Vacuum package with reclosable pour spout and handle, and methods of making the same

Abstract

A flexible package and methods of making the same are disclosed. The package is formed of a flexible sheet material and includes plural panels connected together to form an internal compartment holding a flowable granular or particulate material. The package includes a transverse seal line which includes a permanently sealed section and a releasably securable sealed section. The releasably securable sealed section is configured to be peeled open to form a spout for the package. The package also includes a re-closable connector located adjacent the releasably securable section to close the spout after it has been opened. The package also includes a handle for lifting and carrying the package and for facilitating pouring the contents of the package out of the spout.

Claims

1. A package for holding a particulate material therein, said package being formed of a flexible material and comprising: a front panel having a top edge, a bottom edge, a first side and an oppositely disposed second side; a rear panel having a top edge, a bottom edge, a first side and an oppositely disposed second side; a top transverse seal line having a length as measured between said first side and said second side of said front panel and said rear panel, said top transverse seal line being located below said top edge of said front panel and below said top edge of said rear panel and sealing said front panel to said rear panel along said length of said top transverse seal line; a peelable seal area having a length which is less than the length of said top transverse seal line, said peelable seal area extending below said top edge of said front panel and below said top edge of said rear panel and encompassing a portion of the length of said top transverse seal line from one of said first side or said second side of said front panel and said rear panel, said portion of said top transverse seal line encompassed by said peelable seal area being only a portion of the length of said top transverse seal line, whereupon a first portion of said peelable seal area is located above said top transverse seal line and a second portion of said peelable seal area is located below said top transverse seal line, said first portion of said peelable seal area and said second portion of said peelable seal area having an equal length; a bottom transverse seal line having a length and sealing said front panel to said rear panel along said length of said bottom seal line; a compartment configured for receipt of the particulate material therein, said compartment being formed by portions of said front and rear panels between said bottom transverse seal line and said top transverse seal line, said second portion of said peelable seal area being located within said compartment and being configured to enable said front panel and said rear panel to be peeled open at said second portion of said peelable seal area to form a pour spout in communication with said compartment; and a re-closable connector having a length equal to the length of said second portion of said lower peelable seal line and located in said compartment interposed between said front and rear panels and immediately below said second portion of said peelable seal area, said re-closable connector configured to releasably close said pour spout after it has been opened.

2. The flexible package of claim 1 wherein said lower peelable seal line comprises no more than approximately fifty percent of said length of said top transverse seal line.

3. The flexible package of claim 1 wherein said lower peelable seal line comprises a releasably securable adhesive.

4. The flexible package of claim 2 wherein said lower peelable seal line comprises a releasably securable adhesive.

5. The flexible package of claim 1 wherein said re-closable connector comprises a press-to-close tape.

6. The flexible of claim 2 wherein said re-closable connector comprises a press-to-close tape.

7. The flexible of claim 4 wherein said re-closable connector comprises a press-to-close tape.

8. The flexible package of claim 1 wherein said package is a gusseted bag having a first gusseted side panel and a second gusseted side panel, said first gusseted side panel being secured between said front panel and said rear panel at a first side of said gusseted bag, said second gusseted side panel being secured between said front panel and said rear panel at a second side of said gusseted bag.

9. The flexible package of claim 7 wherein said package is a gusseted bag having a first gusseted side panel and a second gusseted side panel, said first gusseted side panel being secured between said front panel and said rear panel at a first side of said gusseted bag, said second gusseted side panel being secured between said front panel and said rear panel at a second side of said gusseted bag.

10. The flexible package of claim 1 additionally comprising a handle.

11. The flexible package of claim 10 wherein said handle is located in a top portion of said package above said top transverse seal line.

12. The flexible package of claim 11 wherein said handle comprises an opening in said top portion of said package.

13. The flexible package of claim 1 wherein said package is a vacuum package that is self-supporting and can be supported on a pallet without the need for additional support.

14. The flexible package of claim 13 wherein said vacuum package has vacuum pressure inside of said package of at least 300 mm Hg.

