Patent Publication Number: US-2011075954-A1

Title: Reclosable package

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 61/245,699, filed Sep. 25, 2009. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to a reclosable flexible package that is designed to contain products such as liquid and granules. 
     BACKGROUND OF THE INVENTION 
     Flexible packages are used to contain a wide variety of consumer products including liquid and granules, such as shampoos, hair conditioners, laundry detergents, dish detergents, fabric enhancers, liquid soaps, beverages and the like. Some of these flexible packages are made of polymeric film materials such as polyethylene and/or polypropylene. The perimeters of the packages are typically sealed so as to contain the contents. 
     Some flexible packages, i.e., refill flexible packages, are thrown away after the whole contents are transferred to another package such as a jar and a bottle. Such flexible packages are normally provided with no reclosing function because they are neither designed nor intended to be reclosed after initial opening. Therefore, such disposable flexible packages are not suitable for storage, carrying or repeated use after initial opening. If current flexible packages are designed for repeated use, then they need a reclosing function such as a cap and a lid. 
     When the spout of a flexible package is left open without a reclosing function, the contents may leak or spill from the spout if the package falls or is tipped over. Sometimes flexible material for the package is too soft to keep the package standing up. Leaking and/or spilling may cause the outside of the package to be dirty and/or slippery. Thus, there is a need for reclosable flexible packages which control, reduce and/or minimize leakage. 
     Some flexible packages are provided with a reclosing function like a screw cap. However, a separate material like a screw cap is sometimes difficult to use. For example, it is usually not easy to open the package by rotating the screw cap with only one hand. The package typically needs to be held with the other hand. Thus, it would be beneficial if a consumer could open the package with one hand. 
     Further, when the package is opened by releasing the screw cap, the screw cap is typically separated from the package main body. The consumers may drop the screw cap or even lose it, especially when handling the package with wet hands. Therefore, a simple, connected structure is desirable. In addition, reclosable mechanisms such as screw caps and snap-fit caps are not made of the film material itself, but require the use of a separately-formed structure which is then connected to the pouch. This adds undesirable manufacturing complexity as well as cost. 
     There remains a need for a flexible package having a simple, identifiable reclosing mechanism. There is also a need for a flexible package having a reclosing function without using an extra material. The cost requirement in the consumer products is often so severe that addition of another material and/or structure may significantly increase the cost and complexity of the package. 
     Thus, it is one of the objectives of the present invention to achieve a flexible package that is easily reclosable and reopenable, which prevents leakage after opening and reclosing, and/or which can be produced easily and at a reasonable cost. Another objective of the invention is to create a method which enables packages to be reclosed after initial opening. The present invention may control, reduce and/or minimize the leakage of the remaining package contents. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a flexible package with a reclosing function. The package has a first panel and a second panel sealed to each other along their perimeters to form a sealed perimeter surrounding an interior storage space. The sealed perimeter has an upper seal, a bottom seal, a first side seal, and a second side seal opposite the first side seal. The first side seal and the second side seal both connect to the upper seal and the bottom seal. The package also has a spout formed in the sealed perimeter when the package is open along at least a portion of the upper seal. The package further has a discharge channel leading from the spout through the upper seal to the interior storage space. The package has a first recess along the second side seal and a second recess along the upper seal opposite the discharge channel from the first recess. The first recess can engage the second recess such that a fold line is formed that intersects the discharge channel. 
     Without wishing to be bound by theory, the reclosing function provided for the package may be beneficial to the consumers because the consumers can easily reclose/reopen the package with one hand. Further, the consumers can handle the package easily with a wet hand. Further, the package herein can be realized by a simple structure of a flexible material with a combination of recesses. As it does not require other special material than the flexible material, the structure can be manufactured at a very low cost. The package herein serves to control, reduce and/or minimize the leakage and spillage of the remaining contents in the package. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front plan view of a package according to the present invention before tearing off the tearing notch; 
         FIG. 2  is a front plan view of the package of  FIG. 1  after tearing off the tearing notch; 
         FIG. 3  is a front plan view of the package of  FIG. 2  in a configuration where the first recess engages the second recess; 
         FIG. 4  is a front plan view of a self-standing package according to the present invention; 
         FIG. 5  is a front plan view of a self-standing package according to the present invention, where a spout is open; 
         FIG. 6  is a close-up view of  FIG. 5 ; 
         FIG. 7  is a bottom plan view of the package of  FIG. 5 ; and 
         FIG. 8  is a front plan view of a package according to the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Herein, “comprise” means that other elements and/or other steps which do not affect the end result can be added. This term encompasses the terms “consisting of” and “consisting essentially of”. 
