U.S. patent application number 13/896551 was filed with the patent office on 2013-11-21 for easy-open peel pouch.
This patent application is currently assigned to The Tapemark Company. The applicant listed for this patent is The Tapemark Company. Invention is credited to Donald P. Fogle.
Application Number | 20130308882 13/896551 |
Document ID | / |
Family ID | 49581359 |
Filed Date | 2013-11-21 |
United States Patent
Application |
20130308882 |
Kind Code |
A1 |
Fogle; Donald P. |
November 21, 2013 |
EASY-OPEN PEEL POUCH
Abstract
A package for containing and dispensing a product is disclosed.
The package has a first layer, a second layer, and at least a first
seal zone where the first layer is joined to the second layer by a
peelable seal. The first seal zone has an inner perimeter that
defines an unsealed pouch area for containing the sheet product. A
tab cut is defined in the first layer that divides the package into
a package zone and a tab zone. A method and relevant manufacturing
equipment are also disclosed.
Inventors: |
Fogle; Donald P.; (Welch,
MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Tapemark Company |
West St. Paul |
MN |
US |
|
|
Assignee: |
The Tapemark Company
West St. Paul
MN
|
Family ID: |
49581359 |
Appl. No.: |
13/896551 |
Filed: |
May 17, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61648245 |
May 17, 2012 |
|
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|
Current U.S.
Class: |
383/210 ;
493/199; 53/450 |
Current CPC
Class: |
B31B 2110/10 20170801;
B65D 2575/58 20130101; B31B 2105/001 20170801; B31B 2105/00
20170801; B31B 2105/0022 20170801; B31B 2110/20 20170801; B65D
75/5855 20130101 |
Class at
Publication: |
383/210 ; 53/450;
493/199 |
International
Class: |
B65D 75/58 20060101
B65D075/58 |
Claims
1. A package for containing and dispensing a product, comprising: a
first layer; a second layer; at least a first seal zone where the
first layer is joined to the second layer by a peelable seal, the
first seal zone having an inner perimeter that defines an unsealed
pouch area for containing the product and an outer perimeter; and
an unsealed header zone adjacent to the outer perimeter of the
first seal zone, wherein the first layer is not joined to the
second layer in the unsealed header zone; and a first tab cut in
the first layer within the unsealed header zone, wherein the first
tab cut divides the package into a package zone and a first tab
zone.
2. The package of claim 1 wherein the first layer is coextensive
with the second layer so that the first layer and second layer
share a common outer perimeter.
3. The package of claim 1 wherein the unsealed header zone is
positioned substantially along one side of the package.
4. The package of claim 1 further comprising a second seal zone
where the first layer is joined to the second layer, wherein the
second seal zone is within the first tab zone, wherein the second
seal zone is separated from the first seal zone by a portion of the
unsealed header zone.
5. The package of claim 4, wherein the first tab zone is located in
a corner of the package, further comprising: a second tab cut in
the first layer within the unsealed header zone, wherein the second
tab cut defines the boundary of a second tab zone located in a
corner of the package; and a third seal zone where the first layer
is joined to the second layer, wherein the third seal zone is
within the second tab zone.
6. The package of claim 1 wherein the package is substantially
rectangular and wherein the unsealed header zone is positioned
substantially along one side of the package.
7. The package of claim 1 wherein there is no cut in the second
layer at a location corresponding to the first tab cut on the first
layer.
8. The package of claim 1 wherein the product is a sheet
product.
9. The package of claim 1 wherein the package is substantially
rectangular and the unsealed header zone is substantially
rectangular and is located along one side of the package, and
wherein the first tab zone is defined at a corner of the
package.
10. The package of claim 1 wherein the package is substantially
rectangular and the unsealed header zone is substantially
rectangular and is located along one side of the package, and
wherein the first tab cut is curved.
