Flexible package with tearing means

The invention refers to a flexible package comprising a plurality of walls including first and second opposing side walls having side seams. At least a first gusset is formed in at least the first side wall, the first gusset comprising an internal panel and an external panel together forming a pocket. At least the first side wall comprises lines of weakness which are at least partially formed in or through the external panel. The lines of weakness are adapted to create an opening in the first side wall.

FIELD OF THE INVENTION

The object of the application relates to a package suitable as a flexible wrapping especially for diapers that are placed in the package in a consolidated form in one or more series. An opening can be made in one side wall of the package manually for individual removal of the package contents.

BACKGROUND OF THE INVENTION

A flexible package with an opening feature is disclosed e.g. in US 2006/0021894 A1. The opening feature is facilitated in a side wall and, upon opening, provides access to the articles contained in the package. The opening can be initiated by using an aperture. The package will tear open along lines of weakness. The lines of weakness extend to an upper edge of the package, while the aperture is arranged somewhat below this edge. Upon opening, the complete aperture is torn downwardly.

One of the disadvantages associated with this package is that it can accidentally tear if it is lifted at the external panel of a gusset. Moreover, the contents contained in the package will easily fall out of the package upon opening, as the opening provided is relatively large.

It is an objective of the present invention, to provide an opening feature for a flexible package, which does not open inadvertently upon a lifting of the package.

Further, it is an objective of the present invention to provide a package with an opening feature, wherein the articles or parts of the articles contained in the package do not fall out of the package after opening but are contained in the package. For example, if the articles are a multiplicity of diapers, the diapers should not fall out of the package after opening.

SUMMARY OF THE INVENTION

The present invention provides a flexible package being capable and being adapted to contain a multiplicity of articles. The package comprises a plurality of walls, including first and second opposing side walls. Each of the side walls has side seams and each of the side walls has an upper and a lower edge.

At least a first gusset is formed in at least the first side wall, whereby the first gusset comprises an internal panel and an external panel, together forming a pocket.

The at least first side wall further comprises a tearing means being at least partially formed in or through the external panel.

The tearing means is adapted to create an opening in the first side wall. The opening is confined by at least an upper section of the internal panel and by at least a lateral section of the side wall.

At least one lateral edge of the upper section of the internal panel is at least partially bonded to an upper edge of the lateral section of the side wall. Further, the lateral section and the upper section form a frame, which is adapted to retain the articles inside the package after creation of the opening.

The present invention further provides a method of manufacturing a flexible package comprising a plurality of walls, including first and second opposing side walls, wherein at least a first gusset is formed in the first side wall and wherein the first gusset comprises an internal panel being covered by an external panel, together forming a pocket. Further, the first side wall comprises a tearing means being at least partially formed in or through the external panel. The method of manufacturing comprises the steps of:

Providing an endless sheet travelling in a machine direction and comprising in cross machine direction a twofold portion and a fourfold portion. The twofold portion comprises two layers and the fourfold portion comprises four layers. The outer layers of the fourfold portion extend into the two layers of the twofold portion. Further, at least one line of weakness is introduced in each layer of the fourfold portion. The line of weakness forms a tearing means being adapted to provide an opening in the side wall. The opening is confined by at least an upper section of the internal panel and by at least a lateral section of the side wall. The upper and lateral sections form a frame, which is adapted to retain the articles inside the package after creation of the opening.

Further, at least one outer layer of the fourfold portion is at least partially bonded with an adjacent inner layer of the fourfold portion for generating the frame.

Finally, all layers of the twofold and fourfold portion are seamed and cut along a side seam extending in cross machine direction.

DETAILED DESCRIPTION OF THE INVENTION

“Diaper” as used herein refers to absorbent articles generally worn by infants and incontinent persons about the lower torso. The diaper may be fastened onto the wearer using tapes or, alternatively, the diaper may have side seams, which are fastened together—both permanently or refastenably—such that the diaper is applied onto the wear like a conventional underwear (i.e. the user will put his legs through the respective leg openings and the diaper is then pulled up to its final position).

“Comprise,” “comprising,” and “comprises” is an open ended term that specifies the presence of what follows, e.g. a component but does not preclude the presence of other features, elements, steps or components known in the art, or disclosed herein. However, the presence of additional other features, elements, steps or components is not required at the terms “comprise” “comprising,” and “comprises” thus also encompasses the terms “consisting of” and “essentially consisting of”.

The flexible package1of the present invention may be rectangular, and may comprise thermoplastic material. Further, the flexible package1comprises a plurality of walls, typically two opposing, first and second side walls2,3, a front wall, a back wall as well as a top wall4an a bottom wall.

Each side wall2,3has an upper edge6,8lying adjacent a top wall4and further has a lower edge7,9lying adjacent the bottom wall of the package1. Each side wall2,3also has two opposing side edges17,18lying adjacent the front and back wall of the package, respectively.

The material of the filled package1is folded over from the front and back wall to the side walls2,3of the package1. Also, the material at least from the top wall4is folded over to the side walls2,3. However, also the material from the bottom wall may be folded over to the side walls2,3. Each side wall2,3comprises a respective side seam19,39to provide a closed package1. The side seams19,39are essentially extending from the upper edges6,8of the side walls2,3towards the lower edges7,9of the side walls2,3.

Furthermore, at least one gusset12is formed in the first side wall2adjacent the upper edge6of the side wall2. The gusset12comprises an internal panel13, which is overlaid by an external panel14. The internal panel13and the external panel14may have the same dimensions and the same shape and may therefore be coextensive. With respect to the embodiment ofFIG. 1, the external panel14may be smaller in width than the internal panel13because parts of the external panel have been removed. In lateral extension along the upper edge6of the side wall2, the internal panel13is at least partially covered by the external panel14, e.g. in a region including the side seam19.