Description

DESCRIPTION OF THE DRAWING

(1) The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein:

(2) FIG. 1 is an isometric view of one exemplary package constructed in accordance with this invention;

(3) FIG. 2 is an isometric view, similar to FIG. 1, but showing the package during a point in the process of making the package;

(4) FIG. 3 is an isometric view similar to FIGS. 1 and 2, but showing the package at a later point in the process of making the package; and

(5) FIG. 4 is a plan view of a web of flexible material for forming precursor packages in accordance with a method of this invention and which precursor packages when filled and sealed form the completed package of FIG. 1 and the intermediate versions of the package shown in FIGS. 2 and 3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(6) Referring now to the various figures of the drawing wherein like reference characters refer to like parts, there is shown in FIG. 1 one exemplary embodiment of a package 20 constructed in accordance with one aspect of this invention. The package is arranged for holding a flowable particulate or granular material product P, e.g., cat litter.

(7) The exemplary package 20 basically comprises a bag fabricated from a flexible sheet material capable of being sealed for closing off the interior of the bag from ambient atmosphere. In the exemplary embodiment the bag includes a front panel 22, a rear panel 24, a first gusseted side panel 26 and a second gusseted side panel 28. It should be pointed out that the bag may be in different form than a gusseted bag, e.g., it may be a flat bag, a stand-up pouch or some other configuration that has two or more side walls or panels and one or more seams to join the edges of the side walls or panels. The bag has an open upper end portion 30 terminating in a top free edge 32. The top portion of the bag is sealed along a transversely extending seal line 34 (FIGS. 1, 2 and 4) located a short distance below the top free edge 32. The inner surface of the bag's panels have a releasably securable adhesive 36 located in the upper end portion of the bag below the top free edge and encompassing a portion of the transverse seal line 34 to form an openable pour spout S for the bag, as will be described in considerable detail later. In addition, the bag includes a re-closable or releasably securable connector 38 located immediately below the bottom of the releasably securable adhesive 36. The re-closable connector 38 serves as a means for re-closing the pour spout S of the bag after it has been opened. The bag has a closed lower end portion 40 terminating in a bottom free edge 42. The bottom portion of the bag is sealed along a transversely extending seal line 44 located a short distance above the bottom free edge 40. The interior of the bag is in the form of a hollow compartment located between the panels of the bag and the transverse seal lines 34 and 44. It is in this compartment that the particulate material P is located and held for subsequent dispensing through the bag's pour spout S when that pour spout is opened.

(8) The bag 20 is formed from a web of flexible sheet material 10. That web is shown in FIG. 4 and is in the form of a series of sheets or precursors 10A, 10B, 10C, and so on. Each of the precursors of the web is formed, filled and sealed in a continuous operation on a conventional form, fill and seal machine to produce a series of the packages 20. In FIG. 4, only three of the precursors of the continuous web are shown, namely 10A, 10B and 10C. The portion of the web designated as 10A shows the entire precursor which forms the package 20 shown in FIG. 1, whereas the portion of the web designated as 10B only shows a portion, i.e., the trailing edge of the precursor for the prior package to be produced by the form, fill and seal machine, whereas the portion of the web designated as 10C only shows a portion, e.g., the leading edge of the precursor of the next package 20 to be produced and filled after the package 20 is produced and filled from the precursor 10A.

(9) Each precursor section or sheet of the web 10 is of identical construction. In particular, the web includes a first side edge 46, and a second side 48, a first fold line 26A, a second fold line 26B, a third fold line 26C, a fourth fold line 28A, a fifth fold line 28B, and a sixth fold line 28C. The web 10A is formed into a tube by folding it along its fold lines, whereupon the 46 and 48 are overlapped and sealed together, e.g., heat sealed, along lines 46A and 48A located at the marginal edges 46 and 48, respectively. Those sealed overlapped portions form a vertical or fin seal 50 (FIG. 1) located in the center of the rear panel 24.

