Abstract:
A sealing plate for use with a packaging machine that integrates a seal formed indicia into a portion of a package seal. A package having a seal formed indicia integrated into the package seal, which when the package is opened undergoes undergo a visual transformation, and a method of making the same.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Ser. No. 62/327,505 filed Apr. 26, 2016, the disclosure of which is incorporated herein in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
       [0002]    This invention relates to a packaging machine, and more particularly to a seal bar or plate for use in a packaging machine. The invention also relates to a method of making a package using a seal bar or plate in a packaging machine. 
       2. Background 
       [0003]    Many different attempts have been made to develop packaging for per food products, such as deli meats and cheeses or other items. One thermoformed packaging process, generally known as a form, fill, and seal process, includes the steps of forming a cavity in a web of material, placing products into the cavity, and then sealing the cavity using an overlying web of material. Alternatively, the cavity may be defined by a preformed tray or pouch, which is then sealed using an overlying web. In some applications, to prolong shelf life and postpone spoilage, air is removed from the interior of the thermoformed package via a process known as vacuum packaging. Other applications include modified atmosphere packaging (MAP) where an inert gas is injected into the thermoformed package or pouch either with or without prior vacuumization. In still other attempts to postpone spoilage, an oxygen scavenging packet may be placed into each package along with the product being packaged. 
         [0004]    In many of these various prior packaging types, the top web and bottom web of material, or alternatively, single web of material folded over onto itself, which form the thermoformed package or pouch, are sealed together as to maintain the integrity of the package cavity. The seal that surrounds the cavity of the package forms a microbial barrier that prohibits contamination of the perishable food products contained therein. Such packages may also include a resealable closure, such as a zipper-type closure or other means such as resealable adhesive film, to close the cavity for product storage after the seal has initially been broken. However, it is often difficult to visually ascertain whether the initial package seal has been broken or whether the initial seal is still in place. This inability to determine the sealed status of the package may result in consumers questioning the freshness or preservation of the stored food products. Accordingly, there is a need for a package for use with perishable food products that provides an indication of whether the seal is opened or closed. 
         [0005]    Also, in some packaging applications, it has been known for the identifying label or tag that has been adhesively affixed to or printed onto the outer surface of the flexible package material to become separated during use. Accordingly, there is a need for a package that can integrate identifying indicia directly into the package material, rather than one that would rely exclusively on the use of identifying labels or tags. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0006]    By way of summary, in accordance with one aspect, the present invention contemplates a sealing plate for use with a packaging machine that integrates a seal formed indicia into a portion of the package seal. In this configuration, the indicia is integrated into the package without the need of external labels or tags. 
         [0007]    In another aspect of the present invention, a package is provided having an indicia integrated into the package seal, which when the package is opened, i.e., the top and bottom webs of package material are separated, the sealing surfaces of the indicia undergo a visual transformation. 
         [0008]    In one embodiment, the visual transformation of the sealing surfaces of the indicia may include a visibility increasing change, i.e., a color change, such that the indicia is more visible when the package has been opened. 
         [0009]    In another embodiment of the present invention, the visually transformative indicia of the package seal may be a tamper-evident indicator. The tamper indicator may provide a consumer of the perishable food product or other items with an indication of whether the package seal has been previously opened. 