The gusset12of the first side wall2may be at least partially shaped in the form of a triangle pointing down towards the lower edge7of the side wall2. The gusset12formed by the internal panel13being at least partially overlapped by the external panel14. The external panel14is two-ply and therefore comprises two layers of material being folded onto each other, the fold line extending adjacent the upper edge6of the side wall and defines the upper edge of the external panel14.

The external panel14has lateral side edges29,30which may extend substantially parallel to the side edges17,18of the side wall2. The upper edge of the external panel14may be smaller in width than the side wall2. In such embodiments, the internal panel13is only partially overlaid by the external panel14, for example in a region of the side wall comprising the side seam19.

InFIG. 1the lower end portions of the external panel14and of the gusset12are indicated by the dashed fold lines40,41, being symmetrically arranged with respect to the side seam19and extending into the side seam19at an angle of from 40° to 50°; or from 42° to 48° or 45°, upper edge6of the side wall2.

The upper portion of the external panel14as illustrated inFIG. 1provides a kind of tongue- or flap-like appendix serving as a tearing means11. Hence, a user intending to open the package1may grasp the external panel14from above and/or from the side edges29,30and may exert a tearing force directed towards the lower edge7of the side wall, thereby disrupting the internal panel13and possibly also the external panel14and forming an opening35for removing the articles being disposed inside the package1.

The opening may form along at least one line of weakness15,16extending in the side wall2. There may be provided a first15and a second line of weakness16, each of which extending adjacent the opening35to be created in the package1and serving as a weakened structure in the material of the package. The extension and shape of the lines of weakness15,16define at least a part of the shape and geometry of the opening35, because the lines of weakness15,16after disruption of the material coincide with at least one edge of the opening35. Additionally, there may be provided a third line of weakness20connecting the first and second line of weakness15,16and extending in a portion of the internal panel13being covered or overlaid by the external panel14.

The flexible package1may comprise a multiplicity of articles33,34. For example, the package1of the present invention may be used for accommodating a multiplicity of diapers. The diapers33,34may be folded and the multiplicity of folded diapers may be arranged in one or more rows within the package.

A diaper typically has a longitudinal axis and a transverse axis. One end portion of the diaper is configured as a front waist region of the diaper. The opposite end portion is configured as a back waist region of the diaper. An intermediate portion of the diaper is configured as a crotch region, which extends longitudinally between the front and back waist regions. The crotch region is that portion of the diaper which, when the diaper is worn, is generally positioned between the wearer's legs. Further, the transverse axis is typically in the crotch region of the diaper.

In a two-folded diaper, the diaper is folded in the crotch region along its transverse axis or near its transverse axis. In the folded diaper, the front waist region is living adjacent the back waist region and the front and back waist region are substantially coextensive.

Alternatively, the diaper may be tri-folded, whereby one of the front or back waist regions is folded over onto the crotch region where after the remaining waist region is folded over onto the first folded waist region.

The folded diaper comprises two major surfaces. E.g. in a two-folded diaper, the first major surface comprises the front waist region of the diaper and a portion of the crotch region, while the second major surface comprises the back waist region of the diaper and the remaining portion of the crotch portion. However, also a tri-folded diaper has two major surfaces. When placed into the flexible package, the major surfaces should face towards the side walls2of the package1.

If the package1comprises more than one row of diapers, the diapers should be arranged such that in each row, major surfaces33,34face towards the side walls2of the package.

Also, the folded diapers arranged in the package1have an upper part lying towards the top wall of the package and a lower part lying towards the bottom wall.

In the embodiment illustrated inFIGS. 1 to 3only one side wall2comprises opening and tearing means whereas the other oppositely located side wall3comprises gripping means45for lifting and transporting the package1. However, the gripping means is only optional.

The opening35may be created by tearing down the tearing means11or the tongue- or flap-like external panel14. While the external panel14and the associated tearing means11are torn off or torn down, the various lines of weakness15,16,20are disrupted and become disassembled. The disruption of the various lines of weakness15,16,20leads to the creation of the opening35as depicted inFIG. 2. In the closed configuration the third line of weakness20separates the lower edge21of an upper section36of the internal panel13from the upper edge22of the internal panel13. The third line of weakness20is part of the tearing means11, which is torn down for creating the opening35. In the following, the piece, which is torn down, will be referred to as tear-off portion10. In a central section the edge21may comprise a notch23corresponding with a peak portion24of the edge22of the tearing means11.

Further, the tear-off portion10also comprises a lateral side edge26which coincides with a side edge25of a lateral section37of the side wall2. The same applies to the other lateral edge of the tear-off portion or the tearing means11having a lateral edge coinciding with an inner edge of a lateral section38of the side wall2.

The opening35as illustrated inFIG. 2is confined by an upper section36of the internal panel13and by at least one, typically by two lateral sections37,38of the side wall2. The two lateral sections37,38may be symmetrically arranged. The upper and lateral section(s)36,37,38form a frame adapted to retain the articles, e.g. the diapers33,34inside the package1after creation of the opening35.

In the illustrated embodiments, the tear-off motion maybe directed downwards to the lower edge7of the side wall2. In alternative embodiments, the opening35may also extend to other walls of the package1. Then, at least a part of the tear-off portion10extends to one or more other walls, for instance to the front, back, top or bottom wall of the package1. In these alternative embodiments, the opening35may be asymmetric in shape and may also be asymmetrically arranged with respect to the overall geometry and symmetry of the side wall2.

