Abstract:
A flexible package for compressible absorbent articles, where the flexible package comprises a self supporting extension that captures consumer attention and provides acceptable shipping and storage dimensions.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/392,897, filed on Jul. 1, 2002. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates a flexible package containing one or more stacks of compressible absorbent articles maintained in a state of compression, the flexible package comprising a self-supporting extension useful as a display feature.  
         BACKGROUND OF THE INVENTION  
         [0003]    Attracting the attention of the consumer to products is just one of the functions of packaging and packaging displays. Some consumers prefer interactive packaging that is colorful and interesting to look at as well as being functional. The functional aspect of packaging is to keep the products inside protected and to provide ease in shipping and stocking on store shelves. The use of flexible bags and packages for consumer products has previously focused on making the package dimensions regulated for shipping and storage on store shelving by having a rectangular shape that maximizes the space available. However, this has also led to packages that are monotonous and uninteresting to the consumer eye.  
           [0004]    Recent on-package advertising techniques have included placing stickers or decals on the packaging. However, this leads to increased physical labor in placing the stickers on the packaging and the stickers are easily removed when still on display. Additionally, consumers generally must remove the sticker from the packaging in order to effectively use the package.  
           [0005]    Therefore there exists a need to have a flexible package capable of capturing the consumer&#39;s attention in-store while still having acceptable shipping and storage dimensions.  
         SUMMARY OF THE INVENTION  
         [0006]    The present invention relates to a flexible package for holding compressible absorbent articles, the flexible package comprising a first element and a second element. The first element preferably includes a front panel region having a front panel width and a front panel height, a pair of side panel regions each having a side panel width and a side panel height, and a bottom panel region having a bottom panel width and a bottom panel height. The second element preferably includes a top panel region having a top panel width and length, a pair of gusset panel regions each having a gusset panel width and a gusset panel length, a back panel region having a back panel width and a back panel height, a pair of end panel regions each having an end panel width and an end panel height, and a base panel region having a base panel width and a base panel length. When in finished form, the first element and the second element are connected to form an interior space such that the pair of side panel regions of the first element are connected to the pair of end panel regions of the second element. Likewise, the bottom panel region of the first element connects to the base panel region of the second element, and the front panel region of the first element connects to the top panel region of the second element. The front panel height is preferably greater than the side panel height for at least a portion of the front panel width, to form at least one first extension area, and the top panel length is greater than the gusset panel length for at least a portion of the top panel width, to form at least one second extension area. The first extension area is also preferably connected to the second extension area to form a self-supporting extension. 
       
    
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0007]    While the specification concludes with claims particularly pointing out and distinctly claiming the invention, it is believed that the invention will be better understood from the following description of the accompanying figures in which:  
         [0008]    [0008]FIG. 1 is a plan view of a plastic sheet blank, from which the package of the present invention is formed, comprising a first element and a second element;  
         [0009]    [0009]FIG. 2 is a front perspective view of a preferred embodiment of the flexible plastic packaging of the present invention;  
         [0010]    [0010]FIG. 3 is a back perspective view of a preferred embodiment of the flexible plastic packaging of the present invention;  
         [0011]    [0011]FIG. 4 is a side view of a preferred embodiment of the flexible plastic packaging of the present invention;  
         [0012]    [0012]FIG. 5 is a front perspective view of a preferred embodiment of the flexible plastic packaging of the present invention having a self-supporting extension extending the entire width of the front panel region;  
         [0013]    [0013]FIG. 6 is a front perspective view of a preferred embodiment of the flexible plastic packaging of the present invention having a self-supporting extension extending a portion of the width of the front panel region;  
         [0014]    [0014]FIG. 7 is a side view of a preferred embodiment of the flexible package of the present invention folded along the first element/second element intersection and the front panel region/back panel region intersection, during assembly of the package; and  
         [0015]    [0015]FIG. 8 is a front view of a preferred embodiment of the flexible package of the present invention having a heat seal below the self-supporting extension. The figures herein are not necessarily drawn to scale. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0016]    As used herein, the term “self-supporting” means that at least a portion of the flexible package of the present invention remains extended away from the package without any external or internal support structures. The integrity of the self-supporting structure should be such that only one side of the self-supporting structure can be viewed from one direction. In other words, the self-supporting structure does not fold or fall over onto itself.  
