Patent Application
20120195526
This invention relates to an easy-open and reclosable package with a discrete strip and die-cut web, and to methods of making the package.
Food and non-food products, including produce, snack foods, cheese and the like have long been packaged in containers such as pouches, bags, or lidded trays or formed webs made from various thermoplastic materials such as polyethylene, polypropylene, or polyester (PET). These containers can be formed from a web or webs of thermoplastic material on packaging equipment, using various packaging processes, at a processing/packaging facility. Such equipment and processes includes horizontal form/fill/seal (HFFS), vertical form/fill/seal (VFFS), thermoforming/lidstock, and continuous horizontal packaging (sometimes referred to as Flow-wrap). In each case, the product is manually or automatically placed in a pouch, bag, formed web, tray, etc., the filled container is optionally vacuumized or gas flushed, and the mouth of the container is hermetically or non-hermetically sealed to close and finish the package.
Opening of the finished package (i.e. opening with the use of tools such as scissors or knives) can provide access to the product by the consumer.
Common in the industry is the use of plastic zipper closures; press-to-close or slide zippers; interlocking closures; reclosable fasteners with interlockable fastener elements; interlocking rib and groove elements having male and female profiles; interlocking alternating hook-shaped closure members, and the like. These terms appear in the patent literature, and to some extent may overlap in meaning. These features provide reclosability, and in some cases may provide an easy-open feature to the package. However, such features are not always easy to open or reclose.
Also relatively common is the use of pressure sensitive adhesive to provide a reclosability feature to a package. However, based on the position of the adhesive relative to the package, the adhesive can sometimes be contaminated by the contained product before the package is opened, or once the package is opened, when product is removed from the package and comes in contact with the adhesive. This phenomenon can compromise the reclosability of the package.
There is need in the marketplace for a package, and methods of packaging that can be used in a manner that requires relatively little or no modification to the packager's packaging equipment, while providing a manually (i.e. by hand, without the need for tools such as scissors or knives) openable and easy to reclose feature, optionally while maintaining hermeticity of the package when made, and without the need for plastic zipper closures; press-to-close or slide zippers; interlocking closures; reclosable fasteners with interlockable fastener elements; interlocking rib and groove elements having male and female profiles; interlocking alternating hook-shaped closure members, and the like.
Some retail packages currently do not offer an easy-open and/or reclosable feature. Examples are some produce bags and snack food bags. In the produce market, there is a need for a cost-effective way to manually open, and repeatably reclose, retail produce bags, e.g. a package made in HFFS, VFFS, thermoforming/lidstock, or continuous horizontal packaging processes.
The present invention relates to a package, and methods of making the package, which package is manually openable and reclosable, i.e. can be opened and reclosed a number of times, and adapted to package non-food products, as well as food products such as e.g. produce, snack foods, cheese, luncheon meat, sausage, culinary nuts, trail mix, etc., as well products for the medical industry. The package optionally maintains a hermetic seal until the package is opened.
In a first aspect, an easy-open and reclosable package comprises:
a pouch comprising
a first and second side panel each comprising an outer and inner surface, a first and second side edge, and a first and second end, the first and second side panels joined together along their respective first and second side edges;
a first end defined by the first end of at least one of the first and second side panels;
a second end defined by the second ends of the first and second side panels respectively;
a discrete strip, disposed between the first and second side panels, comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the sealing and backing segments and comprising a pressure sensitive adhesive, the discrete strip spaced apart from at least one of the first end of the pouch, and the second end of the pouch;
a first anchor seal whereby a first portion of the first surface of the discrete strip is anchored to the inner surface of the first side panel at a first location on the first side panel, and a second anchor seal whereby a second portion of the first surface of the discrete strip is anchored to the inner surface of the first side panel at a second location on the first side panel; and
a die cut disposed in the first side panel, the die cut defining a die cut segment, the die cut segment so arranged with respect to the discrete strip that when the package is opened, the sealing segment is partially removed from the discrete strip, the intermediate layer comprising a pressure sensitive adhesive is partially exposed, and the package can thereafter be reclosed by adhering one of the first and second panels to the pressure sensitive adhesive; and
the first end of the first side panel joined to the second side panel; and a product disposed in the pouch.
Optionally, according to various embodiments of the first aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surface of the discrete strip is sealed to the inner surface of the second side panel with an easy-open seal.
the first and second side panels are joined together along their respective first and second side edges with a seal.
the first and second side panels are joined together along their respective first and second side edges with a fold.
the first end of the first side panel, and the second side panel, are joined together with a seal.
the first end of the first side panel, and the first end of the second side panel, are joined together with a seal.
the first end of the first side panel, and the first end of the second side panel, are joined together with a fold.
the second end of the first side panel, and the second end of the second side panel, are joined together with a fold.
the discrete strip is spaced apart from the first end of the pouch, and spaced apart from the second end of the pouch.
the discrete strip is spaced apart from the first and second side edges of the first and second side panels.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the package is absent any zipper.
the package can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
when the package is opened, the discrete strip is not torn through the entire thickness of the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the first side panel, and a second portion wherein the die cut extends entirely through the first side panel.
the first side edge of the discrete strip is disposed between and sealed to the first side edge of the first and second side panels respectively, and the second side edge of the discrete strip is disposed between and sealed to the second side edge of the first and second side panels respectively.
In a second aspect, an easy-open and reclosable package comprises:
a pouch comprising
a folded web having an interior surface;
a first transverse seal at a first end of the folded web;
a second transverse seal at a second end of the folded web;
a longitudinal seal extending along the length of the folded web, a discrete strip positioned adjacent to and spaced apart from the longitudinal seal, the discrete strip comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the sealing and backing segments and comprising a pressure sensitive adhesive,
a first anchor seal whereby a first portion of the first surface of the discrete strip is anchored to the interior surface of the folded web at a first location on the folded web, and a second anchor seal whereby a second portion of the first surface of the discrete strip is anchored to the interior surface of the folded web at a second location on the folded web; and
a die cut disposed in the folded web, the die cut defining a die cut segment, the die cut segment so arranged with respect to the discrete strip that when the package is opened, the sealing segment is partially removed from the discrete strip, the intermediate layer comprising a pressure sensitive adhesive is partially exposed, and the package can thereafter be reclosed by adhering the folded web to the pressure sensitive adhesive; and
a product disposed in the pouch.
Optionally, according to various embodiments of the second aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surface of the discrete strip is sealed to the interior surface of the folded web with an easy-open seal.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the package is absent any zipper.
the package can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the folded web, and a second portion wherein the die cut extends entirely through the folded web.
In a third aspect, a method of making an easy-open and reclosable package in a horizontal form/fill/seal process comprises:
providing a lay-flat web, the lay-flat web having a first and second longitudinal edge, and a die cut;
providing a discrete strip comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the sealing and backing segments and comprising a pressure sensitive adhesive;
advancing the lay-flat web to a forming device to convert the lay-flat web to a folded web having an interior surface;
advancing the discrete strip such that when the package is made, the discrete strip is disposed between a first and second side panel of the package;
making side seals in the folded web to produce an open pouch comprising
wherein
the die cut is disposed in the first side panel, the die cut defining a die cut segment, the die cut segment so arranged with respect to the discrete strip that when the package is opened, the sealing segment is partially removed from the discrete strip, the intermediate layer comprising a pressure sensitive adhesive is partially exposed, and the package can thereafter be reclosed by adhering the first or second panel to the pressure sensitive adhesive;
at any time before cutting the web to produce an open pouch, anchoring a first portion of the first surface of the discrete strip to the lay-flat web or the folded web at a first location to form a first anchor seal;
at any time before or during the step of making side seals in the folded web, anchoring a second portion of the first surface of the discrete strip to the lay-flat web, the interior surface of the folded web, or the inner surface of the first side panel at a second location to form a second anchor seal; and
cutting the web at the side seals during the step of making side seals in the folded web, or before, during or after any subsequent steps.
Optionally, according to various embodiments of the third aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surface of the discrete strip is sealed to the inner surface of the second side panel with an easy-open seal.
the first end of the first side panel, and the first end of the second side panel, are joined together with a seal.
the first end of the first side panel, and the first end of the second side panel, are joined together with a fold.
the discrete strip is spaced apart from the first end of the pouch, and spaced apart from the second end of the pouch.
the discrete strip is spaced apart from the first and second side edges of the first and second side panels.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the package is absent any zipper.
the package can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
when the package is opened, the discrete strip is not torn through the entire thickness of the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the first side panel, and a second portion wherein the die cut extends entirely through the first side panel.
the first side edge of the discrete strip is disposed between and sealed to the first side edge of the first and second side panels respectively, and the second side edge of the discrete strip is disposed between and sealed to the second side edge of the first and second side panels respectively.
In a fourth aspect, a method of making an easy-open and reclosable package in a horizontal form/fill/seal process comprises:
providing a lay-flat web, the lay-flat web having a first and second longitudinal edge, and a die cut;
providing a discrete strip comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the sealing and backing segments and comprising a pressure sensitive adhesive, a first portion of the first surface of the discrete strip anchored to a first surface of the lay-flat web at a first location to form a first anchor seal, and a second portion of the first surface of the discrete strip anchored to a first surface of the lay-flat web at a second location to form a second anchor seal;
advancing the lay-flat web with the discrete strip anchored thereto to a forming device to convert the lay-flat web to a folded web having an interior surface;
making side seals in the folded web to produce an open pouch comprising
Optionally, according to various embodiments of the fourth aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surface of the discrete strip is sealed to the inner surface of the second side panel with an easy-open seal.
the first end of the first side panel, and the first end of the second side panel, are joined together with a seal.
the first end of the first side panel, and the first end of the second side panel, are joined together with a fold.
the discrete strip is spaced apart from the first end of the pouch, and spaced apart from the second end of the pouch.
the discrete strip is spaced apart from the first and second side edges of the first and second side panels.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the package is absent any zipper.
the package can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
when the package is opened, the discrete strip is not torn through the entire thickness of the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the first side panel, and a second portion wherein the die cut extends entirely through the first side panel.
the first side edge of the discrete strip is disposed between and sealed to the first side edge of the first and second side panels respectively, and the second side edge of the discrete strip is disposed between and sealed to the second side edge of the first and second side panels respectively.
