Patent Publication Number: US-10329053-B2

Title: Package having a fill and seal feature

Description:
PRIORITY 
     This application is a continuation of U.S. application Ser. No. 12/973,356, filed Dec. 20, 2010, which claims priority to and the benefit of U.S. Provisional Application No. 61/287,778, filed Dec. 18, 2009; each of these applications and disclosures hereby fully incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to flexible packaging and, more particularly, to flexible packaging having at least one fill feature provided therewith. 
     BACKGROUND OF THE INVENTION 
     Conventional flexible packaging having side gussets have grown in usage. These side gusseted packages can include re-closeable devices (e.g., zippers), handles, and miter seals or K-seals with tacked corners. However, incorporation of these desirable features with such packages can create problems. 
     In particular, the ability to fill and seal such packages in a pre-made pouch or package configuration can be limited by their construct and features. For instance, the side gussets on the packages, when tucked in for the final or final end seal, can create thickness variations or additional steps due to the construct of two or more layers of the relevant portion of the package requiring sealing (e.g., combinations of the front and back panels, main and gussets panels or webs, etc.). 
     Because these multiple film layers can make it difficult to provide an air tight seal, leaking, contamination and like undesirable issues may arise with the packages upon final sealing. Moreover, it can be difficult to tuck the side gussets of such packages evenly once the packages are filled with product, which may further make it difficult to get an acceptable leak-proof seal after filling the package with contents or product. 
     Still further, the side gussets of such packages may also create sealing challenges because the heat-seal threshold for sealing through the multiple layers of material or film may vary significantly from the remaining package portions, or may require a level of heat that mandates the use of additional or specialized sealing equipment or steps. 
     These special steps and equipment may be especially problematic for customers or fillers receiving “pre-made” packages, whereby the customer is set up to simply fill the package with product or contents and provide the final package seals after filling is complete. Such customers are likely ill-equipped to provide the desired sealing in view of the unique construct of these packages. For instance, when a customer or filler receives such conventional pre-made side gusseted packages with zippers or other re-closeable devices or features, they must open and fill through the devices, and then seal the top of the package above the device. As such, the sealing and material challenges described above can present a problem. Alternatively, the pre-made package can be provided to the filler or customer with a flange of the device (e.g., zipper) unattached such that the package can be filled from behind the device. However, the unattached zipper must be sealed or attached after filling, again presenting the problems and challenges detailed above. 
     In addition, various side gusseted pre-made packages can include handles cut therein (e.g., die-cut), whereby the area around the handle must be sealed to prevent leakage. The seals required around these cut-out handle portions can require significantly wider sealing equipment or apparatus to seal the larger area. Many conventional sealing and filling machines do not have the equipment to accomplish such seals. 
     In addition to the above-detailed problems presented with final filling and sealing of desirable pre-made side gusset packages, various miter seals, K-seals, and the like are often avoided despite their benefits. Namely, many of these sealing features can assist in preventing product from getting into the deep corners of the package and providing a desirable and often stronger seal between the front and back panels, but are often avoided because they hinder access to the opening or width for filling, and therefore slow down the filling process. They also require wider or more sealing surface areas than commonly found on filling and sealing machines. 
     As a result, there is a need for a package design and method of formation that will allow for the many beneficial features and package constructs described above while still providing a package that is easily fillable and sealable. 
     SUMMARY OF THE INVENTION 
     The present invention solves many of the problems that plague conventional flexible packages and packaging methods. Various embodiments of the present invention are directed to a package having a fill slit or fill feature extending from the first longitudinal edge to the second longitudinal edge of a panel of the package (e.g., front or back panel). The package can be a pre-made side gusseted package, wherein the fill slit or feature is provided generally parallel to the top edge or final top seal of the package, in either machine direction or transverse to machine direction. Providing the pre-made package with a top or other seals already formed allows the package former or manufacturer to include various desirable seals, handles, re-closeable devices, multiple panels, and other features in the package, while still allowing for a filling opening for the customer or package filler. The fill slit or feature can be provided nearly anywhere on the package. In one embodiment, the fill slit or feature can be provided just below a re-closeable device, such as a zipper, with a patch of material added to the inside of the package. 
     The patch can extend a width generally greater than the width of the fill slit or feature on the inside of the package, with at least a top edge or portion of the patch being sealed to the inside of the package above the slit or feature. As such, the patch can include a free end that is not sealed (at least initially) to the inside of the package, extending generally below the fill slit or feature. The patch can be constructed of any compatible polymer or like material. In one embodiment, the patch can be constructed of a laminate material adapted to only seal on one side upon application of heat, such that at least one side has a non-sealable barrier film (e.g., preventing it from sealing to an opposing interior panel surface of the package, and providing a oxygen and/or moisture barrier at the fill slit). In certain embodiments, the patch can be included with or defined as part of an access device, e.g., flange portions of a zipper, re-closeable device, or the like. 
