width of plastic backing 102 and two
pieces of absorbent material 109, 111 are laterally positioned
along the two sides of score 106. As shown in FIG. 4H, pouch 108
dispenses contents 402 along the center portion of score 106. Two
pieces of absorbent material 109, 111 can then be used to apply
contents 402 in a controlled manner. Holding the two ends of
plastic backing 102, a user can then apply contents 402 in a
controlled manner as shown in FIG. 4J. For example, applications
for this embodiment include, but are not limited to, applying a
paint sample to a wall, applying a sterilizer to a surface,
applying a lotion or cosmetic, cleaning a surface, and the
like.
[0066] FIG. 4K is a perspective view illustrating the manner in
which an alternate embodiment of dispensing package 100 is opened
and used. This embodiment is particularly advantageous when
dispensing contents 402 with high viscosities, for example
spackling, toothpaste, peanut butter, and the like. When contents
402 are dispensed, edge 106 is used as the applicator to spread
contents on a wall.
[0067] FIG. 5A is a cutaway view of one embodiment of a dispensing
package 500. As shown in FIG. 5A, dispensing package 500 includes a
plastic backing 502. Plastic backing 502 may be made of polystyrene
or other plastic materials including various polymers. Plastic
backing 502 provides structural rigidity for dispensing package
500. As such, it has a shear modulus that is sufficient to hold
dispensing package 500 in a substantially flat orientation. In one
embodiment, plastic backing 502 has a thickness of about 16 mm.
Placed on the top (exterior) portion of plastic backing 502 is a
label 504. Label is attached to plastic backing 502 with an
adhesive layer 506. Adhesive layer 506 may be a pressure sensitive
adhesive or any desired type of adhesive. Label 504 can be any
desired type of label and can provide advertising and other
information relating to contents 524 of dispensing package 500. A
score 508 is made through label 504, adhesive 506 and extends into
plastic backing 502. In one embodiment, label 504 is about 2.3 mm
in depth and adhesive 506 is about 1.5 mm in depth. Score 508
extends about 4 mm into plastic backing 502 so that the total depth
of score 508 is about 7.8 mm. Of course, these dimensions are
exemplary only, and plastic backing 502, label 504, adhesive 506
and score 508 can be modified depending on customer preference,
material being dispensed and the use application of dispensing
package 500. On the bottom side (interior side) of plastic backing
502 are two co-extruded layers. The first co-extruded layer is a
barrier layer 510 that has a high elastic limit (i.e., is very
flexible). Barrier layer 510 may be an EVOH (ethanol vinyl alcohol)
layer that can have a depth of about 0.5 mm. The outer co-extruded
layer is a sealant layer 512 that is applied over barrier layer
510. Sealant layer 512 also provides structural features and has a
very high elastic limit in the same manner as barrier layer 510.
The elastic limit of barrier layer 510 and sealant layer 512 is
substantially higher than the elastic limit of plastic backing 502.
In this fashion, barrier layer 510 and sealant layer 512 do not
break when plastic backing 502 is broken as a result of flexure of
dispensing package 500. Sealant layer 512 may comprise a linear low
density polyethylene (LLDPE) coating that can be about 2.5 mm
thick. Sealant layer 512 functions as both a structural layer and a
containment film for containing contents 524. Sealant layer 512 can
also act as a FDA layer that prevents contamination of contents 524
from the surrounding materials. A metered slit 514 is formed in the
bottom (interior) side of plastic backing 502. Metered slit 514 may
extend, in one embodiment, about 4 mils into plastic backing 502.
Hence, the total depth of metered slit 514 is about 7 mils. By
scoring both sides of plastic backing 502, plastic backing 502 will
break along the aligned portions of metered slits 508, 514. In
addition, plastic backing 502, as well as label 504 and adhesive
506, will break along the length of score 508. However, barrier
layer 510 and sealant layer 512 have a substantially higher elastic
limit so that barrier layer 510 and sealant layer 512 remain intact
in the portions that are not metered, even though plastic backing
502 is broken by score 508. In this fashion, metered slit 514 can
function as a metering hole for controlling the location and size
of the opening in which contents 524 of dispensing package 500 are
dispensed.
[0068] FIG. 5A also depicts an inner sealant layer 516 that may
also comprise a linear low density polyethylene having a thickness
of about 2.5 mm. Inner sealant layer 516, in a manner similar to
sealant layer 512, functions as both a structural layer and a
containment film for contents 524. Inner sealant layer 516 is heat
sealed to sealant layer 512 at the sides and ends of the pouch 522.