     Herein, “thermoplastic” means any polymeric material that will repeatedly soften when contacted with heat and harden when cooled which can be extruded, casted or otherwise formed into a film or sheet material. 
     The present invention relates to a flexible package with a reclosing function. The package has a first panel and a second panel sealed to each other along their perimeters to form a sealed perimeter surrounding an interior storage space. The sealed perimeter has an upper seal, a bottom seal, a first side seal, and a second side seal opposite the first side seal. The first side seal and the second side seal both connect to the upper seal and the bottom seal. The package has a spout formed in an end of the sealed perimeter when the package is open along at least a portion of the upper seal. The package has a discharge channel leading from the spout through the upper seal to the interior storage space. The package has a first recess along the second side seal, and a second recess along the upper seal opposite the discharge channel from the first recess. The first recess can engage the second recess such that a fold line is formed that intersects the discharge channel to close the discharge channel. 
     The package may further have a bottom so as to form a self-standing package. Such a self-standing package may serve to store the package at home, such as on the shelf and on the floor without further support. The bottom may have a material comprising a fold and the bottom connects the first panel to the second panel. 
     The package may have a reinforced area in a location such as adjacent to the first recess, and/or the second recess. The reinforced area may help the flexible package less deteriorated even if reclosing and reopening are repeated. 
     The sealed perimeter may further have a tearing notch in the sealed perimeter, e.g., in the second side perimeter or in the upper perimeter. The tearing notch serves to open the spout easily without using a cutting device such as a pair of scissors and a knife. 
     The package may have a plurality of second recesses. Then, consumers can choose the appropriate position of the second recess, e.g., according to the volume of the product in the interior storage space. 
     The first recess may be formed by a slit in the first panel and the second panel. The combination of slits can be helpful for the closure of the discharge channel because the consumers can engage the slits intuitively without being annoyed. 
     The first recess and the second recess may be a perforation and/or a series of perforation. The perforation may be torn to form the recess when used to engage. 
     The package may have a flow enhancing mechanism such as an embossment and a rigid material, in the discharge channel. The flow enhancing mechanism assists the consumers to dispense the product out of the package easily. 
     The first panel and the second panel may be formed by a single sheet of material. Alternatively, the first panel may be a different material from the second panel. 
     The present invention is more readily understood by the attached non-limiting drawings. 
       FIG. 1  illustrates a front plan view of a package of the present invention. The package,  20 , has a first panel,  22 , with a perimeter,  24 , and a second panel,  26 , which also has a perimeter,  28 . The package,  20 , is formed from a first panel,  22 , with the second panel,  26 . The first panel,  22 , and the second panel,  26 , are sealed at their respective perimeters,  24  and  28 . The first panel,  22 , the second panel,  24 , and/or other parts of the package,  20 , may be formed from a flexible material conventionally used for packaging a product such as liquid, granules, tablets, pastes, gels and a mixture thereof. The flexible material may contain one or more layers, having a polymeric material such as a thermoplastic film, a thermoplastic coating, a foil or aluminum substrate, a paper or cellulose substrate, and a mixture thereof. The foil or aluminum substrate layer can be layered or laminated on the inner face of the package and the thermoplastic film can form the outer face of the package. 
     Suitable thermoplastic materials include, but are not limited to, polyethylene, polypropylene, polybutadiene, polystyrene, polyethylene terephthalate, polyamides, polyesters, polyvinylchloride derivatives, co-polymers thereof, and mixtures thereof. The thermoplastic film may include polyethylene, high density polyethylene, low density polyethylene, linear low density polyethylene, ethylene-vinyl acetate, 1,2-polybutadiene, and mixtures thereof. The thermoplastic film may be mono-extruded or co-extruded. The thermoplastic film may have one or more layers or coatings of thermoplastic film material which are laminated together. 
