Abstract:
A flexible film package for storing food products comprises a body with a side wall, a closed bottom end, and a closed top end. The body includes a primary line of weakness and a pair of secondary lines of weakness formed in the side wall. Each of the primary and secondary lines of weakness includes a plurality of score lines spaced apart by non-scored portions of the side wall. The score lines of the primary line of weakness have a greater length, width, and depth than the score lines of the secondary lines of weakness. The non-scored portions between the score lines of the primary line of weakness are longer than the non-scored portions between the score lines of the secondary lines of weakness.

Description:
FIELD 
       [0001]    Flexible film packages for food items, and in particular, flexible film packages having lines of weakness for facilitating the opening of the packages and dispensing of the food contents are described herein. 
       BACKGROUND 
       [0002]    Food items are routinely sold in sealed plastic packages. The packages are typically made by vertical-form-fill-and-seal devices such that a web of flexible film material, is formed into a tube. This tube is sealed on one end and then filled with the package contents. The second end is then also cut and sealed to seal the contents of the package therein and then singulated. To open such a package and access the food item, a consumer can tear off and remove a portion of the package. In certain packages, such as stick-pack packages, it can be advantageous to completely remove an end of the package including the end seal to allow for the contents to be dispensed into a suitable container, for example, a cup. 
         [0003]    Flexible film packages include various features to assist the consumer in opening the package. Some packages include a weakening of the package material along a given line such that a tear can propagate along that line when a user opens the package. A disadvantage of such packages is that the tear does not always follow the weakened line. Instead, the tear can deviate from the desired propagation path delineated by the weakened line. 
         [0004]    It is known to make the weakened lines in the packages using a laser. The laser can ablate the package material along a line across the package without cutting entirely through the package material. Frequently, the package is so weakened by the laser scoring that the package loses its structural integrity and does not stay intact during its vertical-form-fill-and-seal manufacturing process, and sometimes even during normal handling by a user before the package is intended to be opened. In packages where the laser scoring is less deep to preserve the tensile strength of the package, the score line can be less pronounced in the side wall and can be difficult for a user to see. To make a laser score more visible for a consumer, printing indicia on the package can highlight the laser score. For example, the package may have the words “TEAR. HERE” and an arrow pointing to the laser score printed thereon. However, when the laser score is applied after printing, alignment of the indicia and the laser score line may not coincide. 
       SUMMARY 
       [0005]    A flexible film package is provided. The flexible film package includes a body having a bottom end including a bottom seal, a top end including a top seal, a longitudinal axis passing through the top and bottom ends, and a side wall, connecting the top and bottom ends and enclosing an interior including a food product. The package further includes a primary line of weakness and a pair of spaced, substantially parallel secondary lines of weakness formed in the side wall. The primary line of weakness is between and substantially parallel to the secondary lines of weakness. The primary line of weakness includes a plurality of score lines spaced apart by non-scored portions of the side wall. Each secondary line of weakness includes a plurality of score lines spaced apart by non-scored portions of the side wall. Each of the non-scored portions has a length and each of the score lines have a length, width, and a depth. Each of the non-scored portions between the score lines of the primary line of weakness has a greater length than the non-scored portions of the side wall between the score lines of the secondary lines of weakness. Each of the score lines of the primary line of weakness has at least one of a greater length, width, and depth than each of the score lines of the secondary lines weakness. The primary line of weakness is configured to propagate a tear through the side wall. At least one of the secondary lines of weakness is configured to propagate the tear through the side wall if the tear deviates from the primary line of weakness. 
         [0006]    The package can have at least one tertiary line of weakness formed in the side wall above one of the secondary lines of weakness and at least another tertiary line of weakness formed in the side wall below the other of the secondary lines of weakness. The side wall can have a first side edge and a second side edge opposite the first side edge, and at least one of the score lines of the primary line of weakness can intersect at least one of the first and second side edges. The package can further include a fin seal extending along the longitudinal axis between the top seal and the bottom seal such that at least one of the score lines of the primary line of weakness can intersect at least a portion of lee fin seal. The package can further include a plurality of fold lines in the side wall about which the package is folded such that at least one of the score lines of the primary line of weakness can intersect at least one of the told lines. 