         [0010]    These and other features and aspects of the present invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating representative embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    A clear conception of the advantages and features constituting the present invention, and of the construction and operation of typical mechanisms provided with the present invention, will become more readily apparent by referring to the exemplary, and therefore non-limiting, embodiments illustrated in the drawings accompanying and forming a part of this specification, wherein like reference numerals designate the same elements in the several views, and in which: 
           [0012]      FIG. 1  is a top plan view of a multi-package sealing plate configured for use with a thermoformed sealing mechanism in accordance with one embodiment of the present invention; 
           [0013]      FIG. 2  is a detailed top plan view of a single package portion of the multi-package sealing plate of  FIG. 1 ; 
           [0014]      FIG. 3  is a front top perspective detailed view of a portion of a sealing bar associated with the single package portion of the multi-package sealing plate of  FIG. 1 ; 
           [0015]      FIG. 4  is a top plan view of a single sealed package, in a full scaled configuration, manufactured in a sealing machine using the sealing plate in accordance with one embodiment of the present invention; 
           [0016]      FIG. 5  is a top plan view of a bottom web of material forming half of a series of sealed packages manufactured in a sealing machine using the multi-package sealing plate of  FIG. 1 ; 
           [0017]      FIG. 6  is a detailed top plan view of a portion of the bottom web of material corresponding to a single package from the web of material of  FIG. 5 ; 
           [0018]      FIG. 7  is a top perspective view of the portion of the bottom web of material shown in  FIG. 6 ; 
           [0019]      FIG. 8  is a front elevation view of the portion of the bottom web of material shown in  FIG. 6 ; 
           [0020]      FIG. 9  is a top plan view of a top web of material affixed to the bottom web of material shown in  FIG. 5 , forming a series of thermoformed sealed packages, including a food product contained therein, that are manufactured in a thermoformed sealing machine using the multi-package sealing plate of  FIG. 1 ; 
           [0021]      FIG. 10  is a detailed top plan view of the top web of material affixed to the bottom web of material corresponding to a single sealed package, from the webs of material of  FIG. 9 ; 
           [0022]      FIG. 11  is a top perspective view of the portion of the sealed package shown in  FIG. 10 ; 
           [0023]      FIG. 12  is a front side elevation view of the portion of the sealed package shown in  FIG. 10 ; 
           [0024]      FIG. 13  is a detailed top plan view of the single sealed package shown in  FIG. 4 , with the seal between the top web of material and bottom web of material partially separated; and 
           [0025]      FIG. 14  is a detailed top plan view of the single package shown in  FIG. 4 , with the seal between the top web of material and bottom web of material fully separated. 
       
    
    
       [0026]    In describing the embodiments of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the word “connected,” “attached,” or terms similar thereto are often used. They are not limited to direct connection, but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art. 
       DETAILED DESCRIPTION 
       [0027]    The various features and advantageous details of the subject matter disclosed herein are explained more fully with reference to the non-limiting embodiment described in detail in the following description. 
       1. Sealing Plate 
       [0028]    Referring to  FIGS. 1-3 , and initially  FIG. 1 , one embodiment of the present invention provides a sealing plate  10  for use in manufacturing thermoformed packages, such as vacuum packages and modified atmospheric packages. As shown in  FIG. 1 , the sealing plate  10  includes a series of individual package sealing forms  12  integrated into the sealing plate  10 . While the plate  10  shown in  FIG. 1  will allow for multiple packages to be simultaneously formed, it should be understood that the present invention is in no way so limited and that any number of package sealing forms  12  may be integrated into the plate  10 . 
         [0029]    A detailed view of an individual package sealing form  12 , which corresponds to the manufacture of an individual thermoformed package, is shown in  FIG. 2 . Each package sealing form  12  includes an elevated inner rim  14 , including a first side edge  16 , an opposed second side edge  18 , a bottom edge  20  extending between the first and second side edges  16 ,  18 , and a top edge  22  opposite the bottom edge  20 . The inner recessed surface  24  of the form  12 , which defines the package cavity as described below, is fully surrounded by the interconnected four sides  16 ,  18 ,  22 ,  20  of the elevated inner rim  14 . One or more apertures  25  may be located within the recessed surface  24  so as to allow atmospheric changes to be applied to the scaling form  12  when in use. For example, such apertures  25  may introduce a vacuum or alternatively modified atmosphere into the area of the recessed surface  24  during the formation of the packages as will be described in further detail below. 