Disposed over inner sealant layer 516 is an outer pouch layer 520
that may comprise a PET material of about 3.0 mm. Outer pouch layer
520 has a barrier layer 518 that may comprise an EVOH layer of
about 0.5 mm. Barrier layer 518 provides additional structural
integrity to pouch 522. Both barrier layer 518 and inner sealant
layer 516 may be a co-extruded layer on outer pouch layer 520.
Again, the entire structure of outer pouch layer 520, barrier layer
518, and inner sealant layer 516 is heat sealed to sealant layer
512 to create pouch 522 in the manner hereinafter described. Those
skilled in the art will appreciate, however, that any method of
sealing could be used including adhesive means, ultrasonic means,
and other such methods.
[0069] FIG. 5B is a cutaway view of an alternate embodiment of a
dispensing package 530 in accordance with the present invention. As
shown in FIG. 5B, dispensing package 530 has a plastic backing 532
similar to the plastic backing disclosed with respect to the
description of FIG. 5A. In addition, a label 534 is applied to the
outer surface of plastic backing 532 with an adhesive 536, in
manner similar to the description with respect to FIG. 5A. A score
538 is formed through label 534, adhesive 536 and extends into
plastic backing 532 a predetermined distance. For example, score
538 can extend into plastic backing 532 by about 4 mm, in
accordance with one embodiment of the invention. Of course, score
538 can extend any distance desired into plastic backing 532, so
long as a fracture is caused in plastic backing 532 as a result of
flexure of dispensing package 530. In other words, score 538 must
be sufficiently deep to create a fracture in plastic backing 532
along the length of score 538, which is dependent upon the depth of
score 538, the elastic modulus of plastic backing 532 and the
elastic limit of plastic backing 532.
[0070] As also shown in FIG. 5B, the backside (interior side) of
plastic backing 532 includes a sealant layer 540. Sealant layer 540
has a much higher elastic limit (is more flexible) than plastic
backing 532 and provides structural support for dispensing package
530 along the areas in which score 538 fractures plastic backing
532, and score 542 is not present. In other words, sealant layer
540 holds dispensing package 530 together even if score 538 extends
across the entire width of dispensing package 530. Further, sealant
layer 540 causes metered slit 542 to function as a metering hole
for dispensing contents of 548 of dispensing package 530 since
sealant layer 540 does not break and only provides an opening along
the length of metered slit 542. Sealant layer 540 can also function
as a containment layer for containing contents 548 and preventing
contamination of contents 548 as a result of leaching of
plasticizers or other undesirable agents from plastic backing 532.
Sealant layer 540 may also function as a containment layer for
containing contents 548 without leakage or dispersal of contents
548. Sealant layer 540 can comprise any desired material including
adhesives, polymers or other materials capable of performing the
specified functions. Pouch layer 544 also provides a structural and
containment layer that forms pouch 546 for containing contents 548.
Pouch layer 544 may be heat sealed to sealant/structural layer 540.
Pouch layer 544 may include an extruded structural layer, but in
general, comprises a flexible material that is capable of
containing contents 548 without being easily penetrated or ruptured
and without contaminating contents 548.
[0071] FIG. 5C is a cutaway view of an alternate embodiment of
dispensing package 500. As shown in FIG. 5C, dispensing package 500
is similar to the dispensing package disclosed with respect to the
description of FIG. 5A. In addition, FIG. 5C depicts continuous
piece of absorbent or non-absorbent material 112 placed over score
508 with an adhesive 526 as disclosed in FIGS. 3B, 4G and 4I. If
absorbent, material 112 can be made of foam, sponge, flock, and the
like. It will be appreciated that non-absorbent materials may also
be used such as sandpaper and scrubber depending on the end use.
Material 112 is sized, placed and optionally scored based on
contents 524 in dispensing package 500 in order to provide
controlled dispensing and application of contents 524.
[0072] FIG. 5D is a cutaway view of an alternate embodiment of
dispensing package 500. As shown in FIG. 5D, dispensing package 500
is similar to the dispensing package disclosed with respect to the
description of FIG. 5A. FIG. 5D also depicts first and second
pieces of absorbent or non-absorbent material 109 and 111 placed on
each side of score 508 as disclosed in FIGS. 3A, 4H and 4J. First
and second pieces of absorbent or non-absorbent material 109, 111
are sized and positioned based on contents 524 in dispensing
package 500 in order to provide controlled dispensing and
application of contents 524.
[0073] FIG. 5E is a cutaway perspective of an alternate embodiment
of dispensing package 530. As shown in FIG. 5E, dispensing package
530 is similar to the dispensing package disclosed in FIG. 5B. FIG.
