Patent Publication Number: US-8540427-B2

Title: Gusseted package with impact barrier

Description:
PRIORITY APPLICATIONS 
     This application claims priority to and the benefit of U.S. Provisional Application No. 61/034,582, filed Mar. 7, 2008, which is hereby fully incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to flexible packaging and, more particularly, to packages, and methods for forming and using packages, having a gusseted portion to provide an internal material impact barrier to protect portions and devices in packages adapted to hold or carry relatively large or heavy material contents. 
     BACKGROUND OF THE INVENTION 
     Flexible packages used for items like pet food and lawn and garden products are generally large in size, and hold and carry relatively large contents. These types of products and packages can be used over and over again. As such, top seals or closure devices, such as zippers and other re-closeable devices and methods, in the packages must be protected and remain functional to ensure this continued use. In addition, the re-closeable devices and methods must remain easy to implement and operate. This presents an inherent problem because the heavier material contents can damage those critical package features. 
     Moreover, larger and heavier packages must undergo what is often called a “drop test” to ensure that the package can withstand the rigors of shipping, handling, and extended use. A typical drop test involves placing a filled package on a platform, normally three feet high from the floor. The platform is then swung out or otherwise removed, allowing the package to drop. The package is typically dropped on its front, back, and ends in further drop testing. 
     Many of the package types being used for these bulk products are packages with side gussets, as they expand to accommodate large volumes of products. Although there are ways of attaching zippers or other re-closable devices in-line (e.g., machine direction) while the package is being made, there are also means of attaching the devices to the package after it is made and before it is filled with product. To date, this is a common means of attaching slider style re-closable zippers. Also, because side gusseted packages can be difficult to open, and easy opening is a feature the consumers expect, most slider zippers being used are exposed at the top of the package. 
     Some packages, such as those disclosed in U.S. Patent Application Publication 20080050056, may include various zipper configurations utilized to protect the structure from shock loading. However, these methods utilize the zipper device materials to increase protection, which in turn can increase formation, material and labor costs. Further, additional membranes or device materials must be made strong enough to handle the shock loading, which in turn makes it more difficult for the consumer to gain access to the package openings. 
     As a result, there is a need for a flexible package that substantially solves the above-referenced problems with conventional package designs, configurations, and manufacturing methods. 
     SUMMARY OF THE INVENTION 
     The present invention solves many of the problems facing flexible packages and the packaging industry. Embodiments of the present invention are directed to a package generally including at least one front and back panel defining an interior compartment accessible through an access opening. The package can further include one or more side panel portions, gusseted or non-gusseted. The interior is capable of storing and dispensing product and other objects, including relatively large or heavy materials. The package includes a gusset portion formed at a portion, such as the top portion, of the front or back panel portions to provide a focal impact region. The gusset portion extends generally between or across the top portions of the front and back panel portions such that a gusseted top region is formed distinct or distinguishable from the front and back panel portions. An edge region of the gusset panel portion can be sealed or otherwise joined, directly or indirectly, to an interior sealant surface of the front or back panel portions to define the impact or material barrier extending into the internal compartment. 
     By forming the gusseted portion in the package, a flexible material is provided proximate the re-closeable device, such as a zipper, that provides an alternate impact region for the contents of the material. This impact region can protect the re-closeable device from the potentially damaging energy and shifting of the material contents of the package during shipping, handling, and use. Because the gusset is taking the vast majority of the impact energy or load, nearly any zipper or other re-closeable device can be employed. Namely, there is no need for zippers made of increased thickness or material strength because the zippers, or other devices, are no longer required to take the damaging impact and pressure of the material contents. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a package having a gusseted impact barrier and side panels in accordance with an embodiment of the present invention. 
         FIG. 2  is a perspective view of a package folded at the side gusset panels in accordance with an embodiment of the present invention. 
         FIG. 3  is a perspective view of the package of  FIG. 2  folded at the side gusset panels in accordance with an embodiment of the present invention. 
         FIG. 4  is a perspective view of the package of  FIG. 2  folded at the side gusset panels and the back panel in accordance with an embodiment of the present invention. 
         FIG. 5  is a cross-sectional schematic view of the package of  FIG. 4  with a front panel flap and folded back and side panels. 
         FIG. 6  is a cross-sectional schematic view of the package of  FIG. 4  with the front panel flap trimmed. 
         FIG. 7  is a cross-sectional schematic view of the package of  FIG. 4  with a re-closeable device attached to the top gusseted panel and front panel. 
