Note: Descriptions are shown in the official language in which they were submitted.
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R.ECLOSABLE FLEXIBLE PACKAGING AND METHODS FOR MANUFACTURING
SAME
Technical Field
[OM] This disclosure relates generally to flexible packaging and, in
particular, to flexible
packaging having a reclosable opening,
Background
[00021 Flexible packaging is well known in the art for use in containing food
products.
Flexible films can provide a lightweight package with a substantially hermetic
seal for shipping
and storage of a variety of food products, including, for exaniple, crackers,
chewing gum,
chocolate, cookies, cheese, sandwiches, biscuits, candy, meat products, and
dried fruits and
vegetables. Some of these flexible film packages also may contain structural
supports, such as a
frame or tray.
[0003] One example of such flexible film packages are tlow-wrap type packages,
which may
employ a continuous film or web to envelop a product during assembly or
formation of the
package. Flow-wrap packages may include, for example, horizontal or vertical
fin seal or lap
seal packages, end seal wrap, horizontal bagging and pillow-pouch packaging.
In one
configuration, flow-wrap packaging positions a flexible film (such as
polyethylene, polyethylene
terephthalate (PET) or polypropylene), adjacent a product, wraps the film
around the product,
forms a seal from the ends or edges of the film, and then forms seals at
either end of the product.
These seals may be permanent and also may provide some structural integrity.
Flexible film
packages have other advantages. For example, they can be. manufactured at
substantially lower
cost than rigid containers, are. lightweight (resulting in lower
transportation costs), and can
reduce space required for storage.
[0004] Despite the advantages of flexible film, these packages are sometimes
difficult for
consumers to open. Further, these packages often contain various amount of
food product, and a
consumer rnay not want to consume all of the food product at one time,
Therefore, a reclose
feature may be included to provide users with an easy, efficient manner of
preserving some of
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the food product for a later time. The reclose feature may provide a partial
barrier to moisture
and gas resulting in a partially hermetic seal, though it may not provide a
complete hermetic seal,
and may help to retain the shelf-life or .freshness of a food product
contained within the package.
[0005] The flexible packages that have a resealable or reclosure feature are
sometimes difficult
to manufacture on equipment that is widely available.. For example., some
flexible film packages
may require specialized die assemblies or heat seal bars to produce the seals,
package openings,
and other package features related to the reclose feature. Another drawback
with the
manufacture of some flexible packages is the common requirement of precisely
calibrated
manufacturing equipment. For example, packages and processes that employ a
pattern-applied
adhesive may require specialized equipment that may need to be properly
calibrated. As another
example, some laminate. structures may employ partial depth die cuts from both
the interior and
exterior surface of the laminate structure, which increases the complexity of
the equipment.
These processes also may require very precise registration of the. package
elements to ensure the
consumer is able to easily and reliably open the package and also to ensure
proper closure or
sealing of the flexible package.
[00061 In addition, previous package designs also tend to require additional
package material
to accommodate the. equipment and various manufacture and consumer
specifications. This
extra film or other material such as a label backing) often resulted in costly
waste, which
increases the cost of the packages.
Brief Description of the Drawings
[00071 FIG. I is a plan view of a section of a series of flexible. film
package blanks;
C0008] FIG. 2 is a cross sectional view of the laminate structure of the
flexible film package
blanks of FIG. 1 along line 2-2;
[00091 FIG. 3 is another configuration of the laminate structure;
[00101 FIG. 4 is a flexible film package formed of one of the flexible film
package blanks of
FIG. 1.;
NOM FIG. 5 is the flexible film package of FIG. 4 in a partially open
configuration;
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[U]
FIG. 6 is a cross sectional view of the flexible film package of FIG. 4 along
line 6-6;
I0013] FIG. 7 is a cross sectional view of the flexible filni package of FIG.
4 along line 7-7;
[00141 FIG, 8 is a plan view of a section of another series of flexible film
package banks;
[0015] FIG. 9 is a plan view of another .flexible film package;
[0016] FIG. 10A is a plan view of a section of another series of flexible film
package blanks;
[0017] FIG. 10B is a plan view of a section of another series of flexible film
package blanks;
[0018J FIG. 11 is a plan view of a section of another series of .flexible film
package blanks;
[00191] FIG. 12 is a flexible film package formed of one of the flexible film
package blanks of
FIG. 1.1.;
[0020] FIG. 13 is the flexible film package of FIG. 12 in a partially open
configuration;
[0021] FIG. 14 is a side view of another flexible film package;
[0022] FIG. 15 is a cross sectional view of the package of FIG. 14 in a closed
configuration;
1:002.3] FIG. 16 is a cross sectional view of the package of FIG. 14 in an
open configuration;
[0024] FIG. 17 is a schematic illustration of a manner of forming the package
of FIG, 14;
[00251 FIG. 18 is a plan view of a section of another series of flexible film
package blanks;
[0026] FIG. 19 is a flexible film package formed of one of the flexible film
package blanks of
FIG. 18;
[0027] FIG. 20 is a portion of the flexible film package of FIG. 19 in a
partially open
configuration;
[0028] FIG. 21 is a plan view of another flexible film package blank;
[0029] FIG. 22A is a plan view of another flexible film package blank;
[0030] FIG. 22B is a side view of a flexible film package;
[0031] FIG. 22C is a side view of the flexible film package of FIG. 228 in an
open
configuration;
[0032] :FIG. 22D is a plan view of another flexible film package blank;
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l:00331 FIG. 23 is a schematic view of a process of applying a closure layer
to a flexible film;
[00341 FIG. 24 is a cross sectional view of the laminate structure of the
flexible film of FIG.
23;
NOM] FIG. 25 is a cross sectional view of another laminate structure;
E00361 FIG. 26 is a schematic view of another process of applying a closure
layer to a flexible
film;
[0037I FIG. 27 is a schematic side view of an off-line process of forming a
series of flexible
film package blanks;
[OM
FIG. 28 is a schematic side view of an in-line process of forming a series of
flexible
film packages;
[009] FIG. 29 is a side view of another configuration of a flexible filial
package;
[0040] FIG. 30 is the flexible film package of FIG. 29 in a partially open
configuration;
[NCO FIG. 31 is a perspective view of another flexible film package;
(0042/ FIG. 32 is a perspective view of another flexible film package;
[00431 FIG. 33 is a perspective view of another flexible film package;
[004,11 FIG. 34- is a perspective view of another flexible film package;
[00451 FIGS. 35 to 38 are perspective views of the flexible film packages of
FIGS. 31 to 34,
respectively, in open configurations;
[0046] FIGS. 39 and 40 are perspective views of the flexible film packages of
FIGS. 31 and 32
in a continuous flow-wrap configuration illustrated ',without the label
applied and prior to
separation into individual packages;
[0047] FIGS. 41 and 42 are perspective views of the flexible film packages of
FIGS. 31 and 32
in a continuous flow-wrap configuration after formation of end seals and
application of the label;
[0048] Fla 43 is a plan view of a series of scored film packages subsequent to
formation of
end seals with a seal jaw;
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[00491 FIG. 44 is a schematic side view of a process for forming flexible film
packages with a
continuous closure label;
[00501 FIG, 45 is a schematic cross sectional view of a seal jaw taken along
section line AA
of FIG. 44;
[00511 FIG, 46 is a top view of another flexible film package;
[00521 FIGS. 47 to 49 are perspective views of flexible film packages;
[00531 FIG. 50 is a top view of another flexible .filin package;
[00541 FIG, 51 is a perspective view of another flexible film package;
[00551 FIGS. 52 to 56 are film score patterns for flexible film packages;
[00561 FIG. 57 is a perspective view of a flexible film package in an unopened
configuration;
[00571 FIG. 58 is a perspective view of the flexible film package of FIG, 57
in an opened
configuration;
[00581 FIG, 59 is a perspective view of another flexible film package in a
resealed or reclosed
configuration;
[00591 FIG, 60 is a schematic side view of a process for forming flexible film
packages with a
scored flexible film and a continuous label;
[00601 FIG. 61 is a schematic cross section of a fin seal jaw;
[00611 FIG. 62 is a perspective view of another flexible film package in a
partially open
configuration;
[0(4511 FIGS. 63 to 68 are perspective views of flexible film packages in
closed configurations;
[00631 FIG. 69 is a perspective view of a flexible film package in a partially
open
configuration;
[00641 FIGS. 70 to 79 are additional exemplary tab portion configurations
(package separation
cut) for flexible fitm packages;
[00651 FIGS. 80 to 98 are exemplary film periineter score patterns for
flexible film packages;
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[0066J FIGS. 99 to 144 are exemplary film lines of weakness score patterns
(e.g., trailing end
of the tab) for flexible film packages;
[0067] FIGS. 145 to 151 are plan views of exemplary flexible film package with
perimeter and
lines of weakness score pat.tem combinations;
[00681 FIGS. 152 to 160 are plan views of a series of front panel sections for
flexible film
packages;
[0069] FIGS. 161 to 189 are additional film score patterns for flexible film
packages;
[0070] FIGS, 190 is a perspective view of an exemplary gusseted vertical
formed flexible film
package;
[0071] FIG. 191 is a plan view of an exemplary vertical formed flexible film
package;
[0072] FIG. 192 is a plan view of another exemplary gusseted vertical formed
flexible film
package;
[0073] FIG. 1.93 is a plan view of another exemplary vertical formed flexible
film package;
[0074] .FIG. 194 is a plan view of another exemplary gusseted vertical formed
flexible film
package;
[0075] FIG. 195 is a plan view of another exemplary vertical formed flexible
film package;
and
[MC
FIG, 196 is a plan view of a section of a flexible vertical formed film
package blanks.
Detailed Description of the Preferred Embodiments
[0077] Pursuant to the various embodiments described herein, flexible film
packages and
methods of producing such packages are provided herein. 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 arid
moisture, for an extended period of time. For example, the initial seal of the
flexible film
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package may provide a light barrier and also a gas and moisture barrier for at
least 6 to 8 months
prior to initial opening. In some applications, a gas and moisture barrier may
be desired for even
longer periods of time prior to initial opening. Further, the flexible Min
packages are generally
resealable 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 reseal feature that
provides a resealable
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,
inedical,
pharmaceutical, industrial packaging applications and the like.
[00'781 In one approach, the flexible film package is generally configured to
accommodate
multiple servings of a food product. Thus, the resealing characteristics of
the flexible film
package help retain freshness or shelf-life of the food product remaining
within the package
subsequent to initial opening. The seals of the flexible film package, such as
any longitudinal
seals including, for e.xample, a fin or lap seal, and any ends seals may 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 food products contained therein. The seals may be formed
by a variety of
process such as, for example, hot seal, cold seal, low tack seal such as that
employing a low tack
adhesive or fastener, sonic waves, and combinations thereof. Any resealabie
seals of the flexible
package, such as that formed around the package opening, may be formed, in
part, by a pressure
sensitive adhesive located between the flexible film and an the elongated
closure layer. This
resealable seal feature may be fon/led by a variety of manufacturing
processes.
[00791 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
rectilinear-shape, among others. For example, the flexible film package may
have squared edges
such as that found on a primarily rectilinear-shaped package, or may have more
curvilinear-
shaped edges, such as that 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
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food products, which may be helpful for various discrete food products. 'The
various
configurations may be easily opened and resealed while. maintaining package
integrity.
[00801 By one approach, the flexible film has two opposing edge portions that
meet to foiiii
longitudinal seal extending from a first end seal to a second end seal. The
flexible film may have
a score that defines a package opening upon initial rupture or initial
opening. In one illustrative
embodirnent, an elongated closure layer extends over the score and extends
from the first end
seal (or to the first package end) to the second end seal (or second package
end) and within the
opposing edge portions that meet to form the longitudinal seal. A pressure
sensitive adhesive
may be located 'between the flexible fil.m and the elongated closure layer.
The elongated closure
layer may have a tack-free gripping portion used to release at. least a
portion of the elongated
closure from the flexible film to form the package opening.
[00811 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 laininate 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.
100821 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 continuous closure layer along the longitudinal axis with a
pressure sensitive
adhesive. By on.e approach, the continuous 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. In one approach, an adhesive-
free grasping
portion may be formed at a first end of the flexible package. As discussed
below, the flexible
package material may be converted into one package blank off-line or in-line
with the packaging
processes and also may be formed in both horizontal and vertical form-fill-
seal operations,
among others.
[00831 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
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continuous film web across less than the entire predetermined width. By one
approach, the
continuous film web is scored to define an opening in the film web upon
initial opening once the
substrate is removed from the continuous film web and an adhesive, such as a
pressure sensitive
adhesive that provides a degree of releaseability and resealablity, is
provided between the
continuous substrate and the continuous film web. If performed in-line, the
method may provide
products in a series for packaging, and the continuous film web and substrate
may be wrapped
around the products. Further, a longitudinal seal, such as a fin or lap seal,
may be provided along
the longitudinal edges of the continuous film web, and leading and trailing
end seals may be
provided between adjacent packages of the series of packages.
