Note: Descriptions are shown in the official language in which they were submitted.
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STRUCTURED RECLOSABLE PACKAGING
CROSS-REFERENCE TO RELATED APPLICATION
This application is related to U.S. Patent Application Serial No. 09/69,009,
filed October 26, 2000, entitled "CUTTING AND LAMINATING APPARATUS FOR
PRODUCING REINFORCED WEB," and U.S. Patent Application Serial No.
60/410,149, filed September 12, 2002, entitled "FLAT-BOTTOMED RECLOSABLE
PACKAGE WITH GUSSETS."
BACKGROUND OF THE INVENTION
The present invention relates to reclosable packaging with interior support,
and
manufacturing processes for the same. More specifically, the present invention
relates
to packaging that may include properties of both a reclosable/resealable bag,
but more
specifically the characteristics of a structured canister that provides
support and
protection to the contents of the packaging. The packaging of the present
invention
may be used to contain foodstuffs in a structured and supported manner that
has the
outward look and feel of a flexible bag.
Various existing packaging designs provide a reclosable feature that allows
the
contents of the packaging to be accessed multiple times and closed after each
time the
packaging is opened. For instance, for the purposes of food packaging,
flexible bags
and rigid canisters both provide distinct benefits. Bag-like designs offer
flexible,
lightweight packaging, which can be resealed with a plastic wrapping film or
adhesive.
Canister-like designs offer a more supportive container, which can be reclosed
with a
lid that is snapped or screwed into the body of the canister. Other packaging
exists that
offers some of the advantages of these designs, such as pouch packaging, which
is
flexible like a bag but can stand upright like a canister.
These existing packaging designs satisfy the basic goal of providing a
reclosable enclosure for foodstuffs. However, the designs fail to address
certain needs
of the modern consumer. For instance, the bag designs offer little if any
protection for
the contents they enclose. Further, bag packaging generally cannot maintain a
predetermined shape or configuration, nor stand upright. While pouch packaging
can
usually maintain its upright position, it fails to offer strong protection for
its contents.
Pouch packaging typically requires more side seals than exist on standard bag
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pacleaging, thereby incurring additional time and expense for the
manufacturing process
of pouch packaging.
Canister designs typically provide more support and protection to their
contents
than bag designs, but available canisters have a limited number of shapes or
configurations and are restricted in the types of reclosable lids they can
use. Perhaps
even more significant, canister designs require dense materials that are
expensive to
acquire, manufacture, and transport.
In order to provide a case effective flexible reclosable package that
maintains a
predetermined shape while offering strong protection for the contents, it is
contemplated that improvements are needed before consumers are provided with a
plastic bag that meets their needs. These improvements must relate to
structured
packaging of the present invention that minimizes the materials required for
producing
each bag and reduces the overall production expenses by decreasing the number
of
manufacturing steps. Additionally, the present invention provides a reclosable
structured packaging that is not limited to the methods of enclosing rigid
canisters.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In order to provide cost effective, bag-like rigid packaging and an efficient
method for manufacturing the same, the present invention provides flexible
packaging
with an interior support that is able to contain products such as snacks,
confections, pet
foods, and liquids. The structured packaging of the present invention provides
for a
bag that has been appropriately sheared and reinforced. The bag has a
supportive
structure affixed inside the package that can~supply support for the product
and provide
a method for keeping the package open for easy access or pouring.
Additionally, the
bag may have a reclosable top portion that encloses the contents of the bag.
The bag of the present invention is preferably formed from a primary web,
wherein a reinforcing material is utilized to selectively reinforce portions
of the bag.
Reinforcing the bag material is particularly useful at sealing points,
reclosing points,
and other locations on the bag that require additional strength and
durability. Because
the overall exterior of the packaging is created from a bag sheared of various
webs, the
manufacturing of the pacleaging requires fewer steps than lenown packaging
designs.
For instance, pouch packages are typically manufactured from webs as well but
require
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multiple side seals, which involve additional manufacturing. The packaging of
the
present invention can provide an upright bag that requires only a single side
seal.
The supportive structure inside the bag may be formed from a variety of
materials, such as a flexible film packaging, into a variety of shapes. The
support
structure is a rigid material that may be manipulated into predetermined
shapes and
configurations using both known methods and those disclosed herein for
manufacturing
packaging. For example, the support may be a heat-sealable structure that is
manipulated using laser scoring. The support structure in its final state is a
relatively
rigid body that has been formed into a predetermined shape, such as a box or
tube.
Alternatively, the support structure may be individual components that, when
incorporated into the package, will form the desired structure.
When the supportive structure is appropriately formed, it is affixed to the
inside'
the primary web such that the bag and structure is formed, and the supportive
structure
is in the lower portion of the bag so that the bag encapsulates the support.
The support
is generally borne by the bag and fits snuggly therein such that the bag fits
around the
exterior of the support and substantially conforms to the shape and
configuration of the
support. The support may be heat sealed or sealed via other methods, i.e.,
pressure
sensitive adhesive, spray adhesive, ultrasonic and the like, to the bag to
ensure that the
support is properly retained therein. The upper portion of the bag may extend
beyond
the height of the support such that the upper portion of the bag is flexible
and has the
general characteristics of a bag without such support.