In a fifth aspect, a method of making an easy-open and reclosable package in a vertical form/fill/seal process comprises:
providing a lay-flat web, the lay-flat web comprising a first and second surface, and a die cut;
providing a discrete strip comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the sealing and backing segments and comprising a pressure sensitive adhesive;
advancing the lay-flat web over a forming device to convert the lay-flat web to a folded web having an interior surface;
advancing the discrete strip such that when the package is made, the discrete strip is disposed between a first and second side panel of the package;
making a longitudinal seal in the folded web;
transversely sealing the folded web to produce a first transverse seal to define a first pouch,
wherein the first transverse seal is a bottom transverse seal of the first pouch; putting a product in the first pouch;
advancing the folded web, with the first pouch, downward a predetermined distance;
transversely sealing the first pouch to produce a top transverse seal in the first pouch, and a bottom transverse seal in a second pouch, the second pouch disposed above the first pouch; and
transversely cutting the folded web to separate the first pouch from the second pouch to make a package, the package comprising
Optionally, according to various embodiments of the fifth aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surface of the discrete strip is sealed to the inner surface of the second side panel with an easy-open seal.
the first and second side panels are joined together along their respective first and second side edges with a seal.
the first and second side panels are joined together along their respective first and second side edges with a fold.
the first end of the first side panel, and the first end of the second side panel, are joined together with a seal.
the first end of the first side panel, and the first end of the second side panel, are joined together with a fold.
the second end of the first side panel, and the second end of the second side panel, are joined together with a seal.
the second end of the first side panel, and the second end of the second side panel, are joined together with a fold.
the discrete strip is spaced apart from the first end of the pouch, and spaced apart from the second end of the pouch.
the discrete strip is spaced apart from the first and second side edges of the first and second side panels.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the package is absent any zipper.
the package can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
when the package is opened, the discrete strip is not torn through the entire thickness of the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the first side panel, and a second portion wherein the die cut extends entirely through the first side panel.
the first side edge of the discrete strip is disposed between and sealed to the first side edge of the first and second side panels respectively, and the second side edge of the discrete strip is disposed between and sealed to the second side edge of the first and second side panels respectively.
In a sixth aspect, a method of making an easy-open and reclosable package in a vertical form/fill/seal process comprises:
providing a lay-flat web, the lay-flat web comprising a first and second surface, and a die cut;
providing a discrete strip comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the sealing and backing segments and comprising a pressure sensitive adhesive, a first portion of the first surface of the discrete strip anchored to the first surface of the lay-flat web at a first location to form a first anchor seal, and a second portion of the first surface of the discrete strip anchored to the first surface of the lay-flat web at a second location to form a second anchor seal;
advancing the lay-flat web with the discrete strip adhered thereto over a forming device to convert the lay-flat web to a folded web having an interior surface;
making a longitudinal seal in the folded web;
transversely sealing the folded web to produce a first transverse seal to define a first pouch,
wherein the first transverse seal is a bottom transverse seal of the first pouch;
putting a product in the first pouch;
advancing the folded web, with the first pouch, downward a predetermined distance; transversely sealing the folded web to produce a top transverse seal in the first pouch, and a bottom transverse seal in a second pouch, the second pouch disposed above the first pouch; and
transversely cutting the folded web to separate the first pouch from the second pouch to make a package, the package comprising
Optionally, according to various embodiments of the sixth aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surfaces of the discrete strip is sealed to the inner surface of the second side panel with an easy-open seal.
the first and second side panels are joined together along their respective first and second side edges with a seal.
the first and second side panels are joined together along their respective first and second side edges with a fold.
the first end of the first side panel, and the first end of the second side panel, are joined together with a seal.
the first end of the first side panel, and the first end of the second side panel, are joined together with a fold.
the second end of the first side panel, and the second end of the second side panel, are joined together with a seal.
the second end of the first side panel, and the second end of the second side panel, are joined together with a fold.
the discrete strip is spaced apart from the first end of the pouch, and spaced apart from the second end of the pouch.
the discrete strip is spaced apart from the first and second side edges of the first and second side panels.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the package is absent any zipper.
the package can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
when the package is opened, the discrete strip is not torn through the entire thickness of the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the first side panel, and a second portion wherein the die cut extends entirely through the first side panel.
the first side edge of the discrete strip is disposed between and sealed to the first side edge of the first and second side panels respectively, and the second side edge of the discrete strip is disposed between and sealed to the second side edge of the first and second side panels respectively.
In a seventh aspect, a method of making an easy-open and reclosable package having a formed web comprises:
providing a formed web comprising a product cavity;
providing a product;
providing a lidstock, having a first and second surface, comprising
a lay-flat web, and
a die cut disposed in the lidstock, the die cut defining a die cut segment;
providing a discrete strip comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the sealing and backing segments and comprising a pressure sensitive adhesive;
placing the product in the product cavity;
sealing the lidstock to the formed web, such that the discrete strip is disposed between the lidstock and the formed web; and
cutting the lidstock and formed web to make the package;
wherein
the die cut segment is so arranged with respect to the discrete strip that when the package is opened, the sealing segment is partially removed from the discrete strip, the intermediate layer comprising a pressure sensitive adhesive is partially exposed, and the package can thereafter be reclosed by adhering the lidstock to the pressure sensitive adhesive;
at any time before or during the step of sealing the lidstock to the formed web, anchoring a first portion of the first surface of the discrete strip to the first surface of the lidstock at a first location to form a first anchor seal; and
at any time during the method of making the package, anchoring a second portion of the first surface of the discrete strip to the first surface of the lidstock at a second location to form a second anchor seal.
Optionally, according to various embodiments of the seventh aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surface of the discrete strip is sealed to the first surface of the formed web with an easy-open seal.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the package is absent any zipper.
the package is absent a discrete release liner for a PSA layer or coating.
the package can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
when the package is opened, the discrete strip is not torn through the entire thickness of the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the lidstock, and a second portion wherein the die cut extends entirely through the lidstock.
the first side edge of the discrete strip is disposed between and sealed to a first side edge of the lidstock and formed web respectively, and the second side edge of the discrete strip is disposed between and sealed to a second side edge of the lidstock and formed web respectively.
In an eighth aspect, a method of making an easy-open and reclosable package having a formed web comprises:
providing a formed web comprising a product cavity;
providing a product;
providing a lidstock, having a first and second surface, comprising
a lay-flat web, and
a die cut disposed in the lidstock, the die cut defining a die cut segment;
providing a discrete strip comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the covering and backing segments and comprising a pressure sensitive adhesive, a first portion of the first surface of the discrete strip anchored to the first surface of the lidstock at a first location to form a first anchor seal, and a second portion of the first surface of the discrete strip anchored to the first surface of the lidstock at a second location to form a second anchor seal;
placing the product in the product cavity;
sealing the lidstock to the formed web, such that the discrete strip is disposed between the lidstock and the formed web; and
cutting the lidstock and formed web to make the package:
wherein the die cut segment is so arranged with respect to the discrete strip that when the package is opened, the sealing segment is partially removed from the discrete strip, the intermediate layer comprising a pressure sensitive adhesive is partially exposed, and the package can thereafter be reclosed by adhering the lidstock to the pressure sensitive adhesive.
Optionally, according to various embodiments of the eighth aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surfaces of the discrete strip is sealed to the first surface of the formed web with an easy-open seal.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the package is absent any zipper.
the package can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
when the package is opened, the discrete strip is not torn through the entire thickness of the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the lidstock, and a second portion wherein the die cut extends entirely through the lidstock.
the first side edge of the discrete strip is disposed between and sealed to a first side edge of the lidstock and formed web respectively, and the second side edge of the discrete strip is disposed between and sealed to a second side edge of the lidstock and formed web respectively.
In a ninth aspect, a method of making an easy-open and reclosable package in a continuous horizontal packaging process comprises:
providing a lay-flat web, the lay-flat web comprising a die cut;
providing a discrete strip comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the sealing and backing segments and comprising a pressure sensitive adhesive;
advancing the lay-flat web to a forming device to convert the lay-flat web into a folded web having an interior surface;
advancing the discrete strip such that when the package is made, the discrete strip is disposed between a first and second side panel of the package;
advancing a product to the forming device such that the folded web envelopes the product; longitudinally sealing the folded web to make a longitudinal seal;
transversely sealing the folded web, with the product therein, to produce a leading transverse seal to define a first pouch;
advancing the folded web, with the leading transverse seal, forward a predetermined distance;
transversely sealing the folded web to produce a trailing transverse seal in the first pouch, and a leading transverse seal in a second pouch, the second pouch disposed upstream of the first pouch; and
cutting the folded web to separate the first pouch from the second pouch to form an individual package comprising the first and second side panel;
wherein
the die cut is disposed in the package, the die cut defining a die cut segment, the die cut segment so arranged with respect to the discrete strip that when the package is opened, the sealing segment is partially removed from the discrete strip, the intermediate layer comprising a pressure sensitive adhesive is partially exposed, and the package can thereafter be reclosed by adhering the folded web to the pressure sensitive adhesive;
at any time before or during the step of longitudinally sealing the folded web, anchoring a first portion of the first surface of the discrete strip to the lay-flat web or the folded web at a first location to form a first anchor seal; and
at any time before or during the step of making a longitudinal seal in the folded web, anchoring a second portion of the first surface of the discrete strip to the lay-flat web, the folded web, or the first side panel at a second location to form a second anchor seal.
Optionally, according to various embodiments of the ninth aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surface of the discrete strip is sealed to the inner surface of the second side panel with an easy-open seal.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the package is absent any zipper.
the package can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
when the package is opened, the discrete strip is not torn through the entire thickness of the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the folded web, and a second portion wherein the die cut extends entirely through the folded web.
the first side edge of the discrete strip is disposed between and sealed to the first side edge of the first and second side panels respectively, and the second side edge of the discrete strip is disposed between and sealed to the second side edge of the first and second side panels respectively.
