The present invention relates generally to packaging and, more particularly, to packages, and methods for manufacturing and using packages or pouches, having a reclosure device, such as a zipper, extending outward from the package.
There are many options already available for flexible packages with recloseable devices, but some products are presented in a way where the current available packaging options are inadequate. One of these products is wet or moist wipes. These products typically require a high oxygen and moisture barrier package where the wipes can be easily dispensed from a pre-folded and pre-wetted stack. The current flexible packages used for these types of products will typically incorporate a label over a precut panel of the package. The label is larger than the precut panel so the user can peel the label back, which has the portion of the precut panel adhered to it. The user can then take the required amount of wipes and place the label back over the opening. The problem with this type of closure is the package material can become wrinkled when replacing the label, especially as more and more wipes are used, and because the package is much larger than the remaining product it is containing. These wrinkles can let air into the package which can cause the wipes to dry out before they are all used. Further, as a considerable amount of the product has been used, there is a lot of air that can get into the package and the package and label can easily become misaligned when trying to press the label down with the extra packaging material. This leads to frustration on the consumer's part as they know the wipes will soon dry out and be of no use. The adhesive on the label can also become contaminated with the products contained in the wipes which, over time, will also compromise the closure seal and further lead to drying out of the product.
The best package format for these types of products (e.g., wet wipes) are pillow pack or fin seal pouches typically run on a flow wrapper, which are typically the style including the referenced pre-cut panel and adhesive/label for access. As described, these types of packages do not include recloseable zippers. There have been some fin seal packages designed with zippers, however, the zipper is located near the end of the package so you can pinch the zipper closed with no product between your fingers and the mating fasteners. This again does not allow for the consumer to peel a wipe from the top of the stack and creates more wasted packaging material. Alternatively, an Inno-Lok style zipper can be placed in the center of the panel. However, to close the zipper the consumer has to press downward against the product, which makes it difficult to line up the mating portions of the zipper and lock them together.
The inherent problem with attempting to make a package like this, is the ability to attach the zipper to the package material without having any leaks around the seal of the zipper and the package. There have been other designs for zippers protruding from a package panel, but they are not provided in a way as to retain the oxygen and moisture barrier needed.
As detailed above, simply using a recloseable zipper, either press-to-close or a slider zipper, does not work well for these products as they have been typically placed on the end or top of the package. Again, wet wipes are placed in a stack and should be pulled from the stack one at a time. Having a recloseable zipper on the end of the package does not easily allow the consumer to take a wipe from the top of the stack. The wipes can be placed within this type of package so the top of the stack is toward the end or top of the package with a zipper, but the package does not fit the shape of the stack well. This can introduce other issues, like the inability to stack the packages in shipping containers or on store shelves without wrinkling the packaging film. This is very undesirable from a cost and marketing perspective. There is also a lot of wasted space within this style of package, which not only adds cost, but allows for more air to remain in the package—which can contribute to the product drying out before they are all used.
Currently, some packaging solutions used to contain and dispense baby wipes and like products include expensive hinged and ridged plastic closures that are attached to a flexible package. These rigid hinged closures are very expensive and are not very airtight and will only keep the wipes inside the package wet for a limited period of time, and the user cannot always determine if they have closed them all the way. If they have not, the wipes dry out even sooner.
As a result, there is a need for a package that substantially solves the above-referenced problems with conventional package and closure designs, configurations, and manufacturing methods.
Embodiments of the present invention include a pouch or package (e.g., flexible package) having an extending or protruding reclosure or recloseable device (e.g., zipper). The reclosure device can protrude out from and above a top panel of a pillow style package (e.g., via a slot or opening), where the consumer can open and close the device like they would on any other pouch. This can allow the product to be presented in a pillow or fin seal style pouch, which fits the product the best, and would solve all the other issues described with conventional closure options.
With various embodiments, the reclosure device, such as a press-to-close zipper or a slider zipper, is adhered to a strip of sealable barrier or non-barrier material—e.g., an extending flange member. This device, made to particular specifications in size and material type, is prepared and applied to the package such that one or more flange sections or members are folded within the package for sealing to an internal surface of a package panel portion, with the reclosure device and its interlocking members extending out externally from the panel for use. The foldable flange members sealed to the internal surface of the package panel can be thinner and/or more flexible than the flange sections having one or more locking members (e.g., male and female locking members). In other embodiments, the flanges themselves can be constructed of a thinner or more flexible material than traditional flanges and directly sealed to the inner surface of the package panel.
Other embodiments of the invention can include the reclosure device provided or sealed behind or under a portion of the package (e.g., a panel portion) such that the package includes a pre-perforated material patch or section that can be removed by the user. The user can then pull the reclosure device out from behind the package material to extend outward from the package for use. Other means of accessing or concealing the reclosure device at or within the package can be employed without deviating from the spirit and scope of the present invention.
The above summary is not intended to describe each illustrated embodiment, claimed embodiment or implementation of the invention. The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations or in isolation, without departing from the scope of the present invention.