The support structure can either conform to the bag's shape or take a shape
distinct from that of the bag. For instance, the packaging may take on a "box-
in-a-bag"
structure, where the support has a square or rectangular shape and the bag has
a round
shape, or the bag conforms to the support's rectangular shape. Alternatively,
both the
support and the bag may have a round shape, where the support is a tube-like
structure
and the round bag fits around the support. A variety of different shapes is
contemplated
being used for both the bag and the support structure while keeping within the
teaching
of the present invention.
In addition to the supportive structure inside the bag, the upper portion of
the
bag material may constitute either a reclosable or non-reclosable opening.
Where the
bag is recloseable, the reclosable means may be achieved with a plastic
wrapping film,
a zipper lock, resealable adhesive strips, easy-snap technology or any number
of bag-
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closing approaches. Any of the existing methods of enclosing bag packaging are
applicable.
Accordingly, the present invention provides a cost effective rigid packaging
that
maintains the versatility and manufacturing benefits of a more flexible
bag/package.
The structured packaging of the present invention minimizes the materials
required for
producing each bag and reduces the overall production expenses by decreasing
the
number of manufacturing steps. Additionally, the present invention provides a
reclosable structured packaging that is not limited to the methods of
enclosing rigid
canisters. Any of the existing methods of enclosing bag packaging are usable
with the
structured packaging of the present invention. This and other benefits of the
dual
nature of a structured bag are achieved by the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully and completely understood from a
reading of the Detailed Description of the Invention in conjunction with the
drawings,
in which:
Figures 1A and 1B are a top and side view, respectively, of one embodiment of
a reclosable package according to the present invention;
Figure 2 is a perspective view of another embodiment of a reclosable package
with a supportive structure where the top portion of the package is in a
closed position;
Figure 3 is a top view of the reclosable package of Figure 2 with a supportive
structure where the top portion of the package is in an opened position; and
Figure 4 is an interior view of a reclosable package with a supportive
structure,
showing the supportive structure in more detail.
Figure 5 is a first view of an alternative embodiment of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in Figures 1A and 1B, a flexible package (bag 1) with a supportive
structure 2 built into the package. The supportive structure 2 is
appropriately formed
and affixed to the lower portion 4 of bag 1 such that the bag encapsulates the
support as
shown. Preferably, the support for the supportive structure 2 is generally
borne by the
bag 1, and the supportive structure 2 fits snuggly therein such that the bag 1
fits around
the exterior of the supportive structure 2 and substantially conforms to the
shape and
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configuration of the supportive structure 2. The supportive structure 2 may be
heat
sealed, or the like, to bag 1 to ensure that supportive structure 2 is
properly retained
therein. The upper portion 6 of bag 1 may extend beyond the height of the
support 2
such that the upper portion 6 of bag 1 is flexible and has the general
characteristics of a
bag without a support. For instance, the support may be 3'/2 inches in height,
while the
bag may extend upward beyond the top of the support an additional 4%z inches.
The
lower portion of bag 1 is shaped into a structured form that may give the
packaging the
ability to stand upright and protect its contents. The lower portion 4 of bag
1 may have
any practical shape, such as square or rectangular, that provides stability
and balance to
the packaging. The upper portion 6 of bag 1 maintains bag-like characteristics
and is
not given the same structured form as lower portion 4. This configuration
offers more
protection to the contents of the packaging than a regular unstructured bag.
The upper portion 6 of bag 1 may constitute either a reclosable or non-
reclosable opening. It is contemplated that the upper portion of the bag may
be
gusseted or not. Where the bag is recloseable, the reclosable means may be
achieved
with a plastic wrapping film, a zipper lock, resealable adhesive strips, or
any number of
bag-closing approaches. For example, as shown in Figure 1A and 1B, easy-snap
technology 8 is used as a reclosable feature. The easy-snap technology is
disclosed in
LT.S. Patent Nos. 6,350,057, 5,983,594, 5,944,425, 5,937,615, 5,928,749 and
4,679,693,
all to Forman, and is incorporated herein by reference. As described herein,
the
reclosable portion of the bag may be created by selectively reinforcing parts
of the main
bag web with sheared reinforcing strips 18 that are laminated to the main bag
web, as
discussed in more detail below. See, Figure 5.
The supportive structure can either conform to the bag's shape or take a shape
distinct from that of the bag. For example, the packaging may take on a "box-
in-a-bag"
structure, where the support has a square or rectangular shape and the bag has
a round
shape or conforms to the support's rectangular shape. See Figures 2-4. As
shown, bag
15 has a supportive structure 26 that has a square or rectangular shape, may
be
manufactured by scoring the supportive material at the fold locations. Various
scoring
methods will achieve the appropriate folds, including the laser scoring as
previously
described.
Alternatively, as shown in Figure 5, both the support 18 and bag 19 may have a
round shape, where support 18 is a tube-like structure and rounded bag 19 fits
around
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support 1 ~. A variety of different shapes are contemplated being used for
both the bag
and the support while keeping within the teaching of the present invention.
