U.S. patent application number 14/115197 was filed with the patent office on 2014-07-03 for reclosable flexible film packaging and methods of manufacture.
This patent application is currently assigned to INTERNATIONAL GREAT BRANDS LLC. The applicant listed for this patent is Deborah A. Lyzenga. Invention is credited to Deborah A. Lyzenga.
Application Number | 20140185965 14/115197 |
Document ID | / |
Family ID | 46148970 |
Filed Date | 2014-07-03 |
United States Patent
Application |
20140185965 |
Kind Code |
A1 |
Lyzenga; Deborah A. |
July 3, 2014 |
RECLOSABLE FLEXIBLE FILM PACKAGING AND METHODS OF MANUFACTURE
Abstract
A reclosable flexible package can have a flexible film forming a
body defining an interior contents cavity and having a first pair
of opposing edge portions forming a first edge seal, a second pair
of opposing edge portions forming a second edge seal, and a third
pair of opposing edge portions forming a fin seal extending from
the first edge seal to the second edge seal; the body having a
first side portion having the 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 defining an opening to the
contents cavity upon initial rupturing; a closure layer covering
the score and a portion of the second side portion around the
score; a resealable adhesive being between the closure layer and
the flexible film; and the closure layer on the second side portion
being capable of at least partial removal from the flexible film to
rupture the score and form an opening.
Inventors: |
Lyzenga; Deborah A.; (Long
Valley, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lyzenga; Deborah A. |
Long Valley |
NJ |
US |
|
|
Assignee: |
INTERNATIONAL GREAT BRANDS
LLC
East Hanover
NJ
|
Family ID: |
46148970 |
Appl. No.: |
14/115197 |
Filed: |
May 7, 2012 |
PCT Filed: |
May 7, 2012 |
PCT NO: |
PCT/US2012/036750 |
371 Date: |
March 20, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61483732 |
May 8, 2011 |
|
|
|
Current U.S.
Class: |
383/99 ;
53/456 |
Current CPC
Class: |
B65B 9/2056 20130101;
B65B 9/213 20130101; B65D 31/16 20130101; B65B 61/184 20130101;
B65D 75/008 20130101; B65B 61/02 20130101; B65D 75/5838 20130101;
B65B 9/207 20130101 |
Class at
Publication: |
383/99 ;
53/456 |
International
Class: |
B65D 30/10 20060101
B65D030/10 |
Claims
1. A package comprising: a flexible film forming a body defining an
interior contents cavity and having a first pair of opposing edge
portions forming a first edge seal, a second pair of opposing edge
portions forming a second edge seal, and a third pair of opposing
edge portions forming a longitudinal seal extending from the first
edge seal to the second edge seal; the body having a first side
portion having the longitudinal seal and a second side portion
generally opposite the first side portion; a score formed in the
flexible film at the second side portion defining an opening to the
contents cavity upon initial rupturing; a closure layer covering
the score and a portion of the second side portion around the
score; a resealable adhesive being between the closure layer and
the flexible film; and the closure layer on the second side portion
being capable of at least partial removal from the flexible film to
rupture the score and form an opening.
2. The package of claim 1, wherein the resealable 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 closure layer extends from
the first edge seal to the second edge seal and generally parallel
to the longitudinal seal.
4. The package of claim 1, wherein the score is arcuate.
5. The package of claim 1, wherein the score includes a pair of
terminal ends configured to resist further rupturing of the
flexible film.
6. The package of claim 5, wherein the terminal ends are configured
as `smiles`.
7. 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.
8. The package of claim 7, wherein the tack free gripping portion
includes a deadener on the resealable adhesive.
9. The package of claim 7, wherein the tack free gripping portion
includes a portion of the closure layer adhered to itself with the
resealable adhesive.
10. The package of claim 7, wherein the tack free gripping portion
is void of resealable adhesive.
11. The package of claim 1, wherein the flexible film comprises a
laminate structure.
12. The package of claim 11, wherein the flexible film comprises a
laminate of polyethylene terephthalate and oriented polypropylene
having a thickness in a range of about 1.5 to 2.5 mils.
13. The package of claim 11, wherein the flexible film comprises a
laminate of polyethylene terephthalate having a thickness in a
range of about 0.4 to 1.0 mils and oriented polypropylene having a
thickness in a range of about 0.6 to 1.2 mils.
14. The package of claim 1, wherein the closure layer is a
bi-axially oriented polypropylene having a thickness in a range of
about 1.2 mils to 5 mils.
15. The package of claim 1, further including a gusset in a third
edge of the film.
16. The package of claim 15, wherein the score formed in the
flexible film at the second side portion of the package is on a top
half of the second side portion, and the third edge is on a bottom
half of the second side portion.
17. The package of claim 15, wherein the gusset is the flexible
film folded into the interior contents cavity to form two opposing
gusset sides extending inwardly from the first side portion and the
second side portion toward the vertical center of the package.
18. The package of claim 1, wherein the score is disposed partially
through a thickness of the flexible film.
19. The package of claim 1, wherein the score is disposed through
an entire thickness of the flexible film.
20. The package of claim 1, wherein the resealable adhesive is a
pressure sensitive adhesive.
21. A flexible film package comprising: a flexible film having two
opposing edge portions forming a longitudinal seal extending from a
first side seal to a second side seal, the side seals forming a
front package panel and a rear package panel, the longitudinal seal
disposed on the rear panel; a score in the flexible film front
panel oriented generally parallel to the longitudinal seal that
defines a package opening upon initial rupturing; an elongated
closure layer extending within the edge portions from the first
side seal to the second side seal and over the score; a resealable
adhesive being between the flexible film and the elongated closure
layer; the elongated closure layer having a tack free gripping
portion to remove at least a portion of the elongated closure layer
from the flexible film to form the package opening; and the package
having a blind fold to define a package top and a pair of folds
directed to a package interior forming a gusset to define a package
bottom.
