Abstract:
A flexible self-standing package and method for making the same provides for a package that has its own support mechanism. Thereby, a package, such as a snack food package, can be displayed in an upright position without the need to be placed against another package or wall. To achieve this, the package is formed with a support flap formed extended away from the tube of the package. When the package is positioned to stand, a pocket forms between the support flap and tube of the package to provide support.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Technical Field  
           [0002]    The present invention relates to flexible packages, and the method for making same. More particularly, the present invention relates to flexible packages, and the method for making the same that are self-standing. The invention allows for use of flexible packages that can be stood upright without the need to be placed against other objects.  
           [0003]    2. Description of Related Art  
           [0004]    Vertical form, fill, and seal packaging machines are commonly used in the snack food industry for forming, filling, and sealing bags of chips and other like products. Such packaging machines take a packaging film from a sheet roll and forms the film into a vertical tube around a product delivery cylinder. The vertical tube is vertically sealed along its length to form a back seal. The machine applies a pair of heat-sealing jaws or facings against the tube to form a transverse seal. This transverse seal acts as the top seal on the bag below and the bottom seal on the package being filled and formed above. The product to be packaged, such as potato chips, is dropped through the product delivery cylinder and formed tube and is held within the tube above the bottom transverse seal. After the package has been filled, the film tube is pushed downward to draw out another package length. A transverse seal is formed above the product, thus sealing it within the film tube and forming a package of product. The package below said transverse seal is separated from the rest of the film tube by cutting across the sealed area.  
           [0005]    The packaging film used in such process is typically a composite polymer material produced by a film converter. For example, one prior art composite film used for packaging potato chips and like products is illustrated in FIG. 1 a,  which is a schematic of a cross-section of the film illustrating each individual substantive layer. FIG. 1 a  shows an inside, or product side, layer  16  which typically comprises metalized oriented polypropylene (“OPP”) or metalized polyethylene terephtalate (“PET”). This is followed by a laminate layer  14 , typically a polyethylene extrusion, and an ink or graphics layer  12 . The ink layer  12  is typically used for the presentation of graphics that can be viewed through a transparent outside layer  10 , which layer  10  is typically OPP or PET.  
           [0006]    The prior art film composition shown in FIG. 1 a  is ideally suited for use on vertical form and fill machines for the packaging of food products. The metalized inside layer  16 , which is usually metalized with a thin layer of aluminum, provides excellent barrier properties. The use of OPP or PET for the outside layer  10  and the inside layer  16  further makes it possible to heat seal any surface of the film to any other surface in forming either the transverse seals or back seal of a package.  
           [0007]    Typical back seals formed using the film composition shown in FIG. 1 a  are illustrated in FIGS. 2 and 3. FIG. 2 is a schematic of a “lap seal” embodiment of a back seal being formed on a tube of film. FIG. 3 illustrates a “fin seal” embodiment of a back seal being formed on a tube of film.  
           [0008]    With reference to FIG. 2, a portion of the inside metalized layer  26  is mated with a portion of the outside layer  20  in the area indicated by the arrows to form a lap seal. The seal in this area is accomplished by applying heat and pressure to the film in such area. The lap seal design shown in FIG. 2 insures that the product to be placed inside the formed package will be protected from the ink layer by the metalized inside layer  26 .  
           [0009]    The fin seal variation shown in FIG. 3 also provides that the product to be placed in the formed package will be protected from the ink layer by the metalized inside layer  36 . Again, the outside layer  30  does not contact any product. In the embodiment shown in FIG. 3, however, the inside layer  36  is folded over and then sealed on itself in the area indicated by the arrows. Again, this seal is accomplished by the application of heat and pressure to the film in the area illustrated.  
           [0010]    As noted, a benefit of both the prior art fin seal and lap seal design is the containment of the product in the package by a barrier layer (the metalized inside layer) that keeps ink and solvent levels in the package to a minimum. Ink and solvent levels in fatty food packages are frequently regulated to insure product safety. It may be desirable, however, to provide a graphics capability inside a package. This would allow for promotional information or coupons to be maintained inside the package and only accessible after the consumer has opened the package. For example, a promotional prize campaign could be offered with the prize announcements being maintained inside the package. Likewise, coupons offering product rebate rewards, promotional prize points, or discounts on products could be maintained within the sealed package.  
           [0011]    One prior art method used to provide a graphics capability inside the package involves the use of a paper insert dropped with the product into the package during filling. When the consumer opens the package, the paper insert can be removed for viewing and use. This method has several drawbacks, however. The reliability of placing a single paper insert in each bag (by dropping the paper with a weighed amount of product) is a major consideration, particularly in small packages. A capacity issue is raised by the need to rent inserters to be used during the filling process. Foreign matter detectors are also frequently set off by the detection of the paper insert within the bag. The insertion of a piece of paper can raise the solvent level in the package beyond acceptable levels. All of the above greatly adds to the expense of each single package.  