In order to form a frame providing a retaining function for the articles33,34, at least one lateral edge of the upper section of the internal panel is at least partially bonded to an upper edge of the at least one lateral section37,38of the side wall2. In this way, a retaining frame comprising an upper section and at least one lateral section can be provided. In particular, after opening the package1, the frame helps to ensure, that the articles33,34comprised in the package1remain within the package1and do not fall out. The upper part of the articles, e.g. the diapers33,34, is maintained in the package1by the frame. In another embodiment the frame may comprise two lateral sections37,38, being at least partially bonded with the upper section36. The upper section36then connects the two lateral sections37,38and leading to a frame comprising three frame sections. The width of the opening35is governed by the lateral size and lateral extension of the lateral section37,38. The two lateral sections37,38may further be symmetric in shape and geometry. Alternatively, their overall shape and lateral extension may vary. The spacing between the first and second lines of weakness15,16and the width of the tear-off portion depends on the size of the articles33,34to be disposed in the flexible package1. Also, if for example the package1comprises a multiplicity of folded diapers33,34, the size of the opening35will also depend on the number of diaper rows comprised in the package1. If the package1comprises only one row of diapers33,34, the spacing between the lines of weakness15,16will typically be smaller compared to a package1comprising two rows of diapers arranged next to each other, as illustrated inFIG. 2. After opening the package1, the first diaper33,34of each row directly faces towards the opening35with one of its major surfaces.

The package1of the present invention may also contain three or four rows of articles, such as the diapers33,34. In embodiments comprising four rows of articles, two rows are arranged with one of their side portions next to each other while two more rows are arranged similarly below or above the first pair of rows. In these embodiments the tear-off portion, the tearing means11and associated first and second lines of weakness15,16may extend further downward towards the lower edge7of the package1. An opening35being smaller in width or height may be torn open first to have access to the upper two rows of diapers. After the upper two rows of diapers have been used up, the opening can be enlarged by exerting a further tear-off force to the tear-off portion in such a way, that also lower portions of the lines of weakness are disrupted and become disassembled along their entire length.

In such a final opening position, the two lower rows of diapers are securely held and maintained within the package1upon using the upper two rows of diapers. Alternatively, a package1containing four rows of diapers may comprise two separate lines of weakness, wherein the upper line of weakness may be associated with the tearing means11. A lower and separate line of weakness may be implemented into the side wall2independently from the tearing means11and also independent and separate from the upper line of weakness.

If the package1comprises only one row of diapers, the spacing between laterally spaced lines of weaknesses15,16confining the opening35to the left and to the right, may be smaller than the width of the article's major surface, which faces towards the opening35. In this embodiment, after opening the package1along the lines of weakness15,16, one of the diaper's major surfaces faces towards the opening35and the side portions of the diaper's major surface may be retained in the package1by the lateral sections37,38of the side wall2, each of which extending from a line of weakness16to a side edge18and from a line of weakness15to the side edge17of the side wall2, respectively.

If the package1comprises two rows of diapers33,34, the spacing between the lines of weakness15,16will typically be smaller than the width of both rows of diapers33,34taken together. However, the spacing between the first and second line of weakness15,16may be larger than the width of a major surface of one diaper33,34. In this embodiment, after opening the package1along the lines of weakness15,16, the side portion of the diapers major surface lying adjacent the side edge17,18of the side wall2and facing towards the opening35may be retained in the package1by the lateral sections37,38of the side wall2.

However, the other side portion of the diapers major surface lying adjacent a diaper33,34of a neighbouring row of diapers may be retained in the package1mainly due to friction forces between the diapers33,34of neighbouring rows.

In the illustrated embodiments at least one lateral edge of the upper section36of the internal panel13is abutting against an upper edge of the at least one lateral section37,38of the first side wall2. Hence, the at least one lateral edge of the upper edge section36and the upper edge of the at least one lateral section37,38form abutting edges. A juncture connecting the upper section36and the at least one lateral section37,38along at least a part of their abutting edges may comprise a spot-like shape. The juncture may also comprise an elongated shape, bended or straight shape. Typically, the upper section36of the internal panel13and at least a lateral section37,38of the side wall2are bonded along a seam31,32extending from the opening35towards an edge6,17,18of the first side wall2. Alternatively, the seam may extend towards the corner formed between the upper edge6and one of the side edges17,18.

The juncture between the upper section36and the at least one lateral section37,38may also comprise a point-like shape or structure. For the juncture of lateral and upper section at least one bond point is required. There may also be provided a plurality of various bond point arranged along the seam31,32. The seam31,32may extend over the entire length of the abutting edges. Alternatively, the seam31,32may also extend only across a section of the length of the abutting edges. The seam31,32or the juncture between the lateral sections37,38and upper section36of the side wall2typically extends in direct vicinity of the opening35to be created in the side wall, e.g. the seam or juncture extends only along up to 25%, or up to 40% of the length of the abutting edges (starting from the opening). Alternatively, the seam or juncture may extend along the whole length of the abutting edges.

In typical embodiments, the seam31,32may extend at an angle of between 40 to 50 degrees, or from 42° to 48°, or 45°, upper with respect to the upper edge6of the side wall2. In these embodiments, the upper section36and the at least one lateral section(s)37,38form a mitered joint. The seam31,32then extends from a location on the edge of the opening35defined by a crossing point of the lower edge21of the upper section36and the side edge25of a lateral section37towards an upper corner of the package1. At this upper corner the side edge17,18and the upper edge6of the side wall2merge into each other, respectively.

By means of connecting or bonding lateral sections37,38and upper section36of the side wall2as a mitered joint, the frame formed by the lateral section(s)37,38and the upper section36may provide an improved stability and may withstand a pressure or an outwardly directed force emanating from the articles33,34being tightly packed and compressed in the inside of the package1. In particular, when after creation of the opening35various diapers33,34tend to bulge out of the opening35, the way the upper and lateral section(s)36,37,38are mutually bonded or connected may provide an enhanced stability and resistivity against forces and pressures exerting mechanical strain and stress on the package1.

