Patent Application
20170121086
The present disclosure relates in general to packaging for products, and more particularly to bags, pouches, and containers incorporating a flexible laminate. The disclosure is especially concerned with integrated structures and techniques for opening a package to facilitate a user's access to the contents held therein.
Flexible materials, such as polymers and flexible films, are often used to construct packages for products, such as bags and pouches. Such packages can be used to hold a variety of items, such as food items including trail mix, chips, nuts, fruit pieces, cookies, crackers, and other foods. Often, the package may be difficult to grasp or open and may, in some cases, require the consumer to user scissors or a knife to gain access to the package contents, either by design or as a result of consumer frustration.
Embodiments of the invention described herein provide improved packages and methods for constructing packages that provide a mechanism for facilitating the opening of a package by providing an integrated pull strip in one layer of the packaging laminate that overlies a predefined cut, such as a slit, that is preformed in another layer of the packaging laminate. Thus, by tearing away the integrated pull strip, the user exposes the underlying predefined cut and is able to access the contents of the package via the predefined cut.
Accordingly, embodiments of the invention provide a package defining a compartment for storing contents, the package comprising a laminate structure including a first layer and a second layer. The first layer defines a first surface, adjacent the compartment, and a second surface opposite the first surface, where the first layer includes a predefined cut through the first and second surfaces. The second layer is laminated to the second surface of the first layer. The second layer comprises an integrated pull strip that is at least partially defined by a line of weakness formed in the second layer, and the pull strip overlies the predefined cut and is configured to be separated from a remainder of the second layer by a user. The predefined cut defines a first edge and a second edge adjacent the first edge, and separation of the pull strip from the package serves to expose the predefined cut and allows the first and second edges to be moved apart to provide access to the compartment and the contents stored therein via the predefined cut. In some cases, the predefined cut extends at least a portion of a width of the package.
The line of weakness may, in some embodiments, comprise a continuous cut line defined through a portion of a thickness of the second layer. In other embodiments, the line of weakness comprises a series of perforations.
In some cases, the package may comprise a first panel peripherally sealed to a second panel to define the compartment therebetween, where at least one of the first or second panels comprises the laminate structure. Each of the first and second panels may define first and second side edges, and the first panel may be peripherally sealed to the second panel via first and second longitudinal seals formed along adjoining first and second side edges. The pull strip may comprise an end defined in one of the first or second longitudinal seals. The end may be configured to be gripped by the user, and the end may be defined via a continuous cut line formed through the thickness of the second layer.
In some embodiments, the second layer may be laminated to the second surface of the first layer via an adhesive. The adhesive may be pattern applied, and the pull strip may be defined in an adhesive-free region of the laminate. The pull strip may comprise an end configured to be gripped by the user, and the end may be defined via a continuous cut line formed through the thickness of the second layer.
In other embodiments, a laminate structure is provided for forming a package. The laminate structure comprises a first layer defining a first surface and a second surface opposite the first surface. The first layer includes a predefined cut through the first and second surfaces and a second layer laminated to the second surface of the first layer. The second layer comprises an integrated pull strip that is at least partially defined by a line of weakness formed in the second layer, where the pull strip overlies the predefined cut and is configured to be separated from a remainder of the second layer by a user. The predefined cut defines a first edge and a second edge adjacent the first edge, and separation of the pull strip from the remainder of the second layer serves to expose the predefined cut of the first layer and allows the first and second edges to be moved apart.
In some cases, the second layer may be laminated to the second surface of the first layer via an adhesive, where the adhesive is pattern applied, and where the pull strip is defined in an adhesive-free region of the laminate. The pull strip may comprise an end configured to be gripped by the user, and the end may be defined via a continuous cut line formed through the thickness of the second layer. The line of weakness, in some cases, may comprise a continuous cut line defined through a portion of a thickness of the second layer. In some embodiments, the predefined cut line may comprise a slit.
In still other embodiments, a method of manufacturing a package is provided that includes an integrated pull strip for providing access to contents stored within a compartment of the package. The method comprises laminating a first layer to a second layer to form a laminate structure, wherein the first layer defines a first surface, adjacent a compartment of the package, and a second surface opposite the first surface. The method further includes forming a predefined cut in the first layer through the first and second surfaces, where the predefined cut defines a first edge and a second edge adjacent the first edge. An integrated pull strip may be defined in the second layer by forming a line of weakness in the second layer, where the pull strip overlies the predefined cut and is configured to be separated from a remainder of the second layer by a user. In this way, separation of the pull strip from the remainder of the second layer serves to expose the predefined cut and allows the first and second edges to be moved apart to provide access to the compartment and the contents stored therein via the predefined cut.