The supportive structure of the present invention inside the bag can be formed
from a variety of materials, such as a flexible film packaging, into a variety
of shapes.
The support is a rigid material (relative to the primary web material) that
can be
manipulated into predetermined shapes and configurations by using both known
methods and those disclosed herein for manufacturing packaging. For instance,
the
support may be a heat-sealable structure that is manipulated using laser
scoring. The
support, in its final state, is a relatively rigid body that has been formed
into a desired
shape such as a box, as shown in Fig~.ires 2-4 or tube.
Alternatively, the rigid body may be comprised of specific components that are
configured to form the desired structure when incorporated into the bag. For
instance,
the rigid body may comprise two components that are fixedly attached to the
bag: a
first component that supports the left side of the bag and the portions of the
front and
back of the bag that are adjacent to the left side, and a second component
that supports
the right side of the bag and the portions of the front and back of the bag
that are
adjacent to the right side.
During assembly, the present invention as shown in Figures 1-5, may be formed
from a primary web, and support structure/reinforcing material is utilized to
selectively
reinforce portions of the bag. Reinforcing the bag material is particularly
beneficial at
sealing points, reclosing points, or any other locations on the bag that
require additional
strength and durability. One method of providing the desired support or
structure
includes using a primary web handling system and a secondary web handling
system, a
cross web shear, a strip handling system and a laminating device. The primary
web
handling system handles the main web of packaging material, or primary web,
which
will be reinforced, via the secondary web handling system for later
operations.
In order to provide the supportive structure/reinforcement, strips may be
produced from a secondary web and then laminated to the primary web.
Specifically,
the secondary supply web may be fed by the secondary web handling system and
provides reinforcing material to the cross web shear, which cuts the secondary
web into
reinforcing strips of selectable predefined width. Subsequently, the
laminating device
is then utilized to attach the reinforcing strip to the primary web at
appropriate
locations. More detail on the laminating process may be found in related
application
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U.S. Serial No. 09/698,009, filed October 26, 2000, entitled "CUTTING AND
LAMINATING APPARATUS FOR PRODUCING REINFORCED WEB", which is
incorporated herein by reference.
It is contemplated, to appropriately reinforce the primary web, the
reinforcing
strip/support structure can be relatively narrow and small compared to the
primary web,
and precisely positioned relative to the primary web. Lamination of the
reinforcing
strip to the primary web in the desired location is then easily accomplished.
While the
use of the above-described system is one way of efficiently reinforcing or
providing
structure to a package, other methods are also possible. For example, a pre-
dimensioned reinforcing tape, pressure sensitive adhesive, spray adhesive, or
ultrasonic
adhesive may be used. Alternatively, the primary web material may be
overlapped to
provide multiple layers at the desired location.
After the appropriate portions of the primary web have been reinforced, [the
web is sheared, if necessary, and then ]the bag is formed therefrom with, for
example, a
top seal, a bottom seal and a length-wise seal, as shown in Figures 1-5.
Referring to
Figures 2-4, the bottom of the bag 15 may be gusseted 20 to form a flat
surface 22 that
causes the package to stand up. The bottom seal 24 is made by first folding
the sides
26 of bag 15 towards the center thereof. While the sides are being held in
place, the
end of the bag is sealed to form a flat, square shaped surface that causes the
packaging
to stand upright. Another seal 28 may be formed length-wise along one side of
the
package to form the sides of the pack, defining the interior volume of the
bag. More
detail on a flat-bottomed stand up package may be found in Provisional
Application
Serial No. 60/410,149, filed September 12, 2002, entitled "FLAT-BOTTOMED
RECLOSABLE PACI~AAGE WITH GUSSETS", which is incorporated herein by
reference.
The top of the bag may be sealed in a manner consistent with existing vertical
form fill and seal technology (VFFS) and horizontal form fill and seal
technology
(HFFS). For example, in an VFFS environment, a flat, full-length seal across
the width
of the top of the bag is made. [Since there are no gussets in the top seal,
the]The
addition of a reclosable feature is possible where the bag material is
reinforced. The
reclosable feature of the present invention may be achieved with any
conventional re-
closing mechanism, such as a zipper, zipper-slider seal, easy-snap technology,
or
adhesive strips.
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A mechanical module, laser module, or the like may be used for scoring or
perforating the reinforcing strips and support structure. The module can also
be used to
cut, slit, or mark selected portions of the support or the primary web used to
form the
bag. The module can be easily integrated into a packaging machine used to
manufacture the present invention. More detail on laser scoring and
perforating may be
found in related application Serial No. 09/698,009, filed October 26, 2000,
entitled
"CUTTING AND LAMINATING APPARATUS FOR PRODUCING REINFORCED
WEB", as stated above.
Those skilled in the art will further appreciate that the present invention
may be
embodied in other specific forms without departing from the spirit or central
attributes
thereof. In that the foregoing description of the present invention discloses
only
exemplary embodiments thereof, it is to be understood that other variations
are
contemplated as being within the scope of the present invention. Accordingly,
the
present invention is not limited in the particular embodiments which have been
described in detail therein. Rather, reference should be made to the appended
claims as
indicative of the scope and content of the present invention.