           [0012]    Another approach to providing graphics within the bag would involve the application of the graphics directly to the inside metalized layer  16  shown in FIG. 1 a.  The application of such graphics can be accomplished using an inkjet printer. However, this method likewise raises a capacity issue, since present technology converters produce packaging film at a speed of 1500 to 2000 feet per minute, while the capacity of present inkjet printer heads is approximately 300 feet per minute. Additional modification to converters must be made in order to keep the inkjet printing in register with the graphics formed by the ink layer  12 . All of the above considerations again add to the cost of the package. In addition, the United States Food &amp; Drug Administration does not presently allow for the use of an ink-carrying layer that comes into contact with a fatty food.  
           [0013]    Another prior art approach to this issue is illustrated in FIG. 1 b,  which is again a schematic cross-section of a packaging film. As with the embodiment shown in FIG. 1 a,  the embodiment shown in FIG. 1 b  comprises an outside OPP layer  10  followed by an ink layer  12 , a laminate layer  14 , and a metalized OPP or PET layer  16 . However, an additional laminate layer  14 ′ is applied to the metalized layer  16  so that an additional ink layer  12 ′ and OPP or PET layer  10 ′ can be used as the new inside layer  10 ′. The use of the ink layers  12 ,  12 ′ as the second to last layer on both the outside and inside of the package allows for a full graphics capability on both the outside and the inside of the film. The additional film, however, adds approximately sixty percent (60%) to the cost of the material when compared with the embodiment shown in FIG. 1 a.  Overall capacity is also cut in half, since the film must be run through a typical converter twice. Further, since the material is 60% thicker, it cannot be run on a vertical form and fill machine at speeds as high as that used to make packages out of the embodiment shown in FIG. 1 a.  This is because longer dwell times must be used to form all the seals involved. As with the inkjet printer solution, the embodiment shown in FIG. 2 a  also requires additional efforts to keep the inside graphics and outside graphics in registration. Importantly, the embodiment shown in FIG. 1 b  again places ink inside a functional barrier layer, the metalized layer  16 , which is not presently permitted for direct contact with many foods by the United States Food &amp; Drug Administration.  
           [0014]    In addition to ink and solvent concerns with package construction, packages, particularly with snack foods, need to be displayed to consumers. These packages are usually displayed in markets in designated areas, such as a supermarket aisle. There, packages are typically aligned so as to stack up against other packages while they rest on a shelf. As consumers remove packages from the shelf, this leaves packages to on its side if not properly supported. To encourage consumer purchases, markets prefer to have their products at the end of the store shelves leaving any empty space behind the products. With prior art packages as described above, it is not possible to leave empty space behind the packages because the packages cannot support themselves as would a boxed or canned product. Therefore, the only solutions are to leave the prior art packages toward the back of the shelf or to design shelves that have minimal depth, both of which are undesirable.  
           [0015]    Consequently, a need exists for a package construction and method that allows for self-standing packages. A self-standing package for snack foods would allow packages to be displayed more effectively to consumers at the end of shelves without the need for other packages or alternatives for support. Additionally, it would be beneficial to have such self-standing packages to be manufactured relatively inexpensively with materials already known in the prior art. It is further desirable for the self-standing package constructions whereby a separate compartment can be formed for placement of materials with graphics so as to avoid or, at least minimize, ink and solvent contact with food.  
         SUMMARY OF THE INVENTION  
         [0016]    The proposed invention involves producing a package made from flexible film having a film body formed as a discrete package. A support flap for supporting the package in a standing position is extended forth from the film body wherein the film body and the support flap are produced from a continuous segment of film. Thereby, when the package is positioned to stand upright, the support flap is extended away from the body of the tube of the package forming a pocket there between for support.  
           [0017]    The method for forming the self-standing package comprises forming a sheet of film into a tube with an over-lapped segment of film extending out from the tube to form a support flap. Thereafter, at least one seal axially along the support flap is provided. The package is finished by sealing both terminal ends of the tube and the support flap to form the self-standing flexible package. Optionally, a pocket can be formed within the support flap for placement of printed graphic materials or other product.  
           [0018]    The above as well as additional features and advantages of the present invention will become apparent in the following written detailed description.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]    The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:  
         [0020]    [0020]FIGS. 1 a  and  1   b  are schematic cross-section views of prior art packaging films;  
         [0021]    [0021]FIG. 2 is a schematic cross-section view of a tube of packaging film illustrating the formation of a prior art lap seal;  
         [0022]    [0022]FIG. 3 is a schematic cross-section of a tube of packaging film illustrating the formation of a prior art fin seal;  
         [0023]    [0023]FIG. 4 is a cross-sectional view of a self-standing flexible package made in accordance with an embodiment of the invention wherein the support flap is sealed completely;  
         [0024]    [0024]FIG. 5 is a cross-sectional view of a self-standing flexible package made in accordance with an embodiment of the invention wherein the support flap not sealed and is open to the body of the package;  
         [0025]    [0025]FIG. 6 is an elevational view of the back of the package of FIG. 4 having the package in a self-standing position.  