In some cases, defining the integrated pull strip in the second layer by forming a line of weakness may comprise defining a continuous cut line through a portion of a thickness of the second layer. In other cases, defining the integrated pull strip in the second layer by forming a line of weakness may comprise defining a series of perforations through a portion of a thickness of the second layer. Moreover, laminating the first layer to the second layer may comprise pattern-applying an adhesive to one of the first or second layers, and the method may further comprise defining the pull strip in an adhesive-free region of the laminate.
In some cases, defining the integrated pull strip may comprise forming a continuous cut line through the thickness of the second layer at an end of the pull strip that is configured to be gripped by the user. Furthermore, the method may comprise peripherally sealing a first panel to a second panel to define the compartment therebetween, wherein at least one of the first or second panels comprises the laminate structure.
Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The present invention now will be described more fully hereinafter with reference to the accompanying drawings in which some but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
Conventional packages made of flexible materials, such as various polymer-based materials, are often used to hold food products, such as cookies, nuts, chips, crackers, and other items. Some conventional packages provide peelable seals or tear notches that allow a user to gain access to the contents of the package. In the case of a peelable seal, for example, a user must grip both sides of the package and pull apart the seal (e.g., at the top of the package) to open the package. The material of the package may, however, make it difficult for the user to grasp the package with sufficient strength to apply the needed force to separate the sealed edges. In addition, in some cases, the seal strength that must be overcome to open the package may be so high that the user is either unable to open the package in the intended manner, or the abrupt opening of the package once the user has applied enough force may cause the contents of the package to shift suddenly as the package is opened, possibly spilling some of the contents.
In the case of a tear notch, the user must apply a separation force in the vicinity of the notch to initiate a tear in the package that is meant to be propagated along a certain distance to create an opening. The tear is generally created through the entire structure, often in a heat seal area. The user is often required to start tearing precisely at the location of the tear notch, and often the necessary tear propagation force may be increased due to a stringy or stretchy sealant or due to material delamination. As a result, the user may again not be able to provide sufficient force to initiate the tear in some cases, and in other cases the tear that is initiated may not be propagated in a controlled manner by the user's continued application of force, which may produce an uneven or misaligned opening (e.g., propagating the tear downward rather than across the package) and can result in loss of product.
The shortcomings of such conventional opening features may often result in the user attempting to open the package using a sharp object, such as scissors or a knife, which can be dangerous and requires the user to have access to these additional opening tools.
Accordingly, embodiments of the present invention provide an integrated pull strip in an outer layer of a laminate that overlies a predefined cut formed in an inner layer of the laminate, such that a user can at least partially separate the pull strip from the rest of the package to reveal the underlying predefined cut. Once exposed, the predefined cut provides an opening for the user to gain access to the contents of the package, such as by pushing his or her fingers or hand through the predefined cut and withdrawing a desired amount of product. Because the cut in the inner layer of the laminate is predefined, the user is not required to exert an undue amount of force to try and overcome a seal strength of the package or cut through the package laminate.
Embodiments of the invention described herein are applicable in, and may be embodied by, various kinds of packages including stand-up pouches, bags, sealed trays, or any other package that includes a flexible laminate. Thus, although the examples depicted in
With reference now to
In some cases, the package may be gusseted, as shown in
Regardless of the particular configuration of the package 5, the package may include a laminate structure 50 that includes a first layer 55 and a second layer 60 that are laminated to each other. The first layer 55 may define a first surface 56 that is adjacent the compartment 10, as well as a second surface 57 opposite the first surface, as shown in
The second layer 60 may be laminated to the second surface 57 of the first layer 55, such as by a permanent adhesive 70. The second layer 60 may include an integrated pull strip 75 that is at least partially defined by a line of weakness 80 formed in the second layer. As best shown in
With reference to
As illustrated in
In some embodiments, the predefined cut 65 may be defined via laser scoring or die cutting through the first layer, from the first surface 56 to the second surface 57, such that the cut goes through both surfaces. In the depicted embodiment, the predefined cut 65 is a continuous cut line; however, in other embodiments, the predefined cut 65 may be discontinuous (e.g., a series of perforations that the user can push through after peeling the pull strip 75 off).
