PACKAGE HAVING A TEARABLE SEAL AND A METHOD OF OPENING SAID PACKAGE

Abstract

A package having a tearable seal is disclosed, along with a method of opening the package. The package is capable of housing a product and includes a front wall, a back wall, a first side, a second side, a bottom and a top, and has a void area formed between the front and back walls which can house the product. The package is completely sealed after the product has been inserted into the void area. The package has a tearable seal formed in both the front and back walls. The tearable seal has an end conterminuous with the first side. The package also has a second seal formed in both the front and back walls which is positioned inward of the first and second sides and which is located between the tearable seal and the top. The second seal has a patterned field of bonds. The tearable seal requires less force to break than does the second seal. A method of opening the package is also taught.

Description

FIELD OF THE INVENTION

This invention relates to a package having a tearable seal and a method of opening the package.

BACKGROUND OF THE INVENTION

Today, many products are enclosed in a package or pouch formed from various materials. The products can be in liquid form, semi-solids or solid form. The package can be constructed from various materials, including but not limited to: paper, cardboard, plastic, thermoplastics, polymer films, polymer film laminates, or combinations thereof. For example, the package can be formed from a laminate that may include two or more different materials. Once the products are enclosed in the package, the package needs to be sealed. At a later time, the package has to be opened to remove some or all of the products. Sometimes it is difficult to open a package that has been tightly sealed. In certain instances, the package cannot be opened without using a sharp object like a pair of scissors, a knife, etc. This can cause frustration, especially when the person trying to open the package does not have access to a sharp object. In other situations, the entire package may rupture as one attempts to open the package. This is detrimental when a person wishes to remove only a portion of the products from the package and use the package to house the remaining products until a later time.

Now a package having a tearable seal has been invented along with a method of opening the package.

SUMMARY OF THE INVENTION

Briefly, this invention relates to a package capable of housing a product. The product can be a liquid, a semi-solid or a solid. The package includes a front wall, a back wall, a first side, a second side, a bottom and a top. The package also has a void area formed between the front and back walls which can house the product. The package is completely sealed after the product or products have been inserted into the void area. The package has a tearable seal formed in both the front and back walls. The tearable seal has an end conterminuous with the first side. The package also has a second seal formed in both the front and back walls which is positioned inward of the first and second sides and which is located between the tearable seal and the top. The second seal has a patterned field of bonds. The tearable seal requires less force to break than does the second seal.

In a second embodiment, the invention relates to a package capable of housing a product. The package includes a front wall, a back wall, a first side, a second side, a bottom and a top. The package also has a void area formed between the front and back walls which can house the product. The package is completely sealed after the product or products have been inserted into the void area. The package has a tearable seal formed in both the front and back walls. The tearable seal has an end conterminuous with the first side. Desirably, the tearable seal extends continuously from the first side to the second side. The tearable seal has a width and the tearable seal is positioned closer to the top of the package than to the bottom of the package. The package also has a second seal formed in both the front and back walls. The second seal is positioned inward of or spaced apart from the first and second sides. The second seal is located between the tearable seal and the top. The second seal has a width which is at least about 5 times larger than the tearable seal. The second seal has a patterned field of bonds. The tearable seal is capable of breaking under a force of less than about 5 pounds.

A method of opening a package is also taught. The package has a front wall, a back wall, a first side, a second side, a bottom and a top. The package also has a tearable seal formed in both the front and back walls. The tearable seal has an end conterminuous with the first side. Desirably, the tearable seal extends continuously from the first side to the second side. The package further has a second seal formed in both the front and back walls which is positioned inward of the first and second sides and which is located between the tearable seal and the top. The method includes the steps of having a person grip the package between a thumb and an index finger of each hand, one hand positioned above the tearable seal and the other hand positioned below the tearable seal. A forward force is applied with one hand and a rearward force is applied with the opposite hand to cause a portion of the tearable seal to start to break. The person continues to tear the tearable seal until the top is at least about 90% torn away from a remaining portion of the package. Alternatively, the tearable seal can be completely torn off from a remaining portion of the package. The front and back walls of the package are then pinched between the two hands and the front and back walls are pulled apart to break a remaining portion of the tearable seal and open the package.

The general object of this invention is to provide a package having a tearable seal which provides an easy way to seal and open the package. A more specific object of this invention is to provide a package with both a tearable seal and a second seal wherein the second seal is not designed to be broken.

Another object of this invention is to provide a package having a tearable seal which is designed to be opened only once.

Still another object of this invention is to provide a package with a tearable seal which is easy to manufacture and easy to break.

A further object of this invention is to provide a package with a tearable seal which is economical to manufacture.

Still further, an object of this invention is to provide a package with a tearable seal which can be sealed before a product is inserted into the package.

Other objects and advantages of the present invention will become more apparent to those skilled in the art in view of the following description and the accompanying drawings and photos.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a package having a tearable seal extending between its first and second sides and having a second seal positioned inward of the first and second sides and which is located between the tearable seal and the top of the package.

FIG. 2 is a side view of the package shown in FIG. 1.

FIG. 3 is a top view of a pillow pouch.

FIG. 4 is a top view of a gusseted pouch.

FIG. 5 is an enlarged view of the upper left corner of the package.