     
    
     DETAILED DESCRIPTION  
       [0026]    [0026]FIG. 4 shows a cross sectional view of a flexible package  50  for containing snack food products. The composition of the package material can be the same as used for prior art packaging as described in relation to FIG. 1 a  or any other prior art film composition used for the product application in the instant invention.  
         [0027]    A film  52  used in the present invention is fed into a vertical or horizontal form, fill, and seal packaging machine capable of manufacturing a package in accordance with the invention. Thereby, package  50  is formed having a front  54  and a back  56 . Since film  52  is a flat film, film  52  is fed into the packaging machine to generally form a cylinder. The leading end of the film is sealed to a trailing end of the same film to form a back seal  64  rendering the cylinder independent. Once package  50  is complete, a transverse end seal  62  can be formed at both ends of package  50 .  
         [0028]    Unlike the prior art though, back seal  64  is not merely a thin seal of overlapped film. Here, a flap  58  is formed of film  52 . More particularly, flap  58  is formed, for example, by allowing terminal ends from a sheet of film  52  to extend outward and away from the formed cylinder. Back seal  64  can then be optionally formed longitudinally down the length of the tube. The length of back seal  64  can be varied. As shown in FIG. 4, back seal  64  extends down to the entire length of flap  58 . However, other embodiments are possible.  
         [0029]    To provide support, terminal portions of flap  58  are joined to transverse seals  62  that form the top and bottom seals of the discreet package  50 . The transverse portion of flap  58  that is sealed to the top and bottom of package  50  forms end seals  68 . An end seal  68  extends from the position where flap  58  begins to extend forth from package  50 , for example, at a middle point on back  56 , down to most outward portion of flap  58 . Thereby, pocket  60  is formed between flap  58  and back  56  of the package. As package  50  is comprised of a flexible material, flap  58  will generally lie flush against back  56 . However, when flap  58  is drawn away from back  56 , pocket  60  becomes open as shown in FIG. 4. Once pocket  60  is opened, package  50  can be positioned to stand erect with the use of flap  58 .  
         [0030]    In another embodiment, a cross sectional view of a package  70  is shown in FIG. 5 and is formed from flexible package material film  72 . Similar to the formation of package  50 , package  70  is formed having a front  74  and a back  76 . A flap  78  is formed however without a back seal like that of back seal  64  on package  50 .  
         [0031]    Instead, flap  78  is formed by creating a bend  84  in film  72  to form the inner portion of flap  78 . If needed, bend  84  can be treated to help retain its shape such as by heat or by sealing a small inner portion of flap  78  to back  76 . Since no back seal is provided, an opening  90  is formed between the inner and outer portions of flap  78 . This allows any product that is packaged within package  70  to be able to move into opening  90 . Optionally, a seal  86  can be provided at the end of flap  78  to provide rigidity to flap  78 . Seal  86  can be formed in either one or a few spots along the length of the terminal end of flap  78  or seal  86  can be formed down the entire length of the terminal end of flap  78 .  
         [0032]    To provide support to package  70 , terminal portions of flap  78  are joined to transverse end seals  82  that form the top and bottom seals of the discreet package  70 . The transverse portion of flap  78  that is sealed to the top and bottom of package  70  forms end seals  88 . An end seal  88  extends from the position where flap  78  begins to extend forth from package  70 , for example, at a middle point on back  76 , down to most outward portion of flap  58 . Thereby, pocket  80  is formed between flap  78  and back  76  of the package. As package  70  is comprised of a flexible material, flap  78  will generally lie flush against back  76 . However, when flap  78  is drawn away from back  76 , pocket  80  becomes open as shown in FIG. 5. Once pocket  80  is opened, package  70  can be positioned to stand erect with the use of flap  78 .  
         [0033]    Various options are available for the arrangement of flaps  58  and  78 . While flaps  58  and  78  are shown having particular lengths, the length of the flaps in relation to the packaging need only be as long so as to be able to support packages  50  and  70  in standing positions. Particularly with flap  78 , various sealing options are available. For example, a seal could be formed at bend  84  so as to create a back seal. However, the seal need not extend down through to the terminal end of flap  78 . Thereby, an open space like opening  90  can be formed. Unlike package  70  though, the open space would be separate from any contents that would be placed into the package. This is beneficial in that printed material such as coupons, contest materials, or sample products can be provided without having to come into with any contents in the main portion of the package. With food products, this is particularly advantageous as the printed materials would not come into with it.  
         [0034]    [0034]FIG. 6 shows a completed package  100  in a standing or display position. Package  100  is formed from a flexible material film  102 . Package  100  is of the design shown in FIG. 4 so a back seal  104  is formed along the back  106  to join together the ends of the tube of package  100 . As package  100  is shown standing, flap  108  extends outward and away from back  106  forming pocket  110 . To enclose and retain any product within the package, transverse end seals  112  seal the terminal ends of package  100 . To retain flap  108  to the terminal ends of package  100 , transverse seals  114  are provided. While package  100  is shown to appear wider than taller, this does not preclude other embodiments where a package could be formed taller than wider while in a standing position.  
         [0035]    While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.