Abstract:
An easy open, reclosable, flexible film package comprising a front wall, a back wall, a pair of opposing side gussets; a bottom; and a top; wherein the top is sealed; wherein the pair of opposing side gussets and the bottom wall connect the front wall to the back wall; wherein one side gusset has a score line extending from front to back; wherein when the score line is broken a spout is formed by pulling the side gusset below the score line.

Description:
[0001]    This application claims priority to provisional U.S. Application Ser. No. 60/912,968, filed Apr. 20, 2007 which is hereby incorporated by reference in its entirety. 
     
    
     FIELD 
       [0002]    The invention relates to flexible bags, in particular flexible bags that are easy open and reclosable. 
       BACKGROUND 
       [0003]    Most current packages for cereals and various snack items are bag-in-box packages. These packages include a box with a flexible bag liner inside the box to provide moisture and oxygen protection to the package contents. The box is first opened and then the bag liner is opened, typically by pinching the sides of the bag liner and pulling the top seam apart. However, current bag liners utilized in the bag-in-box cereal and snack products suffer from poor open-ability and little if any reclosability. These bag liners have been optimized and down gauged over the years to provide maximum cost savings, at the expense of physical strength, resulting in bag liners that tear upon opening. The peel system employed often has a narrow performance window of peel strength with film strength to prevent bag tearing. Modest results have been obtained with zippers, but zippers add expense and complications to the bag production process. 
         [0004]    A cost-effective easy open package has not been achieved with current bag-in-box designs. 
         [0005]    It is desired to have a package for cereal and other snack items that do not require a box but instead comprises a single package to hold the cereal or snack contents. Eliminating the box reduces expense and minimizes waste after consumption. Moreover, as the contents of the package are consumed, an empty box becomes a major waste of space since it is difficult to reduce the physical size of the box due to the structure of the box. However, a non-box package can be reduced in size as the product is consumed. In addition, current bag-in-box type packages have no reclosability other than the box top. This provides little protection for the food product since the bag liner inside the box provides all of the barrier properties and generally this bag liner is not provided with a reclose features other than rolling the top of the bag. 
       SUMMARY 
       [0006]    In a first aspect a package is provided having side gussets. A laser score line is formed in one of the side gussets. The score line may be broken and the lower part of the gusset pulled out to open the package and form a pour spout. The pour spout may be pushed back in to close the package. 
         [0007]    In a second aspect a package is provided having top and bottom gussets. A laser score line is formed in the top gusset. The score line may be broken and the gusset pulled apart to open the package. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  depicts a package having a laser scored opening in accordance with one aspect of the invention. 
           [0009]      FIG. 2  depicts a package in accordance with  FIG. 1  with a spout formed from the scored opening. 
           [0010]      FIG. 3  depicts a package in accordance with  FIG. 2  with the spout pushed in and the package closed together. 
           [0011]      FIG. 4  depicts a package having a laser scored opening in accordance with another aspect of the invention wherein adhesive tape is placed on the upper portion of the score line to use for closing. 
           [0012]      FIG. 5  depicts a package having a laser scored opening in accordance with another aspect of the invention. 
           [0013]      FIGS. 6   a,    6   b,  and  6   c  depict a package having a laser scored opening in accordance with another aspect of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    Aspects of the present invention are directed to box-less packages prepared from flexible film bags. The flexible film bag provides the desired barrier characteristics of a bag liner, and the stand alone structure and easy open and reclosability features of a box, as well as a suitable surface for printing and graphics. The flexible film bag can have a “Quad Seal” design which resembles a box. 
         [0015]    As shown in  FIG. 1 , the flexible film bag  10  has a front side  12 , a back side  14 , side gussets  16  and  18 , a flat bottom  20 , and a top  22  that is formed by the tops of sides  12  and  14 . 
         [0016]    Forming of the top seal is generally done in one step as is well known in the art. The front/back are sealed together at the same time the tops of the side gussets are sealed. The side gussets come together folded at the top seal 
         [0017]    This “Quad Seal” design looks more like a box than other pouch designs such as a SUP (Stand Up Pouch) or fin seal pillow bag. The side gussets  16  and  18  offer more area for graphics and such graphics can be placed similar to a box. These bag styles have been available for at least  10  years and can be produced on various V/F/F/S machines such as Rovema and Bosch. 
         [0018]    The Quad Seal bag structure is more robust than the usual liner bag structure in order to offer more structure to the package as well as to better protect the product within. 
         [0019]    Any suitable film structure may be used for the bags. The type of film structure chosen may be based on a number of parameters including, but not limited to the intended contents for the package such as moisture level and weight of such contents. Other parameters may be intended storage and distribution conditions of the package and desired durability of the package. 
