Note: Descriptions are shown in the official language in which they were submitted.
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BOTTOM-GUSSETED PACKAGE AND METHOD
TECHNICAL FIELD
[0001] The present invention relates generally to packages formed from
polymeric film webs, and more particularly to a bottom-gusseted package
including a
bottom gusset positioned transversely of a longitudinal axis of the package,
with the
configuration of the package, and its method of formation, permitting use with
associated form, fill, and seal equipment.
BACKGROUND OF THE INVENTION
[0002] Packages formed from plastic, polymeric film material have found
widespread application in the market place for convenient and efficient
packaging of all
manner of food and non-food products. Packages of this nature typically are
formed by
folding and sealing a web of polymeric material to form a package body having
front and
rear package panels, with the package panels joined to each other at margins
thereof.
Depending upon the method of formation, the front and rear package panels may
be
joined to each other either by folded portions of the package body, or at
seals (typically
heat seals) joining the package panels to each other.
[0003] Non-gusseted packages of this type are sometimes referred to as
"pillow
packs", and do not include either side gussets or top or bottom gussets.
However, for
many applications it is desirable to form a gusseted package that is,
providing the
package with inwardly-extended, pleat-like gussets at one or more margins of
the
package body. For example, side-gusseted packages include inwardly extending
side
gussets at opposite lateral sides of the package body, which side gussets join
respect
lateral edges of the front and rear package panels to each other.
[0004] For some applications, it is especially desirable to provide a
bottom-
gusseted package, that is, a package having an inwardly extending gusset at
the
bottom of the package body. By virtue of the breadth and stability provided by
the
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bottom gusset, packages of this nature can frequently be configured to be self-
standing,
promoting efficient display for consumer selection.
[0005] Heretofore, bottom-gusseted packages have typically been formed by
pleating a web of polymeric material in a direction parallel to the
longitudinal axis of the
web. Suitable ploughs and forming guides shape and configure the polymeric web
as it
moves longitudinally, including formation of a continuous, inwardly extending
bottom
gusset in the web material. Subsequently, suitable seals are formed
transversely of the
web to define individual package bodies, each including front and rear package
panels,
with each including a bottom gusset. Individual package bodies are formed by
cutting
the web of material at the transversely extending seals, with the contents of
each
package deposited therein either before or after cutting of the web into
individual
packages. Formation of an upper seal, at the margin of the folded polymeric
web
opposite the bottom gusset, closes and seals each package body. By this
formation
technique, the bottom gusset has a width that corresponds to and is the same
as the
width of the front and rear package panels.
[0006] As will be appreciated by this typical formation technique, the
height or
vertical dimension of each package body is approximately equal to one-half of
the width
of the polymeric web, less the dimension of the bottom gusset. As a
consequence, the
maximum height of any package being formed is essentially limited by the
maximum
width of the web of polymeric material which the forming equipment is capable
of
handling.
[0007] The present invention contemplates a bottom-gusseted package, and a
method of formation, which addresses the shortcomings in the conventional
forming of
bottom-gusseted package. In essence, this is achieved by forming each package
with a
bottom gusset positioned transversely of the longitudinal axes of the
polymeric film web
and each package. The bottom-gusseted packages of any selected height can be
readily and efficiently formed.
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SUMMARY OF THE INVENTION
[0008] A bottom-gusseted package embodying the principles of the present
invention comprises a package body formed from a flexible web having a
longitudinal
axis. The flexible web is folded to define a front package panel and a rear
package of
the package body. The front and rear package panels are joined to each other
at
respective lateral side margins of the package body, with the flexible web
being joined
to itself along a seam which extends parallel to the longitudinal axis of the
flexible web.
[0009] Notably, a package formed in accordance with the present invention
includes a bottom gusset positioned between the front and rear package panels,
with
the bottom gusset extending upwardly and inwardly from the lower edges of the
front
and rear package panels. By formation of the present package in accordance
with the
present invention, the bottom gusset is positioned within the package body
transversely
of the longitudinal axis of the package body, and transversely of the
longitudinal axis of
the flexible web from which the package body is formed. As a consequence, a
package
body can be very efficiently formed at any selected height, without
necessarily being
limited by the width of the flexible web from which the package is formed.
[0010] Notably, the versatility of the method of package formation in
accordance
with the present invention permits formation of a bottom-gusseted package in
different
configurations. In one illustrated embodiment, a bottom-gusseted package is
formed
which includes a recloseable fastener assembly at the upper portion of the
package. In
alternative embodiments, a bottom-gusseted package is formed with a top sleeve
portion generally opposite the bottom gusset, wherein the top sleeve portion
can be
configured to include a dispensing feature, or an upper package seal. However,
it is
within the purview of the present invention that the invention be practiced
for forming
packages with a bottom gusset only, without a top sleeve portion.
[0011] The present bottom-gusseted package can be formed by folding the
flexible web of material generally at the longitudinal axis thereof, and
joined lateral
margins of the flexible web providing a seam at one side edge of the package.
The
bottom gusset of the package thus extends generally between the longitudinal
axis of
the web of material and the package seam. In alternative embodiment, a bottom-
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gusseted package is formed with the seam at which the web material is joined
to itself is
positioned in the rear package panel. By virtue of the formation technique,
the bottom
gusset of the package extends less than the width of the front and rear
package panels.
[0012] The
method of formation of a bottom-gusseted package in accordance
with the present invention comprises the steps of providing flexible web of
material
having a longitudinal axis. Suitable polymeric material can be employed by
virtue of its
liquid-impermeable characteristics, and heat-sealing capabilities.
