Patent Publication Number: US-11377284-B2

Title: Resealable bag and method of producing the resealable bag

Description:
BACKGROUND OF THE INVENTION 
     The present invention pertains to the art of food production and, more particularly, to packaging for food products. 
     Food products are often packaged prior to sale. Such packaging can take the form of cans, jars, boxes or bags, for example. In the case of a ready-to-eat (“RTE”) or breakfast cereal, the cereal is commonly packaged in a bag, with the bag optionally being contained within a box. Other food products, such as pet food and crackers, can also be packaged in bags, with or without the use of boxes. When a box is used, the box helps protect the food product during transportation and storage and provides convenient surfaces for marketing and nutritional information. 
     The bags are sealed during production to help keep the food products fresh. However, such bags typically have at least one seal that is meant to be torn, cut or peeled open to form a hole through which the food product can be dispensed by a consumer. Afterwards, there is no way for the consumer to completely reseal the bag. Often, the consumer will simply roll the open end of the bag over itself (and may clip the end) to reduce airflow into the bag. Depending on how quickly the consumer&#39;s household consumes the food product though, this may not be sufficient to maintain the freshness of the food product until it is fully consumed. Accordingly, it would be desirable to provide a way for consumers to reseal such bags. 
     SUMMARY OF THE INVENTION 
     The present invention achieves the above goal through the addition of a resealable seal to a bag that includes multiple non-resealable seals. In particular, a resealable bag comprises a first end and a second end opposite the first end. A first transverse seal seals the first end, while a second transverse seal seals the second end. The second transverse seal is part of a weak seal zone configured to be readily unsealed by a consumer by hand. A third transverse seal is located between the first transverse seal and the second transverse seal, closer to the second transverse seal than the first transverse seal. The third transverse seal is at least partially longitudinally aligned with the second transverse seal. Also, the third transverse seal is configured to be selectively unsealed and resealed by the consumer by hand. 
     In one embodiment, a fourth transverse seal is located between the first transverse seal and the second transverse seal, closer to the second transverse seal than the first transverse seal. In another embodiment, a fourth transverse seal seals the second end. In either case, the fourth transverse seal is at least partially transversely aligned with the third transverse seal. Also, the fourth transverse seal is part of a strong seal zone configured not to be readily unsealed by the consumer by hand. 
     By this construction, a resealable bag, defining a storage area for containing a food product and including first and second longitudinally spaced end portions, is provided with a seal assembly at the second end portion for use in selectively accessing the storage area through the second end portion for dispensing of the product from the bag, with the seal assembly including first, second and third distinct, transverse seals, and with the second seal being a resealable seal. Once the resealable bag is initially opened through the second transverse seal, the third transverse seal can be selectively, repeatedly unsealed and resealed by the consumer to access the contents of the bag and then reseal the bag to maintain freshness. 
     Additional objects, features and advantages of the invention will become more readily apparent from the following detailed description of preferred embodiments thereof when taken in conjunction with the drawings wherein like reference numerals refer to common parts in the several views. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is perspective view of a packaged food product produced in accordance with a first embodiment of the present invention. 
         FIG. 2  is a perspective view of a packaged food product produced in accordance with a second embodiment of the present invention. 
         FIG. 3  is a perspective view of a resealable bag of the first embodiment. 
         FIG. 4  is a perspective view of an end of the resealable bag. 
         FIG. 5  is a top view of the resealable bag. 
         FIG. 6  is a perspective view of the packaged food product of the first embodiment further comprising a box. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Detailed embodiments of the present invention are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a representative basis for teaching one skilled in the art how to construct and employ the present invention. In addition, any specific numerical value listed herein includes a margin of error of +/−5%. Accordingly, a length of 1.00 centimeters includes lengths between 0.95 and 1.05 centimeters. Similarly, a range of 1.00-1.20 centimeters includes lengths between 0.95 and 1.26 centimeters. The term “approximately” increases the margin of error to 10%. For numerical values expressed as percentages, the margin of error refers to the base numerical value. In other words, “approximately 20%” means 18-22% and not 10-30%. 
