Patent Description:
Flexible film-based materials are commonly employed for constructing packages for products that can be dispensed from an opening in the package created when one layer of a multi-laminate construction is peeled away from another layer. Often, such packages are used to hold contents that are intended for dispensing only to the consumer buying the package, such as food items (e.g., cookies) and other types of contents that may be contaminated, diminished in value or quality, or otherwise degraded by the inspection or handling of those other than the ultimate consumer of the particular package. To provide an indication of tampering that may have occurred, for example as the result of a premature opening of the package by someone other than the consumer buying or intending to buy the package, such packages may be designed with package integrity features that make it apparent when a package has been opened, even after the package has been reclosed.

<CIT> describes resealable packaging for food products, comprising: a flexible container having a top, bottom and side faces, a container aperture having lateral edges extending within the top face, a flexible closure flap covered of repositionable adhesive on lateral margins which are peelable from a closed position in which they adhere around the aperture.

<CIT> describes a resealable closure for a container in which package integrity is indicated by a structure which breaks and/or produces an audible sound when the resealable closure is opened for a first time.

Aspects of the invention are in accordance with the appended independent claims. Various optional features are the subject of the appended dependent claims. Embodiments of the invention described herein provide improved package integrity features for packages that provide an indication that a package has been opened in a more consistent, more functional, and more easy-to-produce manner. A package integrity feature may be provided that is defined by an inner film layer of a package. The package integrity comprises a first die cut portion extending from a main die cut portion, wherein the main die cut portion at least partially defines an opening of the package, and a second die cut portion extending from the main die cut portion. The first and second die cut portions are continuous with each other and with the main die cut portion. The first and second die cut portions define a neck region of the package integrity feature having a reduced width and configured to tear as an opening force is applied to the package by a user, wherein tearing of the neck region provides access, via the opening, to contents stored within the package in a tamper evident manner. The first and second die cut portions further define an anchor region configured to resist the opening force applied by the user such that the neck region tears in response to application of the opening force.

In some cases, the package integrity feature may define a nominal width between the first and second die cut portions proximate a juncture between each of the first and second die cut portions and the main die cut portion, wherein the width of the neck region is less than the nominal width of the package integrity feature. A width of the anchor region may be greater than a nominal width of the package integrity feature. The inner film layer may be disposed adjacent an outer film layer of the package. The inner film layer may be permanently adhered to the outer film layer in an area within a peelable flap portion of the package, and the anchor region and a first part of the package integrity feature, defined between the first and second die cut portions proximate the anchor region, may be permanently adhered to the outer film layer. Additionally or alternatively, a second part of the package integrity feature, defined between the first and second die cut portions on an opposite side of the neck region from the first part, may be adhered to the outer film layer via a pressure sensitive adhesive. In some cases, the anchor region may be circular or elliptical.

A flexible package is provided that includes an inner film layer and an outer film layer, where the inner film layer and the outer film layer define a main body defining a compartment configured to hold contents therein and a peelable flap portion configured to be peeled away from the main body by the user. The inner film layer defines a main die cut portion between the peelable flap portion and the main body. The inner film layer further defines at least one package integrity feature extending between the main body and the peelable flap portion. Each package integrity feature may comprises a first die cut portion extending from the main die cut portion and a second die cut portion extending from the main die cut portion. The first and second die cut portions may be continuous with each other and with the main die cut portion.

Each integrity feature comprises a neck region having a reduced width and configured to tear as an opening force is applied to the peelable flap portion by a user to peel the peelable flap portion from the main body and create an opening in the package. Each package integrity feature further comprises an anchor region configured to resist the opening force applied by the user such that the neck region tears in response to application of the opening force.

The width of the neck region may be less than a nominal width of the package integrity feature. Moreover, a width of the anchor region may be greater than the width of the tamper evident region. The anchor region and a first part of the package integrity feature may be permanently adhered to the outer film layer of the peelable flap portion and a second part of the package integrity feature may be adhered to the outer film layer of the peelable flap portion via pressure sensitive adhesive. An outer perimeter of the peelable flap portion may be defined by an outer die cut formed in the outer film layer, such that the outer die cut and the main die cut portion cooperate to create the peelable flap portion. Additionally or alternatively, the peelable flap portion may comprise a pull tab defined by the outer die cut, wherein the pull tab is grippable by the user to pull the peelable flap portion away from the main body.