[00841 In one configuration, the method of manufacturing resealable flexible
film packages
includes scoring a continuous film to define an opening in a subsequently
formed individual
package; applying a continuous pressure sensitive adhesive label or closure
layer to at least cover
the score; feeding the filmIlabel combination around the product to envelop
the product; forming
a longitudinal seal by joining the opposite edges of the film together;
forming two substantially
transverse end seals; and scoring peel tabs in a unsealed film area distal to
an end seals.
[0085l The series of flexible packages 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,
[00861 As used herein, the flexible film may be a formed of a thin polymer
material. For
example, the flexible fihn may be a flexible sheet of material in a roll or as
individual blanks. To
form the flexible film, a variety of processes may be employed. The flexible
film may be, for
example, laminated, extruded, cast, blown, or a combination thereof. By one
approach, the
flexible film may include a laminate having several .thin layers of material.
The laminate
structure may include a polyethylene terephthalate (PET) layer and/or an
oriented polypropylene
(PP) layer, Other optional laminate layers include a polyethylene (PE) layer,
a polypropylene
(PP) layer, a polylactic acid (PLA) layer, a sealant layer, an ink or print
layer, nylon, and a
metalized layer, such as a metalized oriented polypropylene (MET OPP) layer,
to note but a few
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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 flexible film may include a single layer (mono-web)
polymer. If a single
layer polymer is employed, the film may include, for example, polyethylene
.terephthalate,
polyethylene, nylon, or oriented polypropylene. By yet another approach, the
flexible film also
may include a mono-web with a sealant thereon. Further, the components of the
flexible film
laminate may be joined by adhesives or by extrusion processes.
W8'1 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 also may further strengthen the flexible
film and also provide
a useful barrier to permeability.
/00881 The flexible film package may include a score that defines a package
opening upon
initial rupture or initial opening. 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 (i.e., a line or area 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. 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 011C example, the
score is made into the flexible film fanii 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,
[0089] By one approach, the elongated closure layer is disposed or
continuously applied upon
the flexible .film over the score such that there are generally no disruptions
in the elongated
closure layer or 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 label
with a backing, a
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release liner or a linerless label. In another configuration, the elongated
closure layer may
include a second flexible film with pressure sensitive adhesive disposed
between the flexible
film and the second flexible film. As discussed below, the pressure sensitive
adhesive may be an
interstitial layer to a laminated film structure such that the pressure
sensitive adhesive is
laminated 'between the flexible film and the second flexible film layers.
[00901 In yet another configuration, the elongated closure layer may comprise
a tape that is
continuously applied over the flexible film along its longitudinal axis.
Though a linerless label
may be similar to tape, a linerless label oftentimes requires additional
printing, including, for
example, for registration purposes. As illustrated below, the elongated
closure layer may be
applied on both horizontal and vertically formed packages. The continuous
closure layer may be
transparent, opaque, or optionally printed. The continuous closure layer may
include any of a
variety of flexible or semi-rigid polymers, such as, for example, an oriented
polypropylene
including a hi-axial OPP, and a polyethylene terephthalate (PET) layer. In one
illustrative embodiment, the continuous closure layer may have a thickness of
about 0.5 to 5.0
mil (5) to 500 gauge; 0.01.27 to 0.1.27 mm). By one approach, the continuous
closure layer may
be about 1.0 to 3.0 mil (100 to 300 gauge; 0.0254 to 0.(1762 mm)iu thickness.
In one
configuration, the continuous closure layer may have a thickness of about 2.5
mil. (250 gauge;
0,0635 mm), For some applications, PET may be desirable because of its thermal
resistance in
creating non-peelable seals. Further, while the elongated closure layer may be
a continuous strip
of material continuously applied to the flexible film without disruption, it
is noted that in some
configurations, the label may be more of a discrete-type label, as described
below in other
embodiments.
[9091] The continuous closure layer may be applied to cover at least the score
line. Further,
the continuous closure layer preferably extends beyond the score line to
provide sufficient
marginal region around the score to effectively reseal the package opening
once the score has
been initially opened or ruptured.
[0092] As suggested, the package opening is preferably resealable such that at
least a partial
hermetic seal is obtained around the opening in some configurations the
resealable opening is
substantially hermetic). The pressure sensitive adhesive between the flexible
film and the
elongated closure layer helps produce the resealing characteristics of the
package opening. The
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pressure sensitive adhesive is preferably neutral or non-reactive to the
product to be pa -ckaged,
By one approach, the pressure sensitive adhesive may include, for example, a
cold formed
adhesive, a hot melt adhesive, a cold seal adhesive, a natural or synthetic
latex adhesive, a low
tack adhesive, ethylene vinyl acetate (EVA), an acrylic adhesive (such as a
water-based or
solveritt acrylic adhesive), a styrene block copolymer adhesive, a butyl
rubber adhesive, a silicone
rubber adhesive, a natural rubber adhesive, a nitriles adhesive, an acrylic
emulsion adhesive, and
combinations thereof. Further, the pressure sensitive adhesive may be
extruded, coextrud.ed,
printed, or combinations thereof. In one configuration, the pressure sensitive
adhesive is an
acrylic water-based adhesive, The pressure sensitive adhesive niay be a
variety of thicknesses.
By one approach, the pressure sensitive adhesive may be about 0,5 to 1.5 Mil
(50 to 150 gauge;
0,0127 to 0,0381 nun) in thickness. 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.
[0093] In SOMe configurations, the pressure sensitive adhesive may provide a
substantially
hermetic seal even under refrigerated conditions (i.e., the pressure sensitive
adhesive can be
operable in a temperature range of about -10 to 90 degrees Celsius; and
preferably in the range of
about 2 to 7 degrees Celsius). The pressure sensitive adhesive may be applied
directly to the
film but also may be applied to ink or another coating on the film. By one
approach, the pressure
sensitive adhesive remains attached to the continuous closure layer, even
after the closure layer
is repeatedly opened and reclosed. In another configuration, the pressure
sensitive adhesive is a
low tack adhesive or fastener. Optional low tad( adhesives or fasteners are
disclosed in U.S,
Patent Application No. 13/035,399, filed February 25, 2011, which is
incorporated herein by
reference. The low tack adhesive .may include a variety of suitable materials
exhibiting a
relatively low tack to undesired surfaces but, at the same time, still
exhibits a good bond strength
to desired surfaces (such as not delaminating from the flexible film), arid a
relatively good
cohesive or self adhesive bond strength to like surfaces to hold a flexible
package or pouch
closed, but still permit the package to be openable or peelable by hand. If a
low tack adhesive is
employed with the package, it is anticipated that the pressure sensitive
adhesive may be adhered
to either the closure layer, the filrn, or both, once the closure layer is
pulled upward or away from
the film and the package is open. In one illustrative embodiment, a portion of
the low tack
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adhesive (SA ) remains adhered to the film and another portion of the low tack
adhesive (SA)
remains adhered to the continuous closure layer during opening of the package.
[0094] In addition, the initial seal of the package (prior to opening) also
may be substantially
hermetic (e.g., provide a gas and moisture barrier) for extended periods of
time. The initial seal
may be created by the package end seals or longitudinal seal, along with the
continuous closure
layer and pressure sensitive adhesive laminated above the score, which
subsequently defines a
package opening.
[0095) In one configuration, a resealable flexible film package includes a
scored film with
edges that are longitudinally sealed to form a sleeve. A first package or
sleeve end seal is
disposed substantially transverse to the longitudinal seal at a first package
end. A second
package or sleeve end seal is disposed substantially transverse to .the
longitudinal seal at a second
package end. In some configurations, the first and second end seals can be
optionally peelable or
non-peelable. As used herein, a peelable seal is one where the sealant layers
may separate from
one another, arid a non-peelable seal includes a sealant that bonds such that
the sealant layers do
not separate, i.e., a destructive seal. The film between the first and second
end seals defines a
package interior. The flexible film has a label or other continuous closure
layer continuously
disposed over the score of the film and along a longitudinal axis of the
package with a pressure
sensitive adhesive. The label can be employed to reclose or reseal the package
as contents are
removed from the package. In addition, after removal of SOITle of the package
contents, the film
may be rolled or twisted to compress the package, and then, the label may be
applied thereover
reclose or reseal the package. The package size snay then be rolled or twisted
to reduce the
package size to the amount of content remaining in the package.
[0096] By one approach, the pressure sensitive adhesive has a peel strength
between the film
and the label that is greater than a force required to separate sides of the
score. The label may
extend beyond the score line sufficiently enough to reseal the package with
the pressure sensitive
adhesive disposed 'between the label and the film. A wide variety of score
patterns are
anticipated, and several configurations are provided herein. A score may be
disposed generally
longitudinally from the first package end to the second package end. In
addition, the score may
be straight, arcuate, or a combination thereof. Further, the score may include
shapes such as a
"T" shape, a teardrop, and a circle, to note but a few. In one configuration,
the score may define
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an opening at or near the first package end. In some embodiments, the score
line forms a loop
between the end seals. In other embodiments, the score. may begin at an outer
edge of the first
end seal and extend rearward, joining to form a single score line. In one
configuration, the score
line does not extend past the second end seal. ln yet another configuration,
the score may extend
into and/or through the end seals. Since the seal area may be formed by heat
seal bars, the heat
employed to form an end or longitudinal seal in the package, also may melt the
polymers
sufficiently to inhibit any tearing of the score past the heat seal, even if
the score extends into the
heat seal area prior to forming of the seal,
[00971 The terminus of the score line adjacent the second package end niay be
configured to
inhibit or prevent further tearing of the film beyond the score line. The end
of the score line
adjacent the second package end may include configurations having a "II" hook,
a double "J"
hook, a smile, a shepherd's hook, a teardrop, and a double teardrop (providing
a relatively large
package opening at either end of the package), among others. In one example,
the score line
includes an opening, such as a teardrop-shaped opening, adjacent the first
package end that
extends to a single score line running generally longitudinally toward the
second package end,
which provides an opening to the package interior. In another configuration,
the score includes
an opening, such as a teardrop-shaped opening, adjacent the first package end
and two generally
straight portions extending therefrom and extending longitudinally down the
package. The
generally straight portions may be parallel and may be spaced about 5rnm or
less apart. The
score also may include a narrow arcuate section joining the two generally
straight portions
adjacent the second end. In one configuration, the label extends beyond the
first end seal and at
least to the leading edge of the package.
[00981 As discussed below, a second score line or area such as a tab score may
be added to the
package to define a tab portion such as a tab in the film/label laminate. This
second score line or
area may be disposed distal and adjacent to the first sleeve end seal, hi
addition, multiple second
score lines or a score area can be added to assist with proper functioning of
the tab portion. The
multiple score lines can be added to assist with concerns regarding variations
in the registration
of the elements.
[0099] Referring íriitially to FIG. 1, a series of flexible package blanks 1.0
are shown. A
continuous flexible film web 12 has a width and a longitudinal axis along the
length of the
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packages formed therefrom. An elongated or continuous closure layer 14 is
continuously applied
along the longitudinal length of the package blanks to a portion of the width
of the continuous
flexible film web 12. For example, the continuous closure layer 14 rnay be
applied substantially
along the entire longitudinal axis of the continuous flexible film web 12. A
pressure sensitive
adhesive 18 (FIG. 2) is disposed 'between the continuous flexible film web 12
and the continuous
closure layer 14, The pressure sensitive adhesive 18, like the continuous
closure layer 14, is
continuously applied between the continuous flexible film web 12 and the
continuous closure
layer 14 so that there are no areas between the two layers without the
pressure sensitive adhesive.
A score 16 is formed in the continuous flexible .film web 12 and will
subsequently form a
package opening when the continuous closure layer 14 is pulled away from the
continuous
flexible film web .12.
MONO] More specifically, the score 16 is .formed into the flexible film 12 and
may define the
package opening 36 once the flexible film package 5 (FIG. 5) is initially
opened. The package
opening allows a consumer to easily access the product within the package 5.
As mentioned
above, the score 16 may be formed in a variety of operations, including, for
example,
mechanically-formed, such as by a die cut, laser-formed, or any other forming
operation that
compromises the integrity of the film. See, for example, U.S. Patent No.
5,158,499. The score
16 may be formed on the interior or exterior surface of the flexible film. In
addition, the score
16 may be disposed partially through the thickness of the flexible film (a
partial depth score line)
.through the entire flexible film thickness (a full depth score line). In
addition, the score 16
may be a variety of widths, as well as depths. The score 16 may be formed
before the
continuous closure layer 14 is applied to or merged with the flexible .film 12
or after the
elongated, continuous closure layer 14 is applied to the flexible film 12. If
the score 16 is
formed subsequent to application of the continuous closure layer 14, the score
16 ma-y be formed
through the flexible film 12 (from the interior surface) and into the pressure
sensitive adhesive
18. In one approach, the score 16 may be formed through the flexible film 12,
the pressure
sensitive adhesive 18 and partially into the continuous closure layer 14.
