Patent Publication Number: US-2007108088-A1

Title: System and Clip for Holding and Filling a Stack of Flexible Packages

Description:
CROSS REFERENCE TO RELATED APPLICATION  
      This application is related to commonly owned copending Provisional Application Ser. No. 60/737,817, filed Nov. 17, 2005, incorporated herein by reference in its entirety, and claims the benefit of its earlier filing date under 35 U.S.C. 119(e). 
    
    
     BACKGROUND OF THE INVENTION  
      Flexible packages, such as bags, are commonly used to package a wide variety of items. In some cases, it may be desirable to ship and store a plurality of such packages in a configuration that may permit an operator to fill and remove an individual package from the plurality of packages.  
      Traditional means of securing a plurality of packages to each other includes the use of staples, rubber stoppers, or similar devices. Such devices may sometimes damage the flexible packages as they are being separated. Devices such as staples typically include sharp edges that may loosen or detach. In some cases an operator may inadvertently contact a sharp edge of the staple and sustain an injury.  
      Wire wicket devices are also commonly used to retain a plurality of packages. Wire wicket devices typically include a U-shape wire holder that is to hold a stack of flexible packages for easy loading and removal from the holder. Once open, an operator may fill the package. Similar to the devices above, wicket wires may also result in tears or damage to the packaging. In some cases, traditional wicket wires may tear or separate pieces of the package, which may result in accumulation of small particles within a packaging area. In addition, because wicket wires typically are in a form of a U-shaped wire holder, they may also require a bigger foot print. In some packaging applications space may be limited and accommodating a wicket wire may not be feasible. Additionally, the use of wire wickets may include additional parts for retaining the packages on the U-shaped wire holder. In some cases, such parts, such as rubber grommets, rubber tips, chip board header, etc, may be inadvertently separated from the U-shaped wire holder and may fall into a package.  
      Thus, there exists a need for a packaging system that permits a plurality of flexible packages to be stored in compact stack and an individual package to be filled and removed from the stack with minimal damage to the package.  
     BRIEF SUMMARY OF THE INVENTION  
      The invention provides a packaging system that overcomes many of the aforementioned problems. In one embodiment, the packaging system comprises a plurality of flexible packages that are arranged in a stack and held together with a clip having a pair of fingers and a retaining tongue that support and hold the flexible packages in the stack. The clip permits an outermost package to be filled and then removed from the stack with minimal tearing or damage to the flexible package.  
      In one embodiment, the clip comprises a body formed of a resilient flexible material, at least one finger extending outwardly from the body, and a resiliently deformable retaining tongue formed in the body that is configured and arranged to apply a clamping force against the stack so that the packages are retained in a stack. In some embodiments, the clip comprises a pair of fingers that extend outwardly from opposite sides of the body.  
      The flexible packages include at least one opening through which the body of the clip is at least partially insertable so that the fingers engage an outer surface of the outermost package on the stack. The retaining tongue is also configured to engage the outermost package of the stack so that the fingers and the retaining tongue retain the stack of flexible packages. An operator may then remove a flexible package from the stack by applying a pulling force on the outermost flexible package in a direction away from the stack. In one embodiment, the clip and the fingers comprises a flexible material so that as the outermost flexible package is pulled away from the stack, the fingers may collapse and permit the openings to slide over them. As a result, the packaging system may permit the easy removal of a flexible package from the stack with minimal damage to the flexible package.  
      In some embodiments, each flexible package includes a mouth through which an item can be placed into the interior of the package. In one embodiment, each flexible package within the stack may be arranged so their respective mouths are oriented in an upward direction and face outwardly away from the stack. As a result, an operator may efficiently place an item in the mouth without having to fumble about in an attempt to open the package or remove the package before inserting the item into the flexible package.  