     As discussed above, certain food products are commonly packaged in bags, with the bags being sealed during production to help keep the food products fresh. To facilitate the opening of such a bag, the bag can have at least one seal that is relatively weaker so that a consumer can more easily peel open the seal to form a hole through which the food product can be dispensed. Once the seal has been destroyed, there is no way for the consumer to completely reseal the bag, and the resulting airflow into the bag can lead to the food product becoming stale, rancid or otherwise undesirable before being fully consumed. The present invention was developed to address this problem. Specifically, the present invention provides a resealable bag. The bag has a seal at each end, with one of the seals being a relatively weaker seal that is meant to be peeled open by the consumer. A resealable seal is provided adjacent to and aligned with the weaker seal, allowing the consumer to dispense the food product past these seals and then reseal that end of the bag. 
     With reference to  FIG. 1 , a packaged food product  100  is shown. Packaged food product  100  includes a resealable bag  105  and a food product  110  contained within bag  105 . Food product  110  is illustrated as an RTE or breakfast cereal. However, bag  105  can be used with a wide range of products, including snacks for pets or crackers. 
     Bag  105  includes a sidewall  115 , formed by bringing together and then joining two edges of a sheet of material using a longitudinal seal  120 , which can take various forms, such as a fin seal or a lap seal. Bag  105  also has a first end  125 , preferably permanently sealed by a first transverse seal  130 , and a second end  135 , sealed by a second transverse seal  140 . The intent is for second end  135  and second transverse seal  140  to be those that are opened by a consumer. Since bag  105  is typically held vertically when opened, second end  135  and second transverse seal  140  essentially function as a top end and seal at or adjacent an upper terminal edge of bag  105 , while first end  125  and first transverse seal  130  function as a bottom end and seal. 
     To facilitate the opening of bag  105 , second transverse seal  140  is configured to establish or be part of a weak seal zone of bag  105 . That is, second transverse seal  140  is configured to be strong enough to stay intact through further packaging steps, as well as transportation and storage, but a least a portion of second transverse seal  140  is weak enough to be easily pulled apart and permanently unsealed by a consumer by hand, i.e., to be readily unsealed by the consumer by hand. In a preferred embodiment, this corresponds to an opening force of approximately 2.5 pound-force (lb f ) (measured along the width/length of the seal). In contrast, longitudinal seal  120  and first transverse seal  130  are configured to establish or be part of strong or generally permanent seal zones. That is, seals  120  and  130  are configured not to be readily unsealed by the consumer by hand. This corresponds to an opening force of greater than 5 lb f  and preferably greater than 6 lb f . For purposes of the present invention, “by hand” means using one or both hands without any additional tools. 
     Bag  105  further includes a third transverse seal  145  located between first transverse seal  130  and second transverse seal  140 . More specifically, third transverse seal  145  is located closer to second transverse seal  140  than first transverse seal  130  and is at least partially longitudinally aligned with second transverse seal  140 , longitudinally spaced from but directly adjacent a portion of second transverse seal  140 . At this point, it should be understood that by “longitudinal seal”, it is meant that the seal is longer or elongated in the longitudinal direction (denoted  150 ). In addition, by “longitudinally aligned”, it is meant that a straight line can be drawn through both of seals  140  and  145  in the longitudinal direction (denoted  150 ). Since at least a portion of second transverse seal  140  is not longitudinally aligned with third transverse seal  145  in the embodiment illustrated, seals  140  and  145  are only partially longitudinally aligned. 
     The arrangement of seals  140  and  145  provides a pathway for food product  110  to exit bag  105 . In particular, sidewall  115  defines a storage area  155  in which food product  110  is retained. Storage area  155  is further defined by the transverse seals of bag  105 . As a result, to exit storage area  155 , food product  110  must pass by at least one of the transverse seals. Since seals  140  and  145  are at least partially longitudinally aligned, food product  110  can pass by third transverse seal  145  and then second transverse seal  140  to exit storage area  155  and bag  105 . 
     Third transverse seal  145  is configured to be selectively unsealed and resealed by the consumer by hand (i.e., without any additional tools, such as adhesives or heat). In the embodiment illustrated, third transverse seal  145  is a zipper seal. However, other types of resealable seals can be used. A fourth transverse seal  160  is at least partially transversely aligned with third transverse seal  145 . Consistent with the definitions provided above, it should be understood that by “transverse seal”, it is meant that the seal is longer or elongated in the transverse direction (denoted  150 ). In addition, by “transversely aligned”, it is meant that a straight line can be drawn through both of seals  145  and  160  in the transverse direction (denoted  165 ). Since at least a portion of fourth transverse seal  160  is not transversely aligned with third transverse seal  145  in the embodiment illustrated, seals  145  and  160  are only partially transversely aligned. 