22. The package of claim 21, wherein the film is a printed laminate
comprising a co-extruded polypropylene laminated to a heat sealable
polypropylene; and the elongated closure layer is a BOPP bi-axially
oriented polypropylene.
23. A method for making a vertical stand-up pouch having a
substantially symmetrical bottom gusset, comprising the steps of:
tensioning a film roll; continuously scoring the film roll on a
surface directed to an interior the package; laminating a
continuous closure layer on an exterior surface of the package over
the film with a resealable adhesive; forming the film around a
product delivery chamber; sealing opposite longitudinal edges of
the film to form a longitudinal seal; forming a gusset to the film
directed to a bottom of the package; sealing the film to create a
package side seal; cutting the package side seal to separate the
film; and supplying product into the product delivery chamber into
the unsealed film.
24. The method of claim 23, further comprising the step of
deadening a portion of the resealable adhesive before laminating to
the film.
25. The method of claim 23, wherein the longitudinal seal is a fin
seal.
26. The method of claim 23, wherein the step of sealing the film is
performed by a pair of heated reciprocal heating bars to a film
having a heat sealable layer on the interior surface of the film.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 61/483,732, filed 8 May 2011, which is
incorporated herein by reference in its entirety.
FIELD
[0002] The present products and methods relate generally to
flexible packaging and, in particular, to flexible packaging having
a reclosable opening.
BACKGROUND
[0003] Flexible packaging is often used to retain and seal products
for shipping and storage. It is commonly used for a variety of
consumer products, including food products (e.g., cracker sleeves,
chewing gum sticks, chocolate bars, cookies, and the like). By one
approach, the package may be a film laminate and take the shape of
the products contained therein. Packages can be formed by a
plurality of walls sealed to form an interior cavity. Examples can
include flow-wrap packaging, three-sided seals, form-filled seal,
and the like.
[0004] Flow-wrap type flexible film packaging can use a continuous
film (web) to envelop product during assembly. In one
configuration, flow-wrap (also known as horizontal or vertical
fin-seal or lap-seal wrap, end-seal wrap, horizontal bagging and
pillow-pouch packaging) can position a film, such as polyethylene
or polypropylene, adjacent a product, wrap the film around the
product, form a seal from the ends of the film, then form seals at
either side of the product. The seals can be permanent and provide
some level of structural integrity. Flexible film packages have
many other advantages. They can be manufactured at substantially
lower cost than rigid containers, are light-weight resulting in
reduced transportation costs, and pack easier resulting in less
storage space.
[0005] Despite these advantages, flexible packaging can sometimes
be difficult to open and is typically not suitable when a user
wants to reclose/reseal a package after its initial opening, such
as when there is more product within the package than for a single
use. Attempts are known in the art to provide some measure of
reclosure of flexible packaging using discreet closure layers
(labels) that require precise label placement (registration) on the
package over a configured opening in the film (See generally, U.S.
Pat. No. 5,725,311 to Ponsi).
SUMMARY
[0006] Accordingly, provided herein are embodiments for an easy
open vertical formed gusseted flexible flow-wrap package film/web
having a closure layer/label laminated above a score (tear) line in
the flow-wrap film, which defines a package opening. A resealable
adhesive between the film and label can allow easy opening and
reclosing or resealing, while maintaining package integrity.
[0007] In one embodiment, a package can have a flexible film
forming a body defining an interior contents cavity and having a
first pair of opposing edge portions forming a first edge seal, a
second pair of opposing edge portions forming a second edge seal,
and a third pair of opposing edge portions forming a fin seal
extending from the first edge seal to the second edge seal; the
body having a first side portion having the 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 defining an
opening to the contents cavity upon initial rupturing; a closure
layer covering the score and a portion of the second side portion
around the score; a resealable adhesive being between the closure
layer and the flexible film; and the closure layer on the second
side portion being capable of at least partial removal from the
flexible film to rupture the score and form an opening.
[0008] In some embodiments, the resealable 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 some embodiments, the closure layer can extend from the
first edge seal to the second edge seal and generally parallel to
the fin seal. In some embodiments 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 a deadener applied to the resealable adhesive, a portion of
the closure layer adhered to itself with the resealable adhesive,
void of resealable adhesive, or the like. In some embodiments, the
closure layer can be a bi-axially oriented polypropylene having a
thickness in a range of about 1.2 mils to 5 mils.
[0010] In some embodiments, the score can be arcuate or include a
pair of terminal ends configured to resist further rupturing of the
flexible film. In some embodiments the terminal ends can be
configured as `smiles`.
[0011] In some embodiments flexible film for the package can be a
laminate structure. In some embodiments, the laminate can be formed
from polyethylene terephthalate and oriented polypropylene having a
thickness in a range of about 1.5 to 2.5 mils. In other
embodiments, the flexible film laminate can be formed from
polyethylene terephthalate having a thickness in a range of about
0.4 to 1.0 mils and oriented polypropylene having a thickness in a
range of about 0.6 to 1.2 mils.
[0012] In some embodiments, the package can have a gusset in a
third edge of the film. In some embodiments the score formed in the
flexible film at the second side portion of the package can be on a
top half of the second side portion, and the third edge can be on a
bottom half of the second side portion. In some embodiments, the
gusset can be the flexible film folded into the interior contents
cavity to form two opposing gusset sides extending inwardly from
the first side portion and the second side portion toward the
vertical center of the package.
[0013] In some embodiments, the score can be disposed partially
through a thickness of the flexible film or alternately through an
entire thickness of the flexible film. In some embodiments the
resealable adhesive can be a pressure sensitive adhesive (PSA).