FIG. 6 is a side view of the upper left corner of the package shown in FIG. 5.

FIG. 7 is a front view of a package having a tearable seal extending between its first and second sides, and having a second seal, consisting of a patterned field of point bonds, which are randomly arranged, positioned inward of the first and second sides and which is located between the tearable seal and the top of the package.

FIG. 8 is a side view of the package shown in FIG. 7.

FIG. 9 is a front view of a package having a tearable seal extending between its first and second sides, and having a second seal, consisting of a patterned field of angled lines, positioned inward of the first and second sides and which is located between the tearable seal and the top of the package.

FIG. 10 is a side view of the package shown in FIG. 9.

FIG. 11 is a front view of a package having a tearable seal that extends from the first side but stops short of the second side, and having a second seal, consisting of a patterned field of point bonds, which are randomly arranged, positioned inward of the first and second sides and which is located between the tearable seal and the top of the package.

FIG. 12 is a side view of the package shown in FIG. 11.

FIG. 13 is a photograph of a sealed package having a tearable seal extending across its width to form a top portion having a second seal positioned therein.

FIG. 14 is a photograph of a person starting to tear open the tearable seal.

FIG. 15 is a photograph of a person continuing to tear open the tearable seal.

FIG. 16 is a photograph of the package after the top portion has been completely torn off.

FIG. 17 is a photograph of a person pinching the package and pulling the front and rear faces apart so as to break open the remainder of the tearable seal and open the package.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1-6, a package or pouch 10 is depicted which is capable of housing a product or contents. By “package” it is meant a container in which something is packed; a preassembled unit. By “pouch” it is meant something resembling a bag in shape; a bag or sack used to carry various items; a sealed plastic or foil container used in packaging frozen, dehydrated foods or other items. The product or contents (not shown) can be any item, article or substance known to man. The product or contents can be a single item or a plurality of the same, similar or different items. For example, the product or contents could be a food product, such as peas, corn, carrots, etc. or it can be a man made product such as, screws, nuts, washers, etc.

Many different kinds of packages 10 are used to house, enclose or contain various products or contents. The products or contents can be in liquid, powder, semi-solid or solid form. The products or contents can include a solution, an article, an item, a substance, etc. The products or contents can be a single liquid solution or a single article or item. Alternatively, the products or contents can consist of two or more articles or items. When the products consists of multiple articles or items, the articles or items can be identical in size, shape and configuration or vary from one another in some way. Likewise, the articles or items can be different from one another. Once the package 10 is filled, it is normally sealed so that the products or contents cannot be removed until the package 10 is opened. This invention relates to a tearable seal 26 which can seal the package 10 until it is ready to be opened. The tearable seal 26 is designed to break or partially tear as one starts to open the package 10. The tearable seal 26 is then broken open in a second step, thereby allowing access to the products or contents enclosed within the package 10.

The package 10 can be constructed or formed in various sizes and shapes. The package 10 can be formed from one or more different materials. The package 10 can be a flexible container, a rigid container or a semi-rigid container. The package 10 can be formed from various materials, including but not limited to: paper, paperboard, plastic, film, foil, woven fabric, non-woven fabric, fibers, etc. or be a combination of two or more such materials. The package 10 could also be formed from various polymer films, various polymer film laminates, or various polymer film laminates that include, but are not limited to: paper, foil, woven fabric, carbon fiber, etc. The package 10 can also be formed as a pouch constructed of a poly/foil laminate film.

The package 10 can be constructed from any of the following materials, including but not limited to: a polyolefin, a polymer film, metal foil, a paper based material, paperboard, cardboard, or a combination of two or more materials. The materials can include but are not limited to: mono-polymers, co-extrusions or laminates. Common materials used to construct the package 10 include: polyethylene (PE), high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), polypropylene (PP), oriented polypropylene (OPP), biaxially oriented polypropylene (BOPP), ethylene vinyl alcohol (EVOH), polyethylene terephthalate (PET), oriented polyethylene terephthalate (OPET), nylon, ethylene vinyl acetate (EVA), aluminum foil, paper, cardboard, Kraft paper, woven film substrates, as well as other materials known to those skilled in the art and any combinations thereof.

Various film structures presently utilized in commerce include but are not limited to:

HDPE—HDPE—sealant PE;

HDPE—HDPE—tie layer—EVOH—tie layer—HDPE—sealant PE;

BOPP—print—primer—LDPE—met—OPET—primer—LDPE—sealant PE;

Overlacquer—print—paper—LDPE—sealant PE;

BOPP—print—adhesive—paper—LDPE—sealant PE;

Paper—LDPE—foil—sealant PE;

OPP—primer—LDPE—foil—sealant PE;

Foil—sealant PE;

Nylon—tie layer—PE—tie layer—EVOH—tie layer—sealant PE;

OPET—ink—primer—LDPE foil—sealant PE.