     The filler or customer receiving the package in accordance with features of the present invention can open the package to the full width of the fill slit and fill the package with product or contents, even past or above the fill slit. Then, the filler can easily seal the package closed by sealing the slitted panel to the patch or patch material below the fill slit or feature. As such, only one layer or material needs to be sealed, making filling and sealing simpler, easier and more cost effective, while still retaining desired seal features, handles, re-closeable device, and the like, for the package. 
     The features of the present invention can be employed in a myriad of packages, including form-fill-and-seal packages, pre-made packages, stand-up packages, side access packages, top access packages, front and back access packages, and any other package configurations and designs known to those of ordinary skill in the art. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a package having a fill opening and internal fill patch in accordance with embodiments of the present invention. 
         FIG. 2  is a side cross-sectional schematic view of the package at line  2 - 2  of  FIG. 1 . 
         FIG. 3  is a close-up partial schematic view of a portion of the package of  FIG. 2 . 
         FIG. 4  shows a package having a fill opening and internal fill patch, in accordance with embodiments of the present invention. 
         FIG. 5  is a side cross-sectional schematic view of a portion of the package at line  5 - 5  of  FIG. 4 . 
         FIG. 6  shows a package having a fill opening and internal fill patch, with the package being filled with product or material contents, in accordance with embodiments of the present invention. 
         FIG. 7  is a side cross-sectional schematic view of a portion of the package at line  7 - 7  of  FIG. 6 . 
         FIG. 8  shows a package having a fill opening, internal fill patch and bottom gusseted panel, in accordance with embodiments of the present invention. 
         FIG. 9  is a side cross-sectional schematic view of the package at line  9 - 9  of  FIG. 8 . 
         FIG. 10  is a close-up partial schematic view of a portion of the package of  FIG. 9 , with the fill patch finally sealed off at a bottom edge portion. 
         FIG. 11  shows a package having a fill opening and sealed fill patch in accordance with embodiments of the present invention. 
         FIG. 12  is a cross-sectional schematic view of a portion of the package at line  12 - 12  of  FIG. 11 . 
         FIG. 13  is perspective view of a side gusseted package in accordance with embodiments of the present invention. 
     
    
    
     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. For illustrative purposes, hatching or shading in the figures is generally provided to demonstrate sealed portions and/or integrated devices for the package. In addition, the size and proportions of seal or other portions may be exaggerated with respect to the surrounding material and films to improve visual depictions. 
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring generally to  FIGS. 1-13 , a flexible package  10  in accordance with the present invention, and the steps for forming, using and filling the flexible package  10 , are shown. The package  10  generally includes a front panel portion  12 , a back panel portion  14  and one or more side panel portions  18 . The package can further include a bottom panel portion  16 . Any of the panel portions can be gusseted, e.g., the side panel portions  18  ( FIG. 13 ) and bottom panel portion  16  ( FIGS. 2, 9 ). Panel portions  12 - 18  can be joined to form or define an inner cavity  23  of the main package  10  for holding, transporting, or otherwise containing material contents. Each of the panel portions can include internal sealant surfaces. The joining of the front and back panels  12 ,  14  can create corresponding side or seal edges  26 , and top  19  and bottom  21  seals. Alternatively, the panels can be formed of a single web material and folded or formed to define the distinct panel portions. The cross-hatching in the figures is generally used to denote sealing and/or panel edges or folds. Various handles or handle portions  27  as well as re-closeable device  29  or other features or structures can be included anywhere on the package  10  or package panels  12 - 18 . 
     The package panel portions are generally constructed of flexible sheet material such as polyethylene, polyester, metal foil, polypropylene, or polyethylenes or polypropylenes laminated with other materials such as nylon, polyester, and like films. To provide for higher barriers, embodiments can use combination layers of said materials and material of the like. In addition, various panel portions can be constructed of, or incorporated with, materials that provide preferred sealing characteristics. One skilled in the art will understand that a myriad of materials and material laminates are available for selective use for the sealant surfaces to facilitate the bonding attachment described herein. In one embodiment, at least one of the sealant surfaces will comprise “contaminants” that permit a varying level of bonding, wherein the level of bondable attachment depends on the heat applied from a corresponding heat sealing bar or other device. Higher temperatures will create “destructive” (e.g., permanent) bonds while lower temperatures will create a more temporary bond for selective disengagement. Seal pressures and dwells can also affect the bond level. 
     In one embodiment, as depicted in  FIGS. 1-7 , the package  10  includes a fill opening, slit or feature  30  defined in at least one of the panel portions, such as the back panel  14 . The fill opening  30  (and the patch  32  described herein) can be provided in any of the panels and can extend past the panel portion  14  and into the side panels  18 , or any edges/seals of the package  10  (continuous, transverse, machine direction, etc.). In certain embodiments, the fill opening  30  can be covered by a removable material, can be defined by a perforation or scoring in the package panel, or can take on any other configuration adapted to define or selectively provide an opening for filling the package  10  or cavity  23  with material contents. 
