Patent Publication Number: US-7581371-B2

Title: Retail package for flowable products

Description:
FIELD OF THE INVENTION 
   This invention relates to a package suitable for storing and dispensing flowable products. 
   BACKGROUND OF THE INVENTION 
   It is desirable to package and display a unit portion of a flowable product in a sanitary manner, while providing aesthetic graphics to attract customers. One challenge is the need to keep the dispensing portion of any unitized container sanitary until the consumer is ready to open the container and consume the contents. 
   Another challenge is to be able to dispense highly viscous fluids, and blends of fluid and solid components, ,in a unit portion package. 
   SUMMARY OF THE INVENTION 
   In a first aspect, a package comprises a pouch comprising a base portion having a first width, the base portion having a closed bottom; and a neck integrally connected to the base portion, the neck having a second width narrower than the first width, wherein the neck comprises an end portion; and a first easy-open device adapted to remove the end portion from the neck; wherein a common wall formed by the base portion and neck has an outer surface and an inner surface; a discrete cap in connected relationship with the outer surface of the common wall of the pouch, the cap covering the end portion of the neck, wherein the cap comprises a second easy-open device adapted to remove at least part of the cap and provide access to the end portion of the neck; and a flowable product disposed in the base portion of the pouch. 
   In a second aspect, a method for making a package comprises providing a package pre-form comprising a pouch comprising a base portion having a first width, the base portion having an open bottom; a neck integrally connected to the base portion, the neck having a second width narrower than the first width, wherein the neck comprises an end portion; and a first easy-open device adapted to remove the end portion from the neck; wherein a common wall formed by the base portion and neck has an outer surface and an inner surface; and a discrete cap in connected relationship with the outer surface of the common wall of the pouch, the cap covering the end portion of the neck, wherein the cap comprises a second easy-open device adapted to remove at least part of the cap and provide access to the end portion of the neck; filling the base portion of the pouch with a flowable product; and closing the open bottom of the pouch of the package pre-form to make a package. 
   In a third aspect, a method for making a package comprises providing a center-folded film; sealing and trimming the centerfolded film to provide a package pre-form comprising a pouch comprising a base portion having a first width, the base portion having an open bottom; a neck integrally connected to the base portion, the neck having a second width narrower than the first width, wherein the neck comprises an end portion; and a first easy-open device adapted to remove the end portion from the neck; wherein a common wall formed by the base portion and neck has an outer surface and an inner surface; and a discrete cap in connected relationship with the outer surface of the common wall of the pouch, the cap covering the end portion of the neck, wherein the cap comprises a second easy-open device adapted to remove at least part of the cap and provide access to the end portion of the neck; filling the base portion of the pouch with a flowable product; and closing the open bottom of the pouch of the package pre-form to make a package. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention is illustrated by reference to the following drawings, encompassing different views of various embodiments of the invention, wherein: 
       FIG. 1  is a schematic elevational view of a package in accordance with an embodiment of the invention in its sealed and filled condition; 
       FIG. 2  is a schematic elevational view of a package in accordance with an alternative embodiment of the invention in its sealed and filled condition; 
       FIG. 3  is a perspective view of the package of  FIG. 1 ; 
       FIG. 4  is a perspective view of a package similar to the package of  FIG. 2 ; 
       FIGS. 5   a  to  5   c  shows steps in filling package pre-forms in accordance with the invention; 
       FIG. 6  is a schematic elevational view of a package in accordance with an alternative embodiment of the invention in its sealed and filled condition; 
       FIG. 7  is a schematic elevational view of a package in accordance with an alternative embodiment of the invention in its sealed and filled condition; 
       FIG. 8  is a more detailed schematic elevational view of an upper portion of the package of  FIG. 7 ; 
       FIG. 9  is an even more detailed schematic elevational view of the graphics of an upper portion of the package of  FIG. 7 ; 
       FIG. 10  is a perspective view of a centerfolded film for use in connection with the present invention; 
       FIG. 11  is a perspective view of the centerfolded film of  FIG. 10 , wherein the centerfolded film has been sealed along an open side; 
       FIG. 12  is a perspective view of a pouch and cap in accordance with the invention; 
       FIG. 13  is a perspective view of a centerfolded film for use in connection with another embodiment of the present invention; and 
       FIG. 14  shows an alternative scheme for filling pouches in accordance with the invention. 
