Patent Application
20160046409
The present invention relates generally to flexible packaging and, more particularly, to flexible packaging having at least one fill feature provided therewith.
Conventional flexible packaging having side gussets have grown in usage. These side gusseted packages can include re-closeable devices (e.g., zippers), handles, and miter seals or K-seals with tacked corners. However, incorporation of these desirable features with such packages can create problems.
In particular, the ability to fill and seal such packages in a pre-made pouch or package configuration can be limited by their construct and features. For instance, the side gussets on the packages, when tucked in for the final or final end seal, can create thickness variations or additional steps due to the construct of two or more layers of the relevant portion of the package requiring sealing (e.g., combinations of the front and back panels, main and gussets panels or webs, etc.).
Because these multiple film layers can make it difficult to provide an air tight seal, leaking, contamination and like undesirable issues may arise with the packages upon final sealing. Moreover, it can be difficult to tuck the side gussets of such packages evenly once the packages are filled with product, which may further make it difficult to get an acceptable leak-proof seal after filling the package with contents or product.
Still further, the side gussets of such packages may also create sealing challenges because the heat-seal threshold for sealing through the multiple layers of material or film may vary significantly from the remaining package portions, or may require a level of heat that mandates the use of additional or specialized sealing equipment or steps.
These special steps and equipment may be especially problematic for customers or fillers receiving “pre-made” packages, whereby the customer is set up to simply fill the package with product or contents and provide the final package seals after filling is complete. Such customers are likely ill-equipped to provide the desired sealing in view of the unique construct of these packages. For instance, when a customer or filler receives such conventional pre-made side gusseted packages with zippers or other re-closeable devices or features, they must open and fill through the devices, and then seal the top of the package above the device. As such, the sealing and material challenges described above can present a problem. Alternatively, the pre-made package can be provided to the filler or customer with a flange of the device (e.g., zipper) unattached such that the package can be filled from behind the device. However, the unattached zipper must be sealed or attached after filling, again presenting the problems and challenges detailed above.
In addition, various side gusseted pre-made packages can include handles cut therein (e.g., die-cut), whereby the area around the handle must be sealed to prevent leakage. The seals required around these cut-out handle portions can require significantly wider sealing equipment or apparatus to seal the larger area. Many conventional sealing and filling machines do not have the equipment to accomplish such seals.
In addition to the above-detailed problems presented with final filling and sealing of desirable pre-made side gusset packages, various miter seals, K-seals, and the like are often avoided despite their benefits. Namely, many of these sealing features can assist in preventing product from getting into the deep corners of the package and providing a desirable and often stronger seal between the front and back panels, but are often avoided because they hinder access to the opening or width for filling, and therefore slow down the filling process. They also require wider or more sealing surface areas than commonly found on filling and sealing machines.
As a result, there is a need for a package design and method of formation that will allow for the many beneficial features and package constructs described above while still providing a package that is easily fillable and sealable.
The present invention solves many of the problems that plague conventional flexible packages and packaging methods. Various embodiments of the present invention are directed to a package having a fill slit or fill feature extending from the first longitudinal edge to the second longitudinal edge of a panel of the package (e.g., front or back panel). The package can be a pre-made side gusseted package, wherein the fill slit or feature is provided generally parallel to the top edge or final top seal of the package, in either machine direction or transverse to machine direction. Providing the pre-made package with a top or other seals already formed allows the package former or manufacturer to include various desirable seals, handles, re-closeable devices, multiple panels, and other features in the package, while still allowing for a filling opening for the customer or package filler. The fill slit or feature can be provided nearly anywhere on the package. In one embodiment, the fill slit or feature can be provided just below a re-closeable device, such as a zipper, with a patch of material added to the inside of the package.
The patch can extend a width generally greater than the width of the fill slit or feature on the inside of the package, with at least a top edge or portion of the patch being sealed to the inside of the package above the slit or feature. As such, the patch can include a free end that is not sealed (at least initially) to the inside of the package, extending generally below the fill slit or feature. The patch can be constructed of any compatible polymer or like material. In one embodiment, the patch can be constructed of a laminate material adapted to only seal on one side upon application of heat, such that at least one side has a non-sealable barrier film (e.g., preventing it from sealing to an opposing interior panel surface of the package, and providing a oxygen and/or moisture barrier at the fill slit). In certain embodiments, the patch can be included with or defined as part of an access device, e.g., flange portions of a zipper, re-closeable device, or the like.
The filler or customer receiving the package in accordance with features of the present invention can open the package to the full width of the fill slit and fill the package with product or contents, even past or above the fill slit. Then, the filler can easily seal the package closed by sealing the slitted panel to the patch or patch material below the fill slit or feature. As such, only one layer or material needs to be sealed, making filling and sealing simpler, easier and more cost effective, while still retaining desired seal features, handles, re-closeable device, and the like, for the package.
