U.S. patent application number 12/333992 was filed with the patent office on 2010-06-17 for tamper indicator for reclosable packages.
Invention is credited to James A. Bougoulas, Ujjaini Mitra-Shah.
Application Number | 20100147724 12/333992 |
Document ID | / |
Family ID | 42035769 |
Filed Date | 2010-06-17 |
United States Patent
Application |
20100147724 |
Kind Code |
A1 |
Mitra-Shah; Ujjaini ; et
al. |
June 17, 2010 |
TAMPER INDICATOR FOR RECLOSABLE PACKAGES
Abstract
A reclosable package for storing and dispensing product. The
package has a reclosable opening panel that can be selectively
moved from a closed position where product contained within the
package is retained to an open position where product contained
within the package is exposed for dispensing. The package includes
a tamper indicator that provides one or more of a visual, tactile,
or auditory indication that the opening panel is being opened for
the first time or has been previously opened.
Inventors: |
Mitra-Shah; Ujjaini;
(Chicago, IL) ; Bougoulas; James A.; (Chicago,
IL) |
Correspondence
Address: |
WRIGLEY & DREYFUS 28455;BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Family ID: |
42035769 |
Appl. No.: |
12/333992 |
Filed: |
December 12, 2008 |
Current U.S.
Class: |
206/459.1 ;
206/484; 220/214; 220/266 |
Current CPC
Class: |
B65D 85/60 20130101;
B65D 2575/586 20130101; B65D 75/5833 20130101; B65D 2401/00
20200501 |
Class at
Publication: |
206/459.1 ;
206/484; 220/266; 220/214 |
International
Class: |
B65D 55/02 20060101
B65D055/02; B65D 85/00 20060101 B65D085/00 |
Claims
1.-9. (canceled)
10. A reclosable package for consumable products comprising: a. a
laminated sheet comprising an inner layer and an outer layer
wherein the inner layer is oriented toward an inside of the package
and the outer layer is oriented toward an outside of the package;
b. a first laser scored line extending at least substantially into
the inner layer but not extending into the outer layer; c. a second
laser scored line extending at least substantially into the outer
layer but not extending into inner layer, and being laterally
offset from the first laser scored line to define an opening panel
in the package and a marginal region between the first and second
laser scored lines and further defining a surrounding region of the
sheet outside of the marginal region; and d. a tamper indicator
that provides an indication that the opening panel is being opened
for a first time and includes at least one of a frangible link that
breaks when the opening panel is being opened for the first time
and a configuration which causes partial delamination of the inner
or outer layer when the opening panel is opened for the first
time.
11. The reclosable package of claim 10 wherein the second laser
scored line has a configuration such that at least a portion of the
second laser scored line defines the frangible link.
12. The reclosable package of claim 11 wherein the configuration of
the second laser scored line defines a narrow conduit within the
outer layer.
13. The reclosable package of claim 10 wherein, the tamper
indicator includes at least two frangible links located on opposite
lateral sides of the opening panel.
14. The reclosable package of claim 1 wherein the inner layer is a
laminated sheet and the tamper indicator comprises a configuration
of the opening panel such that upon first opening of the opening
panel a portion of the inner layer is at least partially
delaminated.
15. The reclosable package of claim 14 wherein the configuration
includes laminating adhesive applied to a portion of the marginal
region.
16. (canceled)
17. The reclosable package of claim 10 wherein the tamper indicator
further comprises a security tape located over at least a portion
of the opening panel.
18. The reclosable package of claim 17 wherein the security tape
includes printing.
19.-25. (canceled)
26. A package for consumable products comprising: a. a laminated
sheet comprising an inner layer and an opaque outer layer wherein
the inner layer is oriented toward the inside of the package and
the opaque outer layer is oriented toward the outside of the
package; b. a first score line extending at least substantially
into the inner layer but not extending into the opaque outer layer;
c. a second score line laterally offset from the first score line
and extending at least substantially into the opaque outer layer
but not extending into the inner layer, the second score line
defining an opening panel in the package and further defining a
marginal region in the laminated sheet between the first and second
score lines and further defining a surrounding region that extends
throughout the laminated sheet outside of the marginal region; d. a
releasable adhesive disposed between the inner layer and opaque
outer layer in at least a portion of the marginal region; e. a
laminating adhesive disposed between the inner layer and opaque
outer layer and extending substantially throughout the surrounding
region such that the laminating adhesive is effective to bond the
inner layer and opaque outer layer together where it is applied;
and, f. a tamper indicator that provides a visual indication that
the opening panel has been previously opened and comprises at least
one of a frangible link which is broken when the opening panel is
opened for the first time and a configuration which causes partial
delamination of the inner or outer layer when the opening panel is
opened for the first time.
27. The package of claim 26 wherein the frangible link is located
within the outer layer.
28. The package of claim 27, wherein the second score line defines
a narrow conduit within the outer layer.
29. The package of claim 26 wherein a discontinuity in the second
line defines the frangible link.
30. (canceled)
31. The package of claim 26 wherein the opaque outer layer
comprises a laminate of a opaque first layer and a transparent
second layer wherein the transparent second layer is oriented
toward the outside of the package and the tamper indicator
comprises laminating adhesive applied to a portion of the marginal
region between the inner layer and opaque outer layer, wherein the
opaque first layer is delaminated from the transparent second layer
in the portion of the marginal region where the laminating adhesive
has been applied when the opening panel is opened for the first
time.
32. A package for consumable products comprising: a. a laminated
sheet comprising an inner layer and an outer layer wherein the
inner layer is oriented toward the inside of the package and the
outer layer is oriented toward the outside of the package; b. a
first score line extending at least substantially into the inner
layer but not extending into the outer layer; c. a second score
line extending at least substantially into the outer layer but not
extending into inner layer, and being laterally offset from the
first score line to define an opening panel in the package and a
marginal region between the first and second score lines and
further defining a surrounding region of the sheet outside of the
marginal region; and d. a tamper indicator that provides an
indication that the opening panel has previously been opened;
wherein the tamper indicator is selected from the group consisting
of a frangible link in the outer layer, a configuration which
causes partial delamination of the inner or outer layer when the
package is opened for the first time, and a security tape applied
across the second score line.
33. The package of claim 32 wherein the tamper indicator consists
of a frangible link in the outer layer.
34. The package of claim 33 wherein the tamper indicator consists
of at least two frangible links located on opposite lateral sides
of the opening panel.
35. The package of claim 32 wherein the tamper indicator consists
of a configuration which causes partial delamination of the inner
or outer layer when the package is opened for the first time.
36. The package of claim 32 wherein the tamper indicator consists
of a security tape applied across the second score line.
37. The package of claim 32 wherein the tamper indicator provides a
tactile indication that the package is being opened for the first
time.
38. The package of claim 32 wherein the tamper indicator provides
an auditory indication that the package is being opened for the
first time.
39. The package of claim 32 wherein the tamper indicator provides a
tactile indication that the package is being opened for the first
time.
40. (canceled)
41. (canceled)
Description
[0001] The present invention relates to a reclosable product
package for storing and dispensing products, particularly
consumable products and more particularly confectionery products
such as chewing gum and candy. In particular, the present invention
relates to a tamper indicator for a reclosable package to provide
an indication that the package is being opened for the first time
and/or that the package has been previously opened.
[0002] Certain consumable products are provided as individual
pieces in a package. Oftentimes, it is desired to retain these
products within the package yet when the package is opened, an
individual piece can be exposed and removed from the package. In
view of the fact that the package is reclosable, it would be
desirable to provide some indication as part of the package that
the package is being opened for the first time and/or has been
previously opened.
SUMMARY
[0003] The present invention therefore provides a package that
includes, as part of the package, a tamper indicator that provides
an indication that the package is being opened for the first time
and/or has been previously opened. The package of the present
invention is suitable for storing and dispensing individual pieces
of edible product, particularly confectionery products such as
candy and more particularly pieces of chewing gum. The tamper
indicator of the present invention may also be used with a
reclosable container that is configured to removably store one or
more packages that, in turn, contain several individual pieces of
edible product such as chewing gum or other confectionery
products.
[0004] The term reclosable as used herein refers to a package
having an opening feature which may be repeatedly opened and
securely reclosed for at least a sufficient number of times to
permit consumption of the entire contents of the package, one piece
at a time.
[0005] In one embodiment, the reclosable package includes a
laminated sheet having an inner layer and an outer layer. Each or
both of the inner layer and the outer layer may be a single layer
or may include a plurality of layers that act as a single layer for
the purposes of the present invention. A first score line is
created (for example, by a laser scoring operation) and extends at
least substantially into the inner layer but does not extend into
the outer layer. The term "score line" as used in the following
specification and claims means a weakened line in the layer
material that is intended to assist in separating the material
along the score line. The score line may be a continuous line cut
to full or partial depth of the layer or it may be a linear series
of intermittent cuts to full or partial depth of the material. In
any case, it is understood that the line may be straight, curved or
some combination of these along its length. Due to the benefits of
flexibility and precision, laser scoring is the preferred method of
creating the score lines. In the case where the score line is
created through the use of a laser, the score line may be referred
to as a laser scored line.