11. A method of forming a package for containing and dispensing a
product comprising: providing a first layer web and a second layer
web; placing a product on at least one pouch area of one of the
first and second layer webs; forming a combined web by sealing the
first layer web to the second layer web at least at a first seal
zone so that the first layer is joined to the second layer by a
peelable seal surrounding the at least one pouch area, and leaving
an unsealed header zone adjacent to an outer perimeter of the first
seal zone where the first layer web is not sealed to the second
layer web; and cutting at least one individual package around an
outer package perimeter to separate the individual package from the
combined web, wherein cutting further comprises cutting the first
layer of the package at a first tab cut location within the
unsealed header zone to define a boundary of the first tab zone in
the package.
12. The method of claim 11 wherein forming a combined web further
comprises sealing the first layer web to the second layer web at a
second seal zone which is within the tab zone.
13. The method of claim 11 wherein cutting the individual package
comprises die cutting.
14. The method of claim 13 wherein cutting the individual package
comprises rotary die cutting.
15. The method of claim 11 further comprising forming a second seal
zone where the first layer is joined to the second layer, wherein
the second seal zone is within the first tab zone, wherein the
second seal zone is separated from the first seal zone by a portion
of the unsealed header zone.
16. The method of claim 11, wherein the first tab zone is located
in a corner of the package, further comprising: cutting a second
tab cut in the first layer within the unsealed header zone, wherein
the second tab cut defines the boundary of a second tab zone
located in a corner of the package; and forming a third seal zone
where the first layer is joined to the second layer, wherein the
third seal zone is within the second tab zone.
17. The method of claim 11 wherein there is no cut in the second
layer at a location corresponding to the first tab cut on the first
layer.
18. A device for forming a package for containing and dispensing a
sheet product comprising: a heat seal plate for joining a first
layer web and a second layer web with a heat seal at first seal
zones to form a combined web, wherein the seal plate defines at
least one first seal zone having an inner perimeter and an outer
perimeter; and a cutting die for cutting the combined web to form
at least one individual package and for cutting through only the
first layer at a tab cut location, where the first tab cut location
is not within any of the first seal zones on the combined web.
19. The device of claim 18 wherein the cutting die is a rotary
cutting die.
Description
FIELD OF THE INVENTION
[0001] The technology described herein generally relates to a
package having a pouch area. More particularly the technology
described herein relates to a package where layers are peeled apart
to access a pouch area.
BACKGROUND
[0002] Many different types of packages are made with two or more
layers of material that are sealed together to form a pouch for
containing a product, and then can be peeled apart to access the
product. In some areas of technology, it is desirable to have
access to products that are sterile for their eventual use. This is
a common issue in the medical field, for example, where it is
desirable that products used in medical procedures remain sterile
over transport to and from manufacturing facilities, medical
facilities, and the like, in addition to while stored in those
facilities. In some package designs, it is difficult to separate
the layers of package in order to grasp the layers and peel them
apart. Static electricity may play a role in making the layers
difficult to separate. A cutting process for cutting the outer
package perimeter may fuse the layers together at their outer
perimeters to some degree, which can make the layers difficult to
separate.
[0003] Some packages are made with a notch that enables the user to
tear all layers of the package starting at the notch, in order to
gain access to at least part of the pouch area containing the
product. However, tearing all layers across the pouch area can
cause damage to fragile contents. Also, tearing all layers across
one side of a pouch area can still make it difficult to remove the
contents in some situations.
[0004] Time and frustration become issues in situations where a
package requires the manual separation of thin layers to open
especially when the user is wearing gloves or addressing an urgent
medical need.
SUMMARY OF THE INVENTION
[0005] In one embodiment, a package for containing and dispensing a
product includes a first layer, a second layer, and at least a
first seal zone where the first layer is joined to the second layer
by a peelable seal, the first seal zone having an inner perimeter
that defines an unsealed pouch area for containing the product and
an outer perimeter. The package further includes an unsealed header
zone adjacent to the outer perimeter of the first seal zone,
wherein the first layer is not joined to the second layer in the
unsealed header zone. The package also includes a first tab cut in
the first layer within the unsealed header zone, wherein the first
tab cut divides the package into a package zone and a first tab
zone.
