Abstract:
A flexible package is defined by an inner package layer and a surrounding outer package layer. The inner and outer layers define a tubular body and opposing end portions. A first region of weakness is provided within the outer package layer and is spaced from one end of the package. The region of weakness within the outer packaging layer forms an opening mechanism for the outer layer to expose the inner packaging layer. A second region of weakness is provided within the inner package layer and is spaced from the end of the inner package. The second region of weakness positioned offset from the first region of weakness, to permit the two opening mechanism to be separately activated.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates to packaging formed from a flexible laminate material. More specifically, the present disclosure relates to providing a sealed package with an opening mechanism formed within the laminate material. 
       BACKGROUND 
       [0002]    The use of flexible packaging for storing and shipping food and other products is common. It is also known to provide opening mechanisms for controlled access to the contents of the package. The packaging materials may take many forms and may include multiple layers. It is also known to provide separate opening mechanisms for the individual layers within a package. 
         [0003]    U.S. Pat. No. 1,641,408 to Bainbridge et al. shows a package having a secondary cover provided at one end and a sealing means to secure the cover to the end of the package. The cover portion wraps around the package and includes a perforation line within a folded extension of the cover. A metal clip is secured to the end of the package to retain the cover. Removal of the clip exposes the cover, which may be separated from the package by tearing along the perforation line. 
         [0004]    U.S. Pat. No. 6,391,353 to Marbler et al. shows a multilayer package having a score line formed in the outer layer of the package and a separate score line formed on the inside layer of the package. Removal of a portion of the outside layer along the outside score line creates a hood or cap structure. The inside layer and the outside layer are attached at the end seal. Removal of the cap structure causes separation of an end portion of the inner layer along the inside score line. 
         [0005]    U.S. Pat. No. 2,811,455 to Erekson shows a package having an inner container, including a separating score line, and an outer wrapper. A removal tape is provided under the outer wrapper, which overlaps the inner score line. An exposed end of the tape forms a starting tab to create a separation line through the outside layer. The separation of the outer wrapper exposes the inner score line for further separation of the top portion of the package. 
         [0006]    US 2004/0022462 to Markham shows a multilayer package having opening mechanisms within various layers. The package includes a closed end in which both layers are secured together. A line of weakness may be formed in the outer layer, spaced from the closed end as well as within the inner layer. The line of weakness is spaced from an inner seal within the inner package. Additional lines of weakness are provided in the outer package layer and inner layer. Opening of the package is accomplished by tearing across the line of weakness, opening the outer package and exposing the inner package. 
       SUMMARY 
       [0007]    The present invention is contemplated to take the form of a flexible package having an inner package layer and an outer package layer, which surrounds the inner package layer. Preferably, the inner and outer packaging layers define a tubular body having opposing sealed end portions. A first region of weakness is provided within the outer package layer and is spaced from one end of the outer layer. The region of weakness within the outer layer forms an opening mechanism for the outer layer to expose the inner packaging layer. A second region of weakness is provided within the inner layer and is spaced from the end of the inner package. The second region of weakness is preferably positioned offset from the first region of weakness to permit the two opening mechanism to be separately activated. A pattern adhesive is provided for securing the inner packaging layer within the outer packaging layer. The adhesive pattern includes a releasable adhesive portion that is contiguous with the first region of weakness. The first region of weakness and the releasable adhesive portion form an opening mechanism for separating the outer package layer from the package and to expose the inner package layer and the second region of weakness. The second region of weakness forms an opening mechanism for the inner packaging layer that is separately activated from the opening mechanism of the first region of weakness in the outer packaging layer. 
         [0008]    In one aspect of the invention, the first line of weakness includes parallel separation lines extending transversely across the package to define a separable strip portion within the outer layer. A release tab may be further defined within the strip portion, for start-up of the removal of the strip along the line of weakness. 
         [0009]    In another aspect of the invention, the first line of weakness includes a single score line provided in the outer layer. The score line extends around the circumference of the package and defines a removable end cap portion. In removing the cap portion formed by the outer layer, the end of the inner layer is exposed along with the second line of weakness for separate opening of the inner layer. 
