Bridged tab cut for spiral wound container

A spiral wound type composite container of the type that is typically used for packaging refrigerated pressurized dough products includes, as is typical in such containers, an inner liner, a body wall that is wound about the inner layer so as to define a butt joint, and a label member that is wound about the body wall so as to bind the body wall against expansion as a result of forces that are created by the pressurized contents of the container. As is also typical in such containers, the label member has a tab defined at one portion thereof and a predetermined lead path forming the tab so that a consumer can grasp the tab and tear the label member along the lead path, thereby removing enough of the label member from the body wall so that forces of pressurization will cause the body wall to separate and open. According to one novel aspect of the invention, the lead path is defined on a portion of the label member by at least two discrete cuts, with adjacent cuts being separated by a bridge area, so that the portion of the label member in which the lead path is defined will be strong enough to avoid flagging and premature opening during manufacture and handling, yet will be of an adequate length to reduce the potential of premature mis-directional tearing of the label during opening by a consumer.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to an easy-open composite container for packaging 
various products, particularly products under pressure such as biscuit and 
bread dough and the like. 
2. Description of the Related Technology 
Easy-open composite containers for packaging various products, particularly 
products under pressure, such as refrigerated dough products, are in 
common use throughout the world. These containers are usually formed of a 
spirally-wound paperboard or board stock body wall, an interior or liner 
layer for preventing leakage of the contents from the container and an 
exterior label. The body wall is wound in such a manner as to form a tight 
spiral butt joint at its edges. The label is typically wound about the 
body wall and is secured so as to bind the body wall against expansion as 
a result of forces that are created by the pressurized contents of the 
container. 
In many containers of this type, the label member possesses an integral 
gripping tab for the purpose of opening the container by means of a 
predetermined single lead cut, so that the consumer can grasp the tab and 
tear the label member along a lead path, thereby removing enough of the 
label member from the body wall so that the forces of pressurization will 
cause the body wall to separate at the butt joint, thereby opening the 
container. 
One problem that is present in containers of the type described above is 
that the tab will tend to delaminate from the container and stick 
outwardly, in an effect that is termed "flagging" by those, such as the 
inventors herein, who are familiar with this area of technology. The 
longer the lead cut, the greater the potential for flagging. However, if 
the: lead cut is made too short, the risk of mis-directional tearing 
during the opening process increases. When this happens, the consumer may 
pull the tab so as to rip the label in a direction that deviates from the 
intended lead path, which can result in not enough of the body wall being 
exposed to cause the container to properly open as described above. 
It is clear that a need exists for an improved spiral wound type container 
for packaging pressurized products such as refrigerated dough that has 
reduced potential for both tab flagging and mis-directional tearing during 
opening. 
SUMMARY OF THE INVENTION 
Accordingly, it is an object of the invention to provide an improved spiral 
wound type container for packaging pressurized products such as 
refrigerated dough that reduces the potential for both tab flagging and 
mis-directional tearing during opening. 
In order to achieve the above and other objects of the invention, a spiral 
wound type composite container of the type that is typically used for 
packaging pressurized dough products, includes an inner liner; a body wall 
that is wound about the inner layer so as to define a butt jointed edge; 
and a label member that is wound about the body wall so as to bind the 
body wall against expansion as a result of forces that are created by the 
pressurized contents of the container, the label member having a tab 
defined at one portion thereof and a predetermined lead path defined 
adjacent to the tab whereby a consumer can grasp the tab of the label 
member and tear the label member along the lead path, thereby removing 
enough of the label member from the body wall so that forces of 
pressurization will cause the body wall to separate at the butt joint, 
thereby opening the container; and wherein the lead path is defined on a 
portion of the label member by at least two discrete cuts, with adjacent 
cuts being separated by a bridge area, so that the portion of the label 
member in which the lead path is defined will be strong enough to avoid 
premature opening during manufacture and handling, yet will be of an 
adequate length to reduce the potential of premature mis-directional 
tearing of the label during opening by a consumer. 
These and various other advantages and features of novelty which 
characterize the invention are pointed out with particularity in the 
claims annexed hereto and forming a part hereof. However, for a better 
understanding of the invention, its advantages, and the objects obtained 
by its use, reference should be made to the drawings which form a further 
part hereof, and to the accompanying descriptive matter, in which there is 
illustrated and described a preferred embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S) 
Referring now to the drawings, wherein like reference numerals designate 
corresponding structure throughout the views, and referring in particular 
to FIGS. 1, 2 and 3, a conventional a spiral wound type composite 
container 10 of the type that is in common use for packaging pressurized 
material such as refrigerated bread dough includes, as may best be seen in 
FIG. 4, an inner liner 12, a body wall 14 that is wound about the inner 
liner 12 so as to define a butt jointed edge, and a label member 16 that 
is wound about the body wall 14. As is conventional, the inner liner 12 in 
the preferred embodiment is formed from a foil material that has a backing 
of light kraft paper, but can alternatively be formed from any flexible 
material such as paper, foil, polymeric substrates and laminates thereof 
that are substantially impermeable to moisture, grease, and gasses. The 
body wall 14 is preferably formed from kraft or heavy paperboard of 
varying but conventional thickness. The thickness must be sufficient to 
provide structural support to withstand the selected environment. As is 
also conventional, the label member 16 typically contains printed matter, 
such as an illustration or directions, and serves to protect the body wall 
14 from moisture. Appropriate materials for label member 16 may include 
paper, foil, film, emulsions, coatings and laminates of these materials. 