[0006] In one embodiment, a method of forming a package for
containing and dispensing a product includes providing a first
layer web and a second layer web and placing a product on at least
one pouch area of one of the first and second layer webs. The
method also includes forming a combined web by sealing the first
layer web to the second layer web at least at a first seal zone so
that the first layer is joined to the second layer by a peelable
seal surrounding the at least one pouch area, and leaving an
unsealed header zone adjacent to an outer perimeter of the first
seal zone where the first layer web is not sealed to the second
layer web. The method further includes cutting at least one
individual package around an outer package perimeter to separate
the individual package from the combined web, wherein cutting
further comprises cutting only the first layer of the package at a
first tab cut location within the unsealed header zone to define a
first tab zone in the package.
[0007] In one embodiment, a device for forming a package for
containing and dispensing a sheet product includes a heat seal
plate for joining a first layer web and a second layer web with a
heat seal at first seal zones to form a combined web, wherein the
seal plate defines at least one first seal zone having an inner
perimeter and an outer perimeter. The device also includes a
cutting die for cutting the combined web to form at least one
individual package and for cutting through only the first layer at
a tab cut location, where the first tab cut location is not within
any of the first seal zones on the combined web.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention may be more completely understood and
appreciated in consideration of the following detailed description
of various embodiments of the invention in connection with the
accompanying drawings.
[0009] FIG. 1 depicts a front view of a package consistent with the
technology disclosed herein.
[0010] FIG. 2 depicts a side view of the package of FIG. 1 with a
tab portion and part of one layer bent away from the remainder of
the package.
[0011] FIG. 3 depicts a front view of another embodiment of a
package consistent with the technology disclosed herein.
[0012] FIG. 4 depicts a front view of yet another embodiment of a
package consistent with the technology disclosed herein.
[0013] FIG. 5 depicts a front view of another embodiment of a
package consistent with the technology disclosed herein.
[0014] FIG. 6 depicts a front view of another embodiment of a
package consistent with the technology disclosed herein.
[0015] FIG. 7 depicts a front view of another embodiment of a
package consistent with the technology disclosed herein.
[0016] FIG. 8 depicts a flow chart consistent with a method
described herein.
[0017] FIG. 9 depicts an example web consistent with the technology
disclosed herein.
[0018] FIG. 10 is a schematic drawing of one embodiment of
package-making equipment disclosed herein.
DETAILED DESCRIPTION
[0019] The package described herein is generally configured to
contain and dispense a product. The product can be medical in
nature and can be related to surgical needs, pharmaceutical needs,
medical emergency responder needs, and the like. In some
embodiments the product is a wound dressing, a medical care
product, a medical device, and the like. In some embodiments the
product is a sheet product such as a soluble film that can be
relevant to edible applications, oral applications, skin care
applications, cosmetic applications, and the like. A sheet product
generally is very thin and has width and length dimensions that are
significantly larger than its thickness dimension, such as where
the width and length are at least ten times the thickness
dimension, or where the width and length are at least one-hundred
times the thickness dimension. Sheet products sometimes have
parallel sides. In some cases, a wound dressing is a sheet
product.
[0020] FIG. 1 depicts a front view of a package consistent with the
technology disclosed herein. FIG. 2 depicts a side view of the
package of FIG. 1 where a tab zone 154 and part of one layer 170 is
bent away from the remainder of the package 100. The package 100
contains a product 10 and generally has a first layer 160 and a
second layer 170. In FIG. 1, the product 10 is shown in dashed
lines beneath the first layer 160. The product 10 may be visible
through a transparent layer or layers or may not be visible within
the package 100. The package 100 defines a first seal zone 130,
illustrated with cross-hatching, where the first layer 160 is
joined to the second layer 170 by a peelable seal 180. The first
seal zone 130 has an inner perimeter 110 and an outer perimeter
140. In the embodiment of FIG. 1, the inner and outer perimeters
110, 140 both have a substantially rectangular shape, with the
inner perimeter 110 having rounded corners. In other embodiments,
these perimeters have different shapes, such as with or without
rounded corners, with or without square corners, rectangles, ovals,
circles, squares and others. An unsealed pouch area 120 is defined
by the inner perimeter 110 of the first seal zone 130 and contains
the product 10. A tab cut 150 is defined in the first layer 160
that divides the package into a package zone 156 and a tab zone
154.