         [0017]    As used herein, the term “connected” means any method known in the art to attach two components together. A preferred method for connecting according to the present invention is heat sealing.  
         [0018]    As used herein, the term “compressible” means that the absorbent articles should be compressed in the package by at least 20% of their uncompressed thickness, and preferably by at least 30% of their uncompressed thickness. More preferably, the invention allows higher levels of compression, such as 40% or, even more preferably 60% of the uncompressed thickness. Levels of compression greater than 70% have been successfully achieved.  
         [0019]    Although the present invention may be used with many types of compressible absorbent articles, it is particularly useful for disposable absorbent products such as diapers, incontinence products, sanitary napkins, absorbent pads and bandages. Such products are generally bulky in the uncompressed state. In many cases these products are of a composite nature, comprising an absorbent core and one or more flexible sheets. The core may itself be homogeneous or composite in structure. Such absorbent products often comprise a fluid permeable sheet (e.g. a non-woven or perforated polymeric film) that, in use, lies closest to the body of the wearer, and an outer barrier sheet.  
         [0020]    The material from which the flexible package of the present invention may be made includes any polymeric material, preferably a thermoplastic film, such as low density polyethylene (LDPE), high density polyethylene (HDPE), polyester, polypropylene, or combinations, or laminates of these. The plastic film suitable for use in the present invention may be made from virgin or recycled material, or a mixture of these. Preferably a three layer co-extruded film comprising LDPE and linear low density polyethylene (LLDPE)/medium density (MD) and HD and LDPE/LLDPE; having a thickness between about 40 micrometer and about 100 micrometers, and more preferably between about 40 micrometers and about 60 micrometers.  
         [0021]    One embodiment of the flexible package ( 10 ) of the present invention, shown in FIGS.  2 - 6  and  8 , may be formed essentially from a single sheet of plastic film, as shown in FIG. 1. The sheet may comprise two components, a first element ( 12 ) and a second element ( 14 ) intersecting at the first element/second element fold line ( 13 ). The first element ( 12 ) comprises a front panel region ( 20 ), a pair of side panel regions ( 24 ,  26 ), and a bottom panel region ( 30 ). The front panel region ( 20 ) is located adjacent to and between the two side panel regions ( 24 ,  26 ) such that the front panel region ( 20 ) intersects the side panel regions ( 24 ,  26 ) at front panel region/side panel region intersections ( 46 ,  48 ). The bottom panel region ( 30 ) is located adjacent to the front panel region ( 20 ) opposite the first element/second element intersection ( 13 ) such that the bottom panel region ( 30 ) intersects the front panel region ( 20 ) at the front panel region/base panel region intersection ( 50 ). As seen in FIG. 1, the front panel region ( 20 ) has a front panel width (W1) and a front panel height (H1). The side panel regions ( 24 ,  26 ) have a side panel width (W2) and a side panel height (H2). The bottom panel region ( 30 ) has a bottom panel width (W3) and a bottom panel length (L3).  
         [0022]    Herein, the “regions” of the plastic film sheet have been given their specific names and reference numerals according to the location on the final assembled package  10  that that region will form. For example, the “front panel region” will form the front of the assembled package containing products inside the package, when viewed by a consumer. Similarly, the various “intersections” herein generally refer to the locations at which the plastic sheet is folded during the package assembly.  
         [0023]    The front panel height (H1) of the present invention is preferably between about 75 mm and about 1500 mm. The front panel width (W1) is preferably between about 50 mm and about 1000 mm. The side panel height (H2) is preferably between about 25 mm and about 600 mm. The side panel width (W2) is between about 50 mm and about 1000 mm. The bottom panel width (W3) is preferably between about 50 mm and about 1000 mm. The bottom panel length (L3) is preferably between about 25 mm and about 600 mm.  