Still referring to FIGS. 1-6, the package 10 has a front wall 12, a back wall 14, a first side 16, a second side 18, a bottom 20 and a top 22. The package 10 can vary in size, shape, design and configuration. A rectangular shaped package 10 is shown in FIG. 1. Various other shapes known to man can also be used, including but not limited to: a square, a triangle, a circle, as well as a multitude of irregular configurations. The package 10 has a longitudinal central axis X-X, a vertical central axis Y-Y, and a transverse central axis Z-Z. The construction of the package 10 can also vary. In FIG. 3, a top view of a pillow package is depicted having a top opening formed therein. By “pillow package” it is meant a package or pouch formed in the shape of a pillow. In FIG. 4, a top view of a gusseted package is depicted having an opening formed therein. By “gusseted package” it is meant a package or pouch having one or more gussets. By “gusset” it is meant a triangular insert, as in the seam of a package for added strength or expansion.

Generally, the package 10 is constructed in a flat configuration with an opening in either its bottom 20 or its top 22. Product is inserted through the opening and then the opening is sealed to enclose the product. The package 10 is completely sealed after the product has been inserted into the void area 24. Alternatively, one could insert the product through one of the sides 16 and 18, and then seal this location to enclose the product.

The front and back walls, 12 and 14 respectively, of the flat, unfilled package 10 can be pulled apart, squeezed or manipulated to create a void area 24 in the package 10. Alternatively, compressed air can be inserted through the opening of the package 10 to create the void area 24. The void area 24 is situated between the front and back walls. 12 and 14 respectively, the first and second sides, 16 and 18 respectively, and the bottom and top, 20 and 22 respectively. The void area 24 creates a chamber for housing or enclosing a product.

Referring now to FIGS. 1, 2 and 5, the package 10 includes a tearable seal 26. The tearable seal 26 can be a hermetic seal. By “hermetic seal” it is meant a seal which completely seals a package 10, especially against the escape or entry of air. The tearable seal 26 is formed in both the front and back walls, 12 and 14 respectively, and secures the front wall 12 to the back wall 14. The tearable seal 26 can be formed using ultrasonic equipment. Such equipment is commercially available from Aurizon Ultrasonics, LLC having an office at 900 W. Kennedy Avenue, Kimberly, Wis. 54136. Alternatively, the tearable seal 26 could be formed my heat, by pressure, by a combination of heat and pressure, by an adhesive, by a cohesive, etc.

The tearable seal 26 can be formed in various ways, including but not limited to: heat sealing, ultrasonic welding, radio frequency (RF) sealing, pressure welding, mechanical welding, etc.

The tearable seal 26 is usually positioned closer to the top 22 than the bottom 20 of the package 10. Alternatively, the tearable seal 26 could be positioned closer to the bottom 20 of the package 10, if desired. The tearable seal 26 has an end conterminuous with the first side 16. Desirably, the tearable seal 26 extends continuously from the first side 16 to the second side 18. In this case, the ends of the tearable seal 26 are conterminous with the first side 16 and the second side 18. By “conterminous” it is meant sharing a boundary. This feature is important because the tearable seal 26 needs to be broken in order to open the package 10 at a later time to remove the product contained in the package 10. By making one end of the tearable seal 26 conterminuous with the first side 16, the force required to initially start to break the tearable seal 26 is substantially less. The tearable seal 26 is designed to be torn open in two steps. In the first step, the tearable seal 26 is torn relative to the package 10. Then, in the second step, the front wall 12 is pulled away from the back wall 14 which completely opens the tearable seal 26 and thus the package 10. The force needed to tear open the tearable seal 26 from the package 10 can be less than, equal to, or be greater than the force needed to initially break the tearable seal 26. The tearable seal 26 can be torn such that at least about 90% of the tearable seal 26 is torn away from the package 10. The remainder of the tearable seal 26 remains attached to the remainder of the package 10. Alternatively, the tearable seal 26 can extend continuously from the first side 16 to the second side 18, such that when it is broken, the top 22 is completely removed from the remainder of the package 10.

The tearable seal 26 has a width w which can vary in dimension. Desirably, the width w of the tearable seal 26 ranges from between about 0.01 inches to about 0.20 inches. More desirably, the width w of the tearable seal 26 ranges from between about 0.02 inches to about 0.15 inches. Even more desirably, the width w of the tearable seal 26 ranges from between about 0.03 inches to about 0.10 inches. Most desirably, the width w of the tearable seal 26 is less than about 0.09 inches. This means that the tearable seal 26 is a relatively thin line. The tearable seal 26 can be a linear line, a curved line, an arcuate line, a sinusoidal line, or be of some other geometrical configuration. The tearable seal 26 can be aligned horizontally or at some angle relative to the top 22.

Referring now to FIG. 2, the package 10 is formed with a front wall 12 and a back wall 14, which together have a combined thickness t. The combined thickness t is measured when the front and back walls, 12 and 14 respectively, of the package 10 are in a flat configuration and before the package 10 is filled with a product. The tearable seal 26 has a width w which is equal to at least the combined thickness t. Desirably, the tearable seal 26 has a width w which is equal to at least about two times the combined thickness t. More desirably, the tearable seal 26 has a width w which is equal to at least three times the combined thickness t. Even more desirably, the tearable seal 26 has a width w which is equal to at least four times the combined thickness t. Most desirably, the tearable seal 26 has a width w which is equal to at least five times the combined thickness t. The dimensions of the width w of the tearable seal 26 relative to the thickness t of the front and back walls, 12 and 14 respectively, is important to assuring that the tearable seal 26 can be opened with a minimum amount of force. The tearable seal 26 should be visible to the ultimate consumer who purchases the package 10.