[0013]
Together with a flexible web of material, the present method contemplates
that a flexible, sleeve-forming web is provided. The sleeve-forming web is
folded and
generally tubular, and can be configured to include a series of recloseable
fastener
assemblies, a series of upper package seal, or other features. It is presently
preferred
that an inside surface of the folded, sleeve-forming web does not heat-seal to
itself, thus
facilitating formation of a bottom gusset which spreads or opens to permit the
packages
being formed to be generally self-standing. The specific composition of the
materials
from which the package body and bottom gusset are formed can be selected as
appropriate for specific applications. For example, the sleeve-forming web,
which forms
the bottom gussets, can be made from a material which is different than the
flexible web
which forms the package body
[0014] The
present method further comprises the step of cutting the flexible,
sleeve-forming web into a plurality of individual sleeves, each having a
folded, generally
tubular configuration. The individual sleeves are next joined to the flexible
web in
spaced apart relationship longitudinally of the flexible web, transversely of
the
longitudinal axis of the flexible web. The
spacing between individual sleeves
corresponds to the length of each of the bottom-gusseted packages being
formed.
Notably, as will be further described, in some of illustrated embodiments each
individual
sleeve eventually forms the bottom gusset of one package, and the top sleeve
portion of
an adjacent one of the packages being formed. In other embodiments, packages
are
formed such that each individual sleeve is positioned within a respective
package, and
does not span or extend between adjacent packages. Efficient formation is thus
promoted.
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[0015] After the individual sleeves are joined to the flexible web, the
flexible web
is folded and joined along lateral margins thereof to form a generally
tubular, folded
flexible web. The individual sleeves are positioned generally within the
folded flexible
web, in spaced apart relationship. Folding of the flexible web material forms
a package
body for each of the bottom-gusseted packages, with each package body
including a
front package panel and a rear package panel joined at opposite side margins
thereof.
[0016] Next, the folded flexible web is cut at intervals each corresponding
in
length to the length of each of the bottom-gusseted packages being formed. By
this
cutting step individual packages are formed so that each individual sleeve
provides a
bottom gusset for each one of the packages.
[0017] In some of the illustrated embodiments, the cutting step includes
cutting
through each of the individual sleeves positioned within the folded flexible
said cutting
step includes cutting through each of said individual sleeves so that a
portion of each
individual sleeve provides: (1) the bottom gusset for one of the packages
being formed,
and (2) a top sleeve portion for an adjacent one of said packages being
formed.
Alternatively, the individual sleeves are positioned generally within the
folded, flexible
web, with the individual sleeves providing the bottom gusset for a respective
one of the
packages being formed.
[0018] Efficient package formation is promoted by configuring each of the
individual sleeves to have a length which is less than the width of the folded
web of
flexible material. This facilitates formation of the bottom gusset with a
width less than
the width of the package, which desirably permits formation of side seals
between the
front and read package panels of each package at opposite side edges of the
bottom
gusset of the package. Each of these side seals overlaps a respective end of
the
bottom gusset of the package. Such side seals can be formed of a sufficient
width to
permit the package to be readily self-standing and stable.
[0019] In accordance with the illustrated embodiments, the present method
includes joining each of the individual sleeves to the folded flexible web
prior to the step
of cutting the folded flexible web.
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[0020] In accordance with one illustrated embodiment, each top sleeve
portion is
provided with a recloseable fastener positioned within the respective top
sleeve portion.
Each recloseable fastener comprises a pair of fastening elements respectively
joined to
confronting inside surfaces of each top sleeve portion. The fastener elements
may
comprises profile fastener elements, adhesive fastener components, hook-and-
loop
style fastener components, "unisex" self-engaging fastener components, and
other
releasable fastener arrangements as are known in the art.
[0021] In another embodiment, each top sleeve portion is provided with an
upper
seal for closing a respective one of the packages being formed. In the
presently
preferred practice of this embodiment, the upper seal is formed between
inturned edges
of the respective top sleeve portion.
[0022] As noted, the present method can be practiced such the step of
folding the
flexible web of material which forms the packages includes folding the
flexible web
generally at the longitudinal axis thereof, so that each of the individual
sleeves extends
generally between the longitudinal axis and the joined lateral margins of the
flexible web
of material. The resultant bottom gusset for each package thus extends
generally
between the longitudinal axis and the joined lateral margins at the seam at
which the
web of material is joined to itself, and the side edge of the package.
Alternatively, the
web of material can be folded and joined to itself such the package seam is
positioned
in the rear package panel.
[0023] An important aspect of the preferred practice of the invention
promotes
efficient, high-speed formation. Specifically, the present method includes
intermittently
advancing flexible web of material after the individual sleeves have been
joined thereto,
wherein the flexible web of material is advanced with a tolerance range of
dimension
TLD. This tolerance range is dependent upon the specific operational
parameters of the
forming apparatus, such as the associated form, fill, and seal machine.
Notably, the
present method includes forming top and bottom end seals in adjacent ones of
the
packages being formed by operation of a pair of heat sealing jaws, wherein the
spacing
between the ends seals of adjacent ones of the packages is at least two times
TLD. This
ensures proper sealing of the ends of each package, with each bottom gusset
properly
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sealed and configured to open or splay for providing the desired interior
volume to the
package, and desired self-standing characteristics. This spacing can further
be
selected to accommodate the range in variation of the longitudinal positioning
of each of
the individual sleeves on the flexible web of material.