5E shows dispensing package 530 configured to dispense two
materials, a first contents 550 and a second contents 552. This
embodiment is advantageous for dispensing two materials
simultaneously where the materials exhibit favorable
characteristics when mixed as they are dispensed. Examples of such
materials include, but are not limited to, food products, epoxies,
resins, foaming elastomers, cleaning solutions, and the like. FIG.
5E depicts pouch layer 544 having two pouches 546, 547 with a
separating portion 554 therebetween. Separating portion 554 is
provided to maintain contents 550, 552 in separate pouches 546,
547. Separating portion 554 is aligned with metered slit 542 such
that when the two ends of plastic backing 532 are forced toward one
another, metered slit 542 will cause both pouches 546, 547 to
rupture thereby allowing contents 550, 552 to be mixed and
dispensed. Those skilled in the art will appreciate that dispensing
package 530 in accordance with the present invention may have more
than two pouches that are sized and positioned depending on the
contents being dispensed. In addition, there may be more than one
metered slit that is either aligned with or staggered from the
pouches depending on the contents being dispensed.
[0074] FIG. 5F is a cutaway perspective of an alternate embodiment
in accordance with the present invention. Dispensing package 530
shown in FIG. 5F is similar to the dispensing package disclosed in
FIG. 5B with the addition of film 105 as depicted in FIG. 1A. Film
105 is attached to the top of label 534 with an adhesive 509.
Adhesive 509 is selected from the group including pressure
sensitive adhesives, heat curing adhesives or any other desired
type of adhesives. This type of packaging would be ideal when
child-resistant packing is desired, or when evidence or tampering
is desired, to provide additional print or billboard space or as a
safety feature so that the contents will not predispense when
stored in wallets, purses, luggage, etc.
[0075] FIG. 6 is a partial perspective view of one embodiment in
accordance with the present invention. As shown in FIG. 6, a
plastic backing 600 has a score 602 that extends across the width
of the package. Metered slit 604 is formed on the opposite side of
plastic backing 600 and is vertically aligned with score 602, as
illustrated in FIGS. 5A and 5B. As can be seen from FIG. 6, metered
slit 604 has a substantially shorter length than score 602, which
extends across the entire width of the package illustrated in FIG.
6. As also shown in FIG. 6, pouch 606 is heat sealed to the
underside of plastic backing 600. Metered slit 604 provides for
controlled flow of the contents through a smaller opening than
score 602.
[0076] FIG. 7 is a perspective view of the embodiment of FIG. 6
which has been flexed to an open position. As shown in FIG. 7,
plastic backing 600 has been flexed so that score 602 causes
plastic backing 600 to break along the length of score 602. Metered
slit 604 is aligned with score 602 and allows the contents to
dispense when plastic backing 600 is broken along score 602.
Barrier layer 610, which includes metered slit 604, has a much
higher elastic limit than plastic backing 600, the sides of which
remain intact when plastic backing 600 is broken along score 602,
i.e. with the exception of metered slit 604. In this manner, the
contents of the package which are contained in pouch 606 are only
dispensed through metered slit 608 which is formed through barrier
layer 610. Hence, score 602 can be formed across the entire width
of the dispensing package which allows plastic backing 600 to
easily break and quickly dispense the contents, but at the same
time only dispense the contents through a smaller metered slit 604
which is formed by score 604.
[0077] FIG. 7A is a perspective view of the embodiment of FIG. 4F
as the dispensing package is being flexed to an open position. As
shown in FIG. 7A, plastic backing 600 has been flexed so that score
602 causes plastic backing 600 to break along the length of score
602. Metered slits 618, 620, 622 are aligned with score 602 and
create metering holes for dispensing the contents when plastic
backing 600 is broken along score 602. Barrier layer 610, which
includes metered slit 604, has a much higher elastic limit than
plastic backing 600, the sides of which remain intact when plastic
backing 600 is broken along score 602, i.e. with the exception of
metered slit 604. In this manner, the contents of the package which
are contained in pouch 606 are only dispensed through metered slits
618, 620, 622 on the bottom side of plastic backing 600.
[0078] FIG. 7B is a perspective view of the embodiment of FIG. 4H
as the dispensing package is being flexed to an open position. As
shown in FIG. 7B, plastic backing 600 has been flexed so that score
602 causes plastic backing 600 to break along the length of score
602. Metered slits 628, 630, 632 are aligned with score 602 and
dispense the contents when plastic backing 600 is broken along
score 602. Material 624, 626 is placed adjacent score 602 Barrier
layer 610, which includes metered slit 604, has a much higher
elastic limit than plastic backing 600, the sides of which remain
intact when plastic backing 600 is broken along score 602, i.e.
with the exception of metered slit 604. In this manner, the
contents of the package which are contained in pouch 606 are only
dispensed through metered slits 628, 630, 632 on the bottom side of
plastic backing 600. Hence, score 602 can be formed across the
entire width of the dispensing package which allows plastic backing
600 to easily break and quickly dispense the contents, but at the
same time only dispense the contents through smaller metered slits
628, 630, 632. Additional control over dispensing the contents is
provided by material 624, 626 placed adjacent score 602 such that
the contents of the dispensing package can be applied with material
624, 626.