In a tenth aspect, a method of making an easy-open and reclosable package in a continuous horizontal packaging process comprises:
providing a lay-flat web, the lay-flat web having a first and second surface, and a die cut;
providing a discrete strip comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the sealing and backing segments and comprising a pressure sensitive adhesive, a first portion of the first surface of the discrete strip anchored to the first surface of the lay-flat web at a first location to form a first anchor seal, and a second portion of the first surface of the discrete strip anchored to the first surface of the lay-flat web at a second location to form a second anchor seal;
advancing the lay-flat web with the discrete strip adhered thereto to a forming device to convert the lay-flat web into a folded web having an interior surface;
advancing a product to the forming device such that the folded web envelopes the product; longitudinally sealing the folded web to make a longitudinal seal;
transversely sealing the folded web, with the product therein, to produce a leading transverse seal to define a first pouch;
advancing the folded web, with the leading transverse seal, forward a predetermined distance;
transversely sealing the folded web to produce a trailing transverse seal in the first pouch, and a leading transverse seal in a second pouch, the second pouch disposed upstream of the first pouch; and
cutting the transversely sealed first pouch, with the product therein, to form an individual package comprising a first and second side panel;
wherein the die cut is disposed in the folded web, the die cut defining a die cut segment, the die cut segment so arranged with respect to the discrete strip that when the package is opened, the sealing segment is partially removed from the discrete strip, the intermediate layer comprising a pressure sensitive adhesive is partially exposed, and the package can thereafter be reclosed by adhering the first or second side panel to the pressure sensitive adhesive.
Optionally, according to various embodiments of the tenth aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surface of the discrete strip is sealed to the inner surface of the second side panel with an easy-open seal.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the package is absent any zipper.
the package can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
when the package is opened, the discrete strip is not torn through the entire thickness of the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the first side panel, and a second portion wherein the die cut extends entirely through the first side panel.
the first side edge of the discrete strip is disposed between and sealed to the first side edge of the first and second side panels respectively, and the second side edge of the discrete strip is disposed between and sealed to the second side edge of the first and second side panels respectively.
In an eleventh aspect, a pouch comprises:
a first and second side panel each comprising an outer and inner surface, a first and second side edge, and a first and second end, the first and second side panels joined together along their respective first and second side edges;
a first end defined by the first end of at least one of the first and second side panels;
a second end defined by the second ends of the first and second side panels respectively;
the first and second side panels joined together along their respective second ends;
a discrete strip, disposed between the first and second side panels, comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the sealing and backing segments and comprising a pressure sensitive adhesive, the discrete strip spaced apart from at least one of the first end of the pouch, and the second end of the pouch;
a first anchor seal whereby a first portion of the first surface of the discrete strip is anchored to the inner surface of the first side panel at a first location on the first side panel, and a second anchor seal whereby a second portion of the first surface of the discrete strip is anchored to the inner surface of the first side panel at a second location on the first side panel; and
a die cut disposed in the first side panel, the die cut defining a die cut segment, the die cut segment so arranged with respect to the discrete strip that when the pouch is sealed to make a package, and the package is then opened, the sealing segment is partially removed from the discrete strip, the intermediate layer comprising a pressure sensitive adhesive is partially exposed, and the package can thereafter be reclosed by adhering one of the first and second side panels to the pressure sensitive adhesive; and the first end of the first side panel joined to the second side panel.
Optionally, according to various embodiments of the eleventh aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surface of the discrete strip is sealed to the inner surface of the second side panel with an easy-open seal.
the first and second side panels are joined together along their respective first and second side edges with a seal.
the first and second side panels are joined together along their respective first and second side edges with a fold.
the second end of the first side panel, and the second end of the second side panel, are joined together with a seal.
the second end of the first side panel, and the second end of the second side panel, are joined together with a fold.
the discrete strip is spaced apart from the first end of the pouch, and spaced apart from the second end of the pouch.
the discrete strip is spaced apart from the first and second side edges of the first and second side panels.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the pouch, and a package made from the pouch, is absent any zipper.
when the pouch is sealed to make a package, the package can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
when the package is opened, the discrete strip is not torn through the entire thickness of the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the first side panel, and a second portion wherein the die cut extends entirely through the first side panel.
the first side edge of the discrete strip is disposed between and sealed to the first side edge of the first and second side panels respectively, and the second side edge of the discrete strip is disposed between and sealed to the second side edge of the first and second side panels respectively.
In a twelfth aspect, a method of making a bag with a die cut and a discrete strip disposed thereon comprises:
extruding a thermoplastic tube to make a bag tubing;
providing a discrete strip comprising a first and second surface, a first and second end, a first and second side edge, a sealing segment, a backing segment, and an intermediate layer disposed between the sealing and backing segments and comprising a pressure sensitive adhesive;
slitting the tubing at a longitudinal edge thereof to make a slit bag tubing;
placing the discrete strip inside the slit bag tubing; and
transversely cutting and sealing the slit bag tubing at predetermined intervals to make a plurality of individual bags, each bag having a die cut disposed thereon, each bag comprising a first and second side panel each comprising a first and second end, an outer and inner surface, and first and second side edges, the first and second side panels joined together along at least a portion of their respective first and second side edges by a seal;
a first end defined by the first end of at least one of the first and second side panels, an end fold defined by the second ends of the first and second side panels respectively, and the discrete strip disposed between the first and second side panels, and spaced apart from at least one of the first end and the end fold of the bag;
wherein
the die cut is disposed in the first side panel, the die cut defining a die cut segment, the die cut segment so arranged with respect to the discrete strip that when the bag is sealed to make a package, and the package is then opened, the sealing segment is partially removed from the discrete strip, the intermediate layer comprising a pressure sensitive adhesive is partially exposed, and the package can thereafter be reclosed by adhering the first or second side panel to the pressure sensitive adhesive;
at any time before transversely cutting the bag tubing to produce a bag, the bag tubing or slit bag tubing is die cut at predetermined intervals to make a plurality of die cuts in the bag tubing or slit bag tubing respectively;
at any time before transversely cutting the bag tubing to produce a bag, anchoring a first portion of the first surface of the discrete strip to the bag tubing or slit bag tubing at a first location to form a first anchor seal; and
at any time during the method of making the bag, anchoring a second portion of the first surface of the discrete strip to the bag tubing, the slit bag tubing, or the inner surface of the first side panel at a second location to form a second anchor seal.
Optionally, according to various embodiments of the twelfth aspect of the invention, taken alone or in any suitable combination of these embodiments:
both the first and second surfaces of the discrete strip comprises a sealant.
the second surface of the discrete strip is sealed to the inner surface of the second side panel with an easy-open seal.
the discrete strip is spaced apart from the first end of the bag, and spaced apart from the end fold of the bag.
the discrete strip is spaced apart from the first and second side edges of the first and second side panels.
the sealing segment comprises a single layer.
the backing segment comprises a single layer.
the bag, and a package made from the bag, is absent any zipper.
a package made from the bag can be opened with a peel force of from 25 grams/inch to 5 pounds/inch.
the die cut segment is completely underlain by the discrete strip.
the die cut segment is partially underlain by the discrete strip.
when the package is opened, the discrete strip is not torn through the entire thickness of the discrete strip.
the first surface of the discrete strip is substantially free from PSA.
the second surface of the discrete strip is substantially free from PSA.
the package is absent a discrete thread or tear strip.
the die cut segment includes a first portion wherein the die cut extends partially through the first side panel, and a second portion wherein the die cut extends entirely through the first side panel.
the first side edge of the discrete strip is disposed between and sealed to the first side edge of the first and second side panels respectively, and the second side edge of the discrete strip is disposed between and sealed to the second side edge of the first and second side panels respectively.
The present invention is illustrated by reference to the following drawing figures, encompassing different views of various embodiments of the invention, wherein:
“Anchored”, “anchoring” and the like herein refers to sealing or adhering two surfaces together, and refers to the resulting bond between surfaces. Sealing is done by means of a sealant. Adhering is done by means of permanent adhesive. In processes described herein where a strip is anchored to a web or side panel, either during the process wherein the web and strip are advanced, or when a strip has been pre-anchored to the web before the start of the process, anchoring can be done by use of any suitable continuous or discontinuous sealing or adhesive material and method. Such anchoring is done to hold the strip to the web during the relevant packaging process.
In some embodiments, wherein the anchor is already relatively strong or continuous, e.g. a heat seal that constitute either a relatively strong heat seal, or an easy-open seal as defined herein, the anchor functions not only to hold the strip to the web during the relevant packaging process, but also as a final seal of that surface of the strip to the web (lay-flat or folded) or panel made from the web.
Any subsequent disclosed or recited step in the process of sealing one of the surfaces (i.e. the anchored surface) of the strip to a web or panel, is in these embodiments already completed by the anchoring step. In these embodiments, then, contact of a seal device, e.g. a seal bar in the region of the anchor, in a subsequent step, may add no further or separate seal to that surface of the strip.
Any subsequent step in the process of sealing the other surface of the strip to a web or panel, then, may in some embodiments add no further or separate seal to the anchored surface of the strip.
Sealing of a surface of the strip to a web, as a process step disclosed or recited herein, should be understood in this light.
In some embodiments where the bond is a relatively weak or discontinuous one, e.g. a discontinuous seal, spots or narrow stripes of adhesive. etc., in a subsequent step of sealing one of the surfaces of the strip to the web or panel, a seal bar that seals one of the surfaces of the strip to the web or panel can contact the web or panel in the region where the anchor is already disposed. The seal in that region may be either enhanced, or initially created, by the subsequent sealing step.
“Backing segment” refers to a monolayer or multilayer portion of a discrete strip that can be sealed to a web or second side panel by a sealant.
“Closed-loop” herein refers to a die cut that defines a closed pattern or path in the first side panel whereby the web material within the path (the die-cut segment) can be removed from the panel.