[0024] As noted, it is presently contemplated that the folded sleeve-
forming web
from which the bottom gussets are formed has an inside surface of which does
not
heat-seal to itself. Since package formation, and advancement through the
form, fill and
seal machine can sometimes orient the bottom gusset in the "leading"
direction, in can
be desirable to close the individual sleeves against opening during such
advancement.
This can be achieved by closing each of the individual sleeves prior to
joining the
individual sleeves to the flexible web of material by temporarily joining an
inside surface
of each of individual sleeves.
[0025] Thus, a recloseable package configured in accordance with the
present
comprises a package body formed from a flexible web having a longitudinal
axis, with
the flexible web being folded to define a front package panel and a rear
package panel
of said package body. The front and rear package panels are joined to each
other at
respective lateral side margins of the package body, with the flexible web
being joined
to itself along a seam which extends parallel to the longitudinal axis of the
flexible web.
[0026] The present package further includes a bottom gusset positioned
between
the front and rear package panels, with the bottom gusset extending less than
the width
of the front and rear package panels. Laterally opposite side seals, that join
the front
and read package panels to each other at the respective lateral side margins
of said
package body, each overlap a respective end of said bottom gusset.
[0027] In one embodiment, the flexible web from which the package body is
formed is folded generally at the longitudinal axis thereof, with bottom
gusset extending
generally between the longitudinal axis, and the joined lateral margins at the
package
seam at which web of material is joined to itself. Alternatively, the seam at
which the
web of material is joined to itself is positioned in the rear package panel.
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[0028] Other features and advantages of the present invention will become
readily apparent from the following detailed description, the accompanying
drawings,
and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIGURE 1 is a perspective view of a bottom-gusseted package,
configured as a recloseable package, embodying the principles of the present
invention;
[0030] FIGURE 2 is a perspective view similar to Figure 1, with portions of
the
package cut away to illustrate the bottom gusset and recloseable fastener of
the
package;
[0031] FIGURE 3 is a diagrammatic view illustrating formation of the
package
shown in Figures 1 and 2, in accordance with the present invention;
[0032] FIGURE 4 is a cross-sectional view taken generally along lines 4-4
of
Figure 3;
[0033] FIGURE 5 is a diagrammatic view further illustrating formation of a
recloseable, bottom-gusseted package;
[0034] FIGURE 6 is a cross-sectional view taken generally along lines 6-6
of
Figure 5;
[0035] FIGURE 6a is a cross-sectional view taken generally along lines 6a-
6a of
Figure 5;
[0036] FIGURE 6b is a cross-sectional view taken generally along lines 6b-
6b of
Figure 5;
[0037] FIGURE 6c is a cross-sectional view similar to FIGURE 6;
[0038] FIGURE 7 is a diagrammatic view further illustrating formation of
the
present package, including cutting into individual packages;
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[0039] FIGURE 8 is a perspective view of a further embodiment of a
bottom-
gusseted package, including an upper package seal, configured in accordance
with the
present invention;
[0040] FIGURE 9 is a perspective view, partially cut away, of the
embodiment of
the bottom-gusseted package shown in FIGURE 8;
[0041] FIGURE 10 is a perspective view of a further embodiment of a
bottom-
gusseted package, including an upper package seal, configured in accordance
with the
present invention;
[0042] FIGURE 11 is a perspective view, partially cut away, of the
embodiment of
the bottom-gusseted package shown in FIGURE 10;
[0043] FIGURE 12 is a perspective view of another embodiment of a
bottom-
gusseted package, embodying the principles of the present invention;
[0044] FIGURE 13 is a perspective view similar to Figure 12, with
portions of the
package cut away to illustrate the bottom gusset of the package;
[0045] FIGURE 14 is a diagrammatic view illustrating formation of the
package
shown in Figures 12 and 13, in accordance with the present invention;
[0046] FIGURE 15 is a diagrammatic view further illustrating formation
of a
recloseable, bottom-gusseted package; and
[0047] FIGURE 16 is a view illustrating features for facilitating
formation and
filling of packages made in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0048] While the present invention is susceptible of embodiment in
various forms,
there is shown in the drawings and will hereinafter be described the presently
preferred
embodiments, with the understanding that the present disclosure should be
considered
as an exemplification of the invention, and is not intended to limit the
invention to the
specific embodiments illustrated.
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[0049] U.S. Patents No. 4,909,017, No. 4,617,683, No. 5,902,047, No.
6,971,794,
and No. 8,182,407, illustrate variouspackaqe constructions and formation
methods, and
may be referred to for further details.
[0050] With reference first to Figures 1 and 2, therein is illustrated
a bottom-
gusseted package 10 embodying the principles of the present invention. As will
be
further described, bottom-gusseted package 10 is configured to facilitate
formation and
filling on an associated, so-called form, fill and seal packaging machine, as
is known in
the art. Typically, the present invention can be practiced by partial
formation of the
present package as a rolled web of flexible, polymeric film material, with
individual
sleeves positioned thereon, which is supplied to the form, fill and seal
apparatus. The
formation of each package is completed attendant to filling of each of the
packages with
the desired quantity of product.