[0014] In other embodiments the package can be a flexible film
having two opposing edge portions forming a longitudinal seal
extending from a first side seal to a second side seal, the side
seals forming a front package panel and a rear package panel, the
longitudinal seal disposed on the rear panel; a score in the
flexible film front panel oriented generally parallel to the
longitudinal seal that defines a package opening upon initial
rupturing; an elongated closure layer extending within the edge
portions from the first side seal to the second side seal and over
the score; a resealable adhesive being between the flexible film
and the elongated closure layer; the elongated closure layer having
a tack free gripping portion to remove at least a portion of the
elongated closure layer from the flexible film to form the package
opening; and the package having a blind fold to define a package
top and a pair of folds directed to a package interior forming a
gusset to define a package bottom.
[0015] In some embodiments, the film can be a printed laminate
comprising a co-extruded polypropylene laminated to a heat sealable
polypropylene; and the elongated closure layer can be a BOPP
bi-axially oriented polypropylene.
[0016] In other embodiments, methods for forming a vertical
stand-up pouch having a substantially symmetrical bottom gusset,
can have the steps of tensioning a film roll; continuously scoring
the film roll on a surface directed to an interior of the package;
laminating a continuous closure layer on an exterior surface of the
package over the film with a resealable adhesive; forming the film
around a product delivery chamber; sealing opposite longitudinal
edges of the film to form a longitudinal seal; forming a gusset to
the film directed to a bottom of the package; sealing the film to
create a package side seal; cutting the package side seal to
separate the film; and supplying product into the product delivery
chamber into the unsealed film.
[0017] In some embodiments, methods can include the step of
deadening a portion of the resealable adhesive before laminating to
the film. In some embodiments, the longitudinal seal can be a fin
seal. In one approach, the step of sealing the film can be
performed by a pair of heated reciprocal heating bars to a film
having a heat sealable layer on the interior surface of the
film.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates a perspective view of an exemplary
gusseted vertical form filled bag of the present embodiments;
[0019] FIG. 2 illustrates a front view of view of an exemplary
gusseted vertical form filled bag of the present embodiments;
[0020] FIG. 3 illustrates a sectional view of an exemplary gusseted
vertical form filled bag of the present embodiments taken along
section line III-III of FIG. 2;
[0021] FIG. 4 illustrates a sectional view of an exemplary gusseted
vertical form filled bag of the present embodiments taken along
section line IV-IV of FIG. 2;
[0022] FIG. 5 illustrates a rear view of an exemplary gusseted
vertical form filled bag of the present embodiments;
[0023] FIG. 6 illustrates a perspective view of an open exemplary
gusseted vertical form filled bag of the present embodiments;
[0024] FIG. 7 illustrates a sectional view of an open exemplary
gusseted vertical form filled bag of the present embodiments taken
along section line VII-VII of FIG. 6;
[0025] FIG. 8 illustrates a front view of an exemplary gusseted
vertical form filled bag of the present embodiments according to
another approach using a laminated film;
[0026] FIGS. 9-14 illustrate alternate score line and label
embodiments of exemplary gusseted vertical form filled bags of the
present embodiments;
[0027] FIG. 15 illustrates a section of a roll of blanks for use in
forming an exemplary gusseted vertical form filled bag of the
present embodiments;
[0028] FIG. 16 illustrates a partial perspective view illustrating
an apparatus configured to form and fill and seal an exemplary
gusseted vertical form filled bag of the present embodiments;
and
[0029] FIG. 17 illustrates a sectional view of an exemplary
gusseted vertical form filled bag of the present embodiments taken
along section line XVII-XVII of FIG. 8.
DETAILED DESCRIPTION OF THE PRESENT EMBODIMENTS
[0030] Provided herein are various embodiments of an easily opened
and reclosable package having in some embodiments a front and back
panel formed by a flexible film web substrate having a closure
layer or label substrate disposed thereon and a gusset. The label
can be applied continuously to the film. In some embodiments the
label can be top cut to form a shaped continuous label or even a
discrete label package from a continuously applied label. In some
embodiments, a film laminate having top and bottom cuts can be used
to form a package opening and reclose feature. The reclosable
packages can be easily opened and reclosed while maintaining
package integrity. By one approach, the reclosable packages are
formed with a flexible film laminated with a continuous label by a
resealable adhesive. In one configuration, an illustrative
four-sided package is comprised of a folded web of flexible film
that forms the front and back panels having four peripheral
edges--one folded edge, two sealed edges, and one gusseted edge. It
is noted that various configurations are possible for the number of
peripheral edges and the number of sealed, folded and gusseted
peripheral edges within the scope of the present embodiments.
[0031] The flexible film packages 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. Further, the flexible film packages are
generally reclosable such that the shelf life of food products
contained therein is not unnecessarily shortened due to exposure to
the ambient atmosphere once the flexible film package is initially
opened. Thus, the flexible film packages may have a recluse feature
that provides a reclosable seal that is present 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.
[0032] 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 contain product and/or retain freshness or shelf-life of a
food product retained within the package subsequent to initial
opening. The seals of the flexible film package, such as, for
example, a fin or lap seal, and any ends seals (including top,
bottom, and side 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. Any reclosable seals of the flexible package,
such as that formed around the package opening, can be formed, in
part, by a resealable adhesive located/laminated between the
flexible film and the closure layer. This reclosable seal feature
can be formed by a variety of manufacturing processes. It is noted
that the term resealable adhesive as used herein can include any
number of the adhesives capable of resealing and/or reclosing the
closure layer and flexible film together, such as a pressure
sensitive adhesive, a cold seal, a heat seal, a cohesive adhesive,
a low tack adhesive, and the like.
[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
square or 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, and in some
configurations can be referred to as vertical formed filled and
sealed (VFFS) bags. It is noted though that other embodiments of
the present design can allow for Horizontal Form Filled and Sealed
(HFFS) flow wrapped products. In some configurations a VFFS bag can
be gusseted to provide expansion to retain product. Various
configurations may be easily opened and resealed while maintaining
package integrity. In some bag configurations having a bottom
gusset, the bag can stand on the gusset.