         FIG. 8  is a cross-sectional schematic view of the package of  FIG. 4  with a re-closeable device attached to the top gusseted panel and front panel, illustrating product pressure on the top gusseted panel. 
         FIG. 9  is a cross-sectional schematic view of the package of  FIG. 1  with a top gusseted panel, material contents and a re-closeable device, in accordance with an embodiment of the present invention. 
         FIG. 10  is a cross-sectional schematic view of the package of  FIG. 1  turned upside down, with the material contents substantially impacting the top gusseted panel. 
         FIG. 11  is a close-up view of sealed portions of the top gusseted panel of the package of  FIG. 1  in accordance with an embodiment of the present invention. 
         FIG. 12  is a perspective view of a package having a gusseted impact barrier in accordance with an embodiment of the present invention. 
         FIG. 13  is a perspective view of a package folded at the back panel in accordance with an embodiment of the present invention. 
         FIG. 14  is a cross-sectional schematic view of the package of  FIG. 13  with a front panel flap and folded back panels. 
         FIG. 15  is a cross-sectional schematic view of the package of  FIG. 13  with the front flap trimmed. 
         FIG. 16  is a cross-sectional schematic view of the package of  FIG. 13  with a re-closeable device attached to the top gusseted panel and front panel. 
         FIG. 17  is a cross-sectional schematic view of the package of  FIG. 13  with an access device attached to the front panel. 
         FIG. 18  is a close-up view of sealed portions of the top gusseted panel of the package of  FIG. 12  in accordance with an embodiment 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, cross-hatching, dashing or shading in the figures is provided to demonstrate sealed portions and/or integrated regions or devices for the package. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     A purpose of the present invention is to form a package, such as a flexible package, to have a gusseted portion, allowing for increased protection of an access region or device provided in the package proximate the gusseted portion. The various embodiments and teachings provided herein can also be employed with a rigid or semi-rigid package, or simply to create a gusseted portion with or without re-closeable devices. Further, references to “top,” “bottom,” and the like are for illustrative purposes only and are not meant to limit the scope of the disclosed invention. For instance, the “top” gusset invention could be just as easily employed in the bottom or side portions of the package to form a gusseted package. 
     Referring generally to  FIGS. 1-18 , a flexible package  10  and components and configurations in accordance with embodiments of the present invention are shown. The package  10  generally includes a front panel portion  12 , a back panel portion  14 , an access region or device  24 , and a gusseted impact panel portion  20 . In addition, the package  10  can include one or more side panel portions  16 ,  18  and a bottom panel portion  22 , gusseted or non-gusseted. Each side panel  16 ,  18  can be gusseted to define corresponding gusset lines or folds  17 ,  19 . In the depicted embodiments, the joining and/or forming of the above-referenced panels define the package  10  with an internal cavity or compartment  25  accessible through a package opening  23 , generally having an adjustable internal volume capacity for holding material contents  11 . The panels  12 - 22  are often referred to as “webs” or films. Each panel can be formed from an individual web or, alternatively, each of the panels can be portions of a larger single web, wherein the large web is folded, cut and/or shaped to define the individual and distinct panel portions and, ultimately, the shape and size of the package  10 . Further, in one embodiment, the top  20  and bottom  22  panel portions can be formed by the selective joining of the respective end portions of the panels  12 ,  14  some size measurably longer than the panels  16 ,  18  to provide necessary material for folding to form panel portions  20 ,  22 . Regardless of the formation techniques or the use of separate web panels, a designated and distinguishable panel portion is defined for each panel. Further, one or more of the panel portions can be gusseted. 
     In an upright flexible package  10 , the side panels  16 ,  18  can be defined as those panels with a distance measurement between the longitudinal sides being some distance shorter than a distance between the longitudinal sides on adjacent front  12  and/or back panels  14 . 
     The package panel portions  12 - 22  are generally constructed of flexible sheet material such as polyethylene, polyester, metal foil, polypropylene, or polyethylenes laminated with other materials such as nylon, polyester, and like films. To provide for increased barrier properties, embodiments can use composite or laminate layers of said materials and material of the like. Generally, in such composite or laminate embodiments, a material having preferred sealing characteristics can be joined, bonded or laminated to a material having a different preferred characteristic (e.g., beneficial oxygen barrier properties). Regardless, single sheets, composites/laminates, and a myriad of other materials and techniques known to one skilled in the art may be implemented based on particular usage and manufacturing needs without deviating from the spirit and scope of the present invention. The package  10  and its portions can be formed to provide a stand-up pouch, pre-made pouch, bag-top, one formed and filled on a “form-fill-seal” machine, and other known package designs and configurations. Other known package designs and packaging techniques and features can be adapted to incorporate or form the configuration of the present invention as well. 