[0051] In this embodiment, bottom-gusseted package 10 is configured as
a
recloseable package, and includes a recloseable fastener at an upper portion
of the
package. Notably, and as will be further described, package 10 is formed by
joining a
plurality of individual sleeves to an associated web of flexible material, in
spaced apart
relationship along the longitudinal axis of the flexible web. Attendant to
package
formation, each individual sleeve can be cut as individual packages are
formed, with
each individual sleeve providing a bottom gusset in one package, and a top
sleeve
portion, including a recloseable fastener, and/or other package features, in
an adjacent
one of the packages being formed. However, as will be further described, the
present
invention can be practiced without cutting of the individual sleeves, which
are configured
to provide a bottom gusset for each package being formed.
[0052] With further reference to Figures 1 and 2, the bottom-gusseted
package
illustrated therein includes a package body 12 formed from a flexible film web
having
a longitudinal axis, wherein the flexible web has been folded to define a
front package
panel 14 (shown facing rearwardly in Figures 1 and 2) and a rear package panel
16 of
the package body 12. The front and rear package panels 14 and 16 are joined to
each
other at respective lateral side margins of the package body 12. In the
illustrated
embodiment, the front and rear package panels are joined to each other where
the
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flexible film web from which the body is formed has been folded. The flexible
film web
from which the package body 12 is formed is joined to itself along a
longitudinal seam
18 which extends parallel to the longitudinal axis of the flexible web. While
seam 18
has been illustrated generally at the middle of rear package panel 16, the
flexible web
can otherwise be joined to itself, such as at along one of the lateral side
margins of the
package body.
[0053] In accordance with the present invention, package 10 includes a
bottom
gusset 20 which is positioned between the front and rear package panels 14 and
16,
and which extends upwardly and inwardly from lower edges of the front and rear
package panels. As will be further described, the pleat-like bottom gusset 20
is formed
from a sleeve of material which is positioned within the flexible web from
which the
package body is formed, with the sleeve of material cut attendant to formation
of
individual packages.
[0054] The bottom gusset 20 is joined to and integrated with the package
body by
a pair of side seals 22 at opposite lateral margins of the package body, and a
pair of
end seals 23 which respectively join the edges of the bottom gusset 20 to the
front and
rear package panels 14 and 16. It is presently contemplated that the bottom
gusset 20
be configured to have a width less than that of the package 10, which permits
the
formation of side seals to join the front and rear package panels to each
other. This
permits the formation of a stable and self-standing package, by closing the
opposite
ends of the bottom gusset. This can be desirable if the inwardly facing
surfaces of the
bottom gusset do not heat-seal to each other. In previous bottom gusseted
packages,
the bottom gusset typically extends the full width of the package, so that the
length of
the gusset is same as the width of the front and rear package panels.
[0055] In accordance with this illustrated embodiment, the bottom-gusseted
package 10 is configured for recloseable use. To this end, the package 10
includes a
top sleeve portion 24 positioned between the front and rear package panels 14
and 16,
at the upper end of the package body 12. The top sleeve portion 24 preferably
includes
a sleeve seal 26, which may be configured as a so-called "peel seal", or
otherwise
configured for separation attendant to initial opening of the package. The top
sleeve
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portion 24 can be otherwise configured to permit access to the contents of the
package
through the top sleeve portion, such as by the provision of a preferentially
weakened
region. The top sleeve portion 24 is joined to and integrated with the package
body 12
by side seals 28 joining respective opposite ends of the sleeve portion 24 to
the
package body generally at opposite, lateral side margins thereof. A pair of
top seals 30,
respectively join the pair of legs or flanges of the top sleeve portion 24 to
the front and
rear package panels 14, 16.
[0056] In
this embodiment, the top sleeve portion 24 includes a recloseable
fastener 32. The recloseable fastener includes first and second fastener
elements
configured for releasable securement to each other, with the fastener elements
respectively joined to the legs or flanges of the top sleeve portion 24. Thus,
the sleeve
portion 24 provides first and second mounting flanges for the first and second
fastener
elements, with the flanges respectively positioned inwardly of and joined to
the front and
rear package panels.
[0057] As
will be appreciated, access to the contents of the package 10 is
provided via the top sleeve portion 24 and recloseable fastener 32. For
opening, the
legs or flanges of the top sleeve portion 24 are separated, and the first and
second
fastener elements of the recloseable fastener 32 separated. For initial
opening of the
package, the sleeve seal 26 is opened and separated, with access to the
interior of the
package 10 thus provided. By merely pressing the sleeve portion 24 together,
and
urging the components of the recloseable fastener 32 together, the package 10
can be
easily reclosed. As illustrated in Figures 6a-6c, for some applications in can
be
desirable to provide and an additional sleeve seal 27, positioned on the side
of the
fastener 32 generally opposite sleeve seal 26. Sleeve seal may also comprise a
so-
called "peal seal", and is eventually positioned between the mounting flanges
for the
fastener 32 provided by the opposite legs of the legs of the sleeve portion
24. Sleeve
seal 27 can provide tamper-evidence to provide visually discernible evidence
of the
initial opening to the recloseable package 10.
[0058]
Recloseable fastener 32 preferably comprises a pair of interlocking profile
fastener elements. Such
fastener elements may be identically configured, or
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complementary. Adhesive fastener components, hook-and-loop fastener
components,
"unisex" self-engaging fastener components, or like recloseable fastening
arrangements
can be employed for the recloseable fastener 32.