         [0007]    A method of manufacturing the flexible film package is provided. The method includes providing a flexible film material; scoring the primary line of weakness across at least a portion of the side wall; scoring one of the secondary lines of weakness across at least a portion of the film material and above the primary line of weakness; scoring another of the secondary lines of weakness across at least a portion of the film material and below the primary line of weakness; forming the film material into a tube; sealing the bottom end of the tube; filling the tube with the food product; sealing the top end of the tube; and singulating the package from the flexible film material. 
         [0008]    A method of opening the flexible film package is provided. The method includes initiating a tear line in the side wall of the package; propagating the tear line along the primary line of weakness across at least a portion of the side wall of the package; propagating the tear line along one of the secondary lines of weakness across at least a portion of the side wall of the package if the tear line deviates from the primary line of weakness; separating at least a portion of the top seal from the side wall of the package to gain access to the food product in the interior; and dispensing the food product from the package. 
     
    
     
       BRIEF DESCRIPTION OF HE DRAW IN 
         [0009]      FIG. 1  is a side elevational view of an exemplary package having multiple lines of weakness; 
           [0010]      FIG. 2  is side elevational view showing the opposite side and the fin seal of the package of  FIG. 1 ; 
           [0011]      FIG. 3  is a plan view of the film material from which the package of  FIG. 1  is formed; 
           [0012]      FIG. 4  is an enlarged fragmentary view of a portion of the package of  FIG. 1  including the lines of weakness and an end seal; 
           [0013]      FIG. 5  is the same view as in  FIG. 4 , shown with a user&#39;s fingers applying a tearing force and propagating a tear line through the primary line of weakness of the package; 
           [0014]      FIG. 6  is the same view as in  FIG. 5 , shown with a portion of the tear line deviating from the primary line of weakness and propagating along the secondary line of weakness that is above the primary line of weakness; 
           [0015]      FIG. 7  is the same view as in  FIG. 5 , shown with a portion of the tear line deviating from the primary line of weakness and propagating along the secondary line of weakness that is below the primary line of weakness; 
           [0016]      FIG. 8  is a side elevational view of the package of  FIG. 1 , shown with the removable portion completely separated from the package and the food product being dispensed from the package; 
           [0017]      FIG. 9  is a perspective view of some of the layers of the flexible film material that can comprise the side wall of an exemplary package; 
           [0018]      FIG. 10  is a sectional side view of a portion of the flexible film material of  FIG. 9 , showing the depth of the score lines of the primary line of weakness; 
           [0019]      FIG. 11  is a sectional side view of a portion of the flexible film material of  FIG. 9 , showing the depth of the score lines of one of the secondary lines of weakness; and 
           [0020]      FIG. 12  is a perspective view of relevant portions of a vertical-form-fill-and-seal device during the manufacture of the package of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    A flexible film package as described, herein includes a primary line of weakness and a pair of secondary lines of weakness to facilitate the opening of the package. The primary line of weakness is indicated in the side wall of the package in a more visible manner than the secondary lines of weakness, such as in a color contrasting with the color of the side wall such that the primary line of weakness is clearly visible on the package to the consumer. While the secondary lines of weakness may also be visible to the consumer, they are much less pronounced in the side wall of the package such that even in the absence of a “TEAR HERE” instruction, it can be apparent to the consumer that the tear should be initiated proximate the primary line of weakness. 
         [0022]    The package may contain foodstuffs such as drink powders, dessert powders, snack nuts, condiments, and toppings that can be dispensed into a suitable container or directly into a consumer&#39;s mouth. A consumer can open the package by tearing the package along the package&#39;s primary line of weakness. If the tear deviates from the primary line of weakness, the tear can propagate along one of the secondary lines of weakness across the package, ensuring a controlled and predictable pattern for an end of the package to be easily and completely removed to allow the consumer to access the foodstuff contained in the package. The primary line of weakness and the secondary lines of weakness can be formed by a laser in a pattern that allows the consumer to easily see the intended tear line and provides the film material with increased tensile strength so as to avoid breaking during the conventional vertical-form-fill-and-seal process. 