(10) The fold lines 26A, 26B and 26C, when folded form the side gusset panel 26. The gusseted side panel 26 includes a front gusset section 26D and a rear gusset section 26E. The fold line 26A forms an outer fold edge joining the front gusset section 26D to the right side edge of the front panel 22. The fold line 26B forms an outer fold edge joining the rear gusset section 26E to the right side edge of the rear panel 24. The fold line 26C is located midway between the fold lines 26A and 26B and forms an inner fold edge joining the front gusset section 26D to the rear gusset section 26E. In a similar manner, the fold lines 28A, 28B and 28C, when folded form the side gusset panel 28. The gusseted side panel 28 includes a front gusset section 28D and a rear gusset section 28E. The fold line 28A forms an outer fold edge joining the front gusset section 28D to the left side edge of the front panel 22. The fold line 28B forms an outer fold edge joining the rear gusset section 28E to the left side edge of the rear panel 24. The fold line 28C is located midway between the fold lines 28A and 28B and forms an inner fold edge joining the front gusset section 28D to the rear gusset section 28E.

(11) The adhesive 36 is applied to the inner surface of the web 10A at the location at which the transverse seal line 24 will be made and is in the form of a pattern, e.g., a rectangle, wherein the adhesive extends from a point immediately adjacent the seal line 48 inward on the web to no more than the middle of the web. Thus the adhesive does not extend into the side seam or into more than fifty percent of the width of the upper end portion of the package. This feature increases the structural integrity of the bag and, as will be described shortly, creates a peelable portion to form the pour spout for the bag. It should be noted that the adhesive 36 is shown extending from a point immediately adjacent in seal line 48A toward the center of the web. That is merely exemplary. Thus, for example, the adhesive 36 can be applied to extend from a point immediately adjacent in seal line 46A toward the center of the web.

(12) As mentioned earlier a releasably securable connector 38 is located on the inner surface of web of flexible sheet material immediately below pattern applied adhesive 36. In accordance with one preferred embodiment of this invention that connector is in the form of a strip of press-to-close tape, and extends parallel to the pattern applied adhesive 36, just below the pattern applied adhesive. However, if desired the connector 38 can be located just above the pattern applied adhesive 36. In any case, the strip of re-closure tape does not extend into the side seam 48A or into more than fifty percent of the upper end portion package. Rather, it is only applied to the area of the sheet of material intended to be formed into a pour spout. By applying the peel seal and re-closure tape only to the area of the package requiring opening, and specifically stopping the peel seal material prior to extending into the balance of the package mouth and into the package side seams, those areas remain permanently sealed to give the package the desired spout formation and structural integrity.

(13) Importantly, the area of the peel seal of the present invention does not interfere with the other permanent seams of the package. The process of applying a coating to predetermined area of a laminate web is generally referred to in the flexible packaging industry as pattern coating. The peel seal is placed on the laminated material by the pattern coating wherein the peel seal adhesive is placed away from the heat sealed seams and placed in a pattern only on that portion of the laminate that is actually peeled opened. Therefore, the structural integrity of the main seams is maintained.

(14) In accordance with one exemplary preferred embodiment of this invention the web 10 is composed of a lamination typically used for vacuum packaging dry granular products. The laminations from outside to inside consist of: 12 micron polyester film; ink, adhesive; 7 micron aluminum foil, adhesive, 15 micron oriented nylon, adhesive, 75 micron polyethylene, and the pattern applied releasably securable adhesive 36.

(15) As should be appreciated by those skilled in the art, while the package 20 has been described with specific reference for holding cat litter, which is a loose granular or particulate material that is good at absorbing moisture and odors, such as ammonia, the subject package can be used for many different products.

(16) As can be seen in FIG. 1, the package 20 includes a handle 52 for lifting and carrying the package and for facilitating the pouring of the contents of the package out of its spout when the spout is opened. In the exemplary embodiment shown the handle is located in the upper portion 30 of the package within the remaining fifty percent of the package's width that do not make up its openable spout. The handle 20 can be of any shape, configuration or size, but in the exemplary embodiment is in the form of a pair of openings 54 located adjacent each other and surrounded by a permanent heat seal area 56. Moreover, if desired the handle can be located at different locations on the package.