   

   DEFINITIONS 
   The present invention can be used for storing and dispensing flowable products. 
   Flowable product” is used herein to mean products including low viscosity fluids, e.g. water, juice, and non-carbonated beverages, where the viscosity can range from about 0.001 Pascal-seconds (ASTM D-2393) to 0.5 Pascal-seconds; high viscosity fluids, e.g. condiments, oils, syrups, sauces, etc. where the viscosity can range from 0.51 Pascal-seconds (ASTM D-2393) to 25 Pascal-seconds: and fluid/solid mixtures, e.g. diced fruit (peaches, pears, apples, etc.) in a syrup, soups, apple sauce, puddings, flavored gelatins, and even small or comminuted solids such as nuts or shelled nuts, sunflower seeds, trail mix, etc, and other consumable foods such as beans and franks, soup with noodles, etc. Non-food products can also be beneficially packaged in pouches of the present invention provided that they are capable of passing through the neck of the inventive package. The present invention finds particular utility in packaging unit portions of flowable food products, and displaying such packages at retail locations. 
   “Unit portion” is used herein to mean a pre-determined quantity of a flowable product, e.g. a flowable food product intended for consumption by an individual. 
   “Film” is used herein to mean films, laminates, and webs, either multilayer or monolayer, that may be used in connection with the present invention, for the manufacture of the pouch, cap, or both. The FS laminates, such as FS 7055, sold by Sealed Air Corporation through its Cryovac Division, are examples of packaging materials suitable for the invention. These laminates are described in e.g. U.S. Pat. No. 4,746,562 (Fant), incorporated herein by reference in its entirety. An alternative laminate is based on SCLAIR™ sealant film, an ethylene/alpha-olefin copolymer described in e.g. U.S. Pat. No. 4,521,437 (Storms), incorporated herein by reference in its entirety. A commercial monolayer film from DuPont Canada is FS-3. A commercial multilayer laminate is CL 303. Many other films and laminates useful for dry or wet fluid packaging are available, and can be beneficially used in the present invention. One type of film useful in making the pouch or cap of the invention is a monolayer or multilayer film having at least one layer comprising a barrier material having an oxygen permeability, of the barrier material, less than 500 cm 3  O 2 /m 2 ·day·atmosphere (tested at 1 mil thick and at 25° C. according to ASTM D3985), such as less than 100, less than 50 and less than 25 cm 3  O 2 /m 2 ·day·atmosphere such as less than 10, less than 5, and less than 1 cm 3  O 2 /m 2 ·day·atmosphere. Examples of polymeric materials with low oxygen transmission rates are ethylene/vinyl alcohol copolymer (EVOH), polyvinylidene dichloride (PVDC), vinylidene chloride/methyl acrylate copolymer, polyamide, and polyester. Films can include a polyolefin such as an olefin homopolymer or copolymer, such as ethylene polymer or copolymer, propylene polymer or copolymer, ethylene/alpha olefin copolymer, ethylene/vinyl acetate copolymer, ionomer resin, ethylene/acrylic or methacrylic acid copolymer, ethylene/acrylate or methacrylate copolymer, low density polyethylene, or blends of any of these materials. 
   “Pouch” herein includes a pouch, a bag, or like containers, either pre-made or made at the point of packaging. 
   “Filled” with respect to the package herein refers to a package that has been filled with a flowable product in a manner consistent with a commercial filling operation. Thus, the package of the invention may or may not be filled to 100% of its capacity, and can be filled to e.g. 50%, 60%, 70%, 80%, 90% of its capacity, or higher or lower. 