     In addition to being transversely aligned, seals  145  and  160  together extend across almost the entire width of bag  105 . As a result, food product  110  must pass by one of seals  145  and  160  prior to passing by second transverse seal  140 . Like longitudinal seal  120  and first transverse seal  130 , fourth transverse seal  160  is configured as a strong seal. That is, fourth transverse seal  160  is configured not to be readily unsealed by the consumer by hand. Accordingly, fourth transverse seal  160  remains intact, or at least relatively intact, so as to still provide a strategically located sealing region when seals  140  and  145  are opened. This means that sealing third transverse seal  145  can effectively reseal bag  105  after second transverse seal  140  has been opened. As compared with a conventional bag, this provides an extended shelf life for food product  110  by reducing or preventing airflow into bag  105 . 
     In the embodiment of  FIG. 1 , fourth transverse seal  160  is located between first transverse seal  130  and second transverse seal  140 , closer to second transverse seal  140  than first transverse seal  130 . However, alternative arrangements are possible. For example,  FIG. 2  shows a packaged food product  200  including a resealable bag  205  and a food product  210  contained within bag  205 . Bag  205  includes a sidewall  215 , a longitudinal seal  220 , a first end  225 , a first transverse seal  230 , a second end  235 , a second transverse seal  240 , a third transverse seal  245 , a storage area  255  and a fourth transverse seal  260 . For reference, the longitudinal direction is denoted  250 , and the transverse direction is denoted  265 . Packaged food product  200  is substantially the same as packaged food product  100  except for the arrangement of seals  240  and  260 . Essentially, fourth transverse seal  260  has been extended toward second end  235  to replace a portion of second transverse seal  240  (as compared with the embodiment of  FIG. 1 ). As a result, second transverse seal  240  only extends part of the way across bag  205 , and seals  240  and  260  together seal second end  235 . Despite these changes, the end result is the same. Since the portion of second transverse seal  240  aligned with third transverse seal  245  remains, food product  210  can still be dispensed past seals  240  and  245 . Even in the embodiment of  FIG. 1 , most of food product  110  that is dispensed from bag  105  passes by the portion of second transverse seal  140  that is longitudinally aligned with third transverse seal  145 . In fact, it is expected that most consumers will not peel open second transverse seal  140  across its entire width. 
     Turning to  FIGS. 3 and 4 , bag  105  is shown without food product  110 . As shown in these figures, third transverse seal  145  extends less than halfway across bag  105 . In general, third transverse seal  145  should extend across approximately 25-75% of the width of bag  105 . Preferably, third transverse seal  145  extends across approximately 33-66% of the width of bag  105 . Most preferably, third transverse seal  145  extends across approximately 40-60% of the width of bag  105 . The length of third transverse seal  145  is limited by the presence of longitudinal seal  120 , which third transverse seal  145  cannot cross (although it should be recognized that the position of longitudinal seal  120  can be adjusted in transverse direction  165 ). Still, it should be recognized that third transverse seal  145  is more expensive than fourth transverse seal  160 , and it is unnecessary for third transverse seal  145  to span the entire width of bag  105  since food product  110  can be readily dispensed through an opening smaller than the width of bag  105 . 