      In another embodiment, the packaging system may be used in a system for packaging and sterilizing medical devices. In this embodiment, the packaging system may include a plurality of flexible packages that may each include a breathable vent that permits a sterilization agent to be introduced into the interior of the flexible package. An operator may insert an item into the package and then remove it from the stack. The flexible package may then be sealed so that the item is enclosed within the flexible package. Thereafter the flexible package may be placed into a sterilization chamber that introduces the sterilization agent into the package. The sealed and sterilized flexible package may be used, shipped, and/or stored.  
      Thus, the invention provides an efficient means of storing, filling, and removing a flexible package from a stack of such packages. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)  
      Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:  
       FIG. 1  is a perspective view of a packaging system having at least one clip that holds and supports a plurality of flexible packages in a stack;  
       FIG. 2   a  is a graphical illustration of a clip for holding and supporting a plurality of flexible packages;  
       FIG. 2   b  is another embodiment of the clip that includes a projection for attaching two like clips together;  
       FIG. 2   c  is an illustration of an embodiment of the clip wherein the fingers include an angled surface that helps facilitate removal of a flexible package from the clip;  
       FIG. 2   d  is an illustration of an embodiment of the clip wherein the clip includes a single finger for engaging the outermost package of the stack;  
       FIG. 2   e  is an illustration of an embodiment of the clip wherein the clip includes a pair of fingers and a retaining tongue that extends outwardly from a side edge of the clip;  
       FIG. 3  is a perspective view of the packaging system of  FIG. 1  illustrating the removal of a flexible package from the stack and wherein the packaging system is in a suspended position;  
       FIG. 4  is a perspective of the packaging system of  FIG. 1  illustrating the use of a compressed air source to help facilitate opening of a flexible package;  
       FIGS. 5-6  illustrate an embodiment of the invention wherein the clip includes a projection that is used to retain the stack of flexible packages in a folded configuration for shipment and handling;  
       FIG. 7  is a graphical illustration of a flexible package that includes a breathable vent through which a sterilization agent may be introduced into the flexible packaging; and  
       FIG. 8  is a schematic illustration of a system of using the packaging system of  FIG. 1  to fill a flexible package and sterilize its contents. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.  
      With reference to  FIG. 1 , a packaging system for detachably retaining a plurality of flexible packages is illustrated and broadly designated by reference number  10 . In one alternative embodiment, the packaging system  10  may comprise a plurality of flexible packages  12  that are arranged in a stack  13  and a clip  20  for retaining and holding the flexible packages in a stack. The flexible package may include at least one opening  18  formed in the flexible package adjacent to the open edge  14 . The opening  18  defines a channel in the flexible package through which a clip  20  may be removably inserted. The clip may include at least one finger  24  and a retaining tongue  28  that may be used to hold and support the stack of flexible packages. As shown in  FIG. 1 , the clip may include a pair of fingers  24 .  
      In some embodiments, the flexible packages may include a second opening formed in the flexible package which may also be adjacent to the open edge  14 . In the illustrated embodiments, the flexible package includes a pair of two such openings that are spaced apart. In other embodiments, the flexible package system may comprise a single opening and clip for holding and supporting the flexible packages. The opening  18  defines a channel through which at least a portion of the clip may be inserted through the flexible package. The opening may have a variety of shapes and configurations provided that it permits the body of the clip to be at least partially inserted into the opening and permits the finger  24  to engage an outer surface (see briefly  FIG. 3 , reference number  60 ) of the flexible package. For example, the opening may have a slit-like shape, a hole or punch-like shape, oval shape, circular shape, rectangular shape, a u-like shape, and the like.  
      In one embodiment, the flexible package comprises a front sheet  40  and a rear sheet  42  that are oriented face-to-face and affixed to each other at side edges  46 ,  48  and bottom edge  50 . In another embodiment, the top edge  52  of rear sheet  42  may extend from the rear sheet beyond the open edge  14  of the front sheet along mouth  16  to define extension flap  54 . In some embodiments, extension  54  may merely be a continuous extension of rear sheet  42 . In one embodiment, one or more openings  18  may be formed in extension flap  54 . In other embodiments, the flexible packages may include a pair of cooperating openings that are formed in the front and rear sheets through which a clip may be inserted. The term flexible package includes any type of storage medium having an interior space and a mouth through which items may be inserted to fill the package. In one embodiment, the term flexible package may also include, with out limitation, pouches, bags, satchels, flexible containers, and the like.  