         [0010]    In a further aspect of the invention, the second line of weakness is formed within a fin seal extension along one side edge of the inner layer. The seal extension may be formed prior to the provision of the outer layer or as part of the laminate assembly. In one form, the fin seal extension is provided with a side slit provided on the edge of the side seal area. The side slit forms a tearing start for the package layer, while the surrounding seal maintains the integrity of the package layer. The end seal and extension may be formed by a pattern adhesive or by a combination of heat and pressure. 
         [0011]    Further features and advantages of the present invention will become apparent by a review of the description below and a review of the appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    For the purpose of illustrating the invention, the drawings show forms that are presently preferred. It should be understood that the invention is not limited to the precise arrangement and instrumentality shown in the drawings. 
           [0013]      FIG. 1  is an elevational view of a tubular package formed from a flexible material as contemplated by the present invention. 
           [0014]      FIG. 2  is an enlarged partial view of one end of a tubular package having the features of the present invention. 
           [0015]      FIG. 3  is a partial view of the end of the package shown in  FIG. 2 , wherein a portion of the outer layer is partially removed. 
           [0016]      FIG. 4  is a partial view of the end of the package shown in  FIGS. 2 and 3 , wherein a portion of the inner layer of the package is removed. 
           [0017]      FIG. 5  is a cross sectional view of the package embodiment of  FIGS. 2-5 , as taken along line  5 - 5  in  FIG. 2 . 
           [0018]      FIG. 6  shows the formation of an inner packaging layer for use in the package of the present invention. 
           [0019]      FIG. 7  shows the formation of an outer packaging layer for use in the package of the present invention. 
           [0020]      FIG. 8  is a front elevational view of an alternate form of a package having the features of the present invention therein. 
           [0021]      FIG. 9  is a rear elevational view of the package embodiment shown in  FIG. 8 . 
           [0022]      FIG. 10  shows the package of  FIGS. 8 and 9 , wherein a portion of the outer layer is being removed to expose the inner packaging layer. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    Referring to the figures, wherein like numerals are used to identify like elements throughout, there is shown embodiments of a flexible package which is generally designated by reference numeral  10 . The package  10  in  FIG. 1  is in the form of a hollow tube with sealed ends and having a generally rectangular construction, but may have any desired shape. The package  10  includes a generally elongated body  12  with two end seals  14 ,  16  and a side fin seal  18 . The package  10  is of the type that is from a web material and formed in a form, fill and seal machine on a continuous basis. The seals  14 ,  26 ,  18  may be created by the combination of heat and pressure, the use of adhesives or any known means. The body portion  12  defines an interior volume for retaining product, such as powder, pellets or other defined items. 
         [0024]    In  FIG. 2 , the end seal  14  of the package  10  is shown in an enlarged form so as to illustrate various structural features. The package material includes a laminate having an outer layer  20  formed around an inner layer  22 . The laminate layers  20 ,  22  are more clearly defined in the cross sectional view of  FIG. 5 . The layers  20 ,  22  may be adhered to one another by an adhesive or otherwise secured together. The end seal  14  of the package  10  is defined by an end portion  24  and an inner seal  26 . As shown, the end portion  24  of end seal  14  is illustrated by crossed hatch lines. The inner seal  26  is illustrated by the broken line cross hatch. A separation portion  28  is provided in the fin seal  18  and is illustrated by a plurality of dots. A line of weakness  30  is defined in the outer layer  20  and extends around the circumference of the package  10  and across the separation portion  28  of the fin seal  18 . The formation of the seal and separation portions is discussed in further detail below. 
         [0025]    The first line of weakness  30  in  FIG. 2  is defined by a first line  30   a  and a second line  30   b , which are spaced and extend parallel to one another. The lines  30   a ,  30   b  are preferably formed in the outer layer  22  of the laminate material. The lines  30   a ,  30   b  may be formed as a straight cut or as a perforation pattern. Preferably, the lines  30   a ,  30   b  extend through into the outer laminate  20 , but may vary in depth as desired. As shown in  FIG. 3 , the first line of weakness  30  defines a separable strip portion  32  within the outer layer  20 . 
