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