      In one embodiment, each flexible package  12  may include an open edge  14  that defines a mouth  16  through which an item may be inserted into an interior space of the package. In some embodiments, the stack  13  may be arranged so that the open edge  14  of each flexible package is disposed on a common side of the stack. In  FIG. 1 , the plurality of flexible packages are each depicted as having three closed edges and open edge  14  which is disposed facing outwardly away from the stack. The outwardly facing open edge helps facilitate the opening and filling of the flexible packages in an efficient manner.  
      The clip  20  provides a means for retaining and holding the plurality flexible packages in a stack. With reference to  FIGS. 2   a  and  2   b , the clip  20  comprises a body  22  having a pair of fingers  24  that extend outwardly in opposite direction from the body  22 . In one embodiment, the fingers  24  extend outwardly in opposite directions from side edges  26 . The size and length of the fingers may be selected to provide a desired level of holding and/or dispensing force. The clip  20  may also include a retaining tongue  28  formed in the body  22  that is capable of extending outwardly from the body of clip  20 . In this regard,  FIG. 2   b  illustrates the retaining tongue  28  being moved outwardly from the body of the clip. In some embodiments, the body may include front and rear surfaces  30 ,  32  from which the retaining tongue may be configured to extend outwardly.  
      In some embodiments, the clip  20  may also include a hangar opening  34  formed in the body of the clip and spaced apart from fingers  24 . The hangar opening  34  may provide a means whereby the packaging system may be suspended (See briefly  FIG. 3 , reference numbers  34 ,  64 ). As shown in  FIG. 2   b , the clip may also include a projection  36  that may permit two like clips to be fastened together so that the stack of packages can be disposed in a folded condition for storage and shipment. This is discussed in greater detail below.  
      As shown in  FIG. 2   c , each finger  24  may include an angled surface  25  that is configured and arranged to engage an outermost package of the stack of flexible packages. The angled surface  25  may help facilitate removal of the outermost package from the stack. For example, the outermost flexible package may be removed from the stack by applying a pulling force on the package in a direction that is away from the stack. The pulling force causes the edges of the package that are adjacent to the openings to slide along the angled surface  25  until the openings slide off each finger. As a result, the angle surface  25  may help facilitate removal of the package while minimizing tearing that may occur adjacent to the openings.  
      In another embodiment, the clip may include a single finger that is configured and arranged to engage an outermost package of the stack. In this regard,  FIG. 2   d  illustrates a clip  20  having a single finger  24  that projects outwardly from the body  22 . In this embodiment, a lower portion  23  of the body may extend beyond the finger  24  and may also engage the outermost package on the stack. The shape and size of the lower portion  23  may be configured to provide sufficient surface area to engage the flexible package so that the flexible packages are retained on the stack. In yet another embodiment, the clip may include a retaining tongue that extends laterally from a side edge of the body. In this regard,  FIG. 2   e  illustrates an embodiment of the clip  20  comprising a body  22  having a pair of fingers  24  that extend outwardly in opposite direction from the body  22  and a retaining tongue  28  formed in the body  22  and that extends outwardly from a side edge  26  of the body. In this embodiment, the retaining tongue can be configured and arranged to engage and secure the outermost package of the stack to the clip.  
