U.S. patent application number 13/698567 was filed with the patent office on 2013-05-09 for easy open flexible film packaging products and methods of manufacture.
The applicant listed for this patent is Deborah A. Lyzenga, Jeffrey T. Weber. Invention is credited to Deborah A. Lyzenga, Jeffrey T. Weber.
Application Number | 20130114918 13/698567 |
Document ID | / |
Family ID | 44121323 |
Filed Date | 2013-05-09 |
United States Patent
Application |
20130114918 |
Kind Code |
A1 |
Lyzenga; Deborah A. ; et
al. |
May 9, 2013 |
Easy Open Flexible Film Packaging Products and Methods of
Manufacture
Abstract
Packages and methods having a flexible film (12) defining an
interior contents cavity and having a first pair of opposing edge
portions forming a first end seal (18), a second pair of opposing
edge portions forming a second end seal (20), and a third pair of
opposing edge portions forming a longitudinal fin seal (14)
extending from the first end seal to the second end seal; the body
having a first side portion having the longitudinal fin seal and a
second side portion generally opposite the first side portion; a
score (42) formed in the flexible film at the second side portion
and defining an opening to the contents cavity upon initial
rupturing and configured to propagate film tear longitudinally
towards the second end-seal; a closure label (40) covering at least
portion of the score, but less than the entire score; and a
pressure sensitive adhesive being between the closure layer and the
flexible film.
Inventors: |
Lyzenga; Deborah A.; (Long
Valley, NJ) ; Weber; Jeffrey T.; (Lake Zurich,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lyzenga; Deborah A.
Weber; Jeffrey T. |
Long Valley
Lake Zurich |
NJ
IL |
US
US |
|
|
Family ID: |
44121323 |
Appl. No.: |
13/698567 |
Filed: |
May 18, 2011 |
PCT Filed: |
May 18, 2011 |
PCT NO: |
PCT/US2011/037010 |
371 Date: |
January 23, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61345798 |
May 18, 2010 |
|
|
|
Current U.S.
Class: |
383/203 ; 428/43;
53/450 |
Current CPC
Class: |
B65B 61/184 20130101;
B65B 61/02 20130101; Y10T 428/15 20150115; B65B 9/10 20130101; B65D
33/00 20130101; B65D 75/5838 20130101; B65D 75/5827 20130101; B65B
9/067 20130101 |
Class at
Publication: |
383/203 ; 428/43;
53/450 |
International
Class: |
B65D 33/00 20060101
B65D033/00; B65B 9/10 20060101 B65B009/10; B65D 75/58 20060101
B65D075/58 |
Claims
1. A package, comprising: a flexible film defining an interior
contents cavity and having a first pair of opposing edge portions
forming a first end seal, a second pair of opposing edge portions
forming a second end seal, and a third pair of opposing edge
portions forming a longitudinal fin seal extending from the first
end seal to the second end seal; the body having a first side
portion having the longitudinal fin seal and a second side portion
generally opposite the first side portion; a score formed in the
flexible film at the second side portion and defining an opening to
the contents cavity upon initial rupturing and configured to
propagate film tear longitudinally towards the second end-seal; a
closure label covering at least portion of the score, but less than
the entire score; and a pressure sensitive adhesive being between
the closure layer and the flexible film.
2. The package of claim 1, wherein the pressure sensitive adhesive
has a predetermined affinity between the closure layer and the
flexible film such that the score ruptures upon removal of the
closure layer from a portion of the second side portion.
3. The package of claim 1 wherein the score is closer to the first
end seal than the second end seal.
4. The package of claim 3 wherein the score is arcuate.
5. The package of claim 4 wherein a concave side of the arcuate
score faces the second end seal.
6. The package of claim 3 wherein the score is rectilinear.
7. The package of claim 3 wherein the score is pointed.
8. The package of claim 3 wherein the score includes a pair of
terminal ends configured to resist further rupturing of the
flexible film.
9. The package of claim 8 wherein the terminal ends are configured
as hooks.
10. The package of claim 1 wherein the closure layer includes a
tack free gripping portion to remove the closure layer from at
least a portion of the second side.
11. The package of claim 1, wherein the tack free gripping portion
is an arcuate leading edge.
12. The package of claim 1, wherein the closure layer extends
beyond the score to cover sufficient marginal space around the
score to effectively tack close the opening once the score has
ruptured.
13. The package of claim 1, wherein the flexible film is a laminate
structure.
14. The package of claim 13, wherein the laminate film structure is
a co-extruded film structure.
15. The flexible film package of claim 13, wherein the flexible
film comprises a laminate of polyethylene terephthalate and
oriented polypropylene having a thickness in the range of about 1.5
to 2.5 mils.
16. The flexible film package of claim 13, wherein the flexible
film comprises a laminate of polyethylene terephthalate having a
thickness in the range of about 0.4 to 1.0 mill and oriented
polypropylene having a thickness in the range of about 0.6 to 1.2
mils.
17. The flexible film package of claim 1, wherein the closure layer
is a bi-axially oriented polypropylene having a thickness in the
range of about 1.2 mil to 5 mil.
