DIE CUT OPENING FOR MULTI-LAYER FLEXIBLE PACKAGE
20200407140 ยท 2020-12-31
Inventors
- Jacob Donald Prue Branyon (Hartsville, SC, US)
- Donovan Young (Hartsville, SC, US)
- Eugene Smith (Charlotte, NC, US)
Cpc classification
B65D75/5833
PERFORMING OPERATIONS; TRANSPORTING
Y10T156/1064
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B65D75/5827
PERFORMING OPERATIONS; TRANSPORTING
Y10T156/1082
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
Abstract
A reclosable package is described that includes inner and outer film layers. Each of the inner and outer film layers includes die cuts that are designed to create a peelable flap portion that, when pulled back by the user, reveals an opening of the package for providing access to the contents of the package. In particular, the inner film layer has an inner die cut that includes a cross-directional cut line. While the cross-directional cut line in conventional packages is a straight line, the package described herein uses a line that has one or more radii of curvature. In this way, the vibrations that may otherwise be generated during the rotary die cutting process are reduced, and more consistent cut depths can be achieved.
Claims
1. A package comprising: an outer film layer comprising an outer die cut, wherein the outer die cut defines a peripheral edge of a peelable flap portion of the package; and an inner film layer laminated to the outer film layer and comprising an inner die cut, wherein the inner die cut defines a location of an opening of the package and is formed inwardly of the outer die cut, wherein the inner die cut has only one axis of symmetry and comprises: a first cross-directional cut line; first and second longitudinal cut lines extending continuously lengthwise from opposite ends of the first cross-directional cut line, respectively; and a second cross-directional cut line extending continuously between the first and second longitudinal cut lines, opposite the first cross-directional cut line and having a non-zero radius of curvature, and wherein the second cross-directional cut line has a non-zero first radius of curvature at a location between its juncture with the first and second longitudinal cut lines, and a non-zero second radius of curvature at the juncture of each of the first and second longitudinal cut lines with the second cross-directional cut line, wherein the second radius of curvature is smaller than the first radius of curvature, wherein a mid-section of the second cross-directional cut line is disposed further from a midpoint of the peelable flap portion than the juncture of each of the first and second longitudinal cut lines with the second cross-directional cut line is disposed from a midpoint of each of the first and second longitudinal cut lines. and wherein the first and second radii of curvature are selected so that the first and second longitudinal cut lines and the second cross-directional cut line are non-elliptical.
2. The package of claim 1, wherein the first cross-directional cut line, the first longitudinal cut line, the second longitudinal cut line, and the second cross-directional cut line form a closed shape.
3. The package of claim 1, wherein the first cross-directional cut line of the inner die cut is interrupted by at least one package integrity feature.
4. The package of claim 1, wherein the first cross-directional cut line of the inner die cut is discontinuous.
5. The package of claim 1, wherein the outer die cut includes at least one package integrity feature.
6. The package of claim 1, wherein the peelable flap portion is configured to be pulled back to reveal an opening into the package.
7. The package of claim 6, wherein the first cross-directional cut line defines an origination of the package opening as the peelable flap portion is pulled back.
8. The package of claim 1, wherein the first and second longitudinal cut lines are straight lines.
9. The package of claim 1, wherein the first radius of curvature is located at the midsection of the second cross-directional cut line.
10. The package of claim 1, wherein the first radius of curvature is located at the portion of the second cross-directional cut line closest to the longitudinal axis of the package.
11. A package comprising: an outer film layer comprising an outer die cut, wherein the outer die cut defines a peripheral edge of a peelable flap portion of the package; and an inner film layer laminated to the outer film layer and comprising an inner die cut, wherein the inner die cut defines a location of an opening of the package and is formed inwardly of the outer die cut, wherein the inner die cut has only one axis of symmetry and comprises: a first cross-directional cut line; first and second longitudinal cut lines extending continuously lengthwise from opposite ends of the first cross-directional cut line, respectively; and a second cross-directional cut line, opposite the first cross-directional cut line, connecting the first and second longitudinal cut lines and extending away from the first cross-directional cut line, wherein the second cross-directional cut line has multiple non-zero radii of curvature between its juncture with the first and second longitudinal cut lines, and wherein the second cross-directional cut line has a non-zero additional radius of curvature at the juncture of each of the first and second longitudinal cut lines with the second cross-directional cut line, and wherein the additional radius of curvature is smaller than each of the multiple non-zero radii of curvature between the juncture of the second cross-directional cut line with the first and second longitudinal cut lines.