         [0023]    With reference to  FIGS. 1-3 , a package  10  has an elongate body including a side wall  12  with a first side edge portion  14  and a second side edge portion.  16  opposite the first side edge portion  14 . The side wall  12  encloses an interior of the package  10  where a food product  30  can be stored. The package  10  includes a top seal  18  at a top end  20  of the package  10  and a bottom seal  22  at a bottom end  24  of the package  10 . The side wall  12  of the package  10  includes seal areas  15  and  17  along the first and second side edge portions  14  and  16 , respectively, as shown in  FIG. 3 . 
         [0024]    With reference to  FIG. 3 , the side wall  12  of the package  10  can be folded about the fold lines  19  and  21  to bring the seal areas  15  and  17  together and form a fin seal  26 . The fin seal  26  can extend in a direction along the longitudinal axis of the package  10  and may connect the top and bottom seals  18  and  22 . Any of the above-described seals may be made by conventional methods, including, for example, the application of heat and pressure to create a laminate seal. When sealed by such seals, a food product in the interior of package  10  is protected from outside elements such as moisture and oxygen. 
         [0025]    With further reference to  FIGS. 1-3 , the package  10  also includes multiple lines of weakness extending across at least a portion of the side wall  12  of the package  10 . A primary line of weakness  32  includes a series of ablated portions or score lines  34 . An upper secondary line or weakness  36  extends across at least a portion of the side wall  12  of the package  10  above the primary line of weakness  32 . A lower secondary line of weakness  38  extends across at least a portion of the side wall  12  of the package  10  below the primary line of weakness  32 . The secondary lines of weakness  36  and  38  include a series of ablated portions or score lines  40  and  41 , respectively. 
         [0026]    The secondary lines of weakness  36  and  38  can be parallel to each other and to the primary line of weakness  32 , as shown in  FIG. 1 . Alternatively, the secondary lines of weakness  36  and  38  can converge or diverge relative to each other or relative to the primary line of weakness  32 . Further, while the primary line of weakness  32  and the secondary lines of weakness  36  and  38  have been shown as being perpendicular to the longitudinal axis of the package  10 , any one or all of the lines of weakness may be inclined at various angles to the longitudinal axis. Moreover, while the primary line of weakness  32  and the secondary lines of weakness  36  and  38  have been shown as being straight, the lines of weakness  32 ,  36 , and  38  may be curved (e.g., convex, concave, undulating, etc.). 
         [0027]    With reference to  FIGS. 5-7 , the package  10  includes a removable portion  23  formed in the side wall  12 . The removable portion  23  may be separated from the package  10  along the primary line of weakness  32 , or along either one of the secondary lines of weakness  36  and  38 . The removable portion  23  provides an access opening for dispensing the contents as well as a tamper-evident feature. 
         [0028]    The primary line of weakness  32  defines an intended path of a tear line  39  across the sidewall  12  of the package  10 , as shown in  FIG. 5 . As shown in  FIG. 4 , one score line  34  of the primary line of weakness  32  can intersect the first side edge  14  of the package  10  and another score line  34  of the primary line of weakness  32  can intersect, the second side edge  16  of the package  10 . The intersection of the score lines  34  of the primary line of weakness  32  with the side-edges  14  and  16  allows the user to easily initiate a tear along the tear line  39 , as shown in  FIG. 5 . Alternatively, the package  10  may include a tear notch (not shown) aligned with the primary line of weakness  32 . The tear notch could extend completely or partially through the side wall of the package  10 . The tear notch could provide a tear initiation site that facilitates the separation of the removable portion  23  from the package  10  along the primary line of weakness  2 . 