[0021] In the current embodiment, the package 100 has an outer
perimeter 157 that is rectangular and the tab zone 154 is defined
in the corner of the package 100. In some embodiments it can be
desirable to have a package in a different shape with a tab zone in
a different location, however. Some alternatives will be discussed
herein. In one embodiment, the package shape is circular, oval or
tombstone shaped with a rectangular base portion and a curved top
portion.
[0022] The package includes an unsealed header area 122 where the
first layer 160 is unattached to the second layer 170. In the
embodiment of FIG. 1, the outer perimeter 140 of the first seal
zone 130 defines one side of the unsealed header area 122 and the
outer perimeter 157 of the package defines other sides of the
unsealed header area 122. In the unsealed header area 122, a user
can separate the two layers and can grasp the first layer 160 and
the second layer 170 to peel them apart to access the product 10.
However, sometimes static electricity may play a role in making the
layers difficult to separate. Also, the cutting process used to cut
the outer package perimeter may fuse the layers together at their
outer perimeters to some degree, which can make the layers
difficult to separate. Also, if a user is wearing gloves, under
time pressure or both, a delay in separating the two layers to peel
them apart could be especially frustrating.
[0023] The tab cut 150 and tab zone 154 are configured to
facilitate the separation of the first layer 160 from the second
layer 170. The tab cut 150 through the first layer 160 in the
unsealed header area 122 physically decouples the portion of the
first layer 160 within the tab zone 154 from the portion of the
first layer 160 outside of the tab zone 154 (in the package zone
156). As a result, when the user bends the package in the tab zone
154, the first layer 160 separates from the second layer 170 at the
tab cut 150, so that the user can easily grasp the tab zone 154 of
the package, easily grasp the first layer 160 in the unsealed
header and then can pull the second layer 170 away from the first
layer 160.
[0024] In some embodiments, such as the embodiment of FIG. 1, a
second seal zone 132 is present in the tab zone 154 where the first
layer 160 is joined to the second layer 170. The second seal zone
132 physically couples the portion of the first layer 160 within in
the tab zone 154 to the second layer 170. As such, when the user
grasps the tab zone 154, the user is grasping the sealed first and
second layers in the tab zone 154. The second seal zone 132 is
separated from the first seal zone 130 by the unsealed header area
122. Second seal zone boundary 112 defines a boundary of the second
seal zone 132 and divides the second seal zone 132 from the
unsealed header area 122.
[0025] In some embodiments, such as the embodiment shown in FIG. 7
which will be further described herein, the first layer is not
joined to the second layer by a second seal zone. In these
embodiments, a portion of the first layer in the tab zone is
separated from the rest of the package by the tab cut and is no
longer connected to the package. In these embodiments, the first
layer of the package within the tab zone is removed, exposing the
second layer in the tab zone. The first layer in the tab zone can
be removed through use of a vacuum in one embodiment or a blower in
another embodiment, although other methods can certainly be used as
well. Each of the embodiments illustrated in FIGS. 1-6 are
illustrated to include a second and sometimes a third seal zone but
could also be provided without the additional seal zones. Likewise,
the embodiment of FIG. 7 could be provided with the second seal
zone. Where an embodiment includes a second seal zone, the step of
removing the tab zone portion of the first layer is not necessary,
since the tab zone portion of the first layer is adhered to the tab
zone portion of the second layer. In this situation, the tab zone
of the package includes the first and second layers adhered
together, and the tab zone is therefore thicker than either of the
two layers separately.