         [0030]    In addition to the inner rim  14 , each individual package sealing form  12  of the present invention may also include an elevated outer rim  26 . As shown in  FIG. 2 , in one embodiment of the present invention, the elevated outer rim  26  includes a first side edge  28 , which is located generally parallel to the first side edge  16  of the elevated inner rim  14  and is spaced therefrom by a distance  30 . The distance  30  of the form  12  may be generally defined by a side recessed surface  32  that is bordered on opposing sides by the inner side edge  16  and the outer side edge  28 , both of which are elevated relative to the side recessed surface  32 . In one embodiment, as shown in  FIG. 2 , the side recessed surface  32  may be bifurcated by an elevated extension  34 , which spans the side recessed surface  32  and connects the inner side edge  16  to the outer side edge  28 . As will be described in further detail below, the elevated extension  34  will correspond to a rigid portion of the resultant package which may support therein an aperture to allow the package to be hung from a peg display or the like. Additionally, as shown in  FIG. 2 , a first end  36  of the side edge  28  of the elevated outer rim  26 , which defines a corner of the form  12 , may be integrally connected to the first side edge  16  of the inner elevated rim  14  by way of a length  38 . The opposing second end  40  of the side edge  28  may also be integrally connected to the first side edge  16  of the elevated inner rim  14 . While the form  12  shown in  FIG. 2  illustrates the second end  40  of the side edge  28  directly connected to the side edge  16  by a curved portion  41 , it should be understood that alternative integral connection orientations are considered within the scope of this invention. Resultantly, as will be described in further detail below, the side recessed surface  32  of the form  12 , will define an unsealed side portion in the package that is fully surrounded by the interconnected first side edge  16  of the elevated inner rim  14 , the side edge  28  and the length  38  of the elevated outer rim  26 . 
         [0031]    Additionally, the elevated outer rim  26  of each individual package sealing form  12  may also include a top edge  42 , which is oriented generally parallel to the top edge  22  of the elevated inner rim  14  and is removed therefrom by a distance  44 . The distance  44  of the form  12  may be generally defined by a top recessed surface  46  that is bordered on opposing sides by the top edge  22  of the elevated inner rim  14  and the top edge  42  of the elevated outer rim  26 . Additionally, as shown in  FIG. 2 , a first end  48  of the top edge  42 , which defines a corner of the form  12 , may be integrally connected to the top edge  22  of the inner elevated rim  14  by way of a curved portion  50 . A tapered projection  52 , integral with the top edge of the elevated outer rim  26 , may extend outwardly from the curved portion  50 . In use, as will be described below, this projection  52  will result in the formation of a corresponding outward projection in the thermoformed seal, which may be used as a starting location to facilitate opening the thermoformed seal. Still referring to  FIG. 2 , the opposing second end  54  of the top edge  42 , which is also generally located near a corner of the form  12 , may be integrally connected to the top edge  22  of the elevated inner rim  14  by way of a curved portion  56 . As shown in  FIG. 2  the curved portion  56  of the top edge  42  may be contiguous with the curved portion  41  of the adjacent side edge  28 . Furthermore, a tapered projection  58 , integral with the outer elevated rim  26  may extend outwardly from the curved portions  56 ,  41 . As previously described, this tapered projection  57  will also result in the formation of a corresponding outward projection in the thermoformed seal, which may be used as a starting location to facilitate opening the thermoformed seal. As a result of the general orientation of the top edge  22  of the elevated inner rim  14  and top edge  42  of the elevated outer rim  26 , as will be described in further detail below, the top recessed surface  46  of the form  12  will define an unsealed top portion in the package that is fully surrounded by the interconnected top edges  16 ,  42 . 
         [0032]    Furthermore, turning now to  FIG. 3 , the individual package sealing form  12  of the present invention may also include an indicia embossment  58 . The indicia embossment  58  is disposed within the top recessed surface  46  between the top edge  24  of the elevated inner rim  14  and the top edge  42  of the elevated outer rim  26 . In one representative embodiment of the present invention, the indicia embossment  58  may include one or more alphanumeric characters  60 . In another representative embodiment of the present invention, the indicia embossment  58  may include one or more graphical elements (not shown), or a combination of graphical elements and alphanumeric characters  60 . As is shown in  FIG. 3 , in a non-limiting exemplary embodiment, the indicia embodiment  58  is formed of the alphanumeric characters: “D &amp; W”. 