[0059] For package formation, a flexible web 40 preferably comprising heat-
sealable polymeric material is provided, with a flexible web typically
advanced in a
direction along its longitudinal axis web 40. Formation of the present bottom-
gusseted
package is further effected by providing a flexible, sleeve-forming web 42,
also
preferably comprising suitable polymeric, heat-sealable material. The
composition of
the sleeve-forming web can differ from the flexible web 40 for forming the
package of
the body, as may be desired. By way of example, the sleeve-forming material
can be
selected to exhibit certain gas permeability characteristics, or even be
perforated, which
can be desirable for some types of packaging. Perforated plastics allow gas
exchange
and prevent excess humidity, while solid plastics create a better product seal
for
modifying atmosphere and reducing available oxygen respiration and ripening,
thus
extending product shelf life.
[0060] It is presently contemplated that only one side of the sleeve-
forming web
be heat-sealable, so that the inside surface of the folded, sleeve-forming web
does not
heat seal to itself. This permits the eventual opening and spreading of the
legs of the
bottom gusset 20 so that the package 10 can assume a generally self-standing
orientation.
[0061] As shown on Figure 4, the sleeve-forming web 42 may be provided
with a
tubular configuration, including the sleeve seal 26 releasably joining lateral
edges of the
sleeve-forming web. In this embodiment, the sleeve-forming web is provided
with
recloseable fasteners 32, which may be provided in either continuous form, or
as
segmented, pre-cut lengths. As illustrated, the recloseable fastener elements
are
positioned generally within the sleeve-forming web 42, preferably in
interconnected
relationship.
[0062] As further illustrated, individual sleeves 44 are cut from the
sleeve-forming
web 42, and are positioned transversely of the longitudinal axis of the
flexible web 40
from which the package body is formed. For some applications, it can be
desirable to
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seal the ends of each individual sleeve 44, such as with suitable adhesive.
The
individual sleeves 44 are joined to the flexible web 40 in spaced apart
relationship
longitudinally of the web 40. The
spacing between the individual sleeves 44
corresponds to the length of each of the bottom-gusseted packages 10 being
formed.
The ends of each sleeve 44 are joined, such as by heat-sealing, to the web 40,
by end
seals 43 (Figure 6a.) Transverse seals 45 can also be formed between the web
40 and
the sleeve 44 extending generally parallel to fastener 32 along opposite side
margins
thereof (Figure 6b.)
[0063] After
each of the individual sleeves 44 is joined to the flexible web 40, the
flexible web is folded and the lateral margins thereof joined together to form
a folded
flexible web (see Figure 5 and 6). In this way, a package body is formed for
each of the
bottom-gusseted packages. By folding of the flexible web 40, the front and
rear
package panels 14 and 16 of each package are formed. The folded flexible web
40 can
be joined to itself so as to form bag seam 18, with the front and rear package
panels
joined to each other at the folded, lateral margins of the folded web. As
illustrated, the
individual sleeves 44 are positioned within the folded flexible web 40.
[0064]
Notably, the present invention contemplates that in this embodiment, each
individual sleeve 44 spans and extends between two adjacent ones of the
packages
being formed, with subsequent cutting of the flexible web into individual
packages
resulting in each individual sleeve 44 providing a bottom gusset 20 for one
package,
and a top sleeve portion 24 for an adjacent one of the packages. Figure 6
illustrates the
manner in which each individual sleeve 44 extends between adjacent ones of the
packages, with Figure 7 illustrating cutting of the folded flexible web 40
transversely of
its longitudinal axis to form individual packages, including cutting through
each sleeve
portion 44 to form a bottom gusset 20 for one package, and a top sleeve
portion 24 for
an adjacent package. It is presently contemplated that formation in this
manner can be
effected, if desired, during packaging on a form, fill, and seal machine, or
that individual
packages can be formed for subsequent filling. Depending upon the specific
formation
technique, side seals 22 and 28 are typically formed prior to filling, with
one of end seals
23, 30 formed after the contents of each package have been positioned therein.
-15-
[0065] Figure 6c illustrates an example of dimensioning of the bottom
gusset of
the present package, and the manner is which it is configured to accommodate
the
typical operating parameters of a vertical form, fill and seal machine. As
will be
recognized by those familiar with the art, this type of machine intermittently
advances
packaging material through the machine, with typical variation with respect to
the web-
cutting apparatus being plus/minus 0.25 inches. Thus, as shown in Figure 6a, a
typical
sleeve portion 44 can be provided with a folded width of approximately 3
inches, with
seals formed joining each sleeve portion 44 to the web 40. These seals would
typically
each have a 1.0 inch dimension. When the web is cut, the cut can be formed at
the
center of this 1.0 inch seal, so that seals each having a width of 0.5 inches
are formed.
However, because of the typical variation in the operation of the apparatus,
i.e.
plus/minus 0.25 inches, the exact dimensions of the bottom gusset 20 and top
sleeve
portion 24 can vary from one package to another. As will be appreciated, this
dimensioning is meant to be illustrative, but it will be recognized that the
present
invention can readily be practiced to accommodate this typical cutting
position variation
of a vertical form, fill and seal machine.
[0066] With reference now to Figure 8-11, therein is illustrated a
further alternate
embodiment of the present bottom-gusseted package, designated 110. In most
respects, bottom-gusseted package 110 is like the previously-described package
10,
with the exception that the top sleeve portion 124 of each package is
configured to
provide an upper package seal instead of a recloseable fastener assembly. In
this
embodiment, elements corresponding to the previously described package 10 are
designated by like reference numerals in the 100-series.