         [0029]    With reference to  FIG. 5 , to open the package  10 , the consumer can grasp the package  10  and apply a force to initiate a tear in the side wall  12  at the intersection of the score line  34  with the side edge  14 . A tear line  39  can then be formed which follows along a path delineated by the score lines  34  of the primary line of weakness  32 . The tear line  39  can separate the removable portion  23 , together with the top seal  18 , from the rest of the package  10 . The pattern of the score lines  34  and the non scored portions  44  of the primary line of weakness  32  can permit the user to separate the removable portion  23  from the package  10  without substantially deviating from the tear line  39 . 
         [0030]    As discussed herein below, the primary line  32  can have score lines  34  and non-scored portions  44  having approximately equal length. Having non-score portions  44  of such length between the scored portions  34  increases the likelihood that the tear line  39  will deviate from the primary line of weakness  32 . Conversely, the lengths of the non-scored portions  49  and  50  between the score lines  40  and  41  of the secondary lines of weakness  36  and  38  are significantly smaller and increase the likelihood that the tear line  39  will propagate along one of the secondary lines of weakness  36  or  38  without deviation. 
         [0031]    For example, during the propagation of the tear line  39  through a non-scored portion  44  of the primary line of weakness  32 , the tear line  39  could deviate in a direction toward the upper secondary line of weakness  36 , as shown in  FIG. 6 . The tear line  39  could then propagate through the side wall  12  of the package  10  until it intersects with the secondary line of weakness  36  and would follow the secondary line of weakness  36  across the side wall  12  to separate the removable portion  23  from the package  10 . 
         [0032]    Alternatively, the tear line  39  could deviate in a direction toward the lower secondary line of weakness  38  and propagate through the side wall  12  of the package  10  until it intersects with the secondary line of weakness  38 . As shown in  FIG. 7 , the tear line  39  would then follow the secondary line of weakness  38  across the package  10  to separate the removable portion  23  from the package  10 . Thus, the primary line of weakness  32  and the secondary lines of weakness  36  and  38  facilitate propagation of the tear line  39  along a controlled and predictable pattern such that the removable portion  23  including the top seal  18  can be readily removed by a consumer and the food product  30  can be dispensed from the package  10 , as shown in  FIG. 8 . 
         [0033]    While the package  10  has been shown as having only one secondary line of weakness  36  above and one secondary line of weakness  38  below the primary line of weakness  32 , the package  10  can be made with two or more secondary lines of weakness  36  and  38  formed in the side wall  12  above and/or below the primary line of weakness  32 . For example, the side wall  10  may include one tertiary line of weakness above the secondary lines of weakness  36  and another tertiary line of weakness below the secondary line of weakness  38 . The tertiary lines of weakness can be identical or similar to the secondary lines of weakness  36  and  38 , such as in dimensions, pattern, and/or function. Alternatively, the tertiary lines of weakness may have different dimensions and/or pattern. 
         [0034]    In this approach, if the tear line deviates upward from both the primary line of weakness  32  and the secondary line of weakness  36  located above the primary line of weakness  32 , the tear line would intersect and follow a tertiary line of weakness parallel to and located above the secondary line of weakness  36 . Conversely, if the tear line deviates downward from both the primary line of weakness  32  and the secondary line of weakness  38  located below the primary line of weakness  32 , the tear line would intersect and follow a tertiary line of weakness parallel to and located below the secondary line of weakness  38 . The package  10  may have different patterns of primary (P), secondary (S), and tertiary (T) lines of weakness. For example, the pattern could be any one of TSPST, TSPS, SPST, SPSPS, or the like. 
         [0035]    With reference to  FIGS. 9-11 , the flexible film material forming the side wall  12  can include multiple layers of material. For example, the side wall  12  can include at least an outer layer  43 , an ink layer  47 , and an inner layer  45 . The outer layer  43  and the inner layer  45  can be made of at least one material from a group including PET (polyethylene terephthalate) and OPP (oriented polypropylene film). The ink layer  47  can be sandwiched between the outer layer  43  and the inner layer  45 , and can include imprinted branding and product information. Either one or both of the inner layer  45  and outer layer  43  of the side wall  12  of the package  10  may be metalized to increase the protection of the food product  30  contained in the package  10 . 