[0034] By one approach, a flexible film roll may have two opposing
edge portions that meet to form a horizontal seal (relative to a
top opening of the package) extending between a first side seal to
a second side seal across the back of the package. The flexible
film can have a score that can be ruptured to define an opening
across the front panel of the package. In one illustrative
embodiment, an elongated closure layer (such as a continuous label)
extends over the film score from a first side seal to a second side
seal and within the opposing edge portions that meet to form the
horizontal seal. A resealable adhesive may be provided between the
flexible film and the elongated closure layer to hold the closure
layer in place and seal it to the front of the package. On a
surface of the continuous label facing the flexible film web, the
continuous label may have an adhesive-free area (e.g., along all or
a portion of the first edge) to provide a pull tab to facilitate
easy opening of the package. Further, such adhesive-free pull tab
may be disposed on a side of the package with the score line such
that the adhesive-free pull tab is disposed proximate the package
opening or flap.
[0035] 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. In another approach, package configuration
and shape can be primarily influenced by a gusseted side of the
package opposite the package opening.
[0036] In the art, some stand-up pouches have a tear notch or
scored film near the top of the package to begin propagation of a
tear in the film to expose a zipper joining adjacent film sides.
For the consumer, opening this type of package is a two step
process, and the opening process generates a separated piece of
package film to throw away. A zipper configuration can cause some
disadvantages in that it can tend to self recluse due to its
rigidity and the process used to seal it on a package. In other
words adjacent film sides tend to close towards each other rather
than maintaining an opening to allow a consumer to easily access
product. Zippers can also require a thick sealant web to provide
caulkability around the zipper in the seal area to minimize leaks.
Further, zippers can require a higher gauge film to support the
zipper structure, requiring extra weight and material to form the
package. In the present embodiments, given that a zipper is not
needed, a thinner gauge film can be used, thus further reducing
cost, waste, and materials. For example typical zipper package
applications can use a tri lamination film of 3 plus mils gauge in
thickness. In this instance, the sealant alone can be 1.5 mils
thick. In contrast, for illustrative purposes, the present film can
be in the range of about 1.2 to 5 mils, and preferably in the range
of about 1.5 to 2.5 mils. Accordingly, this can represent an
approximately 50 percent reduction of package materials over zipper
packaging.
[0037] Provided herein are specific package embodiments in the form
of a flexible reclosable stand-up pouch. The stand-up feature can
be provided by gusseting one side (here the bottom) of the package
when the package is vertically formed filled and sealed. In some
embodiments, the film can be sat, then covered by a continuous
label tape laminated to the film by a resealable adhesive. The
continuous label can preferably have a non-adhesive portion to
provide a peel tab.
[0038] One of the advantages of some embodiments is that the
package tends to stay open to facilitate access to the contents. In
some embodiments, the package does not require a thick sealant
layer because the reseal feature is on the outside of the film.
Other advantages of some embodiments are that they can provide for
immediate consumption of food products. For example, in some
embodiments, the flexible film package is easy to open, easy to
recluse, allows hand to mouth consumption, provides an opening big
enough to accommodate a typical adult consumer's hand, and has
resealable adhesive exposed only on one side. Consumers often
position snack bags and pouches in a car cup holder or on a desk,
or carry them while walking. When some embodiments of the pouch are
opened, they will retain an opening until a user closes it by
pressing the exposed resealable adhesive against the adjacent side
of the opening. In some embodiments, the exposed resealable
adhesive area can be easily folded down out of the way to help
avoid contact with users' fingers, and to prevent portions of
particulate product or product crumbs from being retained on the
adhesive and compromising its effectiveness.
[0039] A method for producing flexible film packages described
herein may include forming a score in a portion of a continuous web
of flexible film having a horizontal axis and then applying a
continuous substrate such as a closure layer (continuous label)
along the package horizontal axis with a resealable adhesive. By
one approach, the continuous closure layer may be continuously
applied over a partial width of the continuous web of flexible
film. The method also may include forming a continuous horizontal
seal from two edges of the continuous web of flexible material that
are brought together, and forming a first side seal and a second
side seal. In one approach, an adhesive-free grasping portion may
be formed at or adjacent a first (e.g., top) end of the flexible
package. The flexible packages may be formed in off-line and
in-line processes and also may be formed in both horizontal and
vertical form-fill-seal operations, among others.
[0040] As used herein, continuous application of the label,
flexible film, or adhesives indicates that the application of these
is uninterrupted along the direction of application. Further, as
used herein, a continuous package label may extend the entire
length or width of the package and is uninterrupted from one edge
of the package to an opposing edge. Alternatively, a discrete
package label covers only a portion of the width and length of the
package and does not extend across the entire width or length of
the package. By one approach, a continuous label web may be
continuously applied to a film web, which is then formed into
packages having a continuous package label. By another approach, a
discrete package label may be applied in a continuous application
such that a continuous label web is applied to a film web. In such
a configuration, a label cut, such as a top cut, may be formed in
the continuously applied label web. The label cut may define a
shaped package label and the portion of the continuously applied
label that does not form the shaped package label (i.e., the unused
label matrix) may be removed from the flexible film web. Thus, a
portion of the continuously applied label web may be removed from
the film web to thereby form discrete package labels disposed on
the film web.
[0041] 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 a continuous substrate with the continuous
film web across less than the entire predetermined width. By one
approach, the continuous film web may be scored to define what will
become an opening in the film web when the substrate is removed
from the continuous film web and an adhesive, such as a resealable
adhesive that provides a degree of releasability and reclosability,
is provided between the continuous 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 by joining longitudinal
edges of the continuous film web (which as described becomes a
horizontal fin or lap seal parallel to a top opening of the
package), and leading and trailing side seals may be provided
between adjacent packages of the series.
[0042] The series of flexible packages 20 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.