         [0033]    As previously described, the surface area of the sealing form  12  surrounding indicia embossment  5  and defined between the top edge  22  of the elevated inner rim  14  and the top edge  42  of the elevated outer rim  26  is a top recessed surface  46 , where the height of the elevated inner rim  16 , the elevated outer rim  26  and the indicia embossment  32  is greater, i.e., higher, than that of the recessed surfaces,  24 ,  32 ,  46 . As a result of the elevated inner rim  16 , the elevated outer rim  26  and the indicia embossment  32  having a greater height than the adjacent top recessed surface  46 , no seal will be formed in the package at the location of the top recessed surface  46 , as will be described in further detail below. Resultantly, the seal formed in a shape corresponding to the upper surface of the indicia embossment  58  will be visibly formed in the package due to the package&#39;s lack of seal formed in the surrounding area, as will be described in further detail below. 
         [0034]    Returning now to  FIG. 1 , as was previously stated, the sealing plate  10  includes a number of individual package sealing forms  12 . As shown in  FIG. 1 , the top edge  42  of the elevated outer rim  26  of one sealing form  12  may contact or be contiguously formed with the bottom edge  22  of the elevated inner rim  14  of an adjacently located individual package sealing form  12 . Similarly, the first side edge  28  of the elevated outer rim  26  of one sealing form  12  may contact or be contiguously formed with the second side edge  18  of the elevated inner rim  14  of an adjacently located individual package sealing form  12 . In such a configuration, adjacent packages formed from the use of such a plate  10  will initially be formed in an interconnected manner and then be subsequently separated after the sealing of the packages, as will be described in further detail below. 
       2. Thermoformed Package 
       [0035]    Turning now to  FIGS. 4-12 , a representative package  100  formed in-part by use of the above-described sealing plate  10  is illustrated in accordance with one embodiment of the present invention. As shown generally in  FIGS. 4-12 , the package  100  is formed of a first, or bottom, web  102  of material, which is joined to a second, or top, web  104  of material. In one embodiment of the present invention, the material that forms the top and bottom webs  102 ,  104  may be a clear single or multilayer film, formed of plastic or any other satisfactory material that can be molded and/or melted with exposure to heat. Referring now to  FIG. 4 , the package  100  defines a sealed cavity  106  for retaining a perishable food product  108 , such as sliced deli meat or cheese, therein. The sealed cavity  106  is bordered by an inner seal  110  that joins the top and bottom webs  102 ,  104  together. The inner seal  110  includes a first side edge  112 , an opposed second side edge  114 , a bottom edge  116  extending between the first and second side edges  112 ,  114 , and a top edge  118  opposite the bottom edge  116 . The inner seal  110  may be formed by direct or indirect contact of the top and bottom webs  102 ,  104  with the upper surface of the elevated inner rim  14  of the seal plate  10 , as previously described. As such, the shape and configuration of the inner seal  110  is consistent with that of the elevated inner rim  14 . Similarly, and still referring to  FIG. 4 , the package  100  may also include an outer seal  120 , including a first side edge  122  and a top edge  124 , which correspond to the shape and configuration of the upper surface of the first side edge  28  and a top edge  42  of the elevated outer rim  26  of the one or more seal form  12  located on the seal plate  10 . 
         [0036]    Furthermore, as shown in  FIG. 4 , the package  100  may also include a seal extension area  126  extending from the first side edge  112  of the inner seal  100  to the first side edge  122  of the outer seal  120 . As shown in  FIG. 4 , the seal extension area  126 , which corresponds to the shape and configuration of the elevated extension  34  of the one or more seal form  12  located on the seal plate  10 , may be generally centrally located about the longitudinal axis of the package  100 . As such, the seal extension area  126  provides a rigid or semi-rigid sealed surface for which an aperture  128  may extend therein, through the top and bottom webs  102 ,  14 . In this configuration, the package  100  may be evenly hung on a peg-style display or the like. Similarly, the area of the package  100 , between the first side edge  112  of the inner seal  110  and the first side edge  122  of the outer seal  120 , which does not constitute the seal extension area  126  is an unsealed area  127  that corresponds to the location of the side recessed area  32  in the one or more seal forms  12  located on the seal plate  10 . 