     The access region or device  24  can be a re-closeable device that is disposed on or integrated to at least one of the front or back panel portions  12 ,  14 , and capable of multiple re-closeable uses. Fixed zippers, slider zippers, adhesives/tapes, snap or screw cap devices, snap fasteners, hook and latch fastening, spouts, fitments, and other like techniques and devices known to one skilled in the art can be employed for use as the device  24 . In addition, the access device  24  can be provided to the package  10  during the machining or formation process, or pre-applied to a section of material or web prior to package formation. The apparatus and methods disclosed in U.S. Pat. Nos. 6,019,512 and 6,516,850 for integrating zippers into a flexible package are incorporated herein by reference except for express definitions contained therein. In addition, other machines consistent with that disclosed herein, and technologies for attaching access opening devices to flexible packaging sheets or webs are also envisioned for use with the present invention. Alternative embodiments of the access region or device  24  can be single or minimal use access devices, folding flaps, spouts, holes, and the like. For instance, a peel seal as described herein can be included with or without a zipper for such embodiments where re-closeability is not desirable or needed. In such an embodiment, the region  24 , such as that shown in  FIG. 1 , can simply include a temporary peel seal  24 , or a peel seal utilized in combination with and proximate a re-closeable device  24 . Further, the access device can be disposed along any portion of the package  10  without deviating from the present invention. 
     As demonstrated in the embodiment of  FIGS. 1-11 , the package  10  is generally formed to define a top gusseted impact region or panel portion  20 . Such an embodiment of the package  10  can include side panel portions  16 ,  18 , such that the top gusseted portion  20  can be formed by the folding and sealing of portions of the front and/or back panel portions  12 ,  14 . For instance, the juncture of the side panel portions  16 ,  18  with the panel portions  12 ,  14  can include folds and/or seals  30 ,  32 ,  34 ,  36 . These seals  30 - 36  can be defined by folds, folds and seals, and the like. Embodiments employing seals can utilize heat seals, adhesive bonding, and various other known sealing techniques. Seal regions are generally depicted in the figures with cross-hatching. 
     As shown in  FIGS. 1-4 , seals  30 ,  34  are provided at the juncture of the front panel portion  12  with the side panel portions  16 ,  18 . Seals  32 ,  36  are provided at the juncture of the back panel portion  14  with the side panel portions  16 ,  18 . Further, in such an embodiment, the seals  30 ,  34  can run a distance short of the length of the seals  32 ,  36 , leaving a remaining edge length  38  generally free from folds or seals proximate the top of the front panel  12 . In other embodiments, each of the seals  30 - 36  can run various lengths in comparison to the lengths of panels  12 ,  14  without deviating from the spirit and scope of the present invention. The free edge length  38  can be originally formed without a seal or can be created by slitting, scoring or cutting down a distance in the package  10  or seals  30 ,  34 . 
     As demonstrated in the embodiment of  FIGS. 2-8 , the formation, via machine or manual, of the package  10  can include folding, bending or otherwise manipulating the front panel portion  12  to create a front flap  40 . Similarly, the side panel portion  16  along a portion of length  38  can be positioned and collapsed inward toward the back panel portion  14  such that an edge region or portion  42  of the panel  16  angles toward the back panel portion  14 , away from the flap  40 . In addition, the back panel portion  14  can be folded upon itself at fold lines  50 ,  52 , sandwiching or enclosing the edge  42  and a top portion of the side panels  16 ,  18  therein to define first edge portions  42   a  and second edge portions  42   b  on either side of or divided by fold  52 , as shown in  FIG. 4 . These folds  50 ,  52  can define the top gusseted portion  20  with a material impact portion  48  and a top end portion  46 . The top end portion  46  generally includes the layered materials of the folded back panel portion  14  and the top of the folded side panel portions  16 ,  18 . At least first edge portions  42   a  are operatively (e.g., directly or indirectly) sealed or otherwise joined to an inner sealant surface of the front panel portion  12 . Sealing the edges  42   a  to the front panel portion  12  positions the fold  52  within the compartment  25 , providing the impact portion  48  across a significant area within the compartment  25  while simultaneously allowing for contents  11  to traverse a flow gap  55 . The flow gap  55  can vary in size depending on the content traversal needs as well as the length or size of the impact portion  48 . The flow gap  55  is provided between top portion  46  and front panel  12  because the referenced sealing is generally limited to the edges  42   a  and not the entire length of portion  46 . However, a peel seal  47  (shown with exaggerated thickness and proportions in  FIG. 8 ) can be provided along a portion of material  46  (e.g., below an access device  24 ) that extends between the edges  42   a  to temporarily seal material  46  to the opposing panel  12  to further assist in maintaining gusset portion  20  in a position to protect any access device  24  or other structural portions of the package  10  proximate the top portion of the front panel  12 . This peel seal feature can provide additional protection from the material contents  11  during shipping and handling that occurs before the user opens the package. When the user opens up, or tears or releases, a portion of region or device  24 , at a top portion of the front panel  12 , the peel seal can then be released, providing the benefits of access into the internal compartment  25  while simultaneously retaining the benefits of the impact barrier and gusseted portion  20 . The close-up view of  FIG. 11  shows the herein-referenced edge seal portions in cross-hatching, with the thickness and proportions exaggerated for demonstrative purposes. 
