Flexible film plate-mat bag

1. Technical Field

The present invention relates to an easy to open package, designed in a plate-mat bag configuration, and a method for making same. When the package of the present invention is opened it forms a plate which the consumer can set on a surface and consume the packaged contents. Several features of one end of the package provide for easy opening of the package by a consumer.

2. Description of Related Art

Snack foods and other items are often packaged in bags formed from thin, flexible packaging films. These thin films are formed primarily of plastics, such as polypropylene and polyethylene, but can also contain metalized films, foil, paper, or oriented films. These packaging films can have numerous layers directed to achieving specific needs, but are generally formed at least in part by extrusion of a plastic layer, co-extrusion of multiple layers simultaneously, extrusion coating of another material (such as paper), and the lamination of two layers together via either extrusion lamination or adhesive lamination. In the discussions below, both extrusion lamination and adhesive lamination processes are discussed in more detail, but it is noted that any designated layer that is fed into these two processes can already be a multi-layer film formed by any of the above processes.

An exemplary film 100 for packaging of food products is seen in FIG. 1. The outermost layer 102 is an OPP layer, short for oriented polypropylene, while the innermost layer 106 is a metalized OPP or other barrier material. An oriented polymer material has been specially treated so that the long polymeric molecules tend to align in a given direction, causing the material to preferentially tear in that direction. Sandwiched between the two OPP layers 102, 106 is an adhesive such as polyethylene 104 or other adhesive. Printing for the package is done on the inside of the outer layer and becomes sandwiched between the middle and outer layers. The innermost, metallic layer 106 can itself be a layered laminate and contains a sealant layer 108 on what will be the inside, or product side, of the package. This sealant layer 108 is typically formed of a ter-polymer, composed of ethylene, propylene, and butylenes, along with the metallic layers, and provides a barrier to retain taste and freshness of the product contained therein. Other materials used in packaging are polyester, paper, polyolefin extrusions, adhesive laminates, and other such materials, or a layered combination of the above.

Once the material is formed and cut into desired widths, it can be loaded into a vertical form, fill, and seal machine to be used in packaging the many products that are packaged using this method. FIG. 2 shows an exemplary vertical form, fill, and seal machine that can be used to package snack foods, such as chips. This drawing is simplified, and does not show the cabinet and support structures that typically surround such a machine, but it demonstrates the working of the machine well. Packaging film 210 is taken from a roll 212 of film and passed through tensioners 214 that keep it taut. The film then passes over a former 216 which directs the film as it forms a vertical tube around a product delivery cylinder 218. This product delivery cylinder 218 normally has either a round or a somewhat oval cross-section. As the tube of packaging material is pulled downward by drive belts 220, the edges of the film are sealed along its length by a vertical sealer 222, forming a back seal 224. The machine then applies a pair of heat-sealing jaws 226 and accompanying jaw face 233 against the tube to form a transverse seal 228. Different shapes of jaw faces 233 result in different shaped seals. The transverse seal 228 acts as the top seal on the bag 230 below the sealing jaws 226 and the bottom seal on the bag 232 being filled and formed above the jaws 226. After the transverse seal 228 has been formed, a cut is made across the sealed area to separate the finished bag 230 below the seal 228 from the partially completed bag 232 above the seal. The film tube is then pushed downward to draw out another package length. Before the sealing jaws form each transverse seal, the product to be packaged is dropped through the product delivery cylinder 218 and is held within the tube above the transverse seal 228.

The form, fill, and seal machines are quite expensive, in the range of $250,000 each, but pay for themselves easily when compared to the cost of pre-formed bags and the machinery to fill them. However, in order to maximize the productivity of the form, fill, and seal machines, it is common for the product delivery tube 218 and former 216 to be made as a unit that is easily interchangeable, so that different size packages can be made by the same machine. The length of the transverse seal can also be changed, by exchanging the sealing jaws 226, or in some cases, merely by exchanging their facings (the portion of the sealing jaws which actually makes contact with the packaging film). By changing these elements, as well as the width of film roll feeding into the machine and the programming of the machine, one form, fill, and seal machine can handle a number of different products in different size packages, limited primarily by the width of film the machine will handle, the maximum length of bag the machine is designed to handle, and the available former/delivery tube assemblies.