     At this point, it should be understood that fourth transverse seal  160 , if provided, need not combine with third transverse seal  145  to extend all the way across bag  105  as shown. That is, the existence of fourth transverse seal  160  can be considered to mandate the opening of another region of bag  105 , i.e., a transverse bag region or zone not containing fourth transverse seal  160 . However, a significant aspect of the invention is the tactical information conveyed to the person opening bag  105  by the mere presence of a strong seal region, such as provided by fourth transverse seal  160 . More specifically, if opening the right side (as depicted) of bag  105 , a user will need to apply a relatively high opening force to initially break part of second transverse seal  140 . Then, the force (lateral peel force, e.g., 1 lb f ) required to propagate that opening is lowered. However, when that propagation reaches fourth transverse seal  160 , the user will feel a high resistance to further expand the opening in that direction. This resistive force can be referred to as a termination force. This termination force is preferably in the order of 2.5 times the lateral peel force in that direction and, more preferably, over 3 times the lateral peel force, with the minimum termination force being at least 2.5 lb f  (approximately 11.1 N), and preferably at least 3.0 lb f  (approximately 13.3 N). With this in mind, it should be recognized that this feature of limiting propagation and providing tactical feedback could be achieved, by way of example, with just having a relatively short fourth transverse seal  160 , say only from the end of third transverse seal  145  to longitudinal seal  120  in the depicted bag version, e.g., fourth transverse seal  160  would extend only in a small center region of bag  105 . Of course, this arrangement would enable a side of bag  105  which does not have second transverse seal  140  to be mistakenly opened by a user, thereby losing the advantages associated with the resealing characteristics of second transverse seal  140 . In any case, this possibility exists, as does providing dual, transversely extending resealable seals spaced by a short fourth transverse seal. In any case, although some reference has been made to the strength of the various seals, it is really the combined strength of the sealing forces which must be overcome to propagate the opening which is important to this aspect of the invention. Therefore, any given seal need not actually be “stronger” but rather it is the relative arrangement of the seals and the combined strength of the seals in established stronger and weaker seal regions of bag  105  which enables the desired tactical feedback. Therefore, in accordance with the invention, “weaker” in connection with a seal or region means it is easier to both open the bag at that seal region and propagate the opening within that region, as compared to another, stronger seal region of the bag. 
     As most clearly seen in  FIG. 4 , there is a small gap  400  shown between seals  145  and  160 . This spacing helps prevent the sealing jaw used to form fourth transverse seal  160  from damaging third transverse seal  145  during production of bag  105 . However, it is possible, and preferable, to minimize or even avoid this gap. In general, if gap  400  is present, gap  400  should be less than approximately 5 millimeters (mm). Preferably, gap  400  is less than approximately 3 mm. Most preferably, gap  400  is approximately 0-2 mm. However, in other embodiments, no gap can be provided, such as by having seals  145  and  160  overlap, even perhaps with the crushing of that end of seal  145  during the formation of seal  160 . 
     With reference now to  FIG. 5 , a top view of bag  105  is provided, with part of second seal  140  and all of third transverse seal  145  shown unsealed. Because third transverse seal  145  is looped and folded back on itself during production of bag  105  to wrap third transverse seal  145  inside a right, rounded edge  500  of bag  105 , third transverse seal  145  is inherently biased to spring apart at edge  500 . This advantageously helps bag  105  maintain an open state when third transverse seal  145  is unsealed. Specifically, a spout  505  is formed by sidewall  115 , defining an opening or passageway  510 . Preferably, third transverse seal  145  is not sealed during production of bag  105 . Instead, second transverse seal  140  serves to seal second end  135  of bag  105 , obviating the necessity of initially sealing third transverse seal  145 . 
     Turning to  FIG. 6 , packaged food product  100  is shown further comprising a box  600 . Bag  105  and food product  110  are located within box  600  such that they are not visible. The inclusion of box  600  is optional. When used, box  600  helps protect food product  110  during transportation and storage and provides convenient surfaces for marketing and nutritional information. In particular, box  600  includes a front wall  605 , a rear wall (not visible), two sidewalls (one of which is visible and labeled  610 ), a top wall  615  and a bottom wall (not visible). 
     Although there are different ways to produce packaged product  100 , packaged food product  100  is preferably produced using a vertical form-fill-seal process. A horizontal form-fill seal process is certainly a possibility. Certainly less preferable, but certainly possible, a bag could be formed by folding sheet material onto itself, with the fold line obviating the need for making the first transverse seal  130  as the fold line would inherently establish a first transverse seal, while side edge seals would be produced instead of longitudinal seal  120 . Regardless, a resealable bag, defining a storage area for containing a food product and including first and second longitudinally spaced end portions, would still be provided with a seal assembly at the second end portion for use in selectively accessing the storage area through the second end portion for dispensing of the product from the bag, with the seal assembly including at least two distinct, transverse seals, and with one of the two distinct seals being a resealable seal. In the detailed embodiment, it should be noted that third transverse seal  145  is preferably attached to the material used to form bag  105  prior to the other forming steps, i.e., prior to formation of longitudinal seal  120  or any of the other transverse seals. 
     Based on the above, it should be readily apparent that the present invention provides a way for consumers to reseal a bag after a portion of a food product contained within the bag has been dispensed. While certain preferred embodiments of the present invention have been set forth, it should be understood that various changes or modifications could be made without departing from the spirit of the present invention. In general, the invention is only intended to be limited by the scope of the following claims.