      As can best be seen in  FIG. 3 , a portion of the body  22  extends at least partially through one side  58  of the stack of flexible packages (i.e., front sheet) to the opposite side  56  of the stack (i.e., rear sheet). In one embodiment, the widths of the openings  18  may be approximately the same width of the body  22  so that when the body of the clip is inserted through opening(s) on one or more of the flexible packages, the fingers will extend beyond the width of the slip. As a result, the fingers can engage an outer surface  60  of the outermost flexible package  62  of the stack to thereby retain the stack of flexible packages on the clip. In one embodiment, the clip may comprise a resilient flexible material, such as a thermoplastic material. A resilient flexible material may permit the clip to have some flexibility that may help facilitate the insertion and removal of the clip into and out of the opening(s). For example, the fingers may comprise a material that permits the fingers to collapse as one of the flexible packages is being removed from the stack. As a result, a flexible package may be removed from the stack with minimal tearing or damage to the outer surface that is adjacent to the fingers. In one embodiment, when the body of the clip is at least partially inserted through the openings  18  of the plurality of flexible packages, the retaining tongue  28  extends over the back edges  52  of the plurality of flexible packages and engages the opposite side  58  (i.e., front sheet) of the stack of flexible packages. As shown in  FIG. 3 , the body of the clip is depicted as partially extending into the stack of flexible packages through the openings formed in each individual package. In one embodiment, when the body is at least partially inserted into the stack of packages, the pair of fingers are configured to engage an outermost package of the stack of packages and the retaining tongue is also configured to engage the outermost package of the stack and to apply a clamping force against the stack of packages so that the packages are retained in a stack.  
      The retaining tongue may comprise a resiliently deformable material so that when the retaining tongue extends outwardly from the body it may posses an inherent desire to return to a non-extended state. As a result, the retaining tongue may be used to apply a clamping force against the stack of flexible packages so that the flexible packages are retained in a stack.  
      As discussed above, the clip  20  may also include a hangar opening  34  that may be used to support the flexible packages in a suspended position. In this regard,  FIG. 3  depicts an embodiment of the invention wherein the packaging system includes a pair of support pegs  64  that extend laterally through the hanger openings  34 . In one embodiment, the stack of flexible packages may be suspended by clip with the open edges  14  of the flexible packages being oriented in an upward direction and facing outwardly from the stack of flexible packages. While in a suspended position, an operator may easily open and fill the outermost flexible package.  
      As shown in  FIG. 3 , the outermost flexible package  62  may be removed from the stack of flexible packages  13  by applying a pulling action to the outermost flexible package in a direction opposite of the stack. In some embodiments, the outermost flexible package may be removed from the stack by applying a pulling action downwardly and away from the stack. In some cases, the pulling action may permit the openings to slip over fingers and thereby detach the outermost flexible package from the stack. In other cases, the pulling action may cause a perforation of the outer surface  60  as the flexible package is detached from the stack.  
      In some embodiments, one or more items  66  may be inserted into the flexible package. In one embodiment, the one or more items may be inserted into the flexible package before the outermost package has been removed from the stack  13 . In such an embodiment, it may be desirable to orient the stack of flexible packages so that the open edge  14  of each flexible package is facing outwardly away from the stack. As a result, this may help facilitate the quick and efficient filling of the flexible package and may help reduce any difficulties that may be experience in filling the flexible package. In other embodiments, the one or more items can be placed into a flexible package after removal from the stack.  
      In one alternative embodiment, the package system  10  may be used in conjunction with a device that may help open the flexible package while it is still attached to the clip. In this regard,  FIG. 4  illustrates an embodiment of the invention where a compressed air source  70 , such as nozzle, is positioned above the mouth  16  of the outermost flexible package  62 . In some embodiments, the air source may be positioned above the support peg. The air source may be oriented to provide a blast of compressed air that enters the open edge  14  of the flexible package to thereby open the mouth of the flexible package. The opened mouth may permit an operator to fill the flexible package in an efficient manner. As a result, the amount of time that may be associated with trying to find the mouth or open the flexible package may be reduced. In some embodiments, opening of the flexible packages may be an automated process.  