The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
c show reclosure device structures and attachment methods for initially providing the reclosure device beneath or behind package material, and later extendable outside of the package material, in accordance with embodiments of the present invention.
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 or crushed portions and/or integrated devices for the package.
Referring generally to
As shown in
The reclosure device 110, such as a press-to-close or slider zipper, can include a first flange 112, a second flange 114, and one or more interlocking members 116. The interlocking members 116 can include a male member and a female member adapted for selective mating. The reclosure device 110 can be provided in line with the machine direction of the package 100 (e.g.,
In various embodiments, a film material 115 thinner than the flanges 112, 114 can be provided to extend out from and above an end portion of the device 110 to form a top seal. This material 115 can be removed (e.g., cut, via a tear slit, weakened pathway, etc.) to provide access to the device 110.
Certain embodiments of the invention can include the reclosure device 110 provided or sealed behind or under a portion of the package 100 (e.g., a panel portion) such that the package 100 includes a pre-perforated material patch or section that can be removed by the user, as detailed further herein (e.g.,
Referring to
Referring to
Referring to
First, as shown in
Next, the reclosure device 110 section is cut off of, or otherwise removed from, the continuous strip in the approximate center C of the notched area 132 (step 144). This will leave a section of the device 110, made to whatever length is required for the particular use, with the ends/edges of the device 110 and opposing flanges 112, 114 sealed together at seals 120 and 122 (see
The individual sections of the reclosure device 110 will then be presented to and sealed to the packaging material (step 146), which will later be formed into the package 100, as shown in
Referring to
The reclosure device 110 material is then completely sealed to the packaging material with no areas for air to get into the package 100, or moisture from within the package 100 to escape. The package 100 can be formed and filled with methods known to those skilled in the art. This material can be made on a roll-to-roll format to later be run on a form, fill, and seal machine, such as a flow wrapper machine, while it is being filled, or it can be made into a premade pouch to be filled and a final seal placed on it later. A myriad of sealing, crushing, notching, cutting, forming, shaping and other processes can be modified and included with embodiments of the present invention to achieve the reclosure device 110 attachment and package formation methods taught and suggested herein.
When the consumer wishes to open the package initially, they simply tear or cut off section 115 or 113 (and, if present, peel open a frangible seal) above the reclosure device 110 and open the device to access the product P within the package 100 (e.g., See
Referring to
While various embodiments of the reclosure device 110 show one or more flanges 112, 114 attached to separate and distinct film materials 112a, 114a, any of the devices 110 shown or described herein can comprise the locking members 116 simply provided or otherwise attached directly to the flanges 112, 114, or to the extension flange material 112a, 114a (e.g., without separate flanges 112, 114). That film material 112a, 114a would then be attached to the package panel portion 102 to provide the extending or extendable reclosure device 110 of the present invention.
The package 100 including the recloseable device 110 according to the invention can include packages constructed, in whole or in part, of flexible, rigid, semi-rigid, or semi-flexible materials or panels. Briefly, 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 increased barrier properties, embodiments can use composite or laminate layers of said materials and material of the like. Generally, in such composite or laminate embodiments, a material having preferred sealing characteristics can be joined, bonded or laminated to a material having a different preferred characteristic (e.g., beneficial oxygen barrier properties). Regardless, single sheets, composites/laminates, and a myriad of other materials and techniques known to one skilled in the art may be implemented based on particular usage and manufacturing needs without deviating from the spirit and scope of the present invention. The present invention in certain embodiments permits the flexible package to be made using less expensive or cheaper materials than would otherwise be necessary.
In various embodiments, the panel portions will be formed of one contiguous web material. In other embodiments, at least one of the panel portions can be distinct web materials joined or sealed to other respective panel portions to form the package of the present invention.
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. Various unspecified steps and procedures can be performed to create or form the inventive packages and devices. Further, features and aspects of the various embodiments described herein can be combined to form additional embodiments within the scope of the invention even if such combination is not specifically described herein.
References to front and back panel portions for the package 100 and package formation embodiments described herein are provided to facilitate an understanding of orientation and direction and are not intended to be limiting. For instance, reclosure devices, seals, and other structures or portions of the package, can be provided to or along any portion of the package 100 regardless of the references herein to front, back, side, bottom and the like.
This application is a continuation of U.S. patent application Ser. No. 17/827,772, filed May 29, 2022, which is a continuation of U.S. patent application Ser. No. 16/518,849, filed Jul. 22, 2019 and is now U.S. Pat. No. 11,350,802, which claims priority to and the benefit of U.S. Provisional Patent Application No. 62/701,077, filed Jul. 20, 2018; with each of the referenced applications and disclosures fully incorporated herein by reference.
Number | Date | Country | |
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62701077 | Jul 2018 | US |
Number | Date | Country | |
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Parent | 17827772 | May 2022 | US |
Child | 18418631 | US | |
Parent | 16518849 | Jul 2019 | US |
Child | 17827772 | US |