18. The flexible package of claim 5, wherein the score comprises a
pair of parallel score lines extending from the arcuate leading
edge beyond the closure layer.
19. A laminate for producing flexible packages comprising: a
continuous web of flexible film having a width and a longitudinal
axis; a discrete closure layer applied to at most half of the width
of the continuous web of flexible film and along the longitudinal
axis with pressure sensitive adhesive; and the continuous web and
the continuous closure layer configured to be formed into a series
of identical package forming blanks, the flexible film of each
identical package forming blank having a score formed therein that
coincides with at least a portion of the closure layer, but not
within all of the closure layer, and that subsequently forms a
package opening when ruptured.
20. The laminate of claim 19 wherein: the closure layer is a
bi-axially oriented polypropylene having a thickness in the range
of about 1.2 mil to 5 mil; and the continuous film is laminate in a
range of about 1.5 to 2.5 mils having a polyethylene terephthalate
layer and an oriented polypropylene layer.
21. The laminate of claim 20, wherein film laminate can include ink
and primer layer disposed between the polyethylene terephthalate
layer and oriented polypropylene layer.
22. A method of in-line packaging of products in a series of
packages, comprising the steps of: merging a closure layer to a
continuous film web having longitudinal edges spaced a
predetermined width; providing adhesive between the closure layer
and the continuous film web across less than the predetermined
width but more than half of the predetermined width; scoring the
continuous film web corresponding partially to the closure layer to
define an opening in the continuous film web upon initial rupturing
caused by removing the continuous substrate; forming a longitudinal
seal along the longitudinal edges; forming a trailing end seal
between adjacent packages of a series; providing products in a
series to be packaged; and forming a leading end seal.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 61/345,798, filed May 18, 2010, which is
incorporated by reference in its entirety herein.
TECHNICAL FIELD
[0002] This disclosure relates generally to flexible packaging and,
in particular, to flexible packaging having a reclosable
opening.
BACKGROUND
[0003] Flexible packaging is often used to retain products for
shipping and storage. It is commonly used for food products, such
as crackers, chewing gum, chocolate, cookies, cheese, sandwiches,
biscuits, candy, meat products, dried fruits and vegetables, and
the like. Often, the package shape takes on the shape of the
contained products or it may take on the shape of structural
supports, such as a frame or tray within the package. A reclose
feature may be included on a flexible package to provide users with
an easy, efficient manner of retaining some of the product for a
later consumption.
[0004] One approach for a flexible film package is to form it from
a continuous web of material. These `flow-wrap` type packages (also
known as horizontal or vertical fin-seal or lap-seal wrap, end-seal
wrap, horizontal bagging and pillow-pouch packages) can be made
from a variety of webbing material and laminates to envelop and
seal product during assembly.
[0005] Some known package designs also can require excessive
material to facilitate production on various manufacturing
equipment and/or consumer specifications. For example, applying
labels having a label backing removed as part of the manufacturing
process can result in unnecessary waste.
SUMMARY
[0006] Accordingly, provided herein are easy open and reclosable
flexible film packages. The flexible film packages can have an
initial seal against ambient atmosphere (e.g., a gas/oxygen and
moisture barrier) for extended periods of time and have a closure
layer (e.g., a label laminated to the film by a pressure sensitive
adhesive) above a score (tear) line in the flow-wrap film. The
score can define an opening in the film or can be configured to
propagate film tear to create a package opening. The embodiments
can be easily opened and tacked close to retain product after
initial opening, while maintaining package integrity.
[0007] One approach provides a package having a flexible film
defining an interior contents cavity and having a first pair of
opposing edge portions forming a first end seal, a second pair of
opposing edge portions forming a second end seal, and a third pair
of opposing edge portions forming a longitudinal fin seal extending
from the first end seal to the second end seal; the body having a
first side portion having the longitudinal fin seal and a second
side portion generally opposite the first side portion; a score
formed in the flexible film at the second side portion and defining
an opening to the contents cavity upon initial rupturing and
configured to propagate film tear longitudinally towards the second
end-seal; a closure label covering at least portion of the score,
but less than the entire score; and a pressure sensitive adhesive
being between the closure layer and the flexible film.
[0008] In one approach, the pressure sensitive adhesive can have a
predetermined affinity between the closure layer and the flexible
film such that the score ruptures upon removal of the closure layer
from a portion of the second side portion.
[0009] In one approach, the score can be closer to the first end
seal than the second end seal. The score can be score is arcuate,
including one embodiment where the arcuate score faces the second
end seal. The score can also be rectilinear, pointed, and the like.
In some packages, the score can include a pair of terminal ends
configured to resist further rupturing of the flexible film. In one
approach, the terminal ends can be configured as hooks. In another
approach, the score can be a pair of parallel score lines extending
from the arcuate leading edge beyond the closure layer.
[0010] In one approach, the closure layer can include a tack free
gripping portion to remove the closure layer from at least a
portion of the second side. The tack free gripping portion can be
an arcuate leading edge.
[0011] In another approach, the closure layer can extend beyond the
score to cover sufficient marginal space around the score to
effectively tack close the opening once the score has ruptured.