      As discussed above, the clip may also include a projection that permits two like clips to be fastened together so that a stack of flexible packages may be disposed in a folded condition for storage and shipment. In this regard,  FIGS. 5 and 6  illustrate a packaging system  10  wherein at least one of the clips  20  includes a projection  36  that projects outwardly from the body at a distal location  38  from the fingers  24 . The projection has a configuration that permits the projection to pass through an opening in another like clip. In one embodiment, the projection may have a configuration that is adapted to pass through a hangar opening  34  of the other clip. As can be seen in  FIGS. 5 and 6 , the stack of flexible packages may be folded so that the projection may be inserted into the corresponding hanger opening  34  on the other clip  20 . The stack of flexible packages may be retained in this folded configuration for storage and shipment.  
      In some embodiments, the hanger opening may include one or more slits or incisions that help to facilitate inserting the projection into the hanger opening. In this regard,  FIG. 2   c  illustrates an embodiment wherein a slit  35  is formed in the body  22  of the clip adjacent to the hanger opening  34 . As shown, the slit  35  extends from the hanger opening into the body of the clip. To join two clips together, a user can align the projection  36  on one clip with the hanger opening and the slit  35  on a second clip. Thereafter, the user presses the projection through the hanger opening. Pressing the projection through the hanger opening when it is aligned with the slit will cause the slit to slightly separate so that the projection can be inserted into the hanger opening. In some embodiments, the orientation of the slit may be arranged so that once two clips have been joined together, the clip that is inserted into a corresponding hanger opening is rotated slightly so that the stack of packages are maintained in an orderly stack. Rotation of the clip within the hanger opening may also help prevent the projection from inadvertently passing back through the hanger opening, and may also permit a user to easily separate the clips by rotating one of the clips in the hanger opening so that the projection is aligned with the slit.  
      In some embodiments, the projection may have an arrowhead-like shape. The arrowhead shape helps facilitate the insertion of the projection into the hanger opening. As shown in  FIG. 5 , a lower portion of the arrowhead may include a surface  39  that abuts the rear surface of the body after the projection has passed through the opening. The projection may be removed by applying a pulling force to the clip so that surface  39  passes through hanger opening  34 .  
      As discussed above, the flexible package may comprises a front sheet  40  and a rear sheet  42  that are oriented face-to-face and affixed to each other at side edges  46 ,  48  and bottom edge  50 . Preferably, each of the side edges and bottom edge are permanently sealed. In some embodiments the front and rear sheets may comprise two separate sheets, or alternatively, a single sheet that has been center-folded at bottom edge  50 . Together the sheets define flexible package  12  having an interior space for receiving an item and a mouth  16  through which an item can be placed into the interior of the package. The front and rear sheets may be sealed together using adhesive, thermal bonds, ultrasonic bonds, radio frequency sealing, or the like.  
      In another embodiment, the flexible package may comprise a thermoplastic material that may be suitable for medical packaging applications. In one embodiment, the flexible package may comprise a thermoplastic material having barrier properties that may be used to maintain the interior of the flexible package in a substantially sterile condition.  
      In yet another embodiment, the flexible package may include one or more breathable vents, such as a membrane, through which a sterilization agent may be introduced into the interior of the package. In this regard,  FIG. 7  illustrates a flexible package  12  having a breathable vent  80  that permits the introduction of a sterilization agent into the package, while preventing the ingress of contaminants and other pathogens into the package. Sterilization agents may include, but are not limited to, steam and ethylene oxide.  
      In one embodiment, the packaging system may be particularly useful in the packaging and sterilization of medical instruments and devices.  FIG. 8  is a schematic illustration of a method and system  90  of using the packaging system to package and sterilize one or more items within a flexible package. In one embodiment, system  90  may comprise a packaging system  10 , a sealing device  92 , such as a vacuum sealer, and a sterilization chamber  94 . In a first step, an operator may insert one or more items  66  into the interior of a flexible package. The filled flexible packaging may then be removed from the clips  20 . In a next step, the mouth of the flexible packaging may be sealed, for example, with a heat seal. Next, the contents of the flexible package may be sterilized by introducing a sterilization agent into the interior of the flexible package. Alternatively, the contents of the flexible package may be sterilized prior to sealing the mouth of the package closed. In some embodiments, the sterilization chamber may comprise an autoclave or a gas chamber that flushes the flexible package with a sterilization agent such as ethylene oxide. After the package  12  has been sealed and sterilized, it may be packaged in a larger container, stored, and/or shipped.  