[0006] A second score line is created and extends at least
substantially into the outer layer but does not extend into the
inner layer. The second score line is laterally offset from the
first score line to define a marginal region between the first and
second score lines and to further define a surrounding region
outside of the marginal region. The second score line also defines
an opening panel for the package. A releasable adhesive may be
provided between the inner and outer layers in at least a portion
of the marginal region. A laminating adhesive is disposed between
the inner and outer layers and it is provided substantially
throughout the surrounding region such that the laminating adhesive
is effective to bond the inner and outer layers together where it
is applied. The package includes a tamper indicator that provides
one or more of a visual, tactile, or auditory indication when the
opening panel is first opened. The tamper indicator may further
provide one or more of a visual or tactile indication that the
opening panel has been previously opened.
[0007] In one aspect, the tamper indicator includes printable ink
underlying the opening panel that is revealed when the opening
panel is opened. Alternatively, the printable ink (or printing) may
be provided on the outer layer in a manner such that the printing
traverses at least a portion of the second score line. As a result,
when the opening panel is opened, the alignment of the word or at
least a portion of it will be disturbed and when the opening panel
is closed, alignment of the word or at least a portion of it will
be disturbed.
[0008] In another aspect, the tamper indicator includes a frangible
link connected to a portion of the opening panel that, when lifted,
provides an auditory and/or visual indication that the opening
panel is being lifted. For example, the second score line may
create a tab connected to the opening panel through a narrow
conduit which constitutes the frangible link so that when the
opening panel is opened for the first time, the frangible link is
broken to allow access to the contents of the package. In one
embodiment, a discontinuity in the second score line defines the
frangible link. In further embodiments, the tamper indicator
includes two or more frangible links located in key locations at
the periphery of the opening panel. In an embodiment, two frangible
links are located on opposite lateral sides of the opening
panel.
[0009] In other aspect, the opening panel may be configured such
that upon first opening of the opening panel, a portion of the
inner layer or outer layer is delaminated from a second portion of
the same layer. In one embodiment, the laminating adhesive may be
provided in a portion of the marginal region such that in that
portion of the marginal region (i.e., where the laminating adhesive
has been applied), a portion of the inner or outer layer is
delaminated from a second portion of the same layer. In an
embodiment, a tab defined by the second score line may have a
portion that is permanently adhered to the package (for example, by
application of the laminating adhesive) so that when a portion of
the tab is moved away from the package, the score line will tear
providing a visual and auditory indication that the seal has been
broken and that the opening panel may have been opened. After the
tab has been torn, evidence of such will be readily evident.
[0010] In yet another aspect of the invention, the outer layer may
be itself composed of two layers, a first opaque layer oriented
toward the inner layer of the package and a second transparent
layer oriented toward the outside of the package. In an embodiment,
a laminating adhesive is applied (for example, as a pattern) within
a portion of the marginal region. When the package is opened for
the first time, the outer layer is delaminated where the laminating
adhesive was applied, causing a pattern to be revealed in the
second transparent layer where the opaque material was removed and
on the inner layer where the first opaque layer material adheres to
the inner layer of the package. Upon re-closure of the opening
panel, it will be difficult or impossible to re-align the patterns
thus providing an indication that the package was previously
opened.
[0011] For purposes of the present invention, "laminate" and
"lamination" refer to any process which produces a multi-layer
structure. In addition to traditional adhesive lamination,
processes such as coextrusion and vacuum metallization are
specifically contemplated.
[0012] Also for purposes of the present invention, the term
"delamination" refers to the complete or partial separation of
layers that may occur between layers or within a given layer.
[0013] In another aspect, a portion of the package that is covered
by the opening panel may be provided with one or more of a light
sensitive dye or other material such that when the opening panel is
opened to expose the portion, the dye may cause a color change or
other visual indication. In another aspect, the package may include
a security tape located over at least a portion of the opening
panel such that an expectation of the presence is created, which
when the security tape is not present, or is torn, will provide an
indication that the package has been previously opened. While
particular examples of visual, tactile, and auditory indicators
have been noted, the present invention is not limited to these
specified examples. Rather, the invention includes any suitable
visual, tactile, or auditory indicator that does not interfere with
or inhibit the operation of the opening panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 shows an individual flexible product package
according to one embodiment of the present invention with the
reclosable opening panel in an open position to expose contents,
which in this instance is chewing gum.
[0015] FIG. 2 is a view of a portion of a first side of an outer
layer for one embodiment of a package of the present invention
showing a pattern of laminating adhesive applied to one side of the
outer layer so that the outer layer can be adhered to a first side
of an inner layer.
[0016] FIG. 3 is a view of a portion of a first side of an outer
layer for another embodiment of a package of the present invention
showing a pattern of laminating adhesive applied to one side of the
outer layer so that the outer layer can be adhered to a first side
of an inner layer.
[0017] FIG. 4 is a view of a portion of a second side of an inner
layer, which will form the inner surfaces of the package and the
other side of which is laminated onto a second side of the outer
layer of any of the embodiments shown in FIGS. 2 and 3 to form a
laminate roll stock.
[0018] FIG. 5 is a view of a portion of the second side of the
outer layer, which will form the outer surfaces of the package, the
other side of which is laminated onto the second side of the inner
layer to form a laminate roll stock.
[0019] FIG. 6 is a partial cross sectional view of the laminate of
FIG. 5 with the adhesive pattern of FIG. 2.
[0020] FIG. 7 shows the package of FIG. 1 with the reclosable
opening panel in a closed position.
[0021] FIG. 8 shows an embodiment of the package according to the
present invention where the package is formed from a separate front
and rear sheets.
[0022] FIG. 9 shows an embodiment of the package according to the
present invention where the package is formed with a rear side
having a seal.
[0023] FIG. 10a and 10b show the rear of the package of FIG. 9 with
two different rear seals.
[0024] FIG. 11 is a diagrammatic depiction of a method for making a
flexible package according to the present invention.
[0025] FIG. 12 is a view of the outer layer structure before being
laminated to the inner layer structure and after being scored.
[0026] FIG. 13 is a cross-sectional view of a portion of one
package, for example, a package made according to the process shown
in FIG. 11 in a closed configuration.
[0027] FIG. 14 is a cross-sectional view of a portion of the
package of FIG. 13 in an open configuration.
[0028] FIG. 15 is a diagrammatic depiction of a method for making a
flexible package according to the present invention, which contains
features that can be used in the process depicted in FIG. 11.
[0029] FIG. 16 shows a flexible container useful for storing and
carrying a plurality of individual product packages such as those
shown in FIGS. 1 and 7, each of which can contain a plurality of
individual pieces of edible product, particularly chewing gum. The
container is shown in an unopened position.
[0030] FIG. 17 shows the container of FIG. 16 in an open
position.
[0031] FIG. 18 shows a suitable configuration for a piece of gum
that may be stored in the individual product packages.
[0032] FIG. 19 shows a suitable configuration for a slab of gum
that may be stored in the individual product packages.
[0033] FIG. 20 is an alternative individual product package where
the individual product package is in the form of a cylinder with a
reclosable opening panel in a closed position.
[0034] FIG. 21 shows the individual product package of FIG. 19 with
the reclosable opening panel in an open position to expose
individual pieces of gum.
[0035] FIG. 22 shows the individual product package of FIG. 19 with
the reclosable opening panel in an open position to expose a
portion of a roll of gum that has a portion that has been
scored.
[0036] FIG. 23 shows an individual product package according to one
embodiment of a tamper indicator.
[0037] FIG. 24 shows an individual product package according to
another embodiment of a tamper indicator.
[0038] FIG. 25 shows an individual product package according to
another embodiment of a tamper indicator
[0039] FIG. 26 shows an individual product package according to
another embodiment of a tamper indicator.
[0040] FIG. 27 shows an individual product package according to
another embodiment of a tamper indicator.
[0041] FIG. 28 shows an individual product package according to
another embodiment of a tamper indicator.
[0042] FIG. 29 shows an individual product package according to
another embodiment of a tamper indicator.
[0043] FIG. 30 shows an individual product package according to
another embodiment of a tamper indicator.
[0044] FIG. 31 shows an individual product package according to
another embodiment of a tamper indicator.
[0045] FIG. 32 shows an individual product package according to
another embodiment of a tamper indicator.
[0046] FIG. 33 shows an individual product package according to
another embodiment of a tamper indicator.
DETAILED DESCRIPTION
[0047] The invention is described with reference to the drawings in
which like elements are referred to by like numerals. The
relationship and functioning of the various elements of this
invention are better understood by the following description. Each
aspect so defined may be combined with any other aspect or aspects
unless clearly indicated to the contrary. The embodiments described
below are by way of example only, and the invention is not limited
to the embodiments illustrated in the drawings.
[0048] Turning now to FIG. 1, a reclosable package 10 is shown with
a reclosable opening panel 80 in an open position to expose the
contents 2 of the package. The package includes opposed surfaces
12, 14, an opposed top 20 and bottom 22, and opposed ends or sides
24, 26. One of the surfaces is scored to define a reclosable
opening panel 80 that can be opened to expose the contents 2 stored
within the package 10. The package 10 is shown in a closed
configuration in FIG. 7.
[0049] In the description provided below, the package 10 of the
present invention is described as containing sticks (or tabs) 2 of
gum. It is to be understood, however, that the use of the package
10 is not limited to gum, confections, or even consumable products,
unless otherwise noted. For ease of description, however, the
present invention will be described in connection with sticks of
gum.
[0050] Therefore, a reclosable product package 10 having an array
of gum sticks 2 is shown in FIG. 1. The package 10 retains and
encloses the array of gum sticks 2 as will be described below. A
reclosable opening panel 80 provides selective access to the
contents 2 within the package 10.