[001011 In addition to the score 16 that subsequently forms the package
opening 36 (FIG. 5), the
continuous flexible film web 12 also niay have a tab score 15 (FIG, l) formed
therein. The tab
score 15 may be formed sirnilar to the score 16. The tab score 15 may be
disposed on the
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continuous flexible film 12 in an area where. the continuous closure layer 14
is applied thereon.
As discussed in more detail below, the tab score 15 permits a portion 38 of
the flexible film to
separate froni the remainder of the continuous flexible fihn web 12 to form a
tab portion 40 at an
end of the film package with the continuous closure layer 14. In the
illustrative configuration of
FIG, 1, the tab score 15 includes a series of arcuate die cuts that result in
an arcuate portion of
the flexible film 38 separating from the remainder of the continuous flexible
web 12. In
addition, as discussed in more detail below, the tab score 15 includes a
series of score lines so
that the longitudinal registration of the continuous flexible film web does
not need to be
precisely calibrated with the seal bars and separation or knife cuts that form
or separate the
individual film packages 5 from the series of flexible packages 10, Indeed, as
discussed below,
the tab score 15 is formed to intersect with the knife or separation cut 44
subsequently made into
the laminate when the individual packages are formed.
[001021 in one illustrative embodiment, the score 16 and the tab score 15 are
formed after the
continuous closure layer 14 is applied to the flexible film web 12. In such a
configuration, the
score 16 may extend through the entire depth of the flexible film 12 and
possibly through
portions of the pressure sensitive adhesive 18. It also is anticipated that
the score 16 may extend
slightly into the continuous closure layer 14; however, the score 16 does not
extend into the
continuous closure layer 14 sufficiently enough to compromise the integrity of
.the barrier
properties of the continuous closure layer 14. A variety of different score
depths also are
anticipated for tab score 15 as well.
[001031 A pre-scored film or one scored prior application of the. closure
layer) also can define
tear lines to create an opening on the flow-wrap package as the label is
pulled back. The score
16 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
16 may extend
through the .flexible film 12 such that the continuous closure layer 14
substantially provides the
seal prior to initial opening of the flexible package.
[001041 A variety of score 16 configurations are anticipated and a few
examples are discussed
herein. 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 factors. By
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one approach, the score .16 defines a package opening that permits access to
at least 70 percent of
the products within the flexible film package upon initial opening of the
package. More
particularly, when the elongated closure layer 14 is peeled to the end of the
score 1.6 to expose
the entire score 16, it is anticipated that a user may access tie, remove from
the package) any of
at least 70% 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. By yet another
approach, the score 16 defines a package opening that permits access to at
least 90% of the
product within the package. In another configuration, the score 16 defines a
package opening
permitting access to at least 50% of the product within the package.
[00105/ FIG. 1 illustrates the score line 16 having a bulbous or arcuate
section 30 extending into
two generally elongated, straight sections 32 that terminate at ends 34, which
have hooks in the
illustrated configuration. The hooks or .1-shaped ends help prevent the score
16 from
propagating or continuing to tear the flexible film 12. In addition, depending
on the product
contained within flexible film 12, the arcuate section 30 of the score 16
permits the package
opening to be sufficiently large enough to easily serve and access a
substantial portion of the
product contained therein,
[00106] Referring briefly to FIG. 8, another series of flexible package blanks
110 is shown.
The series of flexible package blanks 110 is similar to the series of flexible
package blanks 10
and has a continuous flexible film web .11.2 with an elongated or continuous
closure layer 114,
The primary differences with the series of flexible packages 110 are the score
116 and the tab
score 115. The score 116 includes a bulbous or arcuate portion 130 that is
slightly narrower than
portion 30 and also includes two generally elongated, straight sections 132
that angle inward
toward one another and to ends 134 that include hooks extending away from the
center of the
package. The package opening created with score 116 may be slightly more
narrow than the
package opening created with score 16. In addition, the tab score 115 includes
a series of
straight score lines that are configured to intersect the knife cut 144
subsequently made when
individual packages are formed. FIG. 8 also illustrates an opening or peg hole
154 that may be
formed .through the closure layer 114 and the flexible film 12 to allow the
individual packages to
be hung, for example, for display purposes.
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[001071 Flexible film web 12, 112, as suggested above, 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, andior a PIA layer, to note. a few options. These layers may be joined
by adhesives or by
an extrusion process. Alternatively, the flexible film web 12 may be a single
layer polymer or
mono-web. Since the flexible film package is at least partially hermetically
sealed, the flexible
film web preferably provides a gas and moisture barrier. By one approach, the
flexible film may
be. about 1 mil to about 5 mil (100 to 500 gauge; 0.0254 to 0,127 ram) in
thickness. By another
approach, such as that employed with extrusion lamination, the flexible film
web 12 may be
about 0.47 rnil to about 0.98 mil (47 to 98 gauge; 0,012 MITI to 0.025 nun) in
thickness. :In one
illustrative embodiment employed with extrusion lamination, the flexible film
web 12 may be
about 0.67 mil to about 0.71 mil (67 to 71 gauge; 0.017 mm to 0,018 mm) in
thickness. For the
above extrusion lamination examples, the extrudate also will add about (I.4
mil to about 1.2 mil
(40 to 120 gauge; 0.01 to 3mm) of additional thickness to the flexible
film. The thickness of
the film inay be a function of the desired barrier to gas, moisture, and
light, along with the le-vel
of desired structural integrity, the desired depth of score line, and the
available manufacturing
equipment,
[00108] Flexible, film web 12, 112 may be a heat sealable copolymer. In some
configurations,
the heat sealable polymer forms a seal between, for example, 50 and 300
degrees Celsius.
Flexible film web 12 also may be a pressure sealing film. In one
configuration, the film web 12,
'112 may be a pressure sealing film. For example, the pressure sealing film
may form a seal
between, for example, a pressure of about 0.7 to 7.0 kg/cm. By one approach,
the pressure
sealing film forms a seal at about 5,6 kgfcm,
[00109] In addition to the various laminate layers mentioned above, additional
laminate layers
such as sealants, stiffeners, ink, release layers, also may be incorporated
into the laminate
structure.. For example, a sealant layer can be added to facilitate the
formation of seals that
enclose the product. By one approach, the sealant layer may be oriented on the
film surface
directed to the interior of the package (interior-facing surface). The sealant
layer may be a
variety of polymer sealants, such as a heat activated polymer sealant layer
like ethylene vinyl
acetate (EVA), ionorner plastic (such as that sold under the trade narne SURLY
N by DiiPorit),
metallocene, and organoclay, among others, hi one example, seals, such as fin
seals, can be
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formed .using a heat activated sealant layer. In addition, cold sealant and
pressure sealants also
may be used with the configurations disclosed herein. If the products within
the flexible filin
package are food products, then it is noted that food grade sealants would be
employed.
[00110] In one configuration, stiffeners are added to flexible film 12, 11.2
to increase the
stiffness of the fibril 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 on each side of the nylon layer (i.e., a tie
layer). In one
configuration, a film structure, such as a 2 mil structure, may include a
nylon layer of about 6-10
% of the film thickness or about 0.)03 to 0.005 nun. In one approach, the
nylon layer comprises
about. 8% of the film thickness. By yet another approach, the nylon layer may
comprise about
0.004mm.
[00111] As noted, an ink layer may be thrrned 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. .Altematively, the ink may be a
surface printed
layer with a release over-lacquer such as that used for a mono-web. Other
additional layers may
include a metalized layer, as noted above.
[00112] A release layer may be incorporated in some configurations to provide
more flexibility
in the laminate structure and also may increase the numbers options for
pressure sensitive
adhesives. For example, if a release layer is incorporated, the pressure
sensitive adhesive used in
the packager may have a lower peel force. The release layer may be a homo-
polymer such as an
OPP. By one approach, a release layer also Inay be an over-lacquer that is
printed or extruded
onto the film thereby providing a barrier between the pressure sensitive
adhesive and the flexible
film to provide consistent opening characteristics.
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[00i131 By one approach, the, elongated closure layer 14 is continuously
applied along the
flexible film 12 such that the continuous closure layer 14 extends from one
end seal to another
end seal once the flexible film package 5 is formed. In FIG. 4, the continuous
closure layer 14
extends from a first end seal 26 to a second end seal 28. Furthermore, the
closure layer 14
extends only partially over the width of the flexible. film 12 that forms the
film package 5. It is
also contemplated, however, that the continuous closure layer 14 may extend
the entire width of
the package but only be partially disposed over the length of the flexible
film 12. More
particularly, the continuous closure layer 14 preferably does not extend both
the entire width and
the entire length of the package. The continuous closure layer 14 is partially
disposed in either
direction (i.e., the length or width) and continuously disposed in the other
of the directions. In
one approach, the continuous closure layer 14 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 10 may have an elongated closure 14 that runs
the entire length
of the package and over only a portion of the width or an elongated closure 14
that runs the
entire width of the package and over only a portion of the length of the
package.
[0011.4/ FIG. 2, which shows a cross section of the flexible film along line 2-
2, illustrates a
pressure sensitive adhesive between the flexible film 12 and the elongated
closure layer 14.
Though the elongated closure layer 14 is disposed in a generally centered
position in FIGS. 1-2,
it is also anticipated that the elongated closure layer 14 may be off-center
or offset on the width
or length of the package. FIG. 3 illustrates how the elongated closure layer
14 may be disposed
along an edge of the flexible. film. 12.
[00115] The elongated closure layer 14, whis.li is adhered to the flexible
film 12 and covers
score 16, permits easy manual opening of the flexible package 5. In one
embodiment, the
elongated closure layer 14 can be formed such that the flexible package 5 has
a tab portion 40.
More particularly, a tab portion 40 (FIG. 5) may be formed by she elongated
closure layer 14 and
a portion of the flexible film in an unsealed area of the flexible film
extending distal to an end
seal such as end seal 26, allowing a user to grasp and peel open the upper
layer of the peelable
seal, i.e., the elongated closure layer 14.
[00116] In one configuration, flexible film 12 has a first edge portion 20 and
a second edge
portion 22. The edge portions 20, 22 may be brought together and formed into a
longitudinal
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sea, such as, fin seal 24 extending from a first end seal 26 to a second end
seal 28, as shown in
FIGS. 4-6. The longitudinal seal also may include a lap seal. The longitudinal
seal may run the
length of the package, as illustrated in FIGS. 4 and 5. However, the package
may be configured
such that the longitudinal seal runs along the width of the package as well.
[001171 FIG. 1 illustrates one approach to creating the end seals 26, 28. FIG.
1 generally
illustrates how the seal bar areas 42 (illustrated in dashed lines) create the
first and second end
seals 26, 28 of the packages (shown in FIGS. 4 and 5). In one illustrative
approach, the
continuous flexible film web 12 is wrapped around a forming device such as a
forming tube,
forming collar or in another manner and the edge portions 20, 22 are brought
together for
sealing. At this point, if the continuous flexible film web 12 also has been
wrapped around the
product to be contained therein, the ends seals 26, 28 also may be formed on
the package. The
end seals 26, 28 may include an upper and lower film portion 48, 50, as shown
in FIG, 7, or also
may include a front and back portion, depending on the configuration of the
flexible film
package.
[001I8 In addition, FIG. 1. illustrates where the separation cut 44 may be
formed between the
end seals 26, 28, also illustrated in dashed lines. The separation cut 44
separates the individual
packages 5 from the series of flexible film packages 10 and cuts through the
flexible film web
12, the continuous closure layer 14, and the. pressure sensitive adhesive 18.
In one example, this
separation point occurs between the second end seal 28 of a leading package
and the first end
seal 26 of a trailing package.
[001191 In one illustrative approach, the end portions of the flexible film of
two packages
disposed adjacent the first and second end seals 2.6, 28 are not sealed
together. The free ends 46,
since they are not sealed together, may be graspable by a user. Thus, to open
a package,
especially those lacking a resealable closure, a user may grasp the free ends
of the flexible filrn
that are adjacent the upper and lower portions of the end seal and pull apart
the end seal. More
particularly, in some packages, the free end portions are the pulled apart by
consumers to rupture
the substantially hermetic film-to-film seal that forms the end seal,
sometimes referred to as a
destructive seal. In other configurations, including those lacking free end
portions, a user may
elect to pull the front and back panels (or the upper and lower panels) away
from one another,
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adjacent the seal, to rupture the end seal. Both of these manners of opening a
package, rupture
the permanent or primary seal and are oftendines not resealable.
[001201 The end seals 26, 28 and the longitudinal seal 24 are film-to-film
seals and may be
considered prlinary seals and are oftentimes permanent or destructive seals.
The closure layer 14
also foiins a seal with the flexible package 5 and may be considered a
secondary seal. The
secondary seal is resealable 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).
[001211 In one example, the flexible film package 5 has primary seals,
including end seals 26,
28 and longitudinal seal 24, along with a secondary seal formed by the closure
layer 14 over the
length of the flexible film package 5. The secondary seal is formed, in part,
by the pressure
sensitive adhesive 18 disposed between the continuous closure layer 14 and the
flexible film 12.