   “Centerfolded film” herein refers to a film that has been folded on itself along its longitudinal central axis; and alternatively includes two separate films that are brought together in a congruent arrangement such that a pouch of the invention can be made therefrom. 
   DETAILED DESCRIPTION OF THE INVENTION 
   EXAMPLES 
   Referring to  FIGS. 1 and 3 , a package  10  in accordance with one embodiment of the invention, in its sealed and filled condition, includes a pouch  12  including a base portion  14  having a first width, the base portion  14  having a closed bottom  16 ; and a neck  18  integrally connected to the base portion  14 , the neck  18  having a second width narrower than the first width. The neck  18  includes an end portion  20 ; and a first easy-open device  22  adapted to remove the end portion  20  from the neck  18 . 
   A common wall  23  formed by the base portion  14  and neck  18  has an outer surface  24  and an inner surface  26 . A discrete cap  28  is in connected relationship with the outer surface  24  of the common wall  23  of the pouch  12 . Although for the sake of clarity the cap  28  is shown as spaced slightly from the shoulders of the pouch, i.e. the portion of the pouch  12  where the base portion begins to transition towards the neck portion, those skilled in the art will appreciate that cap  28  will be in contact at at least some points with the outer surface  24  of the base portion of the pouch. The cap  28  covers the end portion  20  of the neck  18 . Cap  28  includes a second easy-open device  30  adapted to remove at least part of the cap  28  and provide access to the end portion  20  of the neck  18 . Package  10  also includes a flowable product  32  disposed in the base portion  14  of the pouch  12 . 
   Referring to  FIGS. 2 and 4 , a package  110  in accordance with an alternative embodiment of the invention, in its sealed and filled condition, includes a pouch  112  including a base portion  114  having a first width, the base portion  114  having a closed bottom  116 ; and a neck  118  integrally connected to the base portion  114 , the neck  118  having a second width narrower than the first width. The neck  118  includes an end portion  120 ; and a first easy-open device  122  adapted to remove the end portion  120  from the neck  118 . 
   A common wall  123  formed by the base portion  114  and neck  118  has an outer surface  124  and an inner surface  126 . A discrete cap  128  is in connected relationship with the neck  118 . The cap  128  covers the end portion  120  of the neck  118 . Cap  128  includes a second easy-open device  130  adapted to remove at least part of the cap  128  and provide access to the end portion  120  of the neck  118 . Package  110  also includes a flowable product  132  disposed in the base portion  114  of the pouch  112 . 
   With respect to  FIGS. 1 to 4 , and like features in the remaining figures: 
   The base portion  14  and neck  18 , base portion  114  and neck  118 , etc. are in one embodiment formed from a continuous single web or container, and thus share common side walls. 
   The end portion  20  of the neck  18 , end portion  120  of the neck  118 , etc. is in one embodiment an annular opening that can dispense the contents of the package. The end portion can be of any suitable geometry and diameter, provided it permits the dispensing of flowable products from the neck of the package. 
   The first easy-open devices  22 ,  122 , etc. can be any device which is adapted to permit the easy opening of the pouch  12 ,  112 , etc. respectively, i.e. the easy removal of the end portion of the neck, without the need for a separate opening device such as a knife. Examples include a tear notch installed along one or more sides of the neck  18 ; a laser score disposed across the neck; a tear strip; or a weakened area in the film. In the case of a tear notch, it is desirable to provide a thermoplastic film for the pouch that exhibits good tear propagation across the neck of the pouch. If laser scoring is used, the scoring could be patterned to give any predetermined shape lip on the pouch. The lip could thus be removed in an arcuate manner, as opposed to a linear manner in the case of a tear notch with a film having good tear propagation. 
   The cap  28 ,  128 , etc. is a discrete member which in one embodiment is made separately from the pouch. The cap can take the form of a cover that is adhered by adhesive, heat sealing, pressure fit, a pressure sensitive adhesive, a relatively weak heat seal (i.e. a tear seal), or the like to the base portion of the pouch. 