[0079] FIG. 7C is a perspective view of the embodiment of FIG. 4G
as the dispensing package is being flexed to an open position. As
shown in FIG. 7B, plastic backing 600 has been flexed so that score
602 causes plastic backing 600 to break along the length of score
602. Metered slits 644, 646, 648 are aligned with score 602 and
dispense contents 642 when plastic backing 600 is broken along
score 602. A continuous piece of for example, absorbent material
640 is positioned over score 602 and metered slits 644, 646, 648
and as can be seen absorbs contents 642 as it is expressed from
pouch 606. Barrier layer 610, which includes metered slit 604, has
a much higher elastic limit than plastic backing 600, the sides of
which remain intact when plastic backing 600 is broken along score
602, i.e. with the exception of metered slit 604. In this manner,
contents 642 contained in pouch 606 are only dispensed through
metered slits 644, 646, 648 on the bottom side of plastic backing
600. Contents 642 are then dispensed directly into absorbent
material 640 in order to provide controlled dispensing and
application. Hence, score 602 can be formed across the entire width
of the dispensing package, or partially depending on the
application.
[0080] The embodiments of FIGS. 7-7C all depict barrier layer 610
under plastic backing 600, where barrier layer 610 has a higher
elastic limit than plastic backing 600. Both barrier layer 610 and
plastic backing 600 are selected depending on the contents of the
dispensing package in order to minimize MVT while providing easy
and controlled dispensing and application of the contents. In one
embodiment, plastic backing 600 is constructed of a base material
selected from the group including rigid styrene, foil, Barex.RTM.
(BP Chemicals, Inc., Naperville, Ill., USA), polyethylene, nylon
and other co-extruded materials. The base material can then be
covered with film, such as printable polystyrene film,
polypropylene, polyester, and the like. The film can also be
covered with an over laminate, such as polystyrene film,
polypropylene, polyester, and the like.
[0081] FIG. 8 illustrates another embodiment of a dispensing
package 800. As shown in FIG. 8, score 802 on the top of dispensing
package 800 does not extend across the entire width, but only
extends across a middle portion of plastic backing 803 of
dispensing package 800. Shoulder portions 804, 806 extend from the
end of score 802 to the side of dispensing package 800. Shoulder
portions 804, 806 provide additional strength to the overall
package and provide stress when plastic backing 803 is flexed. The
embodiment shown in FIG. 8 differs from the embodiments shown in
FIGS. 6 and 7 in that the dispensing package 800 is not opened as
easily in response to a flexing action as the dispensing package
100 illustrated in FIGS. 1 through 3, 6 and 7. As such, the
dispensing package 800, illustrated in FIG. 8, is more robust and
provides additional control for the dispensing of the material
contained therewithin.
[0082] FIG. 9 is a close-up perspective view of dispensing package
800 illustrated in FIG. 8. As shown in FIG. 9, score 802 is
disposed in the top of plastic backing 810. Metered slit 808 is
disposed in the bottom side (underside) of plastic backing 810 and
is vertically aligned with score 802. Score 802 does not extend for
the entire width of dispensing package 800, but provides a shoulder
portion 804 in which plastic backing 810 is not scored.
[0083] FIG. 10 is a perspective view of dispensing package 800 in a
flexed position. As shown in FIG. 10, dispensing package 800 is
flexed which causes plastic backing 810 to break along the score
802. Flexure of dispensing package 800 also causes metered slit 810
to open. Barrier layer 812 prevents dispensing package 800 from
opening across the entire length of score 802. Shoulder portions
804 and 806 in plastic backing 810 provide an elastic spring-like
force that provides additional stress to the deformation of the
flexure of dispensing package 800. Shoulder portions 804, 806, in
this fashion, provide a structure that allows the user to control
the flexure of dispensing package 800, rather than having
dispensing package 800 immediately open. Dispensing package 800, in
this fashion, provides more control over dispensing of the contents
in pouch 814 of dispensing package 800.