Layer Material Options
[0026] The first layer 160 and the second layer 170 can include a
variety of materials and combinations of materials that are
generally known in the art, such as a polyester film, spunbonded
olefin, DuPont TYVEK.RTM. brand spunbonded olefin, linear low
density polyethylene with polybutylene, biaxially oriented
polyester film, polypropylene film, high density polyethylene film,
BAREX.RTM. acrylonitrile co-polymer film available from BP
Chemicals, Inc., cast polyethylene terephthalate (PET) or
polyethylene terephthalate glycol (PETG) film, metal foil, aluminum
foil, poly-vinylidene dichloride (PVDC) film, co-extruded films
containing ethylene vinyl alcohol polymer (EVOH), polyvinyl alcohol
(PVA) film, polyamide film, vinyl film, or composite laminations or
coatings that contain the same. In a variety of embodiments, the
first layer 160 and the second layer 170 are heat sealable. In some
embodiments, only one of the first layer 160 and second layer 170
is heat sealable, and the other is a compatible material to create
a peel seal. In one embodiment, each of the first and second layers
includes a polyester layer, such as a DuPont TYVEK.RTM. brand
spunbonded olefin, a tie layer and a sealant layer. In one
embodiment, the polyester film, tie layer and sealant layer are
coextruded or laminated to form a single film. One example of an
appropriate sealant layer is linear low density polyethylene with
polybutylene, which is activated by heat to bond to the other
layer. In some embodiments, the layers are joined by methods other
than heat sealing. For example, the layers may be joined by
ultrasonic welding in some embodiments. In some embodiments, the
layers may be joined by more than one method, such as both heat
sealing and ultrasonic welding.
[0027] In a variety of embodiments, the first layer 160 and the
second layer 170 are substantially non-permeable. In a variety of
embodiments, the first layer 160 and the second layer 170 are
substantially permeable. For example, a layer that includes a metal
foil layer will be substantially non-permeable, while a layer that
includes a DuPont TYVEK.RTM. brand spunbonded olefin will be
permeable. In a variety of embodiments, the first layer 160 and the
second layer 170 are substantially flexible, although in some
embodiments one of the first layer 160 or the second layer 170 or
both are substantially rigid. In some embodiments, one or both of
the layers is transparent so that the product 10 is visible through
the transparent layer. Alternative terms that can be used to
describe the first layer 160 and the second layer 170 include film,
sheet, web, and the like.
[0028] The first layer 160 is generally coextensive with the second
layer 170 so that the two layers share a common outer perimeter. As
mentioned above, the first layer 160 and second layer 170 are
joined with a peelable seal 180. Generally, the peelable seal 180
is a hermetic bond between the contacting surfaces of the first
layer 160 and second layer 170. The peelable seal 180 can be formed
by any appropriate method known in the art. In a variety of
embodiments, peelable seal 180 is a heat seal or melt bonded
relationship caused by the application of heat and pressure. In an
alternate embodiment, peelable seal 180 is formed with a suitable
adhesive applied to at least one of the contacting surfaces of the
first layer 160 and second layer 170. In at least one embodiment,
the peelable seal 180 is re-sealable, thereby allowing a user to
reclose the package 100.
[0029] In general the peelable seal 180 is configured to have
strength conducive to allowing a user to peel the first layer 160
and the second layer 170 apart without the use of tools, to access
the product 10 there between. In one embodiment, the peelable seal
strength is in the range of 1.25 to 2 pounds per linear inch of
seal when pulled apart at 180 degrees at 12 inches per minute
travel rate according to testing procedure TAPPI T-494 as published
by the Technical Association of the Pulp and Paper Industry. In
some embodiments the peelable seal strength is in the range of 1.0
to 2.5 pounds per linear inch of seal. In a variety of embodiments
the peelable seal has strength in the range of 0.25 to 3.5 pounds
per linear inch of seal.
Options for the Second Seal Zone
[0030] Similar to the first seal zone 130, the second seal zone 132
can be formed by any appropriate method known in the art. The
second seal zone 132 can be formed in an identical way as the first
seal zone 130, a similar way as the first seal zone 130 or in a
different way. In one embodiment, the second seal zone 132 and the
first seal zone 130 are formed through heat sealing the first layer
160 to the second layer 170.
Description of Embodiments of FIGS. 3-7
[0031] Those having skill in the art will appreciate the variety of
configurations consistent with the technology disclosed herein.
