FLEXIBLE PACKAGE AND PROCESS OF MAKING PACKAGE
A flexible package and method for making one includes a thermoplastic film section folded to form first and second opposing body panels. The first and second body panels are joined together along a top seal, first side seal, and second side seal; and have a fold section forming a bottom. A perforated section is provided in the first body panel to provide access to an interior of the package. The package can be used for a variety of packaging contents including, for example, a roll of bags.
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This application claims priority to U.S. provisional patent application 61/789,761, filed Mar. 15, 2013, incorporated herein by reference in its entirety.
TECHNICAL FIELDThis disclosure relates to flexible packages. More particularly, this disclosure relates to a flexible package having a perforated section for accessing a package interior, and methods of making such packages.
BACKGROUNDSome products need to be packaged for displaying and selling at the retail level. Some packages can be bulky and take up undesirable amounts of shelf space. Many packages have no use after being a package, and they result in waste after serving their packaging function. Some packages are not self-supporting, and do not allow the package to be displayed upright. Improvements in packaging are desirable.
SUMMARYIn the first aspect, a method of making a flexible package is provided. The method includes providing a thermoplastic film including a first film portion adjacent to a second film portion joined at a fold. The method includes forming a perforated section in the first film portion; forming a first side seal between the first film portion and second film portion; and inserting packaging contents between the first and second film portions. The method includes forming a top seal and second side seal between the first film portion and second film portion, with the packaging contents contained between the first side seal, second side seal, top seal, and fold. The first film portion contains the perforated section. The method includes cutting along at least the second side seal to result in an individual flexible package.
In some aspects, the method includes inserting a gussetter into the fold to form a gusset between the first film portion and the second film portion.
In another aspect, a flexible package is provided. The flexible package includes a thermoplastic film section folded to form first and second opposing body panels. The first and second body panels are joined together along a top seal, first side seal, and second side seal, and have a fold section forming a bottom. The first and second body panels define an interior volume therein. The package includes a perforated section in the first body panel. The package includes packaging contents in the interior volume.
In some aspects, the perforated section includes a perforated looped section sized to permit access to the packaging contents in the interior volume, when the perforated looped section is removed from the first body panel.
In some aspects, the fold section includes a gusset.
A variety of examples of desirable product features or methods are set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practicing various aspects of this disclosure. The aspects of the disclosure may relate to individual features as well as combinations of features. It is to be understood that both the foregoing general description and the following detailed description are explanatory only, and are not restrictive of the claimed invention.
A method of making a flexible package, such as flexible package 12 shown in
The flexible package 12 will typically be made from a flexible material, such as a polymeric film. The polymeric film can be, for example, a thermoplastic film. In some examples, the thermoplastic film will be a film of polyethylene. One useful film is polyethylene having a thickness of about 2.5 mil.
At a first step 14, the film 16 (
In some methods, the step 14 of providing film 16 includes unwinding the film 16 from a roll, and then after unwinding, folding the film 16 into “C-folded film” 21 (
After providing the film 16, there is a step 18 of forming a perforated section 20 (
In
The perforated section 20 can be of a size and shape that allows access to, or dispensing of, contents of the flexible package 12. This size and shape can vary, depending upon the particular application. In the example shown in
In the step 18 of forming perforated section 20 in the first film portion 17, in this embodiment, the perforated section 20 is formed in only the first film portion 17 in the C-folded film 21. Thus, in some example embodiments, before the step 18 of forming the perforated section 20, there is a step of separating the first film portion 17 from the second film portion 19. This step can be done, for example, by using a separator to split the C-folded film 21, which can be done by moving the first film portion 17 and second film portion 19 away from each other, such that they are not pressing against each other. This physical separation will allow the perforator wheel 34 to form the perforations 22 in the first film portion 17 without cutting the second film portion 19.
The method 10 may include a step 42 of adding a gusset 44 (
Still in reference to
In
In the example embodiment shown, the first side seal 48 is formed by seal bar 60. While there can be many variations, in the variation shown in
In method 10, after the first side seal 48 is formed, there is a step 52 of inserting packaging contents 54. This step 52 will include inserting packaging contents 54 between the first film portion 17 and second film portion 19. In
The packaging contents 54 can be any of a variety of contents. In one non-limiting example, the packaging contents 54 include a roll of bags 68.
The method 10 can include the step 74 of forming a top seal 70 and forming the second side seal 64 between the first film portion 17 and second film portion 19, with the packaging contents 54 contained between the first side seal 48, second side seal 64, top seal 70, and fold 15. The first film portion 17 will include the perforated section 20 therein. In one example of step 74, as mentioned previously, the second side seal 64 can be formed with the seal bar 60. In some embodiments, the seal bar 60 can be in the form of an L-shaped seal bar 72. In
The method 10 can include cutting along at least the second side seal 64 to result in the individual flexible package 12. In example implementations, the step of cutting along the second side seal 64 will occur simultaneously with the step 74 of forming the second side seal 64. As explained previously, this can also occur at the same time as the first side seal 48 is formed for the next package in the line, shown as the upstream incomplete package 66.
When the L-shaped sealing bar 72 is used, the step of cutting along at least the second side seal 64 can also include cutting along the top seal 70. In some example processes, at the same time as forming top seal 70 and second side seal 64, the L-shaped seal bar 72 will cut along both the top seal 70 and the second side seal 64.