“Die cut” and the like herein refers to methods of cutting or scoring materials, including rotary die, steel rule die, platen die cutting, and laser cutting or scoring; and refers to the resulting cut or score. A die cut can extend entirely or partially through the relevant layer or web, and can leave intact a certain amount of material. “Score” and the like herein refers to a partial die cut that extends partly but not entirely through the thickness of a material, layer, web, panel, etc, The purpose of the score in the present invention is to provide for controlled tear or separation of material in the act of displacing or removing the die cut segment. The depth of the cut can vary from package to package, and within a single die cut or die cut segment on a given package.
“Die-cut segment” herein refers to a portion of the first side panel that can be displaced or completely removed because of the presence of a closed-loop or open-loop die cut. The die-cut segment is a piece of the first side panel, and when displaced or removed can function as a tamper evidence device, and facilitates access to the interior of the package.
“Discrete” with respect to the discrete strip is used herein to mean independently made (the strip is not an integral part of the web when the web is made) or constituting a separate entity from the web.
“Easy-open” herein refers to a package that can be manually opened relatively easily. The physical mode of opening may include any one or more of a) actual peeling at the discrete strip/web interface (adhesive failure), or b) a sealant layer of the discrete strip breaking completely through, and peeling then occurring between the sealant layer and an adjacent layer within the strip (delamination failure), or c) breaking within a sealant layer by rupturing of the sealant material itself (cohesive failure). The peel force required to open the package can be measured by an evaluation of seal strength or peel strength in accordance with the test procedure set out in ASTM F88, incorporated herein by reference in its entirety, using a crosshead speed of 8 to 12 inches/minute and an initial jaw gap of from 1.00 inch to 2.00 inch. Typical peel forces for opening the package of the invention can range from e.g. 25 grams/inch to 3 pounds/inch, e.g. from 100 grams/inch to 2 pounds/inch, such as from 200 grams/inch to 1.5 pounds/inch. In some cases, the sealant may actually peel away from the surface to which it is adhered (adhesive failure), or breakage of the sealant and delamination along an adjacent layer interface may occur (delamination failure) or a rupture of the sealant can occur (cohesive failure). Depending on the design and geometry of the seal, peel forces can in some embodiments be higher than 3 pounds/inch, e.g. 3.5, 4.0, 4.5, or 5 pounds/inch, or values intermediate these values. When a die cut segment is displaced or removed from the first side panel, such that the internal PSA layer of the discrete strip is partially exposed, in some embodiments some part of the scored portion of the die cut segment that remains after the die cutting process, may be torn through in the act of opening the package. The peel force required for this step in the opening process will be within the parameters discussed herein.
“Easy-open seal” herein refers to a seal involving the discrete strip and web in which materials and sealing conditions are chosen for the discrete strip and web such that the package is easy-open with a physical mode of opening that includes any one or more of adhesive failure, delamination failure, or cohesive failure as described herein.
“Easy-open sealant” herein refers to a material chosen for one or both surfaces of the discrete strip, such that when such surface is sealed to a web, it provides a package that is easy-open with a physical mode of opening that includes any one or more of adhesive failure, delamination failure, or cohesive failure as described herein.
“Ethylene/alpha-olefin copolymer” (EAO) herein refers to copolymers of ethylene with one or more comonomers selected from C3 to C10 alpha-olefins such as propene, butene-1, hexene-1, octene-1, etc. EAO includes heterogeneous materials such as linear medium density polyethylene (LMDPE), linear low density polyethylene (LLDPE), and very low and ultra low density polyethylene (VLDPE and ULDPE); single-site catalyzed materials such as homogeneous linear ethylene/alpha olefin copolymers and long chain branched ethylene/alpha olefin copolymers; and multicomponent ethylene/alpha-olefin interpenetrating network resin (or “IPN resin”).
“Ethylene homopolymer or copolymer” herein refers to polyethylene (PE) such as ethylene homopolymer such as low density polyethylene (LDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE); ethylene/alpha olefin copolymer such as those defined herein; ethylene/vinyl acetate copolymer (EVA); ethylene/alkyl acrylate copolymer such as ethylene/methyl acrylate copolymer (EMA) or ethylene/ethyl acrylate copolymer (EEA), or ethylene/butyl acrylate copolymer (EBA); ethylene/(meth)acrylic acid copolymer; or ionomer resin (IO).
“FIG.” herein refers to drawing figure; “FIGS.” to drawing figures.
“Film” is used herein to mean a thermoplastic film, laminate, or web, either multilayer or monolayer, that may be used in connection with the present invention. Film can be of any suitable thickness, e.g. between 0.1 and 30 mils.
“Fin seal” is used herein to mean, in the case of a single web, folding one edge of a web towards the opposite edge of the web, and sealing the facing inner surfaces together. In the case of two webs, a fin seal is a seal formed by sealing the inner surface of the edge of one web to the inner surface of a corresponding edge of another web.
“Lap seal” is used herein to mean a seal made by sealing an inside surface of a web to an outside surface of a web. The inside and outside surfaces can both be on a single web; or the inside surface can be of one web, and the outside surface of a second web.
“Lidstock” herein refers to a film used to cover a container or tray that carries a product, and can be sealed to the tray, typically as a perimeter heat seal. Lidstock typically is supplied to a food processor in a lay flat film rolled onto a roll.
“Longitudinal seal” herein refers to a fin seal or lap seal.
“Olefinic” and the like herein refers to a polymer or copolymer derived at least in part from an olefinic monomer.
“Open-loop” herein refers to a die cut that defines an open pattern or path in the first side panel whereby the web material within the path or pattern (the die-cut segment) can be displaced from its original position on the panel, e.g. by acting as a flap.
“Oxygen barrier” and the like herein refers to materials having an oxygen permeability, of the barrier material, less than 500 cm3O2/m2·day·atmosphere (tested at 1 mil thick and at 25° C., 0% RH according to ASTM D3985), such as less than 100, less than 50, less than 25, less than 10, less than 5, and less than 1 cm3 O2/m2·day·atmosphere. Examples of polymeric materials useful as oxygen barrier materials are ethylene/vinyl alcohol copolymer (EVOH), polyvinylidene dichloride (PVDC), vinylidene chloride/methyl acrylate copolymer, vinylidene chloride/vinyl chloride copolymer, polyamide (nylon), and polyester (PET).
“Polymer” and the like herein means a homopolymer, but also a copolymer thereof, including terpolymer, tetrapolymer, block copolymer, etc.
“Pouch” herein means a pouch or bag.
“Pressure sensitive adhesive” (PSA) herein refers to a repositionable adhesive that bonds firmly with the application of light pressure. It adheres to most surfaces with very slight pressure; is available in solvent and latex or water based forms, and is often based on non-crosslinked rubber adhesives, acrylics, or polyurethanes. PSA forms viscoelastic bonds that are aggressively and permanently tacky; adhere without the need for more than hand pressure; and require no activation by water, solvent, or heat. Some PSA materials are cured by hot air, electron beam, UV, or chemical (peroxide) means. They are available in a wide variety of chemical compositions and systems including acrylic and methacrylate adhesives, emulsion-based acrylic adhesive; rubber-based pressure sensitive adhesive, styrene copolymers (styrene/isoprene/styrene and styrene/butadiene/styrene block copolymers), and silicones. In some embodiments, hot melt adhesives may be useful as well, and are included herein for those embodiments as “PSA”; a hot melt adhesive is a thermoplastic adhesive compound, usually solid at room temperature which becomes fluid on heating for use. Suitable commercial examples of PSA include PS-2000™ from Dow, and “acResin®”, available from BASF, and comprising a UV-curable polyacrylate that can be applied by conventional hot-melt coaters at temperatures of about 120° C. Suitable tackifiers can be added to acR-sin® or like compositions to control the tackiness of the adhesive; examples are FORAL® 85 synthetic resin available from Pinova. Tackifiers can be added to the base adhesive composition in any suitable amount, e.g. from 15% to 25% by weight of the total composition of PSA and tackifier. In some embodiments, the PSA can be blended with an olefinic additive such as polyethylene, ethylene/methyl acrylate copolymer, or ethylene/vinyl acetate copolymer. These blends can be in any suitable proportions of the PSA and olefinic additive, as long as the easy-open and reclosable functionality of the package is substantially maintained. Extrudable pressure sensitive hot melt adhesive, having an appropriate melt index and melt strength, can be extruded as an intermediate layer within a multilayer structure made by a blown or cast film process. This layer would impart the reclosable characteristics to the structure. Examples of extrudable PSA materials include but not limited to the M-series materials such as M3156T™ and M551™ available from Bostik; HL2942M™ available from H B Fuller; and VECTOR™ 4114A and 4186A available from Dexco. Alternatively, blends of these materials can be made with compatible materials that may act as processing aids, without unduly compromising the reclose characteristics of the original PSA. Extrudable adhesive chemistries include styrene-Isoprene-styrene and styrene-butadiene-styrene copolymers, including both the linear blocks (e.g. the resins from Bostik) and radial blocks (the VECTOR resins); silicones; high comonomer content EVA, EMA, EBA etc. based formulations; and INFUSE™ olefinic block copolymer based materials. Those skilled in the art will appreciate, after a review of this disclosure, that a particular PSA can be selected based at least in part on the particular process used to produce the film from which the discrete strip is made, e.g. coextrusion, extrusion coating, etc., and the appropriate rheology and process characteristics of the PSA desired for that process, while ensuring that the easy-open and reclosable features of the package made in accordance with the invention are substantially maintained.
“Reclosable” herein refers to a feature or function of a package in accordance with the invention whereby a package can be reclosed by bringing a folded web, panel, or portion of a folded web or panel into contact with the PSA of the discrete strip.