[001221 FIG. 7, which is a cross section taken along line 7-7 of FIG. 4, shows
the flexible film
12 at the first end seal 26. The continuous closure layer 14 and pressure
sensitive adhesive 18
also are disposed adjacent the first end seal 26. Near or at this point, the
user will grasp the tab
portion 40 (FIG. 5) and pull upward to separate the continuous closure layer
14 from the flexible
film 12 to expose package opening 36. So that the COntilltiOUS closure layer
14 is peeled away
from the flexible film 12 without disturbing the primary seal between the
upper arid lower
portions 48, 50 of the first end seal 26, the primary peel force therebetween
is larger than the
secondary peel force required to separate the continuous closure layer 14 from
the flexible film
12. More particularly, if the primary and secondary peel forces are equal the
user may disturb or
negatively impact the primary seals, which may not be resealable. By one
approach, the priinary
seal has a peel force that is 200-300 grams/in.2 higher than the peel force of
the secondary seal.
In another configuration, the difference in peel forces may be between 25-400
grams/M.2.
[001231 As suggested above, many consumers previously opened packages by
rupturing the
primary seals at the end or top of a package. As illustrated in FIG. 5, the
flexible film package 5
is configured to permit the user to pull the continuous closure layer 14,
which is adjacent the end
seal, upward from the end seal 26 without rupturing the end seal 26. In
addition, the flexible
film 12 has a tab score 15 formed therein such that the user c.:an grasp the
continuous closure
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layer 14 without contacting the pressure sensitive adhesive 18. To that end,
the primary and
secondary seals may have peel forces configured to permit a user to easily
open the package
without disturbing the primary seals. In addition, the flexible package 5 may
have a tab portion
40 that penrnits easy opening of the package.
[00124] As noted above, the free ends 46 of the package are adjacent the end
seals but are
generally not sealed together. More particularly, the free ends 46 of the
package rnay be found
in an unsealed area of the film laminate and, by one approach, are distal to
the end seal of the
package thereby allowing a user to grasp arid peel open a portion 38 of the
upper layer or portion
48 of the film and the continuous closure layer 14.
/001251 As noted above, the tab portion 40 may be formed by the combination of
the tab score
15 and the separation cut 44. The leading end of the flexible film package 5
may be defined by
the separation cut 44, which also may be adjacent the location of the tab
portion 40. In one
illustrative approach, a user may grasp at that end to begin opening the
package. Specifically, a
consumer may grasp the free end 46 of the upper portion 48 of the flexible
film 12 and also the
portion of the continuous closure layer 14 adjacent the leading end. To assist
the .user with
lifting or peeling the continuous closure layer 14 from the flexible film 12,
one of the free ends
46 adjacent the upper portion 48 of the end seal 26 may have tab score 15
formed therein. Thus,
a portion of the flexible film 38 may separate from the remainder of the
flexible film 12 at one of
the tab scores 15. The portion 38 may cover the pressure sensitive adhesive 18
disposed
underneath the continuous closure layer 14 and provide the user with a tack
free gripping or tab
portion 40. 'lore particularly, the portion 38 is provided by having the tab
score 15 separate the
flexible film portion 38 from the remainder of the flexible film 12.
[00126] A cut-out 52, shown in FIG. 5, illustrates where the portion 38 of the
flexible film 12 is
removed from the remainder of the flexible film to cover the pressure
sensitive adhesive 18 on
the tab portion 40. As discussed in more detail below, the tab score 15 may be
disposed partially
into the leading end seal 26 of the package .10, the tab score 15 may extend
just along the leading
end seal of the package 10, or may be disposed just outside the leading end
seal 26. In addition,
if a series of tab scores 15 are employed, the tab scores 15 may have lines
disposed in all three
locations. If the tab score 1.5 extends just slightly into the leading end
seal 26, a slight portion of
the end seal 26 may be included in the portion 38 removed from the flexible
film 12; however, if
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the tab score 15 extends significantly into the leading end seal 26, the
forces within the seal will
likely not permit much of the leading end seal 26 to separate therefrom to
form the portion 38 of
flexible film 12. Thus, the configuration of the portion 38 that is removed
from flexible film 12
may depend on the configuration of the separation cut, the tab scores 15, the
relative placement
of the tab scores 15, and also may depend on the strength of the leading end
seal 26. In one
illustrative embodiment shown FIG. 1, the middle arcuate score line of tab
score 15 will typically
define the trailing, perimeter edge of the tab portion 44. This is the largest
of the tab scores 15
that is not welded by the end seal 26 in sealing area 42. Thus, a variety of
configurations may be
employed for the tab portion 44, the tab score 15, and the flexible film
portion 38 and a few
examples are provided herein.
[001271 The separation cut 44, which defines the leading edge of the tab
portion 40 and the
leading edge of the flexible film package 5, also defines the trailing edge of
another flexible film
package 5. Thus, as a leading flexible film package 5 is provided a trailing
edge by a die or knife
cutting assembly, a trailing flexible film package 5 is provided a leading
edge.
[001281 The pressure sensitive adhesive 18, which is disposed or applied
between the flexible
film 12 and the elongated closure layer 14, may have a variety of strengths
and compositions.
As noted above, the pressure sensitive adhesive may include, for example, a
cold formed
adhesive, a hot melt adhesive, a cold seal adhesive, a natural or synthetic
latex adhesive, a li-wv
tack adhesive, ethylene vinyl acetate (EVA), an acrylic adhesive such as a
water-based or
solvent acrylic, adhesive), a styrene block copolymer adhesive, a butyl rubber
adhesive, a silicone
rubber adhesive, a natural rubber adhesive, a nitriles adhesive, an acrylic
emulsion adhesive, and
combinations thereof. Further, the pressure sensitive adhesive may be
extruded, coextruded,
printed, or combinations thereof. By one approach, the pressure sensitive
adhesive has a higher
bonding strength than the strength required to tear or separate the score 15.
In such a
configuration, a user may pull upward on the elongated closure layer 14,
expose the package
opening, remove the desired amount of product, and then reseal the package
using the pressure
sensitive adhesive outside the score. By one approach, the pressure sensitive
adhesives may
have a variety of thicknesses. For example, the pressure sensitive adhesive
could be between
about 0.2 mils to 1 mil thick and may be even thicker,
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[00129] Referring now to FIG. 9, a flexible film package 205 includes a
flexible film 212
having a continuous closure layer 214 disposed thereon. The flexible film
package 25 includes
a score 216 and a tab score 215 disposed adjacent a first end seal 226. In one
approach, the score
216 includes a generally U-shaped configuration that has an arcuate portion
230 and two
generally elongated straight portions 232 that terminate at end portions 234
adjacent end seal
228. Tab portion 240 is adjacent end seal 226 and is defined, in part, by the
score 215, which
include a plurality of repeating straight score :lines through the flexible
film 212. The leading
and trailing edges of the flexible film package 205 are straight and do not
have arcuate sections
as with the package of FIGS. 4-5. As illustrated in FIG. 9, a die cut 260 is
illustrated through, at
least, the continuous closure layer 214. By one approach, the die cut 260 is
formed through the
continuous closure layer 214, the pressure sensitive adhesive 218, and the
flexible film 212.
Thus, a tab portion 240 is created adjacent the first end seal 226 having an
arcuate leading edge
defined by the die cut 260 through the continuous closure, layer 214 and the
score 216 through
the flexible film layer 312. As shown in FIG. 9, pair of cross-hatched score
areas 256 may be
provided adjacent the outside portions of the tab 240. By one approach, the
die cut 260 extends
into the cross-hatched score areas 256. The cross-hatched score areas 256
pemtit easier
separation of the continuous closure layer 214 from the flexible film 212 at
the trailing edge of
the tab portion 240,
[00130] A series 310a of flexible film packages, illustrated in FIG. 10A, is
similar to the
flexible film package blank 205, however, the series of flexible film packages
31.0a lacks a tab
portion with an arcuate leading edge but includes a straight leading edge. The
series of flexible
film packages 310a includes a flexible film 312a with a continuous closure
layer 31.4a disposed
thereon. The flexible film 312a has a score 316a 'that becomes the package
opening and a tab
score 315a that helps form a tab portion 340a. The arcuate shaped tab score
315a extends into
the free ends of the leading and trailing packages to pemlit variation in the
registration of the
package elements with the separation cut 344a. More particularly, tab score
315a does not
require that the longitudinal registration of the continuous flexible film web
be precisely
calibrated with the. separation cut 344a that is employed between the end
seals of leading and
trailing packages. In addition to having the arcuate tab score 315a formed by
a score. forming
mechanism similar to that which founs sc..ore, 316a, the arcuate cuts also may
be formed by the
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separation cut. As illustrated in F1G. 1.0B, a series 3101) of flexible film
packages, which will
subsequently look identical to the series 310a of packages, may be formed by
having a separation
or knife cut 344b configured to create arcuate cuts 345b in the film in the
unsealed areas distal to
the leading end seal. The configurations of FIG. 10A and F1G. 10B both provide
a tab portion
340a, 340b that is relatively wide. The tab portion 340a, 340b may have
arcuate sides and
straight leading and trailing edges.
[001311 Another illustrative series of flexible film package blanks 410 is
shown in FIG. 11, The
series of flexible film package blanks 410 includes a continuous flexible film
412, a continuous
closure layer 414, and a score 416 (illustrated in FIG. 12 in dashed lines)
that provides for a
package opening 436 once the continuous closure layer 414 is at least
partially lifted from the
subsequently formed package 405 (FIG. 13). The continuous closure layer 414,
similar to the
previously described configurations, covers a portion of the width of the
flexible film 412,
Further, the series of flexible film package blanks 410 also includes a
closure layer score 456
disposed in the closure layer 414, The closure layer score 456 extends from a
tab portion 440
(near the leading edge of the package) and is directed inward toward the
package body and
terminates at edges 458 of the continuous closure layer 414. The closure layer
score 456 may be
disposed through the full depth of the closure layer 414, and the score 456
also may extend into
the pressure sensitive adhesive 418 disposed between the continuous closure
layer 414 and the
flexible film 412. The closure layer score 456 assists the user with peeling
the continuous
closure layer 414 from the flexible film 41.2, which can become difficult for
packages with a
relatively wide continuous closure layer 414 that covers more area of the
flexible film 412. The
closure layer score 456 forms cut-outs 459 in the continuous closure layer 414
once the tab
portion 440 and a portion of the continuous closure layer 41.4 it is lifted
from the film 412. The
portions 461 of the continuous closure layer 414 that are cut-out from the
remainder of the
continuous closure layer 414 remain adhered to the flexible film 412 disposed
adjacent the
leading edge of the package 460. In sum, the closure layer score 456 reduces
the peel force
required to lift the continuous closure layer 414 from the flexible film 4-12.
[00132] In addition to the score 416, a tab score 415 is formed in flexible
film 412. The tab
score 415 (illustrated in FIGS, 12 in dashed lines) may extend from a trailing
seal area 442
(which forms a trailing end seal) of one package to the leading seal area 442
(which forms a
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leading end seal) of another package. Thus, the tab score 415 extends at least
partially into the
free ends of the package that are positioned between the two seal areas 442
prior to separation of
the packages. As illustrated in FIG. 12, free ends 446 are adjacent both a
leading edge 460 and a
trailing edge 462. The leading edge 460 is adjacent the tab portion 440 and
forms the leading
edge of the tab portion 440. M addition, the leading edge 460 is formed by the
separation cut
444, which is straight in this example. Thus, the tab portion 440 has a
straight leading edge as
well.. The straight separation cut 444 also provides a straight trailing edge
462 of the packages as
well.
[001331 The tab portion 440 also has a removed portion 438 from the flexible
film 412 that
covers the pressure sensitive adhesive 418 disposed on the continuous closure
layer 414. As
illustrated in FIG. 11, the tab score 415 includes arcuate lines that
intersect the seal area 442 that.
becomes the leading end seal 426. Thus, when the tab portion 440 is pulled
away from the
flexible film package 405, the portion 438 is removed from the remainder of
the flexible film
412 to cover the pressure sensitive adhesive that is adhered to the closure
layer 414,
[001341 In addition to a configuration with a longitudinal seal and two end
seals, it also is
anticipated that the flexible film package may have three side seals. By one
approach, such a
package may have a dead fold.
[00135] FIG. 14 shows another flexible film package 500. By one approach, the
flexible film
package 500 includes a front and a back filni pane/ 520, 522, first and second
end seals 502 and
504, along with a top seal 506 extending from the first end seal 502 to the
second end seat 504,
which is a longitudinal seal, and a dead fold 508, Flexible .filin 512
includes an elongated
closure layer 514 disposed from the first end seal 502 to the second end seal
504.