[0012] The packages can use a flexible film that has a laminate
structure. The laminate film structure can be a co-extruded film
structure. In one approach, the flexible film can include a
laminate of polyethylene terephthalate and oriented polypropylene
having a thickness in the range of about 1.5 to 2.5 mils. In
another approach, the flexible film can be a laminate of
polyethylene terephthalate having a thickness in the range of about
0.4 to 1.0 mill and oriented polypropylene having a thickness in
the range of about 0.6 to 1.2 mils.
[0013] In some packages, the closure layer can be a bi-axially
oriented polypropylene having a thickness in the range of about 1.2
mil to 5 mil.
[0014] Laminates for the producing a flexible package can include a
continuous web of flexible film having a width and a longitudinal
axis; a discrete closure layer applied to at most half of the width
of the continuous web of flexible film and along the longitudinal
axis with pressure sensitive adhesive; and the continuous web and
the continuous closure layer configured to be formed into a series
of identical package forming blanks, the flexible film of each
identical package forming blank having a score formed therein that
coincides with at least a portion of the closure layer, but not
within all of the closure layer, and that subsequently forms a
package opening when ruptured. In one approach, the closure layer
can be a bi-axially oriented polypropylene having a thickness in
the range of about 1.2 mil to 5 mil; and the continuous film is
laminate in a range of about 1.5 to 2.5 mils having a polyethylene
terephthalate layer and an oriented polypropylene layer. In another
approach, the film laminate can include ink and primer layer
disposed between the polyethylene terephthalate layer and oriented
polypropylene layer.
[0015] Methods for in-line packaging of products in a series of
packages can include the steps of: merging a closure layer to a
continuous film web having longitudinal edges spaced a
predetermined width; providing adhesive between the closure layer
and the continuous film web across less than the predetermined
width but more than half of the predetermined width; scoring the
continuous film web corresponding partially to the closure layer to
define an opening in the continuous film web upon initial rupturing
caused by removing the continuous substrate; forming a longitudinal
seal along the longitudinal edges; forming a trailing end seal
between adjacent packages of a series; providing products in a
series to be packaged; and forming a leading end seal.
[0016] Other features will become more apparent to persons having
ordinary skill in the art to which the package pertains and from
the following description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective top view of an exemplary flexible
film package;
[0018] FIG. 2 is a perspective top view of a second exemplary
flexible film package;
[0019] FIG. 3 is a perspective top view of a third exemplary
flexible film package;
[0020] FIG. 4 is a perspective top view of the third exemplary
flexible film package in an opened position;
[0021] FIG. 5 is a top view of an exemplary flexible film
package;
[0022] FIG. 6 is a partial side view of a assembly process to form
and package a series of flexible film packages;
[0023] FIG. 7 is a sectional view of an exemplary fin-seal jaw of
FIG. 6 taken along section lines A-A;
[0024] FIG. 8 is a perspective top view of a fourth exemplary easy
open flexible film package;
[0025] FIG. 9 is a portion of a roll of blanks for use in forming a
flexible film package;
[0026] FIG. 10 is a sectional view of an exemplary film/label
laminate taken along section lines X-X in FIG. 9;
[0027] FIGS. 11-16 illustrate alternate score line embodiments for
a flexible film package;
[0028] FIGS. 17-20 illustrate alternate closure layer embodiments
for a flexible film package; and
[0029] FIG. 21 is a perspective bottom view of an exemplary
flexible film package.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0030] Despite the advantages of flexible film packaging, these
types of packages are sometimes difficult for consumers to open.
Further, these packages often contain various amount of food
product and a consumer may not want to consume the entire contents
at one time. Therefore, a reclose (or tack close) feature can be
included to provide users with an easy, efficient manner of
containing some of the food product for a later time.
[0031] Generally, the present embodiments illustrate a cost
efficient and easy open feature for consumers to obtain full
product access while providing a tack close feature for product
containment not consumed after initial opening. The package also
can facilitate one handed consumption. Pursuant to various
embodiments, flexible film packages and methods of producing such
packages are provided herein that may have at least a partial,
initial seal against ambient atmosphere and are easily openable and
reclosable. More particularly, the initial seal, which is present
prior to initial opening of the flexible film package, may provide
at least a partial barrier against ambient atmosphere including gas
and moisture for an extended period of time. For example, the
initial seal of the flexible film package may provide a light
barrier and also a gas (oxygen) and moisture barrier for at least 6
to 8 months prior to initial opening. In some applications, a gas
and moisture barrier may be desired for even longer periods of time
prior to initial opening.
[0032] Further, the flexible film packages can generally be
reclosable for product containment subsequent to initial opening of
the package. While the present disclosure is described for food
product applications, it also can be applied to non-food, medical,
pharmaceutical, industrial packaging applications, and the like. In
one approach, the flexible film package is generally configured to
accommodate multiple servings of a food product. Thus, the
reclosing characteristics of the flexible film package help
retain/contain product within the package subsequent to initial
opening.