The side wall2has at least a first line of weakness15,16separating the tear-off portion10and the at least one lateral section37,38of the side wall2. Typically, the line of weakness15,16begins at an inner edge or at an inner location (e.g. a corner, if the frame takes a rectangular shape) of the frame being formed by the at least first lateral section(s)37,38and the upper section36of the internal panel13of the side wall2. The line of weakness15,16may further extend towards a lower edge7of the first side wall2. Typically, the line of weakness15,16does not extend all the way down to the lower edge7but ends at a distance from the lower side edge7. In such an embodiment, the retaining frame formed after opening the package1entirely surrounds the opening35, such that each lateral, upper or lower edge of the opening35has a certain distance to an associated side edge6,7,17,18of the side wall2.

The opening defined by the lines of weakness15,16,20may be quadratic, rectangular, oval or round in shape. Alternatively, the opening may take any other form. Also, the opening35may vary in width. Typically, in an upper portion adjacent or close to the upper section36of the side wall2, the opening35may be narrower than in a lower portion of the opening35. Consequently, the lines of weakness15,16specifying the shape of the opening35may diverge with respect to each other as the extend from an upper portion to a lower portion of the side wall2. The shape of the lines of weakness15,16may have the form of a straight line or may comprise bended or curved portions, featuring a concave or convex shape.

In the illustrated embodiment ofFIG. 1, the lines of weakness15,16have an upper portion27featuring a rather straight shape and being arranged substantially parallel to the elongation of the side edge17,18of the side wall2. The lines of weakness15,16further have a lower portion comprising a bended or curved shape. In these lower portions28, the lines of weakness15,16not only extend downward towards the lower edge7but also extend outwardly towards respective side edges17,18of the side wall2.

Hence, along upper sections of the lines of weakness15,16, the opening35is somewhat narrower compared to lower sections of the lines of weakness being closer to the lower edge7of the side wall2.

Those parts of the articles33,34lying adjacent the wider and lower section of the opening35may more easily bulge out through the opening35. Thus, it is easier for a consumer to grip the article (e.g. a folded diaper33,34) upon opening the package1. The article (e.g. the folded diaper33,34) lying closest to the opening35can be easily taken by the consumer in the area of the article (e.g. the folded diaper33,34), which has bulged out of the opening35. Alternatively, the first article (e.g. the first folded diaper33,34) and one or more of the following articles (e.g. folded diapers) may be taken out together, provided that the lateral width of the lower portion of the opening35allows more than one article (e.g. folded diaper) of the row to bulge out of the opening.

Also in embodiments wherein the package1comprises only one row of articles such as diapers33,34, the width of the opening35at an upper portion may be smaller than a width at a lower portion of the opening35. If the package1comprises two rows of diapers33,34, and the lines of weakness15,16each comprise upper and lower section27,28, the distance between lower sections of the lines of weakness15,16may be smaller than the width of both rows of diapers33,34taken together. However, the distance between lower, eventually bended sections28of the lines of weakness15,16may be larger than the width of a major surface of a diaper33,34.

Further, the line of weakness or the various lines of weakness15,16,20may extend into the seam31,32connecting or bonding the upper section36of the internal panel13with the lateral sections37,38of the sidewall. Such an arrangement is beneficial because the lines of weakness15,16,20then inherently provide predetermined breaking lines of the side wall2adjacent to the seam31,32, inherently providing a reinforced structure due to an at least partial doubling of material. Practically, in order to form the seam31,32lateral and upper portions of the upper section36and the lateral sections37,38substantially overlap.

Further, not only one but at least two lines of weakness15,16, namely the first and/or second line of weakness15,16and the third line of weakness20may both extend into a respective seam31,32. Typically, the innermost portion of the seam31,32lying adjacent an upper left or an upper right location (e.g. corner) of the opening35overlaps or coincides with a junction of the first line of weakness15and the third line of weakness20; or with a crossing or junction of the second line of weakness16and the third line of weakness20.

The various lines of weakness15,16,20may comprise a structural weakening being adapted to disassemble or to disrupt upon exertion of a tearing-off force applied via the tearing means11. Further, the lines of weakness15,16,20may comprise a perforation or a zigzag-structure.

The seams31,32connecting the upper section36of the internal panel13with lateral sections37,38of the side wall2extend at least into or over the first and second lines of weakness15,16. Moreover, the seam31,32may further extend to the side seam19of the first side wall2. In typical embodiments, this side seam19is arranged substantially equidistant from the lateral side edges17,18of the first side wall2. If the seam31,32begins at an upper side corner of the first side wall2, it will extend onto or across at least one line of weakness15,16,20, in the closed configuration of the package1. In such embodiments where the seam31,32extends from an upper lateral corner of the side wall2to the side seam19, which in turn typically extends across the entire side wall2from the lower edge7to the upper edge6, the tearing means11becomes structurally reinforced, thus helping to ensure, that the tear-off portion10or the tearing means11itself does not disassemble and break during an opening of the package1. Hence, even in circumstances, where the tongue-like appendix of the tearing means11is gripped near a lateral side edge29,30, the portion of the seam40,41extending into the gusset12should provide a sufficient mechanical stability such that during a tear-off procedure the tearing means11remains in its entirety as e.g. illustrated inFIG. 2.