[001361 As illustrated in FIG, 15, flexible film package 500 includes a
pressure sensitive
adhesive 518 disposed between the flexible film 512 and the elongated closure
layer 514. In
addition, a score may he disposed between one of either the front or back film
panels 520, 52.2,
By one approach, a score 516 is disposed through the front panel 520, and the
elongated closure
layer 514 and the pressure sensitive adhesive 518 are disposed thereon. Thus,
once the package
opening 536 is created by pulling the front and hack film panels 520, 522 away
from one
another, a cut away portion 525 defined by the score 516 is separated from the
front panel 52.0
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and adheres to the back panel 522. More particularly, the top seal 506 is
formed between the
front and back panels 520, 522 and portions of the score 516 may be disposed
above and below
the top seal 506. Thus, once the score 516 is separated, a cut-out portion 525
of the front panel
520 that is sealed (via top seal 506) to the back panel 522 remains adhered
thereto. After
opening (as shown in FIG, 16), a user may access the product within the
flexible film package
505, and then, a user may reseal the package 505 by pressing the pressure
sensitive adhesive 518
underneath the closure layer 514 into contact with the back panel 522 and the
cut away portion
525.
[N137] .FIG. 17 schematically illustrates one method of manufacturing the
flexible film
package 505. The continuous closure layer 514 may be continuously disposed
upon flexible film
web 512. In such a configuration, a forming or folding mechanism 578 may be
used to form the
film into the package shape. for filling with product and forming die 582 may
be used to create
the seals and the separation cut between packages,
[00138] Turning to FIG. 29, another illustrative package 1305 is shown with
three side sealsõAi
first arid second side seal 1302, 1304 and a top seal 1306. A flexible film
1312 has a continuous
closure layer 1314 from one of the side seals 1302 to the other side seal
1304. Indeed, the
continuous closure layer 1314 extends from a first edge 1.360 to a second edge
1362 of the
package 1305, A score line 1316 is disposed in the flexible film 1312
underneath the continuous
closure layer 1314, and the score line 1316 subsequently forms the package
opening 1336 (FIG.
30),
[00139] The package 1305 further includes notches 1386 through the flexible
film 1312
adjacent a tab portion 1340 that is adjacent the first edge 1360. The notches
1386 help remove a
portion 1338 of the flexible film 1312 from the remainder of the film. As
shown in FIG. 30, the
cut-out 1352 is found where the portion 1338 has been removed from the
flexible film 1312.
The portion 1338 covers the pressure sensitive adhesive 1316 on the continuous
closure layer
1314 to provide a tab portion 1340 for grasping. In addition, a tab score
1315, similar to
previously described tab scores, may be formed adjacent or at the side seal
1304 to assist with
removal of the portion 1338, which may remain adhered to the continuous
closure layer 1314.
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[001401 Another package configuration is illustrated in FIGS. 22A to 22. FIG.
22A shows a
package blank 810 that may be formed into package 805 (FIG. 22B). The package
blank 810
includes a flexible film 812 with a continuous closure layer 814 and an
arcuate score line 816
disposed thereunder, as shown in FIG. 22A. FIG. 22A also illustrates tab score
815 disposed
near tab score 840. The package blank 810 of FIG. 22A also illustrates where
the fold lines 812,
823 will be disposed and where the seal areas 844a will form a lap seal 824
and where the seal
areas 844b will form side seals 802, 804 to form a package 805. The formed
package 805
illustrated in FIG, 22B includes two side seals 802, 804 and a fin or lap seal
824. FIG, 22B also
shows tab score 815 and opening score 816 (in dashed lines).
[001411 The package 805 shown in FIG. 2.2B may be formed from two different
package
blanks. For example, FIG, 22A shows package blank 810 that may be formed into
package 805
having a lap seal 824. Alternatively, FIG. 22D shows package blank 810 that
niay be fomied
into a package 805 similar to that shown in FIG. 22B with a fin seal 24, as
opposed to a lap seal.
If a lap seal is desired for the. package 805, the free end 846 is disposed
only adjacent the first
end 860 of the flexible film 812, as shown in FIG. 22A. Alternatively, if a
fin seal is desired for
the package 805, a free end 846 is disposed adjacent the first end 860 and the
second end 862 of
the flexible film 812, as shown in FIG. 22.
[00142] In addition, the package 805 includes a top fold 821 and bottom fold
823. The top fold
821 may be formed in the flexible film 812 and the continuous closure layer
814. In addition, a
score 816 is formed in the flexible film 812 to create a package opening 836
(FIG. 22C) once the
continuous closure layer 814 is lifted from the flexible film 812. As
illustrated, the score 81.6
that forms the package opening may be disposed adjacent the top fold 821 such
.that the fold 821
and the continuous closure layer 814 help avoid additional tearing of the
flexible film 812
beyond the score line 816. By one approach, the ends of score 816 are disposed
at or near the
fold line 821. Once the package 805 is opened, as illustrated in FIG. 22C, a
package opening
836 may be formed by having a portion 837 of the flexible film 812 lifted with
the continuous
closure Iayer 814.
[001431 As shown in FIGS. 22A and 22D, the continuous closure layer 814 is
disposed near free
end 846 that may partly form the tab portion 840. A series of tab scores 815
may be disposed in
flexible film 812 near the tab portion 840. Further, one of the tab score 815
may form a portion
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836 of the flexible film 812 that is removed from the remainder of the film to
cover a portion of
the pressure sensitive adhesive 818 that is disposed on the tab portion 840.
Thus, the tab portion
840 includes a free end 846 of the flexible film 812 and a portion 838 of the
flexible film 812
that is removed .from the remainder of the film 812 (and remains adhered to
the pressure
sensitive adhesive disposed on the underside of the continuous ClOSLIM layer
814). 'To reseal the
package 805, the pressure sensitive adhesive 818 (FIG, 22C) disposed between
the continuous
closure layer 814 and the flexible film 812 may reseal the continuous closure
layer 814 to the
flexible film 812 around the score 816 that forms the package opening 836.
f0014411 Another illustrative series of flexible film package blanks 610 is
shown in FIG. 18. The
series of flexible film package blanks 610 are formed into individual flexible
film packages 605
(FIG. 19). The series of package blanks 610 includes a continuous flexible
film 612, a
continuous closure layer 614, a score 616, and a tab score 615. In one
illustrative example, the
score 616 includes an arcuate .portion that connects two generally elongated
straight portions.
Unlike other examples, the score 616 does not terminate at tear-inhibiting
portions, i.e., hooks or
1-shaped ends, that are configured to inhibit or prevent the score 616 from
tearing beyond the
formed scored. By one illustrated approach, during package opening; ends 664
of the score 616
will continue to tear the flexible film 612 past the initially formed score
616 such that the ends
664 of the score 616 eventually COMC together. In such a configuration, a
closed-shape portion
of the flexible film 61.2 will be formed by the tear lines or the score 616,
and this closed-shape
portion may be lifted from the flexible filrn 612 during package opening.
[00145/ The series of flexible film package blanks 610, which has a continuous
flexible film
612 and a continuous closure layer 614, is .formed into individual packages
605 having an
elongated closure layer 614 over the flexible film 612. The elongated closure
layer 614 extends
from the leading edge 660 to the trailing edge 662 of the package 605. The
separation cut 644 is
a straight cut in the illustrative example of FIG. 18. In addition, a tab
score 615 having an
arcuate configuration is disposed adjacent the leading edge 660 of the package
605. Specifically,
the tab score 615 includes a series of spaced, arcuate scores. The tab score.
615 intersects with
the seal area 642 that forms the first end seal 626. Thus, when a consumer
grasps a tab portion
640 at the free ends 646 arid pulls upward from the package 605, a portion 638
of the flexible
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film 612 will be removed from the remainder of the flexible film and will
cover a portion of the
pressure sensitive adhesive 618 disposed on the closure layer 614 (FIG. 20),
[001461 An additional flexible film package blank 705 is shown in FIG. 21. The
blank 705
includes a flexible film 712 having a score 716 with a continuous, elongated
closure layer 714
disposed thereover. Score ends 764 have a wavy, arcuate score 766 (similar to
two adjacent
"smile" scores) located near the ends '764 that inhibit or prevent further
tearing of the score '716
beyond the wavy, arcuate score '766. A further arcuate score 734 is positioned
on the other side
of the wavy, arcuate score 766, and provides additional resistance to further
tearing of the score
'716,
[00147] A tab score 715 is fomied in the flexible film 712 near the leading
edge 760 and
includes a series of repeating straight lines. A tab cut 768 is formed through
the flexible film
715 and the continuous closure layer 714. The tab cut 768 is positioned in
between the leading
edge 760 of the package and the tab score 715. For a package formed of the
flexible film blank
705, a consumer can grasp a tab portion 740, having a tab leading edge that is
fomied by the tab
cut 768 and a tab trailing edge that is formed by one of the lines of tab
score 715 that intersect
with the first end seal area 742. At the tab portion 74), a portion of the
flexible film 712 is
removed from a remainder of the flexible film to cover the pressure sensitive
adhesive disposed
on the surface of the elongated closure layer 714 that faces the film 712.
[001481 As noted above, the packages described herein may be formed in a
variety of manners.
For example, the packages may be formed in-tine just prior to forming a
package around a
product or may be formed just prior to filling a package with product. As
another example, the
packages may be formed off-tine welt before the products are packaged. If the
packages are
formed off-line, the packages may be formed in a remote location away from the
location where
the packages are filled with product.
[00149] Before the flexible film is formed into a package, a continuous
closure layer 914 may
be applied to a flexible film web 912. In one example shown in FIG, 23, a
continuous closure
layer 914 having a pressure sensitive adhesive disposed on one side is applied
to the flexible film
web 912. The pressure sensitive adhesive is disposed on the side of the
closure layer 914 that
contacts the flexible film 91.2. In one configuration, the continuous closure
layer 914 is wound
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on a roll (such as a roll of tape), that is unwound and then applied to the
flexible film web 912.
To aid release of .the pressure sensitive adhesive from the opposing side of
the continuous
closure layer 914, a release layer may be deposited onto the opposing surface
of the closure layer
914. It also is anticipated that a backing layer could be disposed between the
pressure sensitive
adhesive and the opposing side of the continuous closure layer 914.
[00150] :En yet another configuration, illustrated in FIG. 26, the pressure
sensitive adhesive 1018
is applied separately from the continuous closure layer 1014. More
particularly, instead of
having the pressure sensitive adhesive previously applied to the closure layer
(or previously
applied to the film) before applying the closure layer to the film, the
pressure sensitive adhesive
101.8 may be applied around the time that the closure layer is applied to the
film and in a separate
application process. Thus, once the pressure sensitive adhesive 1018 is
applied to the flexible
film 1.012, the continuous closure layer 1014 may be applied thereon. In
another configuration,
the pressure sensitive adhesive 1018 may be applied to the continuous closure
layer 1014 just
before application of the closure layer 1)14 to the film 1012.
[001.51] FIGS, 24 and 25 illustrate exemplary cross sections of FIG. 23. As
noted above, the
packages may have a release ink 970 incorporated therein. The release ink 970,
as illustrated,
may be disposed between the pressure sensitive adhesive 918 and the flexible
film 912.
Furthermore, as shown in FIG. 24, the release ink 970 rna.y be disposed just
underneath the
continuous closure layer 914. In another configuration, shown in Ha 2.5, the
release ink 970
may be disposed beyond the width of the continuous closure layer 914 and, in
some
configurations, may be disposed over the entire width of the flexible film
912.
[00152] FIG. 27 illustrates one exemplary process 1100 for producing a series
of flexible film
package blanks in an off-line manner. In such a configuration, a continuous
closure layer 111.4
(which may be narrower than the width of the roll of flexible fi.1111 web
1112) may be applied
over a portion of .the flexible film web 1112. In addition, a score may be
formed into at least the
flexible film 1112 by a score forming mechanism 1172. As noted above, the
score may be
formed on the interior surface of the package, i.e., on a side of the flexible
film opposite the
closure layer. In addition, if a score is formed into the continuous closure
layer 1114 (either
partially or completely through the closure layer), such as shown in
configuration of FIG. 11,
then another score fonning mechanism 1174 (illustrated in dashed lines in FIG.
27) may be
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eniployed. Furthermore, though a single score forming mechanism 1172 is
illustrated and may
form both the score that provides a package opening and a score that partially
forms the tab
portion, these scores also may be formed by two separate score forming
mechanisms.
[001531 The laminate including the scored flexible film web 1112 and the
continuous closure
layer 1114 then may be wound on a laminate roll 1184. This laminate roll 1184
may be
subsequently brought to a packaging line for use in forming individual package
filled with
product. The packaging line may be. within the same facility as the laminate
forming equipment
illustrated in FIG. 27, or alternatively, the laminate forming equipment may
be remote from the
packaging facility.
[001.54] One exemplary in-line process 1200 for producing flexible film
packages is shown in
FIG. 28. By one approach, a continuous closure layer 1214 is applied to a
continuous flexible
film 1212. A score fonning mechanisms 1272. may fonn the scores on the
interior surface of the
package. As noted above, if a score is formed through the continuous closure
layer 1214, then a
score forming mechanisms 12.74 may be positioned adjacent the continuous
closure layer 1214.