     The flexible film may have a thickness of from about 10 ♀m to about 400 ♀m, or from about 20 ♀m to about 200 ♀m, or from about 38 ♀m to about 150 ♀m. Suitable materials for use have a film forming polymers having a melting point from about 90° C. to about 300° C., or from about 100° C. to about 200° C. Further, suitable sheet forming polymers for use with the present invention may have a glass transition temperature from about 85° C. to about 300° C., or from about 100° C. to about 150° C. 
     The package when filled may be slacked such that a volume of air is present in the package. The package may comprise from about 5% to about 80%, from about 10% to about 70%, or from about 20% to about 60% of air by volume. 
     The first panel,  22 , and the second panel,  26 , are sealed to each other along their perimeters,  24  and  28 , to form a sealed perimeter,  30 , surrounding an interior storage space,  32 . The package,  20 , contains a product,  33 , such as a liquid fabric enhancer in the interior storage space,  32 . The sealing of the perimeters,  24  and  28 , may be carried out by heat-bonding, ultrasonic sealing, adhesive sealing, pressure sealing, etc. In  FIG. 1 , the sealed perimeter,  30 , is heat-bonded. The sealed perimeter,  30 , has an upper seal,  34 , a bottom seal,  36 , opposite the upper seal,  34 , a first side seal,  38 , and a second side seal,  40 , opposite the first side seal,  38 . The first side seal,  38 , is connected to the upper seal,  34 , and the bottom seal,  36 . The second side seal,  40 , is connected to the upper seal,  34 , and the bottom seal,  36 , but at opposing ends to the first side seal  38 . The package,  20 , also has a spout,  42 , positioned in an end of the sealed perimeter,  30 , when the package,  20 , is open along at least a portion of the upper seal,  34 . The package,  20 , further has a discharge channel,  44 , leading from the spout,  42 , through the upper seal,  34 , to the interior storage space,  32 . 
     The package,  20 , has a first recess,  46 , along the second side seal,  40 , and a second recess,  48 , along the upper seal,  34 , opposite the discharge channel,  44 , from the first recess,  46 . Herein, “recess” refers to a slit or an incision having a narrow cut whose one end is open and the other end is closed. The shape of the first recess,  46 , and the second recess,  48 , may be a linear slit or a curved slit, but it is not limited to them. The first recess,  46 , is capable of engaging the second recess,  48 , such that a fold line,  50 , is formed therebetween. The fold line,  50 , intersects the discharge channel,  44 , to at least partially, or entirely, close the discharge channel,  44 . The first recess,  46 , is a slit in the first panel  22  and the second panel  26 . 
     The package,  20 , has a tearing notch,  47 , which enables consumers to open the spout,  42 . With a notch, consumers need not bother to use a cutting device such as a pair of scissors and a knife. After tearing the tearing notch,  47 , the product,  33 , contained in the interior storage space,  32 , can be dispensed. The tearing notch  47  can be a line of weakness wherein the thermoplastic film is cut or otherwise deformed in a pattern to provide a weaken section of the package, can be an indicator showing the consumer where to cut the package or can be a recess formed by a die cut. See e.g. U.S. Patent Publ. No. 2003/0019780 A1 to Camargo et al. and WO 93/18988 A1 to Scholz et al. 
     In  FIG. 1 , the first panel,  22 , and the second panel,  26  are mirror images to each other. The first panel may be a separate material from the second panel and these separate materials are sealed to each other at perimeters. The material for the first panel and the second panel may be the same or different from each other. The first panel and the second panel may be a integrated material that is folded and sealed to each other to form a package. 
       FIG. 2  illustrates the package,  20 , of  FIG. 1 , after tearing off the tearing notch,  47 , where the spout,  42 , is open so that a product,  33 , in the package,  20 , can be poured out of the interior storage space,  32 . Substantially the whole content of the product,  33 , in the package,  20 , can be dispensed or transferred to another container at once. After dispensing the product,  33 , the emptied package,  20 , can be disposed. Alternatively, the product,  33 , can be dispensed several times out of the package,  20 . In this instance, part of the product,  33 , in the package,  20 , can be dispensed or transferred into another container. The rest of the product,  33 , remains in the interior storage space,  32 . The product,  33 , in the package,  20 , can be dispensed for each use. 