     Various folding configurations and designs can be implemented in alternative embodiments to form the top gusseted portion  20 . For illustrative purposes, the details of the folds and gusset formation are shown and described along side panel portion  16 . However, corresponding like folds and/or seals as described herein can be applied to the opposing side panel portion  18  along and with respect to the relationship with the front and back panel portions  12 ,  14  to create the gusseted top panel portion  20  extending a length between the panel portions  16 ,  18 . Moreover, the gusseted top panel portion  20  can be reversely configured such that the flap  40  extends from the back panel portion  14 , the impact portion  48  (or portion  46 ) extends angled from the back panel portion  14  toward the front panel portion  12 , and the device  24  is integrated or provided along a portion of the back panel portion  14 . 
     As demonstrated with the top gusset configuration of  FIGS. 5-10 , the gusseted impact portion  20  along fold  52  creates the extending material impact barrier  48 , positioned generally below the re-closeable device  24 . In one embodiment, as shown in  FIG. 6 , excess material of the flap  40  is cut down or otherwise reduced in size to generally match the height of the gusseted portion  20  at the top end portion  46 . 
     A device portion or flange  27  of the re-closeable device  24  can be disposed along the front panel portion  12  with a second device portion or flange  29  being disposed proximate the end portion  46  of the gusset portion  20 , as shown in  FIGS. 7-8 . In an embodiment of the invention employing a mating re-closeable zipper, the first device portion  27  can include a male profile member  27   a  and the second device portion  29  can include a female profile member  29   a , interlockable to provide selective access into the internal compartment  25  via the access opening  23 . 
     In other embodiments, the device  24  can be fully disposed along a portion of a single panel, such as the front panel portion  12  demonstrated in  FIG. 17 . As described herein, various device configurations and positions are envisioned for implementation with the present invention. For instance, the top flap  40  can be used as a handle, or otherwise used to assist with handling, use, etc. Non re-closeable, or limited use access devices, such as peel seal films, tear openings, and the like can be utilized and are envisioned for use with the present invention. For instance, the region  24  of  FIG. 1  can be a tear region  24  including a scored or perforated region  24   a  adapted for tearing away by the user to gain access into the package  10 . This tear region  24  could be used in combination with or in lieu of an access device such as a re-closeable device. 
     As shown in  FIGS. 9-10 , seals  60 ,  62  can be provided at the top of the package  10  to seal off the film or package materials of the top gusset portion  20 . Seal  60  can seal the end region of portion  46  to the top of the front panel portion  12 . Seal  62  can seal the fold  50  with a top portion of the back panel portion  14 . The fold  50  can also be included without seal  62  running therealong. Each of the seals  60 ,  62  can be known permanent or destruct seals, peel seal or temporary seals, and the like. With such a configuration, material contents  11  are accessible within the internal cavity  25 , through access opening  23  and re-closeable device  24 . The seal  60  or portions of the front panel  12  proximate access region or device  24  can be notched, tabbed, scored or otherwise adapted to permit a user to pull open, cut or tear off material to gain access to the internal compartment  25 . 
     Gusseted panel portion  20  can be left open, or slit open or unsealed, proximate or at the fold  50  to permit filling of the package  10  with the material contents. The entire package  10  may be formed, including the sealing of edges  42   a  to the front panel portion  12 , with the slit or opening provided at fold  50 . As such, after the package  10  has been filled with content  11  through the referenced opening after formation, fold  50  (or the slit or opening) can be sealed off and the package  10  prepared for consumer use. This may be particularly useful for a package  10  of the present invention having a bottom gusseted panel  22  that is sealed during formation, thus closing off a primary means of filling the package  10 . The opening in gusseted panel portion  20  can provide the necessary fill opening. It is noted that the addition of the gusseted panel portion  20  of the present invention provides an additional external display area, such as that utilized to provided logos, graphics, and the like. 