[0051] As is known, gum sticks may be elongate rectangular shaped
members that are individually wrapped with a wrapper 4 in a
conventional fashion. The wrapper 4 may be a rectangular shaped
member typically made of paper or foil. Typically, the longitudinal
edges of the wrapper are overlapped and the ends of are turned over
against the stick to enclose the stick.
[0052] FIG. 1 shows gum sticks 2 contained in wrappers 4, where the
gum sticks were individually wrapped prior to being placed in the
package 10. The wrapper 4 may be a single sheet or may include one
or more sheets or layers. It is noted that the gum sticks 2 can be
placed in an array directly into the package, without being
individually wrapped.
[0053] While FIG. 1 shows the sticks 2 oriented within the package
10 in one direction, it is contemplated that the sticks could be
oriented in a direction perpendicular to that shown in FIG. 1.
Alternatively, the sticks 2 may be oriented in another direction so
long as when the opening panel 80 is in an open position, access to
the sticks is provided.
[0054] FIG. 1 also shows the gum sticks 2 aligned in a single row.
It is to be understood that the gum sticks (wrapped or not) can be
placed in a face-to-face manner, i.e., in two or more columns to
form the array. When two or more columns are provided, each row may
be encircled partially or completely by a wrapper to better contain
the individual gum sticks. The array of gum sticks is placed in the
package 10 and are retained and enclosed. A portion of the inside
of the package 10 may contain an adhesive to releasably secure the
gum sticks until the consumer removes them from the package 10.
[0055] Although it is not depicted, it is contemplated that one or
more gum sticks may be contained within a flexible package 10 and
that one or more flexible packages 10 may be provided in a
container 800 as described below. Because the package 10 and the
container 800 are intended to be reclosable, as described in more
detail below, the package is provided with a tamper indicator 950
that will provide an indication that the package 10 has been first
opened and/or has been previously opened.
[0056] The package 10 is generally a parallelepiped shape and
formed of any suitable material. Without being limited, it is
contemplated that the package 10 can be formed of a flexible
plastic material, such as polyethylene (including but not limited
to low density polyethylene and linear low-density polyethylene),
polypropylene, mixtures or laminates of such, and other flexible
plastics. The package could also be formed from metalized plastics,
paper, laminated paper material, or other laminates. While it is
contemplated that the package can be formed from a variety of
suitable materials, for ease of understanding and description the
package 10 and its construction will be described as being formed
from a flexible plastic material such as polypropylene.
[0057] In general, the package is a laminated sheet having an inner
layer and an outer layer. Each of the inner layer and outer layer
or both may be a single layer or may include a plurality of layers
that act as a single layer for purposes of the present invention.
Accordingly, in one aspect, the package 10 is formed from a
laminate 30 that includes a polypropylene film and optionally a
polyethylene film. For example, the package 10 may be formed from a
laminate 30 that includes a metal layer 122 disposed between two
layers of polypropylene 42, 120.
[0058] Turning now to FIG. 2, one method of forming of one
embodiment of the package 10 will be explained. Briefly, this
method includes creating a laminate from a first and second
material, scoring each side of the laminate, cutting the laminate,
filling the laminate with the desired contents, forming the
package, and sealing appropriate areas to provide the package 10.
While several methods of forming the package 10 are described
below, each will produce a package having the features identified
and shown in FIGS. 1 and 7.
[0059] Accordingly, an outer layer of material 40 may be unwound
from a web (not shown). The outer layer 40 may be formed of
polypropylene having a first side 44, a second side 46, a
longitudinal direction 48, and a lateral direction 50 as shown in
FIGS. 2 and 6. Desirably, the polypropylene is an oriented
polypropylene with the orientation in the lateral direction 50. As
one skilled in the art will appreciate, orientation in this
direction provides a higher resistance to tearing in the
longitudinal direction 48 as compared to the lateral direction 50.
While FIG. 2 depicts a continuous layer of material, the figure
also identifies a first end 52 and a second end 54, which when cut
and joined to each other in a later operation will form the bottom
22 of the package.
[0060] The first side 44 of the outer layer 40 is patterned with
adhesive so that another layer may be adhered to the first side 44
of the outer layer 40. The second side 46 of the outer layer 40
will form the outer surfaces of the package 12 and 14, as will
become clear. Typically, the outer layer 40 is patterned with a
permanent laminating adhesive 70 and a releasable adhesive 72 (such
as a pressure sensitive adhesive) as it is being unwound and before
it is adhered to an inner layer 100.
[0061] FIG. 2 shows one pattern of adhesive application. As shown
in FIG. 2, a fold line 60 is depicted at about the middle of the
longitudinal length of the outer layer 40. It is to be understood
that the fold line 60 is not provided on the outer layer 40 but
instead it represents the portion of the outer layer 40 where the
laminate 30 will be folded in a later operation to create the top
20 of the package 10. The fold line 60 defines a top section 62 and
a bottom section 64 of the outer layer 40 that will define an inner
back surface 18 and an inner front surface 16 of the package 10,
respectively.
[0062] In the embodiment shown in FIG. 2, a permanent laminating
adhesive 70 well known to those of skill in the art is applied to a
sufficient portion of the top section 62 of the outer layer 40 and
only to a portion of the bottom section 64. The permanent
laminating adhesive 70 may be applied to the entire portion of the
top section, if desired. Put another way, the laminating adhesive
70 is distributed throughout a surrounding region 63 (explained
later in connection with the marginal region) to at least the
extent necessary to effectively join the inner layer 100 and the
outer layer 40 to allow the package 10 to function as intended. The
laminating adhesive 70 may be applied evenly throughout the
entirety of the surrounding region 63. Alternatively, it may be
applied evenly to key areas where delamination could otherwise
occur. It is also contemplated to provide the laminating adhesive
70 as a repeating or random pattern in discrete areas such as by
using a dot matrix or cross hatch patterns. Of course, one or more
combinations could also be used.
[0063] In the bottom section 64, a first smile area 82 is defined.
The first smile area 82 includes a releasable adhesive 72 such as a
releasable pressure sensitive adhesive known to those of skill in
the art. An adhesive-free area 74 may be provided adjacent to at
least a portion of the releasable adhesive area 72. A releasable
adhesive 72 functions to join the outer 40 and inner 100 layers and
it has a relatively low bond force to allow easy separation of the
outer 40 and inner 100 layers. In addition, the releasable adhesive
is capable of re-adhering the outer 40 and inner 100 layers a
sufficient number of times (i.e., a sufficient number of iterations
of joining and separating the layers). An adhesive-free area 74 may
be provided adjacent to at least a portion of the releasable
adhesive area 72. The adhesive-free area 74 does not contain any
adhesive, the reasons for which will become apparent upon further
reading of the description.
[0064] FIG. 3 shows an alternative pattern of applying the adhesive
to the first side 44 of the outer layer 40. This pattern is similar
to that of FIG. 2 except that the adhesive-free area 74 is limited
simply to a tongue portion 84.
[0065] Turning now to FIG. 4, an inner layer 100 is shown. The
inner layer of material 100 may be unwound from a web (not shown).
The inner layer 100 may be formed from any suitable material as
noted above. The material desirably is formed from a composite or
laminate such that one layer can be scored with a laser while the
other layer resists scoring. For example, the material may be a
laminate of paper and metal or foil, or a laminate of a flexible
plastic material and metal or foil. In one aspect of the present
invention, the inner layer 100 is a formed from metalized
polypropylene, i.e., a layer of polypropylene 120 and a layer of
metal 122 provided on one side of the polypropylene 120.
[0066] The inner layer 100 has a first side 102 (best seen in FIG.
6), a second side 104 (best seen in FIG. 4), a longitudinal
direction 106 and a lateral direction 108. Desirably, the
polypropylene is an oriented polypropylene with the orientation in
the lateral direction 108.
[0067] As the inner layer of material 100 is unwound, the first
side 102 of the inner layer 100 is joined with the first side 44 of
the outer layer 40. The outer layer 40 and the inner layer 100 are
laminated in a manner such that the layer of metal or foil 122 is
disposed between the layers of the polypropylene 42 and 120 and
such that a laminate 30 is formed. In other words, the layer of
metal 122 is in contact with the adhesive 70, 72 provided on the
first side 44 of the first layer 40. Desirably, the inner layer 100
is securely adhered to the outer layer 40.
[0068] Optionally, a heat-sealing layer 124 such as a layer of
polyethylene may be provided on the second side 104 of the inner
layer 100. Alternatively, other layers may be provided on the
second side 104 or the inner layer 100, as is known to those of
skill in the art.
[0069] FIG. 4 shows the second side 104 of the inner layer 100. It
is to be understood that FIG. 4 also shows the laminate 30 with the
second side 104 of the inner layer 100 visible. While FIG. 4
depicts a continuous layer of laminate, the figure also identifies
a first end 103 and a second end 105, which, when cut and joined to
each other by folding along fold line 110 in a later operation,
will form the bottom 22 of the package. It is to be understood that
the fold line 110 is not provided on the inner layer 100 but
instead it represents the portion of the inner layer 100 where the
laminate 30 will be folded in a later operation to create the top
20 of the package 10. The fold line 110 defines a top section 112
and a bottom section 114 of the inner layer 100, which will form
the rear 14 and front 12 surfaces, respectively.