12. The package of claim 11, wherein a mid-section of the second cross-directional cut line is disposed further from a midpoint of the peelable flap portion than the juncture of each of the first and second longitudinal cut lines with the second cross-directional cut line is disposed from a midpoint of each of the first and second longitudinal cut lines.
13. The package of claim 11, wherein the multiple non-zero radii and the additional radii of curvature are selected so that the first and second longitudinal cut lines and the second cross-directional cut line are non-elliptical.
14. A method of manufacturing a package, the method comprising: laminating an outer film layer to an inner film layer; forming an outer die cut in the outer film layer to define a peripheral edge of a peelable flap portion of the package; and forming an inner die cut in the inner film layer to define a location of an opening of the package, wherein the inner die cut is formed inwardly of the outer die cut and on the peelable flap portion, and wherein forming the inner die cut comprises: forming a first cross-directional cut line; forming first and second longitudinal cut lines extending continuously lengthwise from opposite ends of the first cross-directional cut line, respectively; and forming a second cross-directional cut line extending continuously between the first and second longitudinal cut lines opposite the first cross-directional cut line, wherein the second cross-directional cut line has a non-zero first radius of curvature at a location between its juncture with the first and second longitudinal cut lines, and a non-zero second radius of curvature at the junction of each of the first and second longitudinal cut lines with the second cross-directional cut line, wherein the second radius of curvature is smaller than the first radius of curvature, wherein the inner die cut has only one axis of symmetry, and wherein the first and second radii of curvature are selected so that the first and second longitudinal cut lines and the second cross-directional cut line are non-elliptical.
15. The method of claim 14 wherein the forming the outer die cut and forming the inner die cut comprise using a rotary die cutting blade.
16. The method of claim 14 wherein a mid-section of the second cross-directional cut line is cut at a different instant in time than the opposite ends of the second cross-directional cut lines.
17. The method of claim 16 wherein vibrations generated during cutting are reduced.
18. The method of claim 14 wherein laminating the outer film layer to the inner film layer comprises applying a pressure sensitive adhesive to one of the inner or outer film layer.
19. The method of claim 14 additionally comprising forming at least one package integrity feature in the outer die cut or the inner die cut.
20. The method of claim 19 wherein the at least one package integrity feature is formed in the first cross-directional cut line of the inner die cut.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0011] 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:
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
DETAILED DESCRIPTION OF THE DRAWINGS
[0018] 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.
[0019] As noted above, some packages for holding food items (e.g., cookies), are designed to be opened by a consumer by peeling back portions of the package that form a peelable portion. When separated from the rest of the package, the peelable portion creates an opening into a main compartment of the package where the contents of the package are held. For example, the package may be made of a laminate that includes two or more film layers. Prior to forming the package, lines may be die cut into each layer of the laminate to define the peelable portion, which in turn may define an opening into the compartment.
[0020] Thus, to create the opening, die cuts are made in each film layer. In a two-layer laminate, for example, cut lines made in the outer film layer (e.g., the film layer that defines an exterior surface of the package) may define the general shape of the peelable portion of the package, and cut lines made in the inner film layer may define the general shape of the opening into the package. Accordingly, with respect to at least the inner film layer, some cuts may be made in the same direction as the longitudinal axis of the package (e.g., longitudinal cut lines) and some cuts may be made in a direction that is transverse or perpendicular to the direction of the longitudinal cut lines (e.g., cross-directional cut lines) to define the opening.
[0021] A conventional package 10 formed by a laminate including an outer film layer 15 and an inner film layer 20 is shown in
[0022] The inner die cut 35 includes a first cross-directional cut line 40 (which may in some cases include one or more package integrity features 70, as shown), first and second longitudinal cut lines 45, 50 extending continuously lengthwise from opposite ends of the first cross-directional cut line 40, respectively, and a second cross-directional cut line 55 extending between the first and second longitudinal cut lines 45, 50 with respect to the longitudinal axis L of the package, as shown. The cut lines 40, 45, 50, 55 thus define the general shape of the opening that will be formed in the package once the peelable portion 30 is peeled back from the main body 60 of the package.
[0023] According to conventional packages 10 and methods, the second cross-directional cut line 55 is a straight line extending approximately perpendicularly from the first and second longitudinal cut lines 45, 50 and having no curvature. Considering a rotary die cutting process, in which the die cut is formed by a blade edge provided on the circumferential surface of the rotary die cutting tool, according to conventional packages 10 and methods, the blade would have a shape that corresponds to the dashed-line shape in
[0024] Through ingenuity and hard work, the inventors have discovered that replacing the straight-line second cross-directional cut line with a cut line that has a nominal radius of curvature (or, in some cases, multiple radii of curvature) can serve to reduce vibrations in the cutting of the various die cuts by providing a gradual impact of the rotary die cutting tool and blade with the material of the inner film layer. In this way, a more consistent depth of cut can be produced, the tolerance for the various die cuts can be minimized, and the overall performance of the peelable portion can be enhanced.