[0084] FIG. 11 shows an alternate embodiment of a dispensing
package 1100. As shown in FIG. 11, score 1102 has even a shorter
length than score 802 of dispensing package 800 (as depicted in
FIG. 10). Hence, shoulder portions 1104, 1106 are much larger and
provide an even greater feedback force to the flexure of dispensing
package 1100.
[0085] FIG. 12 is a close-up perspective view of dispensing package
1100 of FIG. 11. As shown in FIG. 12, score 1102 is formed in the
upper surface of the plastic backing and is vertically aligned with
a similar metered slit 1108 in the opposite surface of the plastic
backing. Shoulder 1104 extends a substantial distance across the
width of dispensing package 1100 and provides a substantial
feedback force to the flexure of dispensing package 1100.
[0086] FIG. 13 is a perspective view of dispensing package 1100
shown in a flexed position. As shown in FIG. 13, score 1102 is
broken open to expose metered slit 1110. Shoulders 1104, 1106 do
not break as a result of the flexure of dispensing package 1100 and
provide an elastic feedback force that opposes the flexure of
dispensing package 1100, which allows the user to accurately
control the amount of flexure and, hence, the amount and flow rate
of the contents dispensed from dispensing package 1100.
[0087] FIG. 14 shows an alternate embodiment of a dispensing
package 1400. As shown in FIG. 14, dispensing package 1400 has a
plastic backing 1402 similar to the other embodiments and a label
1404. In addition, dispensing package 1400 has a promotional item
or resealable layer 1406 that is placed on the top surface of
dispensing package 1400. Promotional item or resealable label 1406
covers a score 1408 on the top surface of dispensing package 1400.
In this fashion, dispensing package 1400 is protected from
accidental breakage causing the contents of the package to dispense
unintentionally while promotional item or resealable label 1406 is
disposed on dispensing package 1400. Item 1406, as indicated, can
be a resealable label so that once part of the contents of
dispensing package 1400 are dispensed, dispensing package 1400 may
be resealed to prevent further dispensing of the contents. As such,
a user may wish to only dispense a portion of the contents and
later dispense another portion of the contents. Further, item 1406
can be a promotional item or game piece, such as a lottery card,
booklet, coupon or any other type of desired promotional item. In
that regard, U.S. patent application Ser. No. 10/162,722, entitled
"Machine for Placement of Multiple Labels," filed Jun. 3, 2002 by
Richard Schaupp, et al., is specifically incorporated herein by
reference for all that it discloses and teaches. Promotional item
or resealable label 1406 can be peeled from the top of dispensing
package 1400 and may be replaced on dispensing package 1400 after
usage. Those skilled in the art will appreciate that label 1404 can
be scored on not scored depending on the use and customer
preference.
[0088] FIGS. 15 through 29 illustrate a press 1500 that can be used
to make various embodiments of the dispensing package disclosed
herein. As shown in FIG. 15, a web roll 1502 of the plastic backing
is mounted on a backing unwind mandrel 1504. The plastic backing
web is unwound from roll 1502 as it is pulled across idler 1506.
Plastic backing web 1508, that is unwound from roll 1502, then
proceeds to other parts of press 1500 as described below. While
FIGS. 15-29 depict only one lane for producing dispensing packages
in accordance with the present invention, those skilled in the art
can appreciate that more than one lane can be run simultaneously to
produce various shapes, sizes and configurations of dispensing
packages according to the various embodiments previously
recited.
[0089] As illustrated in FIG. 16, the press further includes an
in-feed station 1600, a first die cutting station 1602 and a second
die cutting station and label laminator 1604. Plastic backing 1508
moves through and between a pull roller 1608 and in-feed nip roller
1610, located in in-feed station 1600.
[0090] As illustrated in FIG. 17, plastic backing 1508 exits
in-feed station 1600 and proceeds through first die cutting station
1602 which places the first cuts in the backside of plastic backing
1508. Plastic backing 1508 then proceeds to second die cutting
station and label laminator 1604. Printed label webs 1700 are also
fed into second die cutting station and label laminator 1604 where
plastic backing 1508 and printed label web 1700 are laminated.
[0091] FIG. 18 is a close-up view of first die cutting station
1602. As shown in FIG. 18, plastic backing 1508 is sandwiched
between a cylindrical anvil 1800 and a cylindrical die 1802. Those
skilled in the art will appreciate that flat bed, rotary or laser
die cutting may also be used. Cylindrical die 1802 includes a
series of cutting blades 1804 that cut the backside of plastic
backing 1508, which is shown as the top surface of plastic backing
1508 in FIG. 18. Cutting blades 1804 make smaller score 1102 as
shown in FIGS. 11-13 on the underside or backside of plastic
backing 1508. Cylindrical anvil 1804 is adjustable with respect to
cylindrical die 1802 to provide precise control over the depth at
which cutting blades 1804 score plastic backing 1508. Cylindrical
die 1802 is configured such that it cooperates with the cylindrical
anvil 1804 to provide precise control over the depth at which
cutting blades 1804 score plastic backing 1508. The amount of force
necessary to snap the plastic backing 1508 open before dispensing
the contents is changed based on the depth of the score.