     A patch  32 , or other strip or material, can be provided inside the package, with the patch  32  having one or more seal edges or portions  34  and a generally free edge or portion  36 . The patch can be constructed of any compatible polymer or like material, can be formed in any shape or size, and can include various textures, materials, ribs, structures or like features to facilitate sealing and attachment. In one embodiment, the patch can be constructed of a laminate material adapted to only seal on one side upon application of heat, such that at least one side has a non-sealable barrier film configuration (e.g., preventing it from sealing to an opposing interior panel surface of the package—such as front panel  12 ). The patch  32  and its edge portions  34 ,  36  can be included with or defined from flanges or other features of an access device, such as a zipper device, re-closeable device, peel seal material, and the like. 
     The one or more seal edges  34  are adapted for sealing to the inside surface of the corresponding panel portion (e.g., back panel  14 ) proximate the fill opening  30  by the package former or manufacturer, with the free edge  36  remaining initially unsealed to provide an internal flap about the fill opening  30 . While the patch  32  is depicted in various figures for internal attachment or sealing to the back panel portion  14  and across to the side panel portions  18 , the patch  32  can be defined in any of the panel portions  12 - 18 , or combinations thereof. Further, the patch  32  can be applied to the outer surface or portion of a panel, or panels, and can be sealed using various known techniques, such as heat, adhesive, bonding, etc. 
     As depicted in  FIGS. 4-7 , the filling opening or slit  30  in the respective package panel can be manipulated to provide an opening to fill the internal cavity  23  of the package  10  with material contents. As such, the free edge  36  of the patch  32  is configured to permit the contents to enter the internal cavity  23  ( FIG. 7 ). The filler or customer receiving the package  10  in accordance with features of the present invention can open the package  10  to the full width of the fill opening  30  and fill the package  10  with product or contents, generally below the fill opening  30 . However, filling could extend even past or above the fill opening  30 . 
     Upon filling the internal cavity  23  of the package  10  with the desired amount of contents, as shown in  FIGS. 8-11 , the fill opening  30  can be closed off by providing a seal  36   a  to the free edge  36  such that the patch  32  is completely sealed at its edges to the internal surface of the package panel. The seal  36   a  can be applied, as with any of the seals shown or disclosed herein, with a seal bar, band sealer or other equipment or techniques known to one of ordinary skill in the art. Such a configuration means that the filler or customer needs to only seal one layer or material to close off the opening  30  and package  10 , making filling and sealing simpler, easier and more cost effective, while still retaining desired seal features, handles, re-closeable device, and the like, for the package  10 . As shown in the figures, various seals (K-seals, miter seals, top seals, bottom seals, side seals, etc.), handles, re-closeable devices and other features or structures can be finalized and provided by the original package former or manufacturer without generally effecting the ability of the package filler to fill and close off the package  10 . 
     A portion of the patch  32  can include a weakened portion  32   a , such as a perforation, score or other like construct or feature to allow a user or customer to break through, breach or otherwise gain access to the internal cavity contents via the patch  32  even after the patch  32  is sealed (e.g.,  FIG. 12 ). In such an embodiment, the slit opening  30  can be accessed (e.g., via an opening, access device, zipper, etc.) and the user can push through or otherwise breach the weakened feature of the patch  32  to facilitate communication from the interior cavity out through the slit opening  30 . As such, contents can later be accessed or dispensed through the slit opening even after sealing of the free edge  36  at seal  36   a.    
     In various embodiments, the patch  32  can be included with or can be defined by a zipper or other access device (e.g., re-closeable access device). For instance, the patch portions  34 ,  36  can be defined as extending flange or other portions of an access device, such that a first flange portion  34  is sealed on a first side of the slit  30  and the other flange portion provides the free edge portion  36  for later sealing to the interior of the panel portion  14  on a second side of the slit  30 . 
     Various graphics, closeable and re-closeable devices, gussets and like features known to one skilled in the art are also envisioned for use with this invention and can be implemented without deviating from the spirit and scope of the present invention. All references to front, back, top, bottom, and the like are merely for demonstrative purposes and are not intended to limit the variations and positional references and orientations of the panels in the present invention. 
     Various embodiments can further include slits, scores, cuts, removable slugs, perforations, notches, and the like in the package  10  or package panels  12 - 18  to provide or define the features described herein. Other peel-back materials, tabs, or tear portions, can be located proximate the fill opening  30  to facilitate selective access to the package or panels. 
     The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is, therefore, desired that the present embodiment be considered in all respects as illustrative and not restrictive. Similarly, the above-described methods and techniques for forming the present invention are illustrative processes and are not intended to limit the methods of manufacturing/forming the present invention to those specifically defined herein. A myriad of various unspecified steps and procedures can be performed to create or form the inventive package  10 .