[0070] As seen in FIG. 4, a score line 132 is created on the bottom
section 114 of the second side 104 of the inner layer 100.
Desirably, the scoring may be performed after the laminate 30 is
formed. Alternatively, the scoring may be performed before the
inner layer 100 is laminated to the outer layer 40. Desirably, the
score line 132 is created by laser scoring and, as shown in FIG. 4,
can be considered to define an inner smile cut 132. The inner smile
cut or score line 132 will also define an inner smile area 130, as
will become clear upon reading the following description.
[0071] The term score line is means a weakened line that is
intended to assist the consumer in separating the material along
the line. The score line may be a continuous line cut to partial
depth of the layer or it may be a linear series of intermittent
cuts to a full or partial depth of the layer. It is understood that
the score line may be straight, curved, or a combination of these
along the length of the score line.
[0072] The scoring is on the polypropylene layer 120 only (or the
polyethylene and heat seal layers, if a heat seal layer is present)
and does not score beyond the metal layer 122 (i.e., it does not
score the first layer). The depth of the laser cut may be
controlled in a manner known by those of skill in the art to
provide such precision cutting. Specifically, the heat dissipation
of the metal layer (or other laser scoring resistant material)
reduces the likelihood that it is scored when the power of the
laser is controlled for that purpose.
[0073] The score line 132 has a first end 131 and a second end 133
each of which is adjacent the fold line 110. Desirably, the first
end 131 and second end 133 terminate at substantially the same
lateral location so that the inner smile area 130 is substantially
symmetric. Consistent with the objectives of the present invention,
a localized weak portion 135 of the score line 132 may be provided
between the first end 131 and the second end 133. The localized
weak portion 135 has a break force that is less than the break
force of the non-localized weak portion of the score line 132.
[0074] The term break force is used to mean the force required to
separate the inner smile area 130 from the bottom section 114 along
the score line. The break force is dictated generally by the
materials of construction, their orientation, and the score line
itself, (i.e., how many "holes" and how big the "holes", how far
apart are the "holes"). One of skill in the art would understand
that when laser scoring the material one or more operating
parameters can be varied that will affect the break force.
Accordingly, the localized weak portion 135 will have a first end
137 and a second end 139, each of which defines the end point of
the localized weak portion 135 along the score line 132. The
localized weak portion 135 is generally located at the tear
propagation location which generally is located near the tongue 84,
as will become clear from the description below.
[0075] The top section 112 of the second side 104 of the inner
layer 100 may include a releasable adhesive 140 applied along a
line or strip that runs in the lateral direction 108. The
releasable adhesive 140 may be applied in a continuous or
intermittent manner according to methods well known to those of
skill in the art. This adhesive strip 140 may engage some or all of
the gum sticks 2 or their wrappers 4 so that when the package 10 is
formed; the gum sticks 2 are removably adhesively retained in the
package. As a result, the gum sticks 2 may remain positioned in the
package 10 even when one or more gum sticks 2 are removed. In
addition, the adhesive 140 may prevent the gum sticks from becoming
inadvertently dislodged from the package 10.
[0076] Turning to FIG. 5, the second side 46 of the laminate 30 is
shown. It will be understood that FIG. 5 also shows the laminate 30
with the second side 46 of the outer layer 40 visible. As seen in
FIG. 5, an outer score line 86 is created on the bottom section 64
of the second side 46 of the outer layer 40. The scoring may be
performed after the laminate 30 is created and can be performed
before, simultaneously with, or after the scoring is performed on
the second side 104 of the inner layer 100. Alternatively, the
scoring may be performed before the lamination process described
above. Desirably, the score line 86 is created by laser scoring
and, as shown in FIG. 6, can be considered to define an outer smile
cut 86. The outer smile cut or outer score line 86 defines an outer
smile area 82 with a tongue 84. The scoring is on the polypropylene
layer 42 only and does not score beyond the metal layer 122 (i.e.,
it does not score the second polypropylene layer 100). The depth of
the laser cut may be controlled in a manner known by those of skill
in the art to provide such precision cutting. The outer smile area
82 is larger than the inner smile area 130. FIG. 6 shows a partial
side cross sectional view of the portion of the laminate 30 that
has been score cut.
[0077] In addition, as will be appreciated from the foregoing
description, the first or inner score line 132 and the second or
outer score line 86 are located in a manner with respect to each
other (e.g. they are laterally offset) to define a marginal region
73 between them and to also define a surrounding region 63 which is
the area other than the marginal region 73.
[0078] The score line 86 has a first end 81 and a second end 83
each of which is adjacent the fold line 60. Desirably, the first
end 81 and second end 83 terminate at substantially the same
lateral location so that the outer smile area 82 is substantially
symmetric. Consistent with the objectives of the present invention,
a localized weak portion 85 of the score line 82 is provided
between the first end 81 and the second end 83. The localized weak
portion 85 has a break force that is less than the break force of
the non-localized weak portion of the score line 86.
[0079] The term break force is used to mean the force required to
separate the outer smile area 82 from the bottom section 64 along
the score line 86. The break force is dictated generally by the
materials of construction, their orientation, and the score line
it, (i.e., how many "holes" and how big the "holes", how far apart
are the "holes"). One of skill in the art would understand that
when laser scoring the material one or more operating parameters
can be varied which will affect the break force. Accordingly, the
localized weak portion 85 will have a first end 87 and a second end
89, each of which defines the end point of the localized weak
portion 85 along the score line 86. The localized weak portion 85
is generally located at the tear propagation location which
generally is located near the tongue 84.
[0080] Referring back to FIG. 1, it is seen that one surface of the
tongue 84 may be printed or patterned with a rubberized or
elastomeric material to provide a gripping surface. Advantageously,
providing such a grip surface may also work to position the tongue
in a position where it can be easily grasped by the user. For
example, the additional weight caused by the presence of the
rubberized or elastomeric material may work to cause the printed
surface to lay adjacent the front surface 12. While a
representative pattern of printed material is shown in FIG. 1, it
is contemplated that the pattern could take any suitable and
desired shape.
[0081] After the laminate 30 is formed and score cut, the laminate
may be wound to form roll stock (not shown). During the package 10
forming operation, the laminate 30 is unwound from the roll stock.
A portion of the sticks 2 are placed adjacent the second side 104
of the inner layer 100 and the laminate 30 is folded along the fold
line 110. The laminate 30 is folded such that the top section 112
of the second side 104 of the inner layer 100 is juxtaposed with
the bottom section 114 of the second side 104 of the inner layer
100 and such that the top section 62 and the bottom section 64 will
form the rear 14 and front 12 surfaces, respectively, of the
package 10. The laminate 30 is then cut and sealed to create the
bottom 22 and ends 24, 26 of the package 10. Of course, it is to be
understood that these operations could take place in other
sequences. For example, the laminate 30 may be unwound and cut,
after which the sticks are placed adjacent the second side 104 of
the inner layer 100. Thereafter, the laminate 30 is folded along
fold line 110, cut, and then sealed to create the bottom 22 and
ends 24, 26 of the package 10.
[0082] Turning now to FIG. 7, the package 10 is shown with the
outer smile cut 86 visible on the front 12 surface. With the above
in mind, when it is desired to open the package 10, the tongue 84
is lifted or pulled away from the front 12 surface. Because of the
scoring or inner smile cut 132 on the inner layer 100 and because
the metal layer 122 on the inner layer 100 is adhered to the outer
layer 40, the inner smile cut 132 of the inner layer 100 tears
together with the outer smile cut 86 on the outer layer 40. In
addition, because the inner smile area 130 is smaller than the
outer smile area 82, and because of the prior pattern application
of releasable adhesive 72 (as well as the provision of an
adhesive-free area 74), a reclosable opening panel 80 is defined
with releasable adhesive 72 provided adjacent the perimeter 88 of
the opening panel. Moreover, the portion of the opening panel 88
that contains the releasable adhesive 72 is in contact with a
portion of the metal layer 122 to provide an effective reclosable
seal.
[0083] It is understood that the releasable adhesive 72 will have a
delamination force, by which is meant the force required to
separate the opening panel 80 from the package along the releasable
adhesive 72 portion. The delamination force should have a strength
suitable to repeatedly maintain the opening panel in a closed
position yet not be so strong as to be an impediment to the opening
of the opening panel.
[0084] In one aspect a localized weak portion 85 may be provided
adjacent the tongue 84. Thus, when the tongue 84 is lifted or moved
away from the front 12 surface, the initial tear propagation point
will be in the area of the localized weak portion 85 between the
ends 87 and 89 so that as the tongue 84 is moved away from the
front 12 surface, the opening panel 80 will tear along the score
line 86 starting at the localized weak portion 85 and terminating
at the ends 81 and 83. Because the inner score line 132 is
constructed in a similar fashion as the outer score line 86, the
inner score line will operate in a similar manner.
[0085] In addition, it is desirable to provide a delamination force
of the releasable adhesive 72 that is greater than the localized
weak portion 85 break force and/or the break force of the score
line 86, 132. In this instance, a portion of the opening panel 80
will begin to separate from the package 10 along the localized weak
portions 85, 135 and then along the score lines 86, 132 before the
opening panel 80 separates from the package 10 along the releasable
adhesive 72 location. It is also desirable to provide the
laminating adhesive 70 with a bond strength that defines the amount
of force necessary to separate the inner 100 and outer 40 layer
such that the bond strength of the laminating adhesive 70 is
greater than the break force of the first score line 132. In this
way, as the opening panel 80 is moved away from the package 10, the
inner layer 100 is carried with the outer layer 40 in the
surrounding region 63 of the opening panel 80.