     When the package is positioned generally upside down, or subjected to a drop test, the material contents  11  generally flow toward the top of the package  10  and substantially impact the gusset portion  20  rather than the structure of the device  24 , as demonstrated in  FIG. 10 . Namely, the material barrier  48  running from the fold  52  to the top seal  62  or fold  50  absorbs most if not all of the impact and weight of the material contents  11 , while simultaneously permitting expansion or give about the gusset fold  52 . Contents  11  that impact the material barrier  48  of the gusset  20  tend to initiate an impact trigger position whereby barrier  48  and fold  52  are pushed toward the front panel  12  (in a front panel device  24  embodiment), thereby substantially preventing the contents  11  from impacting the device  24  or those panel portions carrying or proximate the device  24 . Moreover, the top gusset  20  can absorb impact even after the user or consumer has initially opened the package  10 . The gusset  20  and impact barrier  48  are not removed with the opening of the package or use of the device  24  (re-closeable or not), thereby retaining the structural impact features of the gusset  20 . 
     While the material barrier  48  of the gusseted impact portion  20  can control impact load and redirect contents  11  away from the device  24 , the access gap  55  is provided that can facilitate access to the contents  11  through the opening  23  or access device  24 . For instance, a user can tip or angle the package  10  to direct the contents  11  along the plane of the panel portion  12  and toward the device  24  through the access gap  55 , without directing the contents  11  into the impact barrier  48  of the gusset portion  20 . In addition, a user can manipulate the flexible, or relatively flexible, panel portions (e.g., panel portions  12 ,  20 ) to open up or expand the access gap  55 , or pull back the gusset portion  20  from its triggered position, thereby pulling fold  52  away from panel portion  12  and increasingly opening up the access gap  55  to allow the contents  11  to flow toward the device  24 . 
     As depicted in  FIGS. 12-18 , the package  10  and the top gusset portion  20  can be formed without side panel portions  16 ,  18 . In such an embodiment, the back panel portion  14  can be folded over itself to form the folds  50 ,  52 , as shown in  FIGS. 13-17 . The flap  40  of the front panel portion  12 , like that of the side panel embodiment, extends out from the front panel portion  12  and can be cut off or otherwise reduced in size to match the top end portion  46  of the folded back panel portion  14 , as shown in  FIGS. 13-15 . Accordingly, the device  24  can be attached to the front panel portion  12 , or as otherwise detailed herein for the present invention. Side seal portions  31 ,  33  can run various lengths of the package as discussed hereinabove. Further, slits, scores or other features can be implemented at the edge junctures of the front and back panels. 
     Again, the gusset material generally defined from fold  52  and on to fold  50  provides the load barrier  48  adapted to protect the device  24  from damage from the material contents  11  during shipping, handling, use or planned drop tests. Edge portions  42   a ,  42   b  are on either side of or divided by fold  52 , as demonstrated in  FIG. 13 . Edge portions  42   a  can be operatively sealed or otherwise joined to the inner sealant surface of the front panel portion  12 . Sealing the edges  42   a  to the front panel portion  12  positions the fold  52  within the compartment  25 , providing the impact portion  48  along a significant area within the compartment  25  while simultaneously allowing for contents  11  to traverse the flow gap  55 . The flow gap  55  is provided between top portion  46  and front panel  12  because the referenced sealing is generally limited to the edges  42   a  and not the entire length of  46 . However, a peel seal  47  as described and depicted herein can be employed to temporarily seal a region of portion  46  to the front panel  12 . The close-up view of  FIG. 18  shows the herein-referenced edge seal portions in cross-hatching, with the thickness and proportions exaggerated for demonstrative purposes. 
     Various figures and descriptions disclose features and accessories. However, it must be noted that these features are merely illustrative in nature and may be placed in varying locations and under varying configurations, and still be consistent with the present invention. Various regions of the package can include a handle portion, access devices, and the like. In addition, the shape and configuration for the panel portions are also merely illustrative and can be altered without deviating from the spirit and scope of the present invention. Any of the panel portions, or selected regions thereof, can include various aesthetic and functional graphics, such as logos, instructions, advertising, bar codes, and the like. These graphics can run transverse, parallel, or even in a diagonal orientation to the longitudinal panel edges discussed herein. 
     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 .