Referring now to FIG. 4, the front wall 12 has a thickness t₁ and the back wall 14 has a thickness t₂. The thickness t₁ of the front wall 12 can be equal to, greater than or less than the thickness t₂ of the back wall 14. Generally, the thickness t₁ of the front wall 12 is equal to the thickness t₂ of the back wall 14. Each of the thicknesses t₁ and t₂ can range from between about 0.001 inches to about 0.010 inches. Desirably, each of the thicknesses t₁ and t₂ can range from between about 0.001 inches to about 0.005 inches.

Referring now to FIG. 6, the tearable seal 26 also has a depth d. The depth d is measured inward into the front wall 12 or inward into the back wall 14. Desirably, the depth d into the front wall 12 is the same as the depth d into the back walls 14. Generally, the depth d of the tearable seal 26 into both the front wall 12 and into the back wall 14 is identical or approximately equal. The depth d of the tearable seal 26 can range from between about 10% to about 90% of the thickness t₁ of the front wall 12 or of the thickness t₂ of the back wall 14. Desirably, the depth d of the tearable seal 26 can range from between about 20% to about 80% of the thickness t₁ of the front wall 12 or of the thickness t₂ of the back wall 14. More desirably, the depth d of the tearable seal 26 can range from between about 30% to about 70% of the thickness t₁ of the front wall 12 or of the thickness t₂ of the back wall 14. Even more desirably, the depth d of the tearable seal 26 can range from between about 40% to about 60% of the thickness t₁ of the front wall 12 or of the thickness t₂ of the back wall 14. Most desirably, the depth d of the tearable seal 26 is about 50% of the thickness t₁ of the front wall 12 or of the thickness t₂ of the back wall 14.

The tearable seal 26 requires a relatively small force in order to partially break it. The force required to initially break the tearable seal 26 will vary depending on the materials from which the package 10 is formed, the number of layers used to form the front and back walls, 12 and 14 respectively, the depth d and width w of the tearable seal 26, how the tearable seal is formed, etc. Generally, the tearable seal 26 can be initially broken using a force of about 5 pounds or less. Desirably, the tearable seal 26 can be initially broken using a force of about 4 pounds or less. More desirably, the tearable seal 26 can be initially broken using a force of about 3 pounds or less. Even more desirably, the tearable seal 26 can be initially broken using a force of from between about 0.5 pounds to about 3 pounds. Most desirably, the tearable seal 26 can be initially broken using a force of from between about 1 pound to about 3 pounds.

Once the tearable seal 26 is initially broken, the force required to tear the remainder of the tearable seal 26, to at least about 90% of the width of the package 10, can be less than, equal to, or greater than the force required to initially break the tearable seal 26. Desirably, this force will be about equal to the force required to initially break the tearable seal 26. This force can range from between about 1 pound to about 3 pounds. Alternatively, the tearable seal 26 could be completely torn away from the remainder of the package 10. This is possible when the tearable seal 26 extends completely between the first and second sides, 16 and 18 respectfully.

With the initial break of the tearable seal 26, at least about 25% of the width w of the tearable seal 26 is broken away. Desirably, at least about 30% of the width w of the tearable seal 26 is broken away. More desirably, at least about 40% of the width w of the tearable seal 26 is broken away. Even more desirably, at least about 50% of the width w of the tearable seal 26 is broken away. Most desirably, at least about 60% of the width w of the tearable seal 26 is broken away. It should be understood that about 70% or less of the width w of the tearable seal 26 will remain secured to the remainder of the package 10 once the top 22 is partially or fully separated.

After the top 22 has been partially or fully separated from the package 10, a portion of the tearable seal 26 will remain intact and the package 10 will still be sealed and closed. A second breaking step is required. In this second breaking step, a person will grasp and/or pinch the front and back walls, 12 and 14 respectively, between his thumbs and index finger of each hand and pull the front wall 12 and the back wall 14 away from one another. This action causes the remaining portion of the width w of the tearable seal 26 to break and the package 10 will be opened so that the product or contents housed therein can be removed. At least about 90% of the width of the package 10 will be open to allow the product or contents therein to be removed. The force required to pull the front and back walls, 12 and 14 respectively, apart and break the remaining portion of the tearable seal 26 is less than about 5 pounds. Desirably, the force needed to pull the front and back walls, 12 and 14 respectively, apart and to break the remaining portion of the tearable seal 26 is from between about 0.5 pounds to about 4 pounds. More desirably, the force needed to pull the front and back walls, 12 and 14 respectively, apart and to break the remaining portion of the tearable seal 26 is from between about 1 pound to about 3 pounds. Even more desirably, the force needed to pull the front and back walls, 12 and 14 respectively, apart and to break the remaining portion of the tearable seal 26 is less than about 2.5 pounds. Most desirably, the force needed to pull the front and back walls, 12 and 14 respectively, apart and to break the remaining portion of the tearable seal 26 is less than about 2 pounds.