FIGS. 3-7 show five different embodiments where the tab zone or tab
zones and the additional seal area or seal areas are configured in
different ways. FIG. 3 depicts a front view of package embodiment
200 which includes a first layer and a second layer (not visible
from the front view angle of FIG. 3) and defines a first seal zone
230 with an inner perimeter 210 and an outer perimeter 240. An
unsealed pouch area 220 is defined by the inner perimeter 210 and
contains a product 10. In this embodiment, however, a first tab cut
250 defines a first tab zone 252 and a second tab cut 254 defines a
second tab zone 256. A second seal zone 232 in the first tab zone
252 and a third seal zone 234 in the second tab zone 256 are
separated from the first seal zone by an unsealed header area 222.
In the embodiment of FIG. 3, there are two tab zones 252 and 256
which both provide a location for the user to grasp when opening
the package which will easily separate from the remainder of the
unsealed header area so that the two layers of the package can be
easily peeled apart. Second seal zone boundary 212 defines a
boundary of the second seal zone 232 and divides the second seal
zone 232 from the unsealed header area 222. The third seal zone 234
also has a boundary 214 that divides the third seal zone 234 from
the unsealed header area 222.
[0032] Those having skill in the art will appreciate that a tab cut
can have a variety of configurations and locations. In some
embodiments the tab cut is a straight line. In other embodiments
the tab cut is curved. In at least one embodiment the tab cut can
include intersecting sides. In some embodiments depicted herein,
the tab cut is near a corner while in some embodiments the tab cut
is near a center of one side of the package. In other embodiments,
the tab cut is located at different positions along a side of the
package. FIG. 4 depicts a front view of yet another embodiment of a
package consistent with the technology disclosed herein. In this
embodiment the package 300 similarly has a first layer and a second
layer (not visible from the front view of FIG. 4) and defines a
first seal zone 330 with an inner perimeter 310 and an outer
perimeter 340. An unsealed pouch area 320 is defined by the inner
perimeter 310 and contains the product 10. A tab cut 350 defined in
the first layer defines a tab zone 352 that is distinguished from a
package zone 354. A second seal zone 332 is in the tab zone 352 and
is separated from the first seal zone 330 by an unsealed header
area 322. A boundary 312 of the second seal zone 332 separates the
second seal zone 332 from the unsealed header area 322. In this
embodiment the tab cut 350 is curved. In this embodiment the tab
cut 350 intersects the edges of the package perimeter 357 at
substantially a right angle. Positioning cutting edges at right
angles on the die can be desirable since material can sometimes
accumulate at acute angles between cutting structures.
[0033] The first seal zone and the second seal zone can have a
variety of configurations. In the embodiments disclosed herein, the
outer perimeter of the first seal zone has a generally rectangular
shape and extends to the edges of the package on three sides. The
inner perimeter is also generally rectangular in shape, where the
rectangle has curved corners. Many other shapes will be conducive
to the technology disclosed herein. For example, the package
perimeter and the first seal area could be oval or circular. The
second seal zone (and third seal zones, where applicable) can also
have a variety of shapes and placements. In the embodiments
disclosed herein, the second seal zone extends to at least one edge
of the package, although there are a variety of instances where the
second seal zone does not extend to an edge of the package. In a
variety of embodiments the second seal zone is triangular in shape.
In some embodiments the second seal zone is rectangular in shape.
In yet other embodiments the second seal zone is circular in shape.
Where the second seal zone is formed through heat sealing, a shape
can be defined in a die that creates the second seal zone.
[0034] FIG. 5 depicts a front view of another embodiment of a
package consistent with the technology disclosed herein. In this
embodiment the package 400 has a first layer and a second layer
(not visible from the front view of FIG. 5) and defines a first
seal zone 430 with an inner perimeter 410 and an outer perimeter
440. An unsealed pouch area 420 is defined by the inner perimeter
410, where the unsealed pouch area 420 is configured to receive a
product 10. A tab cut 450 defined in the first layer defines a tab
zone 452 that is distinguished from a package zone 454. The package
zone includes the remainder of the package excluding the tab zone.