[0043] 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 layers of material. The laminate structure may
include, for example, one or more layers to provide strength and
toughness, and one or more layers to provide oxygen and/or moisture
barrier properties.
[0044] The laminate may include, e.g., a polyethylene terephthalate
(PET) layer and/or an oriented polypropylene (OPP) layer, and/or
other materials. Other 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. In some embodiments,
the flexible film can be a printed laminate such as a co-extruded
polypropylene laminated to a heat sealable polypropylene. 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.
[0045] 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 may
further strengthen the flexible film and enhance its barrier
properties.
[0046] The flexible film package may include a score that will
define a package opening when ruptured. 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 (e.g., 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. If partially cut through the film, the
score also may be formed on either or both sides of the flexible
film such that the score may be cut into the exterior or interior
surface of the flexible film, or both. 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 resealable adhesive. In addition, the
score may also 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.
[0047] By one approach, the elongated closure layer can be disposed
or continuously applied upon the flexible film. In some embodiments
the closure layer can be over the score such that there are
generally no disruptions in the elongated closure layer, and no
portions where the flexible film lacks the elongated closure layer
along one axis of the film. The elongated closure layer may
comprise a label such as a discrete label with a backing, a release
liner or a linerless label. The label can be a bi-axially oriented
polypropylene (BOPP) having a thickness in a range of about 1.2
mils to 5 mils, to note one option. In another configuration, the
elongated closure layer may include a second flexible film with
resealable adhesive disposed between the first flexible film and
the second flexible film. As discussed below, the resealable
adhesive may be an interstitial layer to a laminated film structure
such that the resealable adhesive is laminated between the first
and second flexible film layers. In yet another configuration, the
elongated closure layer may comprise a tape that is continuously
applied over the flexible film along the longitudinal axis of a
continuous roll of film.
[0048] The package opening is preferably reclosable such that at
least a partial seal is obtained around the opening. In some
configurations the reclosable/resealable opening may be
substantially hermetic prior to initial opening. The resealable
adhesive between the flexible film and the elongated closure layer
helps produce the reclosing characteristics of the package opening.
The resealable adhesive may be suitable for resealing in a variety
of conditions, such as room temperature and refrigerated
conditions.
[0049] Referring initially to FIG. 1, an illustrative flexible
package 20 is shown. As shown, flexible package 20 is formed from a
film 21 having side seals 22 that join a front package panel 40 and
rear package panel (back panel) 42; a continuous closure layer 24
(shown here as a continuous label) extends the entire width of
package 20; a score line (shown here as a continuous score line)
26; a gusset 30 formed by a gusset fold 28 (See FIGS. 2-5 and 7-8)
and front panel gusset fold 60 and rear panel gusset fold 62; a top
fold line 34; a fin seal 32 (See, FIG. 5); and product 36 (See
FIGS. 4 and 6). The continuous closure layer 24 is laminated to
film 21 by a resealable adhesive 44 (See FIGS. 3-4, 7 and 16). In
the embodiment as illustrated, a portion of the continuous closure
layer 24 does not have a resealable adhesive 44 exposed to film 21
to form a pull tab or tack free gripping portion.
[0050] This non-resealable adhesive gripping region 38 of the
continuous closure layer 24 can be formed by a variety of means.
For example, a second deadening label (as shown in FIGS. 3 and 4)
may be applied to resealable adhesive 44. Alternately, a coating or
other adhesive deadening means, such as an ink coating or heat
inactivation, may be applied to select areas of the adhesive side
of label by an adhesive deactivating device in-line or prior to
forming the package in a label roll. Further, such adhesive
deactivation may be done in a pattern-applied approach and, indeed,
the adhesive application may also be pattern-applied. The adhesive
deactivating process can also include an adhesive coating
applicator, which can be positioned anywhere along the line before
being laminated to film. Adhesive coating applicator can apply
adhesive in either a machine direction or even zone applied, such
as in a transverse direction. In the instance of a zone application
of an adhesive, the adhesive coating step can be eliminated.
Accordingly, neither deadening label, nor an adhesive deadening
device would be needed if the adhesive on label 24 is pattern
applied so as to have a portion free of adhesive.
[0051] In any event, the non-resealable adhesive region 38 of
continuous closure layer 24 is not laminated to film 21 and can
allow a user to slide a finger therebetween to form a peel tab (See
e.g., FIG. 3). In use, the peel tab formed by non-resealable
adhesive area 38 can be gripped by one of the user's hands while
the top fold 34 is gripped by the other hand. The user may then
pull the tab 38 away from the top fold 34, thereby peeling the
continuous closure layer 24 from an upper portion 41 of the front
panel, rupturing the front panel along score line 26 to provide an
opening 48 for the user to gain access to the products contained
therein as shown in FIGS. 6 and 7. The portion of the film of the
front panel not pulled by closure layer 24 (top portion 41) may
then be pushed back so that products may be manually withdrawn
between upper portion 41 and the peelable closure layer 24. Closure
layer 24 may subsequently be used to recluse a lower portion 43 of
the front panel with the top portion 41 to help provide containment
for the food product. The adhesive seal between the peelable
closure layer 24 and upper portion 41 may be resealable so that, if
desired by the consumer, the package may be reclosed or resealed by
pressing the closure layer 24 and upper portion 41 back together
after initial opening, and if an appropriate adhesive is used, and
if the adhesive remains effective, the package may then be reopened
and reclosed multiple times.
[0052] The continuous flexible film web 21 has a width and a
longitudinal axis along the width of the packages formed therefrom.