Referring again to FIGS. 1, 2, 5 and 6, the package 10 also includes a second seal 28. The second seal 28 is formed in both in the front and back walls. 12 and 14 respectively. The second seal 28 is shown being formed adjacent to the top 22 of the package 10. The second seal 28 is positioned inward of the first and second sides, 16 and 18 respectively. This is very important because the second seal 28 is not designed to break in normal use. The second seal 28 is located between the tearable seal 26 and the top 22 of the package 10. Alternatively, the second seal 28 could be formed adjacent to the bottom 20 of the package 10 provided it is positioned between the tearable seal 26 and the bottom 20.

The second seal 28 can vary in size, shape and configuration. The second seal 28 has a width w₁ and includes a patterned field of bonds 30 within this width w₁. The width w₁ can vary in dimensions. The width w₁ of the second seal 28 can range from between about 0.10 inches to about 2 inches. Desirably, the width w₁ of the second seal 28 can range from between about 0.15 inches to about 1 inch. More desirably, the width w₁ of the second seal 28 can range from between about 0.20 inches to about 0.75 inches. Even more desirably, the width w₁ of the second seal 28 can range from between about 0.25 inches to about 0.60 inches. Most desirably, the width w₁ of the second seal 28 is greater than about 0.12 inches.

The width w₁ of the second seal 28 is larger in dimension than the width w of the tearable seal 26. Desirably, the width w₁ of the second seal 28 is at least three times the width w of the tearable seal 26. More desirably, the width w₁ of the second seal 28 is at least five times the width w of the tearable seal 26. Even more desirably, the width w₁ of the second seal 28 is at least eight times the width w of the tearable seal 26. Most desirably, the width w₁ of the second seal 28 is at least ten times the width w of the tearable seal 26. This extra width w₁ reduces the likelihood that the second seal 28 will break before the tearable seal 26 breaks.

The second seal 28 can consist of a single bond or two or more bonds. Desirably, the second seal 28 includes a plurality of bonds. The bonds in the patterned field of bonds 30 can be constructed in various ways. For example, the patterned field of bonds 30 can include a plurality of point bonds formed ultrasonically, by using heat, by using pressure, by using a combination of heat and pressure, by using an adhesive, by using glue, by using a co-adhesive, etc. Alternatively, the patterned field of bonds 30 can consist of a single sealing line, strip, or area. Furthermore, the patterned field of bonds 30 can include two or more point bonds, line bonds, strip bonds or bond areas, or any combination thereof. The sealing lines, strips or bond areas can be spaced apart from one another, can overlap one another, or can abut or touch one another. The patterned field of bonds 30 can be arranged in any pattern imaginable by man.

Referring again to FIG. 1, the patterned field of bonds 30 is depicted as a plurality of point bonds arranged in a regular array. However, the patterned field of bonds 30 could be randomly arranged, if desired. In FIG. 1, three horizontal rows of multiple point bonds are depicted, with each row being aligned approximately parallel to the top 22. The rows could be offset from the top 22, if desired.

The patterned field of bonds 30 has a density. By “density” it is meant the number of bonds contained within a given area. The density of the patterned field of bonds 30 can vary. The patterned field of bonds 30 has a density ranging from between about 1% to about 60% of the area of the patterned field of bonds 30. Desirably, the patterned field of bonds 30 can have a density ranging from between about 5% to about 50% of the area of the patterned field of bonds 30. More desirably, the patterned field of bonds 30 can have a density ranging from between about 10% to about 40% of the area of the patterned field of bonds 30. Even more desirably, the patterned field of bonds 30 can have a density ranging from between about 15% to about 35% of the area of the patterned field of bonds 30. Most desirably, the patterned field of bonds 30 can have a density ranging from between about 5% to about 25% of the area of the patterned field of bonds 30.

As stated above, the second seal 28 is not designed to be broken or compromised during the normal life of the package 10. Instead, it is the tearable seal 26 which is designed to be torn open. Because of this, the tearable seal 26 requires less force to initially break than would be required to break the second seal 28. The tearable seal 26 also requires less force to be torn completely from the package 10 than the second seal 28. In normal practice, the second seal 28 will not be torn or broken at all. One of the factors that contribute to the second seal 28 not being torn or broken is the fact that the second seal 28 does not extend to the outer edges of the first and second sides, 16 and 18 respectively. By leaving a non-sealed area adjacent to the first and second sides, 16 and 18 respectively, one can limit the possibility that the second seal 28 will be broken. This space can be as small as 1 or 2 millimeters.

Referring now to FIGS. 7 and 8, a second embodiment of a package 10′ is shown which is similar to the package 10, shown in FIGS. 1 and 2, except that the second seal 28 has a patterned field of bonds 30 which include a plurality of point bonds which are randomly arranged. Any random arrangement of the point bonds can be utilized. The package 10′ has a longitudinal central axis X₁-X₁, a vertical central axis Y₁-Y₁, and a transverse central axis Z₁-Z₁.