As further depicted by the dashed lines40and41inFIG. 2, the portion of the seam31,32extending into the tearing means11is typically co-aligned with fold lines, along which an inner layer63,64and an outer layer61,62of the external panel14forming the tearing means1are folded in order to form the triangle-shaped pocket or gusset12. Hence, the seam and its consecutive and co-aligned portions31,41as well as32,40may be adapted to bond the upper section36of the internal panel13with lateral section17,18of the side wall2as well as to bond an inner layer63,64and an outer layer61,62of the two-plied external panel14.

The fold lines or seam portions40,41typically encompass the first gusset12of the first side wall2towards its lower edge7, as can be seen inFIG. 1.

The external panel14comprises a tongue-like appendix which can be gripped to tear open the package. The external panel may further comprise a smaller lateral width compared to the distance between opposing side edges17,18of the first side wall2. Consequently, the external panel14has a first and a second side edge29,30confining the external panel in lateral direction. If a part of the external panel14has been cut away, at least a lateral portion of the upper section36of the internal panel13is not overlaid by the external panel14but directly contributes to the outer appearance of the side wall2. The typically two-plied external panel14comprises a fold line connecting the two layers of the external panel14. This fold line is adjacent to the upper edge6of the side wall2, when the package1is closed. Along the at least one side edge29,30, the inner and outer layers of the external panel14may be mutually unconnected. Alternatively, the external panel14and its inner and outer layers may be bonded or connected along the side edge29,30.

In an alternative embodiment, the external panel14may be co-aligned with the internal panel13but may further comprise a line of weakness transforming into a slit upon opening of the package, wherein the slit coincides with side edge29,30of the external panel14forming the tear-off portion10. Instead of such an additional line of weakness, the external panel may also be directly provided with a slit, at least partially separating the external panel into various portions.

The slit may have any suitable shape and geometry and separates the tearing means11from a residual portion of external panel14which does not contribute to the tear-off portion10. The slit may extend in vertical direction and/or may be an elongation of the first and/or second line of weakness15,16. It may also extend at an angle with respect to the lines of weakness or with respect to the upper edge6of the package1. For instance, the slit may extend along the seam30,31at an angle of between 40° to 50°, 42° to 48° or at an angle of 45°. The slit or the line of weakness may extend from an upper edge6of the side wall2into the seam31,32. The residual portion of the external panel14being disposed outside the tongue-like appendix may be connected or bonded to the internal panel by means of an adhesive or by means of a bonding or welding procedure.

In typical embodiments, as exemplary illustrated inFIGS. 1 and 2, the at least first side edge29,30of the external panel14extends to the seam31,32. Additionally, the at least first side edge29,30may be aligned parallel to the at least first line of weakness15,16. From another point of view, the seam31,32traverses or intersects the alignment of side edges29,30and the line of weakness15,16directly at a juncture connecting side edges29,30and the consecutive line of weakness15,16.

In embodiments, where the side edges29,30of the external panel14are separately seamed in order to bond the two layers forming the two-plied external panel14, the respective layers of the external panel14may no longer have to be seamed along the fold lines40,41. Vice versa, if the outer and inner layers of the external panel14are bonded along their lower fold lines40,41there may be no need to bond or to connect the two layers along the side edges29,30of the external panel. Typically, at least one seam is introduced into the external panel14, either along the fold lines40,41or along the side edges30,29. Otherwise, the content of the package1could be accessible from outside even before the tearing means11is torn away.

The tearing means11is typically comprised only by one of the opposing side walls2,3of the package1. As for example illustrated inFIG. 3, the second side wall3differs from the design of the opposing first side wall2in that it does not comprise tearing means11in order to create an opening35in the side wall3. In contrast, the side wall3may comprise a gripping means45adapted to provide an easy and intuitive transporting and lifting of the package1. The opposing side walls2,3of the package1provide different and spatially separated means, either for transporting and gripping or for opening of the package1. By arranging gripping means45and tearing means11at different and opposing side walls2,3of a package1, an inadvertent opening of the package1upon lifting, e.g. from a shelf can be effectively prevented. In detail, the gripping means45provided at the side wall3are not adapted to create an opening35in the package1whereas the tearing means11provided at the opposing side wall2are rather unsuitable to grip the package, e.g. for transportation or lifting purpose.

The second side wall3of the package1also comprises at least a second gusset42comprising an internal panel43and an external panel44together forming a second pocket. The second side wall3further comprises a gripping means45being formed in or through the external panel44. The gripping means45may be configured as an aperture and/or may be configured as a slit46, whereby the gripping means may take various shapes as long as it ensured, that one or more fingers of a person's hand fit through the gripping means45to allow lifting and transporting the package1. The gripping means45may be formed as an aperture by removing a portion of the external panel44. Alternatively, the gripping means45may be formed as a slit in or through the external panel14, i.e. without removing any material when forming the gripping means45.

Moreover, the gripping means45can be formed as a weakened area, such as an area being at least partially circumvented by a structural weakening50, such as a perforation. In such an embodiment, the perforation or structural weakening may be transformed into a slit when a user, intending to lift the package1, is gripping through the pocket or gusset42with his fingers, thereby at least partially breaking the perforation. In these embodiments, the one or more fingers of a person of course only have to fit through the gripping means45after the perforation has been broken. As illustrated inFIG. 3, the gripping means comprises a substantially horizontally aligned slit adjacent a lower edge51of an upper portion of the external panel44, which forms a strap extending across the entire width of the side wall3adjacent to the upper edge8of the side wall3.

In an alternative embodiment, as e.g. depicted inFIG. 9, the gripping means45comprises a substantially oval- or rectangular-like shape, wherein an inner portion46is entirely circumvented by a structural weakening50being in turn encompassed by a structure of reinforcement52. The strap49of the external panel44is that part of the second side wall3extending in height from an upper edge of the aperture or the slit46of the gripping means45to the upper edge8of the external panel44. The strap49is adapted to be grasped manually from below in order to lift the package1.