The line of weakness 80 defined in the second layer 60 may define a shape of the pull strip 75, as shown in
In some embodiments, the second layer 60 (e.g., the second surface 62 of the second layer 60) may be laminated to the second surface 57 of the first layer via an adhesive 70, such as a permanent adhesive. The adhesive 70 may be pattern applied, and the pull strip 75 may be defined in an adhesive-free region 71 of the laminate. In this way, when a user pulls on the pull strip 75, there is no adhesive holding the pull strip to the underlying portion of the first layer 55, and the pull strip can be separated upon tearing through the lines of weakness 80.
In this regard, the pull strip 75 may comprise an end 85 configured to be gripped by the user to initiate the separation of the pull strip from the package. The end 85 may be defined by the path of the line of weakness 80. For example, as best illustrated in
With reference to
In some embodiments, the pull strip 75 comprises an end 85 defined in one of the first or second longitudinal seals 35, 37. In the depicted embodiment, for example, the grippable end 85 is defined in the second longitudinal seal 37. A close-up view of the end 85 is shown in
The presence of the continuous cut line 80 going all the way through the second layer 60 of the first panel 15 to form the grippable end 85 and the lack of adhesive 70 in the area of the pull strip 75, including at the end 85, thus allow a user to separate the end from the package (e.g., using a fingertip), grip the end 85, and pull the pull strip 75 off the package to gain access to the predefined cut 65 and the contents held inside the package.
By providing a pull strip 75 overlying a predefined cut 65 according to embodiments of the invention as described above, the user is able to open the package more easily by applying a consistent and not unduly burdensome force to separate the pull strip from the package. Moreover, because the underlying cut 65 is predefined, no additional force or action is needed by the user to gain access to the package contents, and the user need only insert his or her hand between the edges 66, 67 of the predefined cut.
Embodiments of a method of manufacturing a package including an integrated pull strip with underlying predefined cut for providing access to contents stored within a compartment of the package as described above are also provided herein. The method may, for example, comprise laminating a first layer to a second layer to form a laminate structure, where the first layer defines a first surface, adjacent a compartment of the package, and a second surface opposite the first surface. A predefined cut may be formed in the first layer through the first and second surface, as described above, where the predefined cut defines a first edge and a second edge adjacent the first edge. An integrated pull strip may be defined in the second layer by forming a line of weakness in the second layer.
As described above with respect to the figures, the pull strip may overlie the predefined cut and may be configured to be separated from a remainder of the second layer by a user. Accordingly, separation of the pull strip from the remainder of the second layer may serve to expose the predefined cut and allow the first and second edges to be moved apart to provide access to the compartment and the contents stored therein via the predefined cut.
In some embodiments, defining the integrated pull strip in the second layer by forming a line of weakness may comprise defining a continuous cut line through a portion of a thickness of the second layer. In other embodiments, defining the integrated pull strip in the second layer by forming a line of weakness may comprise defining a series of perforations through a portion of a thickness of the second layer. Moreover, laminating the first layer to the second layer may comprise pattern-applying an adhesive to one of the first or second layers, and the pull strip may thus be defined in an adhesive-free region of the laminate.
In some cases, defining the integrated pull strip may comprise forming a continuous cut line through the thickness of the second layer at an end of the pull strip that is configured to be gripped by the user, as described above. Furthermore, a first panel and a second panel of material, at least one of which comprises the laminate structure, may be peripherally sealed to each other to form the package and define the compartment therebetween. In some embodiments, for example, the first and second layers may first be laminated together via permanent adhesive, then the cuts in the two layers may be defined (e.g., via precision cutting) to form the pull strip and the underlying predefined cut. The laminate can then be used to form a pouch or other package, such as by heat sealing one or more ends of the package, filling the package with contents, then sealing the remaining sides of the package to form a compartment filled with the consumer item, as described above.
Although the steps in the method of manufacturing the package described above are described in a certain order, it is understood that in some cases the order of the steps may be changed. Moreover, additional steps, such as, for example, printing indicia on the laminate structure, may also be included in some cases. For example, in some embodiments, the end 85 (e.g., shown in
Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