An elongated or continuous closure layer 24 is continuously
laminated along the horizontal width of the package blanks to a
portion of the width of the continuous flexible film web 21. For
example, the continuous closure layer 24 may be laminated
substantially along the entire longitudinal axis of the continuous
flexible film web 21, so that it will extend across the entire
width of the package 20. Although a continuously applied label may
be employed, a discrete label can also be used, such as closure
layer (label) 24i shown in FIG. 14. A resealable adhesive 44 (which
is shown as exposed in FIGS. 7 and 13) is laminated between the
continuous flexible film web 21 and the continuous closure layer
24. The resealable adhesive 44, like the continuous closure layer
24, may be continuously laminated between the continuous flexible
film web 21 and the continuous closure layer 24 so that there are
no areas without the resealable adhesive between the two layers
except for the non-resealable adhesive tab 38. A line of weakness
or frangible region, such as a score line 26 may be formed in the
continuous flexible film web 21 to form a pre-configured opening in
the front panel 40 when the continuous closure layer 24 is pulled
away from the upper portion 41 of the front panel.
[0053] More specifically, score 26 can be formed into the flexible
film 21 and may define the package opening 48 once the flexible
film package 20 (FIG. 1) is initially opened. As mentioned above,
score 26 may be formed in a variety of operations, including, for
example, mechanically-formed, laser-formed, or any other forming
operation that compromises the integrity of the film without
rupturing it. Score 26 may be formed on the interior or exterior
surface of the flexible film. In addition, score 26 may be disposed
partially through the thickness of the flexible film (a partial
depth score line) or through the entire flexible film thickness (a
full depth score line). Score 26 may be formed before the
continuous closure layer 24 is applied to or merged with the
flexible film 21 or after elongated continuous closure layer 24 is
applied to flexible film 21. If score 26 is formed subsequent to
application of continuous closure layer 24, score 26 may be formed
through the flexible film 21 (from the interior surface) and into
resealable adhesive 44. In one approach, score 26 may be formed
through flexible film 21, the resealable adhesive 44 and into
continuous closure layer 24.
[0054] In some embodiments, film 21 may be pre-scored to define the
tear lines to create an opening on a vertical formed and filled
package as the label is pulled out from the package. Pre-scored
means that the film is scored as it is rolled to form a film roll
of package blanks prior to forming and filling. Score 26 may
maintain the seal of the flexible film package prior to opening,
such that the flexible film 12 is not completely scored through the
entire depth. Alternatively, the score 26 may extend through the
flexible film 21 such that the continuous closure layer 24
substantially provides the seal prior to initial opening of the
flexible package.
[0055] A variety of score configurations are anticipated and a few
examples are provided herein for exemplary purposes. The particular
score configuration employed for a given flexible film package may
depend on the products being packaged, whether a structural support
is being incorporated into the flexible film package, and the
manufacturing equipment available, among other concerns. By one
approach, score 26 defines a package opening that permits hand
access by a user to the entire contents of the package within the
flexible film package upon initial opening of the package. In one
approach, when the elongated closure layer 24 is peeled to the end
of the score 26 to expose the entire score 26, it is anticipated
that a user may access (i.e., remove from the package) any of at
least seventy percent of the product within the package. This gives
the consumer access to a substantial portion of the products within
the flexible film package just after initial opening.
[0056] FIG. 1 illustrates the score line 26 as a straight
continuous score. FIGS. 9 through 14 illustrate addition types of
score line configurations. Other types of continuous score lines
are shown in FIGS. 12 and 13. Alternate non-continuous score lines
are shown in FIGS. 9, 10, 11 and 14. `Smiles` 50 can help prevent
the score 26 from propagating or continuing to tear the flexible
film 21 (See e.g., FIG. 11). Also, package integrity features
(PIFs) 52 can be added as shown in FIG. 13. In this instance the
film tears the PIFs on initial opening to indicate that it has been
previously opened.
[0057] FIGS. 8 and 17 provide a front view and cross-sectional view
respectively according to one approach where film 21 is a laminated
film. In this approach, package 20 package can form a label from a
laminated film 21. In this embodiment, film 21 can be at least two
polymer film layers attached with a resealable adhesive 88. A first
film layer (outer layer) can have a top cut score to form a label,
while a second film layer (directed to the interior of the package)
may have a score to define an opening. Scoring can occur before or
after laminating film layers, but preferably after lamination. In
this instance, overall film thickness can be in the range of about
1.8 to 3 mils, and preferably about 2.1 mils. Specifically, in this
approach a film top cut 82 provides an opening score line to form a
package flap 86. Area 84 may be a non-resealable adhesive area and
score line 86 is a bottom cut of the laminate to define a package
opening. FIG. 17 shows a sectional view of 21 showing a resealable
adhesive layer 88 laminating two layers of film 21.
[0058] In the embodiment such as shown in FIG. 1, flexible film web
21, may be a laminate with several layers of material, including,
for example, a PET layer, an OPP layer, a PE layer, a MET OPP
layer, a PP layer, and/or a PLA layer, to note a few options. These
layers may be joined by adhesives or by an extrusion process. In
some embodiments, the flexible film can be a printed laminate such
as a co-extruded polypropylene laminated to a heat sealable
polypropylene. Alternatively, the flexible film web 21 may be a
single layer polymer. Since the flexible film package is at least
partially hermetically sealed, the flexible film web preferably
provides a gas and moisture barrier. Generally, the flexible film
web 21 may be about 0.012 mm and 0.25 mm in thickness. In one
illustrative embodiment, the flexible film web 21 may be about 0.05
mm to about 0.18 mm in thickness. The thickness of the film may be
a function of the desired barrier to gas, moisture, and light,
along with the level of desired structural integrity, the desired
depth of score line, and the available manufacturing equipment.
[0059] Flexible film web 21 may be a heat sealable copolymer. In
some configurations, the heat sealable polymer forms a seal between
50 and 300 degrees Celsius. Flexible film web 21 also may be a
pressure sealing film. In one configuration, the pressure sealing
film forms a seal between a pressure of about 0.7 and 7.0 kg/cm. By
one approach, the pressure sealing film forms a seal at about 5.6
kg/cm.