         [0037]    Additionally, a seal formed indicia  130  is also shown in  FIG. 4 , located between the top edge  188  of the inner seal  110  and the top edge  124  of the outer seal  120 . The seal formed indicia  130  corresponds to the size and shape of the upper surface of the indicia embossment  58  of the one or more seal forms  12  located on the seal plate  10 , as previously described. Similarly, the area of the package  100 , between the top edge  118  of the inner seal  110  and the top edge  124  of the outer seal  120 , which does not constitute the seal formed indicia  130  is an unsealed area  132  that corresponds to the location of the top recessed area  46  in the one or more seal forms  12  located on the seal plate  10 . The seal formed indicia  130  are positioned on the package  100  so as to be located outwardly of the inner seal  110 , which in accordance with one embodiment of the present invention, may be formed with a resealable closure, such as a zipper-type closure, in a manner as is known. 
         [0038]    Additionally, as illustrated in  FIG. 4 , the portions of the top edge  124  of the outer seal  120 , at the opposing first end  134  and second end  136  thereof may be formed of curvilinear portions  138 ,  140 , respectively. The first and second ends  134 ,  136  may intersect the top edge  118  of the inner seal  110 , corresponding to the previously described orientation of the inner and outer elevated rims  14 ,  26  of the one or more seal forms  12  located on the seal plate  10 . Similarly, a tapered seal projection  142  may extend outwardly from the curvilinear portion  138  of the top edge  124  located generally at a corner  144  of the thermoformed package  100 , while a tapered seal projection  146  may extend outwardly from the curvilinear portion  140  of the top edge  124  located generally at an opposing corner  148  of the package  100 . The tapered seal projections  142 ,  144  generally correspond to the tapered projections  52 ,  57  of the one or more seal forms  12  located on the seal plate  10 , respectively, and are configured to function as a starting point to facilitate separating the first web  102  from the second web  104  at the inner seal  110  and outer seal  120 . 
         [0039]    Turning now to  FIGS. 5-12 , the package  100 , as described above, is shown in two orientations during the manufacturing process thereof.  FIGS. 5-8  initially illustrate a bottom portion  150  of the package  100  manufactured in accordance with one embodiment of the present invention. Specifically, as shown in  FIG. 5 , the first or bottom web  102  of material may be subject to a thermoform molding process, in which the first web  102  is heated while resting on a mold and then subject to a negative pressure, which forces the first web  102  to form the series of interconnected bottom portions  150 . Each bottom portion  150  includes a recessed cavity  106  defined within the inner rim  14  of the sealing form  12  and is generally defined by the contours of the underlying sealing form  12 . The recessed cavity  106  is formed by way of the vacuum or negative pressure supplied via the apertures  25  in the recessed surface  24  of the sealing form  12 .  FIGS. 6-8  proved additional exemplary views of a representative bottom portion  150  of a thermoformed package  100 , in accordance with one embodiment of the present invention, as was described above. Alternatively, the cavity  106  may be defined by a rigid or semi-rigid tray in a manner as is known, or by a pouch arrangement in which a single web is folded over onto itself with the food product  108  therebetween, also in a manner as is known. 
         [0040]    Turning now to  FIGS. 9-12 , and initially  FIG. 9 , the perishable food product  108 , or other items, is shown having been placed into each recessed cavity  106  of the multiple interconnected bottom portions  150 . A second or top web  104  of material is shown overlying the recessed cavity  106  of each interconnected bottom portion  150 . The atmosphere of the recessed cavity  106  may then be selectively modified through the introduction of vacuum, i.e., negative pressure, or the introduction of a modified atmospheric agent, such as, but not limited to, a nonreactive gas. Subsequently, the inner seal  110 , outer seal  120  and seal formed indicia  130  are formed in the package  100  by way of transmitting ultrasonic acoustic vibrations or heat through the seal plate  10 , which is in direct or indirect contact with the first and second webs  102 ,  104 . In one embodiment, the sealing of the packages  100  may include forming the various seals  110 ,  120 ,  130  by way of pressing the packages  100  between two opposed compatible sealing plates  10 . After sealing, the interconnected individual packages  100  are then cut from their webs  102 ,  104  and the aperture  128  is punched into the seal extension area  126 , resulting in individual sealed packages as previously shown in  FIG. 4 .  FIGS. 10-12  proved additional exemplary views of a package  100  as described above, in accordance with one embodiment of the present invention. 