[0067] With reference now to Figure 8-11, the bottom-gusseted package
110
illustrated therein includes a package body 112 formed from a flexible film
web having a
longitudinal axis, wherein the flexible web has been folded to define a front
package
panel 114 (shown facing rearwardly in Figures 8 and 9) and a rear package
panel
116 of the package body 112. The front and rear package panels 114 and 116 are
joined to each other at respective lateral side margins of the package body
112. In the
illustrated embodiment, the front and rear package panels are joined to each
other
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where the flexible film web from which the body is formed has been folded. The
flexible
film web from which the package body 112 is formed is joined to itself along a
longitudinal seam 118 which extends parallel to the longitudinal axis of the
flexible web.
While seam 118 has been illustrated generally at the middle of rear package
panel 116,
the flexible web can otherwise be joined to itself, such as at along one of
the lateral side
margins of the package body.
[0068] In accordance with the present invention, package 110 includes a
bottom
gusset 120 which is positioned between the front and rear package panels 114
and 116,
and which extends upwardly and inwardly from lower edges of the front and rear
package panels. As previously described, the pleat-like bottom gusset 120 is
formed
from a sleeve of material which is positioned within the flexible web from
which the
package body is formed, with the sleeve of material cut attendant to formation
of
individual packages.
[0069] The bottom gusset 120 is joined to and integrated with the package
body
by a pair of side seals 122 at opposite lateral margins of the package body,
and a pair
of end seals 123 which respectively join the edges of the bottom gusset 20 to
the front
and rear package panels 114 and 116.
[0070] The package 110 further includes a top sleeve portion 124
positioned
between the front and rear package panels 114 and 116, at the upper end of the
package body 112. The top sleeve portion 124 preferably is provided with an
upper
seal 125, preferably formed between inturned edges of the upper sleeve portion
124.
This seal 125, may be configured as a so-called "peel seal", or otherwise
configured for
separation attendant to initial opening of the package. The top sleeve portion
124 can
be otherwise configured to permit access to the contents of the package
through the top
sleeve portion, such as by the provision of a preferentially weakened region.
The top
sleeve portion 124 is joined to and integrated with the package body 112 by
side seals
128 joining respective opposite ends of the sleeve portion 124 to the package
body
generally at opposite, lateral side margins thereof. A pair of top seals 130,
respectively
join the pair of legs or flanges of the top sleeve portion 124 to the front
and rear
package panels 114, 116.
-17-
[00711 Figures 10 and 11 illustrate a modified form of the embodiment of
the
present bottom-gusseted package illustrated in Figures 8 and 9. In this
modified form of
the package 110, the package includes a bottom gusset 120, but includes a
modified top
sleeve portion 124' which is positioned above an end seal 125' of the package
formed by
joining the front and rear package panels 114, 116 to each other. By virtue of
the top
sleeve portion having a width less than the width of the package, side seals
128 are
provided at respective opposite ends of the sleeve portion 124'.
[00721 This form of the present package can be formed attendant to
formation of a
package having a bottom gusset, without the need to form a top gusset or other
structure
at the top of the package. Given the normal manufacturing variations noted
above on a
vertical form, fill and seal apparatus, formation of packages with bottom
gussets only
could in some instances result in packages having a sleeve portion 124' such
as
illustrated in Figures 10 and 11. Specifically, in some instances, the
individual sleeve
forming the bottom gusset of the package would be positioned so that the
sleeve would
not be cut, and no portion of the sleeve would extend from the bottom gusset
of one
package to provide a sleeve portion of an adjacent package after cutting of
individual
packages. In other instances, the individual sleeve would be positioned so
that cutting
results in formation of the desired bottom gusset for one package, with a top
sleeve
portion such as 124' formed in an adjacent package. The top sleeve portion
124' consists
of first and second elongate strips, Si, S2 placed against each other between
the front
and rear panels 114, 116. Each of the strips Si, Si is in the form of a
single, flat layer.
Each of the strips Si, S2 extends to the top of the front and rear panels 114,
116. The top
sleeve portion 124' is confined generally within the end seal formed by side
seals 128,
and end seal 125' joining the front and rear package panels below the end of
sleeve
material that is in the top seal of the package.
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100731 By way of example, using the typical AI- 1/4" variation of the
typical vertical
form, fill and seal (VFFS) machine, if each package end seal is 3/4", one
extreme case
would be that the gusset is only in the bottom of one package and no sleeve
material in
the top of the adjacent package. The other extreme would be having " of
sleeve
material, i.e., top sleeve portion 124', in the top of the adjacent package,
but there still
would be a 1/4" end seal 125' below the sleeve material to seal off the top of
the package.
The end seal 125' extends: a) over a majority of the side-to-side dimension of
the
package; and b) over a location centrally between the lateral side margins of
the package.
The effect is that the top of the package would appear to not have any sleeve
material in
the top of any of the packages because the end seal would hide it.
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[0074] With reference now to Figure 12-15, therein is illustrated a further
embodiment of the present bottom-gusseted package, designated 210. In many
respects, bottom-gusseted package 210 is like the previously-described package
10.
However, package 210 differs in that the package is provided with a bottom
gusset but
without a top sleeve portion, since formation is preferably effected without
cutting the
individual sleeves which respectively form the bottom gusset of each package.
In this
embodiment, elements corresponding to the previously described package 10 are
designated by like reference numerals in the 200-series.
[0075] With further reference to Figures 12 and 13, the bottom-gusseted
package
210 illustrated therein includes a package body 212 formed from a flexible
film web
having a longitudinal axis, wherein the flexible web has been folded to define
a front
package panel 214 and a rear package panel 216 of the package body 212. The
front
and rear package panels 214 and 216 are joined to each other at respective
lateral side
margins of the package body 212. In the illustrated embodiment, the front and
rear
package panels are joined to each other where the flexible film web from which
the
body is formed has been folded generally at its longitudinal axis, at one side
edge of the
package. The flexible film web from which the package body 212 is formed is
joined to
itself along a longitudinal seam 18 which extends parallel to the longitudinal
axis of the
flexible web. While seam 218 has been illustrated generally at the lateral,
side edge of
the package, opposite the fold formed along the longitudinal axis, the
flexible web can
otherwise be joined to itself, such as along a longitudinal seam 218'
positioned in the
rear package panel 216, as shown in phantom line in Figure 13.
[0076] In accordance with the present invention, package 210 includes a
bottom
gusset 220 which is positioned between the front and rear package panels 214
and 216,
and which extends upwardly and inwardly from lower edges of the front and rear
package panels. As will be further described, the pleat-like bottom gusset 220
is formed
from a sleeve of material which is positioned within the flexible web from
which the
package body is formed.
[0077] The bottom gusset 220 is joined to and integrated with the package
body
by a pair of side seals 222 at opposite lateral margins of the package body.
In the
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illustrated embodiment, one of the side seals 222 coincides with, and can be
provided
by, the longitudinal seam 216 of the package 210. For some applications, it
may be
desirable to form side seals 222, adjacent bottom gusset 220, which do not
extend the
full length of the package. A pair of bottom end seals 223 respectively join
the edges of
the bottom gusset 220 to the front and rear package panels 214 and 216, to
provide a
bottom seal for the package, with the upper edge portions of the front and
rear package
panels joined at a heat-sealed top end seal 230. By virtue of the formation
technique,
the bottom gusset 220, including those portions of the gusset sealed at the
side seals
222, extends less than the width of the front and rear package panels 214,
216.
[0078] As
will be appreciated, access to the contents of the package 210 can be
provided configuring the package to include a suitable preferentially weakened
region,
such as a score line or the like. For some applications, it can be desirable
to provide
the front panel of the package with a recloseable fastener assembly, such as
disclosed
in the afore-mentioned patents. Other suitable opening arrangements can be
provided
as may be desired.
[0079] With
reference now to Figures 14 and 15, formation of the bottom-
gusseted package 210 will be described. For package formation, a flexible web
240
preferably comprising heat-sealable polymeric material is provided, with a
flexible web
typically advanced in a direction along its longitudinal axis. Formation of
the present
bottom-gusseted package is further effected by providing a flexible, sleeve-
forming web
242, also preferably comprising suitable polymeric, heat-sealable material.
The
composition of the sleeve-forming web can differ from the flexible web 240 for
forming
the package of the body, as may be desired. It is presently contemplated that
only one
side of the sleeve-forming web be heat-sealable, so that the inside surface of
the folded,
sleeve-forming web does not heat seal to itself. This permits the eventual
opening and
spreading of the legs of the bottom gusset 220 so that the package 210 can
assume a
generally self-standing orientation.
[0080] As
shown on Figure 14, the sleeve-forming web 242 may be provided with
a tubular configuration. Individual sleeves 244 are cut from the sleeve-
forming web
242, and are positioned transversely of the longitudinal axis of the flexible
web 240 from
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which the package body is formed. For some applications, it can be desirable
to close
or seal each individual sleeve 244, such as with suitable adhesive. This can
be
desirable to maintain the sleeves in a generally closed, flattened
configuration, as
packages are being formed, including during advancement through the associated
form,
fill and seal apparatus.
[0081] Figure 16 diagrammatically illustrates various contemplated
arrangements
for closing each of the sleeves 244. For example, at least one of the ends
each sleeve
244 can be closed by suitable adhesive at the inside surface thereof, such as
by a bead
of adhesive 245, and a plurality of adhesive dots 245'. Alternatively, a
central portion of
each of the sleeve can be provided with a temporary seal or adhesive 246.
Instead of
adhesive, pin-holes seals can be provided to provide the desired closing of
each sleeve,
with any closing or seal provided at the central portion of each sleeve being
temporary
in nature so that the resultant gusset can open and splay at intended
subsequent to
product filling. Other suitable arrangements for closing the sleeves 244 can
be
employed.
[0082] The individual sleeves 244 are joined to the flexible web 240 in
spaced
apart relationship longitudinally of the web 240. The spacing between the
individual
sleeves 244 corresponds to the length of each of the bottom-gusseted packages
210
being formed. Each of the sleeves 244 is joined, such as by heat-sealing, to
the web
240, such as by seals provided at the ends of each sleeve. The sleeves 244 can
otherwise be joined to the web 240, with the understanding that the sleeves
are to be
joined in a manner which does not inhibit the eventual opening and splaying of
each
sleeve as it becomes the bottom gusset of a resultant package.
[0083] After each of the individual sleeves 244 is joined to the flexible
web 240,
the flexible web is folded and the lateral margins thereof joined together to
form a folded
flexible web. In this way, a package body is formed for each of the bottom-
gusseted
packages. By folding of the flexible web 240, the front and rear package
panels 214
and 216 of each package are formed. The folded flexible web 240 can be joined
to
itself so as to form longitudinal seam 218, with the front and rear package
panels joined
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to each other at the lateral margins of the folded web. As illustrated, the
individual
sleeves 244 are positioned within the folded flexible web 240.