[0060] In addition to the various laminate layers mentioned above,
additional laminate layers such as sealants, stiffeners, ink,
release layers, also may be incorporated into the laminate
structure. For example, a sealant layer can be added to facilitate
the formation of seals that enclose the product. By one approach,
the sealant layer may be oriented on the film surface directed to
the interior of the package (interior-facing surface). The sealant
layer may be a variety of polymer sealants, such as a heat
activated polymer sealant layer like ethylene vinyl acetate (EVA),
ionomer plastic (such as that sold under the trade name SURLYN by
DuPont), metallocene, and organoclay, among others. In addition,
cold sealant and pressure sealants also may be used with the
configurations disclosed herein. If the products within the
flexible film package are food products, then it is noted that food
grade sealants would be employed.
[0061] In one configuration, stiffeners may be added to flexible
film 21 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 21. 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 eight percent of the film
thickness or about 0.004 mm. In some embodiments, the film may be a
laminate of polyethylene terephthalate and oriented polypropylene
having a thickness in a range of about 1.5 to 2.5 mils. More
specifically, in another approach the film may be a laminate of
polyethylene terephthalate having a thickness in a range of about
0.4 to 1.0 mils and oriented polypropylene having a thickness in a
range of about 0.6 to 1.2 mils.
[0062] As noted, an ink layer may be formed into the laminate as an
additional laminate layer. For example, one specific laminate can
include ink and a primer disposed between other film layers such as
a PET layer and an OPP layer. Other additional layers may include a
metalized layer, as noted above, and a release layer.
[0063] By one approach, closure layer 24 is continuously applied
along the flexible film 21 such that continuous closure layer 24
extends from one side seal to another side seal once the flexible
film package 20 is formed. Furthermore, closure layer 24 extends
only partially over the width of the flexible film 21 that forms
the film package 20. It is also contemplated, however, that
continuous closure layer 24 may extend the entire width of a
package but only be partially disposed over the height of the
flexible film 21. More particularly, continuous closure layer 24
preferably does not extend both the entire width and the entire
height of the package. Continuous closure layer 24 can be partially
disposed in either direction (i.e., the length or height) and
continuously disposed in the other of the directions. In one
approach, closure layer 24 is continuously applied along one axis
of the flexible film and is only partially applied along the axis
normal to the continuously applied axis. Thus, the flexible film
packages 20 may have an elongated closure 24 that runs the entire
length of the package and over only a portion of the width or an
elongated closure layer 24 that runs the entire width of the
package and over only a portion of the length of the package.
[0064] FIGS. 3, 4 and 7 show cross sections of the flexible film
along line section line III-III in FIG. 2, section line IV-IV in
FIG. 2, and section line VII-VII in FIG. 6 respectively. These
figures illustrate a resealable adhesive 44 between the flexible
film 21 and the closure layer 24 (though resealable adhesive 44 is
exposed in FIG. 7).
[0065] Closure layer 24, which is laminated to the flexible film 21
and covers score 26, permits easy manual opening of the flexible
package 20. In one embodiment, closure layer 24 can be formed such
that the flexible package 20 has a peel tab or tab portion 38 (See
e.g., FIG. 14). More particularly, a tab portion 38 may be formed
by closure layer 24 in an unsealed area of closure layer 24
extending to the top fold line 34, allowing a user to grasp and
peel open the upper layer of the peelable seal, i.e., the elongated
closure layer 14.
[0066] In one approach, side seals 22 and fin seal 32 are
film-to-film seals and may be considered primary seals and are
oftentimes permanent or destructive seals. Closure layer 24 also
forms a seal with the flexible package 20 and may be considered a
secondary seal. The secondary seal is reclosable and generally is
not destructive. In one illustrative embodiment, the peel force
required to separate the primary seals (primary peel force) is
higher than the peel force required to separate the secondary seals
(secondary peel force).
[0067] In one example, the flexible film package 20 has primary
seals including side seals 22 and longitudinal fin seal 32, along
with a secondary seal formed from closure layer 24 over the width
of the flexible film package 20. The secondary seal is formed, in
part, by the resealable adhesive 44 disposed between the closure
layer (a continuous label) 24 and the flexible film 21. In use,
package 20 can be opened by a user by grasping the tab portion 38
(FIG. 1) and pull outward from the package to separate the
continuous closure layer 24 from the flexible film 21 to expose
package opening 48. By one approach, the primary seal has a peel
force that is 200-300 grams/inch.sup.2 higher than the peel force
of the secondary seal. In another configuration, the difference in
peel forces may be between 100-400 grams/inch.sup.2.
[0068] The resealable adhesive 44, which is disposed or applied
between the flexible film 21 and closure layer 24, may have a
variety of strengths and compositions. By one approach, the
resealable adhesive has a higher bonding strength than the strength
required to tear or separate score 26. In such a configuration, a
user may pull outward or downward relative to the top of the
package, to expose package opening 48, remove the desired amount of
product, and then reclose the package using the resealable
material. A user need only pinch the front panel 40 and back panel
42 in the direction 64 as indicated in FIG. 7. By one approach, the
resealable adhesives may have a variety of thicknesses. For
example, the resealable adhesive could be between about 0.2 mils to
1 mil thick and, may be even thicker.
[0069] FIG. 15 shows exemplary blanks from a roll of film 21 for
use in forming a package 20. In one configuration, flexible film 21
has a first edge portion 54 and a second edge portion 56. The edge
portions 54, 56 may be brought together and formed into a
longitudinal seal, such as fin seal 32 extending from a first side
seal 22 to a second side seal 22 as shown in FIG. 5. The
longitudinal seal also may include a lap seal. It is also noted
though that the package may be configured such that the
longitudinal seal runs along the height of the package as well.
This would be in lieu of top fold line 34. A separation cut 58 line
region (see FIG. 15) is shown to define the edges of side seals 22
of package 20. See below discussion associated with FIG. 16.