         [0036]    It will be appreciated that the relative thickness of each of the layers  43 ,  45 , and  47  in  FIGS. 9-11  has been shown for illustration purposes only and has not been drawn to scale. Further, although only the outer layer  43 , the inner layer  45 , and the ink layer  47  of the side wall  12  have been shown in  FIGS. 9-11 , the side wall  12  can include one or more additional inner layers, for example, a foil layer, a PET and/or OPP layer, and a sealant layer. The sealant layer can be made of PE (polyethylene) or other material suitable for being in contact with the food product  30  and having suitable seal characteristics. 
         [0037]    The score lines  34  of the primary line of weakness  32  can be about four to six millimeters in length (designated, for example, by the reference numeral  42  in  FIG. 9 ) separated by non-ablated or non-scored portions  44  of the side wall  12 , which can be from about 4 to 6 millimeters in length (designated, for example, by the reference numeral  46  in  FIG. 9 ). The score lines  40  and  41  of the secondary lines of weakness  36  and  38  can be from about one to three millimeters in length (designated, for example, by the reference numeral  48  in  FIG. 9 ) separated by non-ablated or non-scored portions  49  and  50  of the side wall  12 , which can be from about 0.25 to about 0.75 millimeters in length (designated, for example, by the reference numeral  52  in  FIG. 9 ). 
         [0038]    The score lines  34  of the primary line of weakness  32  can be from about 0.4 to about 0.6 millimeters in width (designated, for example, by the reference numeral  54  in  FIG. 9 ), and can be from about 1 to about 2 millimeters in depth (designated, for example, by the reference numeral  56  in  FIG. 10 ). The score lines  40  and  41  of the secondary lines of weakness  36  and  38  can be from about 0.1 to about 0.3 millimeters in width (designated, for example, by the reference numeral  58  in  FIG. 9 ), and can be from about 0.25 to about 1 millimeters in depth (designated, for example, by the reference numeral  60  in  FIG. 10 ). While the score lines  34 ,  40 , and  41  are shown as extending across the entire package  10 , they can extend across a shorter length and/or different relative lengths. 
         [0039]    The score lines  34  of the primary line of weakness  32  and the score lines  40  and  41  of the secondary lines of weakness  36  and  38  can be scribed with one or more lasers in the flexible film material from which the package  10  is made. A carbon dioxide laser or another suitable laser may be used to scribe the score lines  34 ,  40 , and  41  in the side wall  12  of the package  10 . 
         [0040]    With reference to  FIGS. 10 and 11 , the depth of the score lines  40  and  41  of the secondary lines of weakness  36  and  38  can be less than the depth of the score lines  34  of the primary line of weakness  32 , and the depth of the score lines  34  of the primary line of weakness  32  can be greater than the thickness of the outer layer  43 . In particular, the depth of the score lines  34  of the primary line of weakness  32  can be greater than the depth of the outer layer  43 , but less than the combined, depth of the outer layer  43  and the inner layer  45 . The score lines  34  can pass through the outer layer  43 , the ink layer  47 , and a portion of the inner layer  45  to provide the package  10  with a primary line or weakness  32  that is clearly visible to the consumer. For example, the outer layer  43  may be transparent, the ink layer  47  may be orange, and the inner layer  45  may be white such that the score lines  34  passing through the outer layer  43 , the ink layer  47 , and a portion of the inner layer  45  would result in a white primary line of weakness  32  that would be highly visible on the orange-colored side wall  12 . It is to be appreciated that the inner layer  45  and the ink layer  47  may of any suitable colors, including colors that are selected due to their high contrast relative one another. 