         [0024]    At least a portion of the front panel height (H1) is greater than the side panel height (H2). This difference is herein defined as ΔH and is indicated on FIG. 1. Preferably, ΔH is equal to or less than one half the side panel height (H2). The ΔH of the front panel region ( 20 ) comprises a portion of the front panel width (W1), to form one or more areas, exemplified in FIG. 1 and herein defined as A 40  and A 42 . The change in height between the side panel regions ( 24 ,  26 ) and the front panel region ( 20 ) may be gradual or abrupt, but the delineation of the height from the side panel regions ( 24 ,  26 ) to the front panel region ( 20 ) is continuous.  
         [0025]    The second element ( 14 ) comprises a top panel region ( 28 ), a pair of gusset panel regions ( 36 ,  38 ), a back panel region ( 22 ), a pair of end panel regions ( 40 ,  42 ), and a base panel region ( 44 ). The top panel region ( 28 ) is located adjacent to and between the gusset panel regions ( 36 ,  38 ) such that the top panel region ( 28 ) intersects the gusset panel regions ( 36 ,  38 ) at the top panel region/gusset panel region intersections ( 52 ,  54 ). The top/gusset panel regions ( 28 ,  36 ,  38 ) are bisected by top panel fold line ( 29 ). The back panel region ( 22 ) is located adjacent to and between the end panel regions ( 40 ,  42 ) such that the back panel region ( 22 ) intersects the end panel regions ( 40 ,  42 ) at the back panel region/end panel region intersections ( 56 ,  58 ). The top/gusset panel regions ( 28 ,  36 ,  38 ) are located adjacent the back/side panel ( 22 ,  40 ,  42 ) and intersect at the top panel region/back panel region intersection ( 60 ). The base panel region ( 44 ) is located below the back panel region ( 22 ) such that the base panel region ( 44 ) intersects the back panel region ( 22 ) at the back panel region/base panel region intersection ( 62 ).  
         [0026]    The top panel region ( 28 ) has a top panel width (W4) and a top panel length (L4). The gusset panel regions ( 36 ,  38 ) each have a gusset panel width (W5) and a gusset panel length (L5). The ΔL of the top panel region ( 28 ) is located opposite the back panel region/top panel region intersection ( 60 ). The top panel length (L4) is preferably between about 75 mm and about 1500 mm. The top panel width (W4) is preferably between about 50 mm and about 1000 mm. The gusset panel width (W5) is preferably between about 25 mm and about 600 mm. The gusset panel length (L5) is preferably between about 50 mm and about 1000 mm.  
         [0027]    The back panel region ( 22 ) has a back panel width (W6) and a back panel height (H6). The end panel regions ( 40 ,  42 ) have an end panel width (W7) and an end panel height (H7). The base panel region ( 44 ) has a base panel width (W8) and an end panel length (L8). The back panel height (H6) preferably is between about 50 mm and about 1000 mm. The back panel width (W6) is preferably between about 50 mm and about 1000 mm. The end panel height (H7) is preferably between about 50 mm and about 1000 mm. The end panel width (W7) is preferably between about 25 mm and about 600 mm. The base panel length (L8) is preferably between about 25 mm and about 600 mm. The base panel width (W8) is preferably between about 50 mm and about 1000 mm.  
         [0028]    At least a portion of the top panel length (L4) is greater than the gusset panel height (L5), herein defined as ΔL and indicated on FIG. 1. Preferably, ΔL is equal to or less than one half the gusset panel length (L5). The AL of the top panel region ( 28 ) comprises a portion of the top panel width (W4) to create a single area or a plurality of areas, shown in FIG. 1 as a plurality of areas and indicated herein as A 44  and A 46 . The change in length between the gusset panel regions ( 36 ,  38 ) and the top panel region ( 28 ) may be gradual or abrupt, but the delineation of the length from the gusset panel regions ( 36 ,  38 ) to the top panel region ( 28 ) is continuous. Preferably, areas A 44  and A 46  of the top panel region ( 28 ) are equal in area (substantially the same size and shape) to the areas A 40  and A 42  of the front panel region ( 20 ) of the first element ( 12 ).  