Accordingly, altering the score depth depending on the contents
being dispensed provides additional control over dispensing.
[0092] FIG. 19 is an additional side perspective view illustrating
first die cutting station 1602 and second die cutting station and
label laminator 1604. As shown in FIG. 19, printed label web 1700
is unwound from a mandrel and has a plurality of registration marks
1900. Registration marks 1900 indicate the location of the label
information on printed label web 1700. Printed label web 1700
proceeds from the bottom of the press and upwardly to be mated with
plastic backing 1508 in second die cutting station and label
laminator 1604, as shown in FIG. 19. First die cutting station 1602
is synchronized with registration marks 1900 to ensure that the
scores made by first die cutting station 1602 are placed in the
proper location on plastic backing 1508.
[0093] FIG. 20 is an additional view of the backside of second die
cutting station and label laminator 1604. As shown in FIG. 20,
cylindrical die 1802 has a cutting blade 2002 which cuts along the
length of the cylindrical web. Cutting blade 2002 mates with
cylindrical anvil 1800 to form the score in the plastic backing.
Cylindrical anvil 1800 is adjustable with respect to cutting blade
2002 to provide precise control over the depth at which cutting
blade 2002 scores the plastic backing. Cylindrical die 1802 is
configured such that it cooperates with the cylindrical anvil 1804
is order to provide precise control over the depth at which cutting
blades 2002 scores plastic backing 1508. The amount of force
necessary to snap the plastic backing 1508 open before dispensing
the contents is changed based on the depth of the score.
Accordingly, altering the score depth depending on the contents
being dispensed provides additional control over dispensing.
[0094] FIG. 21 is a side view illustrating second die cutting
station and label laminator 1604 and filler/sealer station 2104. As
shown in FIG. 21, the plastic backing proceeds through second die
cutting station and label laminator 1604, where the plastic backing
and label web are scored and laminated. Plastic backing with
laminated label 2102 proceeds around idler 2100 in an upward
direction to be fed into filler/sealer station 2104.
[0095] FIG. 22 is a side view illustrating filler/sealer station
2104. Plastic backing with the laminated label 2102 proceeds around
an idler 2200 past a pre-heater assembly 2202. Pre-heater assembly
2202 heats plastic backing with the laminated label 2102 prior to
filling and sealing the assembly. The plastic backing with the
laminated label 2102 proceeds around idler 2200 under pre-heater
assembly 2202 and around idler 2208 and then downwardly into
filler/sealer station 2104, as described below. A filler conduit
2204 is connected to a supply of contents that is to be placed in
the dispensing package. The contents may be supplied in drums, such
as 55-gallon drums. The contents can comprise any desired contents
including liquids, lotions, creams, gels and pastes or other
contents that can be pumped to the filler conduit 2204. Pumps used
to deliver contents to the filler conduit can be any suitable pump,
including centrifugal pumps, positive displacement pumps, diaphragm
pumps, and the like selected based on the contents being dispensed.
The pump is servo-driven in order to provide precise dispensing
timing to reduce or eliminate cross seal contamination and provide
enhanced seal integrity. In addition, the type and size of pump can
be easily changed depending on the contents being dispensed
allowing the system to fill a wide variety of contents with varying
viscosities. Once the filler conduit 2204 is connected on one end
to the pump, it is then connected on a second end to a valve 2206
that controls the flow of contents to a filler tube (described
below). A pouch web (described below) wraps around idler 2210 and
also moves downwardly to be mated with plastic backing and
laminated label 2102. Sealing wheel assembly 2212 seals the pouch
web to plastic backing with the laminated label 2102, as described
below.
[0096] FIG. 23 is an additional view of filler/sealer station 2104.
As shown in FIG. 23, pouch web 2300 is fed from a roller 2304
across an idler 2306 and down into filler/sealer station 2104.
Pouch web 2300 is on the close side (right side) of valve 2206 and
the associated filler tubes. Pouch web 2300 proceeds downwardly
across the sealers 2302.