In some example processes, when the cutting occurs along the top seal 70, scrap results at 78 (see
In
The method 10 can include at step 80, putting the individual flexible packages 12 onto a conveyer. In some methods, after the step 74 of forming the seals and cuts is completed, the formed flexible package 12 can fall by gravity onto a conveyer, where it is then moved downstream.
The first body panel 82, which is made from the first film portion 17 having perforated section 20, includes a perforated section 90 in the first body panel 82. The perforated section 90, in the non-limiting example shown, results from the perforated looped section 40 (
As mentioned above, the packaging contents 54 can include the roll of bags 68. In such an example, the user will access the interior volume 88 by removing the perforated section 90 to result in a hole in the first body panel 82. The user will then grasp the roll of bags 68 through the hole in the first body panel 82. The bags in the roll of bags 68 can then be dispensed, individually if desired, through the hole resulting from the removed perforated section 90.
In
The resulting flexible package 12 will utilize less space than current packaging in the form of a cardboard carton. This allows for more product in the same space on the shelf of the retailer. The flexible package 12 uses less material to package the roll of bags 68, than when a carton is used. Typically, there is about an 80% reduction in packaging material weight of flexible package 12, as compared to a cardboard carton. The flexible package 12, made with the polymeric film 16 will protect the packaging contents 54 from fluids, which might otherwise migrate through a cardboard carton. The packaging contents 54, such as a roll of bags 68, will be convenient to dispense through the opening created by the removed perforated section 90.
The above description represents example principles of this disclosure. Many embodiments can be made applying these principles.
Claims
1. A method of making a flexible package; the method comprising:
- (a) providing a thermoplastic film including a first film portion adjacent to a second film portion joined at a fold;
- (b) forming a perforated section in the first film portion;
- (c) forming a first side seal between the first film portion and second film portion;
- (d) inserting packaging contents between the first and second film portions;
- (e) forming a top seal and second side seal between the first film portion and second film portion, with the packaging contents contained between the first side seal, second side seal, top seal, and fold; the first film portion containing the perforated section; and
- (f) cutting along at least the second side seal to result in an individual flexible package.
2. A method according to claim 1 further comprising:
- (a) inserting a gussetter into the fold to form a gusset between the first film portion and second film portion.
3. A method according to claim 1 wherein:
- (a) the step of forming a perforated section includes perforating a looped section in the first film portion.
4. A method according to claim 1 wherein:
- (a) the step of cutting along at least the second side seal further includes cutting along the top seal.
5. A method according to claim 1 wherein:
- (a) the steps of (i) forming a top seal and second side seal, and (ii) cutting along at least the second side seal, occur simultaneously.
6. A method according to claim 1 wherein:
- (a) the step of providing a thermoplastic film includes unwinding pre-folded film from a roll, the pre-folded film including the first film portion adjacent to the second film portion joined at the fold.
7. A method according claim 1 wherein:
- (a) the step of providing a thermoplastic film includes unwinding film from a roll and then folding the film into the first film portion adjacent to the second film portion joined at the fold.
8. A method according to claim 1 wherein:
- (a) before the step of forming a perforated section in the first film portion, separating the first film portion from the second film portion.
9. A method according to claim 1 wherein:
- (a) the step of forming a top seal and second side seal between the first film portion and second film portion occurs simultaneously.
10. A method according to claim 1 wherein:
- (a) the step of forming a top seal and second side seal between the first film portion and second film portion is done with a single seal bar having an L-shape.
11. A method according to claim 1 further including:
- (a) after the step of cutting along at least the second side seal to result in an individual flexible package, putting the individual flexible package on a conveyor.
12. A method according to claim 1 wherein:
- (a) the step of inserting packaging contents between the first and second film portions includes inserting a roll of bags between the first and second film portions.
13. A flexible package made according to claim 1.
14. A flexible package comprising:
- (a) a thermoplastic film section folded to form first and second opposing body panels; the first and second body panels being joined together along a top seal, first side seal, and second side seal; and having a fold section forming a bottom; the first and second body panels defining an interior volume therein;
- (b) a perforated section in the first body panel; and
- (c) packaging contents in the interior volume.
15. A flexible package according to claim 14 wherein:
- (a) the perforated section includes a perforated looped section sized to permit access to the packaging contents in the interior volume, when the perforated looped section is removed from the first body panel.
16. A flexible package according to claim 14 wherein:
- (a) the fold section includes a gusset.
17. A flexible package according to claim 14 wherein:
- (a) the packaging contents include a roll of bags.
18. A flexible package according to claim 14 wherein:
- (a) the package is self-supporting in an upright position when oriented on the bottom.
Type: Application
Filed: Mar 5, 2014
Publication Date: Sep 18, 2014
Applicant: REYNOLDS CONSUMER PRODUCTS INC. (LAKE FOREST, IL)
Inventors: Thomas J. Schweiss (Ingleside, IL), Gregory Haverfield (Roodhouse, IL), Mark Eilers (Franklin, IL), John Wegner (Springfield, IL)
Application Number: 14/197,964
International Classification: B65D 30/20 (20060101); B65D 33/00 (20060101); B65B 5/02 (20060101);