Then, a package fonning or folding mechanism 1278, such a forming collar, may
be employed to
wrap the flexible film 1212 and closure layer 1214 around a product or in a
configuration that
can retain subsequently filled product. A filling mechanism 1277 may be
employed to fill
product 12.80 into the. partially formed web of film. Once the flexible film
12.12 and continuous
closure layer 1214 are filled with product 1280, another package forming or
folding mechanism
1279 may be positioned just upstream of package die 1282 (both of these
functions may also be
perfornied by a combined forming mechanism and package die). The package die
1282 may
include the knife that fOrMS the separation cut between packages and also may
include the seal
bars that form the end seals of the package. In addition, the package die 1282
also may form the
longitudinal seal, though the longitudinal seal may also be independently
formed. Though FIG,
28 ilõlustrates a horizontal fonning configuration, the processes described
herein also may be
performed in a vertical configuration.
[00155] In addition, while these two schematic views illustrate two exemplary
manners of
forming some of the package configurations described herein, additional
elements may be added
to form some of the packages. For example, to form packages from package blank
705 (FIG.
21), the processes may further include. a tab cut assembly,
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[00156j Turning now to FIGS, 31-34, various configurations of a flow-wrap
package generally
indicated at 10' are illustrated therein, in addition, FIGS, 35-38 illustrate
the packages 10' of
FIGS. 31-34 respectively in open configurations. Several of these packages are
illustrated in
various stages of manufacturing in FIGS. 39-43, Further, additional
configurations of the labels
and score lines are illustrated in FIGS. 46 to 50.
[001571 The various configurations of package 10' can be formed by joining
opposing sides of
the flexible film 12' together to form a seal 14'. By one approach, the
flexible film 12'
preferably has a sealant layer on an interior surface thereof. End seals, such
as trailing and
leading end seals 1.8', 20' also may be provided. By one approach, the leading
end seal 20' may
be non-peelable seals, i.e., a destructive seal where the sealant layers are
considered to have
bonded and do not separate from one another when pulled apart, such as that
found in FIGS. 32,
34, 46-47. By yet another approach, the leading end seal 20' is a peelable
seal, ix., a seal having
sealant layers that may be pulled apart or separated from one another, such as
that found in
FIGS. 31 and 31 Generally, at least one of the packages end seals may be a non-
peelable heat
seal, such as trailing end seal 18'.
[00158] Conventional film package end seals may not allow a user to easily
open the package at
the end seal itself, especially if very small or sio free ends or unsealed
portions are distally
adjacent the end seals. In such configurations, the body of the package film
may be grasped, and
the package panels pulled apart to open the package. As disclosed herein, a
tab portion may be
provided to allow easier opening of the package. In one example, the leading
end seal 20' has a
pair of tabs 22' (one formed in the upper and lower portion of the flexible
film) fonrned distal to
the end seal 20'. As illustrated, tabs 22' are radially shaped tabs, though
other shapes are
possible. The tabs 22' provide a finger grip to initiate opening of the
package. A trailing
package edge 24' shows a concave radial shape corresponding to the shape of
the tab 22'
adjacent the leading edge. The reciprocal shape of the leading and trailing
edges are formed
when the flow-wrap package 10' is formed or separated from a roil of film or
when the packages
are separated from one another,
[00159] In the configuration of FIG. 31., the leading end seal 20' Cau be
peelable. Peelability
may be achieved by using a sealant layer on the interior surface of the film
12', The peelable
end seal can be formed by heating the seal area to between about 85 to 205
degrees Celsius,
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though the peelability of the seal is dependent on the range of heat used for
the seal, line speed,
and film thickness. Generally, the higher the temperature, the lower the
peelability and the
stronger the seal. In addition, the peelability and strength of the seal can
be adjusted through the
use of patterns or knurls, For example, if the pressure sensitive adhesive is
not completely
disposed to cover the entire surface area of the label 40. In such a
configuration, the pressure
sensitive adhesive may be provided in a patterned configuration, such as a
cross-hatched pattern.
By another approach, the sealing jaws that create the heat seals may include a
knurl pattern
thereon.
[001601 As noted above, laser-formed scores or mechanically-formed or rotary
die cuts may be
formed into the flexible filrn 12' and may define. a package opening and/or
the tab portion. The
score may be added to the film surface that becomes the interior of the
package, hi addition, the
die cutting or laser scoring of the film 12' is not limited to a particular
gauge of material or
composition. Thus, a variety of films may be used in the packages, which gives
the package and
the process for forming the package some flexibility. In addition, this can
result in a product that
is more cost effective than that found in the prior art. The tear strength of
the score 42' may be
at least weaker than the adhesive strength of the pressure sensitive adhesive
30' to permit a
portion of film 12' to peel back with the label 40'.
[00161] By one approach, the score 42' only extends through a portion of the
package to avoid
negatively affecting the barrier properties of the package 10', If the score
42' is a partial depth
score line, the label 40' may not need to provide the initial hermetic
barrier, though optionally it
can. By yet another approach, the score 42' extends through the entire depth
of the package film.
The optional barrier properties of the label 40' may result from an inherent
characteristic of the
label material, or through an added barrier layer to label 40' not shown).
Further, in.
configurations where the score 42' may affect barrier properties of the film
12', the label 40'
may be configured to compensate for the compromised barrier properties.
[00162] A variety of differently configured score lines may be incorporated
into package 10'.
For example, depending on the packaging materials, configuration, and product
specifications,
the desired package opening and tab may change. The seal area or end seal can
stop or inhibit
propagation of a score or the score pattern itself may be configured to
provide such control.
FIGS. 31 to 34 and 46 illustrate several possible configurations.
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[001631 As shown in FIG, 31, a score line 42a' begins at the leading edge of
the package (near
the end seal 20') with two score lines that extend rearwardly, angling inward
and merging to
form a single tear line before terminating at an arcuate "smile" portion 56'
discussed below. In
this configuration, a consumer may grasp an unsealed lower layer of tab 22
with one hand and
the laminate of label 40' and tab 22' from the upper film 12' with the other.
The upper portion
of tab 22' can be peeled back, rearwardly, to expose opening 44'. Once the
opening 44' is
exposed, the label 44' may be used to reclose the package 10'. As shown in
FIG. 35, the label
40' may be pulled off the package 10' to expose product 46'; however, the
label 40' is preferably
not pulled entirely off the package 10' during use. To prevent removal of the
label 40' from the
package 10', the trailing end seal 18', may include a permanent, non-peelable
seal adhering label
40' to film 12'.
[00164] FIGS. 32-34 illustrate additional score configurations 42b', 42.c%
42e', These lines
may be straight, arcuate, or a combination of both. 'While the score 42a'
extends into the leading
end seal 20', scores 42b', 42c', 42e' are disposed between the end seals 18',
20' of one package
10'. The score lines, such as 42c' and 42e', may be used to provide a portion
or cut-out of film
12' that is completely reinoved from the remainder of the film 12' (See FIGS.
37 and 38). In
addition, the score lines, such as 42a', 42b', 42d' may include a terminus
designed to prevent or
inhibit further propagation of the score line past the score provided in the
Min during
manufacturing,
[00165] To facilitate grasping and pulling of tab 22', the label 40' may
include an adhesive free
area 50'. While some previously described configurations disclosed a portion
38 of the flexible
film 12 peeling upward from the remainder of the package, other configurations
(such as FIG.
33) may include packages where there is no tab score to form a portion 38 for
separation from
the flexible film. If only the closure layer or label is pulled upward from
the film at the end seal,
the grasping, tab portion is formed in another manner, For example, the tab
22' may be formed
without any pressure sensitive adhesive disposed thereon. As illustrated in
FIG. 37, a tack free
or adhesive free area 50' can be employed to form tab 22'. In addition, a
deadening agent may
be used to deaden the adhesive applied thereto. For example, a coating
process, such as that
employing an ink or varnish, may be used to deaden the adhesive on the tab
22'. In addition, the
continuous closure layer or label 40' may be folded over upon itself to form a
tack free area that
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may form tab 22'. If only the label 40' is lifted from the package to expose
the package opening
(i.e., a portion is not removed from the remainder of the film), then the
leading end seal adjacent
the tab 22' can extend to the leading edge of the package or the separation
cut that forms the
package.
[001661 As discussed above, in addition to an adhesive-free or adhesive-
deadened zone, the
tack-free tab may be formed by having a portion of film cover the adhesive. In
sum, a portion of
film 12' may separate .from the rernaind.er of the film 12' to cover the
adhesive. As shown, for
example, in FIG. 32, a score line 42d, such as a crescent shaped score, may be
added into the
.film 12' at the top layer of the end seal 20' to permit a portion of the film
12' to separate
therealong. In FIG. 32, the upper layer of tab 22' is not sealed (or peelable)
with the lower layer
of tab 22' because the scored, removable portion of film 12', remains attached
to the label 40', as
illustrated by the scored cut-out 42d'. In one configuration of FIG. 36, the
leading end seal 20'
is preferably a non-peelable; permanent seal that retains its integrity even
after the label 40' has
been pulled and the package opened and closed. Further, the package 10' may be
opened by
peeling the resealable label 40' upward from the non-peelable seal between the
film layers
without disturbing the end seal 20'. A similar package configuration is
illustrated in FIG. 46,
[IX11671 Exposed score lines tend to propagate a continued tear in use.
Specifically, as a score
line is being separated or ruptured the film will continue tearing past the
point where the score
line is originally formed in the film once the score line has begun
separating. Thus, score lines
may be configured to inhibit or resist this tendency. For example, FIGS, 31
and 34 illustrate an
arcuate "smile" portion 56' at an end or terminus of score line 42a'. FIG, 32
illustrates a
"shepherd's hook" or I-shaped hook at the terminus of the score line 42b'. Fla
33 illustrates a
score line 42c' having a closed shaped loop, which also helps prevent
undirected tearing of film
12'. FIG, 46 illustrates a score line 42f' extending into pemanent, trailing
end seal 18'.
[001681 In addition to the "smile" portion 56', score line 42a' also includes
a single, straight
portion that separates into two portions that angle outward before becoming
parallel to one
another closer to the leading end seal. The score line 42a' extends to the
leading edge of the
package 10'. FIG. 34 includes a score line 42e' similar to that found in FIG.
31, except prior to
reaching the leading end seal 20% the score line 42e' angles inward and
becomes a closed shaped
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loopõiks illustrated in FIG. 38, the package 10' of FIG. 34 includes a portion
of film 12' that is
removed from the remainder of film 12'.
[001691 As discussed above, a continuous closure layer or label 40' may be
applied to the
exterior side of film_ 12' that is directed to the outside of package 10',
preferably using a pressure
sensitive adhesive. The label 40' preferably covers at least the score lines
42'. The peel strength
between the surface of the package 10' and the label 40' is greater than the
force required to
separate sides of the score line 42'. Further, label 40' is peelable with
respect to package 10'.
For example, FIGS. 36 and 37 illustrate a portion of film 12' adhering to
label 40' and the
pressure sensitive adhesive disposed thereon to expose package opening 44'.
Thus, continued
pulling on tab 22' initiates rupture or separation of the score line 42'. In
one illustrative
embodiment, the pressure sensitive adhesive can be configuration, f(-,ir
example, to have an
opening (separating) force of about 350 grams/inch and a closing (adhering)
force of about 200
grams/inch. In addition, other opening and closing force ranges are considered
to fall within the
scope of the present embodiments.
[001701 The label 40' may he any film with an adhesive coving such as, for
example, a flexible
film with pressure sensitive adhesive, a tape, label, or tillerless label that
is continuously applied
longitudinally to the flow of film, unlike discrete labels known in the art.
By one approach, a
tillerless label may be a facestock having a pressure sensitive adhesive
coating on one side and
can be rolled onto a spool without a liner. For example, a release coating
rnay be applied to the
side of the label opposite the side with pressure sensitive adhesive.
Facestocks may include, for
example, standard paper, film, plastic, fabric, foil, direct thermal, and the
like. In addition,
linerless labels are available with removable and repositionable adhesives.
[00171J If tape or a linerless labei are employed, the liner waste is
eliminated. In addition,
precise registration of the label on each package is no longer required due to
the continuous
application of the label on the flow of package film. Though the package 10'
rnay be formed
with a continuously disposed label 40', the package 10' may also be foil/led
with a discrete label
40b', 40c', 40d' as shown in FIGS. 47-49.