A second seal zone 432 is in the tab zone 452 and is separated from
the first seal zone 430 by an unsealed header area 422. In this
embodiment the tab cut 450 is also curved and intersects with an
edge of the package 400. The tab cut 450 is located at the center
of the edge of the unsealed header area 422. The second seal zone
432 is substantially rectangular and is within the tab zone 452. A
boundary 412 of the second seal zone 432 separates the second seal
zone 432 from the unsealed header area 422. In other embodiments,
the tab cut 450 is located at other non-central locations along the
edge of the unsealed header area 422.
[0035] FIG. 6 depicts a front view of another embodiment of a
package consistent with the technology disclosed herein. In this
embodiment the package 500 has a first layer and a second layer
(not visible from the front view of FIG. 6) and defines a first
seal zone 530 with an inner perimeter 510 and an outer perimeter
540. An unsealed pouch area 520 is defined by the inner perimeter
510 and contains a product 10. In this embodiment, a first tab cut
550 and a second tab cut 554 are present in only the first layer,
are curved and are located at the outer perimeter corners of the
package in the unsealed header area 522. The first tab cut 550
defines a boundary of a first tab zone 552 while the second tab cut
554 defines a boundary of a second tab zone 556. The first tab zone
552 and the second tab zone 556 are distinguished from the package
zone 558. A second seal zone 532 in the first tab zone 552 and a
third seal zone 534 in the second tab zone 556 are separated from
the first seal zone 530 by an unsealed header area 522. The second
seal zone 532 and third seal zone 534 are rectangular and border
the corners of the outer perimeter 557 of the package 500. The
second and third seal zones 532, 534 could be formed in different
shapes and located at other locations. For example, the second and
third seal zone could be circular or oval, and could be located at
a location offset from the corners. A boundary 512 of the second
seal zone 532 separates the second seal zone 532 from the unsealed
header area 522. A boundary 513 of the third seal zone 534
separates the third seal zone 534 from the unsealed header area
522.
[0036] FIG. 7 depicts a front view of another embodiment of a
package consistent with the technology disclosed herein. In this
embodiment the package 600 has a first layer and a second layer and
defines a first seal zone 630 with an inner perimeter 610 and an
outer perimeter 640. An unsealed pouch area 620 is defined by the
inner perimeter 610 and contains a product 10. A tab cut 650
defines a tab zone 652, and the remainder of the package is
referred to as the package zone 654. The tab cut 650, is
approximately half-circle shaped, is curved and intersects the
perimeter 657 of the package at substantially a right angle. The
tab cut 650 is located at the center of the outer perimeter edge of
the unsealed header area 622. In this embodiment, the first layer
of the package 600 within the tab zone 652 is removed, exposing the
second layer 670 in the tab zone 652. The first layer in the tab
zone 652 can be removed through use of a vacuum in one embodiment
or a blower in another embodiment, although other methods can
certainly be used as well.
[0037] In another embodiment, the tab cut is a chevron shape
located at the center of the outer perimeter edge of the unsealed
header area. This embodiment can have a second seal area within the
chevron or may lack a second seal area.
[0038] FIG. 8 depicts a flow chart consistent with one method of
manufacturing a package consistent with the technology disclosed
herein. Generally, at least two webs are provided 20, product is
placed 30 on one web, the webs are sealed 40 to enclose the product
within an unsealed area, and then the web is cut 50 into packages
and the tab cut is made. FIG. 9 depicts an example combined web
1000 consistent with the method associated with FIG. 8 prior to
cutting 50. The packages formed from these components can be for
containing and dispensing a product.
[0039] The step of providing webs 20 generally encompasses
providing a first layer web and a second layer web, although
additional webs can be provided also. The first layer web and
second layer web can be a variety of different materials, as
described above with regard to FIGS. 1 and 2. Placing a product 30
generally encompasses placing a product on at least one pouch area
of the second layer web.