(17) The process of making the exemplary package 20 (and other packages in accordance with this invention), will now be described. To that end, a web of flexible sheet material for forming the bag is delivered in continuous roll stock format to a packaging machine, e.g., Goglio G22 form, fill and seal machine, sold by the assignee of this invention Fres-co System USA, Inc. The sheet material is unwound and the re-closure connector (e.g., press-to-seal tape) 38 is heat sealed to the inside of the web in the appropriate area. The continuous sheet is formed into a gusseted tube, applying the vertical fold lines to form the front panel 22, rear panel 24, and the interposed gusseted side panels 26 and 28, each of which as discussed above includes a front gusset section and a rear gusset section. The marginal edges 46 and 48 of the tube form a vertically extending back or fin seal 50 located in the center of the back panel 25. The back or fin seal finishes the continuous tube from the web. The bottom 50 of the package is formed by applying transverse fold lines 58 (FIG. 4) to the front and rear panels a slight distance from what will be the bottom edge 42 of the package. These fold lines cooperate with the inner fold lines 26C and 28C of the gusseted side panels 26 and 28, respectively, to form a conventional bottom of the package. The permanent transversely extending bottom seal 44 is produced by heat sealing the tube below the fold lines 58 and the continuous tube is cut just below this seal. The cut defines the closed bottom edge 42 of the package 20 and the leading or open top edge 32 of the next succeeding package from the precursor 10C in the continuous manufacturing line.

(18) The top of the package 20 formed by the precursor 10A is open, whereupon an appropriate quantity of granular product P is filled into the package via the open top. The filled package is manipulated, such as with vibration, to settle and densify the product. The top 30 of the package is formed by applying transverse fold lines 60 (FIG. 4) to the front and rear panels a slight distance from the top edge 32 of the package. These fold lines cooperate with the inner fold lines 26C and 28C of the gusseted side panels 26 and 28, respectively, to form the top of the package in a manner similar to the formation of the bottom of the package.

(19) The formed and filled package is then placed in a vacuum chamber fitted with a top heat sealing apparatus. In particular, the portion of the top end of the package is placed between heat sealing bars of the top heat sealing apparatus in the appropriate location to seal through the releasably secured adhesive strip 36 and adjacent uncoated area, as shown in FIG. 2. The vacuum chamber is closed and a defined vacuum is placed on the chamber including the inside of the package and product. The transversely extending top heat seal 34 is applied across the entire width of the package. The vacuum is released causing air pressure to collapse the package forming the package's shape.

(20) The package with product in it, now under defined vacuum, is removed from the vacuum chamber. A heat seal apparatus is then applied to the area of the top of the package where the handle is located to permanently seal that portion of the package together and form the area 56 for the handle. The top portion of package in the area 56 is next die cut to form the two openings 54 making up the handle. As should be appreciated by those skilled in the art the heat sealing of the portion 56 of the package around the openings 54 has the effect of reinforcing the handle. The finished top portion of the package after the formation of the handle is in the form of a flap which may be folded flat against contiguous top of the package for convenience of stacking package upon package.

(21) Finished vacuum packages 20 constructed in accordance with this invention can be arranged and stacked in a convenient quantity, such as six packages, and shrink bundled together. The bundled packages can be placed onto a pallet. Multiples of these units can be placed on the same pallet to form a layer. Additional layers of bundled packages may be added to the same pallet until the desired pallet weight and height are obtained. The packages of this invention are under sufficient vacuum pressure inside the package, e.g., of at least 300 mm Hg, to be self-supporting on the pallet and therefore additional support for the packages, such as boxes, is not required.

(22) As should be appreciated by those skilled in the art from the foregoing, packages of the subject invention have an air tight sealed upper end forming a spout which can readily be pulled open, e.g., peeled apart, without resulting in the destruction or tearing of any other portion of the package, particularly the seams, thereby enabling the package to be reclosed. Moreover, the peelable pour spout can be reclosed by simply pressing together the opened portion of the package, whereupon the re-closable connector holds the spout closed. The subject package thus provides an easy to open pour spout and re-closure which can hold the product packaged under vacuum to reduce package space and provide self-support without the need for secondary packaging, such as boxes. Moreover, the package may include a handle to facilitate carrying the package and dispensing the product.

(23) While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.