[0086] Turning now to FIG. 8, another method of making the package
10 is shown. In this embodiment, a first laminate 150 is formed to
define a front surface 152. The first laminate 150 may be formed in
the same manner described above in connection with the formation of
the laminate 30, except that the laminate will not be folded.
Instead, a second material 154 will be used or formed to define a
back 156 surface. The second material 154 may be formed from any
suitable material such as polypropylene, polyethylene, laminates,
or other materials that can effectively seal with the first
laminate 150 to provide a closed package 10 according to the
present invention.
[0087] The first laminate 150 will be scored in the manner
described above to provide a reclosable opening panel 80 in the
same manner as described above. Thereafter, each of the edges of
the first laminate 150 and the second material 154 are sealed to
create a closed package 10.
[0088] Turning now to FIG. 9, another method of making the package
10 is shown. In this embodiment, a laminate 330 is made in the same
manner as described above, except, as seen in FIG. 9, the laminate
will have three sections 302, 304, 306 with two fold lines 308,
310. In addition, the first section 302 has a peripheral edge 320
that will join with a peripheral edge 334 provided on the third
section 306. To finish the package 10, the first section 302 and
the third section 306 are folded away from the outer smile cut 86
and toward each other after the product has been inserted. The
peripheral edges 320 and 334 are sealed, such as by heat sealing or
other suitable means. Alternatively, a fin seal 350 as shown in
FIG. 10a or a lap seal 360 as shown in FIG. 10b may be created at
the rear of the package 10. Of course, other known seals may be
created as is known to those of skill in the art.
[0089] Turning now to FIG. 11, another embodiment of the
manufacturing process of the present invention is depicted. A first
structure 440 is formed by joining a first layer 442 with a second
layer 446. The first layer 442 may be advanced from a supply roll
444 and the second layer 446 may be advanced from a different
supply roll 448. Adhesive 450 may be applied to the first layer
442, the second layer 446, or both. Thereafter, the first layer 442
and the second layer 446 may be joined in a laminating station 452
to form the first structure 440.
[0090] Alternatively, the first structure 440 may be supplied from
a roll of preformed first structure laminate 600 (as best seen in
FIG. 15). In addition, while FIG. 11 shows the first structure 440
being formed from two film layers, it is contemplated that the
first structure 440 could be formed from more than two layers,
e.g., from three or more layers. In addition, the formed first
structure 440 could be rolled up on a spool 600 for later
processing, as described below.
[0091] Various materials can be used for the layer(s) of the first
structure 440, including polymers such polyesters, polyolefins
(including homopolymers and copolymers), polyamides, and others;
paper; metal foil; and the like. Advantageously, when metal foil is
used as an inner layer, it allows partial scoring through the outer
layer while maintaining structural integrity for later operations
such as scoring, batch rolling, transporting, batch unrolling, and
the like.
[0092] The first structure 440 may then be advanced by suitable web
driving and handling equipment (not shown) to an optional print
station 480 comprising a printing apparatus, such as a rotogravure
printer or the like, for printing graphics and/or indicia on the
first structure by applying inks to a surface of the first
structure 440. In one embodiment of the invention, the first
structure 440 includes an outer layer that is substantially
transparent and may be reverse-printed in the print station so that
the inks will be visible through the first structure 440. The inks
may be applied to the surface of the first structure 440 that is
subsequently laminated to another structure, as described below;
from the opposite side of the first structure, which will form an
exterior of a package 10 constructed from the laminate 430 created
according to this embodiment.
[0093] Prior to printing the first structure 440 at the print
station 480, the surface of the first structure 440 to be printed
can be treated by a corona discharge or flame treatment apparatus
482 to render the surface more-receptive to the inks and/or to
render the surface more-readily bondable to the pressure-sensitive
adhesive that is subsequently pattern-applied to the surface as
described below.
[0094] Following the optional corona/flame treatment and/or
optional printing operation, the first structure 440 may be
advanced to the next processing stage or it may be rolled up onto a
spool 602 (as best seen in FIG. 15) and stored for subsequent
processing operations.
[0095] The first structure 440 either from the previous processing
step or from roll 602 is advanced to a scoring station 520 where a
first score line 86 (FIG. 7 and FIG. 13) is formed through the
thickness of the first structure 440. The first score line 86 is in
registration with (i.e., coincides with) the printing of the
graphics or indicia or other features. The first score line 86
extends substantially through the thickness of the first structure
440.
[0096] The first scoring station 520 can comprise a laser. The use
of lasers for scoring through flexible materials is generally
known, for example as described in U.S. Pat. Nos. 3,909,582 and
5,229,180, the contents of which are incorporated herein by
reference. The depth of the score line formed by the laser can be
regulated by regulating the power output or beam intensity of the
laser beam, the width or spot size of the laser beam, and the
amount of time a given spot on the film surface is irradiated by
the beam. These factors generally are selected based on the
characteristics of the material being scored. Some materials are
more readily scored by lasers than other materials, as known in the
art.
[0097] As noted, the first score line 86 should be in registration
with one or more features such as printing, indicia marks, the
location of the outer perimeter of the pressure-sensitive strip 492
(and the outer perimeter of the tongue 84 or thumb tab 500, if
present). To accomplish this registration, the operation of the
laser is controlled to be synchronized with the advancement of the
first structure. A sensor disposed adjacent the first structure can
be used to detect a feature on the first structure (such as
printing) whose location in relation to the strip of
pressure-sensitive adhesive 492 is known, and the sensor's output
signal can be used by a suitable controller (not shown) for
controlling the laser. Subsequent to the scoring, the first
structure 440 may be rolled onto spool 604 for subsequent
processing (as best seen in FIG. 15).
[0098] After scoring, the first structure 440 may be advanced
(either from spool 604 or from the previous continuous scoring
station 520) to a first adhesive application station 490 at which a
pressure-sensitive adhesive 492 (releasable adhesive) may be
applied to the first structure 440 in a predetermined pattern that
recurs at regular intervals along the lengthwise direction of the
first structure 440. The predetermined pattern may be in the form
of a strip of various forms or shapes. As illustrated, one shape
for the strip pattern may be generally U-shaped or smile shaped,
for reasons that will become apparent. Other shapes for the pattern
can be used. The pattern can include a region that is free of
adhesive 500 and that will ultimately form a thumb tab or grasping
portion of the first structure 440 as further described below.
[0099] The pressure-sensitive adhesive 492 can comprise various
compositions. Pressure-sensitive adhesives form viscoelastic bonds
that are aggressively and permanently tacky, adhere without the
need of more than a finger or hand pressure, and require no
activation by water, solvent or heat. Pressure-sensitive adhesives
are often based on non-crosslinked rubber adhesives in a latex
emulsion or solvent-borne form, or can comprise acrylic and
methacrylate adhesives, styrene copolymers (SIS/SBS), and
silicones. Acrylic adhesives are known for excellent environmental
resistance and fast-setting time when compared with other resin
systems. Acrylic pressure-sensitive adhesives often use an acrylate
system. Natural rubber, synthetic rubber or elastomer sealants and
adhesives can be based on a variety of systems such as silicone,
polyurethane, chloroprene, butyl, polybutadiene, isoprene, or
neoprene. When the packaging laminate of the invention is to be
used for food packaging, the pressure-sensitive adhesive generally
must be a food-grade composition. Various pressure-sensitive
adhesives are approved by the U.S. Food and Drug Administration for
use in direct food contact, as regulated by 21 CFR Part 175.300.
Food-grade pressure-sensitive adhesives are preferred for use in
the present invention. Additives (e.g., particulates or the like)
can be added to the pressure-sensitive adhesive to reduce the
tenacity of the bond to the second structure 460, if necessary, so
that the pressure-sensitive adhesive 492 readily detaches from the
second structure 460 on opening (particularly on the very first
opening).
[0100] While denoted as a pressure-sensitive adhesive, the use of a
cohesive is also contemplated. In this regard, the term "cohesive"
refers to a material that is an adhesive that only sticks to a
cohesive surface, most commonly to another layer of itself.
Cohesives are commercially available from a supplier such as Henkel
and the particular cohesive composition is not a feature of the
present invention. Typically, the cohesive is applied to the first
structure 440. The desired cohesive is such that, although it is
applied to the first structure 440, a portion of the cohesive is
transferred to the portion of the outer structure 460 juxtaposed
with the area on which the cohesive is applied. In addition, the
cohesive is formulated such that the bonding affinity between the
cohesive and either of the first structure 440 and the second
structure 460 is greater than the bonding affinity between the
cohesive on each of the first and second structure so that the
portions containing the cohesive are rebondable or reclosable.
[0101] The pattern of pressure-sensitive adhesive 492 is applied to
the first structure 440 at regular intervals along the first
structure 440. The spacing or index distance d between the patterns
can correspond to a dimension, such as a length, of packages 10 to
be produced from the laminate 430.
[0102] The adhesive application station 490 can comprise any
suitable device capable of accurately applying the
pressure-sensitive adhesive 492 to the first structure 440 in the
desired pattern at regular intervals along the first structure 440.