Furthermore, the strap49may also be grasped from above to lift the package1. Hence, the user may enter with his finger(s) into the pocket or gusset42from the upper edge8between the internal panel43and the external panel44. As the finger tips proceed they may reach through or they may penetrate the external panel44in the region of the gripping means45being designed as an aperture or being alternatively designed as a structural weakening to be broken upon a first gripping.

In any gripping manner, the hand of the user is clasped around the strap49allowing for an easy and intuitive raising and transporting of the package1. The strap49takes up the force manually applied and added directly above the gripping means45. When a package is lifted up, the strap49provides sufficient resistance to transfer the force to the rest of the side wall3and to the package1without tearing or disassembling the strap49or the respective side wall3. Thus, unintentional opening of the package1can be effectively prevented.

Since the strap49and its associated gripping means45are separately designed and arranged with respect to the tearing means11, the strap49and its gripping function is nearly not affected by an opening of the package1at the opposing side wall2. Therefore, even after the package1has been opened, the strap49can still be used to assist in lifting or transporting the package1.

The height of the strap49extending from the gripping means45to the upper edge47of the external panel44and hence to the upper edge8of the side wall3may range from 10 millimeters to 50 millimeters. These dimensions allow for convenient carrying and ensure that the strap49does not tear apart upon lifting of the package1. The gripping means45may have an upper edge corresponding to the lower edge51of the strap49.

As further illustrated inFIGS. 3 and 8, the gripping means45is formed through or in the external panel44of the second gusset42. Hence, a portion of the pocket, which is covered by the gusset42, extends from a lower edge of the gripping means45towards the lower edge9of the side wall3. If the pocket takes the form of a downward pointing triangle, a portion of the pocket extending from a lower edge of the gripping means45downwards will also take the form of a, however smaller, triangle. This smaller triangle can be further used to slit at least a part of a user's finger into, providing a universal way of gripping and lifting the package1.

The way, the gusset42is configured in the second side wall3, is well-known in the art. The external panel44comprises two layers, an inner layer and an outer layer. The gusset42has a triangle-shaped geometry and it is confined by two fold lines70,71and by an upper edge47of the external panel44as illustrated by way of example inFIG. 3. In order to reinforce the gripping means45, the inner and the outer layers of the external panel44may be reinforced adjacent lateral and upper as well as lower edges of the gripping means45. The structure of reinforcement52as e.g. depicted inFIG. 9may be introduced by bonding, joining or connecting the inner and outer layer of the external panel44along a predetermined structure. The gripping means45as illustrated inFIG. 9comprises an aperture46being executed as a cut away of material over a region of approximately rectangular shape comprising oval or curved edges. The aperture46is circumvented or surrounded by a closed structure of reinforcement52. However, the reinforcement structure52is not confined to such embodiments, wherein the gripping means45is designed as an aperture46. Such reinforced gripping means can also be facilitated in any other way or embodiment as described above.

It may be desirable to reinforce the inner and outer layers of the external panel44only adjacent the lower edge51of the strap49. In particular, it may be desirable to reinforce the layers in the respective lower area of the strap49being adjacent the upper edge of the gripping means45, since upon lifting up the package1, the strap49will typically experience the major strain compared to the gripping means45arranged below.

To reinforce the external panel44, e.g. in the vicinity of the gripping means45, the inner and outer layer of the external panel44may be bonded to each other adjacent the entire upper and/or lower edge of the gripping means45. Alternatively, the inner and outer layer may be bonded to each other at least adjacent the upper or lower edge of the gripping means45.

The bonding of the inner and outer layers can be achieved, e.g. by adhesive bonding, pressure bonding as well as by means of thermal bonding or ultrasonic bonding, especially, if the flexible package is made of thermoplastic material. Other suitable bonding means known in the art are also within the scope of this invention. The bonding of the inner and outer layers can be done intermittently adjacent the edges of the gripping means45or can be executed as a continuous bonding line extending adjacent the upper and/or lower edge of the gripping means45.

There are several alternative ways of providing the package with gripping means. They do not necessarily have to be disposed at the side wall3opposite to the side wall2comprising the tearing means11. Alternatively, they may comprise a lug or a strap-handle being attached to the front or back wall of the package. Also, the gripping means may be attached to the top wall4. These alternative gripping means may further be detachably fixed to the package1and may be released for gripping purpose by a user interaction.

FIGS. 4 through 6, schematically illustrate a possible way of manufacturing the flexible package1. The manufacture of the package1may start from an endless sheet travelling in machine direction58. The sheet as illustrated inFIG. 4and shown in cross section along A-A inFIG. 5is folded multiple times with respect to fold lines54and55in such a way, that the folded sheet, in machine direction58, comprises a twofold portion57and a fourfold portion56. The fold lines54and55extend in machine direction58along machine direction58. In cross machine direction59, the sheet has a lateral or marginal edge55and66. The upper marginal edge55of the fourfold portion56is coextensive and therefore identical to the fold line55.

The fold line55therefore forms an upper marginal or lateral edge of the folded sheet, whereas the other fold line54separates the twofold portion57and the fourfold portion56. The folded sheet further has a lower edge66, which is at the twofold portion57. The lower edge66of the twofold portion57later on forms at least a part of the bottom wall of the package1, whereas the opposing edge55of the fourfold portion56forms a portion of the top wall4of the package1.

The fourfold portion56of the M-shaped folded sheet comprises two outer layers61,62forming at the same time the two layers61,62of the adjacent twofold portion57. Sandwiched between the two outer layers61,62, the fourfold portion56further comprises two inner layers63,64disposed adjacently in an overlapping manner. The two inner layers63,64as well as the two outer layers61,62are portions of the folded endless sheet. The inner layers63and64mutually merge at the fold line54and each inner layer63,64merges into the adjacent outer layer61,62at the fold line55.

