Flexible Pouch With Easy-Opening Features

Abstract

A flexible pouch is formed from a laminate having built-in opening features. The laminate is wrapped/folded into a generally tubular configuration and sealed at top and bottom ends and along a longitudinal fin. A tear initiation feature is provided in the form of a hole extending through the laminate and located within a top seal of the pouch. The tear initiation feature is located at one longitudinal edge of the pouch when the laminate is wrapped and sealed to form the pouch. A fin tear-propagating feature is also provided in the form of two tear areas formed respectively in the side edges of the laminate such that the tear areas substantially coincide on the fin so as to form the fin tear-propagating feature, the fin tear-propagating feature being substantially in transverse alignment with the tear initiation feature. In another embodiment, the tear initiation feature is provided as a score line extending across the pouch.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation-in-part of application Ser. No. 12/180,709 filed on Jul. 28, 2008, which is currently pending, and the entire disclosure of which is hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

This disclosure relates to food or beverage containers in the form of a sealed pouch or the like formed from flexible laminate material. The laminate typically includes at least a barrier layer and a sealant layer. Edges of the laminate material are sealed together via the sealant layer to create the pouch or other configuration.

A variety of food and non-food products are packaged using flexible packaging materials formed primarily of laminations of one or more of polymer films, metallized polymer films, paper, metal foil, and the like. In many instances, it is desirable to provide easy access to the contents of the package such that a user can provide minimal effort to open the package without the risk of injury. Packages that are easily opened, however, typically suffer from being poorly sealed resulting in the contents of the package being adversely affected (e.g., becoming soggy, drying out, etc.) by exposure to the surrounding environment.

Easy opening of such flexible packaging has been a longstanding problem to which much effort has been devoted toward developing a satisfactory solution by many workers in the field. Mechanical or laser ablation to form a notch or line of weakening in the laminate material, at which tearing of the material can be initiated, has been the typical approach. In the case of laser-formed opening features, a past approach has been to ablate partway through the thickness of the laminate to weaken it while attempting to not compromise the barrier function of the laminate. These techniques have not met with complete success in all cases, particularly when the unablated portions of the laminate are a highly extensible material, because the extensible layers may not tear easily. Instead, the highly extensible materials typically stretch, and thus, result in opening failures of the package.

Further, mechanical processes to form a notch or line of weakening in the laminate material add complexity and scrap to the manufacturing process. The equipment involved with mechanical processes, such as die-cutting equipment, typically involves numerous moving parts. Manufacturing processes involving moving parts typically malfunction more frequently and become misaligned, and thus, additional maintenance of the manufacturing process is required to repair and/or align the moving parts. Mechanical processes also can create scrap that may interfere with the manufacturing process or may need to be removed by a separate process, adding cost and complexity to the overall manufacturing process.

Accordingly, there is a need for an improved manufacturing process to produce opening features for sealed pouches formed from flexible laminate that securely seals the contents of a package during the packing process but allows the package to be easily opened by the consumer.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure addresses the above needs and achieves other advantages, by providing a flexible packaging structure and method for making same, in which the structure has opening features built into the structure. In accordance with one embodiment of the invention, a pouch is formed from a laminate comprising an outer structure joined in face-to-face relation to an inner structure. The outer structure forms the exterior surface of the completed pouch, and the inner structure forms an interior product-contacting surface of the pouch. After the laminate is wrapped and/or folded into a generally tubular configuration, opposite longitudinal edge portions of the laminate are sealed together to form a fin, and opposite ends of the tubular structure are sealed to form top and bottom seal areas. The pouch includes easy-open tear-facilitating features located within the top seal area.

In accordance with an embodiment of the invention, the tear-facilitating features include a tear initiation feature comprising a hole formed through the laminate and straddling a first fold line along which the laminate is folded when it is wrapped about the longitudinal axis. There is a second fold line along which the laminate is folded when it is wrapped. The fold lines respectively become the two longitudinal edges of the completed pouch. The tear initiation feature is located within the top seal of the completed pouch.

The laminate further defines a fin tear-propagating feature comprising two tear areas formed respectively in the side edges of the laminate such that the tear areas substantially coincide on the fin so as to form the fin tear-propagating feature. The fin tear-propagating feature is substantially in transverse alignment with the tear initiation feature. The tear areas can comprise notches formed into the side edges of the laminate so that they extend partway across the widths of the respective fin panels that are sealed together to form the fin.

The top seal is configured such that the tear initiation feature and fin tear-propagating feature are located in the top seal area, so that these features do not compromise the sealing of the pouch. The top seal is further configured so that a portion of the unsealed area of the laminate is in transverse alignment with the tear features. In this manner, when a user opens the pouch by starting the tear at the tear initiation feature and continuing to tear transversely across the pouch, the tear will intersect the unsealed area so as to gain access to the contents through the opening that results.

The tear initiation and fin tear-propagating features are the only tear features in the pouch. There are no further score lines or any other features promoting or facilitating tearing of the laminate material.

In yet another embodiment of the invention, the laminate does not include a tear initiation feature comprising a hole formed through the laminate and straddling a fold line. Instead, the laminate includes a score line that extends across the laminate in the transverse direction. Where the laminate is formed of an outer structure laminated to an inner structure, the score line is formed in the outer structure but not in the inner structure.

There is a second fold line along which the laminate is folded when it is wrapped. The two fold lines respectively become the two longitudinal edges of the completed pouch. One end of the score line is located within the top seal of the completed pouch.

The laminate further defines a fin tear-propagating feature comprising two tear areas formed respectively in the side edges of the laminate such that the tear areas substantially coincide on the fin so as to form the fin tear-propagating feature. The fin tear-propagating feature is substantially in transverse alignment with the score line. The tear areas can comprise notches formed into the side edges of the laminate so that they extend partway across the widths of the respective fin panels that are sealed together to form the fin.

The top seal is configured such that the fin tear-propagating feature is located in the top seal area so that it does not compromise the sealing of the pouch. One end portion of the score line is also located in the top seal area. The top seal is further configured so that a portion of the unsealed area of the laminate contains an opposite end portion of the score line. In this manner, when a user opens the pouch by starting the tear at one end of the score line and continuing to tear transversely across the pouch, guided by the score line, the tear will intersect the unsealed area so as to gain access to the contents through the opening that results.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 is a diagrammatic depiction of a first phase of a manufacturing method for making a flexible packaging structure in accordance with one embodiment of the invention;

FIG. 2 is a diagrammatic depiction of a second phase of the method in accordance with one embodiment of the invention;

FIG. 3 is a diagrammatic depiction of a second phase of the method in accordance with another embodiment of the invention;

FIG. 4 is a plan view of the laminate used to form a flexible packaging structure in accordance with one embodiment of the invention

FIG. 5 is a front view of a package that can be formed from a flexible packaging structure made in accordance with the embodiment FIG. 4;

FIG. 6 shows an enlarged portion of the tear area of the package in FIG. 5 in a partially opened state;

FIG. 7 is a plan view of a top portion of a laminate used to form a flexible pouch in accordance with a further embodiment of the invention;

FIG. 7A is a front view of a top portion of the flexible pouch formed from the laminate of FIG. 7;

FIG. 8 is a plan view of a top portion of a laminate used to form a flexible pouch in accordance with yet another embodiment of the invention; and

FIG. 8A is a front view of a top portion of the flexible pouch formed from the laminate of FIG. 8.

DETAILED DESCRIPTION OF THE DRAWINGS

The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some but not all embodiments of the invention 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. Like numbers refer to like elements throughout.

As an initial overview of preferred embodiments of the invention, a flexible packaging laminate is constructed to have a built-in opening feature. The laminate is constructed as a multi-layer structure by adhesively laminating a first structure to a second structure, wherein each of the first and second structures comprise one or more layers of flexible material. Adhesive may be applied to one of the structures before lamination. Once the laminate is formed, laser ablation operations are performed along portions of the laminate using a laser to penetrate through at least a portion of a thickness of the laminate material. Laser ablation of the tear areas of the laminate preferably begins at the center of a tear area, and progressively the laser moves in a direction radially outwardly from the center until the laser delineates the desired outer perimeter of the tear area. The laser ablation process may also be used to form a score line. Further, laser ablation may also be used to form a sealant reduction area along the second structure of the laminate by, for example, ablating an area of the second structure of the laminate. The second structure of the laminate may be a sealant film.

More particularly, with reference to FIG. 1, a first phase of the manufacturing process is depicted. A first structure 10 is advanced from a supply roll 12 by suitable web driving and handling equipment (not shown) to an optional print station 14 comprising a printing apparatus, such as a rotogravure printer or the like, for printing graphics and/or indicia on the first structure by applying inks to a surface of the first structure. The first structure 10 comprises one or more layers of flexible packaging material. Various materials can be used for the layer(s) of the first structure, including polymers such polyesters, polyolefins (including homopolymers and copolymers), polyamides, and others; paper; metal foil; and the like. The first structure 10 may include an outer layer (not illustrated) that is substantially transparent and is reverse-printed in the print station 14, i.e., the inks are applied to the surface of the first structure 10 that is subsequently laminated to another structure, as described below, from the opposite side of the first structure, which will form an exterior of a package constructed from the packaging laminate, such that the inks are visible through the first structure. As an example, the first structure 10 can comprise a layer of polyester such as polyethylene terephthalate or the like.

Prior to printing the first structure in the print station, the surface of the first structure that is subsequently laminated to the other structure can be treated by a corona discharge or flame treatment apparatus 16 to render the surface more receptive to the inks and/or to render the surface more readily bondable to the adhesive that is subsequently applied to the surface as described below. Alternatively, the first structure 10 can have already been so treated prior to being wound into the supply roll 12, such that the treatment apparatus 16 is unnecessary.

Following the optional corona/flame treatment and/or optional printing operation, and with reference to FIG. 1, the first structure 10 is advanced to an adhesive application station 18 at which an adhesive (not illustrated) is applied to the first structure. The adhesive application station 18 can comprise any suitable device capable of accurately applying a suitable laminating adhesive to the first structure. For example, as shown, the adhesive application station can comprise a roll 24 that picks up the adhesive from a reservoir 26 on the outer surface of the roll. A doctor blade 28 may be used to scrape off any excess adhesive. The first structure 10 is contacted by the roll 24; a backing roll 30 provides support on the opposite side of the first structure 10. After the first adhesive application station 18, the first structure 10 is advanced to a dryer 31 such as an oven or the like, to dry the adhesive applied to the first structure.

The first structure 10 is then advanced to a laminating station 40, comprising a pair of rolls forming a nip therebetween. The first structure 10 is passed through the nip along with a second structure 42 that is advanced from its own supply roll 44, and the first and second structures 10, 42 are laminated to each other. The second structure 42 comprises one or more layers of flexible material, and is coextensive with the first structure 10—i.e., the width of the second structure 42 is substantially equal to the width of the first structure 10 and the longitudinal edges of the second structure 42 substantially coincide with the longitudinal edges of the first structure 10.

The laminate may also optionally include a metallization layer or a metal foil layer between the first structure 10 and the second structure 42. This is beneficial in enhancing the barrier performance of the laminate as already noted. Additionally, however, where a metal foil layer is included, it can also be helpful when a laser is used for ablating only the first structure 10 or the second structure 42. For example, it can be difficult to employ a sufficiently high laser energy to ablate through a polyethylene sealant layer without ablating through the laminate more deeply than desired. Thus, the metal foil layer can be helpful in “tuning” the laser to penetrate only up to the foil layer. However, when a metallization layer is employed instead of a metal foil layer, the metallization layer generally will not stop a laser beam. In that case, the laser can be “tuned” to score to a certain depth by using different polymers for the different layers in the laminate, such that, for example, one layer readily absorbs laser energy and thus is relatively easily ablated, while a layer below that layer is formed of a polymer that does not absorb laser energy as well and hence is not ablated.

The resulting laminate 46 is then advanced to a reel-up (not shown) where it is wound into a roll for subsequent processing in the second phase of the manufacturing process as described below. Alternatively, it is possible for the reel-up operation to be omitted, such that the laminate is directly advanced to the second phase.

With reference to FIG. 2, the second phase of the process is now described. A supply roll 48 of the laminate 46 formed in the first phase of the process is shown. The laminate is advanced from the supply roll to a first laser ablation station 50 at which an ablated area is formed through the thickness of the first structure 10. The first ablation station 50 can comprise a laser 54 and sensor 56 as depicted in FIG. 2. The use of lasers for ablating through flexible materials is generally known, for example as described in U.S. Pat. No. 5,158,499, incorporated herein by reference. The depth of the ablation formed by the laser can be regulated by regulating the power output or beam intensity of the laser beam, the width or spot size of the laser beam, and the amount of time a given spot on the film surface is irradiated by the beam. These factors generally are selected based on the characteristics of the material being ablated. Some materials are more readily ablated by lasers than other materials, as known in the art. Sensor 56 can detect a feature, such as an eye mark, on the laminate 46 whose location is known, so that the ablation by laser 54 is in registration with the parameters of the package design based on signals from the detector, as would be understood by one of ordinary skill in the art.

Next, the laminate is advanced to an optional second ablation station 60 that can comprise a laser 64 and sensor 66. The operation of the laser 64 is synchronized with the advancement of the laminate in a manner as described above.

As an alternative to the use of lasers for ablation of the laminate, ablation of the laminate 46 may be accomplished by cutting or chemical removal. For instance, as depicted in FIG. 3, a first ablation station 50′ can comprise a kiss roll 51 and backing roll 53 that form a nip through which the laminate is passed. The kiss roll 51 comprises a rotary cutting die defining a cutting edge (not shown). The kiss roll acts in conjunction with the backing roll to cut partially through the thickness of the laminate starting from the outer surface of the first structure 10, such that the first structure 10 is substantially ablated through while the second structure 42 is left intact. The second ablation station 60′ likewise comprises a kiss roll 61 and backing roll 63 for ablating through the second structure 42.

Additionally, it is within the scope of the invention to ablate one side of the laminate via laser and to cut or otherwise mechanically or chemically ablate the other side. This can be advantageous, for example, when one of the structures making up the laminate is readily ablated by the particular wavelength of laser radiation employed, but the other structure is not as readily ablated. For instance, when the first structure 10 is a polyester such as PET, it can readily be ablated with a CO₂ laser of a particular wavelength, but if a polyethylene heat seal layer is employed for the second structure 42, that layer is not as readily ablated by the CO₂ laser as is the PET. In this case, kiss cutting or other mechanical process can be used to ablate the second structure 42.

After the ablation operations, the laminate 46 can be sent to a reel-up (not shown) and wound into a roll for subsequent processing. The laminate can also be slit into a plurality of partial widths and wound into multiple rolls. In this latter instance, each partial width would have the recurring patterns of adhesives applied with suitably configured adhesive applicators to the full-width material, and would have the recurring ablated areas formed by suitably configured ablation devices acting on either the full-width laminate prior to slitting or acting on each partial-width portion after slitting.

Some possible applications for the resulting laminate are now explained with reference to FIGS. 4-6. FIGS. 4-6 show a flexible package 94 and the associated laminate portion 70. The flexible package 94 includes a laminate portion 70 cut from the laminate 46 that is manipulated to form a package to hold one or more of an assortment of contents and is sealed to enclose the contents.

As illustrated in FIG. 4, a flexible package 94 is formed from a laminate portion 70 cut from laminate 46 using various methods known in the art. Laminate portion 70 includes a number of sections that make up different parts of a fully formed flexible package 94. The laminate 70 includes a top end 74 with a top seal area 76 represented by a hatched region. Top portion 74 also includes first tear area 78 and second tear area 79 and one or more sealant reduction areas 80. The laminate portion 70 also includes a bottom end 72 with a bottom seal area 76 represented by a hatched region.

FIG. 4 also illustrates parts of the laminate portion 70 that make up the different panels or portions of a finished flexible package 94. The panels spanning the entire height of the laminate portion 70 include the front panel 82, first-visible rear panel 84, visible fin panel 86, second-visible rear panel 88, covered rear panel 90, and interior fin panel 92. Each of the panels of the laminate portion 70 abut one or more other panels at junctions 93 illustrated by dashed lines. In particular, visible fin panel 86 forms a junction 93 with a side of the first-visible rear panel 84, and the front panel 82 forms another junction 93 with the first-visible rear panel 84. The second-visible rear panel 88 forms a junction 93 with the front panel 82, the same junction 93 also separating the first tear area 78 from the second tear area 79. Another junction 93 is located between the second-visible rear panel 88 and the covered rear panel 90. Finally, a junction exists between the covered rear panel 90 and the interior fin panel 92.

The tear areas 78, 79 of the laminate are preferably positioned along the junction 93 between the front panel 82 and the second-visible rear panel 88 in an abutting relationship. The shape of the tear areas 78, 79 may be substantially semi-circular or parabolic segments with respect to the junction 93. Together, tear areas 78, 79, when abutting each other, may form a substantially circular area on the laminate portion 70. A center area formed between the combination of the abutting tear areas 78, 79 may be offset in a perpendicular direction from the junction 93 existing between tear areas 78, 79.

The sealant reduction areas 80 are positioned in the top seal portion 76 of the laminate portion 70. In a preferred embodiment, sealant reduction areas 80 are located in the top seal portion 76 of the front panel 82, the first-visible rear panel 84, and the interior fin panel 92. The sealant reduction areas 80 of the preferred embodiment are also positioned adjacent to one or both of tear areas 78, 79. The sealant reduction areas 80 are also preferably positioned along a path that the laminate portion will be torn by a user of the flexible package 94.

Formation of the first tear area 78, second tear area 79, and sealant reduction areas 80 may be accomplished through the use of a laser ablation process discussed above. By performing laser ablation on a surface of the laminate portion 70, a laser can be configured to penetrate through either a portion or the full thickness of the laminate portion 70. Ablation of a tear area of the laminate portion 70 preferably begins at a center of the area to be ablated and progressively moves the laser in a direction radially outwardly from the center of the tear area. The use of such a technique helps in reducing the amount of scrap material from the laminate portion 70 that may be produced during the ablation process. Ablation of the laminate portion 70 may also include the formation of a score line adjacent to the tear areas 78, 79. Such a score line is preferably oriented in a tearing direction and adjacent the tear areas 76, 78.

FIG. 5 illustrates a fully assembled flexible package 94 constructed from the laminate portion 70 described above. The edges or creases of the flexible package are formed along the respective junctions 93 to form the different panels and fin of the flexible package 94. The flexible package 94 is manipulated into a tubular shape, and bottom end 72 and the top end 74 of the laminate portion 70 are sealed together along seal areas 76. After the flexible package 94 has been sealed, tear areas 76, 78 are exposed along the junction between the front panel 92 and second-visible rear panel 88 to form a groove to assist in beginning the opening process of the flexible package 94.

When the flexible package 94 is opened, a tear is created in the flexible package 94 at the groove formed by the tear areas 76, 78 as illustrated in FIG. 6. After a tear is created in the flexible package 94, the tear is propagated in a transverse direction such that the tear passes through the sealant reduction areas 80 to facilitate opening the flexible package 94. By opening flexible package 94 at the tear areas 76, 78 and through the sealant reduction areas 80, the laminate portion is more readily torn and less susceptible to stretching. Thus, the occurrence of opening failures in the flexible package 94 can be reduced.

FIGS. 7 and 7A illustrate a further embodiment of the invention. In accordance with this embodiment, a laminate 100 is provided for forming a flexible pouch generally similar to the previously described pouch. The laminate has a bottom edge (not visible), a top edge 102, and two opposite longitudinally extending side edges 104 and 106. The laminate is wrapped about a longitudinal axis, and portions 104a and 106a (also referred to herein as fin panels) of the laminate respectively adjacent the opposite side edges 104 and 106 are sealed together to form a fin 108 (FIG. 7A) extending longitudinally along the pouch. Two facing portions of the laminate adjacent the top edge 102 are sealed together to form a top seal 110 (indicated by cross-hatching in FIG. 7A), and two facing portions of the laminate adjacent the bottom edge are sealed together to form a bottom seal (not visible).

The laminate defines a tear initiation feature 112 comprising a hole formed through the laminate and straddling a first fold line 114 along which the laminate is folded when it is wrapped about the longitudinal axis. There is a second fold line 116 along which the laminate is folded when it is wrapped. The fold lines 114 and 116 respectively become the two longitudinal edges 118 and 120 of the completed pouch, as shown in FIG. 7A. The tear initiation feature 112 is located within the top seal 110 of the completed pouch.

The laminate further defines a fin tear-propagating feature 122 comprising two tear areas 124 and 126 formed respectively in the side edges 104 and 106 of the laminate such that the tear areas substantially coincide on the fin 108 so as to form the fin tear-propagating feature 122. The fin tear-propagating feature 122 is substantially in transverse alignment with the tear initiation feature 112. In the illustrated embodiment, the tear areas 124 and 126 comprise notches formed into the side edges of the laminate so that they extend partway across the widths of the respective fin panels that are sealed together to form the fin 108.

As depicted in FIG. 7A, the top seal 110 is configured such that the tear initiation feature 112 and fin tear-propagating feature 122 are located in the top seal area, so that these features do not compromise the sealing of the pouch. The top seal is further configured so that a portion of the unsealed area of the laminate is in transverse alignment with the tear features 112 and 122. In this manner, when a user opens the pouch by starting the tear at the tear initiation feature 112 and continuing to tear transversely across the pouch, the tear will intersect the unsealed area so as to gain access to the contents through the opening that results.

In the embodiment of FIGS. 7 and 7A, the tear features 112 and 122 are the only tear features in the pouch. There are no further score lines or any other features promoting or facilitating tearing of the laminate material.

Yet another embodiment of the invention is depicted in FIGS. 8 and 8A. The laminate 200 illustrated in FIG. 8 is generally similar to the laminate 100 of FIG. 7. The laminate includes a top edge 202, side edges 204 and 206, and a bottom edge (not visible). The laminate is wrapped about a longitudinal axis, and portions 204a and 206a (also referred to herein as fin panels) of the laminate respectively adjacent the opposite side edges 204 and 206 are sealed together to form a fin 208 (FIG. 8A). Two facing portions of the laminate adjacent the top edge 202 are sealed together to form a top seal 210 (FIG. 8A), and two facing portions of the laminate adjacent the bottom edge are sealed together to form a bottom seal (not visible).

The laminate 200 differs from the laminate 100 with respect to the type of tear initiation feature employed. Specifically, the laminate 200 does not include a tear initiation feature comprising a hole formed through the laminate and straddling the fold line 214. Instead, the laminate 200 includes a score line 212 that extends across the laminate in the transverse direction. Where the laminate is formed of an outer structure laminated to an inner structure (similar to the structures 10 and 42 illustrated in FIG. 1), the score line 212 is formed in the outer structure but not in the inner structure.

There is a second fold line 216 along which the laminate is folded when it is wrapped. The fold lines 214 and 216 respectively become the two longitudinal edges 218 and 220 of the completed pouch, as shown in FIG. 8A. One end of the score line 212 is located within the top seal 210 of the completed pouch.

The laminate further defines a fin tear-propagating feature 222 comprising two tear areas 224 and 226 formed respectively in the side edges 204 and 206 of the laminate such that the tear areas substantially coincide on the fin 208 so as to form the fin tear-propagating feature 222. The fin tear-propagating feature 222 is substantially in transverse alignment with the score line 212. In the illustrated embodiment, the tear areas 224 and 226 comprise notches formed into the side edges of the laminate so that they extend partway across the widths of the respective fin panels that are sealed together to form the fin 208.

As depicted in FIG. 8A, the top seal 210 is configured such that the fin tear-propagating feature 222 is located in the top seal area so that it does not compromise the sealing of the pouch. One end portion of the score line 212 is also located in the top seal area. The top seal is further configured so that a portion of the unsealed area of the laminate contains an opposite end portion of the score line 212. In this manner, when a user opens the pouch by starting the tear at one end of the score line 212 and continuing to tear transversely across the pouch, guided by the score line 212, the tear will intersect the unsealed area so as to gain access to the contents through the opening that results.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A flexible pouch for containing a product, the flexible pouch comprising:

a flexible laminate having a top edge, a bottom edge, and two opposite longitudinally extending side edges, the laminate being wrapped about a longitudinal axis and portions of the laminate adjacent the opposite side edges being sealed together to form a fin extending longitudinally along the pouch, two facing portions of the laminate adjacent the top edge being sealed together to form a top seal, and two facing portions of the laminate adjacent the bottom edge being sealed together to form a bottom seal;

a tear initiation feature comprising a hole formed through the laminate and located within the top seal, wherein the tear initiation feature is located at one longitudinal edge of the pouch when the laminate is wrapped and sealed to form the pouch; and

a fin tear-propagating feature comprising two tear areas formed respectively in the side edges of the laminate such that the tear areas substantially coincide on the fin so as to form the fin tear-propagating feature, the fin tear-propagating feature being substantially in transverse alignment with the tear initiation feature.

2. The flexible pouch of claim 1, wherein the top seal is configured such that an unsealed area of the laminate is in transverse alignment with the tear initiation and fin tear-propagating features, such that when the pouch is torn open beginning at the tear initiation feature and proceeding along a tear line transversely across the pouch, the tear line intersects the unsealed area so as to form an opening into the pouch.

3. The flexible pouch of claim 1, wherein the hole is a laser-formed hole.

4. The flexible pouch of claim 1, wherein the two tear areas are laser-formed notches in the side edges of the laminate.

5. The flexible pouch of claim 4, wherein the laminate comprises an outer structure laminated to an inner structure, the outer structure forming an outer surface of the pouch and the inner structure forming an inner product-contacting surface of the pouch.

6. The flexible pouch of claim 5, wherein the outer structure includes a barrier layer and the inner structure includes a sealant layer that forms the product-contacting surface.

7. The flexible pouch of claim 1, wherein except for the tear initiation feature and the fin tear-propagating feature, the laminate is free of any further tear-facilitating features.

8. A flexible pouch for containing a product, the flexible pouch comprising:

a flexible laminate having a top edge, a bottom edge, and two opposite longitudinally extending side edges, the laminate being wrapped about a longitudinal axis and portions of the laminate adjacent the opposite side edges being sealed together to form a fin extending longitudinally along the pouch, two facing portions of the laminate adjacent the top edge being sealed together to form a top seal, and two facing portions of the laminate adjacent the bottom edge being sealed together to form a bottom seal;

a fin tear-propagating feature comprising two tear areas formed respectively in the side edges of the laminate such that the tear areas substantially coincide on the fin so as to form the fin tear-propagating feature; and

a score line extending across the laminate and substantially in transverse alignment with the fin tear-propagating feature.

9. The flexible pouch of claim 8, wherein the top seal is configured such that an unsealed area of the laminate is in transverse alignment with the score line and fin tear-propagating feature, such that when the pouch is torn along a tear line beginning at one end of the score line and proceeding along the score line transversely across the pouch, the tear line intersects the unsealed area so as to form an opening into the pouch.

10. The flexible pouch of claim 8, wherein the laminate comprises an outer structure laminated to an inner structure, the outer structure forming an exterior surface of the pouch, the inner structure forming an interior product-contacting surface of the pouch.

11. The flexible pouch of claim 10, wherein the score line is formed in the outer structure but not in the inner structure.

12. The flexible pouch of claim 8, wherein the fin tear-propagating feature and the score line are formed by a laser.