For example, the adhesive application station 490 can comprise one
or more gravure rolls that pick up the pressure-sensitive adhesive
492 from a reservoir on the outer surface of the roll such that the
adhesive fills one or more recessed areas in the surface. A doctor
blade may then be used to scrape off excess adhesive so that it
remains essentially only in the recessed area(s). The first
structure 440 may be contacted by the gravure roll with a backing
roll that may be used to provide support on the opposite side of
the first structure 440.
[0103] After application of the pressure-sensitive adhesive 492,
the first structure 440 may be advanced to a dryer 496 such as an
oven or the like, to dry the pressure-sensitive adhesive 492. The
first structure 440 may then advanced to a second adhesive
application station 510 at which a permanent laminating adhesive
512 is applied to the first structure 440 in such a manner that a
sufficiently large proportion of the surface is covered by the
permanent laminating adhesive 512 to permit the first structure 440
to be adhesively attached to a second structure 460 at a downstream
laminating station 530. Alternatively, the first structure 440 may
be advanced to the second adhesive application station 510 before
being advanced to the dryer 496. Thereafter, the first structure
440, which contains both the pressure-sensitive adhesive 492 and
the permanent laminating adhesive 512, is advanced to the dryer 516
to dry the adhesives.
[0104] The permanent laminating adhesive 512 does not cover the
pressure-sensitive adhesive 492. Furthermore, when the pattern of
pressure-sensitive adhesive 492 includes an adhesive-free region
500 (74) to form a thumb tab or grasping portion as previously
noted, the pattern of the permanent laminating adhesive 512 also
does not cover the adhesive-free region 500 (74). Thus, the
permanent laminating adhesive 512 should be applied by an apparatus
capable of accurately applying the permanent laminating adhesive
512 in a predetermined pattern, in registration with the
pressure-sensitive adhesive 492 but not covering it or the
adhesive-free region 500 (74), if present. A suitable adhesive
application device can be a gravure roll of the type previously
described.
[0105] The permanent laminating adhesive 512 can comprise various
compositions. Suitable examples include two-component polyurethane
adhesive systems, such as Tycel 7900/7283 available from
Henkel.
[0106] While FIG. 11 depicts a certain order of processing of the
first structure 440, it is contemplated that the various processing
steps can be varied according to manufacturing and processing
desires. Thus, for example, it may be desirable to apply adhesives
prior to scoring.
[0107] After application of the adhesives and any optional drying,
the first structure 440 is advanced to a laminating station 530
that can include a pair of rolls forming a nip therebetween. The
first structure 440 is passed through the nip along with a second
structure 460 that is separately advanced, and the first structure
440 is laminated to the second structure 460.
[0108] As noted above, the second structure 460 is advanced
separately from the first structure 440 to the laminating station
530. The second structure 460 may be formed from one or more
layers. The second structure 460 may be coextensive with the first
structure 440, i.e., the width of the second structure 460 may be
substantially equal to the width of the first structure 440 and the
longitudinal edges of the second structure 460 substantially
coincide with the longitudinal edges of the first structure
440.
[0109] As shown in FIG. 11, the second structure 460 may be formed
from two layers. Accordingly, the second structure 460 is formed by
joining a first layer 462 with a second layer 466. The first layer
462 may be advanced from a supply roll 464 and the second layer 466
may be advanced from a different supply roll 468. Adhesive 470 may
be applied to the first layer 462, the second layer 466, or both.
Thereafter, the first layer 462 and the second layer 466 may be
joined in a laminating station 472 to form the second structure
460.
[0110] Alternatively, the second structure 460 may be supplied from
a roll of preformed second structure laminate. In addition, while
FIG. 11 shows the second structure 460 being formed from two film
layers, it is contemplated that the second structure 460 could be
formed from more than two layers, e.g., from three or more
layers.
[0111] After the laminate 430 is formed, the laminate 430 may be
rolled up on roll 606 for storage and later processing as shown in
FIG. 15. Alternatively, as shown in FIG. 11, the laminate 430 is
advanced to a second scoring station 540 at which a second score
line 542 is formed through the thickness of the second structure
460. The second score line 542 is in registration with (i.e.,
coincides with) the inner perimeter of the strip-shaped pattern of
pressure-sensitive adhesive 492. The second score line 542 extends
substantially through the thickness of the second structure 460,
but preferably does not extend to any substantial extent into the
first structure 440, as illustrated in FIG. 13 and 14.
[0112] The second scoring station 540 can comprise a laser. The
operation of the laser is synchronized with the advancement of the
laminate 430. A sensor can detect a feature, such as an eye mark or
printing, on the laminate 430 whose location in relation to the
pressure-sensitive adhesive strip 492 is known, and the sensor
output can be used for regulating the laser operation so that the
second score line 542 is in registration with the inner perimeter
of the pressure-sensitive adhesive strip 492.
[0113] As an alternative to the use of lasers for scoring the
laminate, the score lines can be formed by mechanical scoring or
cutting. For instance, the first scoring station 520 can comprise a
kiss roll and backing roll that form a nip through which the first
structure is passed. The kiss roll may include a rotary cutting die
defining a cutting edge (not shown). The kiss roll acts in
conjunction with the backing roll to cut partially through the
thickness of the first structure 440 starting from the outer
surface of the first structure, such that the first structure 440
is substantially scored through. The second scoring station 540 may
likewise comprise a kiss roll and backing roll for scoring through
the second structure 460. The kiss roll acts in conjunction with
the backing roll to cut partially through the thickness of the
second structure 460 starting from the outer surface of the second
structure 460, such that the second structure 460 is substantially
scored through while the first structure 440 is left intact.
[0114] Additionally, it is within the scope of the invention to
laser-score one of the first structure or the second structure and
to kiss cut or otherwise mechanically scores the other. This can be
advantageous, for example, when one of the structures making up the
laminate 430 is readily scored by a laser but the other structure
is not. For instance, when the first structure 440 is a polyester
such as PET, it can readily be scored with a laser, but if a
polyethylene heat seal layer is employed on the second structure
460, laser scoring may not be the best choice because polyethylene
does not score well with a laser. In this case, kiss cutting or
other mechanical scoring can be used to score the second structure
460.
[0115] It is also within the scope of the present invention to
conduct the each of the scoring operations after the laminate 430
has been formed. For example, the first scoring station 520 may be
adjacent, opposite, or near the second scoring station 540 so that
each of the first and second scoring operations take place either
simultaneously or relatively soon after each other.
[0116] As noted above, the score line 86 and 132 are located in
relationship to each other to define a marginal region 73 between
the score line 86 and 132 and to define a surrounding region 63
located outside of the marginal region 73.
[0117] After the scoring operation, the laminate 430 can be sent to
a reel-up or take up roll 550 and wound into a roll for subsequent
processing. Alternatively, it is possible for the reel-up operation
to be omitted, such that the laminate 430 is directly advanced to a
fill and seal station.
[0118] The laminate 430 can also be slit into a plurality of
partial widths and wound into multiple rolls. In this latter
instance, each partial width would have the recurring patterns of
pressure-sensitive and permanent adhesives applied with suitably
configured adhesive applicators to the full-width material, and
would have the recurring score lines formed by suitably configured
scoring devices acting on either the full-width laminate prior to
slitting or acting on each partial-width portion after
slitting.
[0119] FIG. 7 shows a flexible package 10 in a closed position made
according to the process described above. The package 10 includes
an outer portion that envelopes the package contents and is sealed
to enclose the contents. The outer portion comprises a laminate 430
made by a method in accordance with the invention, such as the
laminate previously described. The outer portion is manipulated and
sealed along seal lines.
[0120] In the illustrated package, the score lines 86, 132 are
provided to be on a front surface 12 of the package 10. The area of
the package 10 bounded by the score lines can constitute any
fraction of the total front surface of the package, but
advantageously the area is a majority of the total surface area of
front surface 12.
[0121] As noted above, it is desirable to provide a releasable
adhesive 72 on least a portion of the marginal region 73 to provide
a reclosable opening panel 80. In this regard, it is desirable to
provide a sufficient amount of releasable adhesive 72 as well as
provide the releasable adhesive 72 on a sufficient area of the
marginal region 73 so that the opening panel will function to open
and close a desired number of times but also will effectively close
the opening panel 80 when the opening panel 80 is in the closed
position. Thus, the ratio of the area of the marginal region 73
containing releasable adhesive to the area of the opening panel is
from about 1:10 to about 10:1, and may be from about 1:5 to about
5:1, or may be from about 1.2 to about 2:1. Alternatively or
simultaneously, the ratio of the area of the opening panel to the
area of the front is from about 1:10 to about 10:1, and may be from
about 1:5 to about 5:1, or may be from about 1.2 to about 2:1. By
providing a relatively larger opening panel and/or marginal region
73, the area of the marginal region 73 containing releasable
adhesive can be larger and thus provide more surface area for
adhering.
[0122] Based on the previous description of the laminate 430 and
its formation process, it will be appreciated that the presence of
the score lines has little or no impact on the barrier function of
the package 10 because each score line 86, 132 extends only
partially through the total thickness and the score lines are not
aligned with each other. Additionally, the pressure-sensitive
adhesive 492 fills the space between the score lines so that even
if the score lines overlap somewhat in the thickness direction,
there is still no open route between them. Furthermore, the score
lines typically have a small width, on the order of a few
thousandths of an inch.
[0123] Various materials can be used for the construction of the
package 10. As noted above, the first structure 440 that forms the
outer surface of the package 10 may comprise a single layer of
flexible material or several layers of various materials. One
material is a polyester such as polyethylene terephthalate (PET).