         [0026]    A release tab  34  is formed on the fin seal  18 , permitting easy separation of the strip  32  from the remainder of the outer layer  20  and from the underlying inner layer  22 . Preferably, the strip  32  is secured to the inner layer  22  by a pattern applied releasable adhesive. In the area  28  (dotted) of the release tab  34 , no adhesive is preferably applied, or the adhesive is blocked to provide separation of the tab  34  from the portion of the inner layer  20  within the fin seal  18 . The tab  34  may also be formed in another area of the outer layer  22  by similar means. 
         [0027]    In  FIG. 3 , the strip  32  is partially separated from the remainder of the outer layer  20  and removed from adherence to the inner layer  22 . The separation of the strip  32  is defined along the first line of weakness  30 , defined by the parallel lines  30   a ,  30   b . The exposed portion of the inner layer  22  includes a portion of the body  12  of the package  10 . A side portion  36  of the inner seal  26  of the inner layer  22 , as previously covered by the strip  32 , is now exposed (and is shown in full cross hatch). The side portion  36  of the inner seal  26  extends downwardly from the end seal  14  along one side edge of the package  10 . The end seal  14  and the side seal portion  36  are contemplated to be formed as a permanent seal of at least one layer of the package, requiring a destructive force in order to separate the sealed areas. The permanent seal may be formed by a pattern applied permanent adhesive or by a localized heat seal. A heat seal is typically formed by a combination of pressure and heat and requires compatible materials for an acceptable bond. The side seal  36  is formed between the inside surfaces of the inner layer (see  FIG. 5 ). In making an appropriate material selection, where the inner layer  22  is not compatible with the material of the outer layer, the heat seal may be applied through the outer layer  20 . The bond between the inner and outer layers under the strip is preferably a releasable adhesive, which would not be affected by the applied heat seal forming the side seal portion  36 . The remainder of the end seal  14  within the packaging layers may be formed by a permanent adhesive and/or a heat seal. 
         [0028]    As discussed, the strip  32  is releaseably bonded to the inner layer  22 , while the end seal  14  and the side seal portion  36  take the form of a permanent seal. In addition, the portion of the fin seal  18  formed by the inner layer  22  creates a permanent bond, with the adhesive area  28  between the inner and outer layers  20 ,  22  in the fin seal  18  being absent or deadened to create the release tab  34 . 
         [0029]    The side seal portion  36  in the inner layer  22  includes a line of weakness  38  formed within the sealed area along the edge of the package. As shown the second line of weakness  38  is in the form of two parallel cuts. As shown in  FIG. 4 , the cuts  38  create a start up location for a tear line  40  within the inner package layer  22 , to open the package  10 , providing access to the product within the body  12  thereof. Prior to removal of the strip  32 , the side portion  36  and the associated line of weakness  38  are covered by the outer layer  20 . Upon separation of the strip  32  along the first line of weakness, the opening mechanism for the inner layer  22  is exposed. Thus, the opening mechanism for the inner layer is actuated separately from the opening mechanism for the outer layer  20 . Preferably, the line of weakness  30  in the outer layer  20  is offset from the line of weakness  38  in the inner layer  22 , such that the two opening mechanisms are activated by separate actions, and the opening of the outer layer does not readily activate the opening of the inner layer. 
         [0030]    In  FIGS. 6 and 7 , the laminate layers  20 ,  22  are shown as separated webs.  FIG. 6  shows the end portion of the inner layer  22 . The permanent adhesive is shown by cross hatch  46  on the surfaces of the material. The folded edges of the formed package are show by dashed lines  42 ,  44  extending the length of the web. An extension of the adhesive  46  forms the side seal portion  36 , along the side edge represented by dashed hatch lines  42 . Within the side portion  36  is provided cuts that form the line of weakness  38 . 
         [0031]    In  FIG. 7 , the outer layer  20  of the laminate is shown. A cross-hatched permanent adhesive  46  is applied along the top edge of end  14  and along a portion of the side edge that forms the fin seal  18 . The adhesive is deadened in the area  28  of the fin seal  18 , where the separation of the strip  32  is to be started by tab  34 . This release tab  34  may be formed on both sides of the fin seal by a similar deadened area on the opposite side edge of the web. A non-permanent adhesive may be pattern applied in the area of the strip for releasable adhesion of the material to the inner layer  20 . The additional adhesion of the non-permanent or releasable adhesive may add to the integrity of the package in the area, where the strip is defined by score lines extending into the outer layer material. 