[0033] The flexible film packages may have a variety of
configurations, including, for example, a bag, a pouch, or other
shapes, such as a cylindrical shape, a column shape, or a generally
rectangular shape, among others. The flexible film package may have
squared edges, such as those found on a primarily
rectangular-shaped package or may have more curvilinear-shaped
edges, such as those found on more circular or ovoid-shaped
packages. Further, the flexible film package may be formed around
the food product, such as a package having a sleeve configuration
that is wrapped around a discrete stack or stacks of food products.
In other applications, the flexible film packages may be fully or
partially formed and then filled with the food products, which may
be helpful for various discrete food products.
[0034] By one approach, the package configuration and shape may be
primarily influenced by the products contained within the package,
in part, due to the flexibility of the laminate film. In another
configuration, the flexible film may be configured as a flow-wrap
or overwrap around a support structure, such as an internal rigid
support or product tray, preferably a "U" board, though this is not
required to practice the embodiments.
[0035] As used herein, the flexible film may be a flexible sheet of
material rolled or formed as a blank and made of a laminate or
co-extruded film structures, with cast or blown film layers and the
like. By one approach, the flexible film may include a laminate
having several thin layers of material. The laminate structure may
include a polyethylene or polypropylene, such as a polyethylene
terephtalate (PET) layer and/or an oriented polypropylene (OPP)
layer. Other optional laminate layers may include a polyethylene
(PE) layer, a polypropylene (PP) layer, a polylactic acid (PLA)
layer, and a metalized layer, such as a metalized oriented
polypropylene (MET OPP) layer, to note but a few options. These
different layers may have a variety of thicknesses and densities.
Furthermore, the flexible film may be a combination of several of
the above-mentioned film structures. By another approach, the film
may include a single layer polymer. The components of the flexible
film laminate may be joined by adhesives or by extrusion
processes.
[0036] If a PET layer is used in the flexible film laminate, the
PET layer may impact the rigidity of the laminate. More
particularly, the PET layer may have different degrees of stiffness
from flexible to semi-rigid, depending on the thickness of the PET
layer. A PET layer may be incorporated into the laminate because it
is relatively lightweight and strong and can have a high
transparency if desired. The PET layer also may be useful as an
oxygen (gas) and moisture barrier. In addition, an OPP layer also
may further strengthen the flexible film and also provide a useful
barrier to permeability.
[0037] Flexible film packages described herein can be formed from a
continuous web of material sealed in various ways. The seals can
include, for example, a fin or lap seal, and a variety of ends
seals (such as top, bottom, and side seals). By one approach, a
flexible film can have two opposing edge portions meet to form a
longitudinal seal extending from a first end seal to a second end
seal. The seals can be hermetic (and also may have varying degrees
of hermeticity, such as partial or substantial hermetic seals) to
help retain the shelf-life of any products contained therein. The
seals may be formed by a variety of processes, such as, for
example, hot seal, cold seal, or low-tack seal processes, and
combinations thereof and are typically considered primary seals and
are oftentimes permanent or destructive seals. The flexible film
package also can include peelable/reclosable seals. The seals can
be formed around the package opening using, for example, a pressure
sensitive adhesive (PSA) or low-tack adhesive (LTA) located between
the flexible film and a closure layer. The reclose seal feature can
be formed by a variety of manufacturing processes.
[0038] The flexible film may have a score that defines a package
opening upon initial rupture or initial opening. The score also may
be configured to define at least a portion of the package opening
to define in propagation of a tear in the film and to preferably
tear the film longitudinally towards the second end-seal. The term
"score" as used herein may describe any type of mechanically-formed
or cut score line, a laser-formed score, or any other scoring means
that would compromise the integrity of the film without rupturing
it (i.e., a line of weakness). A score may be disposed partially
through the depth of the flexible film, or it may be a die cut
through the entire depth of the film over a given line. If
partially cut through the film, the score also may be formed on
either side of the flexible film such that the score may be cut
into the exterior or interior surface of the flexible film. In one
example, the score is made into the flexible film from the interior
surface of the flexible film and extends through the flexible film
and substantially through the pressure sensitive adhesive. In
addition, the score also may be a discontinuous line, such as a set
of perforations, which also may be either partially through the
depth of the flexible film or completely through the entire depth
of the flexible film.
[0039] In one illustrative package, a closure layer (such as a
discrete label) can extend over at least part of a score line and
within the opposing edge portions that meet to form the
longitudinal seal. A pressure sensitive adhesive may be located
between the flexible film and the closure layer. The closure layer
may have a tack-free gripping portion (e.g., a peel tab) used to
release at least a portion of the closure from the flexible film to
form the package opening. The closure layer preferably extends over
at least a portion of the score and is reclosably adhered to the
film.
[0040] By one approach, the closure layer is disposed upon a
portion of the flexible film over at least part of the score. The
closure layer may comprise a label, such as a label with a backing,
a release liner or a linerless label prior to application to the
package. In another configuration, the closure layer may include a
second flexible film with pressure sensitive adhesive disposed
between the flexible film and the second flexible film. The
pressure sensitive adhesive may be an interstitial layer to a
laminated film structure such that the pressure sensitive adhesive
is laminated between the flexible film and the second flexible film
layers.