[0070] As shown in FIG. 15, a closure layer 24 is continuously
laminated to film 21 in the machine direction. Prior to lamination
of closure layer 24, a non-resealable adhesive area (tab 38) is
formed. Score 26 may be cut into film 21 prior to or after
lamination with closure layer 24, but preferably after lamination.
Fold lines 62 and 34 show where back panel 42 is formed. Fold lines
60, 62 and 28 show where folds are positioned to form a package
gusset 30. Fold lines 60 and 34 show where front panel 40 is
formed.
[0071] Turning now to FIG. 16, there is shown diagrammatic
illustration of one approach to forming a package 20. In this
approach, package 20 is prepared using a modified vertical form,
fill and seal package machine for forming, filling, and sealing
bags of chips, cookies, and other like products and is generally
shown at 100. Packaging machine 100 shown in FIG. 16 is simplified
for ease of understanding and does not show, support structures and
control systems that typically surround this type of machine.
Nevertheless, FIG. 16 is provided to generally demonstrate one
example of a working machine to form packages of some of the
present embodiments. Desired methods to manufacture the flexible
pouches may affect the particular seals, folds, and various other
features of particular flexible pouches. A variety of manufacturing
methods are available to commercially produce the flexible pouches
and FIG. 16 provides but one such example.
[0072] As shown in FIG. 16, a film 21 package blanks (such as shown
in FIG. 15) are taken from a film roll 102 and passed through a
tensioner 104 to keep the film taut. Film 21 passes through
tensioner 104 pulled by drive belts (not shown) in the direction
shown at 112. A scoring device 122 can score the film to form score
line 26. It is also noted that score line configurations as
described herein could also be pre-applied to the film roll 102
during its manufacture as well as after applying a continuous
label.
[0073] In any event, at tensioner 104, label 24 is laminated to the
film by a resealable adhesive 44 that is preferably pre-applied to
the label roll 114. Thus, as film 21 is passed through tensioner
104, a closure layer 24 (label) is continuously applied from a
label roll 114. Label roll 114 as shown can be a linerless roll,
but label rolls with liners could also be used. It is also noted
that in other approaches, label 24 need not be a continuous label,
but can be indexed and discretely applied during forming of the
package, or pre-applied to film roll 102 during the manufacture of
film role.
[0074] Prior to lamination of the label to the film, label 24 has a
portion of the resealable adhesive deadened, covered, or removed at
deadened. The deadened resealable adhesive area of the label is
used to provide a peel tab 38 to allow a user to pull the label
from the formed package. As shown for this approach a resealable
adhesive deadening device 116 can be used. Deadening device 116 can
be configured to operate in a variety of ways such as folding a
portion of the label over itself, apply a deadening agent, apply a
print layer, or in embodiments using labels with liners to strip
away the liner to expose a portion of the label and to retain the
liner in the tab portion. In some embodiments, device 116 could
also be used to apply resealable adhesive to a label without
resealable adhesive and leave a portion of the label unapplied.
[0075] Next, the packaging machine 100 can pull the scored
film/label laminate over a forming shoulder 120 such as a forming
collar and mandrel to provide it with a tubular shape. Opposite
longitudinal edges (see 32 in FIG. 15) of the film may be brought
together around a product fill tube 106. The longitudinal edges are
sealed, such as by a seal tool 108, to form a fin seal, or
overlapped to form a lap seal. In this configuration, the fin seal
32 is used to form a fin seal running parallel to the top of the
package. In this instance, the film may have a heat activated layer
to the side of the film directed to the interior of the package and
seal tool 108 continuously forms a heat seal.
[0076] Gusset 30 of the preferred flexible package can be formed at
a gusseting device 118, which forms the film with the gusset fold
28 and the fold lines 60 and 62 of the package front and rear
panels respectively.
[0077] Side seals 22 for package 20 can next be formed by a
reciprocating sealing tool 110, which may include a pair of
reciprocating sealing bars. The reciprocating sealing bars can be
heat sealing bars maintained at a desired temperature to apply heat
and pressure to the front and rear walls of the film. The film in
this instance would have a heat sealable layer as described above
on the film surface directed to the interior of the package. The
heat seal bars 110 are brought together on opposite sides of the
gusseted tubular web so that heat is conductively transferred to
the film from both sides while pressure is applied. The sealing
bars may be used in an intermittent or continuous operation. In an
intermittent operation, the film is stopped while the sealing bars
engage the film. In a continuous operation, the sealing bars may
move vertically at the machine speed as they engage the film. In
addition, sealing tool 110 may contain a reciprocating knife which
acts to separate the bottom pouch from the upper pouch along cut
line 58. Once the operation is complete and the upper pouch with
one side seal formed can be has been filled with product 36 on the
side where the second side seal will be formed in the next machine
cycle. Accordingly, the upper pouch advances downward and becomes
the bottom pouch in the next machine cycle. In addition to sealing
the pouches, the sealing tool 110 may also be used to impart other
desired package folds.
[0078] Thus, the sealing tool 110 may perform a variety of
functions simultaneously, including: creating the bottom seal of
the pouch that is about to be filled with product; and having a
reciprocating knife or cutting tool which separates the pouch that
was just filled from the following one which is about to be filled.
Accordingly, after a bottom seal (and any optional fold) is formed
in the flexible pouch, the partially formed flexible pouch can then
be filled with food product, which is introduced into the pouch via
the fill tube 106.
[0079] There are a variety of alternative steps to those described
in this vertical FFS operation. Also, high speed techniques may be
employed instead of application of heat and pressure by heat seal
bars as described above. For example, RF energy, ultrasonic energy
or other techniques may be employed to form the edge and fin
seals.
[0080] While preferred embodiments have been described in detail,
variations and modifications can be effected within the
configurations described herein.
* * * * *