Referring now to FIGS. 9 and 10, a third embodiment of a package 10″ is shown which is similar to the package 10, shown in FIG. 1, except that the second seal 28 has a patterned field of bonds 30 which include a plurality of seal lines 32. The seal lines 32 are aligned parallel to one another in a spaced apart relationship. The seal lines 32 are also aligned at an angle to the tearable seal 26. The seal lines 32 are aligned at an angle of at least about 10 degrees to the tearable seal 26. Desirably, the seal lines 32 are aligned at an angle of at least about 15 degrees to the tearable seal 26. More desirably, the seal lines 32 are aligned at an angle of at least about 20 degrees to the tearable seal 26. Even more desirably, the seal lines 32 are aligned at an angle of at least about 25 degrees to the tearable seal 26. Most desirably, the seal lines 32 are aligned at an angle of at least about 30 degrees to the tearable seal 26. The package 10″ has a longitudinal central axis X₂-X₂, a vertical central axis Y₂-Y₂, and a transverse central axis Z₂-Z₂.

Referring now to FIGS. 11 and 12, a fourth embodiment of a package 10′″ is shown which has a tearable seal 26′. The tearable seal 26′ has an end which is conterminuous with the first side 16. The opposite end of the tearable seal 26 is spaced apart from the second side 18. Therefore, the tearable seal 26′ does not extend continuously between the first and second sides, 16 and 18 respectively. The tearable seal 26′ can extend at least about 70% across the width of the package 10′″. Desirably, tearable seal 26′ can extend at least about 80% across the width of the package 10′″. More desirably, the tearable seal 26′ can extend at least about 90% across the width of the package 10′″. In this embodiment, when the tearable seal 26′ is broken, a small portion, about 10%-30% will remain attached to the remainder of the package 10′″. This means that the top 22 will not be completely torn away from the remainder of the package 10′″.

The package 10′″ has a longitudinal central axis X₃-X₃, a vertical central axis Y₃-Y₃, and a transverse central axis Z₃-Z₃. One advantage of creating the package 10′″ in this configuration is that one does not have to worry about separately disposing of the top 22 for it will remain attached to the remainder of the package 10′″. This means the top 22 will not be completely torn away from the remainder of the package 10.

It should be understood that the packages 10, 10′, 10″ and 10′″ can be hermetically sealed. By “hermetically sealed” it is meant that the package 10, 10′, 10″ or 10′″ is completely sealed, especially against the escape or entry of air or other gases. Some packages 10, 10′, 10″ and 10′″ are filled with nitrogen. Alternatively, the package 10, 10′, 10″ or 10′″ does not have to be hermetically sealed but instead the seal can be constructed such that it is able to vent gases. The tearable seal 26 extends across the width of the front and back walls, 12 and 14 respectively. The tearable seal 26 can be a linear line. Alternatively, the tearable seal 26 can be non-linear line. For example, the tearable seal 26 can have an arcuate shape, a sinusoidal shape, etc. Another option is to construct the tearable seal 26 such that it is angled to either the top 22 and/or bottom 20 of the package 10, 10′, 10″ or 10′″. The packages 10, 10′, 10″ and 10′″ can vary in geometrical shape. The tearable seal 26 can also be shaped to create a pour spout in the package 10, 10′, 10″ or 10′″, if desired. It is also possible to seal the packages 10, 10′, 10″ or 10′″ so that it fits into another object or device.

Method

A method of opening the package 10 will now be explained with reference to the photos designated FIGS. 13-17. Referring to FIG. 13, a package 10 having a front wall 12, a back wall 14, a first side 16, a second side 18, a bottom 20 and a top 22 is shown. The package 10 also has a tearable seal 26 formed in both the front and back walls, 12 and 14 respectively, which has an end conterminuous with the first side. Desirably, the tearable seal 26 extends continuously from the first side 16 to the second side 18. The package 10 further has a second seal 28 formed in both the front and back walls, 12 and 14 respectively, which is positioned inward of the first and second sides, 16 and 18 respectively, and which is located between the tearable seal 26 and the top 22. The second seal 28 is not designed to be broken at any time.

Referring now to FIG. 14, the method includes the steps of having a person grip the package 10 between a thumb and an index finger of each hand. One hand is positioned above the tearable seal 26 and the other hand is positioned below the tearable seal 26. The person then applies a forward force with one hand and a rearward force with the opposite hand to cause a portion of the tearable seal 26 to start to break at the first side 16.

Referring now to FIGS. 15 and 16, the person continues to tear the tearable seal 26 until the top 22 is at least about 90% torn away from the remainder of the package. In FIG. 16, the tearable seal 26 is completely removed from a remaining portion of the package 10. With the initial break, at least about 25% of the width w of the tearable seal 26 is broken away. Desirably, at least about 30% of the width w of the tearable seal 26 is broken away. More desirably, at least about 40% of the width w of the tearable seal 26 is broken away. Even more desirably, at least about 50% of the width w of the tearable seal 26 is broken away. Most desirably, at least about 60% of the width w of the tearable seal 26 is broken away. It should be understood that about 70% or less of the width w of the tearable seal 26 will remain secured to the remainder of the package 10 once the top 22 is removed.