[0041] The package opening described herein is preferably
reclosable for product containment. The pressure sensitive adhesive
between the flexible film and the closure layer helps produce the
reclose characteristics of the package opening. The pressure
sensitive adhesive may be suitable for resealing in a variety of
conditions, such as ambient and refrigerated conditions, to note
but a few.
[0042] The method for producing the flexible film packages provided
herein may include forming a score in a portion of a continuous web
of flexible film having a longitudinal axis and applying a closure
layer along a portion of the longitudinal axis with an adhesive
(such as a pressure sensitive adhesive). By one approach, the
closure layer may be applied over a partial width of the continuous
web of flexible film. The method also may include forming a
continuous longitudinal seal from two opposing edges of the
continuous web of flexible material and forming a first end seal
and a second end seal. The flexible packages may be formed in
off-line and in-line processes with respect to the packaging of the
product, and also may be formed in both horizontal and vertical
form-fill-seal operations, among others.
[0043] A method of packaging products in a series of packages may
include feeding a continuous film web having longitudinal edges and
a predetermined width between the longitudinal edges. The method
also may include merging/laminating a substrate with the continuous
film web across less than the entire predetermined width. By one
approach, the continuous film web is scored to define an opening
(or at least a part of the opening) in the film web upon initial
rupture once the substrate is removed from the continuous film web
and an exposed adhesive, such as a pressure sensitive adhesive that
provides a degree of releaseability and reclosability, is provided
between the substrate and the continuous film web. If performed
in-line, the method may provide products in a series for packaging,
and the continuous film web and substrate may be wrapped around the
products. Further, a longitudinal seal, such as a fin or lap seal,
may be provided along the longitudinal edges of the continuous film
web, and a leading and trailing end seals may be provided between
adjacent packages of the series of packages.
[0044] The series of flexible packages 10 described below may be
formed in-line just before the film is being wrapped around a
product or may be formed off-line well before the products are
packaged. For example, a laminate structure may be prepared prior
to being brought to the packaging line to fill the packages with
products. In another configuration, the laminate may be formed
in-line with the packaging operation such that the laminate is
formed around or just before the product is packaged.
[0045] In some embodiments, the package film generally provides a
die or laser cut/score forming an arc, which is covered, at least
in part, by a closure layer (label) with a pressure sensitive
adhesive layer. The label can have a portion without PSA to create
a pull tab that allows that package to be easily opened. In use, as
the pull tab is pulled, the film separates at the score line and
continues to tear in the direction of pull creating a large opening
for product access. Tear propagation of the film can be stopped as
the film reaches one of the primary seals. The exposed PSA on the
label can be used to tack close the package to contain any
remaining product. The package is suitable for a variety of
products that are placed side-by-side, but also can be a short
stack side-by-side. In some embodiments, slug packaging (i.e., a
vertical product stack) also can be used.
[0046] Turning now to the Figures, there are illustrated preferred
embodiments of the present flow-wrap package design generally
indicated at 10, and processes for making same. FIGS. 1-3, 4, 8 and
21 show package 10 formed from a film 12. FIG. 4 shows package 10
in an opened position. Film 12 can be a flexible sheet material
rolled or formed as a blank and made of laminate or co-extruded
film structures, with cast or blown film layers, and the like.
Examples can include a single layer polymer, such as polypropylene,
polyethylene, polylactic acid (PLA), polyester, and the like.
Generally film 12 can be between 1.2 mils to 5 mils, and preferably
1.5 to 2.5 mils in thickness. Film thickness also can be a function
of the desired barrier to gas, moisture, and light; level of
desired structural integrity, and the desired depth of the score
line (described below).
[0047] Film 12 can be a heat sealable copolymer. In some
embodiments, the heat sealable polymer forms a seal between 50 and
300 degrees Celsius. Film 12 also can be a pressure sealing film
(e.g., a cold seal film or otherwise where no heat is needed). In
some embodiments this pressure sealing film forms a seal between a
pressure of about 0.7 and 7.0 Kg/cm, and preferably at about 5.6
Kg/cm.
[0048] Referring to FIG. 10, film 12 can preferably be a laminate,
such as a polyethylene terephthalate (PET) layer 82 and an oriented
polypropylene (OPP) layer 86, or optionally film 12 can be a single
layer polymer. A PET layer is flexible to semi-rigid, depending on
its thickness. PET is preferred in that it is very lightweight,
strong, and can have high transparency when desired for package
specifications. It also can be useful as an oxygen (gas) and
moisture barrier. The OPP layer can add further strength and be a
further barrier to permeability. Lamination components can be
joined by adhesives or by extrusions. The PET layer can have a
thickness in the range of about 0.4 to 1.0 mill (preferably about
0.48 mil) and the OPP layer can have a thickness in the range of
about 0.6 to 1.2 mil (preferably about 0.7 mil).
[0049] Film 12 can optionally also have additional laminate layers.