After having folded the endless sheet to an M-shaped fold comprising a twofold portion57and an adjacent fourfold portion56in cross machine direction59, at least one line of weakness15,16is introduced in each layer61,62,63,64of the fourfold portion56such that the lines of weakness are preferably introduced in the same location of the overlaying layers61,62,63,64. The line of weakness forms the tearing means11for providing an opening35in the at least first side wall2. The line of weakness15,16may be implemented as a perforation, a zigzag-structure or as a partial or complete cut or slit in or through the material of the fourfold portion56. Furthermore, at least one outer layer61,62of the fourfold portion56is partially bonded or connected with an adjacent inner layer63,64of the fourfold portion for generating a frame adapted to retain the articles3334inside a filled package1.

In general, it is sufficient to bond the at least one outer layer61,62and the adjacent inner layer63,64of the fourfold portion56in a singular point or region typically in direct vicinity of the line of weakness15,16. In order to generate a frame comprising an upper section36and two lateral sections37,38it is suggested to at least partially bond the outer layer61with the adjacent inner layer63and to bond the outer layer62with the adjacent inner layer64in an overlapping manner, whereby the adjacent inner layers63and64remain separated from each other and remain practically unaffected by the bonding with the adjacent outer layers61,62.

Bonding of adjacent outer and inner layers61,62,63,64as well as introducing at least one line of weakness15,16can either be executed simultaneously or sequentially. It is further possible to at least partially bond adjacent inner and outer layers61,62,63,64before the at least one line of weakness15,16is introduced into at least the fourfold portion56. Alternatively, it is also possible to bond the adjacent layers61,62,63,64after the line of weakness15,16has been introduced in the above described way.

After introduction of the at least one line of weakness15,16and after a partial bonding of adjacent inner and outer layers63,64,61,62, all layers61,62,63,64of the endless sheet are sealed and cut along a side seam19,39,53extending substantially in cross machine direction59. The side seam bonds and connects all layers of the respective twofold and fourfold portion57,56and further splits first and second packages60,65being consecutively arranged in the endless sheet. The sealing and cutting may be performed simultaneously by means of a combined seaming and cutting stage. By means of the sealing, all layers61,62,63,64of the endless sheet become inherently provided with a side seam19,39connecting in one step the two layers61,62of the twofold portion57as well as all four layers61,62,63,64of the fourfold portion56Forming and generating of the side seam19,39as well as cutting or disassembling of adjacent and consecutive packages60,65may be executed in a single step by means of the a convenient seaming and cutting apparatus.

By way of comparing the illustrations ofFIGS. 4,5as well asFIGS. 7 and 8, the sealing of the various layers61,62,63,64and their final arrangement in the package1becomes apparent. The side seam53and the cutting line separating adjacent and consecutive packages60,65also form the first side seam19of the first side wall2of a package60and the second side seam39of a second side wall3of a consecutive package65. Both side seams19and39connect outer layers61and62and form left and right lateral portions of side walls2,3of the package1.

Furthermore, the side seams19,39are also bonding the two inner layers63,64in cross-machine direction. With respect toFIGS. 1 and 3, these portions of the inner layers63,64in close vicinity to the side seam19,39later on form an inner layer of the external panel14,44, whereas respective portions of the outer layers61,62form the outer layer of the external panel14,44. The internal panel13and its upper section36of the first side wall2is entirely formed by the inner layers63,64.

Further, it is suggested to bond the outer layers61,62with adjacent inner layers63,64along a seam31,32extending in the fourfold portion56of the endless sheet. The seam31,32should be confined to the fourfold portion56. Typically, this seam31,32only bonds the outer layer61with its adjacent inner layer63and the outer layer62with its adjacent inner layer64. Bonding of adjacent outer and inner layers61,62,63,64is executed in such a way, that the inner layers63,64remain separated from each other all the way along the seam31,32. Since the two seams31,32are introduced in the fourfold portion56of the endless sheet in an overlapping manner, after introducing the side seam19,39and cutting consecutive packages60,66along the line53, the side wall2, as illustrated inFIG. 7, has a substantially symmetric configuration with respect to the side seam19.

Further, each seam31,32intersects or extends into lines of weakness15,16, thereby specifying the width of the upper edge of the opening35to be generated by the tearing means11, respectively.

With respect toFIG. 7, the lines of weakness15,16may extend up to the upper edge6of the side wall2. The lines of weakness15,16in particular their upper straight section27at least extend into the seam31,32. The external panel14as it extends above the crossing points of the seam31,32and the lines of weakness15,16may comprise lateral edges29,30confining the lateral width of the tongue-like appendix of the external panel14. Furthermore, the external panel may also be cut from an upper edge6of the side wall2adjacent the seam31,32down to the crossing point of the seam31,32and the lines of weakness15,16in order to remove a triangle-shaped section48of the external panel14. By removing a triangle-shaped portion48being confined by the lateral edges29,30, the upper edge6of the side wall2and the seams31,3, the tongue- or flap-like appendix of the external panel14providing an intuitive and universal tearing means11can be provided.

Alternative to the removal of the triangle-shaped portion48, the external panel14may comprise a slit or an additional line of weakness providing a separation of the flap-like appendix from the external panel14.