Referring now to FIG. 17, the person then pinches the front and back walls, 12 and 14 respectively, between his or her two hands and pulls the front and back walls, 12 and 14 respectively, apart to break the remaining portion of the width w of the tearable seal 26 which is joined to the remainder of the package 10. This action causes the remaining portion of the width w of the tearable seal 26 to break and the package 10 will be opened so that the product or contents housed therein can be removed. The force required to pull the front and back walls, 12 and 14 respectively, apart and break the remaining portion of the width w of the tearable seal 26 is less than about 5 pounds. Desirably, the force needed to break the remaining portion of the width w of the tearable seal 26 is from between about 0.5 pounds to about 4 pounds. More desirably, the force needed to break the remaining portion of the width w of the tearable seal 26 is from between about 1 pound to about 3 pounds. Even more desirably, the force needed to break the remaining portion of the width w of the tearable seal 26 is less than about 2.5 pounds. Most desirably, the force needed to break the remaining portion of the width w of the tearable seal 26 is less than about 2 pounds.

After the top 22 of the package 10 has been completely torn off from the remainder of the package 10, it can be properly disposed off in a trash receptacle or into a recycling bind. In the circumstance where the top 22 is not completely torn away from the remainder of the package 10′″, see FIGS. 11 and 12, a portion of the top 22 will remain secured to the remainder of the package 10′″. In this case, the empty package 10′″, including the partially torn away top 22 can be properly disposed off.

It should also be understood that the tearable seal 26 or 26′ cannot be resealed after it has been broken and the package 10, 10′, 10′ or 10′″ has been opened. It should be understood that the second seal 28 is not intended to be broken at any time. It is the tearable seal 26 which, when fully broken, will create an opening into the package 10, 10′, 10′ or 10′″. Lastly, the tearable seal 26 requires less than about 5 pounds of force to be broken. This means that no special tools, sharp objects, scissors, knives, etc. are needed to open the package 10, 10′, 10′ or 10′″.

The tearable seal 26 or 26′ functions to seal the package 10, 10′, 10″ or 10′″ as well as to provide a means of opening the package 10, 10′, 10″ or 10′″. Alternatively, the package 10, 10′, 10″ or 10′″ can be sealed by another seal after the tearable seal 26 or 26′ is formed in the package 10, 10′, 10″ or 10′″. For example, the tearable seal 26 or 26′ and the second seal 28 can be formed in the package 10, 10′, 10″ or 10′″. The bottom 20 can be left open so that the product can be inserted into the package 10, 10′, 10″ or 10′″ from the bottom 20. Then the bottom 20 is sealed to enclose the product in the package 10, 10′, 10″ or 10′″.

As recited above, a person can initially grasp and/or pinch one edge of the package 10, 10′, 10” or 10′″ between his or her thumbs and index fingers such that one hand is positioned above the tearable seal 26 or 26′ and the other hand is positioned below the tearable seal 26 or 26′. Movement of one hand opposite to the other hand will cause the tearable seal 26 or 26′ to tear or break along its length. This action will cause the upper portion or top 22 of the package 10, 10′, 10″ or 10′″ to be partially or completely removed from the package 10, 10′, 10″ or 10′″ but a lower portion of the tearable seal 26 or 26′ will remain secured to the remainder of the package 10, 10′, 10″ or 10′″. The package 10, 10′, 10″ or 10′″ will still be sealed at this point. The second step for fully breaking the tearable seal 26 or 26′ requires the person to grasp, squeeze, manipulate or pinch the front wall 12 and the back wall 14 between each hand and pull the front and back walls, 12 and 14 apart so as to break the remaining portion of the width w of the tearable seal 260126′. This action will cause the package 10, 10′, 10″ or 10′″ to be opened. The force required to open the remainder of the width w of the tearable seal 26 or 26′ is relatively low, once the top 22 of the package 10, 10′, 10″ or 10′″, along with a portion of the tearable seal 26 or 26′, has been partially or completely removed.

EXAMPLE 1

A first package was constructed of a film having: “HDPE—HDPE—tie layer—EVOH—tie layer—HDPE—Surlyn”. By “tie layer” it is meant a chemical bond located between two layers in a lamination. “Surlyn” is a sealant layer. SURLYN is a registered trademark of E. du Pont de Nemours and Company, having a mailing address of 1007 Market Street, Wilmington, Del. 19898. The Surlyn layer is not necessary for the tearable seal 26 but was used for the construction of the package 10 using heat sealing equipment. This film structure was converted into a package 10 with gusseted sides and a fin seal running down the center of the back wall of the package. By “fin seal” it is meant a seam created when a single layer of film is folded to form a tube shaped package and the two parallel, outer edges are sealed together, with the fin being the material extending beyond the seal line. The sealing process utilized a 0.060 inches (1.5 millimeters) wide continuous tearable seal 26 with an adjacent patterned field of point bonds 30, having about 7% density, located above the tearable seal 26. The tearable seal 26 produced a hermetically sealed package 10. This package 10 could be opened by a consumer by breaking the tearable seal 26 and removing the top 22. The remainder of the width w of the tearable seal 26 was broken by pulling on the front and back walls, 12 and 14 respectively, to open the package 10.

The force required to initially break the tearable seal 26 ranged from between about 1 pound to about 3 pounds. The force required to pull open the front and back walls, 12 and 14 respectively, of the package 10 and thereby open the package 10 also ranged from between about 1 pound to about 3 pounds.