[0025] Turning now to
[0026] The flexible package 100 may, in some embodiments, include an outer film layer 115 and an inner film layer 120. Accordingly, in some embodiments, the inner and outer film layers 120, 115 may define the main body 160 and the peelable flap portion 130. For example, the outer film layer 115 may include an outer die cut 125, and the outer die cut may define a peripheral edge of the peelable flap portion 130 of the package, as shown. The inner film layer 120 may be laminated to the outer film layer 115 using permanent adhesive in some areas and pressure sensitive adhesive in other areas. For example, permanent adhesive may be pattern-applied to first portions 118 of a respective one of an inner surface 133 of the outer film layer 115 or an outer surface 134 of the inner film layer 120, such as in portions that lie outwardly of the outer die cut 125, and pressure sensitive adhesive may be pattern applied to second portions 119 of the respective surface of the inner or outer film layer, such as in portions covering areas of the films that are intended to delaminate. Thus, in the depicted embodiment, the second portions 119 may be areas of the laminate that lie between the outer die cut 125 and the inner die cut 135 (shown in
[0027] Due to the presence of the pressure sensitive adhesive in the second portions 119 and the location of the second portions 119 with respect to the location of the outer die cut 125, the outer film layer 115 may delaminate from the inner film layer 120 as the user grasps a pull tab 132 defined by the outer die cut 125 and applies an opening force F, as shown in
[0028] As the user continues to apply the opening force F and pulls the peelable portion 130 away from the main body 160 of the package, an opening 105 of the package 100 may be revealed due in part to the presence of the inner die cut 135, as shown in
[0029]
[0030] Because the second cross-directional cut line 155 shown in
[0031] In other cases, in which the laminate material is fed into the rotary die cutter in a direction from left to right, the mid-section of the second cross-directional cut line 155 (e.g., starting from near the center point of that line) may be cut first, with the cut gradually extending outwardly towards the opposite ends of the second cross-directional cut line, followed by cutting of the first and second longitudinal cut lines 145, 150 (the two lines being cut simultaneously with each other, from the respective ends closest to the second cross-sectional cut line 155 to the respective opposite ends closest to the first cross-directional cut line 140), and finally followed by the first cross-directional cut line 140.
[0032] Regardless of which direction the laminate is advanced through the rotary die cutter, the relatively gradual cutting of the second cross-directional cut line 155 as described above has been found by the inventors to reduce the vibrations generated during the die cutting process and has led to more consistent die cutting depths and reduced tolerances. For example, preliminary testing by the inventors shows that the tolerances are improved by up to 50% to +/6 microns for packages having an inner die cut 135 made according to embodiments described herein, as compared to tolerances of +/12 microns for conventional packages with a straight die cut having no radius of curvature.
[0033] With reference to
[0034] In some embodiments, the first and/or second radii of curvature R1, R2 may be selected so as to provide a second cross-directional cut line 155 that, although not a straight line, minimizes the degree of curvature may to allow the opening 105 to remain within the working area of the package, such that the rightmost point of the opening (with respect to the depicted views in the figures) does not extend too far towards the end of the package. At the same time, using a first and/or second radius of curvature R1, R2 that is too large may require that the first and second longitudinal cut lines 145, 150 be shortened (e.g., as compared to the lengths shown in the embodiments of the figures), which would effectively reduce the access area provided by the opening 105. Moreover, minimizing the degree of curvature of one or more of the radii R1, R2 may allow the second cross-directional cut line 155 to appear, to the eyes of a consumer, no different than a conventional second cross-directional cut line, thereby minimizing the visual impact of embodiments of the new package as compared to a conventional package.
[0035] As illustrated in
[0036] For example, with reference to
[0037] With respect to the package integrity features 170 defined in the inner film layer 120, for example, each package integrity feature may comprise a neck region 172, as well as an anchor region 174, as illustrated in
[0038] In
[0039] In this regard, in some embodiments, the anchor region 174 may be specifically configured (e.g., sized, shaped, and/or arranged) so as to maintain a secure attachment to the outer film layer 115 of the peelable flap portion 130, e.g., as a result of adhesives applied between adjacent, contacting surfaces of the inner and outer film layers 120, 115 in the area of the anchor region 174. For example, in the embodiment depicted in
[0040] In other embodiments, however, such as the embodiment shown in
[0041] 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.