A method of manufacturing a package having a main body, a peelable flap portion, and a package integrity feature is provided, where the method includes laminating an outer film layer to an inner film layer, wherein a permanent adhesive is pattern applied to an inner surface of a respective one of the inner film layer or the outer film layer and wherein a pressure sensitive adhesive is applied to the inner surface of a peripheral portion of the respective one of the inner or outer film layer. The method further includes forming an outer die cut in a peripheral edge of the peripheral portion of the outer film layer to define a peelable flap portion; forming a main die cut portion in the inner film layer to define a location of an opening of the package; and forming each of first and second die cut portions in the inner film layer continuously with formation of the other of the first and second die cut portions and continuously with formation of the main die cut portion. The first and second die cut portions define a package integrity feature of the package.

Forming the first and second die cut portions comprises defining a neck region of the package integrity feature having a reduced width and configured to tear as an opening force is applied to the package by a user. Tearing of the neck region may provide access, via the opening, to contents stored within the package in a tamper evident manner. Forming the first and second die cut portions may further comprise defining an anchor region configured to resist the opening force applied by the user such that the neck region tears in response to application of the opening force. The width of the neck region may be less than a nominal width of the package integrity feature, and/or a width of the anchor region may be greater than a nominal width of the package integrity feature.

Forming each of first and second die cut portions comprises defining the anchor region and a first part of the package integrity feature in a location of the permanent adhesive and defining a second part of the package integrity feature in a location of the pressure sensitive adhesive. In some cases, forming an outer die cut in the peripheral edge of the peripheral portion of the outer film layer may comprise defining a pull tab configured to be gripped by a user for peeling the peelable flap portion away from a main body of the flexible package.

The present invention now will be described more fully hereinafter with reference to the accompanying drawings in which some but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

As noted above, some types of conventional packages, such as packages for holding food items (e.g., cookies), are designed to be resealable to allow a user to reclose the package after dispensing less than the entire contents of the package. For example, a user may open a package of cookies and take out two cookies to eat, then re-close the package to store the remaining cookies inside the package for future consumption. This may be accomplished, for example, using a resealable flap that can be pulled away from the body of the package to reveal an opening, through which the package contents can be accessed, and can likewise be re-adhered to the package body, thereby covering the opening.

In a retail environment, for example, it may be possible for someone who has not bought (and has no intention of buying) the package to prematurely open the package, take one or more of the items contained inside the package, then reseal the package and place the package back on the shelf, effectively stealing from the contents of the package and possibly contaminating the remaining contents. If the package is carefully resealed, a consumer may later purchase the package that has been tampered with, not knowing that the package was previously opened, contents removed, and the package re-closed.

As such, package integrity features have been developed that indicate to a consumer whether the original seal on the package opening has been broken. For example, a package integrity feature may be configured to cause a portion of the packaging to deform in some way the first time the package is opened, and the deformity may be visible even after the package has been resealed, thereby providing a visual indication of the previous opening of the package.

In packages made from flexible films, for example, discontinuous die cuts may be made in one of the layers of packaging film to create an anchor region that, when the package is opened, causes certain areas surrounding the opening to be stretched and torn to provide the desired visual indication of tampering. Such an anchor configuration is illustrated and described, for example, in <CIT>. , where an "anchor" is created using two outwardly facing J-curves that are not connected to each other.

Conventional methods of providing tamper evident features, however, have resulted in perceived inconsistencies in the manufacturing and performance of the package integrity features and the related packaging structures. Accordingly, as described below in greater detail, embodiments of the present invention provide for an improved tamper evident feature that has a simpler design with respect to the conventional design, is easier to manufacture and reduces the likelihood of inconsistent die cut depths, and improves the performance of the package integrity feature by encouraging a consistent failure mode in a desired location for opening the package.

Turning now to <FIG>, a flexible package <NUM> is shown, such as a package designed for holding food items such as cookies <NUM>. The package <NUM> may include a main body <NUM> and a peelable flap portion <NUM>. The main body <NUM>, for example, may define a compartment <NUM> configured to hold contents (e.g., cookies <NUM>) therein. In some embodiments, the peelable flap portion <NUM> may be configured to be peeled away from the main body <NUM> by the user, as depicted in <FIG>.

The flexible package <NUM> in the invention, includes an inner film layer <NUM> and an outer film layer <NUM>. Accordingly, the inner and outer film layers <NUM>, <NUM> define the main body <NUM> and the peelable flap portion <NUM>, as described in greater detail below. The inner film layer <NUM> defines a main die cut portion <NUM> between the peelable flap portion <NUM> and the main body <NUM> (illustrated in <FIG>, showing a partially open configuration of the package <NUM>). Said differently, the main die cut portion <NUM> may at least partially define an opening <NUM> of the package <NUM>, through which the contents of the package may be accessed, as illustrated in <FIG>.

Moreover, in some embodiments, an outer perimeter of the peelable flap portion <NUM> may be defined by an outer die cut <NUM> formed in the outer film layer <NUM>. In this way, the outer die cut <NUM> and the main die cut portion <NUM> may cooperate to create the peelable flap portion <NUM> of the package <NUM>. Thus, in such embodiments, the peelable flap portion <NUM> may have an area that includes two layers (e.g., the inner film layer <NUM> and the outer film layer <NUM>), such as in a central portion thereof, and the peelable flap portion <NUM> may also have an area that includes only one layer (e.g., only the outer film layer <NUM>), such as in a peripheral portion thereof.

In some cases, the peelable flap portion <NUM> may comprise a pull tab <NUM> that is defined by the outer die cut <NUM>. The pull tab <NUM> may be grippable by the user to pull the peelable flap portion <NUM> away from the main body <NUM>, as shown in <FIG>. For example, the pull tab <NUM> may have a semi-circular or semi-elliptical shape that extends outwardly from the general shape of the rest of the outer die cut <NUM>, as illustrated in <FIG>, for example, and an inner surface <NUM> of the pull tab <NUM> (e.g., the surface that contacts or is adjacent to the outer surface <NUM> of the inner film layer <NUM>) may be devoid of any adhesives between the two layers (described below), such that the pull tab may be easily separated from the package <NUM> (e.g., by the user sliding a finger between the pull tab <NUM> and the rest of the package <NUM>). In this way, the user may grasp the pull tab <NUM> and use it to pull the peelable flap portion <NUM> away from the main body <NUM> of the package <NUM>, as illustrated in <FIG> and described above.

The inner film layer <NUM> further defines at least one package integrity feature <NUM> extending between the main body <NUM> and the peelable flap portion <NUM>. The package <NUM> depicted in <FIG>, for example, includes three package integrity features <NUM>, as shown.

<FIG> provide a close-up view of the package integrity features <NUM>. With reference to <FIG>, for example, each package integrity feature <NUM> comprises a first die cut portion <NUM> extending from the main die cut portion <NUM> and a second die cut portion <NUM> extending from the main die cut portion <NUM>. In contrast with some conventional package integrity features, in which the die cut portions forming each package integrity feature are discontinuous and consist of separate die cuts (e.g., in an anchor region), according to embodiments of the present invention the first and second die cut portions <NUM>, <NUM> are continuous with each other and with the main die cut portion <NUM>, such that a single, continuous cut line forms the main die cut portion <NUM>, the first die cut portion <NUM>, and the second die cut portion <NUM>. In the invention, each package integrity feature <NUM> comprises a neck region <NUM> and an anchor region <NUM>, as illustrated in <FIG>. The neck region <NUM> has a reduced width and is configured to tear as an opening force F (shown in <FIG>) is applied to the peelable flap portion <NUM> by a user to peel the peelable flap portion from the main body <NUM> and create the opening <NUM> of the package. The anchor region <NUM> is configured to resist the opening force F applied by the user such that the neck region <NUM> tears in response to application of the opening force F to the respective package integrity feature <NUM> (e.g., tearing when the opening force experienced by the particular package integrity feature reaches a certain threshold amount of force).

In <FIG>, for example, the user has not yet applied an adequate amount of opening force F over a great enough distance (e.g., has not peeled the peelable flap portion <NUM> far enough back) to tear any of the package integrity features <NUM>; in <FIG>, one of the package integrity features <NUM> (the centrally located one) has experienced an amount of opening force F sufficient to cause that package integrity feature to tear at its neck region <NUM>; and in <FIG>, each of the three depicted package integrity features <NUM> have experienced the sufficient amount of opening force F to tear at the respective neck regions <NUM>. In other words, because one end of each package integrity feature <NUM> is connected to the peelable flap portion <NUM> via the anchor region <NUM> and the other end of the respective package integrity feature is connected to the main body <NUM> of the package, and because the peelable flap portion is being pulled away from the main body by the user's action of opening the package <NUM> as shown in <FIG>, each package integrity feature <NUM> is stretched until the point at which it tears (e.g., at the neck region <NUM>, as illustrated).

Once torn, the now permanently deformed (and no longer intact) package integrity features <NUM> serve as visual indications that the package <NUM> has been opened and, thus, provide evidence of tampering. In some cases, the package integrity features <NUM> may also provide a tactile indication of tampering, as the opening of a package may feel "more difficult" or provide greater resistance to opening when the package integrity features are intact (prior to the first opening) than after the package has been opened. Accordingly, in some embodiments, each package integrity feature <NUM> may define a nominal width, e.g., proximate a juncture between each of the first and second die cut portions <NUM>, <NUM> and the main die cut portion <NUM> and/or proximate a juncture between each of the first and second die cut portions and the anchor region <NUM>. Thus, in some embodiments, the width w<NUM> of the neck region <NUM> may be less than the nominal width w<NUM> of the package integrity feature <NUM> so as to encourage failure (e.g., tearing) of the package integrity feature <NUM> at the neck region, instead of elsewhere on the package integrity feature. Moreover, in some embodiments, the width w<NUM> of the anchor region <NUM> may be greater than the nominal width w<NUM> of the package integrity feature <NUM>, in addition to being greater than the width w<NUM> of the neck region <NUM>. In this way, the anchor region <NUM> may have sufficient surface area to remain secured to the peelable flap portion <NUM>, as described below, such that the tearing of the package integrity feature <NUM> occurs at the neck region <NUM> and causes a portion <NUM> of the package integrity feature <NUM>, once torn, to "hang down" from the main body <NUM> as a visual indication of tampering, as stated above and depicted in <FIG>.

In this regard, in some embodiments, the anchor region <NUM> may be specifically configured (e.g., sized and shaped) so as to maintain a secure attachment to the outer film layer <NUM> of the peelable flap portion <NUM>, e.g., as a result of adhesives applied between adjacent, contacting surfaces of the inner and outer film layers <NUM>, <NUM> in the area of the anchor region <NUM>. For example, in some embodiments, the anchor region <NUM> may be configured to be circular or elliptical, as shown, e.g., in <FIG>. Although various configurations (sizes and shapes) of the anchor region <NUM> may be used to achieve different surface areas over which the inner film layer <NUM> of the anchor region <NUM> may be adhered to the outer film layer <NUM> of the peelable flap portion, a larger anchor region <NUM> may generally yield a package integrity feature <NUM> that performs more consistently. This is because as the surface area of the anchor region <NUM> increases, more shear force is required to pull it apart, which in turn causes the neck region <NUM> of the package integrity feature <NUM> to fail first.

In some cases, the package integrity feature <NUM> may have a first part <NUM> on one side of the neck region <NUM> and a second part <NUM> on the other side of the neck region <NUM>, as shown in <FIG>. With reference also to <FIG>, the anchor region <NUM> and the first part <NUM> of the package integrity feature <NUM> may, for example, be permanently adhered to the outer film layer <NUM> of the peelable flap portion <NUM> (e.g., via permanent adhesive <NUM>), and the second part <NUM> of the package integrity feature may be adhered to the outer film layer <NUM> of the peelable flap portion <NUM> via pressure sensitive adhesive <NUM>. As such, the opening force F applied as the user is peeling the peelable flap portion <NUM> away from the main body <NUM> (as shown in <FIG>), such as via the pull tab <NUM>, may cause the outer film layer <NUM> to be separated from the inner film layer <NUM> in the area of the peelable flap portion <NUM> between the outer die cut <NUM> and the main die cut portion <NUM>, as well as in the second part <NUM> (<FIG>) of the package integrity feature <NUM>, where the pressure sensitive adhesive <NUM> is present.

As the user continues to pull the peelable flap portion <NUM>, the increased attachment force between the inner and outer film layers <NUM>, <NUM> in the area of the first part <NUM> of the package integrity feature should cause the package integrity feature <NUM> to tear at or near the neck region <NUM>. In some cases, the inner and outer film layers <NUM>, <NUM> may at least partially delaminate in areas in which permanent adhesive <NUM> is applied, such as in the first part <NUM> of the package integrity feature <NUM> and/or in a portion of the anchor region <NUM> (as illustrated in <FIG>, for example); however, embodiments of the invention provide an anchor region that is configured (e.g., sized and shaped) such that the surface area of the adhesion between the inner film layer and the outer film layer within the anchor region is sufficient to withstand the amount of opening force F required to tear the package integrity feature <NUM> at the neck region <NUM>, as described above.

Accordingly, a method of manufacturing a package having a main body, a peelable flap portion, and a package integrity feature as described above is also provided according to the invention. The method comprises laminating an outer film layer <NUM> to an inner film layer <NUM>, wherein a permanent adhesive <NUM> is pattern applied to an inner surface of a respective one of the inner film layer or the outer film layer (e.g., where the inner surface is the surface of the respective film layer that is to be in contact with a corresponding inner surface of the other film layer). A pressure sensitive adhesive <NUM> is applied to the inner surface of a peripheral portion of the respective one of the inner or outer film layer, such as to surround a central area in which permanent adhesive <NUM> is applied (e.g., as illustrated in <FIG> and <FIG>). The peripheral portion may be, for example, an area that generally extends between the outer die cut <NUM> and the main die cut portion <NUM>.

As described above, an outer die cut <NUM> is formed in a peripheral edge of the peripheral portion of the outer film layer <NUM> to define the peelable flap portion <NUM>, and a main die cut portion <NUM> is formed in the inner film layer <NUM> to define a location of an opening of the package. Each of first and second die cut portions <NUM>, <NUM> are also be formed in the inner film layer <NUM>. The first and second die cut portions <NUM>, <NUM> are formed continuously with each other (e.g., via a single cutting action) and also continuously with formation of the main die cut portion <NUM>. As such, the first and second die cut portions <NUM>, <NUM> define a package integrity feature <NUM>, as described above.

In the invention, forming the first and second die cut portions <NUM>, <NUM> comprises defining a neck region <NUM> of the package integrity feature <NUM> having a reduced width that is configured to tear as an opening force is applied to the package by a user, such that tearing of the neck region provides access, via the opening, to contents stored within the package in a tamper evident manner. Moreover, forming the first and second die cut portions <NUM>, <NUM> further comprises defining an anchor region <NUM> configured to resist the opening force applied by the user such that the neck region tears in response to application of the opening force.

The anchor region <NUM> may, in some cases, be defined with a first part <NUM> of the package integrity feature <NUM> in a location of the permanent adhesive <NUM>, as described above and illustrated in <FIG> and <FIG>. A second part <NUM> of the package integrity feature <NUM> may be defined in a location of the pressure sensitive adhesive <NUM>. Moreover, a pull tab <NUM> may be defined as part of forming an outer die cut <NUM> in the peripheral edge of the peripheral portion of the outer film layer <NUM>, and the pull tab may be configured to be gripped by a user for peeling of the peelable flap portion <NUM> away from the main body <NUM> of the flexible package <NUM>. For example, at least part of the pull tab <NUM> may not be adhered to the corresponding surface of the inner film layer <NUM>, such as by not having any permanent or pressure sensitive adhesive applied between the two film layers in that area. In addition, the pull tab <NUM> may have a size and/or shape that is conducive to being gripped by the user and pulled.

The package integrity feature <NUM> described above, in particular with respect to the formation of the package integrity feature using first and second die cut portions that are continuous with each other and with the main die cut portion from which they extend, allows for better performance of the package integrity features and result in a simpler design that is easier to manufacture and is more consistently produced from package to package. The use of a continuous cut to create the package integrity feature, for example, reduces the likelihood of inconsistent die-cut depths along the length of the die cut (main die cut portion, first die cut portion, and second die cut portion). For example, according to some embodiments, the cut depths are made to a tolerance of within approximately <NUM>-9µ. In addition, the continuous nature of the die cut described above results in better performance of the package integrity feature by ensuring that the package integrity feature breaks away from the package before reaching the permanent adhesive area (or with minimal delamination of the permanent adhesive area), such that the package integrity feature is able to tear at or near the neck region when the package is opened.

Claim 1:
A package integrity feature (<NUM>), the package integrity feature (<NUM>) comprising:
an outer film layer (<NUM>) of a package;
an inner film layer (<NUM>) of the package disposed adjacent the outer film layer, wherein the inner film layer (<NUM>) comprises:
a first die cut portion (<NUM>) extending from a main die cut portion (<NUM>), wherein
the main die cut portion (<NUM>) at least partially defines an opening (<NUM>) of the package;
and
a second die cut portion (<NUM>) extending from the main die cut portion, and
wherein the first and second die cut portions (<NUM>, <NUM>) define:
a neck region (<NUM>) of the package integrity feature (<NUM>) having a reduced width and configured to tear as an opening force is applied to the laminate by a user, wherein tearing of the neck region (<NUM>) provides access, via the opening (<NUM>), to contents stored within the laminate in a tamper evident manner, and
an anchor region (<NUM>) configured to resist the opening force applied by the user such that the neck region (<NUM>) tears in response to application of the opening force,
wherein the anchor region (<NUM>) is configured to have sufficient surface area to remain secured to a peelable flap portion of the laminate such that tearing of the
package integrity feature (<NUM>) occurs at the neck region (<NUM>), characterized in that the first and second die cut portions (<NUM>, <NUM>) are continuous with each other and with the main die cut portion (<NUM>).