   The cap can be of any suitable geometry and diameter, provided it covers the end portion such that the end portion is kept clean until such time as the user desires to access the contents of the package. 
   The second easy-open device  22  or  122  can be any device which is adapted to permit the easy opening of the package, i.e. the easy removal of at least a portion of the cap, without the need for a separate opening device such as a knife. Examples include a tear notch installed along one or more sides of the cap  28 ; a laser score disposed across the cap; a tear strip; a pressure sensitive adhesive; or an easily peelable seal that seals the cap to the pouch. 
   The pouch, including the base portion and neck, and cap can each be made from any suitable material, such as thermoplastic material or metalized thermoplastic material, e.g. a polymer, with a thickness of preferably between 0.1 and 100 mils. Materials include olefinic or amidic polymers or copolymers. 
     FIG. 2  is similar in most respects to  FIG. 1 , except that the cap  128  of  FIG. 2  is in the form of a label that is adhered to one side of neck  118 , passes over and covers end portion  120 , and is releasably adhered to the other side of neck  118  via  130 . 
   Methodology 
   One way of making a package in accordance with the invention is graphically illustrated in  FIGS. 5A ,  5 B, and  5 C. 
   The method includes the step of providing a package pre-form  210  comprising a pouch  212  including a base portion  214  having a first width, the base portion  214  having an open bottom  215 ; and a neck  218  integrally connected to the base portion  214 , the neck  218  having a second width narrower than the first width. Neck  218  comprises an end portion  220 ; and a first easy-open device  222  adapted to remove the end portion  220  from the neck  218 . Common wall  223  formed by the base portion  214  and neck  218  has an outer surface  224  and an inner surface  226 . A discrete cap  228  is in connected relationship with the outer surface  224  of the common wall  223  of the pouch  212 , the cap  228  covering the end portion  220  of the neck  218 . Cap  218  comprises a second easy-open device  230  adapted to remove at least part of the cap  228  and provide access to the end portion  220  of the neck  218 . 
   Package pre-form  210  can be pre-made at an off-site location, and then provided to the food processor or other customer that is practicing this methodology. Alternatively, the package pre-form  210  can be assembled manually or by suitable machinery. 
   A second step is the filling of the base portion  214  of the pouch  212  with a flowable product  232 . 
   A third step is closing the open bottom  215  of the pouch  212  of the package pre-form  210  to make a package  250 . The open bottom  215  is closed by any suitable method, e.g. by heat sealing, to create a closed bottom  216 . 
   The steps of this process can be carried out by otherwise conventional equipment familiar to those of skill in the art. 
   Those skilled in the art will appreciate that although neck  18 ,  118 , etc. as shown and described throughout this description is illustrated as substantially centrally disposed between the lateral edges of the overall package, i.e. the first and second longitudinal edges of the package and of the pouch, the neck can in some embodiments be disposed such that it is closer to one lateral edge of the pouch and package than the other lateral edge of the pouch and package. Likewise, the exact geometry of the pouch and neck can be varied provided the features of the invention as disclosed and claimed herein are present. Thus for example the pouch can have an end portion that is not at a right angle to the remaining portion of the neck. Also, although the pouch is shown as rectangular in plan view, various shapes can be adopted as desired. These embodiments are also contemplated within the scope of the present invention. 
   EXAMPLES OF ALTERNATIVE EMBODIMENTS 
   Referring to  FIG. 6 , a package  310  in accordance with one embodiment of the invention, in its sealed and filled condition, includes a pouch  312  including a base portion  314  having a first width, the base portion  314  having a closed bottom  316 ; and a neck  318  integrally connected to the base portion  314 , the neck  318  having a second width narrower than the first width. The neck  318  includes an end portion  320 ; and a first easy-open device  322  adapted to remove the end portion  320  from the neck  318 . 