[0040] Now referring to FIG. 9 and the steps of FIG. 8, in a
variety of embodiments multiple products 10 are placed on the
second layer web in corresponding pouch areas 950 of the second
layer web. The webs are sealed at step 40 to form a combined web
1000 by sealing the first layer web to the second layer web at
least at a first seal zone 930 so that the first layer is joined to
the second layer by a peelable seal. In multiple embodiments,
including the embodiment depicted in FIG. 9, forming a combined web
also includes sealing the first layer web to the second layer web
at a second seal zone 932 which is within a tab zone. The webs are
generally sized to create multiple packages, and may be very long,
also referred to as continuous, in the machine direction and have a
cross-machine direction of one to five packages, or more. Combined
web 1000 of FIG. 9 has a width of two packages, and is very long in
the machine direction. Very long in the machine direction is used
to mean a web that is typically substantially longer than it is
wide, such as one-hundred or one-thousand times longer than its
width, and is often processed on rolls.
[0041] In at least one example implementation of the method of FIG.
8, sealing the webs 40 is accomplished in line in a continuous
motion machine. A seal plate can be used for joining a first layer
web and a second layer web with a heat seal at a first seal zone
930 to form the combined web 1000. In such an implementation the
seal plate itself defines a first seal zone having an inner
perimeter and an outer perimeter, as well. In the web embodiment
depicted in FIG. 9, such a seal plate would also define a second
seal zone 932 within individual package tab areas.
[0042] The combined web is then cut 50 to produce at least one
individual package. The package is cut along center
machine-direction cut lines 910, cross-machine direction cut lines
920 and outer machine direction cut lines 925 to separate the
individual package 900 from a matrix 936. The use of a matrix
allows for some tolerance in the sealing and cutting steps.
[0043] In a variety of embodiments, the step of cutting 50 also
includes cutting only the first layer of the package at a tab cut
location 940 to define a tab zone in the package 900. As described
above, the tab cut location is generally outside of the first seal
zone 930 and is within the unsealed header area 922. In a variety
of embodiments, each individual package is die cut around its
respective outer perimeter and at a tab cut location. In at least
one example implementation, the die cutting 50 is accomplished in a
rotary die cutting station. In such an example, the rotary die can
cut against an anvil roll, for example. In other embodiments, the
packages are knife cut or guillotine cut at their outer
perimeters.
[0044] FIG. 10 is a schematic drawing of one embodiment of a
package-making equipment system 1010 that can be used to make
packages as described herein. The system 1010 includes equipment
1012 for providing the input materials for the package, such as the
first layer, second layer and product to be packaged. In one
embodiment these materials are provided on rolls. A preliminary
rotary die station 1014 may be provided in some embodiments before
the heat seal station 1016 in order to perform any preparatory cuts
that are desired. In some embodiments, there is no rotary die
station 1014 before the heat seal station 1016, such as where no
preparatory cuts are needed.
[0045] The heat seal station 1016 performs the step of sealing the
webs to join them together at the seal zones. In one embodiment,
the heat seal station includes multiple heat seal plates that are
used to form different seal zones. In one embodiment, a first seal
plate is used to form a first seal zone, while a second seal plate
is used to form a second seal zone.
[0046] A rotary die station 1018 is provided where each package is
cut along its exterior perimeter, as discussed in relation to FIG.
9, to separate the individual package from a matrix. Additional
rotary die stations may perform additional cuts, such as to cut the
package in one layer at the tab cut location to form the tab zone.
Alternatively, a single rotary die station can perform both the
exterior perimeter cuts and the tab zone cut through one layer.
Output equipment 1020 is also provided for processing the
individual packages made in the process. The schematic of FIG. 10
shows basic equipment components, but it will be recognized by one
of skill in the art that additional equipment could be provide
other processing functionality. It should also be noted that, as
used in this specification and the appended claims, the phrase
"configured" describes a system, apparatus, or other structure that
is constructed or configured to perform a particular task or adopt
a particular configuration. The phrase "configured" can be used
interchangeably with other similar phrases such as "arranged,"
"arranged and configured," "constructed and arranged,"
"constructed," "manufactured and arranged," and the like.
[0047] All publications and patent applications in this
specification are indicative of the level of ordinary skill in the
art to which this invention pertains. All publications and patent
applications are herein incorporated by reference to the same
extent as if each individual publication or patent application was
specifically and individually indicated by reference.
[0048] This application is intended to cover adaptations or
variations of the present subject matter. It is to be understood
that the above description is intended to be illustrative, and not
restrictive.
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