[00172] As noted above, additional scoring, such as tab score 15 previously
discussed, may be
enaployed to assist in forming a tab. As illustrated in FIGS. 32 and 34, score
42d' can be added
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to package 10' to assist in the rupture of film 12' by forming a separable
portion that can adhere
to tab 22'. FIGS. 36 and 38 also show that a user can pinch and pull the
laminate (including
upper film 12' and label 40') rearward to open package 10'. As it is pulled,
score 42d' separates
or ruptures such that a portion of film. 1.2' separates from the remainder of
the film and pressure
sensitive adhesive 30 is exposed on the underside of label 40'. This permits a
portion of the film
12' to remain on label. 40' to provide a tab having no exposed adhesive, while
al.so providing
sufficient adhesive on the label 40' to cover and surround opening 44'. Also,
during open and
reclose of the package 10% the leading end seal 3cr remains intact, despite
separation of a portion
of the. film 12' near the leading end seal 30',
[00173] Another configuration, illustrated in FIG. 50, includes a score line
42g' that is disposed
within ends seals 18'. DT and score line 42i' that is disposed at end seal
20'. Specifically, score
line 42g' is formed in film 12 and includes a slightly arcuate portion
connecting two parallel
portions. The slightly arcuate portion of the score line 42i' is disposed near
end seal 20', and the
parallel portions extend to end seal 18'. The score line 42i' includes a
series of straight parallel
lines .formed in film 12'. Having multiple lines helps ensure that at least
one of the multiple lines
is disposed distal and adjacent to the end seal 20'. In this way, one of the
multiple score lines
42i'will permit a portion of the film 12' to be removed from .the remainder of
the film 12' to
cover the pressure sensitive adhesive on the label 40'. Further, to permit
removal of a portion of
the film 12' for a tab, at least a portion of the score line 42i' is
preferably positioned on film 12'
outside of the interior space of the package 10', i.e., not between the end
seals 18', 20'. In short,
having multiple score lines adjacent the end seal and distal thereto allows a
tab to be created
even if, during production, the registration of the package elements is
misaligned,
[001741 Flexible .film packages 10' may be formed and assembled in a variety
of manners. An
exemplary process 60' for forming flexible film packages is schematically
illustrated in FIGS.
44-45. In one configuration, opposite sides of the film 12' may be joined to
form a fin seal 14',
and a package height and interior space may be defined. More particularly, fin
seal 14' may be
formed as two film edges are brought together and sealed by heated wheels. To
facilitate the
formation of tlut desired type of seal, a sealant layer may be disposed or
applied to the film 12'.
Vihile the sealant or internal adhesive may be applied such that it covers the
entire interior
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surface of the film 12', it also may be applied only where it is needed to
provide a seal, i.e., near
the end and fin seals.
[00175] The end seals 18', 20' may be fomied once product 46' has been placed
in the interior
space of package 10'. End seals 18', 20' also can define package 10' width or
length. The seals
14', 18', 20' are preferably hermetic seals that form a gas and moisture
barrier. Similar to other
seals discussed herein, the seals 14', 18', 20' can be thermoformed (i.e,,
heat welded) or formed
through other welding means. For configurations where the end seal 20' is
peelable, a low tack
adhesive or a cold seal and processes for forming such seals may be used. In
addition, the end
seals 18', 20' may employ patterns, crimps, or knurls,
E001761 As noted, the label 40' can be applied continuously along the
longitudinal length of the
flow or web of the film 12'. Once the products are at least partially
enveloped and sealed within
the web of film 12', the film and label laminate may be cut into individual
packages. FIGS, 41
and 42 illustrate a series of formed packages that have not been separated
from one another. In
one illustrative configuration, the tabs 22' may be formed, in part, by an
arcuate score 42d'
formed, in part, on a roll of film, and disposed at least partially at leading
end seal 20'. 'When the
individual packages are cut from the rol/ of laminate, a leading edge or
profile of the tab 22' may
be formed. For example, the leading seal on a first package has a profile
matching a trailing seal
on a second package. Thus, the tab 22' may have a front edge that is arcuate
and defined, in part,
by the leading edge of the package and may have a rear, trailing edge that is
arcuate and defined,
in part, hy the arcuate score line 42d'.
[00177] As discussed herein, the method of manufacturing and assembling the
packages can
employ heat seal mechanisms, cold seal mechanisms, extrusion and adhesive
lamination
mechanisms, and co-extrusion mechanisms. The equipment employed may depend on
the
desired package configuration. For example, if tab 22' includes a cut-out
portion of film 12'
adhered to the label 40', the tab 22' may be created by adhering or applying
the label 40' to the
film 1.2' and scoring and/or cutting the tab 22'. In addition, various score
configurations may be
employed, and the equipment for forming the score line may depend on the score
configuration
thereof.
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[00178) The exemplary method 60' of making packages, shown in FIG. 44, may
include a
package apparatus that positions the film above or adjacent the product, then
wraps the film
partially around the product to form a fin seal on one side of the product. As
shown, film 12'
and label 40' (which may be transparent) are joined or merged form their
respective feed rolls,
Prior to merging label 40', film 12' may be scored at 52' on the film surface
directed to the
interior of the package, though the top surface also could be scored. In
another configuration,
the label 40' is preferably merged to the film 12' prior to the score station
52'. As noted above.,
the score may be formed in a variety of manners. The fin seal 14' may be.
formed as the film 12'
and label 40' laminate fonrn a container or box 34' around the product 46'
(see, also, FIG. 45).
Though fin seal 14' is oriented on the bottom of package 10' in FIGS. 44 to
45, it may be
oriented on any side of package 10'.
[001.79] In one approach, heated wheels may be pressed together to form the
package seals. For
example, if sealant layers are employed, the heat may activate the heat
sealant layer on the
interior surface of the package. In one configuration, an EVA sealant layer is
disposed on the
film 12', and the heated wheels may be heated to between about 85 and 205
degrees Celsius, As
noted above, line speed, film thickness, and other factors may affect
formation of the seals,
including a seal's peelability and hermeticity.
[00180] FIG. 44 illustrates that, once the film 12' has at least partially
enveloped product 46',
end seals 18', 20' can be formed by adjacent upper and lower seal jaws 62', as
discussed below.
The seal jaws 62' may form end seals of the package (such as heat seals) and
also may form or
define the tabs 22', such as, for example, the tab portion between the end
seals 18', 20'. In
configurations with activated heat seals, seal jaws 62' may be warmed by a
heater element (not
shown). In addition, separate heating elements are possible where different
levels of peelability
are desired between trailing end seal 18' and leading end seal 20'. In
addition, a knife assembly
may be used to fully separate individual packages or, alternatively, partially
cut or perforate a
portion between the packages to hold them together while providing a
convenient manner of
separating the packages when desired.
[001811 The fin seal 14' and end seals 18', 20' optionally may be formed from
patterns
imprinted on heated wheels 38' or seal jaws 62', which may emboss the film 12'
as it is pulled
through the manufacturing process. For example, the seal jaws 62' may rotate
with the film web
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12' as it moves through the production line and the seal jaws 62' may meet to
form end seals 18',
20' and the seal jaws 62' also may form the tab 22' and/or separate the
packages from the film.
Alternatively, the film 12' may be cut with a tab cutter die. As the seal jaw
62' forms a leading
end seal 20' on one package, the seal jaw 62' may form a trailing end seal 18'
on another'
package. In a configuration where the seal jaws 62' form both the trailing end
seal 18' and
leading end seal 20' in the same operation, a space will be provided in the
die where the film 12'
is not sealed together. This space corresponds to the space 42' between the
seals of adjacent
packages. The free, unsealed poitions of the packages 10' between the end
seals 18' 20' of
adjacent packages (illustrated at 42' in FIG, 43) may have a dimension 64'
that is about 6 to 12
rum, The tab 22' is primarily formed in this portion of the package 10',
though the rear, trailing
edge may extend partially into the leading end seal 20'. If the seal jaws 62'
form the two seals
18', 20' of adjacent packages at the same time, the dimension 64' is defined
by the distance
between the end seal areas on the die. Alternatively, the two end seals 18',
20' could be formed
by two separate dies (as opposed to a single die with two separate sealing
areas for the two end
seals) or a single sealing die that is repeatedly applied to the film to form
the two end seals.
[001821 Optional or alternative features also may be incorporated. into the
packages described
herein. For example, an optional frame 32', as shown in FIG, 37, may be added
to the package.
The film 12' may be wrapped around the frame 32' to provide protection to the
product 44'.
Additional configurations, such as a vertical bag package, also may use the
seal and reseal
features described, especially for use with particular products, such as
coffee.
[001831 Other alternative features may include a discrete label, as opposed to
the continuous
closure layer or label. A discrete, registered label may be applied to the
package 10' and the
other seal and reseal features may be incorporated therein. For example, FIG,
37 shows a
package 1.0' having a discrete label 54' that may be applied between the end
seals 20' and 18'.
An unsealed area can extend past leading end seal 20. FIG. 38 illustrates
another package 10'
having a discrete label 54' applied to film 12' so that one end of he label
54' can be sealed to the
trailing end seal 18' of the package 10' such that the discrete label may not
be easily removed
from the package 10'.
[001841 Though the embodiments of FIGS. 31 to 50 were described as having a
fin seal, a lap
seal also may be employed. A lap seal can be formed by first overlapping a
first and second
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surface of the film (typically adjacent the edges of the film) to form a
sleeve (as opposed to
overlapping in the same surface for a fin seal),
[00185] FIG. 51 illustrates another flow-wrap package 10". Package 10" is
formed by joining
opposite sides of the film to form a seal (shown as a fin seal 14"). The film
12"preferably has a
sealant layer on an interior surface thereof, In addition, a trailing end seal
18" and a leading end
seal 20" are also provided. ln one configuration, the leading end seal 20" is
non-peelable.
Package 10" may be formed in a continuous application operation, such as those
described
above with respect to FIG. 1, or may be formed in a process employing inner
and outer die cuts
(see, e.g., FIG. 69), or also may be formed in a discrete label application
(see, e.g., FIG, 68).
[00186] As discussed above, score lines tend to propagate a tear being formed
in the film, and
thus, the score may be configured to inhibit or prevent unintended tearing of
the film. The score
42" may have a pattern to reduce this tendency including, for example, a
double "J" hook (FIG.
53), a "simile" (FIG. 54), or a "tear drop" (FIG. 56). In addition, a
shepherd's hook and a single
"J" hook may be employed.
[001871 FIGS. 52 to 56 illustrate various film score patterns 42" that may be
incorporated into
the film packages disclosed herein. FIG. 52, for example, illustrates a "T"
shaped score 42"
having a straight portion 42a" along with shaped opening portions 28a". FIG.
53 illustrates a
"1" hook-shaped score that has an arcuate portion 42b" and a shepherd's hook
configuration
28b" at one end and two "smile" portions or "J" hooks at the other end. FIG.
54 illustrates a
score 42" having a circular-shape or loop opening 28c" and a generally
straight section 42a"
that terminates at a "smile" portion. FIG. 55 illustrates a score 42" with a
spoon-shaped
configuration 28d" that reduces to two generally straight and substantially
parallel score lines
42c" that terminate in a "smile" configuration, NVhen parallel scores are
formed in film 12",
such as those illustrated in FIG. 55, the parallel score lines are preferably
not more than 5rnm
apart frotn one another. FIG. 56 illustrates a score 42" having a shepherd's
hook configuration
28e" at each end and an arcuate portion 42b" therebetween, Additional film
score patterns and
configurations can be found in Figs. 161-189 and are described below.
[00188] Depending on the score 42" incorporated into the package, the opening
created by the
score 42" may permit the package opening to be sufficiently large enough to
easily serve and
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access a substantial portion of the product contained therein, .Further, in
some configurations,
the tendency of the flexible fihn to create a significant opening is, in part,
due to the tendency of
the flexible film to revert back to its flat sheet form. This tendency may be
especially evident for
discrete stacks of generally round or oval-shaped products, such as a sleeve
of round cookies,
crackers, or biscuits, to note but a few. This occurs primarily when no frame
is used within the
flexible film of the package.
[00189] _Alternatively, the score 42" may include a straight line extending
longitudinally
completely or partially along the length of the package, as shown in FIG. 63.
In one
configuration, the score 42" may be continuously formed in the package film
12", and at the
point where the end seals 18", 20" are formed, the sealant in the films 12"
may be melted at the
heat seal, which may then render the score 42" non-functional at the end seals
18", 20" to
prevent unintended opening of the package at the seals.
[00190] As discussed above, the leading end seal 20", like leading end seal
20', may have a tab
22" formed distal thereto. In one approach, the tab 22" can be a "v" shaped
tab, though other
configurations, such as a square shaped or radial shaped tab, are possible.
The tab 22" provides
a finger grip to initiate opening of the package 10". A trailing package edge
may include a
concave shape corresponding to the shape of the leading edge tab 22". The
leading end seal 20"
may be peelable, i.e., have sealant layers that are separable from one
another.
[001.91] As shown in FIG. 51, the label 40" may be grasped and pulled upward
from the
package 10" to expose score line 42a" and package opening 44". A pressure
sensitive
adhesive 30" is positioned between the label 4(Y' and the film 12". As
discussed above, a score
may be provided through the film 12" at the tab 22" such that a portion of the
flexible film 12"
may separate from the remainder of the film to provide an adhesive-free
grasping portion. In
addition, the adhesive-free grasping portion may be formed by deadening the
adhesive disposed
upon the tab 22" or pattern applying the adhesive on the label 40" or film 12"
such that no
adhesive is disposed on the portion of label 40" that becomes tab 22".