The side seams19,39extending substantially in cross machine direction59as well as the seams31,32may be introduced into the various layers61,62,63,64of the endless sheet separately or simultaneously. Furthermore, with respect toFIGS. 4 and 6, adjacent to the side seam39a structure of reinforcement52extending into the side seam39may also be introduced into pairs of overlapping outer and inner layers61,63as well as62,64. Additionally, also a structural weakening50, which may typically designed as a perforation or a slit may be introduced adjacent the structure of reinforcement52. The structure of reinforcement52may be introduced simultaneous with the structure of weakening50. However, it may also be advantageous to introduce the structure of reinforcement52before the structural weakening50is applied to the endless sheet.

The structure of reinforcement52may take any shape. It can be oval, circular, or may have a slit like geometry. Further, the structure of reinforcement52should be disposed or arranged at a distance from the edge55of the fourfold portion56. The distance between the structural weakening50and the lateral edge55defines the height of strap49in the final package. Hence, the edge55corresponds to the tipper edge6,8of the side walls2,3.

The outer layer62can be joined or bonded with its adjacent inner layer64by any kind of suitable joining or bonding means, such like ultrasonic bonding, thermal bonding or pressure bonding. Accordingly, the outer layer61is joined or bonded with the adjacent inner layer63. However, the two inner layers63,64are not joined or bonded to each other when introducing a structure of reinforcement. For instance, when applying ultrasonic-, thermal- or pressure bonding, it has to be ascertained, that the two inner layers63,64remain separated from each other.

For a selective and systematic separation of the inner layers63,64, it is suggested that a separating means or a separating agent may be inserted or disposed between the inner layers before the outer layer61is bonded or joined with the adjacent inner layer63and when the outer layer62is bonded or joined with the inner layer64along the structure of reinforcement52. Especially when thermal or ultrasonic bonding is applied for introducing the structure of reinforcement52, it is advantageous to make use of heat resistant separating means, such as a heat resistant sheet which may optionally be the coated with a non-stick medium or with a non-stick coating.

In the illustrated embodiments, the structure of reinforcement52is of closed shape and the structural weakening50is adjacently arranged inside the structure of reinforcement52. Typically, the gripping means12and the aperture37or the slit are surrounded by the structure of reinforcement52. However, the structure of reinforcement52does not have to completely encompass the structural weakening50.

The side seams19,39extending in cross machine direction59comprise a certain width in machine direction58. A combined width of both side seams19,39is approximately between 3 and 10 millimeters allowing, that positioning of the side seams19,39as well as positioning of the seam and cut line53does no longer need to be absolute precise but may vary within certain limits. Even though when the side seam is unequally divided into side seams19,53of consecutive packages60,65along a seam and cut line53, a sufficient seaming and sealing of the respective side walls2,3of the packages60,65can still be achieved. In typical embodiments, the side seams19,39disposed in the fourfold portion56are wider in machine direction than the seam53being introduced in the twofold portion57of the endless sheet. For instance, the combined width of the seams19,39is twice as large as the width of the seam53. The width of each seam19,39may vary between 3 to 10 mm. Before the side seams19,39are introduced into the material, thereby joining and bonding the various layers61,62,63,64and disassembling to adjacent packages60,65, the lines of weakness15,16may be introduced at least into the fourfold portion56. The lines of weakness15,16, may also extend into the twofold portion57, respectively. The lines of weakness15,16are typically introduced simultaneously in all layers61,62,63,64of the fourfold portion56and the twofold portion57. Consequently, the lines of weakness15,16substantially take the same overlapping shape in all these layers61,62,63,64. The lines of weakness15,16with their lower or bended portion28traverse the fold line54separating the twofold portion57from the fourfold portion56of the endless sheet. After seaming and disassembling adjacently manufactured packages60,65along the cut and seam line53and after filling the packages60,65with articles33,34the first15and second16lines of weakness become apparent, as depicted inFIGS. 1 and 7, both extending across the seam31,32.

FIG. 6schematically illustrates the two packages60,66ofFIG. 4when not bonded or joined along the side seams19,39and the seams31,32but when unfolded with respect to the fold lines54and55. However,FIG. 6only serves illustrative purposes; the configuration shown inFIG. 6does not occur during manufacture of the package according to the method of the present invention.

There, the two outer sections61and62correspond to the two outer layers ofFIG. 5, whereas the inner sections63and64correspond to the two inner layers.FIG. 6is only exemplary for illustration purpose. In a real life situation, the seams31and32are joined to each other and corresponding reinforcement structures52of the sections61and63as well as62and64are mutually joined or bonded.

The lines of weakness15,16are symmetrically present in the two outer sections61,62as well as in the two inner sections63,64. When the sections are mutually bonded and form various partially overlaying or overlapping layers61,62,63,64the first line of weakness15extends into the seam31of the section64and the second line of weakness16extends into the seam32of the section63. A third line of weakness20extends between the first and the second lines of weakness15,16. Alternatively, the three lines of weakness may also be interpreted as a single continuous line of weakness having a first, second and third section,15,16,20. Upon filling of the package60,65,1the third line of weakness20extends within the internal panel13being almost entirely covered and overlaid by the external panel14.

In the example ofFIG. 4, the lines of weakness15,16traverse the fold line54. Insofar, in the fourfold portion56, the lines of weakness15,16comprise an upper straight section27as well as a lower bended section28. In the illustrated embodiment, the lower residual part of the bended or curved section28of a line of weakness15,16extends in the twofold portion57of the endless sheet. That part of the bended portion28of the lines of weakness15,16extending in the fourfold portion56transforms into a peak portion24and a respective notch23in the internal panel13of the side wall2.

The structure of reinforcement52may be of arbitrary shape. It can be oval, circular, or may have a straight shape. Further, the structure of reinforcement52should be disposed or arranged at a distance from the lateral edge55of the fourfold portion56. The distance between the structural weakening50and the lateral edge55defines the height of the strap49of the second side wall3of the package1.