Note: Descriptions are shown in the official language in which they were submitted.
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RECLOSABLE FLEXIBLE FILM PACK,AGING AND METHODS OF MANUFACTURE
Related Applications
[0001] This appkation claims the benefit of United States Provisional Patent
Application Number 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
pi/low-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
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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 recloseireseal 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. 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
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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
terephtha/ate and
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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
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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. 'I illustrates a perspective view of an exemplary gusseted
vertical form
filled bag of the present embodiments;
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[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 /11-111 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 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 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;
[0028] Figs. 9-14 illustrate alternate score line and label embodiments of
exemplary
gusseted vertical form filled bags of the present embodiments;
[0027] Fig. 15 Hlustrates 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 of Fig. 8.
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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
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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 reclose 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 reciosing
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
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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 roil 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
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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
reclose 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
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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 reciose, allows hand to mouth consumption,
provides
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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 oft-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.
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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 reseaiable adhesive that provides a degree of
releasability
and reclosablility, 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,
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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
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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.
[00461 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
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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 reclosableiresealable
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.
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[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 pane/ gusset
fold 62; a
top fold line 34; a fin seal 32 (See, Fig. 5); and product 36 (See Fig. 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
17
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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
reclose 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
18
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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
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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
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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.
Figures 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,
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[00581 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
22
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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 organociay, 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 terephthaiate 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.
23
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[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
111-111 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).
24
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[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 gramsfinch2
higher than
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the peel force of the secondary seal. In another configuration, the difference
in peel
forces may be between 100-400 grams/inch2.
[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
26
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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
pan&
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,
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[00731 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 /00 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
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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.
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[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 sea/
(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.