A sealant layer, such as a heat sealant layer 88 (FIG. 10) can be
added to facilitate the formation of seals that enclose product
during packaging. As such, the sealant layer would be oriented on
the film surface directed to the interior of the package. The
sealant layer can be a variety of polymer sealants, such as a heat
activated polymer sealant layer like ethylene vinyl acetate (EVA),
ionomer plastic (such as one sold under the trade name SURLYN by
DuPont), metallocene, orgaonclay, and the like. Cold sealant and
pressure sealants are also possible within the scope of the
presented embodiments. It is noted that food grade sealants would
be used when food products are anticipated.
[0050] In one configuration, stiffeners are added to flexible film
12 to increase the stiffness of the film. These stiffeners may be
in addition to the stiffness adjustments that can be made by
changing the thicknesses or densities of the previously mentioned
laminate layers. These stiffeners can be added as a component of
the extruded film or as a separate layer. For example, a laminate
layer, such as a polyamide polymer (e.g., nylon) may be included in
the laminate film structure of flexible film web 12. By one
approach, nylon may be added as a laminate layer that is held to
the remainder of the film structure by an adhesive. Further, in one
configuration, the nylon layer may be positioned in between other
layers such that the other flexible film layers are attached on
each side of the nylon layer (i.e., a tie layer). In one example,
the nylon layer can comprise about 6 to 10 percent of the film
thickness or about 0.004 mm. In one approach, the nylon layer
comprises about 8 percent of the film thickness. By yet another
approach, the nylon layer may comprise about 0.004 mm thick
layer.
[0051] Optional film layers also can include ink layers 84 (FIG.
10). For example, one specific laminate can include ink and a
primer disposed between a PET 82 and OPP layer 86. Metalized layers
and various combinations of laminates also are possible within the
preferred embodiments.
[0052] As shown, film 12 is shaped to contain a single serving tray
of products placed side-by-side, though the embodiments also can be
practiced in various curvilinear shapes and rectilinear (sleeves),
or oval packages depending on the desired product contained
therein.
[0053] Package 10 can be formed by a scored flexible film 12 having
a longitudinal seal 14 generally along adjacent sides to form a
sleeve; a first leading sleeve end-seal 20 substantially transverse
to the longitudinal seal at a first package end; and a second
trailing sleeve end-seal 18 substantially transverse to the
longitudinal seal at a second package end, the area between the
first and second seal defining a package interior. Seal 14 is shown
here as a fin seal (shown more clearly in FIG. 21).
[0054] As stated, film 12 preferably has a sealant layer 88 on an
interior surface of the film. Preferably, seal 14 and end-seals 18
and 20 are non-peelable primary seals as described above. The seals
of the presented embodiments can be formed by heat seal, cold seal,
sonic waves, low tack seal and various combinations thereof and
define a product receiving cavity.
[0055] Film package end-seals typically do not allow a user to open
the package at the end-seal itself. The body of the package film is
usually grasped then pulled to open. The flexible packages
illustrated herein provide easy opening though the use of a closure
layer 40. By way of example, as shown in the Figs., closure layer
40 can be a discrete label laminated to the film by a pressure
sensitive adhesive. A peel tab 22 in label 40 can be provided in
the present embodiments to allow opening the package without the
need to grasp the body of the package. Peel tab 22 is a portion of
closure layer 40 that is not laminated to the film by the PSA. As
illustrated, peel tab 22 can be a radial-shaped tab, though other
shapes, such as square (FIG. 17) or "V" shapes (FIGS. 19-20), are
possible and can provide a finger grip to initiate opening of the
package.
[0056] The present embodiments also provide scoring as described
above to the flexible packaging film 12 structure and is configured
to define or direct a film opening of the package. Preferably, a
score 42 is added to the side of the film directed to the interior
of the package. Score lines can include a multitude of
configurations to suit the packaging and product specifications but
preferably are configured to at least initiate propagation of tear
of the film. For example, FIGS. 1-3, 8 and 11-13 show possible
score 42 configurations. As shown, score line 42 can be an arc
(42a), a pair of substantially parallel scores (42b). Where
parallel scores are used, they are preferably less than the width
of the package or the product contained therein.
[0057] Exposed score lines tend to propagate a continued tear in
use. The present embodiments show score line configurations that
terminate in patterns to reduce this tendency. Specifically, FIG. 3
shows an outwardly directed double "J" hook score line 42c, though
other configurations are possible. These can include an inwardly
directed double "J" hook score line 42e (FIG. 12), a "smile"
terminate 42i (FIG. 13), and the like. Package integrity features
90 (FIG. 11) also can be included as part of a score line 42d. FIG.
14 shows a score line 42f having squared corners disposed under
label 40. FIG. 15 shows a score line 42g having angled corners
disposed under label 40. FIG. 16 shows a score line 42h having a
pyramid shaped pattern disposed under label 40.
[0058] In the present embodiments, a label 40 can be applied to the
side of film 12 directed to the outside of package 10, preferably
using a pressure sensitive adhesive (PSA). Label 40 preferably
covers at least a portion of score lines 42 and is configured to
propagate film tear longitudinally towards a second end-seal. Peel
strength between package 10 surface and label 40 is greater than
the force required to separate sides of score along score lines 42.