[0097] FIG. 24 is a side view of filler/sealer station 2104. As
shown in FIG. 24, pouch web 2300 proceeds across idler 2110 and
downwardly on the right side of filler tube 2400. At the same time,
laminated plastic backing and laminated label 2102 are fed across
idler 2200 and under pre-heater assembly 2202. Pre-heater assembly
2202 pre-heats the plastic backing prior to entry into
filler/sealer station 2104. This assists in the sealing of pouch
web 2300 to the plastic backing. Plastic backing and laminated
label 2102 are then fed across idler 2208 and proceed downwardly on
the left side of filler tube 2400.
[0098] FIG. 25 is a back side perspective view of filler/sealer
station 2104. As shown in FIG. 25, three sealer assemblies 2500,
2502 and 2504 are located on filler/sealer station 2104. Plastic
backing with label and pouch applied 2506 is fed downwardly across
the sealers 2500, 2502, 2504 and is filled and sealed in
filler/sealer station 2104.
[0099] FIG. 26 is a close-up view of one of sealing assemblies
(2500, 2502, 2504) illustrated in FIG. 25. As shown in FIG. 26,
sealing wheel assembly 2212 includes a series of sealing wheels
2600, 2602 and 2604 that heat and apply pressure to the pouch to
seal the pouch to the plastic backing. Cross sealer 2608 provides a
cross seal to the web as the web is moving downwardly. Hence,
sealing wheel assembly 2212 and cross sealer 2608 provide a
U-shaped pouch that is open at the top. Filler tubes 2400 and 2606
are located in-between the sealing wheels. Filler tubes 2400, 2606
insert a predetermined amount of contents into the U-shaped pouch
that is formed. Filler tubes 2400, 2606 are custom sized based on
the contents being sealed in the packages. The web then proceeds
downwardly so that cross sealer 2608 seals across the top of the
U-shaped pouch to provide a completely sealed pouch on the web.
Back barrier over drive is used during filling and sealing to
provide varying over drives that can be matched to the pouch size
in order to avoid channeling in the cross seal area.
[0100] FIG. 27 is a perspective view of a portion of die cutting
assembly 2700. As shown in FIG. 27, a filled and sealed assembly
web 2702 proceeds into a die cutting assembly 2700. A patterned nip
assembly 2704 is then used to cut the assemblies 2702 into
individual packages.
[0101] FIG. 28 is another view of die cutting assembly 2700. As
shown in FIG. 28, filled and sealed assembly web 2702 is fed
between anvil 2804 and cutting die 2800. Cutting blades 2802 cut
filled and sealed assembly web 2702 into individual pouches as
filled and sealed assembly web 2702 pass between anvil 2804 and
cutting blades 2802.
[0102] FIG. 29 is a perspective view of conveyor/stacker assembly
2900. After the individually cut packages leave die cutting
assembly 2700, they are received by receiving conveyor 2902. They
are then transported by transporting conveyor 2904 for stacking and
packaging for shipment. Of course, any desired type of
conveyor/stacker assembly can be used for packaging and shipping
the individual packages.
[0103] FIG. 30 is an illustration of one embodiment of press 3000
connected to a controller 3002 in order to produce dispensing
packages in accordance with the present invention. Operating values
for control parameters such as rotational speed of idlers, position
of anvils, temperatures of heat sealers, fill pump speeds, data
pertaining to label registration, and the like can be programmed
into controller 3002 before operating press 3000. Data files can be
saved for particular contents being packaged, where the operating
values unique to individual contents can be inputted and saved
according to a naming system. In this manner, operators can load
data according to the contents for which they are operating press
3000. Controller 3002 continuously monitors the status of all
operating parameters to provide optimal control over press 3000.
Controller 3002 can be set to provide operators with audible,
visible and production halting alarms depending on the deviation of
actual operating parameters from inputted operating parameters. As
those skilled in the art will appreciate, various changes can be
made to the methods, systems and control parameters used to operate
and control press 3002 without departing from the scope of the
present invention. Alternately, the operating parameters can be
manually set rather than using a computer embodied control system.
Thus, the examples present herein are not intended to limit, in any
way, the scope of the present invention.
[0104] Referring now to FIG. 31, controller 3002 illustrates
typical components of a controller. By way of example, controller
3002 can include a memory 3004, a secondary storage apparatus 3016,
a processor 3018, an input apparatus 3020, a display apparatus
3014, and an output apparatus 3012. Those skilled in the art can
appreciate that controller 3002 can be any computer means used to
operate and control press 3000 to produce dispensing packages in
accordance with the present invention. Memory 3004 may include
random access memory (RAM) or similar types of memory, and it may
store one or more applications 3006, including system software
3008, and a web browser 3010, for execution by processor 3018.