As noted, the PET layer can be reverse-printed if desired, although
alternatively it can be printed on its exterior and covered by an
over-lacquer (not shown). The second structure 460 forming the
inner surface of the package 10 may comprise a barrier layer and a
sealant layer. The sealant layer constitutes the innermost surface
of and can comprise various sealant materials such as heat seals or
cold seals. Heat seals generally are preferred because they provide
stronger seals than cold seals typically are capable of achieving.
Any suitable heat seal material can be employed, such as
polyethylene, polypropylene, ionomer resins such as SURLYN.RTM., or
others.
[0124] The barrier layer can comprise any of various barrier
materials including barrier polymer films such as: ethylene vinyl
alcohol copolymer (EVOH), polyamide, and the like; metallized
polyolefin films such as polyethylene, polypropylene, oriented
polypropylene, and the like; AlOx-coated polymer films; SiOx-coated
polymer films; metal foil; and others. The barrier layer and
sealant layer can be joined in various ways, including adhesive
lamination, extrusion lamination, or coextrusion.
[0125] The laminate 430 may also include a metallization layer or a
metal foil layer between the first structure 440 and the second
structure 460, for example by providing a metallization layer on
the surface that faces the first structure 440. This is beneficial
in enhancing the barrier performance of the laminate 430. The
metallization layer or metal foil layer can also be helpful when a
laser is used for scoring the second structure 460. In particular,
when the sealant layer comprises polyethylene, which is not as
readily scored by laser as some other materials such as polyester,
it can be difficult to employ a sufficiently high laser energy to
score through the polyethylene sealant layer without scoring
through the laminate 430 more deeply than desired. In particular,
it is undesirable to score the entire thickness of the laminate.
The metallization layer or metal foil layer can be helpful in
"tuning" the laser to penetrate only up to the metallization layer
or foil layer.
[0126] The function of the reclosable opening panel provided by the
pattern-applied adhesives and the score lines is described with
respect to FIGS. 1 and 7. The package 10 is shown in a closed
condition (FIG. 7), for example as initially filled and sealed in a
packaging plant. The package 10 has edges 22, 24, 26, that are
sealed to each other with a top edge 20 that may be formed by
folding the laminate 430 on itself. On the front surface 12, the
first or outer structure is adhesively joined to the second or
inner structure via the permanent adhesive. The outer score line 86
bounds an outer opening portion of the outer structure. In this
embodiment, the outer opening portion has a generally U-shaped or
smile shaped perimeter having three sides defined by the score line
86, and is attached to the remainder of the outer wrapper along a
fourth side (i.e., an imaginary line extending between the free
ends of the two legs of the U-shaped score line). The inner score
line 132 is also generally U-shaped or smile shaped with its
portions parallel to adjacent portions of the outer score line 86,
but is spaced inwardly of the outer score line 86 so as to define
an inner opening portion of smaller area than the outer opening
portion. Accordingly, there is a marginal region of the outer
opening portion that extends beyond the edge of the inner opening
portion. The pressure-sensitive adhesive 72, 492 is disposed
between this marginal region and an underlying surface of the inner
structure. The outer opening portion and inner opening portion are
permanently joined by the permanent adhesive.
[0127] Consequently, when the outer opening portion is detached
from the outer wrapper along the outer score line 86 and is peeled
back as depicted in FIG. 1, the inner opening portion remains
affixed to the outer opening portion and comes with it, thereby
creating an opening in the front surface 12 as defined by the inner
score line 132. The outer and inner opening portions essentially
form a panel 80 that remains attached along a hinge line defined
between the free ends of the two legs of the U-shaped score
lines.
[0128] In one embodiment, the outer structure has a greater
affinity for bonding with the pressure-sensitive adhesive 72, 492
than does the surface of the inner structure, and hence the
pressure-sensitive adhesive 72, 492 is detached from the surface
and remains attached to the marginal region of the outer opening
portion. The package 10 is reclosable by re-attaching the
pressure-sensitive adhesive 72, 492 to the surface of the inner
structure to restore the package 10 to the condition shown in FIG.
7.
[0129] The greater bonding affinity of the outer structure can be
achieved in various ways. When the outer structure comprises a
layer of PET and the layer of the inner structure to which the
pressure-sensitive adhesive 72, 492 is attached comprises a
polyolefin such as polypropylene, oriented polypropylene, or
metallized oriented polypropylene, the PET will naturally have a
greater affinity for bonding to the adhesive than will the
polyolefin layer. Additionally or alternatively, the surface of the
outer structure can be treated, as previously noted, by corona
discharge or flame treatment, to increase the surface energy and
enhance the bonding affinity. It is also possible, as already
noted, to control the bond strength of the pressure-sensitive
adhesive to the layer by including an additive in the adhesive to
reduce the bond strength, if desired.
[0130] Although the pressure-sensitive adhesive 72, 492 may be
applied to the outer structure and to remain on the outer structure
upon opening, it is also within the scope of the invention to apply
the pressure-sensitive adhesive to the inner structure and to
remain on the inner structure upon opening.
[0131] In addition, the pressure-sensitive adhesive (releasable
adhesive) 72, 492 has a delamination force that is greater than the
break force of each of the localized weak portions 85, 135 and the
score lines 86, 132 so that the opening panel 80 tears from the
surface before the pressure sensitive adhesive 72, 492 allows the
desired portion of the opening panel 80 to be detached. In another
embodiment, particularly where a cohesive is used, a portion of the
cohesive is transferred from the surface to which it was initially
applied to the other surface and because the cohesive is formulated
in a desired manner, the marginal region containing the cohesive is
rebondable and reclosable. A cohesive may be desired since it does
not exhibit adhesive properties to structures that do not also
contain a cohesive. Thus, during processing or use, undesired
material will not stick to those areas containing the cohesive;
yet, those areas containing the cohesive will readily stick to each
other.
[0132] It should be noted that the terms "line of weakness" and
"score line" as used herein refer either to a complete cutting
through of one or more layers of the laminate or to a weakening of
such layer(s) allowing the layer(s) to be severed along the score
line.
[0133] Referring back to FIG. 1, the package 10 of the present
invention is shown with the reclosable opening panel 80 in an open
position to expose the contents of the package 10. The package 10
includes opposed surfaces only one of which is shown, an opposed
top and bottom, and opposed ends or sides. One of the surfaces is
scored to define a reclosable opening panel 80 that can be opened
to expose the contents stored within the package.
[0134] The package of the present invention is shown as containing
sticks of gum 2. It is to be understood, however, that the use of
the package 10 is not limited to gum but also includes other
confectionery products. Therefore, as is known and shown in FIG.
18, a gum stick 2 may be elongate rectangular shaped member having
a first face 702, a second face 704 opposite the first face, a
first end 710 and a second end 712 opposite the first end, and a
third end 706 with a fourth end 708 opposite the third end. The gum
stick also has a thickness 714. Specifically, the thickness is
substantially smaller than the width (the distance between 706 and
708), which itself is substantially smaller than the length (the
distance between 710 and 712). In other words, [L>W>T].
[0135] Referring back to FIG. 1, the individual product package 10
will contain one or more sticks of gum 2. As shown in FIG. 1, the
sticks of gum 2 may be oriented so that one of the third end 706
and fourth end 708 and one of the first face 702 and second face
704 of the stick of gum 2 are exposed when the opening panel 80 is
in an open orientation. In this orientation, one of the first face
702 and second face 704 of the stick of gum 2 is juxtaposed with
one of the inner front surface 16 or inner rear surface 18. Also,
it will be appreciated that a plane of one of the third end 706 or
fourth end 708 is parallel to a plane defined by first side 20 and
second side 22 of the package 10 and that a plane of one of the
first face 702 and the second face 704 is parallel to the a plane
of one of the front surface 12 or the inner rear surface 18 of the
package. Of course, it is contemplated that the sticks of gum 2 can
be oriented in other directions. Advantageously, in each of these
orientations, when the package 10 is opened, only one or a few
sticks are exposed for easy removal.
[0136] Turning to FIG. 19, an alternative form of a gum product
that can be usefully stored and dispensed from the individual
product package 10 according to the present invention is shown. In
this alternative form, the gum is in the form of a slab 720 that is
shaped and sized to be complementary to the shape and size of the
product package 10, for example, generally rectangular. The slab
may have a first face 722, a second face 724 opposite the first
face 722, a first end 730 and a second end 732 opposite the first
end 730, a third end 726 and fourth end 728 opposite the third end
726. The slab 720 also has a thickness 734. Specifically, the
thickness is substantially smaller than the width (the distance
between 726 and 728) and the length (the distance between 730 and
732). The slab 720 may be provided with at least one and desirably
more than one score line 736, which will allow the consumer to
easily break a portion of the slab from the remaining portion along
the score line 736. The slab 720 is desirably oriented within the
package 10 such that the third end 726 or fourth end 728 is
parallel to the plane defining the opening of the package 10. In
other words, the third end 726 or fourth end 728 is parallel to the
plane defined by the first side 20 of the package. Put another way,
the slab 720 is oriented such that one or both of the first end 710
and the second end 712 are in a plane substantially perpendicular
to the opening or a plane defined by the first side 20 of the
package. Desirably, when provided, the score line 736 or lines 736
are oriented such that they are parallel to the plane defining the
opening of the package or by the first side 20 of the package. Put
yet another way, the first face 722 of the slab is juxtaposed with
one of the inner front surface 16 or inner back surface 18 of the
package 10. Likewise, the second side of the slab 724 is juxtaposed
with one of the inner front surface 16 or inner back surface 18 of
the package 10.