   A common wall  323  formed by the base portion  314  and neck  318  has an outer surface  324  and an inner surface  326 . A discrete cap  328  is in connected relationship with the outer surface  324  of the common wall  323  of the pouch  312 . Although for the sake of clarity the cap  328  is shown as spaced slightly from the shoulders of the pouch, i.e. the portion of the pouch  312  where the base portion begins to transition towards the neck portion, those skilled in the art will appreciate that cap  328  will be in contact at at least some points with the outer surface  324  of the base portion of the pouch. The cap  328  covers the end portion  320  of the neck  318 . Cap  328  includes a second easy-open device  330  adapted to remove at least part of the cap  328  and provide access to the end portion  320  of the neck  318 . Package  310  also includes a flowable product  332  disposed in the base portion  314  of the pouch  312 . 
   The package  310  of  FIG. 6  differs from the package  10  of  FIG. 1  in that package  310  includes a header tab  334  that allows the package  310  to be suspended from a display rack in a retail store environment. Header tab  334  includes a cut-out  336  of any suitable geometry, such as round or triangular as shown, for suspending the package. 
   Referring to  FIG. 7 , a package  410  in accordance with yet another alternative embodiment of the invention, in its sealed and filled condition, includes a pouch  412  including a base portion  414  having a first width, the base portion  414  having a closed bottom  416 ; and a neck  418  integrally connected to the base portion  414 , the neck  418  having a second width narrower than the first width. The neck  418  includes an end portion  420 ; and a first easy-open device  422  adapted to remove the end portion  420  from the neck  418 . 
   A common wall  423  formed by the base portion  414  and neck  418  has an outer surface  424  and an inner surface  426 . A discrete cap  428  is in connected relationship with the neck  418 . The cap  428  covers the end portion  420  of the neck  418 . Cap  428  includes a second easy-open device  430  adapted to remove at least part of the cap  428  and provide access to the end portion  420  of the neck  418 . Package  410  also includes a flowable product  432  disposed in the base portion  414  of the pouch  412 . 
   The package  410  of  FIG. 7  differs from the package  110  of  FIG. 2  in that package  410  includes a header tab  434  that allows the package  410  to be suspended from a display rack in a retail store environment. Header tab  434  includes a cut-out  436  of any suitable geometry, such as round or triangular as shown, for suspending the package. 
   With respect to  FIGS. 6 and 7 , and other embodiments herein that can make use of header tabs, these can be made from any suitable material, such as thermoplastic material, a metal or metalized foil, a metalized thermoplastic, paperboard, or the like, and can form an integral part or extension of a cap (as shown in  FIGS. 6 and 7 ), or an integral part or extension of the pouch, or can be a discrete component that is separately made and then attached to the cap or pouch. 
     FIG. 7  is similar in most respects to  FIG. 6 , except that the cap  428  of  FIG. 2  is in the form of a label that is adhered to one side of neck  418 , passes over and covers end portion  420 , and is releasably adhered to the other side of neck  418  via  430 . 
     FIG. 8  shows an optional detail of header tab  434 , including graphic and/or textual indicia for aiding the consumer in opening the package. The indicia is shown in an enlarged view, with modified text, in  FIG. 9 . 
   Alternative Methodology 
   In another embodiment, referring to  FIGS. 10 through 12 , a film  502  is folded along fold line  504  such that an open side  505  of the now centerfolded film is made (see  FIG. 10 ). The open side is then sealed, e.g. by heat sealing, to create a tubular preform  508  having side seal  506  (see  FIGS. 11 and 12 ) and an open bottom  515 . A pouch pre-form  514  (see  FIG. 12 ) having neck  518  is made by trimming and sealing the tubular pre-form along a predetermined pattern  509 . A separate and discrete cap  528  is brought into contact with, and overlaps a portion of pouch pre-form  514  to produce a package pre-form  510 . The downward pointing arrow of  FIG. 12  indicates relative movement of the cap  528  over a portion of pouch pre-form  514 . The cap is then adhered to the pouch pre-form by any of the devices disclosed herein to result in the package pre-form  510  . Suitable easy-open devices (not shown) like those of the preceding examples, are installed on both the neck  518  and cap  528 . This package pre-form  510  can then be filled and closed e.g. as disclosed herein in  FIGS. 5A to 5C . The steps of this process can be carried out by otherwise conventional equipment familiar to those of skill in the art. 