         [0020]    The film structure may be one or more layers. Typically, the film layer is a two-layer or three-layer structure, but any number of layers suitable for the desired package may be used. The layers may be any suitable film material including, but not limited to, polymeric film materials and foil-type film materials. For example, the outer layer may be a polymeric film, such as oriented films including, but not limited to, PET and BON or OPP. The inner layer(s) may be any suitable inner layer such as, but not limited to, polyolefin-based or foil films. Generally, the layers are selected so that the laser is more effective on the outer layer and has less of an effect on the inner layer(s). 
         [0021]    This allows the laser to efficiently score the substrate without any need to refocus the beam during the cross machine movement. Typical, non-limiting, film structures for this package include 48 ga PET/ink/LDPE/2.5 mil HDPE/tie/EVOH/tie/LL-SSC and 48 ga PET/ink/adh/60 ga Met-OPP/adh/3 mil LDPE. 
         [0022]    The barrier properties of the package are at least as good as or better than current liner film bags typically used in the box. Barrier properties include WVTR and OTR. (Moisture and oxygen.) Moisture transmission rates typically are less than 1.0 g/100 in 2 .day. Oxygen transmission rates typically are less than 1.0 cc/100 in 2  day. 
         [0023]    In accordance with an aspect of the invention, a CMD (Cross machine direction) laser score line is placed on the side gusset of the bag. See  FIG. 1 , laser score  24 . When the score line is broken by the consumer, the portion of the gusset below the broke score line is pulled outward to form a pour spout. As shown in  FIG. 1 , the score line is at most, the width of the gusset which minimizes any chance of premature breakage either on the filling line or during distribution in contrast to a complete CMD score. 
         [0024]    This score can either be a continuous line or a row of dashes or dots, all providing a line of weakness in the film structure. The score line can be defined by a tensile property tested across the score line. Tensile values can range from 4.0 lbs/in to 16 lbs/in. 
         [0025]    The shape of the score line may be any suitable shape such as a straight line or a curved line or any combination thereof. For example, a “U” shape or upside down “U” is possible which still forms the pour spout. Advantages with these shapes include wider opening spout for pouring. The consumer either pulls open or pushes in the scored spout. 
         [0026]    Current opening features for flexible films and packages include tear tape and tear notches, perforations and scoring of films. However, except for scoring of the films by laser scoring, none of these methods are effective to provide an effective scored line. 
         [0027]    To open, the consumer pinches the gusset above and below the score line and pulls to break the score line and form a spout  26  with portion of the gusset below. See  FIG. 2  The product would then be dispensed thru this opening in the package. 
         [0028]    The bag geometry could have any combination of gusset width, bag width and height. The wider the gusset, the larger the open pour spout. 
         [0029]    To reclose, the pour spout is pushed back in and the gusset pinched together as shown in  FIG. 3 . If the gusset opening is small enough, then closure is complete. If the gusset provides a larger opening, a simple, low cost reclose tape  28  could be placed across the gusset, pulling both sides tight to provide a tighter seal. A tight reclose may not be necessary if the package only has a limited number of servings. 
         [0030]    Another aspect of the invention relates to including a piece of adhesive tape to aid in the closing of the bag after breaking the laser score. As shown in  FIG. 4 , a small stripe of permanent adhesive tape  30  could also be placed on one or both sides of the score line. This tape can be used by the consumer maintain the bag in a closed position as shown in  FIG. 3 . The reclose tape is used to pinch shut the side gusset creating a simple reclose. 
         [0031]    As shown in  FIG. 5 , a small ridge or fold  34  is placed down the center of this gusset which further allows the consumer to grasp and pull the score apart. 
         [0032]    In one aspect, the bag could also have a clear side wall or gusset so the consumer can see how much product is left in the package. 
         [0033]    The square or rectangular nature of the packages provides good stackability for display and shipping. 
         [0034]    A further aspect of this invention aligns the laser score line with the machine direction of the film and package. Attention is drawn to  FIG. 6   a  which shows a flexible film bag  40  which is similar to the flexible film bag described in  FIG. 1  except rotated 90 degrees. This allows the pouch to stand up on bottom gusset  42  instead of the traditional bottom seal. As shown in  FIG. 6   a,  a score line  46  runs along and down the center of top gusset  44 . Thus top gusset  44  and the laser score  46  provides the easy open feature of the package. As shown in  FIG. 6   b  and  FIG. 6   c,  the pouch opens very easily along score  46  by pulling the top gusset in the direction of the arrows shown in  FIG. 6   b.    FIG. 6   c  shows the opened package with contents  48  exposed. 
         [0035]    While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques that fall within the spirit and scope of the invention as set forth in the appended claims.