Secondary storage apparatus 3016 may include a hard disk drive,
floppy disk drive, CD-ROM drive, or other types of non-volatile
data storage. The local cache that includes data related to
particular setups for press 3000 may be stored on secondary storage
apparatus 3016. Processor 3018 may execute system software 3008 and
other applications 3006 stored in memory 3004 or secondary storage
3016, or received from the Internet or an intranet. Processor 3018
may execute system software 3008 in order to provide the functions
described in this specification including controlling the various
stages of press 3000 in order to produce dispensing packages in
accordance with the present invention.
[0105] Input apparatus 3020 may include any device for entering
information into controller 3002, such as a keyboard, mouse,
cursor-control device, touch-screen, infrared, microphone, digital
camera, video recorder, control instrumentation inputs or any other
instrument or device necessary to operate and control press 3000 in
order to produce dispensing packages in accordance with the present
invention.
[0106] Display apparatus 3014 may include any type of device for
presenting visual information such as, for example, a computer
monitor or flat-screen display so that an operator can observe
alarms, inputs, outputs, operating parameters and other information
related to the operation of press 3000. Output apparatus 3012 may
include any type of device for presenting a hard copy of
information, such as a printer, and other types of output devices
including speakers or any device for providing information in audio
form.
[0107] Web browser 3010 is used to access patient data stored in
memory 3004 and on secondary storage apparatus 3016 and display the
data, through which operators can operate and control press 3000
for producing dispensing packages in accordance with the present
invention. Web browser 3010 can also be used to access the Internet
and/or intranet. Any web browser, co-browser, or other application
capable of retrieving content from a network and displaying pages
or screens may be used.
[0108] Examples of controllers 3002 for operating and controlling
press 3000 in accordance with the present invention include
personal computers, laptop computers, notebook computers, palm top
computers, network computers, Internet appliances, or any
processor-controlled device capable of executing a web browser
3010, system software 3008 and any other type of application 3006
stored in memory 3004 or accessible via secondary storage apparatus
3016.
[0109] Advantages of the present invention include, but not by way
of limitation as to interpretation of the claims, the ability of a
user to open a package with one hand and control the dispensing of
the contents of the package in accordance with the flexure of the
package. A plastic backing is provided which can maintain the
structural integrity of the package and provide a surface on which
a label can be applied. The plastic backing material can be easily
flexed with force applied by a thumb and a single finger of one
hand. Flexure of the plastic backing causes the plastic backing to
exceed its elastic limit along a score on the convex side of the
package, which causes the package to open. A second score on the
interior of the package provides a metering hole through a
structural layer that regulates the dispensing of fluid. The depth
of both scores on the plastic backing and/or the number of metering
holes can be altered depending on the contents being dispensed such
that varying degrees of force are necessary to open the dispensing
package. The score on the outside of the package can be selected to
have various lengths, which results in shoulder portions of various
selected sizes. Since the plastic backing only breaks along the
length of the score on the outside of the package, the shoulder
portions provide a stress that is dependent upon the elastic
modulus of the plastic backing which allows the user to easily
control the dispensing of the contents of the package. Since the
size of the shoulders is related to the stress generated by the
shoulders, the required force to dispense the contents of the
package and the degree of control as to how quickly the contents of
the package are dispensed are parameters that can be advantageously
included in the package design. In addition, absorbent material can
be placed adjacent to or covering the score in order to provide
controlled dispensing and application of the contents of the
dispensing package. Alternately, film or labels can be placed over
the score in order to allow users to reseal the dispensing package.
The ends of the dispensing package can be particularly shaped such
that it can be used as an applicator and/or handle for the contents
being dispensed.
[0110] The present invention therefore provides a novel and unique
dispensing package that is capable of dispensing any desired type
of contents in a desired fashion and a method for producing the
same. The packages are inexpensive and simple to manufacture and
provide a desirable manner of carrying various contents. The
package can be easily carried by a user and dispensed in an easy
and simple fashion using one hand. In addition, promotional items
can be carried on the package including sequentially numbered game
items and other types of game items, booklets or any other type of
desired material. These materials can also be used for resealing
the package if the entire content of the package is not
dispensed.
[0111] The foregoing description of the invention has been
presented for purposes of illustration and description. It is not
intended to be exhaustive or to limit the invention to the precise
form disclosed, and other modifications and variations may be
possible in light of the above teachings. The embodiment was chosen
and described in order to best explain the principles of the
invention and its practical application to thereby enable others
skilled in the art to best utilize the invention in various
embodiments and various modifications as are suited to the
particular use contemplated. It is intended that the appended
claims be construed to include other alternative embodiments of the
invention except insofar as limited by the prior art.
* * * * *