As such, label 40 is peelable with respect to package 10 surface.
Thus, continued pulling on tab 22 initiates rupture of score line
42, such as shown in FIG. 4. It is noted that score 42b in FIG. 2
can continue to propagate film tear until end seal 18 is reached,
since end seal 18 is a primary (non-peelable) seal.
[0059] Closure layer (label) 40 and film 12 can be transparent,
opaque or optionally printed. It is noted though that label 40 can
be generally described as any film with an adhesive covering and be
within the scope of the presented embodiments. It is also noted
that labels with liners also can be used within the scope of the
presented embodiments. Label 40 can be embodied in a variety of
ways within the scope of the present flexible film packages.
Additional illustrative embodiments can be found in FIGS. 17-20.
FIG. 17 shows a rectilinear label 40a. FIG. 18 shows a curvilinear
label 40b. FIG. 19 shows a pyramidal label 40c. And, FIG. 20 shows
a `arrow` label 40d.
[0060] Linerless labels can be a facestock having a pressure
sensitive adhesive coating on one side but can be rolled into a
spool without a liner. This can be accomplished by a release
coating applied to the side opposite the adhesive coating or in the
alternative a homo-polymer, such as polypropylene. Facestocks can
include standard paper, film, plastic, fabric, foil, direct
thermal, and the like. Linerless labels are available with
removable and repositionable adhesives. Alternatively an adhesive
covered flexible film can be used for label 40.
[0061] The label can be an oriented polypropylene (OPP), including
a bi-axially OPP in the range of about 1.2 mil to 5 mil a
preferably about 2 mil or other type of semi-rigid polymer, such as
PET and the like. PET is preferred because of its thermal
resistance in creating a non-peelable seal. The PSA is preferably
neutral or non-reactive to the product and configured to provide a
substantially hermetic seal even in refrigerated conditions (i.e.,
the PSA is operable in a temperature range of about -10 to 90
degrees Celsius; and preferably in the range of about 2 to 7
degrees Celsius). Preferably PSA is applied directly to the film
but can be applied to ink or any other coating on the film. The PSA
should remain attached to the label 40, even after repeated
openings and reclosures.
[0062] It is noted that label 40 can be applied to cover score line
42 at least in part. As illustrated in the Figures, film 12
provides a package opening 44 defined or directed by a score line
42 to allow a user access to product 46. Score line 42 can be of
various depths and widths within film 12 and can be formed by
various cutting means, such as the use of a laser or die cutter.
Also, the tear strength of score line 42 must be weaker than the
adhesive strength of a PSA 30 to allow film to peel back with
label. For illustrative purposes only, in one embodiment, PSA 30
can be configured to have an opening (separating) force of 350
gms/inch and a closing (adhering) force of 200 grams/inch. It is
noted though that other opening and closing force ranges would be
considered to fall within the scope of the presented package
designs.
[0063] Preferably, score line 42 only goes through a portion of the
package to not affect the barrier properties (e.g., gas or
moisture) of the package. In this instance, label 40 would not need
to provide the initial hermetic barrier, though optionally and
inherently, it can. The optional label 40 barrier properties could
result from inherent characteristic of the label material, or
through an added barrier layer to label 40 (not shown). Score 42
can be cut through the exterior or interior surface of film 12, but
preferably on the interior surface. It is noted that even in
embodiments where score 42 can affect barrier qualities of film 12,
the application of label 40 should compensate for the compromised
barrier created by the score where the entire scored portion of
film 12 is covered by label 40.
[0064] In use in the configuration of FIGS. 3-4, a user can grip an
unsealed inner surface 50 of a label 40 peel tab with one hand and
a region on or near end-seal 20 with the other hand. The label peel
tab can be peeled back rearwardly/downwardly to form opening 44
until it reaches the "J" hook shown in FIG. 4. In any event,
preferably, label 40 and its attached film are not pulled off
package 10 in use. In the embodiments of FIGS. 1-2 and 8, this can
be achieved by a non-peelable seal on trailing end-seal 18. In
these embodiments, peel tab 22 on label 40 can be used to
intitate/propogate a longitudinal tear towards end-seal 18, where
the film is restricted from further rupture. The parallel lines,
such as 42b in FIG. 2, can extend to any length up to end-seal 18.
In an optional embodiment, FIG. 8 illustrates tab 22 extends into
the end-seal 20. In any event, tab 22 should have non-adhesive
portion 50. The adhesive may be excluded on that portion of the
label, or it can be deadened in a variety of ways, such as with an
ink, varnish, and the like. Alternately, tab non-adhesive portion
50 can be covered by another laminate, such as an additional
polymer layer between the PSA and the film or folding over a
portion of the label over on itself. If a user wants to reclose the
package to retain any remaining product after initial opening, the
exposed PSA 30 (See e.g., FIG. 4) can be retacked back onto the
film. It is noted then that the closure layer should be configured
to extend beyond the score to cover sufficient marginal space
around the score to effectively tack close the opening once the
score has ruptured.
[0065] Thus, the present embodiments can utilize the film
properties to control tear beyond the score area under the label.