     When the first recess,  46 , and the second recess,  48 , are engaged (see  FIG. 3 ), the discharge channel,  44 , can be fastened to the first panel,  24 , by an optional pair of fasteners,  49  and  51 , in this case, a mechanical fastener of a hook and loop fastener (Velcro®). The fasteners may also be an adhesive fastener such as an adhesive tape or an adhesive material such as glue. The fastener may also be strong enough to keep the two faces of the first panel,  22 , to assist in maintaining the engagement of the first recess,  46 , and the second recess,  48 . 
       FIG. 3  illustrates the package,  20 , of  FIG. 2 , where the first recess,  46 , and the second recess,  48 , are engaged. The engagement of the first recess,  44 , and the second recess,  48 , forms a fold line,  50 , therebetween. The fold line,  50 , ensures at least a partial closure, or even a complete closure, of the discharge channel,  44 . This may be sufficient to prevent leakage or spillage of the product,  33 , from interior storage space,  32 , under normal usage conditions, even if the package,  20 , tips over. After reclosing the package,  20 , by engaging the first recess,  46 , and the second recess,  48 , the package,  20 , can be kept for storage as the discharge channel,  44 , is closed. 
     To reopen the package,  20 , of  FIG. 3 , the first recess,  46 , is released out of the second recess,  48 , and is brought back to its original position as shown in  FIG. 2 . The reclosing and reopening procedure can be repeated until the package,  20 , has been substantially completely emptied. The package,  20 , can be disposed after being emptied. When the first recess,  46 , is released from the second recess,  48 , to reopen the package,  20 , the first recess,  46 , does not separate from the package,  20 . Therefore, the consumers need not fear losing a separate closure device such as a screw cap. 
       FIG. 4  illustrates a front plan view of a self-standing package. The package,  20 , has a bottom,  52 , so as to form a self-standing package. In the package,  20 , a first recess,  46 , is formed by a series of perforations,  49 . When the package,  20 , is opened, the perforation,  49 , is torn off to form the first recess,  46 . The first recess,  46 , is formed from a series of perforation,  49 , torn to form a slit. The consumers may be able to tear and/or cut the perforation,  49 , when engaging the first recess,  46 , to the second recess,  48 . The first recess and/or the second recess may be formed by a die cut, which is a conventional technique to make flexible packages. 
     The package,  20 , has a discharge channel,  44 , which has a flow enhancing mechanism, i.e., an embossment,  58 , therein. The embossment,  58 , extends along the discharge channel,  44 , from the spout,  42 , toward the interior storage space,  32 , to help prevent the discharge channel,  44 , from collapsing and/or closing when the product,  33 , is poured out. The embossment,  58 , may be formed on the first panel,  22 , and/or on the second panel,  26 . The embossment may include a circle, a straight line, a wavy line, an oval, a square, a rectangle, etc. may be preferably employed. The embossment may extend along the discharge channel from the interior storage surface toward the spout. The embossment may be formed parallel, obliquely or perpendicular to the product communication direction. The embossment,  58 , forms an indentation (or alternatively a protrusion, a more rigid or a more resilient part) in the pathway of the product,  33 . The embossment,  58 , may prevent the sides of the discharge channel,  44 , from sticking to each other and serves to improved handling of the package,  20 , when the product,  33 , is dispensed. 
       FIG. 5  illustrates another embodiment of the reclosable flexible package of the present invention, after the tearing notch,  47 , is torn off. The package,  20 , has a reinforced area,  56 , around the first recess,  46 , and the second recess,  48 . The reinforced area,  56 , may have a larger thickness than the rest area of the sealed perimeter,  34 . The reinforced area,  56 , may have a separate material between the first panel,  22 , and the second panel,  24 . The separate material may be selected from thermoplastic materials as described above. As the first recess,  46 , and the second recess,  48 , may receive a strong force when they are engaged together, such a reinforced area,  56 , would be beneficial for maintaining the quality of the package,  20 , during use. Since the first recess,  46 , and the second recess,  48 , are intended to be used to engage each other repeatedly, it is recognized that after repeated engagement and disengagement, the part around the recesses may be weakened. So, the reinforced area,  56 , increases the strength of the material especially at these specific points. The reinforced area,  56 , may include another material inside such as glue, thermoplastic material, an additional layer of the film material, a thicker layer of the film material, etc. 