         [0032]    In the embodiment of the package  10 ′ shown in  FIGS. 8-10 , the body  12 ′ is defined by a laminate material having layers  20 ′ and  22 ′. In  FIGS. 8 and 9 , the end seal  14 ′ is formed by both the inner and outer layers  20 ′,  22 ′ of the laminate. A curved first line of weakness  30 ′ is formed in the outer layer  20 ′ and extends across the front and back of the package  10 ′ ( FIGS. 8 and 9 , respectively). A releasable adhesive may be provided under the end portion of the outer layer, above the first line of weakness  30 ′, as shown by the dotted area  31 ′. The combination of the curved line  30 ′ and release between the two layers creates a separation or release tab  34 ′ in the outer layer  20 ′. An adhesive void may be provided above the releasable adhesive  31 ′ (below the permanent end seal  14 ′) for easy separation of the top portion of the outside layer  20 ′. Alternatively, the area  31 ′ adjacent the line of weakness  30 ′ may include an adhesive void, with the area above (and below the end seal  14 ′) having a relatively low adhesion. 
         [0033]    As shown in  FIG. 10 , the first line of weakness  30 ′ creates a separation point for a defined cap portion  50  formed by the outside layer  20 ′ of the package  10 ′. The cap  50  may include a portion of the sealed end of the inside layer  22 ′. As such, a separation line  52  is provided in the inside layer  22 ′ for removal of the end of the portion of the inside layer included in the end seal  14 ′. The end of the of inside layer  22 ′ remains sealed after removal of the cap  50  by positioning the separation line  52  within the seal extension  36 ′. The seal extension  36 ′ as illustrated, extends across the width of the package  10 ′ within the inside layer  22 ′. The seal extension also includes a side seal portion  36   a . A second line of weakness  38 ′ is formed in the side seal extension  36   a  for opening the seal  36 ′ of the inside layer  22 , similar to that provided in the embodiment of  FIGS. 2-7 . 
         [0034]    In the embodiment of  FIGS. 8-10 , the end seal  14 ′ may be formed by a permanent adhesive, a heat seal or the like. In the preferred structure, it is contemplated that the layers will be at least partially adhered to one another. Thus, normally the space between the layers would be filled with an adhesive, except for the strategic removal of adhesion within the releasing portions. In the package  10 ′ in  FIGS. 8-10 , a releasable adhesive is also contemplated to be provided in the fin seal area (not shown). Thus, the cap portion  50  of the outer layer  20 ′ separates from the body of the inner layer  22 ′ and peels away from the fin seal (above the first line of weakness  30 ′, which preferably extends around the package similar to line  30   b  in  FIGS. 2-7 ). 
         [0035]    In the illustrated embodiments of the package, the layers include separate opening mechanisms, which are separately activated. The first line of weakness, preferably in conjunction with a patterned adhesive, forms an opening mechanism for the outer layer. Once the outside layer is opened, the inside layer is exposed, along with its separate opening mechanism. The second line of weakness provides for opening of the inside layer and access to the contents of the package. The form of the two opening mechanisms as illustrated are different and are offset within the package. This variation in form, position and the selective adhesive pattern create the separate activation. 
         [0036]    It is contemplated that the separate activation of the two opening mechanisms for the two package layers creates a tamper evident structure. In addition the separate forms of the opening mechanisms, coupled with the separate activation, serve to deter opening by small children. Even if one layer is opened, the inner layer maintains the integrity of the seal, until such time that the second opening mechanism is figured out and activated. Control of the ease of opening of the package layers may be controlled by the selection of the form of the opening mechanisms, the materials within the package layers and the adhesive pattern between the layers. 
         [0037]    In a preferred embodiment, the package may be formed by an outer layer of polyethylene terephthalate (PET) and an inner layer formed by metallized oriented polypropylene with a sealing layer of low-density polyethylene (LDPE). A pattern adhesive of any desired form is preferably provided between the PET and oriented polypropylene layers in the manner described. 
         [0038]    Although the invention has been described and illustrated with respect to the exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without parting from the spirit and scope of the present invention. Accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.