Although there is no one perfect package for all uses, there are a number of desirable features that manufacturers strive for in packages made on a vertical form, fill, and seal machine. One such feature is the ability to easily open the package. Consumers now must grip and open the package, usually with a thumb and one or several fingers on both hands. The thumb and fingers must pinch and tear with sufficient force to break the seal. This can become more difficult as a consumer gets older. For example, some consumers have arthritis or have lost strength in their hands. Grasping the sides of a flexible bag and opening it as previously described may be a difficult task for them. Therefore, it is desirable to have a bag that is easier to open by hand than is available from the prior art. There have been some attempts at this to include an easy open package containing, for example a tear notch and perforations that allow for easier opening. However, even these traditional pillow containers have a downside in that when opened the package falls on its side and consequently must be balanced to keep product from spilling. Thus, it is desirable to have a package that does not need to be balanced for fear of spillage. New stand-up packages have been developed that ease the balancing problem such as the package disclosed by commonly owned U.S. Pat. No. 6,722,106 to Bartel et al. However, these vertical stand-up packages still only offer a small cross-sectional area from which product can be retrieved. Many consumers prefer the ease of eating snacks from a plate or a bowl that offers a relatively large surface area for product retrieval rather than a package wherein a consumer\'s hand must be inserted into the package to retrieve a food product. Thus, it is also desirable to have a package that offers maximum surface area from which product can be retrieved. Consequently, it is desirable to have an easy to open package that upon opening functions as a “plate-mat” which holds food product. The word “plate-mat” comes from combining plate and placemat, and means a container that is generally horizontal when opened such that it can be eaten from like a plate. A feature of the container can also be used as a placemat once the container is open. Finally, because of the speed and productivity achieved on a vertical form, fill, and seal machine, it is desirable that any such package alteration be capable of being produced on such a machine.

A flexible easy to open package that also serves as a plate for storing and eating food and method for making same is provided. The package comprises two seals: a lower seal and an upper peelable seal. The upper seal has geometry so that as the seal is pulled downward, the force gets distributed downward and outward. There is a portion of unsealed film above the upper seal which forms a tab. This allows a consumer to easily grip the tab and pull downward, breaking the upper seal and opening the package. The inner layer of the package has score lines. Consequently, as the consumer breaks the upper seal, the package continues to tear along the direction of the score lines. Once opened, the package resembles a plate. Further, the torn top portion of the package can be used as a place-mat upon which cups or drinks or other items may be placed.

The package is capable of being produced on a vertical, form, fill, and seal machine with only minor alterations. First, a film is obtained wherein the first layer, or product side, of a film web comprises score lines. The film is oriented so that it preferentially tears in the direction of the score lines. The resulting film is fed to a vertical, form, fill and seal machine. The package is then formed into a tube, sealed at the bottom, filled with product, and then sealed at the top with a peelable seal. The peelable seal is made peelable by adjusting such factors as time, temperature, pressure, as well as the geometry of the seal. Further, the peelable seal has a force distributing configuration which directs the force downward and outward along the package as the consumer opens the package.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:

FIG. 1 depicts a cross-section of an exemplary prior art packaging film.

FIG. 2 depicts a vertical form, fill, and seal machine that is known in the prior art.

FIG. 3 depicts a perspective view of one embodiment of a package in the instant invention.

FIG. 4 depicts a top planar view of one embodiment of the instant invention wherein the top has been torn to reveal a plate of product.

FIG. 5 depicts a cross-section of a packaging film of one embodiment of the current invention.

FIG. 6 depicts the formation of the packaging film of FIG. 5 according to one embodiment.

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