   As an alternative to a centerfolded film in which one side of the film is formed by a longitudinal fold, two separate films can be brought together in a congruent arrangement such that a pouch of the invention can be made therefrom. In this embodiment,  504  represents a heat seal that joins the congruent side edges of the respective films together. 
   In yet another alternative embodiment,  FIG. 13  shows a centerfolded film  602  so arranged that the fold line  604  can be utilized as the closed end portion  620  of the neck of a pouch, such that the open side  606  serves as the open bottom of the pouch. In this embodiment, pouch pre-forms  614  are made by sealing the pre-forms along a predetermined pattern  609 , for example by heat sealing. Sealing occurs through both plies of the centerfolded film  602  to create pouch pre-forms with sealed sides, each pouch pre-form having a base portion and neck. The array of pouch pre-forms is shown in  FIG. 14 , where a filling arrangement similar to that shown in  FIGS. 5A to 5C  can be used, in which the pouch pre-forms can be aligned in a row and fed into a filling machine, either singly or in a connected array or train of pouch pre-forms. Side heat seals or other appropriate seals can be used to close the sides of each respective pouch either before or during the filling process. Caps can be installed on each pouch or pouch pre-form either before the filling operation, as in the embodiment of  FIGS. 5A to 5C , or alternatively during or after the filling operation, by any suitable manual or mechanical means. 
   As shown in  FIGS. 13 and 14 , some pouch material may in some embodiments be present between adjacent pouch pre-forms  614 . This material may be kept intact to facilitate advancing and filling of the pouches in an array as shown in  FIG. 14 . At some point after filling, this material can than be removed with a knife or other cutting or separating device in order to separate the resultant filled pouches. Drawing reference numeral  611  can represent in one embodiment a centerline defining film material disposed between and connecting two adjacent pre-forms  614 . In another embodiment, reference numerals  614  represent the lateral edge of a side heat seal of one pouch pre-form, and a side heat seal of an adjacent pouch pre-form. 
   The present invention offers the ability to keep a dispensing portion of a unit portion package clean. This facilitates the marketing of a wide variety of goods, particularly food products and more particularly highly viscous food products, and fluid/solid combinations, in single servings at e.g. convenience stores. The package of the invention can also be beneficially used for camping and for school lunches because of the sanitary feature of the package. 
   By providing a package where the cap is discrete from the pouch, different materials can be used for the cap and pouch respectively. This provides an opportunity to separately select and optimize the material for the cap and pouch. For example, the material for the pouch can be chosen based on properties such as toughness, oxygen transmission rate, food law compliance, etc. The material for the cap can be chosen based on properties such as printability (for graphics). If the cap is in the form of a label, an adhesive label can be used that provides for resealability of the pouch after initial use by the consumer. 
   First easy-open devices  22 ,  122 ,  222 ,  322 , and  422 , and second easy-open devices  30 ,  130 ,  230 ,  330 , and  430 , can be installed or created on or in the neck of the respective pouch, pouch pre-form, or on or in the cap, at any suitable time during the making of the pouch, pouch pre-form, cap, or package. For example, a tear notch can be made by any suitable knife or seal bar/knife combination, in the perimeter area of the neck of the pouch or pouch-preform, or the cap, e.g. in the seal area created during production of the profile  509  or  609 , or during production of the pouch or pouch pre-form. The tear notch of the cap can be made during production of the cap before being attached to the pouch or pouch pre-form, or after being so attached. A pressure sensitive adhesive can be of any suitable type, and can be applied manually or by otherwise conventional techniques to the cap, including a cap in the form of a label.