EXAMPLE 2

A second package 10 was constructed of a liner within a paperboard box. The tearable seal 26 was made by bonding through both the paperboard and the liner to create a hermetic seal between the two liner layers. The tearable seal 26 could later be broken to open the package 10 in a similar fashion as was described above in Example 1. The liner in this case was constructed of: “overlacquer—print—paper—LDPE—Surlyn”. By “print” it is meant the ink reverse printed on the inside of the outermost layer of the package for advertising and instruction purposes. Again, the Surlyn layer was not necessary for the tearable seal 26 but was used for the construction of the package 10 using heat sealing equipment.

While the invention has been described in conjunction with several specific embodiments, it is to be understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description.

Claims

1. A package capable of housing a product, said package comprising: a) a front wall, a back wall, a first side, a second side, a bottom and a top, and having a void area formed between said front and back walls which can house said product, and said package being completely sealed after said product has been inserted into said void area;b) a tearable seal formed in both said front and back walls, said tearable seal having an end conterminuous with said first side;c) a second seal formed in both said front and back walls which is positioned inward of said first and second sides and which is located between said tearable seal and said top, and said second seal having a patterned field of bonds; andd) said tearable seal requires less force to break than does said second seal.

2. The package of claim 1 wherein said patterned field of bonds include a plurality of point bonds having a density ranging from between about 1% to about 60%, and a portion of said tearable seal, located adjacent to said second side, remains secure to said package after said tearable seal has been broken.

3. The package of claim 2 wherein said plurality of point bonds are randomly arranged and have a density ranging from between about 10% to about 40%, and said tearable seal has a width which is partially broken in an initial tear and then is completely broken thereafter.

4. The package of claim 2 wherein said plurality of point bonds are regularly arranged and have a density ranging from between about 5% to about 25%.

5. The package of claim 1 wherein said tearable seal extends from said first side to said second side, and said tearable seal has a width ranging from between about 0.03 inches to about 0.10 inches, and said width is partially broken in an initial tear and then is completely broken thereafter.

6. The package of claim 1 wherein said front and back walls have a combined thickness, and said tearable seal has a width equal to at least about two times said combined thickness.

7. The package of claim 7 wherein said tearable seal has a width equal to at least about three times said combined thickness.

8. The package of claim 1 wherein said tearable seal requires a force of from between about 1 pound to about 3 pounds to break.

9. The package of claim 1 wherein said front wall has a thickness and said back wall has a thickness, and said tearable seal has a depth d which can range from between about 10% to about 90% of either the thickness of said front wall or the thickness of said back wall.

10. A package capable of housing a product, said package comprising: a) a front wall, a back wall, a first side, a second side, a bottom and a top, and having a void area formed between said front and back walls which can house said product, and said package being completely sealed after said product has been inserted into said void area;b) a tearable seal formed in both said front and back walls, said tearable seal having an end conterminuous with said first side, said tearable seal having a width, and said tearable seal being positioned closer to said top of said package than to said bottom of said package;c) a second seal formed in both said front and back walls which is positioned inward of said first and second sides and which is located between said tearable seal and said top, said second seal having a width which is at least 8 times larger than said width of said tearable seal, and said second seal having a patterned field of bonds; andd) said tearable seal s capable of breaking under a force of about 5 pounds or less.

11. The package of claim 10 wherein said tearable seal extends continuously from said first side to said second side, said tearable seal is a hermetic seal having a width ranging from between about 0.03 inches to about 0.10 inches, and said tearable seal requires a force of from between about 1 pound to about 3 pounds to break.

12. The package of claim 10 wherein said front wall and said back wall have a combined thickness, and said tearable seal has a width equal to at least about four times said combined thickness, and said width is partially broken in an initial tear and then is completely broken thereafter.

13. The package of claim 10 wherein said second seal has a patterned field of bonds having a density ranging from between about 5% to about 25%.

14. The package of claim 10 wherein said front wall has a thickness and said back wall has a thickness, and said tearable seal has a depth which can range from between about 10% to about 90% of the thickness of said front wall or said back wall.

15. The package of claim 14 wherein said second seal is aligned at an angle to said tearable seal and said angle is at least about 15 degrees.

16. A method of opening a package having a front wall, a back wall, a first side, a second side, a bottom and a top, a tearable seal formed in both said front and back walls which has an end conterminuous with said first side, and a second seal formed in both said front and back walls which is positioned inward of said first and second sides and which is located between said tearable seal and said top, said method comprising the steps of: a) gripping said package between a thumb and an index finger of each hand, one hand positioned above said tearable seal and the other hand positioned below said tearable seal;b) applying a forward force with one hand and a rearward force with the opposite hand to cause a portion of said tearable seal to start to break;c) continuing to tear said tearable seal until said top is at least about 90% torn away from a remaining portion of said package;d) pinching said front and back walls between said two hands; ande) pulling said front and back walls apart to break a remaining portion of said tearable seal and open said package.

17. The method of claim 16 wherein when said tearable seal is broken, a portion of the tearable seal remains attached to a remainder of said package.

18. The method of claim 16 wherein when said tearable seal is broken, said top is completely torn off from said package, and said torn off top is properly disposed off after being torn off from said package.

19. The method of claim 16 wherein said tearable seal cannot be resealed after being opened.

20. The method of claim 16 wherein said tearable seal requires less than about 5 pounds of force to be opened, and said second seal is not designed to be broken.