[001921 FIG. 57 illustrates another package 10" having an unsealed inner
surface 50" of the
tab, which can be grasped by a consumer with one hand, while the package may
grasped with the
other. The label 40" may then be pulled backward to expose opening 44", as
shown in FIG, 51.
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The label 40" is preferably not pulled entirely off package 10" during use,
and therefore, the
trailing end seal 18" may be fonrn a non-peelable or permanent seal between
the label 40" and
the film 12". Alternatively, in some configurations, it is anticipated that
both ends of the
package 10" will be able to have label 40" peeled upwards, and thus, both end
seals may be
peelable. For example, the score 42" illustrated in FIG. 6 may be used along
with a label 40"
and two tabs at both ends of the package 10". This permits a user to open the
package 10" at
either end with resealable seals provided for both openings.
[00193] As discussed above, package 10" may be formed in a variety of
processes. ln one
illustrative package illustrated in FIG, 69, a laminated film 12" has at least
two polymer film
layers 12a" and 1.2b" attached with a pressure sensitive adhesive 30". The
film layer 12a" may
have a score 58" formed therein to create a label 40". The film layer 12b" may
have a score
42" formed therein to define opening 44". The score formation may occur before
or after
lamination of the film layers 12a, 12b, but preferably after lamination. In
this configuration, the
film thickness m.ay be in the rage of about 1.8 to 3.0 mils. By one approach,
the film may be
about 2.1 mils for this type of configuration,
[001941 One exemplary manner of forrning film packages 10" is illustrated as
60" in FIG, 60.
Process 60" is similar to that discussed above and illustrated in FIG. 44,
FIG. 61 illustrates a
schematic cross section of the seal jaws that may be employed with process
60".
100195/ The various configurations of the flexible film package disclosed
herein may be
provided a package integrity feature that would indicate to a consumer whether
or not the
package has been previously opened.
[001961 By one approach, after the consumer has removed some of the products
from the
flexible film package, the flexible film may be rolled, folded, or otherwise
flattened to evacuate
air from inside of the package. Then, the elongated closure layer 14 may be
wrapped over the
rolled film arid the product within the package making the package smaller,
with less air space
arid, thus, may improve shelf-life of the product (see, e.g., FIG. 59), Such
configurations are
generally employed for packages without a structural support, such as a frame
or tray; however,
it is also anticipated that such a configuration may be employed with certain
structural supports,
depending on the configuration of the structural support and the flexible
film.
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[00197] In addition to the configurations of the embodiments described above,
a multitude of
additional flexible package embodiments are possible when applying a discrete
or continuous
closure layer 14, such as a label having a pressure sensitive adhesive as
described above, over
scored film. These configurations can include variations and combinations of
several package
aspects. Generally, as will be described in more detail below, illustrative
flexible packages can
include variations and combinations of pull tabs, multiple lines of weakness
formed in and
beyond the end seals into end portions extending beyond the end seals between
the trailing end
seals arid the leading end seals of packages formed in a series, a perimeter
score formed arowid
the end seals alone or in combination of the multiple lines of weakness, and
various scoring
patterns to add further variety and utility to the package openings.
1001981 In addition to flexible film, as described above, it is noted that
some embodiments may
be formed from other materials including, but not limited to paper, paperboard
(including poly-
lined paperboard), rigid and semi-rigid polymers, metals, foils, composites,
and the like.
Materials can be selected based on .the need for package integrity,
maintaining shape,
maintaining a barrier (such as an oxygen or moisture barrier), light barrier,
and the like.
[001991 By one approach, where a package is formed.1 by a flexible film, the
flexible film has
two opposing edge portions that ineet to form a longitudinal seal extending
from a first end seal
to a second end seal. It is noted though that other embodiments can be formed
such as a hollow
tubular package having two end seals to seal each end of the tube. In this
instance the package
material can be an extruded polypropylene resin to form a hollow tube.
Vertical form and fill
packages as described above and shown in Figs. 190-1.96 can also be provided,
including
gusseted embodiments, such as shown in Fig. 190.
[00200] The flexible film may have a "score" as described above that defines a
package opening
upon initial rupture or initial opening. In addition to the score patterns
described above, FIGS.
161-189 show additional score pattern configurations. It is noted that in some
embodiments
where the score line is enclosed (or partially enclosed), such as FIGS. 167,
170, 175, 180-183,
186 and 187. For example, the score may create a cut away portion (film
portion surrounded by
a score) that remains adhered to the closure layer via the pressure sensitive
adhesive when the
closure layer is lifted away frorn the package. The cut away portion may
create a larger opening
into the package when the closure layer is lifted from the package. In
addition, the embodiments
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can also include tear propagation restrictions such as J-hooks (FIG. 161),
Sheppard hooks (FIG.
169), or smile hooks (FIG, 188).
[002011 The embodiments described herein can provide a closure layer (label)
which can be
built into the film as a laminate, applied discreetly to a package surface
(such as the surface that
will become the interior or exterior surface of a flexible film), or applied
continuously to the
package material prior to forming the package (which can be applied as he.
interior or exterior
surface of a flexible film). Continuous closure layer applications, such as
shown, for example, in
.Fig,1 and 18, can be formed from flexible film which has had a label pre-
applied (see Fig. 23).
Exemplary variations of the elongated or continuous closure layer (label 14)
are shown in Figs,
1.52-160, 185, 189-19, It is noted though that in continuous label embodiments
the label can be
applied to the longitudinal axis of the package (i.e., from one end seal to
another) or even
transverse to the longitudinal axis, such as shown in FIG. 191(from side to
side). A closure layer
score or top cut 13 (see FIG. 154) of label 14 provides a cut or separation of
the label such that a
narrower portion of the label is lifted from the package at that point such
that the user has an
easier time opening the package. Since pressure sensitive adhesive is disposed
between the label
14 arid the film 12, the area of label I. between the edges of the label and
the score opening
2200 facilitates resealing of the package after initial opening.
[002021 As described above, the elongated closure layer preferably extends
over the score and
extends from the first end seal (or to the first package end) to the second
end seal (or second
package end) and within the opposing edge portions that meet to forrn the
longitudinal seal. A
pressure sensitive adhesive may be located between the flexible film and the
elongated closure
layer. It is also noted that in embodiments where film is removed from an
enclosed score line,
the label's exposed pressure sensitive adhesive directed to the package
interior can be deadened
prior to placement of the label onto the package,
[002031 The embodiments described herein can provide several types of lines of
weakness 2400
(see e.g., tab scores 15 described above) to facilitate the separation of film
from the closure layer.
Some illustrative examples can be found in FIGS. 99-144. In some
configurations, the lines of
weakness 2400 are within the leading end seal region, but can also extend
beyond the end seal in
the direction away from the package interior and into the free ends between
the end seals of
adjacent packages. Preferably the lines of weakness do not extend on the fihn
towards the
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package interior. Otherwise, the lines of weakness could tear into the film.
Also, while the lines
of weakness may be nested, such as ShOWII in FIG. 121, in some applications,
the lines do not
overlap at any point along the rise and fall of the. line (see e.g., FIG 117).
[002041 The multiplicity of the lines of weakness allow for the reduction in
accuracy of
alignment of the score within the end seals, thus providing ease of alignment
of the lines of
weakness scoring device. The lines of weakness 2400a in FIG. 99 provide
reduced lateral force
as the peel tab is pulled down to open the score line defining the package
interior. The niultiple
sinusoidal ridges allow opening at several points along the length of the end
seal. It is noted that
angular and pointed multiple lines of weakness are preferably provided with at
least a small
radius in the range of about 0.1 .mm to 25 nam (preferably in the range of
about 0.25 mm to 2.5
inm) to reduce tear propagation.
[002051 Also provided in some embodiments are various perimeter score 2300
embodiments.
FIGS. 80-98 illustrate SOIrle approaches. Perimeter score 2300 is designed to
catch the tear
propagation across the lines of weakness 2400 as the package is opened such
that at least one of
the lines of weakness will tear and terminate at the perimeter score after
opening. In these
embodiments, the perimeter score 2300 preferably does not touch the lines of
weakness 2400. In
other embodiments, a perimeter score can be added to a package configuration
without a line of
weakness. Generally, the perimeter score is oriented within the package end
seal and extends
distally frolic' the package interior outward and, where present, upward
around the multiple lines
of weakness. In other words, the perimeter score extends distal to the package
body and toward
the free ends/edges of the package. The perimeter score can extend to the
flexible film edge,
even if the flexible film extends beyond end seal.
[002061 The combinations of the lines of weakness 2400 with a perimeter score
2300 provide
excellent tear propagation management. Various combinations are shown in FIGS.
146-160.
For example, FIG. 152 shows a portion of a series of packages that are
ultimately cut along line
2100a (also, see separation line at 2102, FIGS. 152-153). As shown in FIG.
152, as a package is
cut, tab 2100a is formed in the gripping portion of the free end portions of
the film between the
packages that are not joined by end seals. In the free end portion of the
flexible film front and
rear package panels are not connected allowing a user to pull the tabs 2100a
apart. The top panel
of the package is a film/label laminate. As a user pulls the film
label/laminate away from the
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package, resistance is net when the end seal 28 is reached. The peel force of
the pressure
sensitive adhesive between the label and film is less than the peel force of
the end seal.
Accordingly, as force is applied, the label begins to delaminate from the
flexible film as the
peeling reaches a first line of weakness 2400 within the end seal. As shown in
FIG, 152, the first
line of (weakness 24000 is the point of delaminating of the label from the
film. Line of
weakness 2400a is sinusoidal in shape and according can provide several points
of delarnination
evenly across the length of the line of weakness.
mar] As the peel force continues during the opening of the package the
delimitation
continues across the line of weakness until it terminates on each side. At
this point, the film tears
slightly. This tear is stopped by the perimeter score 2300, which captures the
filin tear so that
further delarnination of the label from the film continues until the score
line defining the package
opening 2200 is reached,
[002081 Other approaches are possible. For example, in FIG. 1.53, a perimeter
score 2300f
causes a label dclaminating from the film without a line of weakness 2400.
[002091 In another approach shown in FIGS. 1.90-196, a vertical fonrned and
filled bag 2500 is
shown in two configurations. FIGS. 190, 192 and 194 show a package 2500a
having a gusset
2508, while FIGS. 191, 193, 195-196 illustrate packages without a gusset.
Instead, packages
2500b have a longitudinal seal (not shown). In the package illustrated in FIG,
194, label 14 is a
discrete label applied in the region of end seal 28 and covering a perimeter
score 2502. In the
package illustrated in FIG, 193, label 14 is applied continuously transversely
to the longitudinal
axis of the package. E,11 the package illustrated in FIG. 195, label 14 is
applied continuously
along the longitudinal axis of the package.
[002101 In any event, a perimeter score 2502 is scored into film 12 beneath
label 14 and end
seal 28. In this embodiment, there is no film score to provide a package
opening. Accordingly,
the package is opened similar to opening a conventional fin seal package. That
is, to peel open
the end a user grabs the package front and back film layers and pulls the end
seal 28 apart to
expose the interior of the package through the package end. In this
embodiment, a portion of the
end seal remains intact as defined by the perimeter score. This portion is
shown at 2504 in FIG.
190, The end seal peel force being stronger than the peel force of the label
PSA. Since a portion
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of the PSA is exposed, a user can tack closed the opening at the end seal by
pinching the film
and label layers adjacent to the in tact end seal.
[00211] Fig. 196 shows a blank of a package shown in FIG, 195 having first end
seal area
(leading seal area) 42a, second end seal area (trailing seal area) 42b,
longitudinal seal area 42c
and fold lines 2506.
[00212] It is also noted that multiple configurations of a scoring pattern are
possible to practice
this embodiment. For example, a series of holes such as shown on Fig. 12.3
could also be used as
well as any other lines of weakness that are enclosed (e.g., 120, 124, 125-
128, 130, 133-135),
[00213] The present embodiments can also vary tab 2100 configurations as shown
in FIGS. 70-
79. The variations can be geometric such as round (FIG. 70), pyramid (FIG.
76), trapezoid (FIG.
72), horizontal (FIG. 74), square (FIG. 77), etc. Variations can also be
positional, such as an
offset (FIG. 73) or side pull (FIG. 70). As shown in FIGS. 75 and 78-79, tab
2100 can be form
by notches in the film to initiate tear propagation. The end tabs are fomi as
the packages are cut
apart to form package leading and trailing edges, such as ShOWII at cut line
2102 in FIG. 152.
[002.14] As shown in most of the present embodiments, end seals 28 and 29 are
shown as
horizontal lines. In one approach, such as shown in FIG. 1.44, the lines of
weakness 2400at are
horizontal lines. In this approach, the end seals could be formed as
sinusoidal wave patterns. In
SOille embodiments, temper evidence features can also he added such as found
in FIGS. 157-160.
Those skilled in the art will recognize that a wide variety of modifications,
alterations, arid
combinations can be made with respect to the above described embodiments
without departing
from the scope of the invention, and that such modifications, alterations, and
combinations are to
be viewed as being within the ambit of the inventive concept.
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