      In some embodiments, the system  90  may also include a compressed air source (see briefly,  FIG. 4 , reference number  70 ) that may help facilitate filling of the flexible packages in a relatively more efficient manner. In some embodiments, the system  90  may include a means of conveying  96  the flexible package between subsequent steps. Such conveyance means may include a conveyor belt, carts, and the like.  
      After the flexible package has been manufactured, sealed, and filled, it is ready for sterilization. Autoclaving is a method that is commonly used for sterilizing medical products. In one technique, the sterilized package is placed into a plastic overwrap or container. The overwrap may serve as a dust cover and help protect the contents of the package from any external foreign contaminants, moisture loss, gas permeation, etc. If desired, the sterilization process could be performed following the overwrapping process.  
      In one alternative embodiment, the flexible package of the present invention may be prepared from a variety of suitable plastic materials whereby a strong, lightweight, reliable, yet economic container is provided. Preferably, each sheet comprises a plastic material having an inner surface capable of forming a strong heat seal with the inner surface of the opposite sheet to define the package. Suitable plastic materials include both multi- and mono-layered films, webs, laminates, and the like. In other embodiments, the flexible packages may comprise both multi- and mono-layered paper and cellulose materials.  
      In some embodiments, the flexible package may comprise one or more thermoplastic materials. In one embodiment, the flexible package may comprise a thermoplastic material that may be useful in medical applications. Suitable thermoplastic material may include polyolefins including, ethylene homopolymer, ethylene copolymer, propylene homopolymer, propylene homopolymer, propylene copolymers, and blends thereof. Suitable ethylene copolymers may include ethylene/alpha-olefin copolymers. The term “ethylene/alpha-olefin copolymer” generally designates copolymers of ethylene with one or more comonomers selected from C 3  to C 20  alpha-olefins, such as 1-butene, 1-pentene, 1-hexene, 1-octene, methyl pentene and the like, in which the polymer molecules comprise long chains with relatively few side chain branches. A more in depth description of ethylene/alpha-olefin copolymer is contained in U.S. Pat. Nos. 5,695,840 and 6,027,776, the contents of which are hereby incorporated by reference.  
      Suitable material may also include film/laminates comprising a blend of polyethylene and an ionomer. In one embodiment, the polyethylene-ionomer blend may contain from about 12 to about 95% ionomer and from about 5 to about 88% polyethylene, the blends in such ranges may provide films/laminates having excellent properties as well as excellent linear tear qualities in the direction of extrusion.  
      Preferably, flexible packages for use in the medical field are prepared from films or laminates that can withstand the high-temperature sterilization and storage conditions that are commonly associated with medical solutions and powders. Particularly useful films for medical packages are described in U.S. Pat. No. Re 30,726, the contents of which are hereby incorporated by reference.  
      The flexible package may be prepared in a variety of ways. In one embodiment, the package may be prepared from a roll of double-wound film wherein the sheets are separated to form the front and rear sheets of the package. The separate sheets may then be conveyed in a substantially parallel manner. In other embodiments, the front and rear sheets may be formed from a tubular film, slit tubular film, or from sheets of film that are provided on separate supply rolls. In one embodiment, the flexible packages may comprise a tubular or slit tubular film wherein the opposing faces of the tubular film define the front and rear sheets. In some embodiments, any excess sheet material can be trimmed away from around the perimeter heat seals. If desired, the front or rear sheets may be printed with any necessary labeling information.  
      Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.