The label member 16 is bonded to the body wall by an adhesive that will 
permit the label member 16 to delaminate from the body wall when pulled 
with sufficient force during opening. The label member 16 is secured about 
the body wall 14 sufficiently to bind the body wall 14 against expansion 
as a result of forces that are created by the pressurized contents of the 
container 10. 
As may be seen in FIG. 2, the conventional label member 16 possesses an 
integral gripping tab 18 and has a predetermined lead path defined thereon 
adjacent to the gripping tab 18 by a single lead cut 20, so that a 
consumer can grasp the label member 16 by the tab grip 18 to tear the 
label member 16 along the lead path, thereby removing enough of the label 
member 16 from the body wall 14 that the forces of pressurization will 
cause the body wall 14 to separate at the butt joint, thereby opening the 
container 10. As has been discussed above, this type of product design is 
susceptible to the problem of "flagging." The longer the lead cut 20, the 
greater the potential for flagging. However, if the lead cut 20 is made 
too short, the risk of mis-directional tearing during the opening process 
increases. When this happens, the consumer may pull the tab 18 so as to 
rip the label in a direction that deviates from the intended lead path, 
which can result in not enough of the body wall 14 being exposed to cause 
the container to properly open as described above. 
Referring now to FIG. 5, a label 22 for a spiral wound container according 
to preferred embodiment of the invention will now be discussed. As may be 
seen in FIG. 5, label 22 includes an integral gripping tab 24 and has a 
predetermined lead path defined thereon adjacent to the gripping tab 24 by 
two discrete cuts 26, 28, with the adjacent cuts being separated by a 
bridge area 30, so that the portion of said label member 22 in which the 
lead path is defined will be strong enough to avoid flagging and premature 
opening during manufacture and handling, yet will be of an adequate length 
to reduce the potential of premature mis-directional tearing of the label 
during opening by a consumer. 
Referring to FIG. 6, a label 32 for a spiral wound container that is 
constructed according to a second preferred embodiment of the invention 
includes an integral gripping tab 34 and has a predetermined lead path 
defined thereon adjacent to the gripping tab 34 by a plurality of aligned 
discrete cuts 36, with adjacent cuts 36 being separated by bridge areas 
38. As in the previously described embodiment, this construction will 
ensure that the portion of the label member 32 in which the lead path is 
defined will be strong enough to avoid flagging and premature opening 
during manufacture and handling, yet will be of an adequate length to 
reduce the potential of premature mis-directional tearing of the label 
during opening by a consumer. 
The bridges 30, 38 in the above-described embodiments preferably are 
constructed to have a width that is within an outer preferred range of 
about 0.070 inches to about 0.110 inches, and within an inner preferred 
range of about 0.080 inches to about 0.090 inches. Most preferably, the 
bridge areas have a width of about 0.080 inches. 
Looking now to FIG. 7, spiral winding is the preferred process for 
manufacturing the tab cut spiral wound containers. Accordingly, the 
process will now be discussed. The spiral winding process is accomplished 
through the use of a system 40 that includes a continuous spiral wrapped 
driver belt 44 wrapped around a stationary mandrel 42. The driver belt 
brings together the composite materials at a particular angle to form a 
composite tube. As may be seen in FIG. 7, provided in system 40 are a 
supply 46 of liner material, a supply 48 of body wall material, and a 
supply 50 of label material. System 40 is set up so that these materials 
meet at a predetermined angle with respect to the cylindrical axis of the 
mandrel. 
As the winding belt 44 rotates, a continuous strip of inner liner material 
46 is deposited onto the mandrel 42 of the winder. Next, a continuous 
strip 48 of fibrous body wall material which is adhesively coated on the 
surface facing the impermeable inner liner layer 46 is deposited onto the 
mandrel. The abutting edges of the fibrous body wall material 48 define 
the helical butt joint discussed above. As the winding belt 44 rotates, 
the impermeable inner liner 46 and the body wall material 48 are joined 
and form a continuous, cylinder. A helical joint defined by overlapping 
edges of the inner liner 46 preferably includes a heat sealed anaconda 
fold proximate the butt joint. A label layer 50 is then adhesively applied 
to the body wall layer 48, after the label material is scored or cut by a 
tab cutting station 54. At station 54, cuts 26, 28 and bridge 30 are made, 
in the case of the first embodiment, or the cuts 36 and bridges 38 are 
made, in the case of the second embodiment. In the preferred embodiment, 
scoring station 54 includes a scalloped rotary blade for forming the 
respective cuts and bridges. 
The formed tube is then cut to a plurality of discrete lengths. An end 
member is preferably placed onto one end of the container prior to 
inserting a dough product. After inserting the product, the container may 
be sealed by applying a second end member (not shown) to the open end. 
It is to be understood, however, that even though numerous characteristics 
and advantages of the present invention have been set forth in the 
foregoing description, together with details of the structure and function 
of the invention, the disclosure is illustrative only, and changes may be 
made in detail, especially in matters of shape, size and arrangement of 
parts within the principles of the invention to the full extent indicated 
by the broad general meaning of the terms in which the appended claims are 
expressed.