“Registration device” herein refers to any mark, pattern, die cut or feature of a web or strip, that facilitates the advancement of the web or discrete strip, in a controlled manner, into a packaging machine, where the web or discrete strip is used to make individual packages. The device can be e.g. printed or placed in uniformly spaced fashion along or near an edge of the web or discrete strip, i.e. registration marks, or in an area near the middle of a web that does not interfere with decorative printed graphics. These marks are used in connection with appropriate sensors to controllably advance the web or strip. Where die cuts are used as a registration device, detected by sensors, it may not be necessary to print registration marks on the web or discrete strip.
“Seal” herein means a bond between two thermoplastic surfaces, e.g. as produced by heat sealing, radio frequency (RF) sealing, ultrasonic sealing, or permanent adhesive, but excluding repositionable adhesive or PSA.
“Sealant” is a polymeric material or blend of materials, such as olefinic polymer or copolymer such as an ethylenic polymer or copolymer, that can form a surface of the discrete strip of the invention, or a web to which the discrete strip is sealed, and form a bond between two thermoplastic surfaces. A permanent adhesive can also be a sealant. “Sealant” herein, with respect to the discrete strip, or a web to which the discrete strip is attached, excludes a repositionable adhesive or PSA.
“Sealing segment” refers to a monolayer or multilayer portion of a discrete strip that can be sealed to a web or first side panel by a sealant.
“Strip” herein refers to an elongate piece of thermoplastic material, typically longer in a first direction than in a direction perpendicular to the first direction, e.g. rectangular; but can also be square, round, oblong, elliptical, or any appropriate shape in plan view. The strip can be of any suitable thickness, e.g. between 0.1 and 30 mils.
“Tamper evidence”, “tampering”, and the like herein refers to visual evidence of a breach in a package; i.e. that someone has accidentally or intentionally opened or partially opened the package, or attempted to do so.
“Thermoplastic” herein includes plastic materials that when heated to a softening or melting point may be reshaped without significant thermal degradation (burning). Thermoplastic includes both materials that are not crosslinked, or that are crosslinked by chemical or radiation means.
“Tray” herein refers to a formed member that has a tray bottom, tray sides, and a tray flange around the upper perimeter of the tray, where the tray bottom and tray sides form an internal cavity within which a product can be placed. The cavity can be enclosed by a lidstock sealed to the tray flange.
“Web” is used herein to mean a thermoplastic film, laminate, or web, either multilayer or monolayer, that may be used in connection with the present invention. The web can be of any suitable thickness, e.g. between 0.1 and 30 mils, and the web can be of any suitable length and width.
“Zipper” and the like herein refers to a plastic zipper closure; press-to-close or slide zipper; interlocking closure; reclosable fastener with interlockable fastener elements; interlocking rib and groove elements having male and female profiles; interlocking alternating hook-shaped closure, and the like.
All compositional percentages used herein are presented on a “by weight” basis, unless designated otherwise.
Drawings herein are not necessarily to scale, and certain features of the invention may be graphically exaggerated for clarity.
Referring to the drawings, a package 5 according to the invention is shown. Package 5 includes a pouch 7 that can be made from either a single web, or two webs, to form a first or front side panel 12, and a second or back side panel 14.
A. Web(s)
In either embodiment, the web or webs comprises a thermoplastic material of any suitable composition, including those having as at least one component olefinic materials such as ethylene or propylene polymers or copolymers, e.g. polyethylene or ethylene/alpha olefin copolymers; polyethylene terephthalate (PET); and including webs typically used in, or useful in, HFFS, VFFS, lidstock/tray, continuous horizontal packaging, and bag making apparatus and processes. The web or webs can be monolayer or multilayer in construction, can be coextruded, laminated, or made by any suitable film making process, and can have any suitable thickness.
Examples of web(s) useful in the invention include H7225B™, a barrier hybrid material used for products requiring a high oxygen barrier, such as shredded cheese; H7525B™, a barrier hybrid material used for products requiring a high oxygen barrier, such as bacon and smoked and processed meat; H7530B, like H7525B but having a thickness of about 3 mils; CP04140™, a low barrier (high OTR) material used in produce packaging; CPM4090, a microwaveable packaging film for fresh cut produce; and T7225B™, a barrier material used as lidstock for products requiring a high oxygen barrier, such as luncheon meat. These are all commercial products produced by the Cryovac business unit of Sealed Air Corporation.
H7225B™ is a laminate having the construction PET//adhesive//coextruded barrier film, where the PET is a biaxially oriented polyester film, and the barrier film has in one embodiment the construction LDPE (low density polyethylene)/EVA tie/nylon/EVOH+nylon/nylon/EVA tie/EAO. The overall thickness of the laminate can be any of several gauges, being typically about 2.5 mils. The LDPE is the surface of the barrier film adhered, by the adhesive, to the PET film. The EAO typically acts as the heat sealant layer of the film, and finished laminate, and in packaging made from the laminate, the EAO will form the inner or sealant surface of the package, facing the contained product, and the PET will form the outer or skin surface of the package. H7225B™ can be used as a lidstock (non-forming) web.
H7525B™ is a laminate having the construction PET//adhesive//coextruded barrier film, where the PET is a biaxially oriented polyester film, and the barrier film has in one embodiment the construction LDPE (low density polyethylene)/EVA/LLDPE tie/EVOH/LLDPE tie/EVA/EAO. The overall thickness of the laminate can be any of several gauges, being typically about 2.5 mils. The LDPE is the surface of the barrier film adhered, by the adhesive, to the PET film. The EAO typically acts as the heat sealant layer of the film, and finished laminate, and in packaging made from the laminate, the EAO will form the inner or sealant surface of the package, facing the contained product, and the PET will form the outer or skin surface of the package. H7525B™ can be used as a lidstock (non-forming) web.
CP04140™ is a laminate having the construction BOPP//adhesive/monolayer LLDPE film. A typical gauge for the laminate is about 1.8 mils. The LLDPE typically acts as the heat sealant layer of the finished laminate, and in packaging made from the laminate, the LLDPE will form the inner or sealant surface of the package, facing the contained product, and the BOPP will form the outer or skin surface of the package.
CPM4090™ is a laminate having the construction BOPP//adhesive/monolayer LLDPE+LDPE film. A typical gauge for the laminate is about 2 mils. The LLDPE+LDPE layer typically acts as the heat sealant layer of the finished laminate, and in packaging made from the laminate, the LLDPE+LDPE will form the inner or sealant surface of the package, facing the contained product, and the BOPP will form the outer or skin surface of the package.
T7225B™ film has the construction EAO/EAO/LLDPE tie/nylon/EVOH/nylon/EVA tie/EVA tie/nylon. The first layer of EAO typically acts as the heat sealant layer of the film, and in packaging made from the laminate, the EAO will form the inner or sealant surface of the package, facing the contained product, and the nylon of the last layer will form the outer or skin surface of the package. T7225B™ is used as a lidstock (non-forming) web.
Referring to the drawings, the first side panel 12 has a top portion 9, a first side edge 31, a second side edge 33, and a lower portion 17. The second side panel 14 has a top portion 11, a first side edge 35, a second side edge 37, and a lower portion 18. The first and second side panels 12 and 14 are joined together along their respective first and second side edges by either a seal or a fold. As shown, first side edge 31 of first side panel 12 is joined to first side edge 35 of second side panel 14 by a seal 30. Second side edge 33 of first side panel 12 is joined to second side edge 37 of second side panel 14 by a heat seal 32. The second end 34 of the pouch 7 can be either a seal or a fold. Where a single web is used to make the pouch, second end 34 will typically be a fold, although even after the web is folded, a seal such as a heat seal can optionally be installed in the area of the fold. Where two webs of film are used to make panels 12 and 14, second end 34 will be a seal that joins panels 12 and 14 together along their respective lower portions 17 and 18. The two webs can be from the same material, or can be different in composition, structure, etc.
B. Discrete Strip
1. Geometry and Placement in Package
A discrete strip 10 is disposed between first panel 12 and second panel 14, typically near and spaced apart from the first end of the pouch, and spaced apart from the second end of the pouch. In one embodiment (see
In some embodiments, an opening flap 26 (
Discrete strip 10 comprises a first surface 23 and a second surface 25. The first surface 23 is sealed to the inner surface 27 of the first side panel 12 with a relatively strong sealant. The second surface 25 is in some embodiments sealed to the inner surface 29 of the second side panel 14 with an easy open sealant. In some embodiments, the second surface 25 of the discrete strip is sealed to the inner surface 29 of second side panel 14 only along the first and second side edges of the package. In other embodiments, the second surface 25 of the discrete strip is sealed to the inner surface 29 of second side panel 14 along the entire width of the package, with an easy-open seal. In still other embodiments, the second surface 25 of the discrete strip is sealed to the inner surface 29 of second side panel 14 at all (see
When a product 24 is placed in the pouch 7, by processes herein disclosed, and the pouch 7 is closed, the package 5 is made.
In embodiments where no seal is required between surfaces 25 and 29, the seal between surfaces 23 and 27 can be made either before or after the finished package is made.
In some embodiments, at least one die cut, or a portion of a die cut, is disposed closer to the first end of a pouch than the first end 28 of the discrete strip, i.e. the end of the discrete strip closest to the first end of the pouch.
As shown in the drawings, a first portion of the first surface 23 of the discrete strip is anchored to the inner surface 27 of first side panel 12 at a first location on the first side panel 12 to form a first anchor seal 63, and a second portion of the first surface 23 of the discrete strip is anchored to the inner surface 27 of first side panel 12 at a second location on the first side panel 12 to form a second anchor seal 68. The functionality of this arrangement in providing an easy-open and reclosable package is disclosed in more detail herein.
2. Strip Construction
The discrete strip of the invention is made from a multilayer film. A representative film structure suitable for use as the discrete strip 10 according to the invention is shown in
In the embodiment of example 1, layer 22 functions as a sealant layer for sealing to a first portion of an inner surface of a front panel or surface of a web to be made into a package. Layer 22 also comprises a single layer, and comprises sealing segment 22. Layer 20 functions as a skin layer, and can function as a sealant for sealing to an inner surface of a back panel or surface of a web to be made into a package. Layer 20 also comprises a single layer, and comprises backing segment 20. Thus, either or both of sealing segment 22 and backing segment 20 can comprise, and consist of, only one layer.