Preferably, given the added material and expense, label 40 is a
small discrete label to provide a peel tab and a means to propagate
the score to open and to direct the tear longitudinally towards the
trailing end-seal, but not past the trailing end-seal. The
orientation of the film controls the tear in a generally straight
line towards the trailing end-seal. As such, the present
embodiments only need a partial score to initiate the tear or
rupture.
[0066] Optional or alternate features also are possible within the
scope of the present embodiments. Vertical bag embodiments (not
shown) for particulate products (e.g., coffee) also can use the
seal and reseal features as described. Although the present
embodiments have been presented as having a fin-seal, the present
embodiments also can cover lap-seals (not shown). A lap-seal is
formed by first overlapping a first and second surface of the film
to form a sleeve (as opposed to overlapping the same surface in a
fin-seal).
[0067] Generally, package 10 can be assembled by a variety of ways,
such as by first joining film 12 at opposite sides (opposing
longitudinal sides) to form fin-seal 14 and define a package height
and interior space. End-seals 18 and 20 can be formed after product
46 (and optional tray, if any) has been placed within package 10
interior space. End-seals 18 and 20 can thus define package 10
width. Fin-seal 14 and end-seals 18 and 20 can be thermo formed
(i.e., heat welded) or other welding means. Optionally, seals 18
and 20 can use patterns, crimps or knurls. In any instance, seals
18 and 20 are preferably considered to be hermetic seals (i.e.,
forming a gas (oxygen) and moisture seal).
[0068] During assembly of the present embodiments, fin-seal 14 can
be formed as the two longitudinal film edges (See FIG. 9 edges 72
and 74) are joined and sealed by heated wheels. As discussed above,
an inner sealant layer (88, FIG. 10) can be applied to the film to
facilitate the type of desired seal. This internal adhesive can be
applied up to 100 percent of the interior surface or only where it
is needed to provide a seal.
[0069] The method to assemble the package can use heat seals, cold
seals, extrusion and adhesive lamination, or co-extrusion. FIG. 9
illustrates a section of a roll of blanks for use in forming the
flexible film package of FIG. 3. When the products are enveloped
and sealed within the flow film, the flow film/label laminate can
be cut into individual packages (See FIG. 5).
[0070] One exemplary method of making one package embodiment is
generally shown by device 60 in FIG. 6 using a packaging apparatus
that positions the film above the product, and then wraps the film
downwards to form the fin-seal beneath the product. As shown, a
discrete label 40 is registered on film 12 at label applicator 54.
Prior to adding label 40, film 12 can be scored at 52 on the film
surface directed to the interior of the package, though the top
surface also could be scored. Preferably, though scoring occurs
after the label is applied. As described above, scoring can be by a
laser, mechanical means, such as a knife, and the like.
[0071] Next, fin-seal 14 can be formed by fin sealing device 38 as
the film 12/label 40 laminate form a box 34 around a product 46
(See also, cross sectional view on FIG. 7). The sealant layers can
be heated wheels pressed together, which activates the heat sealant
layer on the interior layer. Where EVA, and the like, are used for
a sealant layer, the heated wheels can be heated between 85 and 205
degrees Celsius. Again, line speed and film thickness also are a
factor in the seal formation and its peelability and hermeticity.
As shown in FIG. 7, fin-seal 14 is oriented to the bottom of
package 10. It is noted though that fin-seal 14 can be oriented on
any side of package 10.
[0072] As shown in the illustration of FIG. 6, once the film has
enveloped product 46, end-seals 18 and 20 can be formed by adjacent
upper and lower seal jaws 62, which not only can heat seal the ends
of the package. A knife can fully separate individual packages or
alternately partially cut or perforate the cut between the packages
to hold them together.
[0073] Fin-seal 14 and end-seals 18 and 20 can optionally be formed
from patterns imprinted on heated wheels 38 or seal jaws 62, which
emboss the film as it is pulled through the manufacturing
process.
[0074] Seal jaws 62 can rotate with film 12 moving through a
production line where they meet to form end-seal 20 by an
end-sealer. Next, as seal jaws rotate further, the film can be cut
with a cutter die within the seal jaws, followed by the forming of
trailing end-seal 18. In embodiments using activated heat seals,
seal jaws 62 can be heated by heater element (not shown). Separate
heating elements are possible where different levels of peelability
are desired between end-seal 18 and end-seal 20.
[0075] The film roll 12 for use in the device 60 of FIG. 6 can be
shown as section of blanks generally indicated at 70 in FIG. 9.
This section of film would represent the film after scoring and the
discrete label are applied. Section 70 can have edges 72 and 74
that are joined to form fin seal 14. End seals 18 and 20 can be
formed by seal jaws 62 where the film also can be cut at line 76 to
separate packages 10. Side package panels can be formed by folding
the film at fold lines 78 and 80 in box 38.
[0076] It will be understood that various changes in the details,
materials, and arrangements of the flexible package, the
laminations, and methods, which have been herein described and
illustrated in order to explain the nature of the package and
methods, may be made by those skilled in the art within the
principle and scope of the embodied package, laminates and methods
as expressed in the appended claims.
* * * * *