         [0029]    Areas A 40  and A 42  of the front panel region ( 20 ) are connected to areas A 44  and A 46  of the top panel region ( 28 ) to form a self-supporting extension ( 32 ) that can extend away from the flexible package ( 10 ) of the present invention. The self-supporting extension ( 32 ) can take any shape desired as long as the material is still self-supporting and does not fall or bend over to obscure any printing that is displayed on the self-supporting extension ( 32 ). The self-supporting extension ( 32 ) is shown in FIGS.  1 - 3  as comprising a plurality of areas (A 40 - 46 ).  
         [0030]    In other embodiments of the present invention, the self-supporting extension ( 32 ) may comprise a single area extending the entire top panel width and the front panel width, exemplified in FIG. 5. Another embodiment of the present invention comprises a single area extending only a portion of the top panel region ( 28 ) and the front panel region ( 20 ), exemplified in FIG. 8.  
         [0031]    The self-supporting extension ( 32 ) preferably has an aesthetically pleasing appearance such that consumers are attracted to it. For example, the package can be made so that it resembles a cute or whimsical animal, with the self-supporting extensions forming like the animal&#39;s ears, see FIG. 1. In another example, the self-supporting extension ( 32 ) can be made to look like a whimsical animal&#39;s face attached to the package. The appearance of the self-supporting extension and/or package can be tailored to type of product contained in the package, and any such appearance is intended to be with the scope of the present invention.  
         [0032]    The flexible package ( 10 ) of the present invention may be formed by folding the sheet of plastic film along the first element/second element intersection ( 13 ) so that the areas A 40  and A 42  are superposed on the areas A 44  and A 46  to form the self supporting extension ( 32 ). The sheet of plastic film is then folded along the top panel region/back panel region intersection ( 60 ) and is superposed on first element ( 12 ) and a portion of the second element ( 14 ). The combined top/gusset panel regions ( 28 , 36 ,  38 ) are further folded approximately in half along the top panel fold line ( 29 ) to form a modified “M” shape as shown in FIG. 9. The edge of the side panel regions ( 24 ,  26 ) of the first element ( 12 ) are sealed to the edge of the end panel regions ( 40 ,  42 ) and gusset panel regions ( 36 ,  38 ) of the second element ( 14 ) to connect the first element ( 12 ) to the second element ( 14 ). Additionally, the flexible package ( 10 ) of the present invention is sealed along the desired design of the self-supporting extension ( 32 ) with portions of the front panel region ( 20 ), side panel regions ( 24 ,  26 ), top panel region ( 28 ), and gusset panel regions ( 36 ,  38 ) being cut away from the flexible plastic sheet. These cut away regions can be seen in the shaded area of FIG. 1. Optionally, an additional seal ( 64 ) can be placed below the self supporting extension ( 32 ) of the front panel region ( 20 ) and the top panel region ( 28 ) as shown in FIG. 10. The compressible absorbent articles are placed inside the flexible package and the bottom panel of the first element ( 30 ) is sealed to the base panel of the second element ( 44 ).  
         [0033]    In an alternative embodiment of the present invention, the defined regions of the first element ( 12 ) and the defined regions of the second element ( 14 ) may be made and assembled in a plurality of smaller individual parts to form a similarly shaped flexible package, and such should be considered within the scope of the present invention.  
         [0034]    Additional Elements  
         [0035]    An optional element of the present invention includes providing a carrying handle as an integral part of the flexible package ( 10 ). Another optional element of the present invention comprises an opening means in the flexible package. Any opening means that is conventionally used in the art may be found to be suitable. Such an opening means may take the form of a substantially continuous line of weakness, for example a line of perforations, and it may include an opening tab which enables the consumer to grip the plastic of the covering at a point adjacent to the opening means in order to tear the covering open. Another optional element is to construct the present invention such that comprises a hanging means to suspend the flexible package ( 10 ) from a wall or display.  
         [0036]    While particular embodiments and/or individual features of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Further, it should be apparent that all combinations of such embodiments and features are possible and can result in preferred executions of the invention. Therefore, the appended claims are intended to cover all such changes and modifications that are within the scope of this invention.