A film of the construction of the film of Example 1 is commercially available in Europe, and sold as T174RC2™ from B-Pack, used as a primary web for a package, not as a discrete strip to be used in a package as disclosed herein.
Alternative three layer coextruded film structures, suitable for use in the invention, that were made in-house on a flat cast line include the films shown below in Table 2:
In each of examples 2 through 9 of Table 2, sealant layer 22 was 0.4 mils thick; the reclose layer 19 was 0.6 mils thick; and skin layer 20 was 1 mil thick.
Another representative film structure suitable for use as the film strip 10 according to the invention is shown in
In the embodiment of example 10, layer 109 functions as a sealant layer for sealing to a first portion of an inner surface of a front panel or surface of a web to be made into a package. Layer 108 functions as a sealant support layer, and also as a tie layer to bond the sealant layer 109 to the PSA layer 119. Thus, in this embodiment, sealing segment 22 comprises two layers, layers 109 and 108. In general, sealing segment 22 can comprise any suitable number of layers, such as one, two, or three or more layers, as long as the easy-open/reclose functionality of the package made from the web and discrete strip is maintained.
In the embodiment of example 10, layer 101 functions as a skin layer that in some embodiments can be used for sealing to the inner surface of a back panel or surface of a web to be made into a package. Layer 102 functions as a tie layer to bond the skin layer 101 to the PSA layer 119. Thus, in this embodiment, backing segment 20 comprises two layers, layers 101 and 102. In general, backing segment 20 can comprise any suitable number of layers, such as one, two, or three or more layers, as long as the easy-open/reclose functionality of the package made from the web and discrete strip is maintained. In some embodiments, backing segment 20 can include one or more functional layers such as e.g. oxygen barrier layers.
A commercial example of a film of the construction of the film of Example 10 is available in Europe, used there as a primary web for a package.
Another representative film structure suitable for use as the film strip 10 according to the invention is shown in
In the embodiment of example 11, layer 109 functions as a sealant layer for sealing to a first portion of an inner surface of a front panel or surface of a web to be made into a package. Thus, in this embodiment, sealing segment 22 comprises one layer, layer 109.
In the embodiment of example 11, layer 101 functions as a skin layer that in some embodiments can be used for sealing to the inner surface of a back panel or surface of a web to be made into a package. Layer 103 functions as an oxygen barrier layer, and tie layers 102 and 104 bond the oxygen barrier layer 103 to the skin layer 101 and PSA layer 119 respectively. Thus, in this embodiment, backing segment 20 comprises four layers, layers 101, 102, 103 and 104.
A film is made like the film of Example 11, but in which PSA2 is used instead of PSA1.
A film is made like the film of Example 11, but in which layer 109 comprises 98% EA3+2% AB3.
A film is made like the film of Example 13, but in which PSA2 is used instead of PSA1.
The materials disclosed in Tables 1 to 4, and other materials referred to elsewhere in the present application, are identified in Table 5.
All percentages herein are by weight unless indicated otherwise.
The oxygen barrier layer 103 of Examples 11 to 14 of the above film structures can comprise any suitable oxygen barrier material, such as EVOH, and can be blended in any suitable proportion with other polymeric materials or organic or inorganic additives as desired. Optionally, intermediate layers can be included on each respective side of layer 103, each comprising a nylon, e.g. 100% semicrystalline polyamide such as nylon 6. An intermediate layer of nylon can, in one embodiment, be placed on either or both adjacent surfaces of an EVOH or other barrier layer 103.
In packaging embodiments where the second surface 25 of discrete strip 10 is sealed to the inner surface of the back panel along the entire width of the discrete strip 10, an easy-open sealant, such as EZ1, can be used as sealant layer 101 of the discrete strip 10.
Tie layers 102 and 104 can comprise any suitable polymeric adhesive that functions to bond two layers together, e.g. EVA, EAO, LDPE, EMA, and anhydride grafted derivatives of these polymers. Tie layers 102 and 104 can be the same, or can differ.
Layer 108 can comprise a suitable polyolefin, such as an EAO; and/or a polymeric adhesive such as those disclosed herein for tie layers 102 and 104.
Additional materials that can optionally be incorporated into one or more of the film layers of the discrete strip or the primary web, as appropriate, include antiblock agents, slip agents, antifog agents, fillers, pigments, dyestuffs, antioxidants, stabilizers, processing aids, plasticizers, fire retardants, UV absorbers, etc.
A first anchor seal, of any suitable geometry, is disposed near the first end of the package, seals the first side panel to the first end of the discrete strip. See e.g.
The sealant layers of the discrete strip, e.g. layer 22 and optionally layer 20 as depicted in
The web and discrete strip of the invention can be made by any suitable process, including coextrusion, extrusion coating, lamination, extrusion lamination, etc.
3. Opening Mechanisms
The package of the invention can be easily manually opened. Any suitable mechanism or combination of mechanisms for obtaining this functionality and feature can be used according to the invention. The following are examples of such mechanisms.
If the second surface 25 of strip 10 is sealed to the inner surface 29 of second side panel 14 along substantially the entire length of the strip, this seal is an easy-open seal involving one or more of the following mechanisms. In other embodiments, the second surface 25 of strip 10 is sealed to the inner surface 29 of second side panel 14 only along the side edges of the strip, as part of the perimeter seal or side seals of the package. In these embodiments, the seal between the second surface 25 and the surface 29 can be a relatively strong seal, provided the die cut segment is so positioned with respect to the discrete strip that the package can be opened and reclosed as disclosed herein.
The first surface 23 of strip 10 is sealed with a first and second anchor seal to the inner surface 27 of the first side panel 12. The second anchor seal 68 is a relatively strong seal; the first anchor seal 63 is an easy-open seal that will typically exhibit a combination of cohesive and delamination failure, or delamination failure, as disclosed herein.
a. Adhesive Failure
In this embodiment, surface 25 and inner surface 29 each comprises a polymeric composition that, when surface 25 is sealed to surface 29, forms an easy-open seal. This seal provides the interface that breaks apart upon manually opening the package.
In some embodiments, the polymeric composition of surfaces 25 and 29 will be the same or similar. Useful in these embodiments are the peel systems disclosed in U.S. Pat. Nos. 4,189,519 (Ticknor) (blend of EVA or EMA or EEA with crystalline isotactic polybutylene, and optionally with anhydride grafted EVA); 4,252,846 (Romesberg et al.) (blend of EVA and HDPE, optionally with IO or polybutylene (PBU)); 4,550,141 (Hoh) (blend of IO and polypropylene/ethylene copolymer (EPC)); 4,666,778 (Hwo) (three component blend of PE, that can be LLDPE, LDPE, MDPE, or HDPE, or EVA or EMA, with PBU, and PP or EPC); 4,882,229 (Hwo) (butene-1 polymer or copolymer blended with modified or unmodified LDPE); 4,916,190 (Hwo) (blend of butylene polymer or copolymer, with PE polymer or copolymer (LLDPE, LDPE, MDPE, EVA, EMA, EEA, EBA, or HDPE), with propylene polymer or copolymer); 4,937,139 (Genske, et al.) (propylene polymer or copolymer blended with HDPE); 5,547,752 (Yanidis) (blend of PBU and IO); and 5,997,968 (Dries et al.)(blend of Component 1 (a copolymer of ethylene and propylene or ethylene and butylene or propylene and butylene or ethylene and another -olefin having 5 to 10 carbon atoms or propylene and another -olefin having 5 to 10 carbon atoms or a terpolymer of ethylene and propylene and butylene or ethylene and propylene and another -olefin having 5 to 10 carbon atoms) and Component 2 (HDPE, MDPE, LDPE, LLDPE or VLDPE); these U.S. patents all incorporated herein by reference in their entirety.
In other embodiments, the composition of surfaces 25 and 29 will differ, i.e. dissimilar sealants are used. Useful in these embodiments are the peel systems disclosed in U.S. Pat. Nos. 3,655,503 (Stanley et al.) (LDPE or MDPE sealed to polypropylene (PP), EPC, saran, nylon 6, polycarbonate (PC), polyvinyl chloride (PVC), or polyethylene oxide (PEO); PP sealed to saran, nylon 6, PC, PVC, PEO, IO, phenoxy, or EVA; or nylon sealed to IO); 4,729,476 (Lulham et al.) (a blend of EVA and IO sealed to IO); 4,784,885 (Carespodi) (PP, HDPE, or LLDPE sealed to substantially linear PE (HDPE, LLDPE) blended with a polyolefinic thermoplastic elastomer such as ethylene propylene diene monomer (EPDM), EPM, butyl rubber, halogenated butyl rubber, isoprene rubber, and styrene butadiene rubber); 4,859,514 ((Friedrich et al.) (IO or IO blended with EVA, sealed to a blend of EVA and ethylene butene copolymer (EBC) and PP); 5,023,121 (Pockat, et al.)(a blend of PBU and PP and a third polymeric material selected from EVA, LDPE, LDPE, and IO, sealed to EVA, LDPE, LLDPE, or IO); these U.S. patents all incorporated herein by reference in their entirety.
In some embodiments, surface 25 is not sealed to surface 29, and strip 10 thus remains unattached to second side panel 14 in the finished package, except for any side seals in the package that hold the two ends of strip 10 between the first and second side panels.
b. Delamination Failure
In this embodiment, one of the interlaminar bonds between layers of the strip itself can be broken. Thus, the interlaminar bond provides the interface that will break apart upon manually opening the package. Useful in this embodiment are the peel systems disclosed in U.S. Pat. No. 4,944,409 (Busche et al.), this patent incorporated herein by reference in its entirety.
c. Cohesive Failure
In this embodiment, one of the layers of the discrete strip itself fractures when the package is opened. Useful in this embodiment is the peel system disclosed in U.S. Pat. No. 6,476,137 (Longo) (internal rupture of a sealant layer comprising a blend of an ionomer having a melt flow index of less than 5, and a modified ethylene/vinyl acetate copolymer having a substantially higher melt flow index, where the melt flow indices of the two polymers in the seal layer differ by at least 10), this patent incorporated herein by reference in its entirety.