         [0041]    In another approach, the score lines  34  of the primary line of weakness  32  may have a depth that is less than a thickness of the outer layer  43  of the side wall  12  of the package  10 . Furthermore, although the score lines  34 ,  40 , and  41  have been shown as passing through the outer layer  43 , the ink layer  7 , and a portion of the inner layer  45 , the score lines  34 ,  40 , and  41  may alternatively pass through the inner layer  45 , the ink layer  47 , and a portion of the outer layer  43 . This approach can be achieved by laser scribing an opposite surface of the flexible film material from which the side wall  12  of the package  10  is made. 
         [0042]    The multiple lines of weakness  32 ,  36 , and  38  having the above-indicated dimensions do not undermine the structural integrity of the side wall  12  of the package  10  to an unsuitable degree. Instead, the pattern of the scored portions  34  and  40 ,  41  and the respective non-scored portions  44 ,  49 , and  50  of the primary and secondary lines of weakness  32 ,  36 , and  38  can provide the side wall  12  with sufficient tensile strength to remain intact during the vertical-form-fill-and-seal process as well as routine handling by a user. It will be appreciated that although the pattern of the score lines  34 ,  40 , and  41  has been shown as being uniform, the score lines  34 ,  40 , and  41  may have a non-uniform pattern within the length ranges for the scored and non-scored portions as taught herein. 
         [0043]    The package  10  can have a length as measured from the top end  20  to the bottom end  24  from about 75 millimeters to about 200 millimeters, and a width as measured from the first side edge  14  to the second side edge  16  from about 15 millimeters to about 40 millimeters. It is to be appreciated that the dimensions of the package  10  and the lines of weakness  32 ,  36 , and  38  have been provided for illustration purposes only, and that the principles of this disclosure can be utilized to provide multiple lines of weakness in flexible film packages of any size. 
         [0044]    Referring now to  FIG. 12 , an exemplary method for manufacturing the flexible film package  10  is shown. One or more rollers  82  can be used to feed a flexible film material  80  into and along a vertical-form-fill-and-seal device  100 . A laser applicator  90  can be used to score the flexible film material  80  to form the primary line of weakness  32 , the upper secondary line of weakness  86 , and the lower secondary line of weakness  38 . It is to be appreciated that while a laser applicator has been shown, the primary and secondary lines of weakness  32 ,  36 , and  38  can be formed by another suitable technique, for example, micro-abrasion or a die-cut. 
         [0045]    The primary and secondary lines of weakness  32 ,  36 , and  38  can be formed in the flexible film material  80  prior to feeding the flexible film material  80  into the vertical-form-fill-and-seal device  100 , as shown in  FIG. 12 . By another approach, a laser applicator may be incorporated into the vertical-form-fill-and-seal device  100  such that the primary and secondary lines of weakness  32 ,  36 , and  38  may be added during the feeding of the flexible film material  30  through the vertical-form-fill-and-seal device  100 . By yet another approach, two laser applicators may score the flexible film material  30  on two sides to form the primary and secondary lines of weakness  32 ,  36 , and  38 . 
         [0046]    As the flexible film material  80  is being fed over a forming tube  110  of the vertical-form-fill-and-seal device  100 , a portion of the flexible film material  80  generally corresponding to the sealing areas  15  and  17  of  FIG. 3  can fold around the forming tube  110  and is sealed along a vertical direction by a pair of longitudinal sealing jaws  120  to form the fin seal  26 . The flexible film material  80  is then sealed in a horizontal direction by a pair of transverse sealing jaws  130  to form the end seals  18  and  22 . The jaws  130  can also be used to either cut or pull away the flexible film material  80  to singulate the package  10  having the primary line of weakness  32  and the secondary lines of weakness  36  and  38 , as shown in  FIG. 12 . 
         [0047]    So configured, the package  10  created by such a method and as otherwise described herein provides a consumer with a clearly visible starting point to tear open a package when compared to previous packages provided to the consumers. Further, the tear more reliably propagates along the tear line either along the primary line of weakness or along one of the secondary lines of weakness. Moreover, the package  10  having the primary and secondary lines of weakness  32 ,  36 , and  38  has sufficient tensile strength to withstand both the vertical-fill-and-seal process and routine handling by a consumer. 
         [0048]    Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the spirit and scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the concept.