[0137] While it is contemplated that a single package 10 may be
sold or otherwise provided to a consumer, it is also contemplated
that two or more individual packages may be bundled together in a
suitable fashion. For example, two or more individual packages may
be wrapped with suitable wrapping to provide a multiplicity of
individual packages. It is also contemplated to provide a flexible
container 800, as shown in FIGS. 16 and 17, which can be made using
the same material described above for the packages 10 and can be
made by any of the processes described above and which can
resealably store and contain two or more individual product
packages 10. The flexible container 800 is similar to the package
10 described above except that it is wider, i.e., configured such
that the distance between its front 812 and rear 814 is can be
greater that the distance between the front 12 and 14 rear of the
individual package 10 so that two or more individual packages 10
can be stored within the container 800.
[0138] Inasmuch as the container 800 shares common characteristics
of the flexible package 10 described above, such as the opening
panel, the scoring, the releasable adhesive, etc. Suffice to say,
the container 800 includes a front 812, a rear 814 opposite the
front, a top 820, a bottom 822, opposite the top, a first side 824
and a second side 826 opposite the first side. An opening panel 880
is provided monolithically with the rear 814 and is configured to
fold over and resealably join to the front 812, in a manner similar
to that described above for the individual package. Advantageously,
because the container 800 is flexible, when an individual package
10 is removed from the container, the size of the package can be
reduced by, for example pushing the front 812 toward the rear
814.
[0139] Turning now to FIGS. 20-22, an alternative individual
package 900 is shown. This alternative individual package 900 is in
the form of a cylinder having a first end 902 and a second end 904
disposed between a surface 906 that is cylindrically shaped. An
outer score line 910 is provided so that an opening panel 912 is
defined. The package 900 may be made from the same material
described above for the packages 10 and can be made by the
processes described above for the package 10. Therefore, one of
skill in the art will understand that the construction,
manufacture, and operation of the package 900 are understood from a
review of such with respect to the package 10. As shown in FIG. 21,
the sticks of gum 2 are oriented in the same direction as shown in
FIG. 1. In other words, the ends of the sticks of gum are oriented
perpendicular to the opening of the package 900. FIG. 22 shows the
container of FIG. 20 but with a slab of gum 720. The slab 720 may
be rolled to conform to the shape of the cylinder.
[0140] It will be appreciated from the above description that
laminates made in accordance with the invention may provide a
tamper-evidence function for a package because after opening it is
very difficult to replace the opening portions in such a way as to
achieve a completely smooth, flush condition with the surrounding
portion of the laminate. It tends to be readily ascertainable that
the package has been opened. When printing is included on the
laminate, it is even more noticeable when the package has been
opened because it is difficult to achieve perfect registration of
the printed matter across the score line when reclosing the
package.
[0141] Notwithstanding the ability of the package itself to provide
tamper evidence, it may be desirable to provide other tamper
evident features. For example, when the outer structure is
reverse-printed with ink, an area on the marginal region of the
outer opening portion can first be treated (such as by applying a
release coating or the like) to reduce the adherence of the ink so
that when the package is first opened, the ink on the area of the
marginal region detaches from the marginal region of the outer
opening portion and remains with the pressure-sensitive adhesive on
the inner structure adjacent the package opening. The release
coating can be applied in a pattern (e.g., spelling out a word such
as "Opened" or the like). Other types of tamper-evidence features
can be included.
[0142] Referring to FIGS. 23 and 24, one form of a tamper indicator
950 is shown. In this embodiment, the tamper indicator 950 includes
an opening tab 952 that, as shown in FIG. 23, is connected to the
opening panel 80 by a frangible link 954. The frangible link 954 is
configured such that when the opening tab 952 is moved in a
direction away from the package 10, the frangible link 954 will
break causing the opening tab 952 to be separated from the opening
panel 80. The frangible link 954 may be defined by a narrow conduit
956 created by the pattern of the second score line 86. By
providing a narrow conduit 956 to define the frangible link 954, a
sufficient area adjacent the frangible link 954 will contain the
laminating adhesive 70, 512, which will provide resistance to the
moving of the opening tab 952 away from the package 10 and assist
in the breaking of the frangible link 954. The breaking of the
frangible link 954 may provide an auditory, visual, and tactile
indication that the opening panel 80 is being opened for the first
time.
[0143] After the opening tab 952 is separated from the opening
panel 80 by virtue of the breaking of the frangible link 954, it
will be apparent from viewing the package 10 that the opening tab
952 has been removed and thus, that the package 10 has been
previously opened. The underside of the opening tab 952 is
generally free of adhesive. In addition, as seen in FIGS. 23 and
24, the shape of the second score line 86 within the area of the
opening tab 952 may have any suitable shape so that the opening tab
952 may be easily separated from the package and so that the
frangible link 954 is defined in a manner to allow the frangible
link 954 to break when the opening tab 952 is moved away from the
package 10. It is also contemplated that the opening tab 952 will
have any suitable shape, even though a rectangular shape is shown
in FIGS. 23 and 24.
[0144] It is possible to increase the effectiveness of the tamper
indicator 950 by using two or more frangible links 954 placed in
key locations on the periphery of the opening panel 80. In general,
it will be advantageous to position two frangible links 954 on
opposite lateral sides of the opening panel 80. Such a
configuration increases the difficulty of partially opening the
opening panel 80 to gain access to the contents without breaking at
least one of the frangible links 954. An example of such a
configuration is shown in FIG. 25 where each frangible link 954
includes a narrow conduit 956. Lifting or moving the opening panel
80 away from the package will cause the frangible links 954 to
break and also cause the material encircled by the frangible links
954 to remain laminated or attached and thus provide a visual
indication that the package 10 has been opened. It will also be
appreciated that, when the opening panel 80 is moved to a closed
position after the initial opening, it will be evident that the
frangible link has been previously broken and that the package has
been previously opened.
[0145] Alternatively, as seen in FIGS. 26-30, the tamper indicator
50 includes configuring the opening panel 80, the score line 86 and
the laminating adhesive 70, 512 in a manner such that upon first
opening the opening panel 80, a portion of the outer layer is
delaminated from another portion of the outer layer. For example,
as shown in FIG. 25, the score line 86 is configured to provide a
pair of wings 970 that extend beyond the outer periphery of the
opening panel 80 and between which laminating adhesive 70 is
present. Put another way, laminating adhesive is present not only
in the surrounding region 63 but also in a portion of the marginal
region 73. As a result, as the opening panel 80 is lifted (moved
away from the package), the area within the wings delaminates a
portion of the outer layer 40 from another portion of the outer
layer. As a further example, where the outer layer 40 includes two
layers (such as a plastic layer laminated with a metal layer) in
the wing area, the metal layer is lifted with the opening panel
80.
[0146] FIG. 27 shows another configuration where the opening panel
80 has a shape such that a portion of the marginal region 73
contains laminating adhesive 70. The score line 86 in the area of
the opening panel 80 may have a "boot shape", with the heel of the
boot containing a laminating adhesive, which when the opening panel
80 is lifted, will cause a portion of the outer layer 40 to
delaminate from another portion of the outer layer. FIGS. 28-30
show other configurations to provide delamination of one portion of
the outer layer from another portion of the outer layer. In each
instance, once the opening panel 80 has been opened for the first
time, it will be evident that a portion of the outer layer has been
delaminated from another portion of the outer layer.
[0147] In each of FIGS. 27-30, certain configurations of the
delamination portion are shown. It is contemplated that, instead of
the shapes shown, letters or words may be created by the patterning
of the laminating adhesive. For example, as illustrated in FIG. 33,
words such as OPENED, ENJOY, or the like may be used. In addition,
in each of these embodiments and configurations, the outer layer 40
could include a laminate formed of an opaque first layer and a
transparent second layer. Desirably, the transparent second layer
is oriented toward the outside of the package 10. In other words,
the transparent second layer may be the outermost layer.
Accordingly, as the opening panel 80 is lifted the first time, a
portion of the opaque first layer will be delaminated from the
transparent second layer. As a result, not only will the package
contain evidence of the delamination but the opening panel 80 will
also contain evidence of the delamination (i.e., the portion that
has been delaminated will be transparent).
[0148] Turning to FIG. 31, another form of a tamper indicator 950
is shown. In this form, the tamper indicator 950 includes printing
980 on or in the outer layer 40 such that the printing traverses at
least a portion of the score line 86. In this way, when the opening
panel 80 is opened for the first time and it is later closed, it is
likely that each of the portions of the letters forming the line
will not be aligned, which will provide a visual indication that
the opening panel 80 has been opened.
[0149] Turning to FIG. 32, another embodiment of a tamper indicator
950 is illustrated. In this embodiment, a security tape 990 is
provided to overlap at least a portion of the opening panel 80. The
security tape 990 is removably adhered to the outer layer 40 of the
package and may or may not contain printing 992. The printing 992
may be incorporated with the security tape 990 through a permanent
adhesive so that when the security tape 990 is removed, the
printing 992 remains on the outer layer 40 of the package.
[0150] The foregoing detailed description has described only a few
of the many forms that this invention can take. For this reason,
this detailed description is intended by way of illustration, and
not by way of limitation. It is only the following claims,
including all equivalents that are intended to define the scope of
this invention.
* * * * *