         [0041]    Turning now to  FIGS. 13 and 14 , the package  100  is shown in various stages of unsealing or opening. As illustrated in  FIGS. 4 and 9-12 , the inner seal  110 , outer seal  120  and the seal formed indicia  130  are identified by stippling, when the first and second webs  102 ,  104  are connected together. That is to say, when the seals  110 ,  120 ,  130  are formed and the package  100  is in a closed configuration, the seals  110 ,  120 ,  130  are represented by stippling. In use, the seals  110 ,  120 ,  130  are generally preferably transparent when the package  100  is in this closed or sealed configuration. Turning now to  FIG. 13 , as illustrated, the package  100  is partially opened, resulting in the separation of the first web  102  from the second web  104  in-part at the inner seal  110 , the outer seal  120  and the seal formed indicia  130 . The separated, or opened portions of these seals  110 ,  120 ,  130  are represented by hatching or diagonal parallel lines, as to distinguish them from the closed portions of the seals  110 ,  120 ,  130  that remain represented by stippling. In use, the seals  110 ,  120 ,  130  of the package  100  each may undergo a visual transformation as the first web  102  is separated from the second web  104  at the location of the seals  110 ,  120 ,  130 . That is to say, that the surface area of the first and second webs  102 ,  104 , which form the various seals,  110 ,  120 ,  130 , may change color as the respective seals are separated or broken and the thermoformed package  100  is opened. In one illustrated embodiment of the present invention, the surface area of the first and second webs  102 ,  104 , which form the various seals,  110 ,  120 ,  130 , changes from transparent to an opaque or a translucent white color as the respective seals  110 ,  120 ,  130  are broken and the package  100  is opened. Of course, other visual transformations are considered within the scope of this invention.  FIG. 14  provides an additional exemplary view of the package  100  in a fully opened orientation, in which all portions of the various seals,  110 ,  120 ,  130  have been opened. That is to say that the first web  102  has been generally entirely separated from the second web  104  at the inner seal  110 , the outer seal  120  and the seal formed indicia  130 , resulting in the surface areas of the seals  110 ,  120 ,  130  having undergone a visual change from transparent to an opaque or a translucent white color, as was described above. 
         [0042]    As a result of this visual transformation of the seals, the surface area of the first and second webs  102 ,  104 , which form the various seals,  110 ,  120 ,  130 , and particularly the seal formed indicia  130 , becomes increasingly visible as the package  100  is opened. As such, the graphical elements and/or alphanumeric characters  60  that formed the seal formed indicia  130 , which were imprinted via the embossment  58  of the seal plate  10 , become increasingly visible as the package  36  is opened. As is shown in  FIGS. 4, 13, and 14 , in a non-limiting exemplary embodiment, the seal formed indicia  130  is formed of the alphanumeric characters: “D &amp; W,” which corresponds to the indicia embodiment  58  shown In  FIGS. 1-3 . However, alternative alphanumeric characters  60  and/or graphical elements are considered within the scope of the present invention. By way of example, the indicia embodiment  58  and resultant seal formed indicia  130  may display the word “OPEN,” which becomes visible through the visual transformation of the seals once the first and second webs  102 ,  104  have been separated. As such, the seal formed indicia  130  may function as a temper-evident indicator in the thermoformed package  100 . 
         [0043]    It should be understood that the invention is not limited in its application to the details of construction and arrangements of the components set forth herein. The invention is capable of other embodiments and of being practiced or carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It also being understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention.