U.S. patent application number 12/466193 was filed with the patent office on 2010-11-18 for packaging membrane with built-in opening feature.
Invention is credited to Douglas Neil Frost, Paul Edward Miller, Catherine Anne Stanley, James Stevens, Robert Thor Versluys, I, Kurt Allen Ziegenfelder.
Application Number | 20100288764 12/466193 |
Document ID | / |
Family ID | 43067684 |
Filed Date | 2010-11-18 |
United States Patent
Application |
20100288764 |
Kind Code |
A1 |
Frost; Douglas Neil ; et
al. |
November 18, 2010 |
PACKAGING MEMBRANE WITH BUILT-IN OPENING FEATURE
Abstract
A packaging membrane comprising a laminate of at least first and
second layers, having a removable portion formed by substantially
coincident first and second score lines, the first score line being
formed in the first layer but not breaching the second layer, and
the second score line being formed in the second layer but not
breaching the first layer. Optionally, a third layer is disposed
between the first and second layers, and the third layer is not
breached by either score line. In the removable portion, an
adhesive-free region is provided within which the first layer is
not adhered to the underlying layer(s). An integral tab is defined
in the first layer within the adhesive-free region, the tab being
formed by a cut line in the first layer. The tab is located
entirely inside the first and second score lines and does not
project beyond any edge of the membrane.
Inventors: |
Frost; Douglas Neil;
(Charlotte, NC) ; Miller; Paul Edward; (Cheraw,
SC) ; Stanley; Catherine Anne; (Hartsville, SC)
; Stevens; James; (Florence, SC) ; Versluys, I;
Robert Thor; (Florence, SC) ; Ziegenfelder; Kurt
Allen; (Florence, SC) |
Correspondence
Address: |
ALSTON & BIRD LLP
BANK OF AMERICA PLAZA, 101 SOUTH TRYON STREET, SUITE 4000
CHARLOTTE
NC
28280-4000
US
|
Family ID: |
43067684 |
Appl. No.: |
12/466193 |
Filed: |
May 14, 2009 |
Current U.S.
Class: |
220/200 |
Current CPC
Class: |
B32B 2307/7265 20130101;
B32B 27/08 20130101; B32B 27/36 20130101; B65D 65/40 20130101; B32B
7/12 20130101; B32B 27/32 20130101; B32B 15/20 20130101; B32B
2307/7242 20130101; B32B 15/08 20130101; B32B 3/266 20130101; B32B
2307/31 20130101; B32B 2439/00 20130101 |
Class at
Publication: |
220/200 |
International
Class: |
B65D 90/02 20060101
B65D090/02 |
Claims
1. A membrane for forming at least a portion of a container for
products, comprising: a laminate comprising at least first and
second layers laminated together by an adhesive, the first and
second layers being coextensive; a first score line formed in the
first layer, the second layer being unbreached by the first score
line; a second score line formed in the second layer and located
substantially coincident with the first score line, the first layer
being unbreached by the second score line, the first and second
score lines together delineating a removable portion of the
laminate that is at least partially removable from a remainder of
the laminate for creating an opening through the membrane; an
adhesive-free region located in the removable portion of the
laminate and occupying less than an entire area thereof, the first
and second layers being unadhered to each other in the
adhesive-free region; and an integral tab formed in the first layer
within the adhesive-free region, the tab being formed by a cut line
extending through a thickness of the first layer, the tab being
located entirely inside of the first and second score lines.
2. The membrane of claim 1, wherein the first and second score
lines form a closed loop such that the removable portion is
completely removable from the remainder of the laminate.
3. The membrane of claim 2, wherein the membrane is rectangular
having a first edge, a second edge perpendicular to the first edge,
a third edge perpendicular to the second edge and parallel to the
first edge, and a fourth edge perpendicular to the first and third
edges and parallel to the second edge, and wherein the removable
portion of the laminate is spaced relatively close to the first
edge and relatively far from the third edge.
4. The membrane of claim 3, wherein the second and fourth edges are
longer than the first and third edges.
5. The membrane of claim 4, wherein the tab is oriented such that a
pulling direction, in which the tab is pulled to detach the
removable portion from the remainder of the membrane, extends
generally perpendicular to the second and fourth edges.
6. The membrane of claim 1, wherein a coating of a release material
is disposed between a lower surface of the tab and an upper surface
of the second layer underlying the tab to prevent the tab from
sticking to the second layer.
7. A membrane for forming at least a portion of a container for
products, comprising: a laminate comprising first, second, and
third layers laminated together by adhesive, the layers being
coextensive, the third layer disposed between the first and second
layers; a first score line formed in the first layer, the second
and third layers being unbreached by the first score line; a second
score line formed in the second layer and located substantially
coincident with the first score line, the first and third layers
being unbreached by the second score line, the first and second
score lines together delineating a removable portion of the
laminate that is at least partially removable from a remainder of
the laminate for creating an opening through the membrane; an
adhesive-free region located in the removable portion of the
laminate and occupying less than an entire area of the removable
portion, the first and third layers being unadhered to each other
in the adhesive-free region; and an integral tab formed in the
first layer within the adhesive-free region.
8. The membrane of claim 8, wherein the first and second layers
comprise polymer layers and the third layer comprises a metal foil
layer.
9. The membrane of claim 8, wherein the first and second score
lines form a closed loop such that the removable portion is
completely removable from the remainder of the laminate.
10. The membrane of claim 8, wherein the membrane is rectangular
having a first edge, a second edge perpendicular to the first edge,
a third edge perpendicular to the second edge and parallel to the
first edge, and a fourth edge perpendicular to the first and third
edges and parallel to the second edge, and wherein the removable
portion of the laminate is spaced relatively close to the first
edge and relatively far from the third edge.
11. The membrane of claim 10, wherein the second and fourth edges
are longer than the first and third edges.
12. The membrane of claim 11, wherein the tab is oriented such that
a pulling direction, in which the tab is pulled to detach the
removable portion from the remainder of the membrane, extends
generally perpendicular to the second and fourth edges.
13. The membrane of claim 8, wherein a coating of a release
material is disposed between a lower surface of the tab and an
upper surface of the second layer underlying the tab to prevent the
tab from sticking to the second layer.
14. The membrane of claim 8, wherein the tab is located entirely
inside of the first and second score lines.
15. The membrane of claim 1, wherein the membrane comprises a lid,
and further comprising a separately formed container defining an
opening, the lid being affixed to the container to cover the
opening.
16. The membrane of claim 8, wherein the membrane comprises a lid,
and further comprising a separately formed container defining an
opening, the lid being affixed to the container to cover the
opening.
Description
BACKGROUND OF THE INVENTION
[0001] The present disclosure relates generally to containers for
products, and more particularly to containers formed at least in
part by a flexible membrane material, and wherein the membrane
defines an opening feature for creating an opening through the
membrane to gain access to the contents of the container.
[0002] Various types of such containers have been developed or
proposed over the years, having a variety of opening features. Some
such containers employ additional separately formed components such
as labels or tabs affixed to the membrane to allow the consumer to
grasp and pull the tab in order to sever the membrane along a
preformed line of weakness. The use of such separate components
complicates the process of manufacturing the containers, as the
components have to be procured, inventoried, fed into the
manufacturing process, properly registered with the membranes to
which they are attached, etc.
[0003] It is also known to provide a membrane with an integral tab
that projects beyond an edge of the membrane, or beyond an edge of
a removable portion of the membrane, to facilitate grasping and
pulling the membrane or removable portion thereof. Such projecting
tabs can cause problems in automated handling of packages because
they can get stuck on equipment and cause jams in the manufacturing
line. In other cases, such a projecting integral tab is folded back
onto the membrane so as not to project beyond the edge of the
membrane, but to keep the tab from unfolding it is frequently
necessary to tack the tab down with a spot of adhesive or by other
means. The tab folding and tacking operations further complicate
the manufacturing process.
BRIEF SUMMARY OF THE DISCLOSURE
[0004] The present disclosure relates to a membrane for a
container, in which the membrane has an integral opening feature in
the form of a removable portion that is at least partially
removable from the remainder of the membrane. The membrane
comprises a laminate of at least first and second layers adhesively
laminated together. The removable portion is formed by
substantially coincident first and second score lines, the first
score line being formed in the first layer but not breaching the
second layer, and the second score line being formed in the second
layer but not breaching the first layer. In one embodiment there is
a third layer disposed between the first and second layers, and the
third layer is not breached by either score line. The third layer
can comprise an easily severable material such as aluminum foil or
the like, which also serves as a barrier to the passage of moisture
and gases through the membrane. The first and second layers can
comprise polymer film materials and/or paper, or the like.
[0005] In the removable portion of the membrane, an adhesive-free
region is provided within which the first layer is not adhered to
the underlying layer(s). The adhesive-free region occupies less
than the entire area of the removable portion. An integral tab is
defined in the first layer within the adhesive-free region, the tab
being formed by a cut line in the first layer. The tab is located
entirely inside the bounds of the first and second score lines, and
thus the tab does not project beyond any edge of the membrane. The
tab can be lifted and pulled in order to sever the membrane along
the score lines so as to at least partially remove the removable
portion of the membrane and thereby gain access to the interior of
the container through the resulting opening formed in the membrane.
A coating of a release material can be disposed between a lower
surface of the tab and an upper surface of the underlying layer to
prevent the tab from sticking thereto, although in many cases no
release material may be required.
[0006] In one embodiment, the score lines form a closed loop such
that the removable portion is completely removable from the rest of
the membrane.
[0007] In some embodiments, the membrane comprises a lid that is
attached to a separately formed container to close an opening in
the container.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0008] Having thus described the disclosure in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0009] FIG. 1 is a perspective view of a container having a
membrane lid in accordance with one embodiment of the
invention;
[0010] FIG. 2 is a cross-sectional view through the membrane lid
along line 2-2 in FIG. 1, with the layers of the membrane shown
disproportionately thick for improved clarity of illustration;
[0011] FIG. 3 is a view similar to FIG. 2, showing another
embodiment; and
[0012] FIG. 4 is a diagrammatic depiction of a process for making a
membrane in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0013] The present invention now will be described more fully
hereinafter with reference to the accompanying drawings in which
some but not all embodiments of the inventions are shown. Indeed,
these inventions may be embodied in many different forms and should
not be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will
satisfy applicable legal requirements. Like numbers refer to like
elements throughout.
[0014] A first embodiment of the invention is illustrated in FIGS.
1 and 2. FIG. 1 shows a container 10 comprising a container body 12
and a lid in the form of a membrane 20 affixed to a surface of the
container body covering an opening therein. The container body 12
can comprise any of various materials, constructions, and shapes.
For example, the container body can be made of plastic, paper,
metal, or combinations of two or more such materials. In the case
of plastic, the container body can be made by molding (e.g.,
injection molding, blow molding, etc.), thermoforming, or the like.
In the case of paper or composites of paper with plastic and/or
metal foil, the container body can be made by winding or wrapping
layers of the materials about a suitable forming mandrel and
adhering the layers together to form a tubular container body, a
lower end of which can be closed with a separate closure (not
shown). In the case of metal, the container body can be formed by
drawing or die forming. The particular details of the container
body and its manufacture are not of particular importance to the
invention.
[0015] The membrane 20 comprises a flexible laminate of at least
two layers that are adhesively joined together. The layers are
coextensive with each other, i.e., they have the same surface area
and their respective edges are aligned such no edge of any layer
extends beyond a corresponding edge of the other layer(s). The
layers can comprise various materials such as polymer film, metal
foil, paper, or combinations thereof. Suitable examples of polymer
films that can be employed include but are not limited to
polyethylene, polypropylene, polyamide, polyester, and the like.
The film can be oriented if desired. Metallized film (i.e., film
having a vapor-deposited layer of non-oxidized metal such as
aluminum) can be employed. Film coated with a ceramic layer such as
silicon oxide or aluminum oxide can be used.
[0016] The membrane 20 includes a removable portion 22 that can be
at least partially removed from the remainder of the membrane in
order to form an opening through the membrane into the interior of
the container. The removable portion 22 is provided by scoring the
layers of the membrane to create a line of weakness along which the
membrane can be severed.
[0017] More particularly, with reference to FIG. 2, in this
embodiment the membrane 20 comprises a laminate of a first layer 24
and a second layer 26 laminated to the first layer by an adhesive
layer 28. The removable portion 22 of the membrane is formed by
scoring the first layer along a first score line L.sub.1. The first
score line extends partially or entirely through the thickness of
the first layer 24, but does not breach the second layer 26. The
second layer is scored along a second score line L.sub.2 that
extends partially or entirely through the thickness of the second
layer 26 but does not breach the first layer 24. The score lines
can be formed by mechanical means such as kiss cutting or by using
a laser to score the layers. The first and second score lines
L.sub.1 and L.sub.2 are substantially coincident in location with
respect to directions in the plane of the laminate--that is, the
first score line substantially directly overlies the second score
line. When there is no intervening film or foil layer between the
first and second layers as in the embodiment of FIG. 2, if desired
the score lines can be slightly offset relative to each other in
order to reduce the likelihood of premature inadvertent separation
of the laminate along the score lines.
[0018] In order to facilitate grasping the removable portion 22 to
sever it from the rest of the membrane, the membrane includes an
integral tab 30 formed in the first layer 24. The tab is formed by
a cut line 32 that extends entirely through the thickness of the
first layer. The cut line 32 can have various shapes, a generally
U-shaped cut line being shown in FIG. 1, so as to define a tab that
has a free end at the closed end of the "U" and a fixed end at the
open end of the "U".
[0019] In order to allow the tab 30 to be lifted from the layer
underlying it, the membrane 20 includes an adhesive-free region 40
that is within the bounds of the score lines L.sub.1,2. The
adhesive layer 28 is absent in the adhesive-free region, and thus
the layers 24, 26 are not affixed to each other in this region. In
the embodiment illustrated in FIGS. 1 and 2, the adhesive-free
region 40 is spaced on all sides from the score lines defining the
removable portion 22 of the membrane. Accordingly, between the
edges of the adhesive-free region 40 and the edges of the removable
portion 22 there is a marginal region 42 in which the layers 24, 26
are adhesively joined to each other, and this marginal region
completely surrounds the adhesive-free region. The ends of the cut
line 32 for the tab can lie in the adhesive-free region 40 as shown
in FIG. 1, or alternatively can lie in the marginal region 42 where
there is adhesive.
[0020] If desired or needed, a coating of a release material can be
applied to the underside of the tab 30 or to the surface of the
layer directly underlying the tab to prevent the tab from sticking
to the underlying surface.
[0021] The membrane 20 in the embodiment of FIG. 1 is rectangular
in shape, although other shapes can be used. The rectangular
membrane 20 includes a first edge E.sub.1, a second edge E.sub.2
that is perpendicular to the first edge, a third edge E.sub.3 that
is perpendicular to the second edge and parallel to the first edge,
and a fourth edge E.sub.4 that is perpendicular to the first and
third edges and parallel to the second edge. In the illustrated
embodiment, the removable portion 22 of the membrane is positioned
closer to the first edge E.sub.1 than to the third edge E.sub.3,
although other positions can be used. The pulling direction along
which the tab 30 is pulled extends from the fourth edge E.sub.4
toward the second edge E.sub.2, and thus is generally parallel to
the first and third edges and perpendicular to the second and
fourth edges.
[0022] To open the container shown in FIG. 1, the user lifts the
tab 30 and grasps it, and pulls the tab generally upwardly and in
the pulling direction from the fourth edge E.sub.4 toward the
second edge E.sub.2, which causes the membrane to sever beginning
at the edge of the removable portion 22 adjacent the fixed end of
the tab and proceeding around the score lines L.sub.1,2 toward the
second edge E.sub.2. In the illustrated embodiment, the score lines
form a closed loop such that the removable portion 22 comes
entirely free of the rest of the membrane. Alternatively, the score
lines could be configured to leave a portion of the removable
portion still attached to the membrane, thus forming a flap. In any
event, an opening is thereby created through the membrane into the
container.
[0023] A second embodiment of the invention is depicted in FIG. 3.
The membrane 120 of this embodiment is a three-layer laminate,
whereas the membrane 20 of the previous embodiment is a two-layer
laminate (the adhesive layer(s) not being counted in both cases).
The membrane 120 includes a first layer 124, a second layer 126,
and a third layer 129. The third layer is disposed between the
first and second layers. The first and second layers 124, 126 each
comprise a polymer film. The third layer 129 comprises a metal foil
such as aluminum foil. An adhesive layer 125 is disposed between
the first layer 124 and the third layer 129 for joining these
layers together, and an adhesive layer 127 is disposed between the
second layer 126 and the third layer 129 for joining these layers
together.
[0024] In one embodiment, the first layer 124 can comprise a
polyester film such as polyethylene terephthalate. The second layer
126 can comprise an oriented polypropylene (OPP) film. The OPP film
is heat-sealable to a compatible heat seal material disposed on the
container. Other heat-sealable films can also be used instead of
OPP.
[0025] The first layer 124 and second layer 126 include respective
first and second score lines L.sub.1 and L.sub.2 as in the previous
embodiment for defining a removable portion 122 of the membrane.
The first score line extends through the first layer 124 but does
not breach the third layer 129. The second score line likewise
extends through the second layer 126 but does not breach the third
layer 129. A tab 130 is defined in the first layer 124 by a cut
line 132. An adhesive-free region 140 is defined within the
removable portion 122, in which the first layer 124 is not adhered
to the third layer 129, and the tab 130 is located in the
adhesive-free region.
[0026] The membrane 120 operates in a manner similar to the
membrane 20 previously described. Pulling on the tab 130 causes the
membrane to sever along the score lines. Although the foil layer
129 is not scored, the foil will easily sever when the plastic
layers 124, 126 begin to sever. However, prior to being severed,
the foil layer provides a good barrier against moisture and
gases.
[0027] The membranes 20, 120 can be manufactured using a continuous
web process in which continuous webs of the various layers are
advanced through a series of stations at which various operations
are performed on the webs and the webs are laminated together. For
example, a manufacturing process for making the laminate 120 is
depicted in FIG. 4. A continuous web of the second layer 126 is
advanced from a supply roll thereof to an adhesive applicator 150
that applies a coating of the adhesive 127 to the second layer. The
web is then conveyed to a lamination station 160 where the second
layer 126 is laminated to the third foil layer 129, which is
advanced to the lamination station from its own supply roll, thus
resulting in a laminate 170 of these two layers.
[0028] Either concurrently or non-concurrently with the formation
of the laminate 170, a continuous web of the first layer 124 is
advanced from a supply roll thereof to a tab-forming station at
which a cutting mechanism 180 forms the cut lines defining the tabs
in the first layer. The tab cut lines are formed in the laminate at
fixed distance intervals along the length of the web such that a
series of interconnected membrane lids can be formed from the
continuous web. In the illustrated embodiment, the cutting
mechanism 180 comprises a laser, but other cutting mechanisms can
be used instead. Next, the first layer is advanced to an adhesive
applicator 190 that pattern-applies the adhesive 125 onto the first
layer such that adhesive-free regions are left. The adhesive-free
regions are in registration with the tab cut lines such that the
tabs are located in the adhesive-free regions. The adhesive
applicator 190 can comprise any suitable device capable of
pattern-applying the adhesive, such as a gravure roll or the like.
The first layer with the adhesive thereon is then advanced to a
lamination station 200 where the first layer is laminated with the
laminate 170 comprising the second and third layers 126, 129.
[0029] Finally, the resulting laminate is advanced to a second
scoring station 210 at which the second score lines are formed in
the second layer 126 in registration with the tab cut lines and
adhesive-free areas, and a first scoring station 220 at which the
first score lines are formed in the first layer 124 in registration
with the second score lines. The scoring stations 210, 220 are
illustrated as comprising lasers, but other scoring mechanisms can
be used instead. The scoring stations 210, 220 are shown as being
separated by a distance in the web travel direction, but
alternatively they can be located at the same place along the
travel direction.
[0030] The order of operations shown in FIG. 4 can be altered. For
example, the tab-forming station 180 can be located downstream of
the lamination station 200, and one or both of the scoring stations
210, 220 can be located upstream of the tab-forming station. It is
also possible for the tab-forming station 180 and the first scoring
station 220 to be the same station such that the tab cut line and
the first score line are formed in the first layer 124
substantially simultaneously. Other changes also can be made to the
process.
[0031] Many modifications and other embodiments of the inventions
set forth herein will come to mind to one skilled in the art to
which these inventions pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the inventions are
not to be limited to the specific embodiments disclosed and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
* * * * *