The features of the present invention can be employed in a myriad of packages, including form-fill-and-seal packages, pre-made packages, stand-up packages, side access packages, top access packages, front and back access packages, and any other package configurations and designs known to those of ordinary skill in the art.
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. For illustrative purposes, hatching or shading in the figures is generally provided to demonstrate sealed portions and/or integrated devices for the package. In addition, the size and proportions of seal or other portions may be exaggerated with respect to the surrounding material and films to improve visual depictions.
Referring generally to
The package panel portions are generally constructed of flexible sheet material such as polyethylene, polyester, metal foil, polypropylene, or polyethylenes or polypropylenes laminated with other materials such as nylon, polyester, and like films. To provide for higher barriers, embodiments can use combination layers of said materials and material of the like. In addition, various panel portions can be constructed of, or incorporated with, materials that provide preferred sealing characteristics. One skilled in the art will understand that a myriad of materials and material laminates are available for selective use for the sealant surfaces to facilitate the bonding attachment described herein. In one embodiment, at least one of the sealant surfaces will comprise “contaminants” that permit a varying level of bonding, wherein the level of bondable attachment depends on the heat applied from a corresponding heat sealing bar or other device. Higher temperatures will create “destructive” (e.g., permanent) bonds while lower temperatures will create a more temporary bond for selective disengagement. Seal pressures and dwells can also affect the bond level.
In one embodiment, as depicted in
A patch 32, or other strip or material, can be provided inside the package, with the patch 32 having one or more seal edges or portions 34 and a generally free edge or portion 36. The patch can be constructed of any compatible polymer or like material, can be formed in any shape or size, and can include various textures, materials, ribs, structures or like features to facilitate sealing and attachment. In one embodiment, the patch can be constructed of a laminate material adapted to only seal on one side upon application of heat, such that at least one side has a non-sealable barrier film configuration (e.g., preventing it from sealing to an opposing interior panel surface of the package—such as front panel 12). The patch 32 and its edge portions 34, 36 can be included with or defined from flanges or other features of an access device, such as a zipper device, re-closeable device, peel seal material, and the like.
The one or more seal edges 34 are adapted for sealing to the inside surface of the corresponding panel portion (e.g., back panel 14) proximate the fill opening 30 by the package former or manufacturer, with the free edge 36 remaining initially unsealed to provide an internal flap about the fill opening 30. While the patch 32 is depicted in various figures for internal attachment or sealing to the back panel portion 14 and across to the side panel portions 18, the patch 32 can be defined in any of the panel portions 12-18, or combinations thereof. Further, the patch 32 can be applied to the outer surface or portion of a panel, or panels, and can be sealed using various known techniques, such as heat, adhesive, bonding, etc.
As depicted in
Upon filling the internal cavity 23 of the package 10 with the desired amount of contents, as shown in
A portion of the patch 32 can include a weakened portion 32a, such as a perforation, score or other like construct or feature to allow a user or customer to break through, breach or otherwise gain access to the internal cavity contents via the patch 32 even after the patch 32 is sealed (e.g.,
In various embodiments, the patch 32 can be included with or can be defined by a zipper or other access device (e.g., re-closeable access device). For instance, the patch portions 34, 36 can be defined as extending flange or other portions of an access device, such that a first flange portion 34 is sealed on a first side of the slit 30 and the other flange portion provides the free edge portion 36 for later sealing to the interior of the panel portion 14 on a second side of the slit 30.
Various graphics, closeable and re-closeable devices, gussets and like features known to one skilled in the art are also envisioned for use with this invention and can be implemented without deviating from the spirit and scope of the present invention. All references to front, back, top, bottom, and the like are merely for demonstrative purposes and are not intended to limit the variations and positional references and orientations of the panels in the present invention.
Various embodiments can further include slits, scores, cuts, removable slugs, perforations, notches, and the like in the package 10 or package panels 12-18 to provide or define the features described herein. Other peel-back materials, tabs, or tear portions, can be located proximate the fill opening 30 to facilitate selective access to the package or panels.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is, therefore, desired that the present embodiment be considered in all respects as illustrative and not restrictive. Similarly, the above-described methods and techniques for forming the present invention are illustrative processes and are not intended to limit the methods of manufacturing/forming the present invention to those specifically defined herein. A myriad of various unspecified steps and procedures can be performed to create or form the inventive package 10.
This application is a continuation of U.S. application Ser. No. 12/973,356, filed Dec. 20, 2010, which claims priority to and the benefit of U.S. Provisional Application No. 61/287,778, filed Dec. 18, 2009; each of these applications and disclosures hereby fully incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61287778 | Dec 2009 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12973356 | Dec 2010 | US |
| Child | 14925900 | US |