[0084] It is presently contemplated that formation in this manner can be
effected,
if desired, during packaging on a form, fill, and seal machine, or that
individual
packages can be formed for subsequent filling. Depending upon the specific
formation
technique, side seals 222 are typically formed prior to filling, with each of
the side seals
overlapping the respective end of the bottom gusset 220, with one of end seals
223
formed after the contents of each package have been positioned therein.
[0085] In connection with formation of the bottom end seals 223, an
important
aspect of the preferred practice of the invention promotes efficient, high-
speed
formation. Specifically, the present method includes intermittently advancing
the flexible
web of material 240 after the individual sleeves 244 have been joined thereto,
such as
during advancement through the associated form, fill and seal machine. During
this
process, the flexible web of material is advanced with a longitudinal
tolerance range of
dimension TLD, that is, is advanced with a precision that varies, plus or
minus, by a
generally known amount. This specific tolerance range is typically dependent
upon the
specific operational parameters of the forming apparatus, such as the
associated form,
fill, and seal machine, with the tolerance range typically increasing at
increasing
operating speeds. Additionally, it will appreciated that there can be some
inaccuracy in
the longitudinal positioning of the individual sleeves 244 on the flexible web
of material
240, with this range of longitudinal variation, which may be zero, designated
CLD.
[0086] Notably, the present method includes forming top and bottom seals
end
230, 223 in adjacent ones of the packages being formed by operation of a pair
of heat
sealing jaws 250, wherein the spacing between the top and bottom end seals of
adjacent ones of the packages is equal to or greater than the sum of: (1) two
times the
tolerance range with which the flexible 240 is advanced (e.g., 2 X TLD), and
(2) the
range of variation of the longitudinal placement of each sleeve 244 (e.g.,
CLD.) This is
diagrammatically illustrated in Figure 15, which shows the two pairs of heat
sealing jaws
250, 250 are positioned to provide a dimension D between the end seals 223,
230 of
adjacent packages, which is equal to or greater this sum. This ensures proper
sealing
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of the ends of each package, with each bottom gusset properly sealed and
configured
to open or splay for providing the desired interior volume to the package, and
desired
self-standing characteristics. Thus, the spacing between the top and bottom
end seals
of adjacent ones of the packages is equal to or greater than two rimes TLD
plus CLD.
[0087] As will be recognized by those familiar with the art, this type of
machine
intermittently advances packaging material through the machine, with typical
variation
with respect to the web-cutting apparatus being plus/minus 0.25 inches. Thus,
a typical
sleeve portion 244 can be provided with a folded width of approximately 3
inches, with
seals formed joining each sleeve portion 244 to the web 240 being of
sufficient length
and width to accommodate this variation, while still ensuring that a
sufficiently large
portion of each seal remains, after cutting of the web, to form the bottom end
seals 223
and the top seals 230 of the necessary size to ensure package integrity. As
will be
appreciated, this dimensioning is meant to be illustrative, but it will be
recognized that
the present invention can readily be practiced to accommodate this typical
cutting
position variation of a typical forming apparatus.
[0088] Efficient package formation is promoted by configuring each of said
individual sleeves to have a length which is less than the width of the folded
web of
flexible material. This provides formation of the bottom gusset with a width
less than the
width of the package, to permit formation of side seals 222 between the front
and rear
package panels 214, 216 of each said package at opposite side edges of the
bottom
gusset 220 of the package. As noted each of these sides seals 222 overlaps a
respective end of the bottom gusset 220 of the package 210.
[0089] The preferred dimensioning of the individual sleeves 244 for
formation of
respective bottom gussets 220, and the preferred dimensioning of the side
seals 223
joining the front and rear package panels 214, 216 is illustrated in Figure
14. As
discussed above in connection with end seals of the packages, this preferred
dimensioning accommodates manufacturing variations and tolerances.
[0090] As will be appreciated, the flexible web of material 240 can exhibit
some
transverse variation in its positioning as it is intermittently advanced, with
this transverse
tolerance range being designated Till Additionally, each of the individual
sleeves 244
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being positioned transversely of said flexible web of material may exhibit
some variation
in the positioning transversely of the web of material 240, with this
transverse tolerance
range being designated CTD.
[0091] Given these inevitable minor variations in the manufacturing
process, it is
contemplated that the width of the package gusset, designated Gw, which
corresponds
to the length of each individual sleeve 244, be selected to correspond to the
width of the
front and rear package panels, designated BP. As shown, this relationship can
be
stated as the gusset width Gw is less than or equal to: (1) the package panel
width BP,
(2) less two times the tolerance range TTD, and (3) less the tolerance range
CTD.
[0092] In turn, the side seals 222 which are formed in each package joining
the
front and rear package panels 214, 216 at opposite side edges of the bottom
gusset of
the package are dimensioned to ensure the preferred overlapping of the side
seals with
the opposite ends of the respective bottom gusset. As shown, the width
dimension of
each side seal, designated Gss, is equal to or greater than: two times the
transverse
tolerance range TTD, plus the transverse tolerance range CTD. Again, this
ensures the
preferred overlapping of the side seals with the associated gussets,
notwithstanding the
normal manufacturing tolerances exhibited by the equipment employed for
practicing
the present invention.
[0093] From the foregoing, it will be observed that numerous modifications
and
variations can be effected without departing from the true spirit and scope of
the novel
concept of the present invention. It is to be understood that no limitation
with respect to
the specific embodiments illustrated herein is intended or should be inferred.
The
disclosure is intended to cover, by the appended claims, all such
modifications as fall
within the scope of the claims.