Other peel systems useful in connection with the present invention are those disclosed in U.S. Pat. Nos. 4,058,632 (Evans et al.), 4,615,926 (Hsu et al.); 5,128,414 (Hwo); 6,395,321 (Schaft et al.), 7,055,683 (Bourque et al.), and US Patent Publication Nos. 20030152669 (Vadhar et al.) and 2008/0260305 (Shah et al.) (disclosing as easy-open sealant, DuPont APPEEL™ resins, such as those based on EVA, modified EVA, EAA, or modifled EAA; polyethylenes such as LDPE and/or EVA blended with PP; LDPE or EVA blended with polybutene-1, or random propylene/ethylene copolymer blended with polybutene-1; EVA or LDPE blended with PP; LDPE blended with EVA and PP; such blends provide an easy-open sealant when adhered to polyethylene sealants); these U.S. patents and publications all incorporated herein by reference in their entirety.
Referring to
Referring to
In general, strip 10 can have any total thickness desired, and each layer can have any thickness desired, so long as the strip and package provide the desired functionalities. Typical total film thicknesses are from 0.1 mils to 15 mils, such as 0.2 to 12 mils, such as 0.5 mils to 10 mils, 0.8 mils to 8 mils, and 1 mil to 4 mils. Suitable gauges include 1.5 mils, 2 mils (as in Example 1); and 3 mils.
In an alternative embodiment,
As shown in
For many products, it is important to ensure hermeticity of the package during storage and distribution. This may be more difficult where one or more die cuts are present in the first side panel of the package. Hermeticity is achieved in various embodiments of the invention where a seal anchors the first side panel to the strip in regions “A” and “D”, and another seal adheres the second side panel to the strip (
In each of the embodiments of the package and process disclosed herein, a non-hermetic or hermetic package can be made in accordance with the invention.
In accordance with the invention, at least one open-loop or closed-loop die cut is disposed on the first side panel. Two or more die cuts can be disposed on the first side panel, one optionally at a position closer to the first end of the package than the strip, as well as a second die cut below or in the vicinity of the strip (see
A. Horizontal Form/Fill/Seal (HFFS)
HFFS packaging systems are generally well known to those of skill in the packaging industry, and can be used to make packages of the present invention.
Referring to
Discrete strip 310, equivalent to discrete strip 10 of
The strip 310 includes a first surface with a first and second portion. The first portion is closer to a longitudinal end of the pouch, e.g. the first end of the pouch, than the second portion. The first portion of the first surface of the strip is anchored to the inner surface of folded web 305 at a first location on the folded web, by a suitable sealing mechanism such as a heat sealer (not shown). The second portion of the first surface of the discrete strip is anchored to the inner surface of the folded web at a second location on the folded web, by a suitable sealing mechanism such as a heat sealer (not shown). Optionally, the second surface of the strip is sealed to the inner surface of the folded web. Strip 310 would thus be installed on the pouch in the same overall HFFS process that achieves production of the pouch, loading of a product into the pouch, and completion of the final package. Strip 310 is incorporated into the pouch material and after cutting and sealing as described hereinabove, is disposed between and sealed to the two side panels of each pouch as shown in
Alternatively, and referring to
The embodiment of
At any time during the method of making the package in an HFFS process, a second portion of the first surface of the discrete strip is anchored by the second anchor seal to the lay-flat web, the folded web, or the inner surface of the first side panel. This can be done e.g. on the lay-flat web prior to supplying the web to the processor, or prior to or as the lay-flat web is advanced to a forming device, or before or after a product is put in the open pouch.
In the embodiment of
In the embodiment of
B. Vertical Form/Fill/Seal (VFFS)
Apparatus 40 utilizes a lay-flat web 41 as a rollstock. Web 41 includes die cuts made in a predetermined pattern (see
Lay-flat web 41 of
Alternatively, and referring to
Alternatively (
In some embodiments, e.g.
Discrete strip 74 can extend entirely across the transverse width of pouch 7 (
For the sake of clarity, die cuts 21 and optionally 36, present in lay-flat web 41 and the first side panel of the package, are not shown in all of the drawings, e.g. in
In embodiments where strip 74 extends across only selected segments of the pouch, easy-open access to the package (the ability to manually open the package under normal conditions) will be roughly proportionate to that part of the package occupied by the strip. Thus, In
Alternatively (
At any time before or during the method of making the package in an VFFS process, a first portion of the first surface of the discrete strip is anchored to the lay-flat web, the folded web, or the inner surface of the first side panel at a first location to create first anchor seal 63, and a second portion of the first surface of the discrete strip is anchored to the lay-flat web, the folded web, or the inner surface of the first side panel at a second location to create second anchor seal 68. This can be done on the lay-flat web prior to supplying the web to the processor, or prior to or as the lay-flat web is advanced over a forming device, or before or after a product is put in a pouch.
C. Lidstock/Formed Web
Each tray 602 has a tray bottom 604, tray sides 606, and a tray flange 608 along its perimeter to which the lidstock 612 can be sealed by heat or other means. Tray bottom 604 and tray sides 606 define tray cavity 610. Prior to any thermoforming step, tray 602 can be of any suitable thickness, e.g. from 2 to 30 mils thick, and any suitable construction.
If a pre-made tray is used according to the invention, it can be rigid or semi-rigid, can be in the form of a flat or shaped tray, and can be made from any suitable material, including solid or expanded embodiments, such as PP, polystyrene, polyamide, 1,4-polymethylpentene (e.g. TPX™ available from Mitsui), or crystallized polyethylene terephthalate (CPET). A tray liner can optionally be used that adheres to the surface of the pre-made tray on which the product is to be placed. This liner can be of any suitable design, and can be a multi-layer structure with at least one layer with gas-barrier properties. Such a liner can be adhered to the tray by heat lamination, extrusion lamination, extrusion coating, adhesives, corona treatment, etc. Tray 602 can be a flexible or semi-rigid, or rigid formed web.
Referring to
Referring to
At any time during the method of making the package having a formed web, a first portion of the first surface of the discrete strip is anchored to the lay-flat web at a first location, to create first anchor seal 63, and a second portion of the first surface of the discrete strip is anchored to the lay-flat web at a second location to create second anchor seal 68. This can be done on the lay-flat web prior to supplying the web to the processor, or before or after sealing the lidstock to the formed web.
D. Continuous Horizontal Packaging
In another embodiment, and referring to
Alternatively, the sealing function of transverse sealing device 716 and the cutting function of cutting device 718a and 718b can be combined at a single station, rather than being performed at separate locations on the production path.
Web 702 and strip 724 can be of any suitable dimension and composition, such as those disclosed herein. As strip 724 is fed to forming device 710, it can be brought into contact with, and anchored to a surface of web 702. This embodiment is shown in
At any time during the method of making the package in a continuous horizontal packaging process, a first portion of the first surface of the discrete strip is anchored to the lay-flat web or the formed web at a first location to create first anchor seal 63, and a second portion of the first surface of the discrete strip is anchored to the lay-flat web or the formed web at a second location to create second anchor seal 68. This can be done on the lay-flat web prior to supplying the web to the processor, or prior to or as the lay-flat web is advanced to a forming device, or before or after advancing a product to a forming device. Alternative methods of assembly, such as those disclosed for the HFFS process, can also be implemented.
E. “Window Pane” Label
In another embodiment, a discrete strip 10 is made as a web of material, slit to a suitable width, and wound into rolls. A roll of labels so made is installed in a label applicator 72 (see
A series of labels can thus be applied to a lay-flat web as discrete strips, to produce a package of the invention using the various processes disclosed herein. In these embodiments, it is required to have a sealant only on the surface of each discrete strip that will be in contact with and sealed to the web.
Any suitable in-line label applicator can be adapted for use in this embodiment, such as those available from Label-Aire of Fullerton, Calif., or Arca Etichette SPA Milan, Italy.
In one embodiment, to initiate the application of labels 70 to layflat web 41, a sensor or other suitable detection device detects a registration mark, or other suitable feature that has been pre-marked at pre-determined intervals on the web, on the moving web that is a known distance from the die cut on the web. This sensor signals the label applicator 72 to initiate the process of placing a label. The leading edge of a label advances from the label applicator in a manner that closely matches the web speed, and its leading edge touches the web at a desired point in relation to the die cut. A vacuum device (not shown) may assist in placing the label on the web at the desired location and in the desired orientation. Heat is then applied by a heat sealing device (not shown) to seal the label to the web.
Thus, in any of the processes described herein, in one embodiment the die cut or die cuts on the web can be partially or completely framed by a heat seal on each perimeter of a discrete strip to form a label 70, with a central area 60 within which all or part of one or more closed-loop or open loop die cuts are present (see
For clarity, label 70 is not shown in
The label thus supplies the easy-open and reclosable functionalities for the package, and frames the die cut in the web that provides the easy-open functionality for the package. In the case of an open-loop die cut, a flap may be present.
In some embodiments, the die cut is completely framed by the lanes of heat seal. Alternatively, part of the die cut can be outside the frame of the label.
Labels can be of any desired shape to suit the shape of the die cut in the web. For example, considered in plan view, the center section of the top edge of the label can be lower than the outer edges of the top edge of the label to allow the hinge of an opening flap to extend above it, allowing access to the interior after opening. Hence, the outer ends will be slightly higher to cover the “stress relief hooks” of some embodiments of die cuts that form the ends of the opening flap, assuring hermeticity of the package before opening, if desired.
F. Side Seal Bags
In one embodiment, and referring to
A bag with a die cut and discrete strip disposed thereon can be made by extruding a thermoplastic tube to make a bag tubing; die cutting the bag tubing at predetermined intervals; slitting the tubing at one longitudinal edge thereof; and periodically transversely cutting and sealing the bag tubing to make a plurality of individual bags each with a discrete strip disposed thereon. The discrete strip and die cut can function as described herein for other embodiments and processes, in providing an easy-open and reclosable package. Some of the steps set out in US 2008/0138478 A1, for making a bag, are optional with respect to the present invention; such steps including irradiation and orientation of the tubing.