       FIG. 6  illustrates a close-up view of the spout of the package of  FIG. 5 . The package,  20 , has a discharge channel,  44 , containing a flow enhancing mechanism, in this case a tube,  64 , inside, which allows easy pouring and draining of the product,  33 , during use. The tube,  64 , is positioned inside the discharge channel,  44 , adjacent the spout,  42 . The tube,  64 , may also be affixed to the inner surface of the discharge channel,  44 . The tube,  64 , may be formed of a material such as plastic, rubber, metal and a mixture thereof. The material for the tube may somehow have more rigidity than the package material. The rigidity of the tube may help consumers dispense the product out of the package easily. If present, then the tube,  64 , should be located and/or designed so that it does not interfere with the fold line,  50 , formed when the first recess,  46 , and the second recess,  48 , are engaged together. The spout,  42 , is located along at least a portion of the upper seal,  34 , and is located opposite the bottom,  52 . Therefore, the product,  33 , may not leak out of the spout,  42 , when the package,  20 , is standing. 
       FIG. 7  illustrates a bottom view of the package of  FIG. 5 . The bottom,  52 , has a fold,  54 , therein, and the bottom,  52 , connects the first panel,  22 , to the second panel,  24 , via bottom seals,  36 . The first panel,  22 , and the second panel,  26 , may be formed of a single sheet of material or separate materials, as described above. The single sheet of material may be folded and sealed together at perimeters. The bottom,  52 , may be a single sheet of material connected to the first panel,  22 , and the second panel,  26 . The bottom,  52 , may be the same material integrated to the first panel,  22 , and/or the second panel,  26 . 
       FIG. 8  illustrates an embodiment of a package having two second recesses,  148  and  248 , along the upper seal,  34 . When the first recess,  46 , engages the second recess,  148 , a first fold line,  150 , is formed. When the first recess,  46 , engages the second recess,  248 , a second fold line,  250 , is formed. Whichever second recess,  148  or  248 , is chosen, the discharge channel,  44 , is closed. The consumers may be able to choose the preferable second recess,  148  or  248 , for the first recess,  46 , to engage. 
     After filling the interior storage space,  32 , of the package,  20 , with the product,  33 , the package,  20 , is sealed. When the consumer dispenses the product out of the package,  20 , the tearing notch  47  (see  FIG. 2  and  FIG. 5 ) is first torn off. 
     Apart from the features of first/second recesses of the invention, such packages may be of any shape and size and may serve as containers for liquid and granular products. 
     The package,  20 , may contain a product,  33 , in the interior storage space  32 , such as a laundry detergent composition, a fabric softening composition, a hard surface cleaning composition, a shampoo composition, a hair conditioning composition, a skin care composition, a bleach and a mixture thereof. The product,  32 , contained in the package,  20 , typically has a physical form such as liquid, a granule, a tablet, a paste, a gel and a mixture thereof. The package herein may contain, by weight, from about 10 g to about 5000 g, or from about 100 g to about 4000 g, or from about 500 g to about 3000 g of product therein. The package herein may contain, by volume, from about 10 ml to about 5000 ml, or from about 100 ml to about 4000 ml, or from about 500 ml to about 3000 ml of product therein. 
     The reclosing function provided for the package is beneficial to the consumers because the consumers can easily reclose and reopen the package with one hand. Further, the consumers can handle the package easily with a wet hand. Further, the package herein can be realized by a simple structure of a flexible material with a combination of recesses. As it does not require other special material than the flexible material, the structure can be manufactured at a very low cost. The package herein serves to control, reduce and/or minimize the leakage and spillage of the remaining product in the package. 
     It is understood that the examples and embodiments described herein are for illustrative purpose only and that various modifications or changes will be suggested to one skilled in the art without departing from the scope of the present invention. 
     The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”. 
     Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. 
     While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.