At any time before transversely cutting the bag tubing to produce a bag, a first portion of the first surface of the discrete strip is anchored to the bag tubing or slit bag tubing at a first location to create first anchor seal 63, and at any time during the method of making the bag, a second portion of the first surface of the discrete strip is anchored to the bag tubing or slit bag tubing at a second location to create second anchor seal 68.
Method of Operation
To reclose the package, the flap of the first side panel can be placed down on the PSA, or the first and second side panels can both be folded over, along with the exposed portion of the PSA layer, to contact the lower part of the first side panel with the exposed PSA. The package can be opened and reclosed several times. When the package is opened, the PSA is positioned facing the outside of the package. This is useful especially with food products where it is undesirable to have the PSA facing the interior of the package, and thus potentially in contact with the product.
Another embodiment for opening a package in accordance with the invention is shown in
To reclose the package, the flap of the first side panel can be placed down on the PSA, or the first and second side panels can both be folded over, along with the exposed portion of the PSA layer, to contact the lower part of the first side panel with the exposed PSA. Here, and in
Method of Making a Die Cut in a Web
A conventional die cutter can be used to create a first die cut 21, and optionally one or more additional die cuts 36 in a web that is used to make first side panel 12. Die cuts can be made by any suitable conventional process and equipment. Any suitable pattern of die cut can be used, open or closed-loop, as long as it serves the function of providing an easy open package in which the packaged product can be accessed by means of a flap created at least in part by the die cut. Alternative patterns include elliptical, oval, triangular, three side rectangle, hour glass, “dog bone”, and other regular and irregular shapes.
The die cut extends completely through the first side panel, or may extend through most of, but not entirely through, the thickness of the panel. The die cut may extend through e.g. at least 50% of the thickness of the first side panel, e.g. at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or 100% of the thickness of first side panel 12.
A laser system can be configured to produce a laser cut that cuts partly or completely through the panel, or alternatively, a die cut can be made using a mechanical cutting system using rotary engraved dies, or steel rule dies supported in platens as used in reciprocating presses. The choice of die cutting technique depends on several factors, including the thickness and physical nature of the film or web to be cut.
The die cut may act as a tamper evident feature.
The die cutting of a web to produce a first side panel, and the assembling of a package incorporated a die cut web and a discrete strip, can be done at a single location, but more practically will typically be done at separate locations, with the assembling of the package by a packager using a pre-provided discrete strip and a die cut web prepared elsewhere and provided in advance of the packaging process.
A package is made in accordance with the embodiment illustrated in
where the PET is a biaxially oriented polyester film, and the coextruded barrier film has the construction:
The overall thickness of the coextruded barrier film is about 2.50 mils. Layer gauges in mils for each layer are indicated below each layer. Layer 7 is the layer of the barrier film adhered, by the adhesive, to the PET film. Layer 1 is the heat sealant layer of the film, and the EAO (PE2) of layer 1 forms the inner or sealant surface of the package, facing the contained product, and the PET forms the outer or skin surface of the package. The thickness of the PET film is about 0.48 mils. The overall thickness of the laminate is about 3.0 mils.
Alternatives to the composition of layer 7 include various combinations of materials, including:
The discrete strip of the package is a film as described herein for Example 11.
Before the package is made, the discrete strip is anchored to the H7530B web (specifically, to layer 1 of the coextruded barrier film of the H7530B laminate) to form first and second anchor seals while the latter is in a lay-flat condition. A closed loop die cut is made in the web by a CO2 laser prior to applying the strip to the web; the die cut defining a die cut segment that is positioned so as to result in the package as shown in
A package like that of Example 1 is made, but in which the coextruded barrier film of the first and second side panel is a nine-layer film with a composition very similar to the seven layer film construction of Example 1, but having an additional intermediate layer of EV1, and an additional intermediate layer of a LDPE or a blend including LLDPE.
The above descriptions are those of embodiments of the invention. All parts and percentages are by weight, unless otherwise indicated or well understood in the art. Except in the claims and the specific examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material, reaction conditions, use conditions, molecular weights, and/or number of carbon atoms, and the like, are to be understood as modified by the word “about” in describing the broadest scope of the invention. Any reference to an item in the disclosure or to an element in the claim in the singular using the articles “a,” “an,” “the,” or “said” is not to be construed as limiting the item or element to the singular unless expressly so stated. All references to ASTM tests are to the most recent, currently approved, and published version of the ASTM test identified, as of the priority filing date of this application. Each such published ASTM test method is incorporated herein in its entirety by reference.
Terms referring to polymers, such as polyester, polyamide, and polyolefin, refer herein to both homopolymers and copolymers thereof, unless otherwise specified.
With reference to the drawings, the flow of materials is in the direction of the arrows.
Those of skill in the art will recognize that the drawings herein are not necessarily to scale, and certain features of the invention may be graphically exaggerated for clarity.
The web or webs used in the manufacture of the package according to the invention, and the discrete strip, can be made by any suitable process, including coextrusion, extrusion coating, extrusion lamination, and conventional lamination using polyurethane or other adhesives. These manufacturing processes are well known in the art. Extrusion can be done in annular or flat (slot) dies. The extrudate can be hot blown or cast, and optionally solid-state oriented as desired. For example, in one embodiment the film from which the discrete strip is made can be fully coextruded. In a second embodiment, in an extrusion coating process, a multilayer substrate film is coextruded, having an intermediate layer of coextruded PSA; and another layer of material is extrusion coated onto the multilayer substrate to make up the final laminate from which the discrete strip is made by slitting. In this second embodiment, the multilayer substrate comprises the sealing segment and the PSA layer; the extrusion coated layer of material comprises the backing segment. In a third embodiment, the multilayer substrate comprises the backing segment and the PSA layer; the extrusion coated layer of material comprises the sealing segment. In a fourth embodiment, in an extrusion lamination process, a multilayer substrate film is coextruded; a second multilayer substrate film is coextruded; a PSA is coated onto a surface of at least one of the substrates; and the first and second substrates are brought together, such that they are bonded together at the PSA-coated surface, to form a multilayer laminate having an intermediate layer of PSA. In this embodiment, the first multilayer substrate comprises the sealing segment; and the second multilayer substrate comprises the backing segment. Chemical or electronic crosslinking of one or more layers of the webs or the strip can be done. Both web and strip can be advanced by suitable motive means (not shown, and well known in the art, such as a motor) from their respective rolls.
A package according to the invention can optionally carry printed indicia, which can be decorative or informational in nature. Decorative printed indicia can include a logo, a trademark, product information, etc. with text and/or graphics.
Printed indicia can be in the form of a message e.g. “easy open” or “open here”. This can be printed in scattered process (i.e. registration is not required) on or near the first end of the package. The message is surface printed or reverse printed.
In some embodiments, such as those shown in
In the embodiments disclosed herein, the first end of the package can be sealed, typically where two webs are used to make the package. Alternatively, the first end of the package can be a fold, e.g. where a single web of material is used to make the package.
The present invention, including the package and methods as disclosed herein, is provided in several embodiments in the absence of: plastic zipper closures; press-to-close or slide zippers; interlocking closures; reclosable fasteners with interlockable fastener elements; interlocking rib and groove elements having male and female profiles; interlocking alternating hook-shaped closure members, and the like. The package of the invention is provided herein in the absence of a release liner for a PSA layer or coating. None of these aforementioned closures, zippers, elements, etc. is present in the package of the invention.
Although the invention is described in some embodiments herein as a package comprising a pouch comprising a first and second side panel each having a top edge, a first side edge, and a second side edge, those skilled in the art will understand, after a review of this disclosure, that in some embodiments, wherein a single web is used, the terms “side panel”, “top edge”, “first side edge”, “second side edge”, and the like are used for convenience to describe the relative locations or regions on a single web made into a pouch, so that the overall geometry of the package, and relative positions of the various features of the invention can be described. Thus, for instance, the first and second panels in a single web embodiment of the invention can be simply defined regions of the pouch, and the package made therefrom, and side edges are simply the side end lines of those regions. In such embodiments, the line of joinder of the side edges are the two side folds in the web that define the sides of the package. In contrast, in embodiments with two webs, each web when produced will have an identifiable first and second side edge, that will each be joined to a respective side edge of a second web.
Although the first and second side panels are shown in various embodiments as having the same length, the second side panel can in some embodiments be longer than the first side panel, i.e. the first end of the second side panel can extend beyond the first end of the first side panel, or vice versa. The extended portion can e.g. accommodate a hang tab with a hole therein, or function as a fold-over flap for reclosing the package after opening.
In some embodiments, a seal can be applied obliquely across each of the two corners of the first side panel of a package of the invention, closest to the first end of the package, such that they cross over and seal two corners of the discrete strip to the first side panel. These angled seals can be useful in facilitating the reclosure of the package after opening, and/or in assuring the integrity of the package before initial opening. The seals can overlap a portion of a die cut 21 in the first side panel at upper edges of the die cut. Optionally, the die cut can be discontinuous in the regions of the die cut where the angled seals are present.
In some embodiments, a die cut can be installed on the second side panel near its first end, or the region of a lay-flat web or folded web that will form the second side panel, that can act as a fold line for facilitating production of or reclosure of the package. This die cut, which can be a score, can be of any suitable geometry, e.g. a straight line, positioned to ease or direct the folding of the web during processing, or of the second side panel to reclose the package after opening.
Those skilled in the art will appreciate that in describing a panel, strip or the like being “sealed” to another panel, strip, or the like, sealing is done by conventional means as described, and typically occurs in seal widths consistent with industry practice for packaging.
Packages of the various embodiments of the invention disclosed herein can optionally be vacuumized or gas flushed by otherwise conventional means. A package in accordance with the invention can contain a modified atmosphere.
The invention is characterized by the fact that:
