FLEXIBLE PACKAGE, FLEXIBLE MATERIAL FOR A FLEXIBLE PACKAGE AND METHOD FOR MANUFACTURING THE RECLOSAB

专利摘要:
flexible package, flexible material therefor, flexible contour package, reclosable package set and method to manufacture this set. a flexible, stackable, reclosable container (12) for storing a quantity of products comprising a plurality of walls (16) defined by a first sheet (14) and a second sheet (24) secured to at least a portion of the first sheet (14 ). the second sheet (24) extends over at least three of the walls (16). the opposing container walls (16) each have a sealed portion and one or more folds, the folds comprising a portion of the first sheet folded towards the inner volume. a portion of the second sheet (24) defines a resealable feature (623) located over an opening for resealing the container (12). the second sheet (24) includes a reduced strength line (653) at or adjacent to at least one boundary adjacent the folds and disposed between opposing container walls (16) each having a sealed portion and a container wall ( 16) adjacent. the second sheet (24) may include a hinge (28) around which the reclosable feature (653) pivots from the closed position to the open position.
公开号:BR112015009254B1
申请号:R112015009254-3
申请日:2013-10-25
公开日:2021-08-17
发明作者:James J. Sanfilippo；John E. Sanfilippo；Jeanne M. Skaggs；Francisco Javier Soria；Milorad Radenovic；Bohdan Wyslotsky；Paul Georgelos；Pat Montefusco；Roy Speer；Roman Forowycz
申请人:Primapak, Llc；
IPC主号:

专利说明:

CROSS REFERENCE TO RELATED ORDERS
[001] The benefit under 35 USC § 119(e) of US Provisional Patent Application 61/719,340, filed October 26, 2012, 61/739,535, filed December 19, 2012, 61/769168, filed on February 25, 2013, 61/801,186, filed March 15, 2013 and 61/860,233, filed July 30, 2013, is hereby claimed and the disclosures of each are incorporated herein by reference in their entirety. . DISCLOSURE FIELD
[002] This disclosure relates generally to packages and more particularly to a resealable lid that is secured to a container and methods for preparing the package and flexible materials to form the same. FUNDAMENTALS
[003] Resealable or resealable packaging sets are commonly used to store food items, liquids, powders, wet wipes, chemicals, detergents, dry goods, pharmaceuticals, nutraceuticals and other packaged products, for example. Typically, resealable packaging assemblies include a container portion and a flap portion that covers an opening in the container. One end of the flap portion is secured to the container adjacent the opening such that a user can pivot or fold the flap portion around the end to expose the opening, thereby allowing the user to access a product contained in an interior volume defined by the container walls. The underside of the flap and/or the surface of the container covered by the flap in a closed position may have an adhesive coating, such that when the flap is in the closed position the flap releasably adheres and sealingly engages the container. However, dust, moisture or other debris, such as powder stored in the container, may adhere to the adhesive coating and the adhesive coating may subsequently lose capacity or the release resistance will be substantially reduced to sealably engage the container.
[004] One solution to the problem of adhesive coating contamination involves attaching an injection molded plastic lid assembly to the container such that the lid assembly is disposed around the opening. To access the interior volume of the container, a lid element is hinged upwardly around a living hinge of the lid assembly to an open position in which the opening is exposed. To close the cap assembly, the cap member is hinged downwardly around the living hinge to sealingly engage a base of the cap assembly. Although the injection molded plastic cap assembly is typically not affected by debris, moisture or dust that accumulates in or near the sealing area, the plastic cap assembly can be relatively expensive to produce and can add weight to the reclosable packaging assembly . Furthermore, attaching the closure assembly to the container involves a relatively complicated production step that adds time and cost to production.
[005] Therefore, there is a need to provide a reclosable packaging assembly that is simple and inexpensive to manufacture that minimizes production time and that provides reliable sealing when exposed to contamination. SUMMARY
[006] A reclosable packaging assembly includes a container (also referred to herein as a "pack") formed at least partially of a first sheet and the container has a plurality of walls that cooperate to define an interior volume. The container has an opening through at least one of the plurality of walls. The resealable packaging assembly also includes a closure assembly secured to the container adjacent the opening. The closure assembly at least partially comprises a second sheet and a portion of the first sheet. The closure assembly includes a cap element and a hinge portion. The lid element is pivotable around the hinge portion between a first position, in which the lid element releasably engages a first portion of the container surrounding the opening, and a second position, in which the lid element is hinged away from the opening around the hinge portion, thereby allowing a user to access the interior volume through the opening. A first engaging feature may be arranged on the container adjacent to the opening. A second engaging feature may be arranged on the cap element of the closure assembly. The first engagement feature engages the second engagement feature to releasably secure the lid member to the container when the lid member is in the first position. The first engagement feature can be integrally formed with the container. The first engaging feature can be formed as a rib and the second engaging feature can be formed as a channel adapted to receive the rib, for example.
[007] A method for manufacturing a reclosable packaging assembly comprising a container defining an interior volume is provided and the method includes providing a first sheet and providing a second sheet attached to a first portion of the first sheet. The method further includes forming a cap element of a closure assembly of a portion of the second sheet such that at least a portion of the cap element is secured to the first portion of the first sheet. A hinge portion of the closure assembly is formed from the second sheet and the hinge portion is disposed adjacent to the cap element. The lid element is pivotable about the hinge portion between a first position, in which the element releasably engages a first portion of the container surrounding an opening formed in the first sheet, and a second position, in which the lid element is hinged to away from a portion of the opening. BRIEF DESCRIPTION OF THE DRAWINGS
[008] Figure 1 is an isometric view of one embodiment of a resealable packaging assembly with a lid element in a second open position;
[009] Figure 2 is a top view of the lid element of the resealable package assembly modality of Figure 1;
[010] Figure 3 is a sectional view of the cap element taken along line 3-3 of Figure 2;
[011] Figure 4 is an isometric view of the modality of the resealable packaging assembly of Figure 1 with the cover element in a first closed position;
[012] Figure 5 is a cross-sectional view of the top wall of a container taken along line 5-5 of Figure 4;
[013] Figure 6 is a sectional view of the cap element taken along line 6-6 of Figure 2;
[014] Figure 7 is a top view of a top wall of the container of the reclosable packaging assembly modality of Figure 1;
[015] Figure 8 is an isometric view of a portion of the cap element of the resealable package assembly modality of Figure 1;
[016] Figure 9 is a sectional view of the cap element taken along line 9-9 of Figure 2;
[017] Figure 10 is a partial cross-sectional view of the first attachment feature and the second attachment feature of the resealable package assembly modality of Figure 1;
[018] Figure 11A is a partial isometric view of the first attachment feature of the resealable package assembly modality of Figure 1;
[019] Figure 11A is a partial cross-sectional view of the second attachment feature of the resealable package assembly modality of Figure 1;
[020] Figure 12 is a sectional view of the top wall of the container along line 7-7 of Figure 5 which includes a third sheet attached to a first sheet;
[021] Figure 13 is a partial isometric view of the first engaging feature of one embodiment of the reclosable package assembly;
[022] Figures 14A to 14H are various views of a mold used to form the first and second engaging features and the hinge portion on the container and lid member;
[023] Figures 15A to 15H are various views of a mold used to form the first and second engaging features and the hinge portion on the container and lid member;
[024] Figures 16A to 16J are various views of a mold used to form the first and second engagement features and the hinge portion on the container and lid member;
[025] Figures 17A to 17H are various views of a mold used to form the first and second engagement features and the hinge portion on the container and lid member;
[026] Figure 19A is a first isometric view of an embodiment of a packaging machine used to manufacture an embodiment of a reclosable packaging assembly 10;
[027] Figure 19B is a second isometric view of the packaging machine embodiment illustrated in Figure 19A;
[028] Figure 19C is a third isometric view of the packaging machine embodiment illustrated in Figure 19A;
[029] Figure 19D is a fourth isometric view of the packaging machine embodiment illustrated in Figure 19A;
[030] Figure 19E is a front view of the packaging machine embodiment illustrated in Figure 19A;
[031] Figure 19C is a side view of the packaging machine embodiment illustrated in Figure 19A;
[032] Figure 20A is a top view of a container closure assembly of one modality of a resealable packaging assembly;
[033] Figure 20B is an isometric view of the closing assembly of the resealable package assembly of Figure 20A, in a second position;
[034] Figure 21 is an example forming matrix for one modality of resealable packaging assembly;
[035] Figure 22 is an example forming matrix for one modality of resealable packaging assembly;
[036] Figure 23 is an example forming matrix for one modality of resealable packaging assembly;
[037] Figure 24 is an example forming matrix for one modality of resealable packaging assembly;
[038] Figure 25 is an example forming matrix for an embodiment of the resealable packaging assembly;
[039] Figure 26 is a perspective view of a container according to an embodiment of the disclosure;
[040] Figure 27 is a top view of the container of Figure 26 illustrating the closure assembly of a container according to an embodiment of the disclosed packaging assembly;
[041] Figure 28 is a perspective view of the packaging assembly of Figure 26 illustrating the lid in the open position;
[042] Figure 29 is a schematic illustrating modalities of the first and second projections of a closure set according to disclosure modalities;
[043] Figures 30a-30c are schematic illustrations of an opening panel region of a flexible material according to embodiments of the disclosure illustrating the areas of the opening panel region;
[044] Figure 30d is a schematic illustration of an opening panel region according to embodiments of the disclosure illustrating the cuts made in the various layers to form the closing assembly;
[045] Figure 31 is a perspective view of a container according to an embodiment of the disclosure, the container having a portion of film that is transparent or translucent to provide a window through which the product disposed in the container can be viewed;
[046] Figure 32 is a schematic illustrating embodiments of the first and second projections of a closure assembly and extensions of the second sheet to two side walls according to embodiments of the disclosure;
[047] Figure 33 includes several views of one embodiment of a tube forming assembly of a packaging machine used to manufacture one embodiment of a reclosable packaging assembly 10;
[048] Figure 34 includes several views of one embodiment of a forming tube of one embodiment of a forming tube assembly;
[049] Figure 35 is a partial side view of one embodiment of a forming tube of one embodiment of a forming tube assembly;
[050] Figure 36 is a perspective view of an embodiment of a packaging machine used to manufacture an embodiment of a reclosable packaging assembly 10;
[051] Figure 37 is a perspective view of an embodiment of a packaging machine used to manufacture an embodiment of a reclosable packaging assembly 10;
[052] Figure 38 is a perspective view of an embodiment of a forming station of a packaging machine used to manufacture an embodiment of a reclosable packaging assembly 10;
[053] Figures 39 to 45 illustrate various components of the form of the forming station of Figure 38;
[054] Figure 46 is a perspective view of one embodiment of a packaging machine used to manufacture one embodiment of a reclosable packaging assembly 10;
[055] Figure 47 is a first example of a graphic layout for modeling and/or coloring in the film;
[056] Figure 48 is a second example of a graphic layout for modeling and/or coloring in the film;
[057] Figure 49 is a graph of the secant modulus of several polymeric films;
[058] Figure 50 is a schematic illustration of a flexible material according to an embodiment of the disclosure;
[059] Figure 51 is a schematic illustration of a flexible material according to an embodiment of the disclosure;
[060] Figure 52A is a perspective view of one embodiment of a packaging machine used to manufacture one embodiment of a reclosable packaging assembly 10; and
[061] Figure 52B is a side view of the embodiment of Figure 52A.
[062] Figures 53A to 53F are several views of a reject station;
[063] Figures 54A to 54C are several views of the removable cover element;
[064] Figures 55A to 55B are several views of a container and a removable lid element;
[065] Figures 56A to 56D are several views of a container and a removable lid element;
[066] Figure 57 is an example forming matrix for one embodiment of the reclosable package assembly;
[067] Figure 58 is an example forming matrix for one embodiment of the reclosable package assembly;
[068] Figure 59 is an example forming matrix for one embodiment of the reclosable package assembly;
[069] Figures 60A to C are a packaging assembly according to an embodiment of the disclosure;
[070] Figures 60D to H are an example forming matrix for an embodiment of the resealable packaging assembly;
[071] Figure 61 is an example forming matrix for an embodiment of the resealable package assembly;
[072] Figure 62 is an example forming matrix for one embodiment of the resealable package assembly;
[073] Figure 63 is an example forming matrix for one embodiment of the reclosable package assembly;
[074] Figure 64 is an example forming matrix for one embodiment of the resealable package assembly;
[075] Figures 65A to E are views of an example forming matrix for one embodiment of a reclosable package assembly;
[076] Figure 65F is a top view of a cap element of a resealable package assembly according to an embodiment of the disclosure;
[077] Figure 66 is a schematic illustration of a packaging machine for forming a reclosable packaging assembly according to an embodiment of the disclosure;
[078] Figure 67 is a schematic illustration of a forming die for forming an embodiment of the reclosable package assembly;
[079] Figure 68 is a cross-sectional image of a cap element according to an embodiment of the disclosure;
[080] Figure 69a is a schematic illustration of a resealable package assembly according to an embodiment of the disclosure;
[081] Figure 69B is a cross-sectional illustration of a closure assembly according to an embodiment of the disclosure, which illustrates a groove embedded in the inner wall of the channel, for better sealing when the lid is in the closed position;
[082] Figure 70 is a schematic illustration of a forming die to form an embodiment of the reclosable package assembly;
[083] Figure 71 is a schematic illustration of a forming die for forming an embodiment of the reclosable package assembly;
[084] Figure 72 illustrates a film layout for forming a package according to an embodiment of the disclosure;
[085] Figure 73A illustrates an embodiment of a second sheet illustrated in a configuration as provided in a package according to an embodiment of the disclosure;
[086] Figure 73B illustrates an embodiment of a package having a second sheet according to an embodiment of the disclosure;
[087] Figures 74A-74C are schematic illustrations of a thermal plate for thermal sealing a sealing flap to one side of the package;
[088] Figures 75A and 75B are a schematic illustration of a forming die having an integrated cutting die and external forming station according to an embodiment of the disclosure;
[089] Figures 76A and 76B are several views of a schematic illustration of the packaging machine having a racetrack type conveyor according to an embodiment of the disclosure;
[090] Figure 76C is a schematic illustration of the racetrack type conveyor illustrated in Figures 76A and 76B;
[091] Figure 77 is a table illustrating exemplary two-layer and three-layer film laminate configurations suitable for use in various embodiments of the present disclosure;
[092] Figure 78 is a perspective view of an embodiment of a VFFS machine;
[093] Figures 79a to 79f are several views of the VFFS embodiment of Figure 78;
[094] Figures 80a to 80b are several views of an embodiment of an edge folding station;
[095] Figure 81 is a perspective view of one embodiment of a sealed container;
[096] Figures 82a to 82b are various views of one embodiment of a flap sealing station assembly;
[097] Figures 83a to 83b are various views of one embodiment of a flap sealing station assembly;
[098] Figures 84a to 84d are several views of an embodiment of a forming boss;
[099] Figures 85a to 85g are several views of an embodiment of an edge folding station;
[0100] Figures 86a to 86g are various views of one embodiment of a flap sealing station assembly;
[0101] Figures 87a to 87g are several views of one embodiment of a flap sealing station assembly;
[0102] Figures 88a to 88g are several views of one embodiment of a flap sealing station assembly;
[0103] Figures 89a to 89g are several views of one embodiment of a flap sealing station assembly;
[0104] Figure 90 is a schematic illustration of a film layout for a container according to an embodiment of the disclosure;
[0105] Figure 91 is a schematic illustration of a flexible container according to an embodiment of the disclosure showing the resealable flap on the top panel and in an open position;
[0106] Figure 92 is a schematic illustration of a flexible container according to an embodiment of the disclosure showing a resealable flap on the front panel and in an open position;
[0107] Figure 93 is a schematic illustration of an outline package according to an embodiment of the disclosure;
[0108] Figure 94 is a schematic illustration of a film layout for the wraparound packaging of Figure 93,
[0109] Figure 95 is a schematic illustration of an outline package according to another embodiment of the disclosure;
[0110] Figure 96 is a schematic illustration of a film layout for the wraparound packaging of Figure 95,
[0111] Figure 96 is a schematic illustration of a film layout for a wraparound package according to an embodiment of the disclosure; and
[0112] Figure 97 is a schematic illustration of a film layout for a wraparound package according to another embodiment of the disclosure. DETAILED DESCRIPTION Resealable Packaging Set
[0113] As illustrated in Figure 1, a reclosable packaging assembly 10 includes a container 12 formed at least partially by a first sheet 14 (also called a first film) and the container 12 has a plurality of walls 16 that cooperate to define a interior volume 18. Container 12 has an opening 20 through at least one of the plurality of walls 16. Resealable packaging assembly 10 also includes a closure assembly 22 secured to container 12 adjacent opening 20 (or an area in which the opening 20 is set). The closure assembly 22 comprises at least partially a second sheet 24 (also called a second film) and optionally a portion of the first sheet 14 (see Figure 3). For example, a portion of the first sheet 14 may detach from the first sheet 14 and remain adhered to the second sheet to form an opening in the first sheet. In other embodiments, a portion of the first sheet 14 may be peeled from the remaining portion of the first sheet and discarded rather than adhered to the second sheet 24 to form the opening. The terms container and packaging are used interchangeably herein.
[0114] In one embodiment, the closure assembly 22 includes a cap element 26 and a hinge portion 28. The cap element 26 is pivotable around the hinge portion 28 between a first position 30 (shown in Figure 4), in which the cap element 26 releasably engages a first portion 32 of the container 12 surrounding the opening 20, and a second position 34 (shown in Figures 1 and 28) in which the cap element 26 is hinged away from the opening 20 at around hinge portion 28, thereby allowing a user to access interior volume 18 through opening 20. As illustrated in Figures 1 and 5, a first engaging feature 36 may be disposed on container 12 adjacent to opening 20. As illustrated in Figures 1, 2 and 3, a second engagement feature 38 may be disposed on the cap member 26 of the closure assembly 22. The first engagement feature 36 engages the second engagement feature 38 to securely remove. Connecting the cap element 26 to the container 12 when the cap element 26 is in the first position 30. The first engaging feature 36 may be integrally formed with the container 12. As illustrated in Figures 1, 3 and 5, the first engaging feature 36 is latch 36 may be formed as a rib 40 and the second latch feature 38 may be formed as a channel 42 adapted to receive rib 40, for example.
[0115] Thus configured, in a single manufacturing step, the cap element 26, the first engagement feature 36 and the second engagement feature 38 can be formed on the film of the container 12, thereby eliminating the need to secure an assembly separately manufactured cap that is attached to a container. As the features are formed in a single process step and as the separately manufactured cap assembly is not necessary, one skilled in the art would recognize that manufacturing time and costs are reduced. Furthermore, one skilled in the art would recognize that such features allow reliable release of the cap element 26 to the container 12 by a mechanical closure which is not degraded by the presence of surface contaminants in the sealing area.
[0116] Turning to container 12 of reclosable packaging assembly 10 in more detail, container 12 includes the plurality of walls 16 that cooperate to define the interior volume 18, as illustrated in Figure 1. The plurality of walls 16 may cooperate to form any suitable shape or combination of shapes. For example, the plurality of walls 16 can include a top wall 16a, a first side wall 16b, a second side wall 16c, a third side wall 16d, a fourth side wall 16e, and a bottom wall 16f. Top wall 16a may be planar or substantially planar and may extend in a horizontal direction (ie, parallel to the X-Y plane of the reference coordinate system given in Figure 1) or in a substantially horizontal direction. Bottom wall 16f may be planar or substantially planar and may extend in a horizontal direction or a substantially horizontal direction and bottom wall 16f may be vertically (i.e., in a direction parallel to or along the Z axis of the given reference coordinate system in Figure 1) displaced from the top wall 16a. First side wall 16b may extend vertically between top wall 16a and bottom wall 16f and first side wall 16b may be parallel or substantially parallel to plane XZ of the reference coordinate system provided in Figure 1. A first portion of the first sidewall 16b may extend vertically beyond top wall 16a to form a portion of top rib wall 44 that extends along and around the perimeter of top wall 16a. A second portion of the first sidewall 16b may extend vertically beyond the bottom wall 16f to form a portion of a bottom rib wall 46 that extends along and around the perimeter of the bottom wall 16f.
[0117] Still referring to Figure 1, the second side wall 16c can extend vertically between the top wall 16a and the bottom wall 16f and the first side wall 16b can be displaced from the second side wall 16c along the Y axis of the system of reference coordinates provided in Figure 1. A first portion of the second side wall 16c may extend vertically beyond the top wall 16a to form a portion of the upper rib wall 44. A second portion of the second side wall 16c may extend vertically beyond the bottom wall 16f to form a portion of bottom rib wall 46. Third side wall 16d may extend vertically between top wall 16a and bottom wall 16f, and third side wall 16d can be parallel or substantially parallel to plane YZ of the reference coordinate system provided in Figure 1. A first portion of the third sidewall 16d may extend vertically beyond of top wall 16a to form an upper rib wall portion 44. A second portion of third side wall 16d may extend vertically beyond bottom wall 16f to form a lower rib wall portion 46. A sealed first edge 48 may extend extend vertically from the top rib wall 44 to the bottom rib wall 46. The third side wall 16d may not be directly attached to the top wall 16a and a portion of the first sheet 14 making up the top wall 16a may be inserted through a gap between the third side wall 16d and the top wall 16a, such that the first sheet portion 14 is disposed against a portion of an inner surface of the third side wall 16d (i.e., overlaying the top wall portion 16a in the gap). Likewise, the third side wall 16d may not be directly affixed to the bottom wall 16b and a portion of the first sheet 14 making up the bottom wall 16b can be inserted through a gap between the third side wall 16d and the bottom wall 16b, of so that the first sheet portion 14 is disposed against a portion of the inner surface of the third side wall 16d (i.e., overlaying the bottom wall portion 16b in the gap).
[0118] Referring again to Figure 1, the fourth side wall 16e can extend vertically between the top wall 16a and the bottom wall 16f, and the fourth side wall 16e can be parallel or substantially parallel to the YZ plane of the coordinate system of reference provided in Figure 1 . A first portion of fourth side wall 16e may extend vertically beyond top wall 16a to form a portion of upper rib wall 44. A second portion of fourth side wall 16e may extend vertically beyond bottom wall 16f to form a portion of lower rib wall 46. A second sealed edge 50 may extend vertically from the upper rib wall 44 to the lower rib wall 46. The fourth side wall 16e may not be directly attached to the top wall 16a and a portion of the first sheet 14 making up the top wall 16a can be inserted through a gap between the fourth side wall 16e and the top wall 16a so that the portion of the first sheet 14 is disposed against a portion of an inner surface of the fourth side wall 16e (i.e. , covering the top wall portion 16a in the gap). Likewise, fourth side wall 16e may not be directly affixed to bottom wall 16b and a portion of first sheet 14 composing bottom wall 16b may be inserted through a gap between fourth side wall 16e and bottom wall 16b, of so that the first sheet portion 14 is disposed against a portion of the inner surface of the fourth side wall 16e (i.e. overlying the bottom wall portion 16b in the gap).
[0119] The plurality of walls 16 of container 12 may cooperate to form any suitable shape or combination of shapes that form a sealed or partially sealed enclosure. In other contemplated embodiments, for example, the plurality of walls 16 can form a substantially elongated tubular shape. Container 12 may include any container known in the art, such as quad-sealed packages, Horizontal Flow Roll-up Packages (such as those manufactured by Ilapak, Hayssen-Sandiacre, Bosch, or Doboy), Fill and Sealing Pillow Bags Vertical (such as those manufactured by Hayssen, Ilapak, Bosch or Triangle), Horizontally Shaped Fill Sealing Packs including a formed bottom and lid material (such as those manufactured by Multivac or Tiromat), Vertical Bags (such as those manufactured by KHS-Bartelt or Laudenberg) and tray sealing equipment such as those manufactured by Pack-Line, Osgood or Modern.
[0120] An exemplary quad-seal package and methods of folding a quad-seal package that can be used as the container for the packages of the disclosure is described in US Patent Application Publication 2012/0312868, the disclosure of which is incorporated herein by reference. in your totality. Such quad-seal packages may include corner seals that extend and encircle one or more panels of the package. For example, the package may include a top wall on which the opening is disposed and an oppositely disposed bottom wall. Sealed corners can extend from and surround one or both of the top and bottom walls. In alternative embodiments, the sealed corners may extend from one or more of the side walls.
[0121] As illustrated in Figure 1, one or more ribs 51 may be formed along one or more surfaces of container 12. For example, one rib 51 may extend along top wall 16a of adjacent and aligned container 12 with the third sidewall 16d of the container. In some embodiments, as illustrated in Figure 26, for example, a first rib 251a may extend along the top wall 216a of the adjacent container and aligned with the third side wall 216d and a second rib 251b may extend along the adjacent container top wall 216a and aligned with fourth side wall 216e. The one or more ribs 51 may be formed as an elongated protrusion extending upwardly from the top wall 16a of the container 12 and the protrusion may provide rigidity to a desired area of the container 12. In addition, the one or more ribs 51 may extending along all or part of one or more of the side walls 16b-d of the container 12 and upwards from the wall of the container, as described above with respect to the top wall. In various embodiments, the one or more ribs 51 may be formed on the wall containing the closure assembly 22, as well as on one or more of the walls adjacent to the panel having the closure assembly. The one or more ribs 51 can be formed in a thermoforming operation which will be described in more detail below.
[0122] The plurality of walls 16 of the container 12 can be formed from a single sheet of material, (for example, the first sheet 14) and the material can be flexible. However, container 12 can be made from any suitable number of sheets of material. First sheet 14 can include any suitable number of laminate layers necessary to obtain the desired compositional and/or film properties. The first sheet 14 can have a structure and composition that are appropriate for the product to be stored within the container 12. The first sheet 14 can be formed from materials such as polypropylene (PP), ethylene vinyl alcohol (EVOH), polyethylene (PE ), ethylene vinyl acetate (EVA), copolymers, foil (such as aluminum foil), paper, polyester (PET), polyamide or nylon (PA) and laminates and composites thereof. In other embodiments, first sheet 14 can be formed of metallized polypropylene or metallized polyethylene terephthalate (PET) or combinations of such materials. Still further, first sheet 14 can include or be infused with a degradable or biodegradable component that can allow the container to degrade in a relatively short period of time after the useful life of container 12, such as after container 12 is disposed of in a landfill. or other disposal facility. If necessary or desired, based on the implementation, the first sheet 14 may include an outer layer of heat-sealable polypropylene or other material suitable for heat sealing so that the seals joining portions of the film when the container 12 is manufactured can be sealed and/or affixed to the outer surface of container 12 to form and mold container 12.
[0123] As illustrated in Figure 1, container 12 includes opening 20 through at least one of the plurality of walls 16. Opening 20 may be disposed through any suitable wall or walls of the plurality of walls 16. For example, opening 20 may be disposed through top wall 16a (i.e., an access panel or opening panel), as illustrated in Figure 1. As used herein, the term opening panel is used to describe any panel in which the opening is formed or defined. Opening 20 can be any suitable shape or combination of shapes to allow a user to access interior volume 18 through opening 20. For example, as illustrated in Figures 1 and 7, opening 20 can have an elongated shape that extends to the along a horizontal opening axis 52 which is parallel to the X axis of the reference coordinate system of Figure 1. The opening axis 52 may extend from a first end 53 of opening 20 to a second end 54 which is opposite the first end 53 and the opening axis 52 may at least partially extend along or adjacent to an upper surface of the first sheet 14 comprising the upper wall 16a. The opening axis 52 may be equidistant from the first sidewall 16b and the second sidewall 16c when viewed along the Z axis of the reference coordinate system of Figure 1. The perimeter of the opening 20 may be defined by an opening edge 55 which can include one or more segments. For example, opening edge 55 can include a first side edge 56a and a second side edge 56b and each of the first side edge 56a and second side edge 56b can be parallel and equidistantly offset from the axis of the opening 52. the first side edge 56a and the second side edge 56b may be disposed a first distance D1 from the axis of the opening 52. The opening edge 55 may also include an end edge 58 which may extend between a first end of the first side edge 56a and a first end of the second side edge 56b at the second end 54 of the opening 20. A curved front edge 60 may extend from a second end of the first side edge 56a and a second end of the second side edge 56b toward the first end. 53 of opening 20. Front end 60 may be formed symmetrically about opening axis 60 and at a distance between front edge 60 and axis d. and opening 24 may extend from the first end 53 of the opening 20 to the second end of the first and second side edges 56a, 56b. Front edge 60 may be in the form of a portion of a circle, a portion of an oval, or a portion of a parabola, a square, or a rectangle, for example. Front end 60 may also have a dot or chevron (not shown) to create a starting point. The edge surface of the opening edge 55 may be smooth, wavy, scalloped, or any other suitable shape or texture. The opening 20 can have a symmetrical or an asymmetrical shape.
[0124] The opening 20 can be formed in a cutting operation. For example, in one embodiment a cutting operation may include forming cuts for the first and second side edges 56a, 56b and the front edge 60 of the first sheet 14, while all or a portion of the end edge 58 may remain integrally secured. to the first sheet 14 to form a portion of the hinge portion 28. In such an operation, a lower portion 62 of the first sheet 14 is formed that is disposed within the first and second side edges 56a, 56b and within the front edge 60 (when formed during the cutting operation) and which can be hingedly coupled to container 12 around the portion of first sheet 14 at or adjacent to end edge 58. In alternative embodiments, opening 20 may be formed in a cutting operation. cut that cuts along the entire opening edge 55. The cutting operation may cut substantially along the entire opening edge 55 and gaps or bridges may be provided along the opening edge 55 as desired.
[0125] In alternative embodiments, an opening 20 may be defined in the container 12 (such as in the container top wall 16a) forming or defining the bottom portion 62 in a portion of the top wall 16a, so that when the bottom portion 62 is at least partially removed from the remaining portion of the top wall 16a opening 20 is defined. That is, the lower portion 62 may not be secured to the cap element 26. This may allow the resealable packaging assembly 10 to remain sealed, e.g., hermetically sealed, until first use by users. Such an embodiment can be advantageously used to provide a tamper evident package assembly 10 in which the user would readily be able to determine whether package 10 has been previously opened by observing whether lower portion 62 has been at least partially detached from container 12. Any other mechanism known tamper evident may be provided in container 12 as is known in the art. Lower portion 62 may be configured to detach completely or partially from the remaining portion of container 12. For example, lower portion 62 may be configured to partially detach from container 12 so that it remains at least partially secured to container 12. in other embodiments, the lower portion 62 may detach completely from the access panel 14.
[0126] Referring to Figure 3, the lower portion 62 of the first sheet 14 may be at least partially secured to the second sheet 24 of the cap element 26. More specifically, all or a portion of a first surface 90 of the lower portion 62 may be secured to all or a portion of a second surface 92 of the second sheet 24 of the lid element 26. Preferably, the entire first surface 90 of the lower portion 62 may be secured to a portion of the second surface 92 of the lid element. 26. The lower portion 62 can be secured to the second sheet 24 of the cap element 26 in any way known in the art, such as by using an adhesive, heat sealing, ultrasonic sealing, etc. Suitable adhesives can be pressure sensitive acrylics, two-part dry bonding, single-component and thermally activated polyurethanes, for example. As the lower portion 62 may be formed in the cutting operation that forms the opening 20, the lower portion 62 may have dimensions that are equal to or substantially equal to the corresponding dimensions of the opening 20. Specifically, the lower portion 62 may have first and second edges. sides 94a, 94b that dimensionally correspond to the first and second side edges 56a, 56b of the opening 20 and a front edge 96 that dimensionally corresponds to the front edge 60, as illustrated in Figures 2, 3, 6, and Figure 8. In the first position 30, a longitudinal axis of the lower portion 62 may be collinear with the opening axis 52, and the lower portion 62 may be formed symmetrically about the longitudinal axis.
[0127] The lower portion 62 may be defined in any suitable way. For example, bottom portion 62 (and by extension opening 20) may be defined by a path of reduced strength that allows lower portion 62 to be at least partially detached along the path of reduced strength when a force is applied to pulling the lower portion 62 away from the remaining portion of the container 12. The reduced strength path defining the lower portion 62 on the container 12 can be provided by any suitable method including, for example, by laser marking, mechanical marking or a process similar to forming perforations in the first sheet 14 without perforating the sheet, but allowing punching, if necessary or desired, based on the requirements for the reclosable packaging assembly 10 and/or the stored product. Alternatively, blade marking with approximately 60%-100% penetration, for example, can be used to form a marking line defining the lower portion 62 rather than individual perforations. In such embodiments, it may be possible to retain an airtight seal of the container until the first opening of the container, when there is no complete penetration through the first sheet 14 to the lower portion 62, is separated from the first sheet 14. In other embodiments, the penetration complete through the first sheet 14 can be accomplished by blade marking to facilitate the detachment of the lower portion 62. For example, a continuous blade marking with full penetration through the first sheet 14 can be performed with intermittent breaks or score line bridges being provided to hold the lower portion 62 in place until the lower portion 62 is detached by the user. The distance between the bridges can range from 200 microns to 2.0" and the length of the bridges can fall within the range of 50 microns to 2500 microns depending on implementation.
[0128] Other suitable methods of forming a marking or perforation to define the opening edge include laser marking/cutting, laser perforation or microperforation methods, for example using dies or knives.
[0129] As illustrated in Figure 1, the first engagement feature 36 may be disposed on the container 12 adjacent to the opening 20 and the first engagement feature may be formed integrally with or with the container 12. The first engagement feature 36 may be adapted to engage the second engagement feature 38 disposed on the cap member 26 of the closure assembly 22 so that the first engagement feature 36 engages the second engagement feature 38 to releasably secure the cap member 26 to the container 12 when the cap element 26 is in the first position 30 illustrated in Figure 4. The first engaging feature 36 may be any element or combination of elements that engage a corresponding second engagement feature 38 to allow the cap element to engage the container 12. For example, the first engagement feature 36 may be a rib 40 which may extend vertically upwards from the part. go from the top wall 16a and which may be formed integrally with or with the top wall 16a. Rib 40 may extend along a rib axis 64 which is generally U-shaped (when viewed along the Z axis of the reference coordinate system of Figure 1) and which extends around aperture 20 and the open end of the U-shaped rib axis 64 can be at or adjacent to the second end 54 of the opening 20. The rib axis 64 can be offset outward a uniform distance from the first side edge 56a, of the second side edge 56b and front edge 60.
[0130] As illustrated in Figures 1 and 5, the rib 40 may be formed on the first sheet 14 and may have any suitable cross-sectional shape or combination of shapes (when viewed along the rib axis 64). For example, rib 40 may include a pair of internally tapering sides 66a, 66b and a top wall 68. The cross-sectional shape of rib 40 may be uniform or substantially uniform along rib axis 64. However, the ends of the rib 40 forming the U-shaped legs that are adjacent to the second end 54 of the opening 20 may taper gradually downward, such that the top wall 68 is flush or substantially flush with an upper surface of the first sheet 14 (i.e. is, an upper surface of the top wall 16a). Instead of a gradual taper, the ends of rib 40 can be chamfered or can be rounded. Alternatively, the ends of rib 40 may not taper and the cross-sectional shape of rib 40 may be uniform or substantially uniform along the entire axis of rib 64.
[0131] As explained above, the rib 40 can be adapted to engage a corresponding channel 42 (see Figure 3) formed in the cap element 26 of the closure assembly 22 when the cap element 26 is in the first position 30 shown in Figure 4 and channel 42 will be described in more detail below. Instead of a single rib 40, the first engagement feature 36 may include two or more rib segments (not shown) that are not continuous along the length of the rib axis. That is, gaps can separate the two or more rib segments and each of the rib segments can be adapted to engage a corresponding channel segment or a portion of a channel 42 formed in the cap element 26 of the closure assembly 22 when the cap element 26 is in first position 30.
[0132] As illustrated in Figure 1, the reclosable packaging assembly 10 also includes the closure assembly 22 secured to the container 12 adjacent to the opening 20 or adjacent to an area in which the opening is defined (such as when the lower portion 62 acts as a removable seal to cover the opening 20). The closure assembly 22 includes the cap element 26 and the hinge portion 28, and the cap element 26 is pivotable about the hinge portion 28 between the first position 30 and the second position 34. At least a portion of the assembly closure 22 may include second sheet 24 and a portion of first sheet 14. More specifically, lid element 26 may partially include second sheet 24 and second sheet may be designed and sized to cover opening 20 when the closing element lid 26 is in first position 30. Second sheet 24 may be of any suitable material, such as any of the materials described above which may comprise first sheet 14. Specifically, second sheet 24 may be of PP, PET or PLA, or any other suitable material. The second sheet 24 may have a uniform thickness, or the thickness may vary. In this first position 30, the cap element 26 may have an elongated shape that extends along a longitudinal cap axis 70 from a first end 72 to a second end 74 that is adjacent to the hinge portion 28, as illustrated. in Figures 2 and 4. The lid axis 70 may at least partially extend along or adjacent to a lower surface of the second sheet 24 (and an upper surface of the first sheet 14) so that the lid axis 70 is collinear. (or substantially collinear) with the opening axis 52 when the cap element 26 is in the first position 30. In alternative embodiments, the cap element 26 of the closure assembly 22 may include only the second sheet 24 and the lower portion 62 may remain attached to container 12 to cover opening 20 and to act as a seal, as described above.
[0133] As illustrated in Figures 2 and 8, the lid element 26 may include a lid edge 76 that defines the outer edge (or an outer perimeter edge) of the lid element 26 and the lid edge 76 may include a or more segments. For example, lid edge 76 may include a first side edge 78a and a second side edge 78b and each of the first side edge 78a and second side edge 78b may be parallel to and equidistantly displaced from the lid axis 70. the first side edge 78a and the second side edge 78b may be disposed at a second distance D2 from the cap axis 70 and the second distance D2 may be greater than the first distance D1 separating each of the first side edge 56a and the second edge side 56b of opening shaft 52. A first end of first side edge 78a and a first end of second side edge 78b may be disposed adjacent to hinge portion 28 at second end 54 of opening 20.
[0134] The lid edge 76 may also include a curved front edge 80 that extends from a second end of the first side edge 78a and a second end of the second side edge 56b toward the first end 53 of the opening 20. The end The front edge 80 may be formed symmetrically about the cap axis 60 and a distance between the front edge 80 and the cap axis 70 may increase from the first end 72 of the cap element 26 to the second end of the first and second side edges 78a , 78b. Leading edge 80 may have the same or substantially the same overall shape as leading edge 60 of opening 20. That is, leading edge 80 may be shaped like a portion of a circle, a portion of an oval, or a portion. of a parabola, a square, or a rectangle, for example. The leading edge 80 can be moved outwardly from the opening leading edge 60 and the displacement distance can be uniform. For example, the offset distance may be the difference between the second distance D2 of the cap element 26 and the first difference D1 of the opening 20. The front edge 80 may include a pull tab 117 (shown in Figures 20A and 20B) which projects away from the second latch feature 38 to facilitate opening and closing of the cap element 26 by a user.
[0135] As illustrated in Figures 2, 3, 4 and 8, the cap element 26 of the closure assembly 22 includes the second engagement feature 38 adapted to engage the first engagement feature 36 arranged on the container 12 to releasably secure the element. from lid 26 to container 12 when lid member 26 is in the first position 30 illustrated in Figure 4, and second engagement feature 38 may be formed integrally with or with lid member 26. Second engagement feature 38 may be any element or combination of elements that engages a corresponding first engagement feature 36 to allow the cap member to sealingly engage the container 12. For example, the second engagement feature 38 may be a channel 42 adapted to receive the rib 40 formed in the top wall 16a of the container 12. As illustrated in Figure 3, the channel 42 can extend vertically upward (or substantially vertically to top) from a first surface 82 of the second sheet 24 and, as shown in Figure 2, the channel may extend along a channel axis 84. The channel axis 84 may have a general U-shape and The open end of the U-shaped channel shaft 84 may be at or adjacent to the second end 74 of the cap element 26. Referring to Figures 54A and 59-65, in various embodiments, the channel may be continuous around the entire perimeter of the opening. As described in detail below, in such embodiments, the lid element may be completely removable from the container or it may be hinged to the container, for example, at a second end of the lid element. The channel axis 84 may be internally displaced a uniform distance from the first side edge 78a, the second side edge 78b and the front edge 80 of the cap element 26. The channel axis 84 may substantially overlap or overlap (i.e., have the same shape, dimension and relative position) of rib axis 64 when viewed along the Z axis of the reference coordinate system of Figure 1 when cap element 26 is in first position 30. Channel 42 may have a shape of uniform or substantially uniform cross-section along channel axis 84. Alternatively, channel 42 may have a non-uniform cross-sectional shape.
[0136] Referring to Figure 3, channel 42 may be formed in first sheet 14 and may have any suitable cross-sectional shape or combination of shapes (when viewed along channel axis 84). For example, channel 42 may include a pair of inwardly tapered surfaces 86a, 86b and a bottom surface 88, and surfaces 86a, 86b, 88 are adapted to contact or be adjacent a corresponding surface of rib 40 (i.e., the inwardly tapered sides 66a, 66b and a top wall 68, respectively) when the cap element 26 is in the first position 30. The cross-sectional shape of the channel 42 may be uniform or substantially uniform along the channel axis 84 and may correspond to the cross-sectional shape of the rib 40 along the rib axis 64. The ends of the channel 42 forming the U-shaped legs that adjoin the second end 74 of the cap element 26 may taper gradually to receive the corresponding tapered ends of rib 40.
[0137] Instead of a single channel 42, the second engagement feature 38 may include two or more channel segments (not shown) that are not continuous along the length of the channel axis 84. Each of these channel segments may correspond to a previously described rib segment formed in the top wall 16a of the container 12 so that each of the rib segments can be adapted to engage a corresponding channel segment or a portion of a channel 42 formed in the cap element 26 of the closure assembly 22 when cap element 26 is in first position 30.
[0138] In an alternative embodiment, the first engagement feature 36 may be a channel 42 which may extend vertically downward from the top wall 16a of the container 12 and the second engagement feature 38 may be the rib 40 which may extend vertically downwards from cap member 26 of closure assembly 22. In first position 30, rib 40 may be received in channel 42 to allow cap member to sealably engage container 12.
[0139] Referring to Figures 59-65, the cap element may include one or more additional closure features 500 including cutout, button or snap-on features or other interacting locking features. For example, as shown in Figure 59, the cap element may include a single closure feature 500 disposed at a first end 502 of the cap 26 and disposed approximately at the center, the closure feature may include a downwardly projecting portion formed on the second. sheet. The downwardly projecting portion formed in the second sheet may interact, for example, to reside in a correspondingly formed and sized recess in the first sheet when the lid is in the closed position. Figure 61 shows a cap which may include a closure feature 500 which is defined by an upwardly projecting portion formed in the first sheet and a receiving recess formed in the second sheet, with the receiving recess being arranged such that the upwardly projecting portion resides in the receiving recess when the lid is in the closed position.
[0140] The cap element can include any number of closure features. For example, Figure 60 illustrates an embodiment having two closure features 500a, 500b disposed at the corners of the cap near the first end of the cap. Closure feature(s) 500 may be disposed at any suitable location on the cover to aid in securing the cover 26 in the closed position. For example, the closure feature 500 may be provided in a central region of the cap 26 (as illustrated, for example, in Figure 70) or near an edge of the cap 26 (as illustrated, for example, in Figures 60 and 71) . The closing feature 500 can have any suitable shape. For example, Figures 59 and 60 illustrate embodiments in which the closing feature is circular in shape. Figure 61 illustrates an embodiment in which the closing feature is oblong in shape. For example, the closing feature can be any shape including circular, elliptical, square, rectangular, triangular or any other polygonal shape. Figure 64 illustrates an embodiment in which the closure feature 500 has a teardrop shape that projects down from the second sheet 416 towards the opening. The closure feature 500 may have increasing depth as it approaches the first end of the cap element 26, for example, as illustrated in Figure 64.
[0141] As illustrated in Figures 1, 6 and 8, the cap element 26 of the closure assembly 22 may include a convex portion 98 to provide structural support to the cap element 26. The convex portion 98 may extend from the second end 74 of cap element 26 towards first end 72 and a trailing edge 100 of convex portion 98 adjacent second end 74 may comprise a portion of hinge portion 28. More specifically, cap element 26 may pivot about of the trailing edge 100 of the convex portion to shift from the first position 30 to the second position 34. The trailing edge 100 may be in the shape of a portion of an arc when viewed along the Z axis and the shape of the trailing edge 100 coupled with the The shape of the convex portion 98 cooperate to hold the cap element 26 in a rigidly erect position when in the second position 34. For example, the cap axis 70 may form an angle between 45 degrees and 125 degrees with the opening axis 52 when the cap element 26 is in the second position 34. Instead of an arc, the trailing edge 100 may include a plurality of arc segments or linear segments that form a zigzag pattern.
[0142] Referring again to Figures 1, 6 and 8, the convex portion 98 may have a parabolic shape or a substantially parabolic shape when viewed along the Z axis of the reference coordinate system of Figure 1. The convex portion 98 may is formed symmetrically along the lid axis 70 and the distance between an upper surface of the first sheet 14 comprising the convex portion 98 and the lid axis 70 may gradually decrease as the convex portion 98 extends from the second end 74 of the cap element 26 towards the first end 72 as illustrated in Figure 6. For example, the distance between an upper surface of the first sheet 14 comprising the convex portion 98 and the cap axis 70 may gradually decrease as the convex portion 98 extends from the cap axis 70 toward each of the first and second side edges 78a, 78b, as illustrated in Figure 9. Furthermore, when viewed in cross-section throughout. shaft cover length 70; the convex portion 98 may have a curved or substantially curved shape. In alternative embodiments, the convex portion 98 may be generally triangular in shape when viewed along the Z axis of the reference coordinate system of Figure 1, as provided in the thermoforming mold illustrations of Figures 17A to 17J.
[0143] Referring now to Figure 1, the closure assembly 22 may include a support portion 102 extending from the second end 74 of the cap element 26 toward the fourth side wall 16e of the container 12 and a portion of the support portion 102 adjacent to second end 74 of cap element 26 may comprise a portion of hinge portion 28. Support portion 102 may be formed from second sheet 24 and all or a portion of second sheet 24 of support portion 102 can be secured to a portion of the first sheet 14 (e.g., the top wall 16a of the container 12) adjacent the fourth side wall 16e of the container 12. The support portion 102 can structurally secure the lid member 26 to the container 12 and allow that the cap element 26 hinges around the hinge portion 28. A portion of the support portion 102 (each or both of the first sheet 14 and the second sheet 24) may extend from the hinge portion 28 across the gap between the fourth side wall 16e and the top wall 16a such that the portion of the first sheet 14 is disposed against a portion of the inner surface of the fourth side wall 16e. Support portion 102 may be partially defined by a pair of side edges 103a, 103b which may extend parallel or substantially parallel to the first and second side edges 78a, 78b when cap element 26 is in first position 30. However, the distance between each of the pair of side edges 103a, 103b and the lid axis 70 may be less than the distance between the first and second side edges 78a, 78b and the lid axis 70.
[0144] As illustrated in Figures 1, 4, 6 and 7, the resealable package assembly 10 may also include a first attachment feature 104a and a second attachment feature 104b. First fastening feature 104a may be a protrusion formed in container 12 and second fastening feature 104b may be a cavity formed in cap member 26 that is adapted to receive first fastening feature 104a as illustrated in Figure 10. More specifically, the first attachment feature 104a may be an elongated protrusion formed along a portion of the rib axis 64 and the protrusion may have a plurality of side walls 106a-d that extend vertically beyond the top wall 68 of the rib 40, as shown in Figure 11A. First sidewall 106a and oppositely disposed second sidewall 106b may be curved to match the contour of rib axis 64, and third 106c and fourth 106d sidewalls may extend between first 106a and second 106b sidewalls. The third 106c and fourth 106d sidewalls may have any suitable cross-sectional shape, such as curved, linear, a chevron, a triangle, or partially curved. A top surface 108 may be parallel or substantially parallel to and vertically displaced from top wall 68 of rib 40. All or part of any or all of the plurality of side walls 106a-d may be formed as an undercut. That is, the one or more side walls 106a-d or a portion of the one or more side walls 106a-d may form an acute angle with the upper surface of the top wall 16a (i.e., the first sheet 14) of the container 12. Such a cutout will allow the cap element 26 to "positively" attach to the container 12. The cutout may also be formed in or for the first rib 40.
[0145] As explained above, the second fastening feature 104b may be a cavity formed in the cap element 26. More specifically, the second fastening feature 104b may be an elongated cavity 109 formed on an underside of a protrusion formed along a portion of the channel shaft 84, and the cavity 109 may be adapted to receive the first attachment feature 104a. As illustrated in Figures 2 and 11B, cavity 109 may have a plurality of side surfaces 110a-d each extending vertically above a lower surface 112 of second sheet 24 of cap element 26. A first side surface 110a and an oppositely disposed second side surface 110b may be curved or contoured to match the curved shape of the first side wall 106a and the second side wall 106b, respectively, of the first attachment feature 104a. Similarly, a third side surface 110c and a fourth side surface 110d can be molded to match the shape of the third 106c and fourth side walls 106d of the first attachment feature 104a.
[0146] With reference to Figures 2, 8 and 11B, an upper surface 114 may be parallel or substantially parallel and vertically displaced from the lower surface 88 of the channel 42 and with a vertical distance between the upper surface 114 and the lower surface 112 of the second sheet 24 of cap element 26 may be greater than a vertical distance between the lower surface 88 of the channel 42 and the lower surface 112 of the second sheet 24. The first attachment feature 104a may be dimensioned and designed such that the first fastening feature 104a is engageable (e.g., received) with second fastening feature 104b to allow cap member 26 to sealably engage container 12. All or part of any or all of the plurality of side surfaces 106a -d can be formed as a snip. That is, the one or more side surfaces 110a-d or a portion of the one or more side surfaces 110a-d may form an acute angle with the lower surface 112 of the second sheet 24 of the cap element 26. attachment 104a may engage a corresponding cutout in second attachment feature 104b to releasably lock or secure lid member 26 to container 12. Instead of an acute angle, a portion of the one or more side surfaces 110a-d may include a retainer that starts 0.050" from the top surface 108, proceeds down and in at an angle of 45° for about 0.070" and transitions down by 0.050", then down and out to 35°. are for illustrative purposes only, other dimensions may be suitable One skilled in the art will recognize that a retainer or similar protrusion correspondingly may be formed on or on the first fastening feature 104a.
[0147] In alternative embodiments, the first attachment feature 104a may be a cavity formed in a channel 42 that may extend vertically downward from the top wall 16a of the container 12 and the second attachment feature 104b may be a protrusion that may extend downwardly from the cap member 26 of the closure assembly 22. In the first position 30, the protrusion may be received in the cavity to allow the cap member to sealably engage the container 12.
[0148] An alternative closure assembly 22 is illustrated in Figures 20A and 20B. In this embodiment, support portion 102 may be at least partially disposed on or secured to top wall 16a of container 12. When viewed parallel to the Z axis of the reference coordinate system of Figure 1, support portion 102 may be defined. a pair of parallel side edges 103a, 103b, and a trailing edge 105 extends between the side edges 103a, 103b so that the support portion 102 is disposed on the top wall 16a. Alternatively, a portion of support portion 102 may be inserted through a gap between top wall 16a and fourth side wall 16e. Hinge portion 28 may include a pair of oppositely disposed cutouts 107a, 107b which may extend into each of the pair of parallel side edges 103a, 103b (and inwardly from the first and second side edges 78a, 78b of the cap element 26 adjacent to the second end 74 of the cap element 26). The cuts 107a, 107b may be symmetrical about the cap axis 70. Each of the cuts 107a, 107b may include a first segment 111a, 111b normal to the corresponding side edge 103a, 103b. A second segment 113a, 113b may extend obliquely from one end of the first segment 111a, 111b towards the first end 72 of the cap element 26. A third segment 115a, 115b may extend into a corresponding end of the second segment 113a, 113b parallel to the first segment 111a, 111b. An end end of the third segment 115a, 115b may be disposed at a suitable distance from the cap axis 70 such that the cap element 26 can pivot from a first position 30 to a second position 34 around a portion of the element. of closure extending between an end end of each of the cuts 107a, 107b (i.e., an end end of each of the third segments 115a, 115b). Specifically, the cap element 26 can pivot from a first position 30 to a second position 34 around a crease or fold (which can be marked, perforated or formed as a feature on the closure element 22) that extends between the ends. terminals of each of the third segments 115a, 115b.
[0149] When the cap element 26 is hinged to a second position 34 illustrated in Figure 20B, a first cap projection 119a and a second cap projection 119b may grip, deform or move to a position in which an edge formed by a or more of segments 111a, 111b, 113a, 113b, 115a, 115b engage support portion 102 to support cap element 26 in second position 34. Alternatively, first cap projection 119a and second cap projection 119b may remain stationary with respect to the remainder of the cap element 25 when engaging the support portion 102 to support the cap element 26 in the second position 34. When the cap element 26 is pivoted from the first position 30 to the second position 34, the cap element 26 may deform (e.g. assume a convex shape) to provide longitudinal rigidity to cap element 26. Second position 34 may be a position that is intermediate between a first position (by example, a closed position) and a fully open position (a third position) in which the cap element 26 or a portion of the cap element may be adjacent an upper portion of the fourth side wall 16e. In the second position, the cap axis 70 may form an angle with the top wall 16a of the container 12 (or with the position of the cap axis 70 when the cap element is in the first position 30) that is between 30° and 120° .
[0150] The hinge portion 28 including the cutouts 107a, 107b can be used in embodiments in which the cap element 26 includes a lower portion 62 and the cutouts 107a, 107b can extend through each of the first sheet 14 (a lower portion 62) and second sheet 24. Alternatively, the cuts 107a, 107b may extend only through the second sheet 24 and not the lower portion 62. The hinge portion 28, including the cuts 107a, 107b, may also be used in embodiments in which the lid element 26 is formed of only the second sheet 24 (i.e., when the lid element 26 does not have a lower portion 62). The cuts 107a, 107b may extend through the second sheet 24 (and optionally the lower portion 62), partially through the second sheet 24 (and optionally the lower portion 62), or a combination thereof. The cuts 107a, 107b can be continuous or can comprise cut segments and gaps between the segments. The cuts 107a, 107b can be punched or scored (or any combination thereof).
[0151] The above-described hinge portion 28 which includes cutouts 107a, 107b, may also be suitable for use in a package not including a lid element 26. For example, packages may generally include a resealable or resealable label disposed on the first sheet 14 covering the opening 20. The hinge portion 28 as described above may be formed, as described above, on the resealable tag to allow the resealable tag to hinge around the hinge portion 22 and reside in a position that is intermediate from a closed position and a fully open position (ie, the second position).
[0152] As illustrated in Figure 18, the closure assembly 22 may include a locking mechanism 126 that includes a locking feature 128 that is received in a receiving feature 130 when the cap element 26 is in a fully open position. The locking feature 128 may be a protrusion extending upwardly from the cap member 26 and the protrusion may have a rectangular, square, round, or any other suitable cross-sectional shape or combination of cross-sectional shapes. The receiving feature 130 may be formed in the support portion 102 (or the container 112 itself) on an opposite side of the hinge portion 28 and the receiving feature 130 may include a pair of receiving protrusions 132 which are separated to form a receiving slot 134 between them. Each of the pair of receiving protrusions 132 may have a rectangular, square, round, or any other suitable cross-sectional shape or combination of cross-sectional shapes. The width of the receiving slit 134 is approximately equal to or slightly smaller than a corresponding width of the locking member 128, so that the locking feature 128 (and hence the entire cap element 26) is retained in the receiving slit 134 when the cap element 26 is hinged about the hinge portion 28 so that the cap element 26 is in a fully open position. A cutout can be formed in the pair of receiving protrusions 132 and/or in the locking feature 128 to positively lock the locking feature 128 within the receiving slot 134. The locking mechanism 126 can be formed in a thermoforming operation using one of the molds illustrated in Figures 16A to 17J, for example. Features for Retaining the Resealable Lid or Flap in an Open Position
[0153] In various embodiments, the closure assembly or the resealable flap may include features arranged on the cover element that retain the cover element in the open position (second position), which can facilitate access to the package. Referring to Figure 26, cap element 226 may include first and second protrusions 219a, 219b which pivot upon opening cap element 226 from a first (closed) position to a second (open) position. While the description below is given in relation to the cap including two projections, it is to be understood that the cap may include any appropriate number of projections, including a single projection or more than two projections. The projection or projections facilitate holding the cap element 226 in the second position. The first and second projections 219a, 219b may be disposed in the region of the hinge portion 228 of the cap element 226 and are positioned so that the hinge axis lies between the projections and the distal end of the cap 226. With reference to Figure 27, the first and second projections 219a, 219b each have a first end 230a and a second end 230b. The projections are formed by cuts in the cap element such that the first end 230a of the projections 219a, 219b remains secured to the cap element 226 and the second end 230b and periphery of the projections 219a, 219b may detach from a portion of the second sheet 224 and pivot from a first position to a second position when the cap element 226 is moved from the first position to the second position. In the first position, the lid projections 219a, 219b can be generally arranged in parallel with the top wall 216a of the pack. Referring to Figure 28, in the second position the lid projections 219a, 219b may be positioned generally perpendicular to the top wall 216a of the pack 212, with the second end 230b of each lid projection 219a, 219b being in contact with the top wall 216a , thereby retaining the cap member 226 in the second position. For example, friction between the projections 219a, 219b and the top wall 216a can resist the lid from closing under gravity. The frictional interference between the projections 219a, 219b may be a function of the distance that the top wall 216a is deflected by the projections 219a, 219b during movement from the first to the second position. The amount of friction is sufficient to retain the cover 226 in the second position, but it can be overcome without damage for the projections 219a, 219b to return the cover and projections to the first (closed position).
[0154] The first and second projections 219a, 219b may have any suitable shape such as, for example, semicircular, triangular, semi-hexagonal and "W-shaped". Figure 29 is a schematic illustration of the region of hinge portions 228 of lid elements 226 having differently shaped and sized projections 219a, 219b. In various embodiments, the first and second projections 219a, 219b are the same shape and size. In some embodiments, the first and second projections 219a, 219b may have different shapes and/or different sizes.
[0155] The first and second projections 219a, 219b have a length between the first and second ends such that upon hinge of the lid, the first and second projections 219a, 219b move from the first position to the second position, the first and second projections 219a, 219b may contact top wall 216a at least at their respective second edges 230b. The length of the projections 219a, 219b can be adjusted to suit the amount of force acting on and the resulting deflection of the top wall 216a by the projections 219a, 219b. In various embodiments, the first and second projections 219a, 219b are of a length such that the projections 219a, 219b do not bend or deform excessively during movement of the first and second positions and may retain sufficient rigidity to retain the cap member 226 in the second (open) position.
[0156] Referring to Figure 30, the first and second projections 219a, 219b may have any suitable width or diameter. In various embodiments, the width of the projections 219a, 219b is selected so that the cutouts in the cap element 226 to form the projections 219a, 219b do not overlap with cutouts in the first sheet and lower portion (if provided) to form the opening in the package. By arranging the various cuts in such a way, the pack can be supplied in such a way that there is no opening in the pack that is not covered by the cap element.
[0157] The top wall of the container may include one or more features disposed below the first and second projections to aid movement of the projections. The features can be formed, for example, when forming, such as by thermoforming, the engagement and/or any other closure features on the lid. For example, the top wall may include one or more ribs over which the first and second projections can slide and ultimately reside against which to aid in maintaining the cap element in the open position.
[0158] Referring to Figures 59-64, 70 and 71 the cap element may include additional features to aid in retaining the cap in the open position and/or to add additional rigidity to the cap element. For example, the lid may include a rib that protrudes above the top wall of the container. The lid may include corner portions 506 having a greater thickness than a central portion disposed between the corner portions. The varying thickness of the rib 51 and the location of the rib 51 relative to the channel 42 can be arranged such that a rear region of the channel resides in the central portion when the cap element 26 is in the open position. The cap element 26 may further include cutaway portions adjacent the rear region of the channel which are adapted to reside in raised corners of the rib when the cap element is in the open position.
[0159] Referring to Figure 65, in various embodiments, the cap element can be free of such additional features which can beneficially maximize the opening of the package. Figures 65A-E illustrate a mold for forming the cap 26 and Figure 65F illustrates a cap formed using the mold of Figures 65A-E. As illustrated in Figure 65, the hinge 28 around which the lid 26 hinges can be arranged closely adjacent to an end, e.g., the second end, of the lid element 26. The first and second engaging features 34,36 they can be channels and a corresponding rib defining the perimeter of the opening. Cover 26 may further include projections 219 (described above) to assist in retaining cover 26 in an open position.
[0160] The lid 26 may also include one or more closure features 500 to help retain the lid in the closed position. Any of the closing features as discussed above can be used. Figure 65 illustrates an embodiment in which cutouts are positioned at the corners of the lid to aid in closing.
[0161] Referring to Figure 67, it illustrates an embodiment of the lid channel having a hexagonal shape with corner regions 508 of the lid 26 being substantially flat or having a sudden curvature. The corners can be angled, for example, from about 30 degrees to about 60 degrees, about 30 degrees to about 45 degrees, about 30 degrees to about 35 degrees. Other suitable values for corner angle include, for example, about 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47 , 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59 and 60 degrees. Locking mechanisms 510, provided as cutouts in corner regions, may be provided to assist in retaining the cover in the closed position.
[0162] In various embodiments, the lid may be provided with a pull tab disposed in the corner region 508 of the lid 26, as opposed to a central portion of the lid 26. It is to be understood here that lids in accordance with the disclosure may include one or more pull tabs 117 disposed anywhere on the lid 26. Without wishing to be bound by theory, it is believed that providing a pull tab 117 in a corner region 508 of the lid 26 can facilitate opening of the lid 26 by reducing the amount. of mechanical closing force of the lid 26 which must be overcome to open the package compared to a pull tab 117 disposed in the central region of the lid 117. It has been observed that providing a pull tab 117 at the corner 508 has the mechanical force to opening the container can be reduced from approximately 1000 grams of mechanical strength for a central pull tab to 150 grams of mechanical strength. The embodiment of Figure 70 illustrates an embodiment having two pull tabs 117a, 117b disposed at opposite corners 508 of the front of the cap 26. Any appropriate number of pull tabs, including zero or a single one, may be supplied in packages according to embodiments. of disclosure.
[0163] Referring to Figure 68, the lid 26 may have a central portion 512 with a curvature that extends downwardly (concave) into the interior of the package. The concave central portion 512 can provide the package, and particularly the lid 26, with high resistance to opening due to internal pressure in the container. For example, during transport packages may experience different pressure environments even though they are subjected to significant vacuum pressure. The concave portion of the lid may provide some tolerance of the lid for such pressure changes that may be experienced during, for example, transport.
[0164] Additionally, referring to Figures 68 and 69A and 69B, by providing the lid with a downwardly concave portion 512, a portion of the lid may be disposed below the upper surface of the opening panel region and may interact with the side wall 512 of the channel below the top surface of the opening panel region. The sidewall 514 of the channel may be provided with a recessed groove 516 disposed around all or a portion of the opening for which a corresponding projection on the edge of the lid may reside when the lid is in the closed position. This can enhance the lid's sealing ability and the lid's resistance to accidental opening when dropped or otherwise during handling, transport or storage.
[0165] Referring again to Figure 27, a hinge portion 228 of cover 226 is disposed between the first and second projections 219a, 219b. In one embodiment, the hinge portion 228 is disposed in line with the first end of the projections 230a. Hinge portion 228 may be provided by a cutout in the lid. The cut that defines the hinge portion extends between, but does not overlap with, the cuts that define the first and second projections. The cut may be of a length such that the cut for the hinge portion also does not overlap with cuts in the first sheet 214 and the lower portion 262 (if provided) to define the opening 220 of the pack 212.
[0166] The above-described first and second projections 219a, 219b and associated hinge portion 228 may be incorporated into embodiments of package 212 including either the formed lid or the unformed lid to which a portion of the second sheet 224 is fixedly attached. removable to the first sheet for 214 to cover the opening 220 of the package of 212.
[0167] One or more additional features may be arranged on the rib 40 of the first engaging feature 36 to further secure the cap element 26 to the container 12. For example, as illustrated in Figure 13, one or more oblong protrusions 124 may be projecting outwardly from the outer tapered side 66b of rib 40 and each protrusion 124 may be adapted to engage a corresponding surface of channel 42 of lid element 26 to secure lid element 26 to container 12 in first position 30. Alternatively, either in addition, one or more protrusions or cutouts 124 may be disposed on a surface of channel 42 of cap element 26 to engage a corresponding surface or cutout of rib 40 to secure cap element 26 to container 12 at first position 30.
[0168] To further aid in coupling the lid element 26 to the container 12 in the first position 30, a releasable surface adhesive can be applied to all or a portion of the lid element 26 that contacts (and sealably engages) the top wall 16a of the container 12 when the lid member 26 is in the first position 30. Alternatively, or in addition to the adhesive described above, a releasable surface adhesive can be applied to all or a portion of the top wall 16a of the container. 12 which contacts cap element 26 when cap element 26 is in first position 30. For example, a releasable surface adhesive. The surface adhesive can be any suitable adhesive that provides adhesion between the cap element 26 and the container 12 over a suitable number of openings and closures by the user. Suitable adhesives can be pressure sensitive acrylics, for example.
[0169] As illustrated in Figure 12, a stabilizing portion 180, such as a third sheet 116 (or a third film), may be attached (or integrally formed) to the first sheet 14 comprising the container 12 to increase the caliper of the container. 12 in the region of stabilizing portion 180 to provide additional rigidity to container 12 in a desired area. The stabilizing portion 180 may advantageously be provided on only a portion of the top wall 16a of the container 12 without affecting the caliper of other portions of the container 12. This may be advantageous when forming various reclosable packaging assembly 10 configurations in which the edge sealing and/or folding of portions of the first sheet 14 may be made more difficult if a film having a large overall gauge was used. Referring to Figure 32, in some embodiments, the third sheet may have one or more portions extending outwardly from a main body such that upon formation of the pack the main body remains in the region of the top wall and the ones. or more outwardly extending portions are disposed on one or more side walls. Stabilizing portion 180 may be secured (or integrally formed) to first sheet 14 in any manner known in the art. Specifically, all or a portion of an upper surface 118 (i.e., a first side or first surface) of the third sheet 116 can be secured to all or a portion of a lower surface 120 (i.e., a second or second side. surface) of first sheet 14 comprising all or a portion of top wall 16a, with an top surface 122 (i.e., a first side or first surface) of first sheet 14 may be an outer surface of top wall 16a. For example, the third sheet 116 may be secured to the lower surface 120 of the first sheet 14 such that the opening 20 in the first sheet 14 is entirely surrounded by the third sheet 116. The third sheet 116 may extend to the opening edge 55 , or may be displaced externally from opening edge 55. Third sheet 116 may also extend to any one or more of the first, second, third and fourth side walls 16b-16e, or third sheet 116 may be displaced internally of any one or all of the first, second, third, and fourth sidewalls 16b-16e. The inward displacement distance may vary or may be uniform from each sidewall 16b-16e. To secure the third sheet 116 to the first sheet 14, an adhesive may be applied to all or a portion of the upper surface of the third sheet 116. Additionally, or alternatively, an adhesive may be applied to all or a portion of the surface. bottom 120 of the first sheet 14. As an alternative to adhesive, the third sheet 116 may be integrally formed, heat sealed or ultrasonic welded to the first sheet 14. The thickness of the third sheet 116 may be uniform or may vary and may be of any thickness. which provides a desired rigidity to the top wall 16a of the container 12 to allow proper sealing engagement of the lid member 26 and the container 12 in the first position 30.
[0170] The stabilizing portion 180 may also include a coating, such as a paint or adhesive, selectively applied to the lower surface 120 of the first sheet 14. The stabilizing portion 180 may also include a layer of additional material disposed on the lower surface. 120 of the first sheet 14. For example, the material may have a foam structure. In one embodiment, a coating of a polymeric material can be applied to at least a portion of the lower surface 120 of the first sheet 14 and reacted to form a foam structure and thereby form the stabilizing portion 180. In various embodiments, the stabilizing portion 180 may be provided when forming first sheet 14. For example, first sheet 14 may be extruded to have a high gauge portion in the region of first sheet 14 that is adapted to be adjacent opening 20. For example, the first sheet 14 can be provided with an additional laminated layer in the region of the first sheet 14 which is adapted to be adjacent to the opening 20 compared to the number of layers in other regions of the first sheet 14, thereby increasing the caliper of the first sheet. 14 in the region of the opening 20.
[0171] The one or more ribs 51 (see Figure 18) or any other protrusion or combination of protrusions formed in or along the top wall 16a of the container 12, including the second hook feature 38, may allow for vertical stacking of sets of reclosable packaging 10. More specifically, the vertically projecting feature/features may engage a portion of the wall which projects downwardly from the bottom wall 16f of the container and such engagement limits or prevents relative horizontal movement between stacked assemblies 10.
[0172] As illustrated in Figures 55A, 55B and 56A to 56D, the resealable-packaging assembly 10 may include a closure assembly 339 which may include a lid element 340 similar (or identical) to the hinged mode of the lid element previously disclosed 26 with the exception that the lid element 340 is completely removable from the container 12. That is, the lid element 340 is movable between a first position (Figure 55A) in which the lid element 340 releasably engages a first portion of container 12 surrounding opening 20, and a second position (Figure 55B) in which the cap element is not in contact with container 12, thereby allowing a user to access the interior volume through the opening. The opening 20 may have any suitable shape or combination of shapes, such as a rectangular, oval, oblong, round and/or polygonal shape.
[0173] With reference to Figures 54A to 54C, 55A, 55B and 56A to 56D, the cap element 340 may have any suitable shape or combination of shapes, such as square, oval, oblong and/or polygonal, for example. More specifically, the cap element 340 may be rectangular. The cap element 340 may be defined by a first side edge 341 and a second side edge 432 parallel or substantially parallel to the first side edge 341. Alternatively, the first side edge 341 and the second side edge 432 may each have any. proper guidance. A first end edge 343 may extend between a first end of the first side edge 341 and a first end of the second side edge 432. A second end edge 344 may extend between a second end of the first side edge 341 and a second end of second side edge 432. First end edge 343 may be parallel or substantially parallel to second end edge 344, but first end edge 343 and second end edge 344 may have any suitable orientation. Each of the edges 341-344 can be linear or can be curved, partially curved, contoured, partially contoured, scalloped and/or partially scalloped, for example.
[0174] The cap element 340 of the closure assembly 339 may include the second engagement feature 38 adapted to engage the first engagement feature 36 disposed on the container 12 to releasably secure the cap element 26 to the container 12 when the cap element 339 is in the first position 30 illustrated in Figure 55A, and the second engagement feature 38 may be formed integrally with or with the cap element 340. The second engagement feature 38 may be any element or combination of elements that engages a first feature of mating engagement 36 to allow the lid member 340 to sealably engage the container 12. For example, the second engagement feature 38 may be a channel 42 adapted to receive the rib 40 formed in the top wall 16a of the container 12, as described. previously. In a further example, the first engagement feature 36 may be a channel 42 which can extend vertically downwards from the top wall 16a of the container 12 and the second engagement feature 38 may be the rib 40 which may extend vertically downwards. from cap member 340 of closure assembly 339. At first position 30, rib 40 may be received in channel 42 to allow cap member 340 to sealably engage container 12.
[0175] The second engagement feature 38 may include a first portion 38a, a second portion 38b, a third portion 38c and a fourth portion 38d, and the first portion 38a, the second portion 38b, the third portion 38c and the fourth portion 38d may be in alignment with a first portion 36a, a second portion 36b, a third portion 36c, and a fourth portion 36d of the first engaging feature 36, respectively, when the cap element 339 is in the first position 30 illustrated in Figure 55A. Each of the first portion 38a, the second portion 38b, the third portion 38c and the fourth portion 38d may be internally (and optionally equidistant) from the first side edge 341, the second side edge 342, the first end edge 343 and of the second end edge 344, respectively. Each of the first portion 38a and the second portion 38b may be elongated and may have a longitudinal axis parallel to the first side edge 341. Alternatively, each of the first portion 38a and the second portion 38b may be elongated and may have a longitudinal axis that is curved or arcuate (or internally curved or arcuate) relative to the first side edge 341. Each of the third portion 38c and the fourth portion 38d may be elongated and may have a longitudinal axis parallel to the first end edge 343. Alternatively, each one of the third portion 38c and the fourth portion 38d may be elongated and may have a longitudinal axis that is curved or arcuate (or inwardly curved or arcuate) relative to the first end edge 343. Each of the corresponding first portion 36a, second portion 36b, third portion 36c and fourth portion 36d of the first engaging feature 36 may be similarly formed on the container 12. Each of the first portion The 38a, the second portion 38b, the third portion 38c and the fourth portion 38d of the second engagement feature 38 can form a single, uninterrupted, continuous feature that completely surrounds the opening 20. Alternatively, one or more gaps or interruptions can be arranged at or between the first portion 38a, the second portion 38b, the third portion 38c and the fourth portion 38d of the second engagement feature 38.
[0176] The reclosable packaging assembly 10 may also include a pour spout feature 345, as illustrated in Figure 54C. The pour spout feature 345 may include any feature or combination of features that allows easier pouring or dispensing of materials stored in the interior volume of the container 12. For example, the pour spout feature 345 may be a contoured edge 346 defining partially opening 20 formed in container 12 or partially defining an edge of a removable cutout through cap element 340. In addition, pour spout feature 345 may comprise or partially comprise a vertical projection in contact with or adjacent to opening 20 and the vertical projection may be an upwardly extending rib or lip extending from the top wall 16a of the container. The vertical projection can be a thermoformed feature that can be formed when the features of the closure assembly 22 are formed. Alternatively, the vertical projection can be formed before or after forming the features of the closure assembly 22. Releasable Flexible Container
[0177] In various embodiments, the package can be provided with a resealable opening as opposed to a closing assembly. Any of the features described above including, for example, the projections 219a, 291B, a hinge, pull tabs, etc., can be used on packages in accordance with embodiments of the disclosure having a resealable opening.
[0178] With reference to Figures 72 and 73, in one embodiment, the package can be provided with only the first sheet 614 and the second sheet 616 arranged on the first sheet 614, such that the second sheet 616 defines at least a portion of the outer surface of the package on at least one panel of the package. The second sheet 616 may be disposed in the opening panel region 620 of the pack and may extend over at least three walls, each of the three walls being adjacent to one of the other walls on which the second sheet is disposed. Second sheet 616 may be disposed over all or only a portion of any one of the at least three walls. An opening 20 can be defined on the first sheet 614 and a resealable tab 623 can be defined on the second sheet 616 in the opening panel region 620 to cover the opening. The resealable tab 623 is movable between a closed position, in which the tab 623 is releasably secured to the first sheet and covers the opening, and an open position, in which the tab 623 is disposed away from the opening and the opening is accessible. The opening panel region 620 may be any of the walls defining the package including, for example, the top wall, as illustrated in Figure 72, the front or rear wall, or both the top wall and one or both of the front wall or later. In some embodiments, as illustrated in Figure 73b, opening 20 may extend from opening panel region 620 to one or more side walls or panels 624 of the package. Figure 73b illustrates an embodiment in which opening panel 20 extends through opening panel region 620 and into a side panel 624 with pull tab 617 being located in side panel 624. Aperture 20 in this embodiment is provided both in the opening panel region 620 and in the side panel 624 and the resealable tab 623 provided by the second sheet 616 is sized to extend through the opening 20 in both the opening panel region 620 and the side panel region 624. The second sheet 616 may be scored, cut or otherwise perforated to provide the resealable flap portion 623 which is adapted to resealably seal to the first sheet 614 in the opening panel region 620 to resealably close the package.
[0179] The second sheet 616 is attached to the first sheet 614 in the regions of the first sheet that it contacts. In various embodiments, the second sheet may be attached to the portion of the film defining the opening and the portion of the first sheet may separate from the first sheet and remain attached to the second sheet during the first opening of the package. Alternatively, the first sheet may have a removed portion defining the opening and the second sheet may be disposed over the opening (in which the first sheet portion has been removed). The second sheet can be attached to the first sheet using any known adhesives. For example, portions of the second sheet may be permanently attached to the first sheet with only the portion of the second sheet defining the resealable tab being resealably attached to the first sheet. In other embodiments, the second sheet may be secured to the first sheet entirely with resealable adhesive. Any known methods of attaching film sheets can be used.
[0180] Referring to Fig. 72, opening panel region 620 may have first and second edges 626a, 626b that are configured to define first and second edges of the package opening panel. The second sheet 618 may overlap one or both of the first and second boundaries 626a, 626b and extend across the boundary and be secured to the first sheet on opposite sides of the boundary along one or more walls of the pack. For example, the second sheet 614 may extend substantially over an entire length and width of opposing walls 624c, 624d of the pack. In alternative embodiments, the second sheet 616 may be provided to partially extend over one or more walls 624 of the container. The second sheet may also be provided to extend along one or more side edges of the pack, which can enhance the strength and rigidity of the pack. In one embodiment, the second sheet is provided along each of the four edges defining opening panel 620, as well as along the four side edges of the package. When combined with lines of reduced strength of the second sheet (described below) such an arrangement can allow the film to essentially self-assemble in a box in a box-like arrangement. Lines of reduced strength may include perforations and/or score lines.
[0181] Without intending to be bound by theory, the one or more lines of reduced strength in the second sheet 616 in various regions of the second sheet at the boundaries of the panels and walls, corresponding to the edges and corners of the package, are believed to reduce the flexural strength of the second sheet such that the second sheet will force the first sheet into a folded orientation in which the edges and corners (corresponding to the location perforation) preferably form and are maintained in the folded orientation with minimal application of a bending force. That is, the opening panel edges and the side edges of the pack may preferably be formed from the flat sheet material based on the incorporation of the perforated second sheet material along these regions. This can advantageously provide a package having sharp edges as well as improved crush resistance when a load is applied against one of the walls and particularly in the opening panel region.
[0182] Referring to Figure 90, in various embodiments, the second sheet 616 can extend over a top panel and to a fold formed in the side wall of the package. Figure 91 illustrates a package defined by the film layout illustrated in Figure 90. Figure 92 illustrates an embodiment of the package in which the opening and resealable tab are provided on the front panel. In the embodiments of Figures 91 and 92, the second sheet is shown as extending over the entirety of the top wall, front wall and rear walls. It should be understood that the second sheet can be disposed over only portions of any of the respective walls. For ease of reference, reference numerals of Figures 91 and 92 generally refer to portions of the second sheet, as described below. The packages include opposing sidewalls 668 and each sidewall includes a seal 667 (shown in Figure 93, for example) disposed along the sidewall.
[0183] The folds are formed by folding portions of the first sheet inwards towards the inner volume of the container, such that the folding portions of the first sheet are arranged below the seal. The second sheet may include a fold portion 650 that extends into the folds. As shown in Figure 90, the fold portion 650 may extend from an adjacent portion of the second sheet which extends over an adjacent wall. In the embodiment shown in Figure 90, the fold portion extends from an upper wall portion of the second sheet and the upper wall portion includes the resealable tab 623 defined therein. It is contemplated, however, that the opening 620 and the corresponding resealable flap may be arranged on a different wall of the pack, for example the front or rear wall, or may be arranged along multiple walls of the pack. The fold portion 650 extends from the top wall portion 652, with the boundary between the fold portion and the top wall portion being the edge between the container side wall and the container top wall. The second sheet includes one or more lines of reduced strength at or adjacent to the boundaries between the fold portion and the upper wall portion of the second sheet. Figure 90 illustrates a single line of reduced strength 653 at each of the boundaries between the top wall portion 652 and the bend portions 650.
[0184] Figure 72 similarly illustrates an embodiment in which the container includes at least one fold and the second sheet includes at least one fold portion 636 that is adjacent a boundary of the opening panel region and/or a boundary 638 of at least one wall region 624c. The fold fold region is set to fold inward to define a wall or panel edge of the package. The flexible film may include a portion of the second sheet (e.g. detached from other portions of the second sheet) 634 secured to the first sheet at the fold fold region 636. As described above, the fold fold region portion of the second sheet may include a reduced strength line 639 in the boundary region 638 to facilitate bending of the flexible film at bend bending. The fold folding region of the second sheet can provide improved rigidity for the edge of the package at the fold fold, which in turn can provide improved rigidity for the panel or wall of the package adjacent to the fold fold. In some embodiments, the second sheet may be provided as a single continuous sheet extending through the opening panel region and the fold fold regions. For example, the flexible material can be folded into the package such that fold folding regions are provided at the boundaries of the opening panel region. For example, the reduced strength line 653 adjacent to the bend portion may include perforations and/or score lines. As used herein, score lines refer to one or more continuous or non-continuous lines (linear or non-linear) that penetrate through a defined portion of the thickness expressed herein as a percentage penetration through the thickness. In the fold region, the perforations can include apertures cut from about 50% to about 100% or score lines having about 50% to 100% penetration through the thickness of the second sheet to facilitate folding of the fold portion and provide a well-defined edge. As used herein, "cut open percentage" refers to the percentage of the perforated line that is cut. Perforations include cuts and bridges between adjacent cuts, a cut opening percentage of 50%, for example, refers to a perforation having cuts and bridges of equal length, so 50% of the perforation length is cuts and 50% of the perforation length of perforation are bridges. An 80% cut gap, for example, refers to perforations having cuts that are longer in length than bridges, such that 80% of the total perforation length is cuts and 20% of the total perforation length is bridges . Other suitable percentages of cut openings from perforations or percentage penetration of score lines for lines of reduced strength 653 adjacent to bends include about 50% to about 99%, about 60% to about 95%, about 55% at about 80%, about 70% to about 99%, about 75% to about 90%. The cut opening percentage can be, for example, about 50, 52, 54, 56, 58, 60, 62, 64, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86 , 88, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99 and 100%. The percentage of perforation or reduction in thickness of the reduced strength line having perforations and/or score lines may depend on the thickness of the second sheet. For second sheets having a high thickness, for example, above 10 mils, a high degree of stress reduction in the strength line may be required to allow preferential folding of the first and second sheets at the folds.
[0185] As noted above, the line(s) of reduced strength(s) facilitates the folding of the first and second sheets during the folding operation and advantageously provides a sharp edge to the top wall in the folded portion. Without the inclusion of a reduced strength line, forming the folds can be difficult, if not impossible, depending on the total thickness of the first and second sheets. Furthermore, although with relatively thin materials such folding can be performed, there are often defects such as dents in the folded regions because the flexible material resists folding. It has been advantageously determined that the inclusion of the reduced strength line in the second sheet, at the boundary between the fold portion and the upper wall portion, induces the first sheet to form an edge preferentially along the reduced strength line to form a good edge. set . As described in detail below, it has been unexpectedly confirmed that selective placement of reduced strength lines at various boundaries of the pack, including the boundary adjacent to the fold portion, as described above, can allow the first sheet to fold preferentially into the configuration of desired package, including to form a contoured package without the need to change the package forming equipment. This is advantageous as it avoids the need for costly modification of packaging equipment, such as sealing bars, and downtime associated with adjusting the packaging equipment for each flexible package configuration.
[0186] Referring to Figure 72, in any of the embodiments in which the second sheet 416 overlaps a boundary or edge of the container, the second sheet 616 may further include a reduced resistance line 430a, 430b or perforation in the portion of the second sheet 416 that overlaps with the boundary or edge. The line of reduced resistance 630a, 630b can be defined by one or more paths or lines of reduced resistance, for example two paths of reduced resistance disposed on opposite sides of the boundary or edge. As described above, extending the second sheet to overlap one or more boundaries and even extend across the boundary can beneficially reinforce a corner or edge of the package when formed. The reduced strength line facilitates the folding of the first and second sheets attached to the edge region and can aid in defining a sharp or curved edge of the package that has improved stiffness. This can also help define the shape of the package, and in some embodiments it can help the film to preferentially form into the shape of the defined package assembly during processing.
[0187] As illustrated in Figures 72 and 73, the extension of the second sheet to overlap with the boundary of a region can be provided in any of the film regions, including the opening panel region and one or more wall regions . Figures 72 and 73 illustrate an embodiment in which the second sheet is secured to the first sheet in the opening panel region and two adjacent wall regions. In this embodiment, the second sheet overlaps and extends beyond the boundaries 626a, 626b, 628a, 628b of the opening panel region and the wall regions. In the embodiment illustrated in Figures 72 and 73, the second sheet further extends around the edges of the container, partially extending to the side walls of the package. The second sheet is configured so as not to extend and interfere with the lead and trail seals.
[0188] The second sheet may overlap substantially along the entire length of the boundaries and/or edges. Alternatively, the sheet may overlap with only a portion of the boundaries/edges in one or more of the regions. Furthermore, the second sheet may overlap with both opposing boundaries 626a and 626b and 628a and 628b of the region. If desired, however, the second sheet can only overlap with a boundary.
[0189] Referring to Figure 90, as noted above, the second sheet may also include lines of reduced strength at or adjacent to other boundaries between portions of the second sheet, corresponding to the edges of the container. For example, Figure 90 illustrates an embodiment in which the second sheet includes first and second face portions 654, 656 that extend over at least a portion of the front and rear walls of the container. The first and second face portions 654, 656 extend from the top wall portion 652. The respective boundary between the first and second face portions 654, 656 and the top wall portion 652 may also include one or more lines of resistance. reduced 658 on the second sheet at or adjacent to the boundary. The lines of reduced strength 658 can assist in providing sharply defined side edges on the top wall and similarly other walls of the pack. However, the reduced strength lines 658 reduce the stiffness of the second sheet in the boundary edge region, which can reduce the overall stiffness of the pack when, for example, the pack is gripped by a user on or around the top wall. from which reduced resistance lines are provided. Reducing stiffness is a concern with flexible packaging as the pack may tend to collapse or dent during handling or grip by a user if not rigid enough, which can make the pack difficult to use. It has been advantageously determined that the reduced strength lines 658 may be provided on the second label on the side edges of the top wall or another user gripped side edge controlling the degree of reduction of strength in the reduced strength line. For example, in the handle region, for example, lines of reduced strength 658 illustrated in Figure 90 may include perforations that have about 1 to about 50% of cut openings or score lines that have about 1% to 50% penetration through the thickness of the second sheet to facilitate folding of the fold portion and provide a sharp edge. Other suitable cut aperture percentages and/or penetration percentages include about 5% to about 50%, about 10% to about 45%, about 15% to about 40%, about 20% to about 30%, about 20% to about 50% and about 10% to about 50%. The cut opening percentages and/or can be, for example, about 1, 2, 3, 4, 5, 6, 7, 9, 10, 12, 14, 16, 18, 20, 22, 24, 26 , 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50%. The percentage of cut openings and/or the penetration percentages will vary depending on the thickness of the second sheet. For example, if the second sheet is thick, for example having a thickness greater than 10 mils, then the high percentages of cut opening or marking can be used to facilitate folding of the relatively thick sheet, which by virtue of its thickness will maintain enough rigidity to resist denting or collapsing when the package is gripped. Thinner second sheets, for example, second sheets having a thickness of less than about 10 mils may require low percentages of cut opening or marking to maintain sufficient strength of the pack in the grip region.
[0190] In accordance with embodiments of the disclosure, the first lines of reduced strength 653 disposed at the boundary between bend portions 650 and an adjacent wall portion (e.g., an upper wall portion 650) may have a cut-off percentage or percentage of score line penetration that is greater than the cut opening percentage or score line penetration percentage of a second reduced strength line disposed in a handle region, e.g., reduced strength lines 658 disposed between the portion of top wall 650 and the front and rear wall portions 654, 656. When perforating or selectively marking, as described above, a pack may be provided in which the first sheet defining the walls of the pack preferably folds into the pack configuration, whilst maintaining Sufficient strength in various regions of the package that can be gripped by a user during handling.
[0191] Still referring to Figure 90, the second sheet may include side wall portions 660 that extend to respective side walls of the container and extend from the first and second face portions 654, 656 of the second sheet. The side wall portions 660 may be dimensioned so as not to extend into a region of the first sheet that is sealed to form seals disposed in the side walls. In some embodiments, one or more of the sidewall portions 660 may extend into a seal, but not into the seal. In such embodiments, the seal can be folded over and sealed to one of the sidewall portions. One or more of the sidewall portions may alternatively terminate in an edge which is spaced apart from the seal, such that the seal may be sealed to a portion of the first sheet defining the sidewall. In still other embodiments, one or both of the seals may remain extending outwardly from the sidewall. In such embodiments one or both of the seals may include, for example, an opening defined in a portion of the seal so that the seal can act as a handle and a user can grip through the opening.
[0192] The second sheet may be configured such that the endpoints of the sidewall portions 662 and the fold portion 664 lie along the same line. Such second sheet configuration can facilitate the application of the second sheet to the first sheet and ensure that the coincidence of the second sheet and the first sheet is maintained during the package folding process.
[0193] The second sheet may include one or more lines of reduced strength 666 disposed at or adjacent to the boundary between the side wall portions and the adjacent face portions, which corresponds to the edges of the container between the front and/or rear wall and one of the side walls. The line of reduced resistance can include perforations having any suitable percentage of cut openings and/or score lines having any suitable percentage penetration. For example, if one or more of the lines of reduced resistance are provided in a handle region of the container, there may be advantages to having a lower percentage of cut openings or percentage penetration, as described above.
[0194] In one embodiment, the reduced strength line 666 at or adjacent to the boundary between the sidewall portions and the face portions includes perforations having a percentage of cut openings and/or score lines having a percentage penetration that is equal to that of the reduced strength line 658 between the top wall portion and the face portions. In another embodiment, the reduced strength line 666 at or adjacent to the boundary between the side wall portions and the face portions includes perforations having a percentage of cut openings and/or score lines having a percentage penetration that is equal to that of the line of reduced resistance 653 at or adjacent to the boundary of the bend portion. In yet another embodiment, the reduced strength line 666 at or adjacent to the boundary between the sidewall portions and the face portions includes perforations having a percentage of cut openings and/or score lines having a percentage penetration that is greater than than that of the reduced strength line 658 between the top wall portion and the face portions, but less than that of the reduced strength line 653 at or adjacent to the boundary of the bend portion.
[0195] As with the reduced strength lines described above, the percentage of cuts and/or penetration may vary depending on material thickness.
[0196] It has been found advantageous that by selectively perforating or marking the second sheet in a controlled manner, a package can be provided in which the first sheet defining the plurality of package walls can be induced by the second sheet and the controlled perforations to preferentially fold for package configuration. Furthermore, controlled perforation or marking, as described above, in the various regions of the second sheet can allow such preferential folding while maintaining rigidity and even improving container rigidity for greater durability, stability and ease of use.
[0197] As discussed above, it has been unexpectedly confirmed that controlled application of non-linear lines of reduced strength in selected regions of the second sheet can circumvent the shape of the pack, without the need for specialized pack forming equipment to check the shape of the contour. .
[0198] Figure 93 illustrates an embodiment of a package with contour. Figure 94 illustrates the film layer of the first and second sheets corresponding to the contoured pack of Figure 93. As illustrated in Figures 93 and 94, the reduced strength line formed in the second sheet between the boundary between the sidewall and portions of the face portions are curved. The curvature of the reduced strength line 666 in these regions will induce the first sheet to preferably form package edges having a substantially similar curvature. The curvature of the side walls 668 can also be controlled using the second sheet. For example, as illustrated in Figure 93, sidewalls 667 curve inward. This curvature can be achieved, for example, by forming the sidewall portions 660 of the second sheet to have an end edge 670 which has a curvature corresponding to the curvature of the reduced strength line 666. In the embodiment of Figures 93 and 94, the second sheet is provided with two opposing side portions 660 extending from adjacent ends of the first face portion 654 (disposed on the front panel). Each side portion 660 terminates in a curved edge 670. The curvature of curved edge 670 may be similar or the same as, for example, the curvature of lines of reduced strength 666. The second face portion 656 that is disposed on the back wall includes edges opposing terminals 672 having a curvature that is the same as the curvature of the lines of reduced resistance 666 and corresponds with the location of the lines of reduced resistance 666. Alternatively, the second face portion 656 may include lateral portions extending therefrom. , as with the first face portion, and lines of reduced strength having a curvature may be provided on the second sheet at the boundary between the second face portion and the side portions, as with the first face portion. The embodiment of Figures 93 and 94 also does not include a bending portion. However, such portions may optionally be included in this or any of the described embodiments.
[0199] Figure 94 also illustrates an embodiment in which the bottom panel 674 includes an optional reinforcing sheet 676. The reinforcing sheet 676 may be similar to the second sheet and optionally can be attached or detached (as shown in the figure) of the second sheet. The reinforcing sheet can be disposed on either the outside of the first sheet or the inside of the first sheet. The reinforcing sheet may optionally have dimensions to reside in the bottom wall region only. Additionally, a third sheet can be provided on the inside or outside of the first sheet, as described above, to further provide reinforcement. The third sheet, when provided in a region corresponding to the second sheet, may be perforated or similarly marked for preferential folding of the first sheet.
[0200] Figures 95 and 96 (film layout package, respectively) illustrate another modality of a contoured package. In the embodiment of Figures 95 and 96, lines of reduced resistance 666, 678 are provided as mirror images around the boundary between the sidewall portions and the face portions, with a reduced line of resistance extending into the portion of face and a line of reduced resistance extending to the sidewall portion. As illustrated in Figure 95, the reduced strength mirror image lines provide a contoured package having sidewall shapes that are different from those illustrated in Figure 93, thus illustrating the controlled and selective punching capability of marking the section sheet in the control of the contour of the package. In the embodiment of Figure 95, the side walls include two angled portions and a flat portion raised above the angled portions, the flap portion having the seal.
[0201] Figures 97 and 98 illustrate other configurations of film layouts to achieve preferential folding of a first sheet in a contoured package configuration.
[0202] Other configurations and contours are contemplated and can be achieved by modifying the curvature of the reduced resistance line at the boundary between the sidewall portions and the face portions, the shape of the terminal edge of the sidewall portion and/or lines secondary low strength including in the sidewall portion. Additionally, one or more of the regions described as having lines of reduced strength could also alternatively be mechanically folded prior to folding the first sheet into the bundle configuration.
[0203] The characteristics described above, including the percentage of cuts or penetration of the various lines of reduced resistance that can be included in the second sheet, are applicable to packages with contours, as well.
[0204] Any of the above package configurations may include a pull tab 617. The pull tab may extend above or along an adjacent edge of the container for easy grip. In some embodiments, it may be advantageous to space the pull tab a distance away from an edge of the container, for example, at least about 0.03 inch to about 0.1 inch, about 0.05 inch to about 0.8 inch, about 0.4 to about 0.6, and about 0.02 to about 0.9 inch from the edge of the container. Other spacings include, for example, about 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, and 0.1 inch. This spacing may be advantageous if the pull tab extends adjacent to a line of reduced strength on the second sheet. This spacing can help maintain edge resistance by having the line of resistance reduced. Extension of the pull-up tab or across the reduced resistance line, however, is also contemplated.
[0205] In any of the above embodiments, the second sheet may include openings or otherwise be sized such that the second sheet does not extend through one or more corners of the package. For example, Figure 90 illustrates a film layout in which corner reliefs 678 are provided at each of the four corners of the top panel. Corner reliefs 678 may be provided on any number of corners of the package. Corner reliefs 678 are arranged such that the second sheet 616 is disposed around and not above the one or more corners. Although corners can be formed with the second sheet 616 being disposed in the corner regions, such corners can be sharp and unpleasant to the user when picking up the container.
[0206] In one embodiment, the opening is arranged in the front or rear wall and arranged such that the pull tab extending from the resealable tab extends toward a lower panel of the package. The bottom panel may optionally include a corner seal 677, for example, as illustrated in Figure 95. In such embodiments, extending the pull tab toward the corner seal 676 may allow a user to grasp the corner seal. 676 and pull tab 617 when opening the package to provide better grip of the package when opening the package. Flexible Materials to Form Flexible Containers
[0207] A flexible material 400 to form a flexible package 400 includes an opening panel region 420 that is configured to define a package panel having an opening to access the interior volume of the package (herein also referred to as an opening panel) . For ease of reference, Figures 30a-c and 50-51 illustrate features formed 422 in the region of opening panel 420 that correspond to the closing assembly. It should be understood that the formed feature need not be included in flexible material 400 and may be formed during pack formation as described herein. Flexible material 400 may further include one or more wall regions 424 that are configured to define one or more walls of the flexible package including, for example, one or more side walls and/or a bottom wall.
[0208] The flexible material can be provided as a web of material capable of forming a plurality of packages which can be wound on a roll of flexible material. The flexible material may include a plurality of opening panel regions and, optionally, a plurality of wall regions discretely spaced along a longitudinal direction of the flexible material, wherein the plurality of opening panel regions and the plurality of regions of walls comprise the first sheet. That is, the first sheet may be a common sheet material extending between each of the plurality of regions configured to be folded or formed into the plurality of packages. The flexible material may further include a plurality of second sheets and/or third sheets in the opening panel regions and wall regions as described below.
[0209] The flexible material includes a first sheet 414 which as described above is configured to be formed in the opening panel and provide an opening and/or can be configured to be formed in further walls of the first sheet 414. opening 420 and one or more wall regions 424 comprise first sheet 414. Flexible material 400 may further include a second sheet 416 that is secured to first sheet 414 in opening panel region 420. In various embodiments, the second sheet or at least a portion of it is thermoformable.
[0210] As used herein, the term "attached" refers to the joining of one layer or sheet to another layer or sheet and may include intermediate layers or adhesives. Layers or sheets can be joined using any known methods, including adhesive, heat sealing, ultrasonic sealing, welding, crimping and combinations thereof. It is to be understood herein that, unless otherwise specified, the sheets or layers may be affixed in whole or in part to another sheet or layer. Layers or sheets can be permanently attached or releasably attached. As used herein, the term "permanently attached" refers to a connection between two adjacent layers or sheets that requires at least partial destruction of one or both layers or sheets to separate the layers or sheets in the connection. As used herein, the term "releasably attached" refers to a connection between two adjacent layers or sheets so that the layers or sheets can be separated substantially without destruction. In some embodiments, two sheets can be releasably attached, which means that the layers of sheets can be separated and then re-attached without applying an adhesive or additional sealing.
[0211] The flexible material may further include a third sheet 418, secured to the first sheet 414 at least in the region of opening panel 420. In one embodiment, the third sheet 418 is secured to the first sheet 414 and the second sheet 416 is secured to the third sheet 418. In another embodiment, first sheet 414 is disposed between second and third sheets 416, 418. As described in detail below, third sheet 418 may additionally or alternatively be secured to first sheet 414 in one or more regions. 424 of the flexible sheet 400. The third sheet 418 may partially or completely overlap with the first sheet in the opening panel region 420 and/or the one or more wall regions. For example, Figure 50 illustrates an embodiment in which the third sheet 418 completely overlaps the first sheet in the opening panel region 420 and two adjacent wall regions 424a, 424b. Figure 51 illustrates an embodiment in which the third sheet 418 only partially overlaps the first sheet 414 at two adjacent wall regions 424a, 424b.
[0212] Referring to Figure 30b, which illustrates an opening panel region of the flexible material, the flexible material may include a reduced resistance line or path 440 on the first sheet 414 of the opening panel region 420 that is configured to define opening the package. In embodiments in which flexible material 400 further includes a third sheet 418, a line or path of reduced strength may be provided on the third sheet to define the opening through the first and third sheets 414, 418. As used herein, the terms "line of reduced resistance" and "path of reduced resistance" are used interchangeably and may be straight, curved, or any suitable shape. A reduced strength line or path can be formed in a flexible material or sheet using any known method including, for example, laser marking, mechanical marking or a similar process to form perforations. Perforations can either perforate the sheet or be provided without perforating the sheet, if desired.
[0213] The flexible material may further include a reduced strength line or path 442 or a continuous cut defining the second sheet 416 in the opening panel region 420 which is configured to define a hinge 442 around which a cover 26 of a 22 package closure assembly can articulate. Additional cuts or reduced strength lines or paths 444a, 444b may be provided on the second sheet 416, if desired, to define first and second protrusions 219a, 219b of the closure assembly, as described in detail below. The cuts or paths or lines of reduced strength for the hinge (442) and the protrusions 219a, 219b may be provided on the second sheet such that they do not overlap each other or with a reduced strength line or path 440 defining the opening. of the package. This can help ensure the pack remains airtight before first use.
[0214] In various embodiments, as illustrated in Figures 50 and 51, the third sheet 418 may be a single sheet that extends through one or more regions of the flexible material, for example, the opening panel region 420 and one or more wall regions 424. In other embodiments, the third sheet 418 may be provided as separate sheets overlapping with the first sheet 414 in one or more regions of the flexible material. The third sheet may be between the boundaries of a region 426a, 426b, 428a, 428b, as illustrated in Figures 50, 51. Alternatively, the third sheet 418 may extend only partially on one face of a region and/or it may be provided as separate sheets that overlap with boundaries but are not contiguous. Figure 50 illustrates a third sheet portion 434 that extends only partially across the face of the region. As described in detail below, the third sheet portion 434 may, in some embodiments, be selectively placed at a boundary in a fold-fold region of the flexible material. In such embodiments, the third sheet portion 434 is also referred to herein as a fourth sheet 434. It is to be understood herein that, in such embodiments, the fourth sheet may be of the same or a different material as the third sheet.
[0215] Referring to Figures 50 and 51, in some embodiments, the flexible material may include first 414, second 416 and third 418 sheets in the opening panel region 420. The opening panel region 420 may have first and second boundaries 426a, 426b which are configured to define first and second edges of the package opening panel. The third sheet 418 may overlap with one or both of the first and second boundaries 426a, 426b and optionally extend across the boundary and be secured to the first sheet 414 on opposite sides of the boundary. The third sheet 418 may further include a reduced strength line 430a, 430b on the portion of the third sheet 418 that overlaps the boundary 426a, 426b. As shown in Figure 50, the line of reduced resistance 430a, 430b can be defined by one or more paths or lines of reduced resistance, for example two paths of reduced resistance disposed on opposite sides of the boundary. Extending the third sheet 418 to overlap one or more boundaries and even extend across the boundary can beneficially reinforce a corner or an edge of the package when formed. The reduced strength line facilitates the folding of the first and second sheets 414, 416 affixed to the edge region and can aid in defining a sharp or curved edge of the package that has improved stiffness. As described in detail below, this can also help define the shape of the package, and in some embodiments it can help the film to preferentially form into the shape of the defined package assembly during processing. As illustrated in Figure 50, the extension of the third sheet 418 to overlap a region boundary may be provided in any of the film regions, including the opening panel region and one or more wall regions. Figure 50 illustrates an embodiment in which the third sheet 418 is secured to the first sheet 414 in the opening panel region 420 and two adjacent wall regions 424a, 424b. In this embodiment, the third sheet overlaps and extends beyond the boundaries 426a, 426b, 428a, 428b of the opening panel region and the wall regions. In the embodiment of Figure 50, the third sheet 418 overlaps substantially along the entire length of the boundaries. As illustrated in Figure 51, the third sheet 418 may overlap with only a portion of the boundaries in one or more of the regions. Additionally, the third sheet may overlap with both opposing boundaries 426a and 426b and 428a and 428b of the region. If desired, however, the third sheet can only overlap with a boundary.
[0216] In some embodiments, for example, for flexible materials for quad sealing packages as described in US Patent Application Publication 2012/0312868, the flexible film may include at least one fold region 436 that is adjacent a boundary of the opening panel region and/or a boundary 438 of at least one wall region 424c (as illustrated in Figure 50). The fold fold region is set to fold inward to define a wall or panel edge of the package. The flexible film may include a fourth sheet 434 secured to the first sheet in the fold folding region 436. As described above with the third sheet, the fourth sheet may include a reduced strength line 439 in the boundary region 438 to facilitate the folding of the Flexible film for pleat folding. The fourth sheet 434 can provide improved rigidity for the edge of the pack at the pleat fold, which in turn may provide improved rigidity for the panel or wall of the pack adjacent to the pleat fold. In some embodiments, as noted above, third sheet 418 may function as fourth sheet 434 and be disposed in the pleat fold region. For example, the flexible material can be folded into the package such that fold folding regions are provided at the boundaries of the opening panel region. Extending the third sheet 418 over the boundary as illustrated in Figure 50 may result in the third sheet 418 extending to and supporting the pleat fold, as described in relation to the fourth sheet 434.
[0217] The film may include any suitable print and/or graphics. For example, the entirety or portions of the film can be colored. Referring to Figure 31, in one embodiment, the film may be colored so that a portion of the film remains transparent or translucent to provide a window for viewing the product contained therein. The graphic layout for patterning and/or coloring the film can be adapted based on the package configuration and graphics to be displayed in the package. In embodiments in which a closure assembly is formed on the cap, the graphic layout illustrated in Figure 47 can be used when the cap forming process is performed on the forming tube side. In other embodiments in which a closure assembly is formed on the cap, the graphic layout illustrated in Figure 48 can be used when the cap forming process is performed in front of the forming tube. The cap forming process can be carried out on either side of the forming tube. For example, in one embodiment multiple sides of the forming tube can be used in the cap forming process to provide alternative formation of caps in the forming die to increase the rate per pack of the forming process. The First Sheet
[0218] The first sheet 414 can have any suitable thickness and the thickness can be a uniform thickness or can vary. In various embodiments, the first sheet 414 has a nominal thickness of about 1 mil to about 10 mils, about 3 mils to about 9 mils, about 4 mils to about 8 mils, about 5 mils to about 7 mils, about 2 mils and about 6 mils. Other suitable nominal thicknesses include, for example, about 1, 2, 3, 4, 5, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5 .8, 5.9, 6, 7, 8, 9, and 10 mils. As used herein, the term "nominal thickness" refers to the thickness of a film or sheet material, not including ink or adhesive layers.
[0219] Examples of materials suitable for use as the first sheet 414 include, but are not limited to, a 150 ga cast polypropylene laminate, 120 ga polylactic acid and 2.875 mils coex including ethylene vinyl alcohol (EVOH) (12321,302) W), a laminate of 150 ga cast polypropylene, 76 ga formable polyethylene terephthalate (PET) and 3.5 mil high clarity polyethylene, a 140 ga biaxially oriented polypropylene laminate, 92 ga PET, and high polyethylene 3.5 mil clarity. The laminate layers can be adhered together using any suitable adhesives. The thicknesses mentioned in this paragraph are nominal thicknesses of the laminate layers. Inks desired to color or apply graphics to the film can be applied between the laminate layers or can be applied to an exposed surface of the film.
[0220] Material can be selected based on the product to be incorporated into it. For example, for savory snack foods, the wrapping film material generally provides one or more of a moisture barrier to keep the food crispy, an oxygen barrier to reduce the rancidity of oils that are often used as ingredients or food aids. baking for the product, and a light barrier to reduce the presence of light in the package, which for some products may cause or increase the rancidity of the product. Figure 69 illustrates a number of exemplary two-layer and three-layer film embodiments suitable for use with various embodiments of the disclosure.
[0221] The first sheet can be polypropylene which can provide good moisture barrier properties. Polypropylene can be metallized to improve moisture barrier properties as well as provide oxygen barrier properties and reduce light transmission. Other exemplary materials include, for example, polyesters such as PET and nylons such as polyamides.
[0222] As described above the first sheet can be a composite or laminated structure. For example, in some embodiments, the first sheet material can include a polyethylene as a bonding or adhesion layer between two layers of polypropylene. Such layers can improve the film's ability to resist tearing or tear propagation. Sealants can also be used in the film. Sealants can be supplied as co-extrusions (ie, as distinct layers within a film), blends (polymer blends in a single layer) and combinations thereof. Suitable sealants include linear low density polyethylene, ultra low density polyethylene, high density polyethylene, metallocene, plastomer, hexene, butene polyethylenes and combinations thereof. Other sealants include copolymers of EVA, SURLYN®(Ionomers) and ethylene methacrylic acid (EMA) and ethylene acrylic acid (EAA).
[0223] Additional coatings or structures can be added to the base material or laminate of the first sheet to improve the desired properties. For example, PVDC (SARAN®) can be coated onto the first sheet material to enhance oxygen barrier properties. Acrylic coating can be applied to the first sheet material to provide the desired surface energies and characteristics to enhance film processing efficiency in a packaging machine. The Second Sheet
[0224] The second sheet can be formed from materials such as polypropylene (PP), ethyl vinyl alcohol, polylactic acid (PLA), polyethylene terephthalate (PET), polyethylene (PE), EVA copolymers, sheet (such as aluminum foil) , paper, polyester (PET), nylon or polyamide (PA) and laminates and composites thereof.
[0225] In various embodiments, the second sheet can be a resealable label. For example, the resealable label may be as described in US Patents 6,113,271, 6,918,532, 7,344,744, 7,681,732 and 8,182,891, the disclosures of which are incorporated herein by reference. For example, the resealable label 20 can be formed by delaminating a web of pressure sensitive film, e.g., biaxially oriented polypropylene (BOPP) having a resealable pressure sensitive adhesive from a release liner. Other suitable materials for the resealable label include, for example, EarthFirst® polylactic acid (PLA), BOPP (e.g. clear or white), polystyrene (PS) and polyethylene terephthalate (PET). Any other known resealable label materials can also be used. The resealable label can also include any known pressure sensitive adhesive including, but not limited to, emulsion acrylic and solvent acrylic. Suitable tags are commercially available as well, such as R5195 and R5423 tags from Avery Dennison and V-312, V-314, V-233 tags from Flexcon.
[0226] The second sheet can have any suitable thickness. For example, the second sheet can have a nominal thickness in the range of about 1 mil to about 30 mils, about 1 mil to about 15 mils, about 2 mils to about 10 mils, about 3 mils to about from 7 thousand, about 4 thousand to about 10 thousand, about 7 thousand to about 12 thousand, about 10 thousand to about 30 thousand, about 1 thousand to about 10 thousand, about 11 thousand to about from 25 thousand or about 1 thousand to about 8 thousand. Other suitable nominal thicknesses include, for example, about 1, 2, 3, 4, 5, 6, 7, 8, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 , 20, 21, 22, 23, 24, 25, 26, 27, 28, 29 and 30 mils. In one embodiment, the second sheet is formed of 10 mil PET (nominally thick). In some embodiments, the second sheet may be adhered to the first sheet such that at least a portion of the second sheet is adhesively resealable to the first sheet. For example, a portion of the second sheet can be secured to the second sheet using a resealable adhesive. In one embodiment, a portion of the second sheet is permanently adhered to the first sheet, such that the second sheet cannot be completely removed from the first sheet. As used herein, the term "permanently adhered" refers to the bond between the sheets that cannot be broken without at least partial destruction of at least one of the sheets.
[0227] In other embodiments, the second sheet is not resealably adhered to the first sheet, but with at least a portion of the second sheet being removable from the first sheet. For example, the second sheet can be adhered to the first sheet such that the second sheet has a peel strength in the range of 500 to 1200 grams/inch when peeled from cast polypropylene film. The cast polypropylene film can have, for example, a surface energy in the range of about 30 dynes/cm to about 50 dynes/cm, about 32 dynes/cm to about 44 dynes/cm, about 32 dynes/cm /cm to about 36 dynes/cm, about 45 dynes/cm to about 50 dynes/cm, about 30 dynes/cm to about 45 dynes/cm and about 40 dynes/cm to about 50 dynes/ cm. Other suitable surface energies include about 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 dynes/cm. The second sheet is selected and adhered to the first sheet such that there is no residual tackiness as the package is opened and at least a portion of the second sheet is pulled away from the first sheet. In some embodiments, portions of the adhesive used to adhere the second sheet to the first sheet can be erased, for example, using a varnish or lacquer, in regions where it is not desirable to include an adhesive. For example, regions of adhesive can be erased to facilitate opening the package and to reduce the strength required to open a package. In some embodiments, the second sheet is adhered to the first sheet using an adhesive and upon peeling the second sheet from the first sheet, there is no transfer of adhesive to the first sheet. In some embodiments, for example embodiments where a wet or wet product will be stored in the package, a moisture resistant adhesive can be used to adhere the first and second sheets. For example, the moisture resistant adhesive can be an unbleached adhesive. As used herein, the term "no whitening adhesive" refers to adhesives that are not aesthetically altered when in contact with water or moisture. As described in detail below, the package may further include a third sheet attached to the first sheet in the opening region. The third sheet can add stability to the region around the opening by increasing the caliper of the pack in that region. In one embodiment, the third sheet is applied to the first sheet on a surface opposite the surface to which the second sheet is applied. In another embodiment, the third sheet is applied to a surface of the first sheet and the second sheet is applied to a surface of the third sheet. The Third Sheet
[0228] The third sheet can be formed from materials such as polypropylene (PP), ethyl vinyl alcohol, polylactic acid (PLA), polyethylene terephthalate (PET), polyethylene (PE), EVA copolymers, sheet (such as aluminum foil) , paper, polyester (PET), nylon (poly amide) and laminates and composites thereof.
[0229] The third sheet can have any suitable thickness. For example, the third sheet may have a thickness in the range of about 1 mil to about 15 mils, about 2 mils to about 10 mils, about 3 mils to about 7 mils, about 4 mils to about 10 mils or about 7 mils to about 12 mils. Other suitable thicknesses include, for example, about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 and 15 mils. In one embodiment, the third sheet is formed from 10 mil PET. In another embodiment, the third sheet is formed from a laminate of PLA and EVOH and has a thickness of 7 mils.
[0230] The third sheet can be affixed to the first sheet using any known permanent adhesion methods such as, for example, heat sealing and application of permanent adhesives.
[0231] Depending on the end use of the product, the film, including the optional first, second, and third sheet and any glues or inks used on it, can be formed from FDA compliant materials. Fixation in Zones
[0232] In various embodiments, the second sheet may be adhered to the first sheet (or in some embodiments a third sheet disposed on the portion of the first sheet defining the outer portion of the package) using zoned adhesion. For example, overprint varnish (erase agent) can be printed over a heat sealable layer, eg a molten polypropylene, at 0% to 100% filtration levels, eg in 10% increments. For example, every 10% or 20% or 30% etc. from the surface until it filters (or covers) 100% of the surface with the erasing agent. A cover film can be sealed to multiple samples. Peel strength can be measured. Samples can be sealed at 300'F, 1.0 second of residence to various OPV coverage areas for the purpose of measuring peel strength. Some exemplary coatings and peel strengths are illustrated below.


[0233] 60% coverage of an etching agent can provide a significant decrease in bond strength. Varying the percentage and zoning of the percent coverage of an erasing agent can allow for variations in peel strengths from more than 100 grams to as little as 80 grams.
[0234] The adhesion between the first and the second sheet can be defined by an adequate number of zones, with each zone having a different level of adhesion. For example, in one embodiment, the second sheet may be adhered to the first sheet using two adhesion zones. The first zone can be defined by the region that is disposed inside the edge of the opening - which is the region in which the portion of the first sheet separates and is designed to remain adhered to the second sheet upon opening the package. The second zone can be defined by the region disposed outside the edge of the opening and to which the second sheet reseals to the first sheet and/or in which the closure assembly provides a mechanical closure between structures formed in the first and second sheets to reseal the package. In various embodiments, the first zone may have greater adhesion than the second zone to facilitate opening the package. In some embodiments, such as embodiments having a mechanical closure, the second zone may be a region of substantially no chemical adhesion between the first and second sheet, instead depending on the mechanical closure. For example, the second zone can be coated with an erasing agent or varnish to reduce or eliminate any adhesive properties of an adhesive that is applied to adhere the second sheet to the first sheet in the first zone. This can eliminate the need to selectively apply adhesive and can ease the manufacturing process. Adhesion by zones can be done with heat sealing techniques, selective application of erasing agents and/or selective application of adhesives. An exemplary erasing agent is Sun Chemical Opt-T-Flex overprint varnish.
[0235] In the embodiments illustrated in Figure 30, adhesion can be provided in three adhesive zones. For example, the first and second sheets are adhered in an area defining a portion of the second sheet that is configured to remain adhered to a portion of the first sheet upon opening the package. The zone may be defined in an overlapping portion provided in a region of the opening within the edge of the opening, in which the second sheet is adhered to a portion of the first sheet surrounding the opening to provide a hermetic seal, despite the perforations that are provided on the first sheet to define the opening. The overlapping portion is dimensioned such that a sufficient seal is provided between the first and second sheets to retain an airtight seal, although the perforations in the first sheet used to define the opening and the second sheet are able to detach from the first. sheet in the overlapping portion upon opening the package for the first time when a portion of the first sheet is peeled off at the perforations or other edge feature defining the opening. This zone can have an adhesion property such that it is less than the adhesion between the first and second sheet in the first zone, to facilitate opening of the package while maintaining an airtight seal. Another zone can be defined in a region disposed outside the edge of the opening. For example, this zone can be defined where thermoformed features are formed on the first and second sheet to define a closure assembly. This zone may have substantially no adhesion between the first and second sheets to further facilitate opening of the package.
[0236] The second sheet can be adhered to the first sheet using an adhesive. A process of zoning the adhesive may include applying an erasing agent to the first sheet in the region where adhesion between the first and second sheet is not desired. An adhesive can then be applied to the entire second sheet and adhered to the first sheet. The erasing agent will eliminate the adhesive properties of the adhesive in the regions to which it is applied, thereby zoning the adhesion without the need to apply the adhesive in a zoned manner. This can simplify the adhesive application process.
[0237] Selective application of the erasing agent or varnish can be performed, for example, during the printing process to print graphics on the package. This can advantageously provide a quick process for defining an erased or reduced adhesive zone with high-throughput printing machines.
[0238] In some embodiments, selective application of an adhesive or different types of adhesives can be achieved using a printing machine, such as for printing illustrations on a film package.
[0239] In various embodiments, the flexible material may include the first second sheet secured to the first sheet in areas of the opening panel region. As described above, the third sheet may be interposed between the first and second sheets in some embodiments. It is contemplated that the zones and relative peel strengths described below with respect to securing the first sheet to the second sheet in the opening panel region apply to the peel strengths associated with the opposite of attaching the second sheet to the third sheet. Peel strength between the first and second sheets 414, 416 in the opening panel region 420 can be defined by a suitable number of zones. Some of the zones may have different peel strengths. As used herein, the term "peel strength" refers to the bond strength of adhesion between two sheets or layers. In modalities in which one sheet or layer is permanently attached to another sheet or layer, the peeling resistance between the layers or sheets is infinite, i.e., greater than the structural strength of the laminate, as the separation of the sheets or layers results in destruction of one or both sheets or layers. In embodiments in which two sheets or layers are arranged on top of each other but not secured together, there is no peel strength, which is described herein as a peel strength of 0 g/in.
[0240] Referring to Figure 30a, for example, in one embodiment, the opening panel may include first and second zones 446, 448. The first zone is adjacent to the second zone and in some embodiments directly adjacent to each other with no intervening zone ( as illustrated in Figure 30a). A first portion of the first sheet is secured to a first portion of the second sheet in the first region and a second portion of the first sheet is secured to a second portion of the second sheet in the second region. The peel strength between the first and second sheets in the first zone is greater than the peel strength between the first and second sheets in the second zone. For example, the peel strength in the second zone can be from about 10% to about 60% of the peel strength of the first zone. A portion of the second zone may be configured to be thermoformed to include closure assembly features or other features formed as described herein. Figures 30a-30c illustrate features formed in a portion of the second sheet to illustrate regions of the second sheet that can be configured to be thermoformed. It should be understood that such features need not be formed included in the flexible material, before packaging and forming can be formed during the shaping/forming of the flexible material within the pack, as described herein.
[0241] The first zone 446 may include at least the portion of the opening panel region configured to define the opening of the package. Referring to Figures 30a-c, opening panel region 420 includes an opening limit which may optionally be defined by reduced resistance line 440. The opening limit is an outer limit of the opening of the package. In various embodiments, the first region 446 corresponds to a portion of the opening panel region in which the first sheet 414 is configured to remain attached to the second sheet 416. For example, when opening a pack formed from the flexible material 400, a portion of the first sheet may detach from a remaining portion of first sheet 414 at the opening boundary and remain attached to second sheet 418 upon opening of the package. In addition, as illustrated in Figure 30a, in some embodiments, the first region 446 may also include an opening panel lid rear region that is configured such that a lid of the closure assembly of a pack remains attached to the rear region of a package. cover.
[0242] As illustrated in Figure 30a, the first zone 446 may include portions of the opening panel region disposed on opposite sides of the opening boundary. Referring to Figure 30b, the first region 446 can be disposed only internally of the opening limit. The first zone can have a peel strength of at least 500 g/in. For example, the peel strength of the first zone can be from about 500 g/in to about 2000 g/in, about 600 g/in to about 1500 g/in, about 1000 g/in to about 2000 g/in. Other suitable peel strengths include about 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, and 2000 g/in. In some embodiments, the first sheet is permanently attached to the second sheet in the first region.
[0243] Referring to Figures 30a-c, the second zone 448 may be directly adjacent to the first zone. Second region 448 generally includes a portion of the opening panel region configured to be thermoformed. For example, the second zone may include a thermoformed portion of the opening panel region configured to have the second engagement feature or thermoformed channel therein. The second zone may have a peel strength of about 0 g/in to about 200 g/in, about 5 g/in to about 175 g/in, about 10 g/in to about 150 g/in. in, about 25 g/in to about 125 g/in, about 50 g/in to about 100 g/in about 75 g/in to about 150 g/in or about 0 g/in to about 2 g/in. Other suitable peel strengths include, for example, 0, about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 125, 150, 175 or 200 g/in.
[0244] Referring to Figure 30a, for example, the first zone 446 may extend to a portion of the second sheet 416 that is configured to be thermoformed (herein referred to as the "thermoformed portion"). As illustrated in Figure 30a, for example, the first region 446 extends to the thermoformed portion of the opening panel region (illustrated in Figure 30a by the inclusion of the formed channel). The second region 418 contains the thermoformed portion and a portion of the opening panel region having the first sheet secured to the second sheet outside the thermoformed portion.
[0245] Referring again to Figure 30b, in some embodiments the second zone 448 can be disposed inside the thermoformed portion up to the opening limit.
[0246] Referring to Figure 30c, in some embodiments, the opening panel region may include a third zone 452 disposed between the first and second zones 446, 448. For example, as illustrated in Figure 30c, the first zone 446 can be limited, in part, by the opening limit, the third zone 452 can be disposed between the opening limit and the second zone 448. The third zone 452 can have a peel strength that is less than the peel strength. tion in the first zone 446. Optionally, the third zone 452 may have a peel strength that is substantially equal to the peel strength in the second region.
[0247] The third zone can have a peel strength of about 0 g/in to about 200 g/in, from about 5 g/in to about 175 g/in, from about 10 g/in to about 150 g/in, from about 25 g/in to about 125 g/in, from about 50 g/in to about 100 g/in from about 75 g/in to about 150 g/in , or from about 0 g/in to about 2 g/in. Other suitable peel strengths include, for example, 0, about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 125, 150, 175 or 200 g/in.
[0248] In various embodiments, the second zone 448 may be disposed only in the thermoformed portion (i.e., the region in which the second engagement feature will be formed. The fourth zone optionally may be provided externally to the second zone thermoformed region 448. A fourth zone 454 may have a peel strength that is less than or greater than the peel strength of the second zone 458, but is less than the peel strength of the first zone 446.
[0249] Figures 30a-c further illustrate an embodiment in which the opening panel region includes a pull tab region. The pull tab region can define a pull tab zone 450. The pull tab zone can have a peel strength from 0 g/in to about 30 g/in, from about 0 g/in to about from 5 g/in, from about 1 g/in to about 10 g/in, from about 3 g/in to about 7 g/in, from about 10 g/in to about 30 g/in , from about 15 g/in to about 20 g/in and about 5 g/in to about 25 g/in. Other suitable values include, for example, about 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29 and 30 g/in. In some embodiments, the second region may include the pull tab region, in other embodiments, the second region may have a different peel strength than the tongue region of 450.
[0250] In various embodiments in which the flexible material is configured to form a package having first and second protrusions 219a, 219b on the closure assembly 22, the portion of the opening panel region in which the first and second protrusions (illustrated in Figures 30a-30c as defined by reduced resistance lines 444a, 444b) are defined can define a protrusion zone. The peel strength of the protrusion zone 443a, 443b can be from about 0 g/sec to about 30 g/in. Having reduced peel strength in the protrusion zone 443a, 443b can help to allow the protrusions 219a, 219b to move freely along the first sheet when pivoting between the first and second positions, as described below.
[0251] In some embodiments, such as embodiments having a mechanical closure, the second zone 448 may be a region of substantially no chemical adhesion between the first and second sheets 414, 416, instead depending on the mechanical closure. For example, second zone 448 can be coated with an erasing agent or varnish to reduce or eliminate any adhesive properties of an adhesive that is applied to secure second sheet 416 to first sheet 414 in first zone 446. This can eliminate the need to selectively apply adhesive and can facilitate the manufacturing process. Adhesion by zones can be done with heat sealing techniques, selective application of erasing agents and/or selective application of adhesives.
[0252] An adhesive zoning process in the opening panel region may include applying adhesive to one or both of the first and second sheets. The process may then include applying an erasing agent to the first or second sheet in the opening panel region in an area where reduced peel strength is desired. For example, an erasing agent can be applied to the second zone and the third zone optionally at a percentage coverage of about 50% to about 100% to achieve the desired peel strength in the second zone. By way of further example, the erasing agent can be applied at 100% coating percentage in the pull tab region to achieve no peeling resistance between the pull tab on the second sheet and the first sheet in the pull tab region. pull. The lightening agent reduces peel strength where applied with the amount of reduction corresponding to the coating percentage of the lightening agent. The use of an etching agent to achieve the desired peel strengths in the various zones can simplify the manufacturing process for a flexible material by avoiding the need for zone adhesive. Erasers can be printed, for example, similarly to printing inks and illustrations on a sheet material, allowing precise control over the location and percentage of erasing agent coating. In alternative embodiments, an adhesive or sealing process can be applied/preformed in a zoned fashion. For example, heat seals can be formed in the first zone to achieve the desired peel strength, although adhesives can be used in the second and third or fourth optional zones to achieve the desired reduced peel strengths. In some embodiments, different adhesive chemistries resulting in different bond strengths can be selectively applied to regions to achieve the desired peel strengths.
[0253] Selective application of the erasing agent or varnish can be performed, for example, during the printing process to print graphics on the package. This can advantageously provide a quick process for defining an erased or reduced adhesive zone with high-throughput printing machines.
[0254] In some embodiments, selective application of an adhesive or different types of adhesives can be accomplished using a printing machine, such as for printing illustrations on a film package.
[0255] Any one of the second, third, fourth zones, pull tab zones and/or projection zones can have the first and second sheets secured using a sealing layer. In one embodiment, the sealing layer can be comprised of materials that contain both compatible and incompatible polymers as the surface of the second sheet is adapted to contact the first sheet. The second sheet can be adhered to the sealing layer using known processes such as, for example, heat sealing. When the package is opened, the two joined surfaces separate in the area that has undergone the sealing process because of the chosen controlled incompatible polymer. In a second embodiment, the sealing layer on the first sheet can be identical to the sealing layer on the second sheet. The second sheet can be adhered to the sealing layer using heat that melts and bonds the two surfaces. In this embodiment, one of the two sealing surfaces is designed to have only a thin layer of polymer and then adjacent to it (away from the sealing interface) has a layer that is designed to rupture. This rupture allows the transfer from one polymeric surface to the other surface and through this transfer opens the package. In various embodiments, the flexible material including the first sheet, the second sheet and, optionally, the third sheet, can be thermoformed to form a closure assembly having a lid formed in the flexible material. In such embodiments, the flexible material must be adapted for thermoforming and have a desired heat transfer through the flexible material structure (i.e., second sheet, first sheet and optionally third sheet). In some embodiments of the forming process, the flexible material can be heated on one side, for example, the side of the flexible material that is disposed on the outside of the package. When heating on one side, the flexible material can have a structure such that higher melting point materials are disposed closer to the heat source than lower melting point materials. The thermal conductivity of polymers can be controlled and customized based on desired packaging machine line speeds.
[0256] Other flexible material parameters that can be selected or customized to provide desired line speed, thermoforming, and/or sealing properties include elastic modulus E. Elastic modulus is a measure of a material's resistance to deformation or its stiffness .
[0257] The mechanical properties of polymers, such as those that can be included in the flexible materials of the disclosure, are temperature dependent. For example, the flexible materials of the disclosure can have a 1% secant modulus greater than about 60,000 psi in the stackable direction, as measured using ASTM D882 at 23°C. Method and Apparatus for Fabricating a Flexible Container
[0258] Returning to the assembly of the reclosable packaging assembly 10, the container 12 may be formed or assembled in any manner known in the art. For example, container 12 can be formed as described in US Patent 8,231,024, which is incorporated herein by reference in its entirety. For example, the first sheet 14 can be provided as a roll of material and the second sheet 24 can be secured to desired portions of the first sheet 14 along the roll. Aperture 20 may also be precut in the first sheet 14. In some embodiments in which the lid is formed on the film, the second sheet may be precut to the dimensions of the lid edge 76, such that no cutting operation is performed. Additional may be needed on the second sheet 24 subsequent to the attachment of the first sheet 14. In embodiments in which the cap is formed of the flexible material, one or more forming stations may be provided at a desired location along the assembly line to form desired features of container 12 and/or closure assembly 22. While embodiments of method and apparatus for forming the package may include and illustrate one or more forming stations to form a closure assembly, it is contemplated that the methods and apparatus described herein, without the forming station(s) can be used in forming a resealable package that does not include a formed closure assembly.
[0259] The first forming station may include thermoforming the desired characteristics of the container 12 and/or the closure assembly 22. Thermoforming is a manufacturing process in which a plastic sheet, such as the first sheet 14 and/or the second sheet 24 is heated to a stackable forming temperature and formed to a specific shape in a mold. The sheet, or "film" when referring to finer gauges and certain types of materials, is heated in an oven to a high enough temperature that it can be stretched in or over a mold and cooled into a final shape. Rather than thermoforming, one skilled in the art will recognize that other fabrication operations can be used to form the first engagement feature 36 and the first attachment feature 104a (or any other features described herein).
[0260] In a typical thermoforming process, a plastic sheet (such as the first sheet 14) is fed from a roller to a set of indexing chains that transport the plastic sheet through an oven for heating to a temperature of formation. The heated sheet then indexes into a forming station where a mold (such as the molds illustrated in Figures 15A to 17J) and pressure box close over the sheet with vacuum then applied to remove trapped air and to pull material to o or over the mold together with pressurized air to form the plastic into the detailed shape of the mold. After a short forming cycle, a reverse air pressure burst is actuated on the vacuum side of the mold as the forming tool opens, commonly referred to as air ejection, to break the vacuum and help the formed parts out of the mold. A separator plate can also be used in the mold when it opens to eject more detailed parts or those with negative drag, jagged areas. As explained above, one or more training stations can be provided at any suitable location along the assembly line. For example, a system for making disclosure packages can include a forming tube around which the film is folded to make a package. Along the forming tube, one or more heating stations (see heating stations 138 in Figures 19A through 19F, for example) and forming stations to make thermoformed features can be included. Referring to Figure 33, in one embodiment, the machine may be equipped with two preheat stations 303 which heat the film to a suitable temperature for thermoforming and a forming station 306 which includes a die in which the preheated film is shaped to form the desired features, such as the closure assembly. The heating and/or forming stations can be arranged such that the thermoforming process takes place while the film is folded around the forming tube process to form the package structure. In one embodiment, the film is fed to the machine from a roll of film and is folded around the forming tube by passing the film over a collar. While in the forming tube, a portion of the film is preheated for thermoforming. The film then passes through a die having the desired structures for thermoforming and compressed to conform the film to the structures of the die. The film can then proceed to stations to form package seals.
[0261] The forming tube can be adapted in such a way that, for a portion of the forming station, for example, the matrix can be incorporated integrally into the forming tube or can be directly attached to the forming tube. As illustrated in Figure 34 and 35, forming tube 307 may have a first portion having a first diameter and a second portion 192 downstream of the first portion having a second diameter smaller than the first diameter. The forming tube 307 may also have a square or rectangular cross-sectional shape and the perimeter of the second portion 192 may be less than the perimeter of the first portion. A die 193 (such as or similar to the die illustrated in Figure 40, for example) for thermoforming may be attached to or integrally formed on forming tube 191 in the second portion 192. The first and second diameters (or perimeters) are selected from such that when the film passes from the first portion of the forming tube to the second portion of the forming tube with a die installed therein, the film remains substantially in the same plane. In some embodiments, the forming tube can also be used as the filling tube to fill product into the container. In such embodiments, the interior of the forming tube may include a restriction portion which reduces the diameter within the forming tube to the size of the second diameter such that the product flow through an interior portion of the forming tube has a consistent diameter. .
[0262] For example, a first forming station may form the first engagement feature 36 (eg rib 40) and optionally the first attachment feature 104a. The first forming station may also form all or any of the second engagement portion 38, the convex portion 98, the second attachment feature 104b, the hinge portion 28 of the closure assembly 22, the one or more ribs 51 and/or of the locking mechanism 126, for example. Other desired features can also be formed at the first training station. The first engaging feature 36, the first engaging feature 104a, the second engaging portion 38, the convex portion 98, the second engaging feature 104b, the hinge portion 28 of the closure assembly 22, the one or more ribs 51 and/or the closure mechanism 126 can all be formed at the first forming station using a single mold (such as the molds illustrated in Figures 15A to 17J) in a single process step. Alternatively, the first engagement feature 36 and the first clamping feature 104a may be formed at the first forming station using a single mold in a single manufacturing operation and the second engagement portion 38, the convex portion 98, the second engagement feature. attachment 104b and hinge portion 28, or example, may be formed at a second forming station which is remote from the first forming station. If the opening 20 (and/or the cuts 107a, 107b of the hinge portion 28 of the embodiment of Figures 20A and 20B) is not precut, the opening 20 or the cuts 107a, 107b may be die cut at the first station forming at the same time as the first locking feature 36, the first locking feature 104a, the second locking portion 38, the convex portion 98, the second locking feature 104b, the hinge portion 28 of the closure assembly 22, the one or more ribs 51 and/or the locking mechanism 126 are formed. Alternatively, opening 20 or cuts 107a, 107b can be cut by a die cut before, during or after the forming operation at the first forming station. The cutting operation for cutting opening 20 or cuts 107a, 107b would include inserting a blade of a cutting die (which corresponds to the shape of opening 20 or cuts 107a, 107b) through the first sheet 14 to (but not through da) the second sheet 24.
[0263] In various embodiments, the forming matrix and/or the forming structure may include structures to retain the film so that it is able to stretch in a controlled manner during the forming process. This can help to reduce or prevent tearing or pulling of the film when the film is compressed against the forming matrix to form the closure assembly structures in the film.
[0264] In one embodiment, the opening can be formed or defined in the package at the time of formation of the closing assembly. For example, the die used to form the closure assembly on the film may include a cutting die incorporated within the forming die. For example, the cutting die may be included on a rear side of the forming die and arranged so that upon sufficient compression of the forming die the cutting die will pass through an opening provided in the face of the forming die to contact an disposed film. on the face of the cutting die. In another embodiment, the forming dies may include two dies with a first dies arranged on the rear side of the dies for cutting the first and third sheets, and a second dies disposed on the front side of the dies. formation to cut the second sheet. The cutting dies can be, for example, forged steel knives. Figures 75A and 75B illustrate an exemplary forming die having forged knives disposed within the forming die. For example, in an exemplary forming operation, a heated film may be disposed on the face of a forming matrix and compressed at a first compressive pressure to conform the heated film to the structure defined in the forming matrix and to cool the film to retain the shape. then formed, the film can be compressed in the die at a second compression pressure greater than the first compression pressure to engage the cutting die disposed on a rear side of the forming die such that the cutting die contacts the movie to set the aperture. For example, in another exemplary forming operation, a heated film may be disposed on the face of a forming matrix and compressed at a first compressive pressure to conform the heated film to the structure defined in the forming matrix and to cool the film to retain the In the formed shape, then, the film can be compressed on the first die and engaged with the second die at a second compression pressure greater than the first compression pressure to engage the first die disposed on a rear side of the forming die. , such that the cutting die contacts the film to define the opening through the first and third sheets, and to engage the second cutting die to cut defining the movable lid portion on the second sheet including, for example, defining the hinge feature. As the die extends into contact the film and/or the second press pressure can be configured such that the die cuts through the first sheet and the optional third sheet, but preferably does not cut through the second sheet. In some embodiments, the die cutter may contact the second sheet, partially marking the second sheet, as long as the second sheet is not weakened by the marking.
[0265] Figures 75A and 75B further illustrate an embodiment of a forming station that includes a secondary forming plate that provides a secondary forming operation to further force the film further into the internal forming cavity, which can improve the formation of indentations and other features in the formed cap assembly.
[0266] Any suitable packaging machine can be used to form the reclosable packaging assembly 10. For example, as illustrated in Figures 19A to 19F, a vertical form fill and seal (VFFS) packaging machine 135 can be used. The packaging machine 135 is capable of intermittently forming a series of reclosable packaging assemblies 10 from a web of film, such as a roll 136 of the first sheet 14 which can be fed to the packaging machine 135. The roll 136 can be adapted to have a larger diameter than conventional film rolls to accommodate a locally thickened portion of the film, for example by including a third sheet in the films and/or locally thickened portions of the first sheet. For example, the roll may have a diameter increased from % inch to 1 inch. In such a film web, the opening 20 (and/or the cutouts 107a, 107b of the hinge portion 28 of the embodiment of Figure 20A and 20B) may be precut (or pre-marked or pre-perforated) in the first sheet 14 and the second sheet 24 can be secured to desired portions of the first sheet 14. One skilled in the art will recognize that the second sheet 24 can be applied while the film web is directed through the packaging machine 135 at any point prior to heating and packaging. thermoforming. In some applications, the film web may be preprinted with graphics related to the product being disposed within the resealable package assembly 10, such as product information, manufacturer information, nutritional information, bar code and the like. Roll 136 can be rotatably mounted on a shaft at the inlet end of wrapping machine 135. The film web is typically fed to wrapping machine 135 through a series of dancer rolls and guide rolls 137, one or more of which can be actuated to direct the first sheet 14 towards the transport path of the packaging machine 135.
[0267] Before being formed into the shape of the container 12 of the resealable-packaging assembly 10, the film web may be directed through one or more heating stations 138 which heat the film web to a further thermoforming step . The film web is then directed through a first forming station 140 which can thermoform the desired characteristics of container 12 and/or closure assembly 22, as described above. For example, in this first forming station 140, the first engagement feature 36, the first engagement feature 104a, the second engagement portion 38, the convex portion 98, the second engagement feature 104b, the hinge portion 28 of the assembly of closure 22, the one or more ribs 51 and/or the optional locking mechanism 126 can all be formed simultaneously using a single mold. Pressure forming or pressure and vacuum forming can be used. An inert gas can be used for pressure formation and/or reverse air ejection. Following the first forming station 140, the film web can then be directed through one or more subsequent forming stations (not shown) which can perform other manufacturing operations, such as marking or further thermoforming of desired features. , as described above. However, it is preferable that the entire training be done in a single training station, such as the first training station 140. After passing through the first training station 140 (and any/any subsequent training station(s) hot(s)), the film web is directed to a package forming station 142 having a forming boss 144, or other device, such as a forming box or sequential folding system, configured to wrap the film around of a forming tube 146 in a manner known in the art. In the present example, the forming tube 146 is a product filling tube 148 having a funnel 150 for receiving the product to be disposed in the reclosable packaging assembly 10 and filling the reclosable packaging assembly 10 with the product as the film proceeds to the along the forming tube 146. It is contemplated that the filling of the pack may occur in or outside the forming tube. For example, the pack can be removed from the forming tube having an unsealed open end and filled in a separate operation. Forming tube 146 is configured to form the film into the desired shape based on characteristics of the final packaging design, such as square, rectangular, oval, trapezoidal, round, irregular, and the like. Of course, when other types of non-VFFS packaging machines are used, a forming tube may not necessarily be used and instead the film may be wrapped directly around the product to be stored in the reclosable packaging assembly 10. How described above, first forming station 140 (or any further forming station) may be disposed and integrally formed with a downstream end of forming tube 146.
[0268] After the film is formed around the forming tube 146, the film web moves along the transport path to a combination edge seal/corner seal station 152 to form corner seals at the corners between sides 16a-f of container 12, and creating edge seals and corner seals combining, if desired, on the side edges of the film web. In various embodiments, corner seals can surround and encircle one side of the pack or opposite sides of the pack. The film web can pass through a series of forming plates and forming bars and the film web can then be directed by welding devices at station 152 which weld overlapping portions of the film to complete the corner seals of the film. container 12. Obviously, the corner seals and edge seals of container 12 can be formed by different work stations, depending on the particular configuration of the packaging machine.
[0269] The one or more heating stations 138, the first forming station 140 and any subsequent forming stations have been described as being located upstream of the bundle forming station 142 or the edge sealing/corner sealing station at combination 152. However, in alternative embodiments of packaging machine 135, the film web may be directed to one or more heating stations 138, first forming station 140, and any subsequent forming stations following the sealing/sealing station. corner sealing 152. Alternatively, the film web may be directed to the one or more heating stations 138, the first forming station 140 and any subsequent forming stations at a point between the package forming station 142 and the packaging station. corner sealing/sealing 152.
[0270] In order to further control the movement of the film web along the forming tube 146 and the conveyor path, drive belts 154 may be provided after stations 152 (or after one or more heating stations 138 , first forming station 140 and any subsequent forming stations) to engage the film and pull the film through the previous stations 142, 152.
[0271] Following the corner sealing/sealing station 152, the edges of the container 12 can be sealed to close the container 12 and bent and pleated to conform to the shape of the container 12 at a closure station 156. At the closure station 156, sealing bars 158 can simultaneously close over the film and can seal a trailing edge (such as the first and/or second edge 48, 50, for example) of a previous container 12 and a leading edge of a container. current 12 in a manner known in the art.
[0272] As discussed above, the forming tube 146 of the illustrated embodiment of the packaging machine 135 is a product filling tube 148. Since the leading edge of the container 12 is closed during the sealing process at the closure station 156, the product can be added to the package 12. At that point, a specified amount of the product can be poured through the funnel 150 into the filling tube 148 and dropped into the container 12. After or when the container 12 receives the product, the container 12 is advanced to align a trailing edge of container 12 at closure station 156 and the trailing edge can be folded over and is sealed in the manner described above, thereby sealing container 12 with the product disposed therein.
[0273] At the same time as the seals of the adjacent containers 12 are formed, a gas washing operation can be carried out, if necessary, to place a desired atmosphere in the container 12. Since the container 12 of the reclosable packaging assembly 10 is sealed, it can be detached from the film web in preparation for any final processing and containerization steps. Therefore, the closure station 156 may further include a knife or other separating device (not shown) proximate the seal bars 158 to cut the common and separate seal from the adjacent container 12. Alternatively, separation can take place at a downstream station.
[0274] After separation, the reclosable package assembly 10 may be dropped or otherwise transported to a conveyor 160 for supply to the remaining processing stations. Referring to Figures 76A-76C, the conveyor may be provided in some embodiments as a continuous running track type design. The racetrack type conveyor can be provided with several stations, for example, to provide folding and sealing of an end (flap) seal. In some embodiments, as discussed in detail below, the carrier may include a packet receiving element. The conveyor may be further equipped with a tilting portion or open portion, for example, for tilting or dropping packages from the package receiving element into a take-out box or conveyor. Alternatively, an arm can remove the pack from the carrier. For example, resealable packaging assembly 10 may fall through a package chute 162. Resealable packaging assembly 10 may fall freely at a first conveyor location 164, but for the most part aligned over conveyor 160. At a second conveyor location 164. conveyor 166, package side guides 167a, 167b may abut against reclosable package assembly 10 and may positively locate it via a third conveyor location 168. At fourth conveyor location 170, package side guides 167a, 167b may begin to taper down towards the reclosable package assembly 10. At a fifth conveyor location 172, the upper package guide 173 can abut against the reclosable package assembly 10 and positively locate it in a vertical direction. One or more glue applicators 175 may deposit glue onto one or more open tabs (e.g., portions of first sheet 14, fourth side wall 16e illustrated in Figure 1) which will be disposed across a gap between the top of the embedding assembly. resealable package 10. At a sixth conveyor location 174, package side guides 167a, 167b transition from a low profile to a high profile and fold the flaps of the reclosable package assembly 10 into the position illustrated in Figure 1. Thus arranged , the glue begins to "cure" or harden" and can be completely cured or hardened in this position. At a seventh conveyor location 176, the package side guides 167a, 167b are high profile and continue to hold the one or more tabs. in a desired position. If the glue is not fully cured or hardened, it may continue to cure or harden in this position and/or subsequent positions. Alternatively, the one or more tabs could be sealed by ca. lor to a corresponding sidewall 16d, 16e. If necessary, a post-processing station (stations) (not shown) can be added along conveyor 160 for any additional operations to be performed prior to shipment, such as code dates, weight check, quality control, labeling or marking, installing RFID and the like. On completion of the sealing and post-processing activities, the finished resealable packaging assembly 10 can be removed from the conveyor 160 by a box packer (not shown) and placed inside a box (not shown) for storage and/or transport to customers.
[0275] Figure 66 illustrates an embodiment in which the carrier includes a package receiving element that guides the package along the transportation locations. For example, the package set falls from the packaging machine onto the package receiving element disposed on the conveyor. The package receiving element can assist in retaining the shape of the packaging assembly while remaining assembly steps, such as forming and/or folding the leak seal (also called end seals), are performed on the conveyor. The package receiving element may, for example, have a size and a shape that correspond to the size and shape of the package assembly. For example, the package receiving element may have the same cross-sectional shape as the package assembly and be sized so that the package assembly resides within the package receiving element. The package receiving element can be, for example, open at the top and at the bottom, so that the side walls are provided corresponding to the side walls of the package. For example, the pack may reside firmly within the pack receiving element so as to provide a compressive force to maintain the desired folded shape of the pack. The package receiving element can be any suitable height. For example, the packet receiving element can have a height such that it extends to cover at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or 100% of the height of the packaging assembly (as measured from the bottom wall). In embodiments in which the package receiving element is approximately the same height as the packaging assembly, it is to be understood that a leakage seal, which may or may not be formed when the packaging assembly is placed on the packaging receiving element. package, may extend above the top of the package receiving element so that it can be formed and/or further processed to fold and/or adhere to the wall of the package. For example, the leak seal (also called an end seal or flap) can be folded and heat sealed to the outside of the package and/or glued using an adhesive. Figures 74A-74C illustrate embodiments of a heating plate that can be incorporated into the conveyor to heat a flap formed by the leak seal enough to be secured to the side of the package using a heat seal. As illustrated in Figure 74C, the heat plate may include two downward extensions and a recessed region to receive the tab, while the sides of the tab are heated by the downward extensions. In an alternative embodiment, illustrated in Figures 74A and 74B, the heat plate may include a flat plate or a single projection plate, respectively, to contact and heat the tab before and/or after the tab is bent to contact the side of the container. to thereby seal the flap by the container. The conveyor can include one or more heating plates to seal the flap to the side of the package. For example, a first heating season can be supplied with lower heat than a second heating season. For example, the first heating station may include a heat plate in accordance with the embodiment shown in Figure 74C having two protrusions and a second heating station may include a heating plate with none or a single protrusion, for example, as illustrated. in Figures 74A and 74B, respectively. For example, the conveyor may include the heating plate having first and second protrusions for a first heating step when the flap is in the upright position and a heating plate having no protrusion or a single protrusion for further heating after the flap has been folded to contact one side of the package.
[0276] The carrier may include any appropriate number of package receiving elements spaced at appropriate intervals along the carrier. The number and spacing of packet receiving elements can be determined, for example, by one or more of the speed of the packet forming process, the length of the conveyor, and the number and duration of processes to be performed on the packet while in the conveyor. For example, the carrier can include about 1 to about 30, about 5 to about 10, about 12 to about 24, about 6 to about 18, about 7 to about 20, or about 10 to about 25 elements of receiving packages. Other suitable numbers of packet receiving elements include about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29 and 30. The spacing can be determined, for example, by the different processes performed on the package set while on the carrier and by the timing of the processes to be performed . For example, in an embodiment in which the leak seal is folded and secured to one side of the pack, the pack receiving elements can be spaced apart from about 2 to about 24 in.
[0277] Figures 36, 37 and 46 illustrate various types of VFFS machines. Figure 46 illustrates a VFFS machine 300 (Vertical Folding Station Mode) having an embodiment of the vertical forming station 301 illustrated in Figure 38. The vertical forming station 301 includes the forming tube assembly 302 illustrated in Figure 33 and the forming tube assembly 302 may include a forming tube 307 that extends along a first longitudinal axis 330 from a first longitudinal end 331 to a second longitudinally opposite end 332. The first longitudinal axis 330 may be vertical or substantially vertical . As used herein, the term vertical includes a direction parallel or substantially parallel to the Z axis of the reference coordinate system provided in Figures 33 and 52A. Alternatively, the first longitudinal axis 330 can be horizontal or substantially horizontal. As used herein, the term horizontal includes a direction normal or substantially normal to the Z axis of the reference coordinate system provided in Figures 33 and 52A, such as a direction within or substantially within the XY plane of the reference coordinate system provided in Figures. 33 and 52A. The forming tube assembly 302 can be modular and can be releasably attached to a primary frame assembly or a portion of the primary frame assembly. The forming tube assembly 302 of Figure 33 may include one or more (e.g. two) heating stations 303 and the heating stations 303 may each be identical to the embodiment of Figure 39. In some embodiments, the heat station 303 can be designed to selectively heat zones of the film portion disposed within the heating season. The forming tube assembly 302 of Figure 33 may also include a forming station 304, such as a thermoforming station, which may include an internal forming cavity or a first mold element 305 (shown in Figure 40) and a cavity of external forming or a second mold element 306 (shown in Figure 41) to form all or some of the first engagement feature 36, the first attachment feature 104a, the second engagement portion 38, the convex portion 98, the second fastening feature 104b, the hinge portion 28 of the closure assembly 22, the one or more ribs 51, and/or the optional locking mechanism 126. The forming tube assembly 302 of Figure 33 may further include a forming tube 307 (illustrated in Figure 34) extending longitudinally (i.e., along the first longitudinal axis 330) with respect to the forming tube assembly 302, and the forming tube 307 may function identically to the forming tube 146 described above. That is, the forming tube 307 can be adapted to mold the film when the film moves in a direction parallel to the first longitudinal axis 330. The first mold element 305 (which may be identical to die 193 of Figure 35), or any forming station portion 304 may be attached directly to a forming tube portion 307 and the forming tube portion may be at or adjacent to the second end of forming tube 332.
[0278] The forming tube assembly 302 of Figure 33 may further include a pressure compensating assembly 308 (shown in Figure 42) that applies pressure to the forming tube 307 opposite the inner forming cavity 305 and the outer forming cavity 306. The pressure applied to the forming tube assembly 302 by the pressure compensation assembly 308 may be equal to or approximately equal to the pressure applied by the inner forming cavity 305 and the outer forming cavity 306 and this compensation pressure improves stability and reduces deflection in forming tube assembly 302. Forming tube assembly 302 of Figure 33 may additionally include a product funnel 309 for receiving product to be disposed in reclosable packaging assembly 10.
[0279] A primary structure assembly 333 may extend along or substantially along the first longitudinal axis 330, with at least a portion of the forming tube 307 directly or indirectly coupled to a portion of the primary structure assembly 333 to support the forming tube 307 or any portion of forming tube assembly 302. A first end of primary structure assembly 333 may be disposed adjacent (or vertically extending above) first end 331 of forming tube 307 and a second end of the assembly The frame assembly may extend beyond (or extend vertically below) the second end 332 of the forming tube 332. The primary frame assembly 333 may include a frame or other support assembly, such as a plate, (or multiple frames and/or support assemblies) which is adapted to be a permanent or semi-permanent base for the components comprising the VFFS 300 machine. In contemplated, one or more modular structure assemblies 334, such as a first modular structure assembly 334a, may be removably attached to primary structure assembly 333. One or more components, such as first heating station 303, may be secured a first portion of the first modular structure assembly 334 and at least a portion of the first thermoforming station 304 (such as the second mold element of the first thermoforming station 304) may be secured to a second portion of the first modular structure assembly. 334. One skilled in the art will recognize that such modular frame assemblies 334 allow a user or technician to disconnect components attached to modular frame assemblies 334 quickly and efficiently. The second modular structure set 334b may have one or more different heating stations 303 and/or one or more different thermoforming stations 304 (or a portion of a thermoforming station) than the first modular set 334. modular frame assemblies 334 are optional and the first heating station 303 and at least a portion of the thermoforming station 304 can be attached directly (or indirectly) to the primary frame assembly 333.
[0280] In other embodiments, such as vertical forming station 335 of Figures 52A and 52B, film reel station 136 may be coupled to primary structure assembly 333 in any suitable manner and film reel station 136 may be adapted to support a roll of film 14. The film roll station 136 may be positioned such that the film 14 extends from the film roll station 136 to a point at or adjacent to the first end 331 of the forming tube. 307. More specifically, the film 14 may extend from the film reel station 136 to a portion of the forming tube 307 between the first end 331 and at least one of the heating stations 303 (such as the first heating station). The film may engage one or more dancer rollers 137 to guide the film along the film path. Each of the dancer rollers 137 and the film roll support rod 136 may have a diameter of 2" to prevent the label 24 from separating from the film 14 when the film 14 moves over the rolls 136, 137. In this embodiment, one first segment of film 14 may extend between film reel station 136 and first end 331 of forming tube 307 along a second longitudinal axis 336. Second longitudinal axis 336 may have any suitable orientation and second longitudinal axis 336 may be non-parallel and non-coaxial with first longitudinal axis 330. For example, second longitudinal axis 336 may be normal (extend obliquely) to first longitudinal axis 330.
[0281] In this embodiment, one or more heating stations 303 may include a first heating element 303a to heat a first portion of the film 14 as the film moves toward the first end 331 of the forming tube 307, the first station of heater 303a being disposed between film reel station 136 and first end 331 of forming tube 307. A second heating station 303b may be disposed between first heating station 303a and first end 331 of forming tube 307. The first thermoforming station 304 may be disposed between the first heating station 303a (or the second heating station 303b) and the first end 331 of the forming tube 307. Thus configured, the one or more heating stations 303 and the first thermoforming station 304 can be arranged upstream (relative to the direction of displacement of film 14 through vertical forming station 335) of the tube. shaping 307 or first end 331 of forming tube 307.
[0282] In contemplated embodiments, as illustrated in Figures 52A and 52B, one or more modular structure sets 334, such as a first modular structure set 334a, may be removably attached to the primary structure set 333 at one or more locations between film roll 136 and first end 331 of forming tube 307. One or more components, such as first heating station 303, may be attached to a first portion of the first modular structure assembly 334 and at least a portion of the first thermoforming station 304 (such as the second mold element of the first thermoforming station 304) can be secured to a second portion of the first modular structure assembly 334. One skilled in the art will recognize that such modular structure assemblies 334 allow a user or a technician disconnects components attached to the 334 modular frame assemblies quickly and efficiently. For example, a first modular frame assembly 334 can be removed from primary frame assembly 333 and a second modular frame assembly 334b can be secured to primary frame assembly 333. Second modular frame assembly 334b can have one or more stations different heating stations 303 and/or one or more different thermoforming stations 304 (or a portion of a thermoforming station) than the first modular assembly 334. However, these modular structure assemblies 334 are optional and the first heating station 303 and at least a portion of thermoforming station 304 may be attached directly (or indirectly) to primary frame assembly 333.
[0283] Referring to Figure 38, the vertical forming station 301 of Figure 38 may include an upper lower flap folding assembly 310 (or a first folding assembly or a first folding station illustrated in Figure 43) downstream of a sealing bar assembly 313 and forming tube assembly 302. First folding station 310 may be coupled to primary frame assembly 333 or modular frame assembly 334 and may be disposed between second end 332 of the forming tube. formation and the second end of the primary structure assembly.
[0284] The upper lower flap folding assembly 310 may also include a product seating vibrator and/or a heater. The vertical forming station 301 may also include an upper flap folding assembly 311 (shown in Figure 44) and a bottom lower flap folding assembly 312 (shown in Figure 45) and the bottom lower flap folding assembly 312 may also include a product settling vibrator and/or a heater. The upper lower flap folding assembly 310, the upper flap folding assembly 311 and/or the lower lower flap folding assembly 312 may cooperate to form flaps, corners and/or folds in the film to form portions of the assembly. resealable package 10. Vertical forming station 301 may also include seal bars 313 to seal film edges to form portions of reclosable packaging assembly 10. Sealing bars 313 may also form end seals and cut the packages apart.
[0285] In the VFFS 300 machine illustrated in Figure 46, the resealable packaging assembly 10 is formed or formed substantially in the vertical forming station 301 and each complete or substantially complete resealable packaging assembly 10 is placed on a withdrawal conveyor 314 that carries the resealable packaging set 10 for later inspection or additional packaging.
[0286] Referring now to Figure 37, an embodiment of a VFFS machine 315 (Horizontal Top End Seal Fold and Glue Mode) includes an embodiment of a vertical forming station 316 that includes the illustrated forming tube assembly 302 in Figure 33. Vertical forming station 316 may be similar to vertical forming station 301 of Figure 38. However, vertical forming station 316 can only include a package bottom folding assembly 317. In this embodiment, partially formed reclosable packaging assemblies 10 are placed on conveyor 314 and partially formed reclosable packaging assemblies 10 are routed through side guides which are snug against reclosable packaging assembly 10 and positively locate them in a desired fixed position, such as a vertical orientation. On the conveyor, the partially formed reclosable packaging assemblies 10 may pass through a product settling station/station 318 and thereafter additional folding and gluing stations to complete the reclosable packaging assemblies 10. The gluing stations may include equipment to apply glue to a flap and fold the flap to seal next to the package. Alternatively, heated bars can be provided at the gluing station to heat the film material and then folding devices can be provided to fold the heated tab and apply pressure to secure the tab to the side of the pack by a heat seal. In various embodiments, the packaging machine can include mechanically driven belts that can, for example, facilitate moving the film/packs through the machine.
[0287] Referring to Figure 36, an embodiment of a VFFS machine 318 (Horizontal Top End Sealing and Sealing Folding Mode) includes an embodiment of a vertical forming station 319 that includes the forming tube assembly 302 illustrated in Figure 33. Vertical forming station 319 may be similar to vertical forming station 301 of Figure 38. However, vertical forming station 316 may only include a package bottom folding assembly 317 and may include sealing jaws 320 adapted to form seals having vent channels for venting the resealable packaging assembly 10 in a manner which will be described in more detail subsequently. In such sealing jaws 320, each of the sealing bars has a channel extending therethrough and the channel of each of the sealing bars is aligned such that when the sealing bars engage to seal a portion of the film of the packaging assembly 10, the channels cooperate to create an elongated unsealed vent in the film. The vent can be arranged in any orientation, including vertical direction. In this embodiment, partially formed reclosable packaging assemblies 10 are placed on the conveyor 314 and the partially formed reclosable packaging assemblies 10 are routed through side rails, as described above. On the conveyor, the partially formed reclosable packaging assemblies 10 may pass through a product/vibration laying station 318. In addition, the partially formed reclosable packaging assemblies 10 may pass through a sealing control and deflation station. end seals 321 and then an end seal station 322, 323 to seal the vent and/or tighten the package.
[0288] As illustrated in Figures 53A through 53F, a VFFS machine may include a reject station 337 disposed between the second end of the primary structure assembly 333 and the second end 332 of the forming tube 307. The reject station 337 may include at least one chute (e.g., a first chute 338 alone or one or more than one chute) and the at least one chute 338 may be disposed at any position below the second end of the forming tube to allow containers to be displaced under the the second end of the forming tube contacts a surface of the first ramp 338. For example, the at least one ramp 338 may be disposed at an angle to a reference plane normal to the first longitudinal axis 330. Thus configured, the first ramp has a first end which is disposed adjacent to and below the second end of the forming tube such that the film forming a partially formed reclosable container is Contact the first end of the first ramp when the partially formed reclosable container is released from the forming tube 307. The partially formed reclosable container moves under the influence of gravity to the second end of the ramp and into a waste receptacle, for example. Reject station 337 can be attached directly or indirectly to any portion of the assembly, such as primary structure assembly 333 or vertical forming station 301, for example. The reject station 337 can be deployed at the beginning when the partially formed containers are released from the forming tube 307 that would be trapped in downstream folding stations. The reject station can also be deployed if under or overweight product fills are detected or if metal is detected in the package, for example. A reject station can alternatively be provided on the conveyor. For example, a portion of the conveyor can hang or a robotic arm can be provided to remove a package from the conveyor at a reject location. Figure 76A illustrates an embodiment in which a reject station is provided on the conveyor.
[0289] The components of the packaging machine 135 and the steps to form the reclosable packaging assembly 10 therein can be rearranged as needed to properly form the reclosable packaging assembly 10, and do so efficiently and cost-effectively. For example, as explained above, the film web may be directed to the one or more heating stations 138, the first forming station 140, and any subsequent forming stations following the corner sealing/sealing station 152.
[0290] In various embodiments, the package can be formed using a process to vent the inner atmosphere of the package. In packaging various materials, it may be necessary to provide a particular air space in the package during the package sealing filling process to protect the product. Methods in accordance with the disclosure may include ventilating this airspace, which may advantageously reduce package size. The package can be vented, for example, forming a vent hole when sealing the attack or escape seal of the package. For example, the sealing jaw can form the seal in the package leaving a small gap in the seal through which air can vent. Once vented, the seal can be resealed to seal the vent hole. In quad-seal type packages, for example, an initial seal can be provided to include the vent and then, upon ventilation of the air in the package, the seal can be reformed to close the vent and then the seal can be folded and adhered to the outer side of the package.
[0291] In some embodiments, the process may include seating the product in the package before forming the seal to close the package. For example, an attack seal can be formed on the package and the product can be filled into the package. Prior to sealing the leak seal, the product may be subjected to a sedimentation process, for example, by vibration or by other methods known in the art, to sediment the product to the portion of the package adjacent to the formed attack seal. The leakage seal can then be formed. In some embodiments, the package can be dropped or placed on a conveyor from the forming tube before forming the leakage seal. The conveyor may include a sedimentation station in which the product is sedimented to the portion of the package adjacent to the leak seal. The etch seal can then be formed and optionally can include a vent as described above.
[0292] In various package embodiments, the attack and escape seals can be bent and adhered to the outer portion of the package. Such operations of folding and sealing the attack seal can be completed either when forming the attack seal with the film disposed around the forming tube or when the package is disposed on the conveyor. Such leakage sealing folding and sealing operations can be completed either when the film is provided around the forming tube or on the conveyor. When the leakage seal is formed on the conveyor, the folding and sealing operations to adhere the seal to the outside of the package will be carried out on the conveyor. In some embodiments, the leakage seal may be formed while the film is around the forming tube, such that a sealed package is provided to the conveyor for folding and sealing the attack and/or leakage seals to the outside of the package. In some embodiments, the attack and escape seals can be both formed and folded and sealed to the outer portion of the pack when the pack is arranged in-line with the forming tube and prior to placing the pack on a carrier.
[0293] One skilled in the art will understand that the containers 10 can be formed by other types of machines or combinations of machines, such as horizontal forming, filling and sealing machines (HFFS), StandUp Pouch machines, sequential assembly machines and similar, and the use of such machines or combinations of machines performing the various tasks in forming containers in accordance with the present disclosure is contemplated by the inventors. One skilled in the art would also recognize that any suitable product can be disposed within container 12 of resealable packaging assembly 10. For example, food products, such as peanuts, can be disposed within container 12. Alternatively, baby towels can also be arranged inside container 12.
[0294] As explained above, and unlike conventional reclosable packaging sets, the cap element 26, the first engagement feature 36 and the second engagement feature 38 can be formed on the container 12 and the closure assembly 22 in a manufacturing operation, thereby eliminating the need to attach a separately fabricated cap assembly that is attached to a container. As the features are formed in a single process step and as the separately manufactured cap assembly is not necessary, one skilled in the art would recognize that manufacturing time and costs are reduced. Furthermore, one skilled in the art would recognize that such features allow reliably resealing the cap element 26 to the container 12, notwithstanding the presence of surface contaminants in the sealing area.
[0295] Referring now to Figure 78, an embodiment of a VFFS machine 1000 includes an embodiment of a flap folding station assembly 1002 adapted to replace the racetrack type conveyor that includes several stations, for example, to provide folding. and sealing an end sealing tab (see, for example, Figures 76A to 76C). In this embodiment, a roll of film 1004 similar or identical to any of those described above (e.g., a first sheet 14 and a second sheet 24) can be guided along a forming shoulder 1006 and around a forming tube 1008 which extends along (or substantially along) a vertical axis (along or parallel to the Z axis of the reference coordinate system of Figure 78) in the manner described above or in any conventional manner. However, to reduce or eliminate curling of the first sheet 14 and/or the second sheet 24, the forming boss 1006 may have one or more radii 1007 (as illustrated in Figures 84a to 84d) that allow a radius of curvature of the first sheet. 14 and second sheet 24 which is larger than the corresponding radii of conventional forming shoulders. Forming stent 1006 may have one or more spokes 1007 which may be disposed at any suitable location on forming stent 1006 and spokes 1007 may have any suitable geometry to increase the radius of curvature of the first sheet 14 and the second sheet 16. For example, each radius 1007 can be a ramp-like projection onto an edge of the forming boss 1006 that provides a radius of curvature of 0.063" to 2,000", depending on the thickness of the first sheet 14. For example, the radius of curvature can be 0.375". As the first sheet 14 and second sheet 24 are folded around the forming tube 1006 in a conventional manner, one or more vertical sealing stations 1010 may apply a vertical seal - such as a seal to hot - to one or more vertically aligned edges of first sheet 14 such that first sheet 14 is sealed around the perimeter of forming tube 1008.
[0296] As previously described, one or more edges of the second sheet 16 may be perforated or scored to aid in edge bending, additionally or alternatively, one or more edge bending stations 1012 may be disposed along forming tube 1008 to help further edge fold and/or mechanically set a curl on the first and second sheets at the edge when no reduced resistance lines are provided. As illustrated in Figures 80a and 80b, edge forming stations 1012 may include a projection tongue 1014 that may be disposed vertically along an edge of forming tube 1006 and may transversely (i.e., normal to the Z axis of the system of the reference coordinate system of Figure 78, such as, for example, along or parallel to the X or Y axis of the reference coordinate system of Figure 78) extends beyond the perimeter of the outer surface of forming tube 1008. projection 1014 can be aligned with a marking and/or a perforation on the first sheet 14 (and the second sheet 24) such that one or more rollers 1016 - such as a cylindrical roller - can engage on one or both sides of a portion of the perforated/marked edge to fold that edge around the projection tab 1014. One skilled in the art would understand that, as described, the projection tab 1014 cooperating with the roller(s) 1016 allows for a curve. that exceeds 90 degrees form a steeper curl in the first sheet 14 along a marking or perforation than is possible in forming tube 1008 alone, as illustrated in Figure 80b. Figures 85a through 85g illustrate an embodiment of edge folding station 1012 having two rollers 1017 (the axes of rollers 1017 are not shown) disposed adjacent to the projection tabs 1014 formed on the edges of the forming tube 1008. The projection tab 1014 or the forming tube 1008 may have portions that are contoured to match contoured shapes of marked or perforated portions of the first sheet and/or the second sheet 24 to facilitate folding of the contoured shapes.
[0297] After the vertical perimeter edge of the first sheet 14 is sealed, the first and second sheets 14, 24 are vertically advanced to a first horizontal sealing station 1018 that may include one or more folders (not shown) that can shift in a horizontal direction (or in a substantially horizontal direction) to displace a portion of a first end of a segment of the first sheet 14 in a known manner. In some embodiments, a first and second corrugator may converge toward the vertical axis of forming tube 1008 to symmetrically displace opposite portions of the first end of a segment of first sheet 14 in a known manner. A pair of horizontally arranged sealing bars can then seal (e.g. heat seal) the first end of a segment of the first sheet 14 in a known manner. A horizontal cut may be made adjacent to the seal of the first end of a segment of the first sheet 14 to create a partially formed container with a second open end.
[0298] The partially formed container with a second open end (eg a top end) can then be advanced vertically to a second horizontal sealing station 1020. While advancing between the first horizontal sealing station 1018 and the second station of horizontal sealing station 1020 (or while in either the first horizontal sealing station 1018 or the second horizontal sealing station 1020), the partially formed container with the second open end may be filled with the product from the filling tube of a conventional way. For example, the first and second horizontal sealing stations 1018, 1020 may cooperate cooperatively and substantially simultaneously to define the bottom seal of a first container and the top seal of a second container, disposed downstream of the first container, the first and the second containers being secured until the seal disposed between them (cooperatively formed by the first and second horizontal seal stations) is cut. The container can be filled with product after the bottom seal of the container is filled and immediately before or, alternatively, while the web is in transition from the container such that the top seal region is disposed on the second horizontal seal.
[0299] The second horizontal seal station 1020 may be similar or identical in function to the first horizontal seal station 1018. That is, the second horizontal seal station 1020 may include one or more folds (not shown) that can move in a direction horizontally (or in a substantially horizontal direction) to displace a portion of the second end of the partially formed container in a known manner. In some embodiments, a first and second ply may converge toward the vertical axis of forming tube 1008 to symmetrically displace opposing portions of the partially formed container in a known manner. The horizontally disposed sealing bar can then seal (e.g., heat-seal) the second end of the partially formed container in a known manner (e.g., while sealing the first end of the partially formed container at the first horizontal sealing station 1018 ), thereby creating a sealed container 1024 having a transverse sealed flap 1022 at the second end (e.g., the upper end). Transverse sealed flap 1022 (see Figure 81) is the transverse flap created when the second end of the partially formed container is sealed to close the partially formed container in the sealed container 1024.
[0300] A support structure (eg a retractable platform) can be arranged normal to the vertical axis of the forming tube 1008 to support the first end of the partially formed container in the second horizontal sealing station 1020. cutting the first sealed end of a segment of the first sheet 14 (to create a partially formed container with a second open end) at the first horizontal sealing station 1018, such cutting could be made at the second horizontal sealing station 1020 to create the partially container. formed (or to create the sealed container 1024). The first and second sheets 14, 24 may pause at the first horizontal sealing station 1018 and the second horizontal sealing station 1020 to form the seals and/or perform the horizontal cutting operation. However, the first and second sheets 14, 24 can move continuously in and between the first horizontal sealing station 1018 and the second horizontal sealing station 1020. In such an embodiment, the first horizontal sealing station 1018 and/or the second horizontal sealing station 1020 can move vertically downward at the same rate as the first sheet 14 for the duration of the sealing/cutting process, as is known in the art. The first horizontal sealing station 1018 and/or the second horizontal sealing station 1020 may then move vertically upwards to initiate the next sealing process, as is known in the art.
[0301] A flap sealing station assembly 1002 may be disposed downstream (e.g. vertically offset from or below) the first horizontal sealing station 1018 and/or the second horizontal sealing station 1020. As illustrated in the Figures 82a, 82b, 83a, 83b and 86a to 89g, the flap sealing station assembly 1002 may include a vertically disposed guide structure 1028 that is adapted to ensure proper positioning of the sealed container 1024 after the sealed container 1024 exits the second station. 1020 horizontal seal (for example, is removed from the support structure). For example, guide frame 1028 can include a plurality of vertical walls disposed at right angles to form a rectangular perimeter that is slightly offset from the vertically aligned perimeter side walls of sealed container 1024. Guide frame 1028 can be hinged about of a vertical edge to allow one or more walls of guide frame 1028 to be opened by a technician. In some embodiments, flap sealing station 1024 may also include a displaceable support (not shown) that can support the bottom (e.g., first end) of sealed container 1024. The displaceable support may retract or pivot from a first position in or adjacent to a lower portion (e.g., below) of guide structure 1028 to a second position remote from the lower portion of guide structure 1028 to temporarily support sealed container 1024. In the first position, sealed container 1024 may rest on support displaceable so that all or a portion of the sealed container 1024 is surrounded by the guide frame 1028. In such a position, a transverse sealed tab 1023 (see Figure 81) is held against the lower portion of the sealed container 1024. transverse 1023 is still heated from the sealing operation, the transverse sealed flap 1023 is secured (e.g., heat sealed) to the lower portion of the container. te sealed 1024, thereby allowing for a more aesthetically simplified package. In the second position, the sealed container 1024 can fall (under the influence of gravity alone) to a position directly below and in line with the guide frame 1028. In alternative embodiments, no displaceable supports can be used and the sealed container 1024 can fall ( under the influence of gravity alone) to a position directly below and aligned with the guide structure 1028. After falling, the bottom (e.g., the first end) of the sealed container 1024 can be disposed on a support structure, such as a horizontal surface of a conveyor 1030 as illustrated in Figure 78.
[0302] In the support structure, the sealed container 1024 can be engaged (e.g., immediately engaged or encircled) by a retaining structure 1032 of the flap sealing station assembly 1002 and the retaining structure 1032 may have a shape of cross section corresponding to sealed container 1024. For example, retaining structure 1032 may include a plurality of vertical walls disposed at right angles to form a rectangular perimeter that is slightly offset from the vertically aligned perimeter side walls of sealed container 1024. retaining structure 1032 may include a first portion 1032a and a second portion 1032b that can move horizontally from a first closed position to a second open position and vice versa. In the first closed position, shown in Figure 83a, an end portion of first portion 1032a may be adjacent to or contact an end portion of second portion 1032b such that first portion 1032a and second portion 1032b cooperate to form an envelope surrounding the sealed container 1024 when the sealed container 1024 is disposed on the support structure. That is, each of the plurality of vertical walls that form retaining structure 1032 (e.g., first portion 1032a and second portion 1032b), can be directly adjacent to or in contact with a corresponding vertical wall of sealed container 1024. In the second open position shown in Figure 82a, the end portion of the first portion 1032a can be displaced from the end portion of the second portion 1032b such that the sealed container 1024 is not enclosed by the first portion 1032a and second portion 1032b when the sealed container 1024 is disposed on the support structure. For example, each of the first portion 1032a and the second portion 1032b can be disposed horizontally a predetermined distance away from the vertical axis of the forming tube 1008.
[0303] In the first closed position, one or more pressure plates 1034 of the flap seal station assembly 1002 may engage the top (e.g., second end) of the sealed container 1024. The one or more pressure plates 1034 can retract or pivot from a first position in or adjacent to an upper portion (e.g., over) retention structure 1032 to a second position remote from the upper portion of retention structure 1032. In some embodiments, the sealed container 1024 may be disposed within retaining structure 1032 - and retaining structure 1032 may be in the first closed position - before the one or more pressure plates 1034 move into the first position. With the sealed container 1024 engaged by the retainer structure 1032 in the first closed position, pressure is provided against the vertical sides and bottom of the sealed container 1024 by the retainer structure 1032 and the support structure cooperates to compress the residual fluid (e.g., air) in the sealed container 1024, thereby providing a high pressure within the sealed container 1024. When the one or more pressure plates 1034 are hinged or otherwise moved to the first position to engage (i.e., contact) the top ( for example, the second end) of sealed container 1024, the elevated pressure allows the one or more pressure plates 1034 to compress transverse sealed flap 1022 against the upper portion of sealed container 1024. As transverse sealed flap 1022 is still heated to From the sealing operation, the transverse sealed flap 1022 is secured (e.g., heat sealed) to the upper portion of the sealed container 1024, thereby enabling o A more aesthetically simplified package. When the transverse sealed flap 1022 has thus been secured, the one or more pressure plates 1034 are retracted, the retaining structure 1032 moves to the second open position, and the conveyor transports the finished sealed container 1024 to a remote station for packaging or processing. additional. The process is then repeated for the next sealed container 1024. EXAMPLES Example 1: Blue Printed Film
[0304] The film had a first sheet with a laminated structure as follows: 150 g of Cast Polypropylene INK Adhesive 120 g of PLA EVOH Adhesive Coex (12321.302W) of 2.875 mil
[0305] The first sheet had a nominal thickness of 5.575 mils. The film further included a second sheet disposed on the first sheet in a region to be formed in the top wall. The second sheet had a nominal thickness of 10 mils and was formed from PET. The film also includes a third sheet disposed on the first sheet opposite the second sheet. The third sheet had a nominal thickness of 7 mils and was formed from PLA/EVOH/PE. The ink gave the film a blue color across the entire surface of the film. The film was able to be thermoformed to include a closure assembly having a cap formed on the film. Example 2: Blue Printed Film with Transparent Window
[0306] The film had a first sheet with a laminated structure as follows: 150 g of Cast Polypropylene INK 76 g Formable PET Adhesive 3.5 mils High Clarity Polyethylene Adhesive
[0307] The first sheet had a nominal thickness of 5.76 mils. The high-clarity polyethylene was disposed on a portion of the film such that when the pack was formed a transparent window was provided in a portion of the side walls of the pack. The film further included a second sheet disposed on the first sheet in a region to be formed in the top wall. The second sheet had a nominal thickness of 10 mils and was formed from PET. The film also includes a third sheet disposed on the first sheet opposite the second sheet. The third sheet had a nominal thickness of 7 mils and was formed from PLA/EVOH/PE. The ink gave the film a blue color across the entire surface of the film. The film was able to be thermoformed to include a closure assembly having a cap formed on the film. Example 3: Transparent Film
[0308] The film had a first sheet with a laminated structure as follows: 140 g BOPP ADH 92 g PET ADH High Clarity Polyethylene 3.5 mil
[0309] The first sheet had a nominal thickness of 5.82 mils. The package produced from the film was transparent. The film further included two sheets of PLA, each having a nominal thickness of 4.75 mils, arranged one above the other on the first sheet and in a region of the film corresponding to the top wall of the pack. Example 4: Elastic Modulus
[0310] The films were evaluated for their stiffness. It was noted that the films need to have sufficient stiffness so that the pack retains its shape when the product is filled into the pack, but must remain flexible enough to pass through the filling and forming material. Table 1 provides a list of materials and measured secant modulus. Table 2 gives the secant modulus of different laminate. Laminate stiffness is an average value between the stiffest weft in the laminate and the softest weft. Stiffness (as measured by the 1% secant modulus) was measured using ASTM D882 at 23°C.


[0311] The values in Table 1 are graphically represented in Figure 49. Table 2 below presents the Secant Modulus of various laminates that can be used in various aspects of the disclosure. Table 2. Secant Module of Different Laminates

Disclosure Aspects Aspect 1. An apparatus for forming a film in a reclosable container, the apparatus comprising: an elongated forming tube extending along a first longitudinal axis from a first end to a second longitudinally opposite end, the forming adapted to mold the film when the film moves in a direction parallel to the first longitudinal axis, the forming tube having a hollow interior adapted to receive a product to be disposed within the container; a first heating station including a first heating element for heating a first portion of the film as the film moves in a direction parallel to the first longitudinal axis, the first heating element being disposed offset from the forming tube between the first and second ends. of the forming tube; and a first thermoforming station for thermoforming the first portion of the film, the first thermoforming station including a first mold element disposed between the first heating element assembly and the second end of the forming tube. Aspect 2. The apparatus of aspect 1, further comprising a primary structure assembly extending along the first longitudinal axis, with at least a portion of the forming tube coupled to a portion of the primary structure assembly to support the forming tube. Aspect 3. The apparatus of any of the foregoing aspects, wherein a first end of the main frame assembly is disposed adjacent the first end of the forming tube and wherein a second end of the frame assembly extends beyond the second end of the tube. of training. Aspect 4. The apparatus of any of the foregoing aspects, further comprising a first modular structure assembly releasably attached to the primary structure assembly, wherein the first heating station is secured to a first portion of the first modular structure assembly and by the at least one portion of the first thermoforming station is secured to a second portion of the first modular frame assembly. Aspect 5. The apparatus of any of the foregoing aspects, wherein the first mold element is secured to a portion of the forming tube. Aspect 6. The apparatus of any of the foregoing aspects, wherein the forming tube portion is adjacent to the second end of the forming tube. Aspect 7. The apparatus of any of the foregoing aspects, wherein the first thermoforming station includes a second mold element which cooperates with the first mold element for thermoforming the first portion of the film, the second mold element being displaceable with respect to the first mold element. Aspect 8. The apparatus of any of the foregoing aspects, wherein the second mold element moves in a direction normal to the first longitudinal axis with respect to the first mold element. Aspect 9. The apparatus of any of the foregoing aspects, wherein the first mold element is not directly attached to the forming tube. Aspect 10. The apparatus of any of the above aspects, in which the longitudinal axis extends in a horizontal direction or in a vertical direction. Aspect 11. The apparatus of any of the foregoing aspects, further comprising a first folding assembly adapted to fold a first folded feature into the film, the first folding station coupled to the primary frame assembly and disposed between the second end of the forming tube and the second end of the primary frame assembly. Aspect 12. The apparatus of any of the foregoing aspects, further comprising a second folding assembly adapted to fold a second folded feature into the film, the second folding assembly disposed between the first folding assembly and the second end of the primary frame assembly. Aspect 13. The apparatus of any of the foregoing aspects, further comprising a first seal claw assembly disposed between the thermoforming station and the first folding assembly, the first seal claw assembly having a pair of seal bars which extends in a direction normal to the longitudinal axis. Aspect 14. The apparatus of any of the foregoing aspects, wherein each of the seal bars has a channel extending therethrough, the channel of each of the seal bars being aligned so that when the seal bars engage to sealing a portion of the film, the channels cooperate to create an elongated unsealed vent in the film. Aspect 16. The apparatus of any of the foregoing aspects, further comprising a second set of sealing jaws disposed downstream of the first set of sealing jaws to seal the vent in the film. Aspect 17. The apparatus of any of the foregoing aspects, further comprising a product laying station upstream of the second set of sealing jaws. Aspect 18. The apparatus of any of the foregoing aspects, wherein the primary structure assembly includes at least one support plate disposed normal to the first longitudinal axis, wherein a portion of the forming tube is disposed through a cutout formed in the at least a support plate. Aspect 19. The apparatus of any of the foregoing aspects, further comprising a second modular frame assembly adapted to be removably attached to the primary frame assembly, wherein a second heating station is secured to a first portion of the second frame assembly. modular and at least a portion of a second thermoforming station is secured to a second portion of the first modular frame assembly, wherein the second thermoforming station is different from the first thermoforming station. Aspect 20. The apparatus of any of the foregoing aspects, further comprising a film reel station coupled to the primary structure assembly, the film reel station adapted to support a film reel, the film reel station so positioned that the film extends from the film reel station to the first end of the forming tube. Aspect 21. The apparatus of any of the foregoing aspects, further comprising a product funnel for receiving a product that will be disposed within the container, the product funnel being coupled to the primary structure assembly and the product funnel having a first open end and a second open end longitudinally opposite the first end, the second end of the product funnel being disposed adjacent the first end of the forming tube such that product entering the first end of the product funnel is directed into the hollow interior of the training tube. Aspect 22. The apparatus of any of the foregoing aspects, further comprising a reject station disposed between the second end of the frame assembly and the second end of the forming tube. Aspect 23. The apparatus of any of the foregoing aspects, wherein the reject station includes a first ramp disposed at an angle to a reference plane normal to the first longitudinal axis, the first ramp having a first end that is disposed adjacent to and below the second end of the forming tube such that the film forms a partially formed reclosable container contacts the first end of the first ramp when the partially formed reclosable container is released from the forming tube. Aspect 24. An apparatus for forming a film in a reclosable container, the apparatus comprising: an elongated forming tube extending along a first longitudinal axis from a first end to a second longitudinally opposite end, the forming tube adapted to shaping the film as the film moves from the first end of the forming tube to the second end of the forming tube in a direction parallel to the first longitudinal axis, the forming tube having a hollow interior adapted to receive a product that will be disposed within the container. ; a primary frame assembly extending along the first longitudinal axis, with at least a portion of the forming tube coupled to a portion of the primary frame assembly to support the forming tube. a film reel station coupled to the primary structure assembly, the film reel station adapted to hold a roll of film, the film reel station positioned such that the film extends from the film reel station to the first end of the forming tube. a first heating station including a first heating element for heating a first portion of the film as the film moves towards the first end of the forming tube, the first heating station being disposed between the film reel station and the first end of the forming tube; and a first thermoforming station for thermoforming the first portion of the film, the first thermoforming station including a first mold element disposed between the first heating element and the first end of the forming tube. Aspect 25. The apparatus of any of the foregoing aspects, wherein the first thermoforming station includes a second mold element cooperating with the first mold element for thermoforming the first portion of the film, the second mold element being displaceable relative to the first template element. Aspect 26. The apparatus of any of the foregoing aspects, wherein a first end of the main frame assembly is disposed adjacent the first end of the forming tube and wherein a second end of the frame assembly extends beyond the second end of the tube. of training. Aspect 27. The apparatus of any of the foregoing aspects, wherein the first longitudinal axis extends in a vertical direction or in a horizontal direction. Aspect 28. The apparatus of any of the foregoing aspects, further comprising a first modular structure assembly removably attached to the primary structure assembly, wherein the first heating station is secured to a first portion of the first modular structure assembly and by at least one portion of the first thermoforming station is secured to a second portion of the first modular frame assembly. Aspect 29. The apparatus of any of the foregoing aspects, further comprising a first folding assembly adapted to fold a first folded feature into the film, the first folding station coupled to the primary frame assembly and disposed between the second end of the forming tube and the second end of the primary frame assembly. Aspect 30. The apparatus of any of the foregoing aspects, further comprising a second folding assembly adapted to fold a second folded feature into the film, the second folding assembly disposed between the first folding assembly and the second end of the primary frame assembly. Aspect 31. The apparatus of any of the foregoing aspects, further comprising a first seal claw assembly disposed between the second end of the thermoforming tube and the first bending assembly, the first seal claw assembly having a pair of seal bars which extends in a direction normal to the longitudinal axis. Aspect 32. The apparatus of any of the foregoing aspects, wherein each of the sealing bars has a channel extending therethrough, the channel of each of the sealing bars being aligned so that when the sealing bars engage to sealing a portion of the film, the channels cooperate to create an elongated unsealed vent in the film. Aspect 33. The apparatus of any of the foregoing aspects, further comprising a second set of sealing jaws disposed downstream of the first set of sealing jaws to seal the vent in the film. Aspect 34. The apparatus of any of the foregoing aspects, further comprising a product laying station upstream of the second set of sealing jaws. Aspect 35. The apparatus of any of the foregoing aspects, further comprising a second modular frame assembly adapted to be removably attached to the primary frame assembly, wherein a second heating station is secured to a first portion of the second frame assembly. modular and at least a portion of a second thermoforming station is secured to a second portion of the first modular frame assembly, wherein the second thermoforming station is different from the first thermoforming station. Aspect 36. The apparatus of any of the foregoing aspects, further comprising a product funnel for receiving a product that will be disposed within the container, the product funnel being coupled to the primary structure assembly and the product funnel having a first open end and a second open end longitudinally opposite the first end, the second end of the product funnel being disposed adjacent the first end of the forming tube such that product entering the first end of the product funnel is directed into the hollow interior of the training tube. Aspect 37. The apparatus of any of the foregoing aspects, further comprising a reject station disposed between the second end of the frame assembly and the second end of the forming tube, the reject station including a first ramp disposed at an angle to a reference plane normal to the first longitudinal axis, the first ramp having a first end which is disposed adjacent to and below the second end of the forming tube such that the film forms a partially formed reclosable container contacting the first end of the first ramp when the partially formed reclosable container is released from the forming tube. Aspect 38. The apparatus of any of the foregoing aspects, wherein a first segment of film extends between the film reel station and the first end of the forming tube along a second longitudinal axis. Aspect 39.The apparatus of any of the foregoing aspects, wherein the second longitudinal axis is not parallel or coaxial with the first longitudinal axis. Aspect 40. A method of forming a film in a reclosable container using a forming apparatus, the forming apparatus including an elongated forming tube extending along a first longitudinal axis from a first end to a second longitudinally opposite end , the forming tube having a hollow interior adapted to receive a product to be disposed within the container, the method comprising: advancing a first portion of the film from the first end of the forming tube towards the second end of the forming tube in a parallel direction to the first longitudinal axis; heating the first portion of the film at a first heating station downstream of the first end of the forming tube; and forming a first feature of the first portion of the film at a thermoforming station downstream of the first heating station. Aspect 41. The method of any of the foregoing aspects, further comprising: advancing the first portion of film from a film reel station to the first end of the forming tube before advancing the first portion of film from the first end of the forming tube towards the second end of the forming tube. Aspect 42. The method of any of the foregoing aspects, wherein forming a first feature in the first portion of the film at the thermoforming station includes forming the first feature in the first portion of the film by a first mold element secured to a portion. of the formation tube. Aspect 43. The method of any of the foregoing aspects, wherein a second mold element cooperates with the first mold element to form the first feature, the second mold element being displaceable relative to the first mold element. Aspect 44. The method of any of the foregoing aspects, wherein forming the first feature of the first portion of the film at the thermoforming station includes forming a resealable lid on the first portion of the film, the lid being adapted to allow a user access an interior volume of the resealable container. Aspect 45. The method of any of the foregoing aspects, wherein forming the reclosable lid on the first portion of the film includes forming a hinge portion and a flap portion, the hinge portion hingedly coupling the flap portion to a reclosable container body panel. Aspect 46. The method of any of the foregoing aspects, wherein forming the first feature of the first portion of the film at the thermoforming station includes forming a release cap on the first portion of the film, the release cap being adapted to allow a user accesses an interior volume of the resealable container. Aspect 47. The method of any of the foregoing aspects, further comprising: folding a second portion of the film by a first folding assembly disposed downstream of the second end of the forming tube. Aspect 48. The method of any of the foregoing aspects, further comprising: folding a third portion of the film by a second folding assembly disposed downstream of the first folding assembly. Aspect 49. The method of any of the foregoing aspects, further comprising: sealing a fourth portion of the film by a set of sealing jaws before folding the second portion of the film by a first folding assembly. Aspect 50. The method of aspect 43, wherein sealing the fourth portion of the film includes partially sealing the fourth portion of the film to create a vent channel in the fourth portion of the film. Aspect 51. The method of aspect 34, further comprising: inserting a product to be disposed within the container at a first open end of a product funnel, the product funnel having a second open end longitudinally opposite the first end, the second end of the product funnel being disposed adjacent the first end of the forming tube such that product entering the first end of the product funnel is directed into the hollow interior of the forming tube. Aspect 52. The method of aspect 34, further comprising: attaching a first modular structure assembly to a primary structure assembly, wherein the forming tube is coupled to the primary structure assembly to support the forming tube, and wherein the first heating station is secured to a first portion of the first modular structure set and at least a portion of the first thermoforming station is secured to a second portion of the first modular structure set. Aspect 53. The method of aspect 34, further comprising: attaching a first set of modular structure to a set of primary structure, wherein the forming tube is coupled to the first set of modular structure, and wherein the first heating station is secured to a first portion of the first modular structure assembly and at least a portion of the first thermoforming station is secured to a second portion of the first modular structure assembly. Aspect 54. The method of aspect 46, further comprising: removing the first modular structure assembly from the primary structure assembly; and attaching a second modular frame assembly to the primary frame assembly, wherein a second heating station is secured to a first portion of the second modular frame assembly and at least a portion of a second thermoforming station is secured to a second portion. of the first set of modular structure, wherein the second thermoforming station is different from the first thermoforming station. Aspect 55. A method of forming a film in a reclosable container using a forming apparatus, the forming apparatus including an elongated forming tube extending along a first longitudinal axis from a first end to a second longitudinally opposite end the forming tube having a hollow interior adapted to receive a product to be disposed within the container, the method comprising: advancing a first portion of film from a film reel station to a first end of the forming tube; heating the first portion of the film in a first heating station upstream from the first end of the forming tube; and forming a first feature of the first portion of the film at a thermoforming station downstream of the first heating station and upstream of the first end of the forming tube. Aspect 56. The process of aspect 48, wherein forming a first feature of the first portion of the film at the thermoforming station includes forming the first feature of the first portion of the film by a first mold element and a cooperating second mold element with the first mold element to form the first feature, the second mold element being displaceable relative to the first mold element. Aspect 57. The method of aspect 48, wherein forming a first feature of the first portion of the film at the thermoforming station includes forming a resealable lid on the first portion of the film, the lid being adapted to allow a user to access a interior volume of the reclosable container. Aspect 58. The method of aspect 50, wherein forming the reclosable lid on the first portion of the film includes forming a hinge portion and a flap portion, the hinge portion hingedly coupling the flap portion to a panel of reclosable container body. Aspect 59. The method of aspect 48, wherein forming the first feature of the first portion of the film at the thermoforming station includes forming a removable cap on the first portion of the film, the removable cap being adapted to allow a user to access a interior volume of the reclosable container. Aspect 60. The method of aspect 48, further comprising: advancing the first portion of the film from the first end of the forming tube toward the second end of the forming tube in the direction parallel to the first longitudinal axis; Aspect 61. The method of aspect 48, further comprising: folding a second portion of the film by a first folding assembly disposed downstream of the second end of the forming tube. Aspect 62. The method of aspect 48, further comprising: folding a third portion of the film by a second folding assembly disposed downstream of the first folding assembly. Aspect 63. The method of aspect 54, further comprising: sealing a fourth portion of the film by a set of sealing jaws before folding the second portion of the film by a first folding assembly. Aspect 64. The method of aspect 56, wherein sealing the fourth portion of the film includes partially sealing the fourth portion of the film to create a vent channel in the fourth portion of the film. Aspect 65. The method of aspect 48, further comprising inserting a product to be disposed within the container at a first open end of a product funnel, the product funnel having a second open end longitudinally opposite the first end, the second end of the funnel of product being disposed adjacent the first end of the forming tube such that product entering the first end of the product funnel is directed into the hollow interior of the forming tube. Aspect 66. The method of aspect 48, further comprising: attaching a first modular structure assembly to a primary structure assembly, wherein the forming tube is coupled to the primary structure assembly to support the forming tube, and wherein the first heating station is secured to a first portion of the first modular structure set and at least a portion of the first thermoforming station is secured to a second portion of the first modular structure set. Aspect 67. The method of aspect 59, further comprising: removing the first modular structure assembly from the primary structure assembly; and attaching a second modular frame assembly to the primary frame assembly, wherein a second heating station is secured to a first portion of the second modular frame assembly and at least a portion of a second thermoforming station is secured to a second portion. of the first set of modular structure, wherein the second thermoforming station is different from the first thermoforming station. Aspect 68. A reclosable packaging assembly comprising: a container formed at least partially of a first sheet, the container having a plurality of walls cooperating to define an interior volume, the container having an opening through at least one of the plurality of walls ; a closure assembly secured to the container adjacent the opening, at least a portion of the closure assembly comprises a second sheet and a portion of the first sheet, the closure assembly including a lid member and a hinge portion, wherein the closure member lid is pivotable around the hinge portion between a first position, in which the lid element releasably engages with a first portion of the container surrounding the opening, and a second position, in which the lid element is hinged away from an opening portion around the hinge portion, thereby allowing a user to access the interior volume through the opening, wherein a first engaging feature is arranged on the container adjacent the opening and a second engaging feature is arranged on the cap element of the closure assembly, such that the first engagement feature on the second engagement feature to releasably secure the element. tion of the lid to the container when the lid element is in the first position. Aspect 69. A reclosable packaging assembly comprising: a container formed at least partially of a first sheet, the container having a plurality of walls cooperating to define an interior volume, the container having an opening through at least one of the plurality of walls ; a closure assembly secured to the container adjacent to the opening, at least a portion of the closure assembly comprising a second sheet and a portion of the first sheet, the closure assembly including a removable lid element, the lid element being movable between a first position, in which the removable lid element releasably engages a first portion of the container surrounding the opening, and a second position, in which the lid element is not in contact with the container, thereby allowing a user to access the interior volume through the opening, wherein a first engagement feature is disposed on the container adjacent the opening and a second engagement feature is disposed on the cap member of the closure assembly such that the first engagement feature on the second engagement feature to releasably secure the lid member to the container when the lid member is in the first position. Aspect 70. The reclosable packaging assembly of any of the foregoing aspects, wherein the first engaging feature extends at least one donor above or below the container. Aspect 71. The reclosable package assembly of any of the foregoing aspects, wherein the second engagement feature extends at least one of or up or down from the cap member of the closure assembly. Aspect 72. The reclosable packaging assembly of any of the foregoing aspects, wherein the second sheet is secured to the first sheet by an adhesive and the adhesive is applied to one or both of a second side of the second sheet and a first side of the first sheet. Aspect 73. The reclosable packaging assembly of any of the foregoing aspects, wherein the second engagement feature is integrally formed on the cap element of the closure assembly. Aspect 74. The reclosable packaging assembly of any of the foregoing aspects, wherein the first engaging feature is formed integrally with the container. Aspect 75. The reclosable package assembly of any of the foregoing aspects, wherein the first engaging feature is a rib and the second engaging feature is a channel adapted to releasably receive the rib. Aspect 76. The reclosable package assembly of any of the foregoing aspects, wherein the first engagement feature is a channel and the second engagement feature is a rib adapted to be releasably received in the rib. Aspect 77. The reclosable packaging assembly of any of the foregoing aspects, wherein the cap member has a first side edge and a second side edge parallel to the first side edge. Aspect 78. The reclosable packaging assembly of any of the foregoing aspects, wherein a first portion of each of the first engaging feature and the second engaging feature is elongated and has a longitudinal axis parallel to the first side edge and a second portion of each of the first engagement feature and the second engagement feature is elongated and has a longitudinal axis parallel to the second side edge. Aspect 79. The reclosable packaging assembly of any of the foregoing aspects, wherein a pouring spout is disposed adjacent to or in contact with the opening. Aspect 80. The reclosable packaging assembly of any of the foregoing aspects, wherein the pour spout is integrally formed in the container. Aspect 81. The reclosable packaging assembly of any of the foregoing aspects, wherein the pour spout extends at least one of or up or down from the container. Aspect 82. The reclosable package assembly of any of the foregoing aspects, wherein the cap member has a first end edge extending between a first end of the first side edge and a first end of the second side edge. Aspect 83. The reclosable packaging assembly of any of the foregoing aspects, wherein the first end edge is disposed normal to the first side edge and the second side edge. Aspect 84. The reclosable packaging assembly of any of the foregoing aspects, wherein at least a portion of the first end edge is non-linear. Aspect 85. The reclosable packaging assembly of any of the foregoing aspects, wherein at least a portion of the first end edge is at least partially curved. Aspect 86. The reclosable package assembly of any of the foregoing aspects, wherein a third portion of each of the first engagement feature and the second engagement feature is elongated and has a longitudinal axis parallel to the first end edge. Aspect 87. The reclosable packaging assembly of any of the foregoing aspects, wherein a third portion of each of the first engagement feature and the second engagement feature is elongated and has a non-linear axis that is displaced from the first edge of far end. Aspect 88. The reclosable package assembly of any of the foregoing aspects, wherein the cap member has a second end edge extending between a second end of the first side edge and a second end of the second side edge. Aspect 89. The reclosable packaging assembly of any of the foregoing aspects, wherein the second end edge is disposed normal to the first side edge and the second side edge. Aspect 90. The reclosable package assembly of any of the foregoing aspects, wherein any one of the first end edge, the second end edge, the first side edge, and the second side edge cooperate to define a pour spout. Aspect 91. The reclosable packaging assembly of any of the foregoing aspects, wherein at least a portion of the second end edge is non-linear. Aspect 92. The reclosable package assembly of any of the foregoing aspects, wherein the cap member has a second end edge extending between a second end of the first side edge and a second end of the second side edge. Aspect 93. The reclosable package assembly of any of the foregoing aspects, wherein a fourth portion of each of the first engagement feature and the second engagement feature is elongated and has a longitudinal axis parallel to the second end edge. Aspect 94. The reclosable package assembly of any of the foregoing aspects, wherein a fourth portion of each of the first engagement feature and the second engagement feature is elongated and has a non-linear axis that is displaced from the second edge of far end. Aspect 95. The reclosable package assembly of any of the foregoing aspects, wherein the first portion of the first engagement feature, the second portion of the first engagement feature, and the third portion of the first engagement feature form a single continuous feature. Aspect 96. The reclosable package assembly of any of the foregoing aspects, wherein the first portion of the first engagement feature, the second portion of the first engagement feature, the third portion of the first engagement feature, and the fourth portion of the first engagement feature hitch form a continuous, unique feature that surrounds the opening. Aspect 97. The reclosable packaging assembly of any of the foregoing aspects, wherein the opening is any of a rectangular, oval, oblong, round and/or polygonal shape. Aspect 98. The reclosable packaging assembly of any of the foregoing aspects, wherein a third sheet is secured to a second portion of the container adjacent the opening to stiffen the second portion of the container. Aspect 99. The reclosable package assembly of any of the foregoing aspects, wherein a second side of the second sheet is adjacent to a first side of the first sheet and a first side of the third sheet is adjacent to a second side of the first sheet. Aspect 100. The reclosable packaging assembly of any of the foregoing aspects, wherein the third sheet is attached to the first sheet. Aspect 101. The reclosable packaging assembly of any of the foregoing aspects, wherein the third sheet is bonded to the first sheet by an adhesive, heat seal, glue and/or ultrasonic welding. Aspect 102. The reclosable packaging assembly of any of the foregoing aspects, wherein the third sheet is integrally formed with the first sheet. Aspect 103. The reclosable packaging assembly of any of the foregoing aspects, wherein the lid element of the closure assembly has a convex portion that touches the hinge portion, the convex portion adapted to cooperate with the hinge to maintain the lid element in the second position. Aspect 104. The reclosable packaging assembly of any of the foregoing aspects, wherein the hinge portion comprises a pair of oppositely disposed cuts that may extend internally from a lid edge defining an outer perimeter edge of the lid element, and at that the cap element pivots from the first position to the second position around a portion of the closure element extending between an end end of each of the cuts. Aspect 105. The reclosable packaging assembly of any of the foregoing aspects, wherein, when the lid element is hinged to the second position, a first lid projection and a second lid projection deform to a position in which an edge formed by one or more segments comprising the cutout engages a portion of the closure assembly to support the cap member in the second position. Aspect 106. The reclosable package assembly of any of the foregoing aspects, wherein the closure assembly includes a locking mechanism that includes a locking feature that is received in a receiving feature when the cap member is in the second position. Aspect 107. The reclosable packaging assembly of any of the foregoing aspects, wherein the locking feature is a protrusion extending upwardly from the cap member and the receiving feature is a receiving slit that releasably retains the boss. Aspect 108. The reclosable packaging assembly of any of the foregoing aspects, wherein the lid comprises first and second projections disposed in a vicinity of the hinge portion, the first and second projections being movable between a first position, in which the projections are generally parallel to the wall having the opening, and a second position, in which the projections are generally perpendicular to the wall having the opening, to thereby retain the cap in the second position in which the cap element is hinged away from a portion of the opening at around the hinge portion. Aspect 109. The reclosable packaging assembly of any of the above aspects, in which the projections have a semicircular shape. Aspect 110. The reclosable packaging assembly of any of the foregoing aspects, wherein the projections are disposed equidistant from a cut in the lid that defines the hinge portion. Aspect 111. The reclosable packaging assembly of any of the foregoing aspects, wherein the projections are arranged not equidistant from a cut in the lid that defines the hinge portion. Aspect 112. A method of making a reclosable packaging assembly comprising a container that defines an interior volume, the method comprising: providing a first sheet; providing a second sheet attached to a first portion of the first sheet; forming a lid element of a closure assembly of a portion of the second sheet such that at least a portion of the lid element is secured to the first portion of the first sheet. forming a hinge portion of the closure assembly from the second sheet, the hinge portion being disposed adjacent the cap element; and wherein the lid element is pivotable about the hinge portion between a first position, in which the element releasably engages a first portion of the container surrounding an opening formed in the first sheet, and a second position, in which the lid element is hinged away from a portion of the opening. Aspect 113. A method of making a reclosable packaging assembly comprising a container defining an interior volume and having an opening adapted to access the interior volume, the method comprising: providing a first sheet; providing a second sheet attached to a first portion of the first sheet; and forming a lid element of a closure assembly from a portion of the second sheet such that at least a portion of the lid element is secured to the first portion of the first sheet, wherein the lid element is movable between a first position, in which the lid element releasably engages a first portion of the container surrounding the opening, and a second position, in which the lid element is not in contact with the container, thereby allowing a user to access the interior volume through the opening. Aspect 114. The method of any of the foregoing aspects, wherein the attachment of the first sheet portion to the second sheet first portion occurs prior to forming the second sheet lid member. Aspect 115. The method of any of the foregoing aspects, wherein the attachment of the first sheet portion to the first sheet portion of the second sheet occurs simultaneously with the formation of the cap element from the second sheet. Aspect 116. The method of any of the foregoing aspects, further comprising forming the container from the first sheet, the container having a plurality of walls that cooperate to define the interior volume. Aspect 117. The method of any of the foregoing aspects, wherein the formation of the first sheet container takes place after the formation of the lid member and the hinge portion of the closure assembly. Aspect 118. The method of any of the foregoing aspects, wherein forming a container from the first sheet includes forming a portion of the container simultaneously with forming the lid member and the hinge portion of the closure assembly. Aspect 119. The method of any of the foregoing aspects, further comprising forming a first engagement feature disposed on the container adjacent the opening and a second engagement feature disposed on the cap member of the closure assembly such that the first engagement feature in the second engagement feature for releasably securing the lid member to the container when the lid member is in the first position. Aspect 120. The method of any of the foregoing aspects, wherein the formation of the first engagement feature and the second engagement feature occurs simultaneously with the formation of the cap member. Aspect 121. The method of any of the foregoing aspects, wherein forming the first engagement feature includes forming the first engagement feature as a rib and forming the second engagement feature includes forming the second engagement feature as a channel adapted to releasably receive the rib. Aspect 122. The method of any of the foregoing aspects, wherein forming the first engaging feature includes forming the first engaging feature as a channel and forming the second engaging feature includes forming the second engaging feature as a rib adapted to be releasably received at the rib. Aspect 123. The method of any of the foregoing aspects, further comprising: providing a third sheet attached to a second side of the first sheet adjacent to the first portion of the first sheet, wherein the second sheet is secured to a first side of the first sheet, the third sheet stiffening the first sheet. Aspect 124. The method of any of the foregoing aspects, further comprising: wherein the attachment of the third sheet to the second side of the first sheet occurs prior to forming the cap element of the closure assembly. Aspect 125. The method of any of the foregoing aspects, wherein attaching the third sheet to the second side of the first sheet includes applying an adhesive or glue to one or both of the third sheet and the first sheet. Aspect 126. The method of any of the foregoing aspects, wherein attaching the third to the second side of the first sheet includes ultrasonically soldering or heat sealing one or both of the third sheet and the first sheet. Aspect 127. The method of any of the foregoing aspects, wherein attaching the third sheet to the second side of the first sheet includes integrally forming the third sheet with the second side of the first sheet. Aspect 128. The method of any of the foregoing aspects, wherein the formation of the opening occurs simultaneously with the formation of the cap element and the hinge portion. Aspect 129. The method of any of the foregoing aspects, wherein formation of the opening occurs prior to forming the cap member and the hinge portion. Aspect 130. The method of any of the foregoing aspects, wherein forming the cap element of the closure assembly includes thermoforming the cap element of a closure assembly. Aspect 131. The method of any of the foregoing aspects, wherein forming the first engagement feature and the second engagement feature includes thermoforming the first engagement feature and the second engagement feature. Aspect 132. The method of any of the foregoing aspects, wherein thermoforming of the first engagement feature and the second engagement feature occurs simultaneously with the formation of the cap element. Aspect 133. A flexible material for a flexible package, comprising: an opening panel region comprising a first sheet; and a second sheet attached to at least a portion of the first sheet in the opening panel region, wherein: the opening panel region is configured to define a pack panel having an opening for accessing an interior volume of the pack, the region The opening panel comprises an opening boundary configured to define the opening panel region comprises a first region and a second region adjacent to the first region, a first portion of the second sheet is secured to a first portion of the first sheet in the first region, a second portion of the second sheet is secured to a second portion of the first sheet in the second zone, a peel strength between the first and second sheets in the first region is greater than a second peel strength between the first and second sheets in the second zone; and at least portion of the second portion is configured to be thermoformed. Aspect 134. The flexible material of aspect 133, wherein the second peel strength is from about 10% to about 60% of the first peel strength. Aspect 135. The flexible material of aspect 133 or 134, wherein the first peel strength is at least 500 g/in. Aspect 136. The flexible material of any one of aspects 133 to 135, wherein the second peel strength is from about 0 g/in to about 200 g/in. Aspect 137. The flexible material of any of the foregoing aspects, wherein the first peel strength is from about 500 g/in to about 2000 g/in. Aspect 138. The flexible material of any of the foregoing aspects, further comprising an adhesive disposed in the opening panel region on one or both of the first and second sheets and an erasing agent disposed in the second zone on one or both of the first and of the second sheet, wherein the erasing agent in the second zone is applied having coverage of about 50% to about 100%. Aspect 139. The flexible material of any of the foregoing aspects, further comprising a marking on the first sheet in the opening panel region, wherein the marking defines the opening of the package and the first region is disposed on opposite sides of the marking. Aspect 140. The flexible material of any of the above aspects, wherein the second zone surrounds the first zone on at least three sides. Aspect 141. The flexible material of any of the foregoing aspects, further comprising a marking on the first sheet in the opening panel region, wherein the marker defines an outer boundary of the first region and the opening of the package. Aspect 142. The flexible material of aspect 141, wherein the opening panel region further comprises a third region between the first and second regions, the marking defining a third portion of the second sheet is secured to a third portion of the first sheet, and the third zone has a third peel strength that is less than the first peel strength. Aspect 143. The flexible material of aspect 142, wherein the third peel strength is substantially equal to or less than the peel strength of the second zone. Aspect 144. The flexible material of aspect 142, wherein the third peel strength is from about 0 g/in to about 200 g/in. Aspect 145. The flexible material of any one of aspects 142 to 144, further comprising an adhesive disposed in the opening panel region in one or both of the first and second sheets and an erasing agent disposed in the second and third zones in a or both of the first and second sheets, wherein the erasing agent in the second zone is applied having a coverage of about 50% to about 100%, and the erasing agent in the third zone is applied having a coverage of about 50% to about 100%. Aspect 146. The flexible material of any of the foregoing aspects, wherein the opening panel region further comprises a fourth region adjacent to the second region opposite the first region, wherein the fourth portion of the second sheet is secured to a fourth portion of the first sheet in the fourth zone and the fourth zone have a fourth peel strength that is less than the first zone. Aspect 147. The flexible material of any of the foregoing aspects, wherein a second portion of the second sheet is secured to a second portion of the first sheet in the second region. Aspect 148. The flexible material of any of the foregoing aspects, wherein the panel further comprises a pull tab portion, wherein a pull tab portion of the second sheet is disposed on a pull tab portion of the first sheet and has a third peel strength with the pull tab portion of the first sheet. , and the pull tab portion of the second sheet is configured to define a pull tab. Aspect 149. The flexible material of Aspect 148, wherein the peel strength of the pull tab is in the range of 0 g/in to about 30 g/in. Aspect 150. The flexible material of aspect 148, wherein the pull tab portion further comprises an erasing agent disposed on the first or second sheet. Aspect 151. The flexible material of any of the foregoing aspects, further comprising an adhesive disposed in the opening panel region on one or both of the first and second sheets and an erasing agent disposed in the second, third, and pull tab zones on one or both of the first and second sheets, wherein the erasing agent in the second zone is applied having a coverage of about 50% to about 100%, the erasing agent in the third zone is applied having a coverage of about from 50% to about 100%, and the erasing agent in the pull-tab region is applied having a coverage of about 100%. Aspect 152. The flexible material of any of the foregoing aspects, wherein the first portion of the first sheet is sealed to the first portion of the second sheet by at least one seal. Aspect 153. The flexible material of aspect 152, wherein the at least one seal is selected from the group consisting of a heat seal, an ultrasonic seal, a weld, a ripple, and combinations thereof. Aspect 154. The flexible material of aspect 152 or 153, wherein the second portion of the first sheet is secured to the second portion of the second sheet with an adhesive. Aspect 155. The flexible material of any of the foregoing aspects, further comprising a third sheet secured to a portion of the first sheet in the opening panel region. Aspect 156. The flexible material of aspect 155, further comprising at least one wall region comprising the first sheet, wherein the at least one wall region is configured to define at least one wall of the pack and the third sheet is secured to a portion of the first sheet in the at least one wall region of Aspect 157. The flexible material of aspect 156, wherein the at least one wall region comprises opposite first and second boundaries configured to define first and second wall boundaries and a portion of the third sheet at least partially overlaps with one or both of the first and second boundaries. Aspect 158. The flexible material of aspect 157, wherein the third sheet comprises a reduced line of strength in a portion of the third sheet that at least partially overlaps the first and/or second boundary. Aspect 159. The flexible material of aspect 155 or 156, wherein the third sheet completely overlaps the opening panel region. Aspect 160. A flexible material for a flexible package, comprising: a opening panel region comprising a first sheet, a second sheet attached to at least a portion of the first sheet in the opening panel region, and a third sheet attached to the fur. minus a portion of the first sheet in the opening panel region, wherein: the opening panel region is configured to define a package panel having an opening for accessing an interior volume of the package, the opening panel region further comprising first and second opposite edges configured to define first and second edges of the package panel having the opening, the third sheet comprises a reduced strength portion that at least partially overlaps with one or both of the first and second edges of the opening panel region , and the third sheet comprises a line of reduced strength on at least a portion of the reduced strength portion. Aspect 161. The flexible material of aspect 160, wherein a first region of the third sheet overlaps the first boundary of the at least one opening panel region and a second region of the third sheet overlaps the second boundary of the at least one panel region and the first and second regions of the third sheet are not contiguous. Aspect 162. The flexible material of aspect 160 or 161, further comprising at least one wall region comprising the first sheet, wherein the at least one wall region is configured to define at least one wall of the pack and a portion of the third sheet is secured to at least a portion of the first sheet in the at least one wall region Aspect 163. The flexible material of aspect 161, wherein the at least one wall region comprises opposite first and second boundaries configured to define edges of the wall, a portion of the third sheet at least partially overlaps one or both of the first and second edges and the third sheet comprises a reduced strength line in the portion of the third sheet which at least partially overlaps the first and/or second edges . Aspect 164. The flexible material of aspect 163, wherein the third sheet extends between and overlaps with the first and second boundaries. Aspect 165. The flexible material of aspect 161 to 164, wherein the third sheet completely overlaps the first sheet in the at least one wall region. Aspect 166. The flexible material of aspect 160, wherein a first region of the third sheet overlaps the first boundary of the at least one panel region and a second region of the third sheet overlaps the second boundary of the at least one panel region. wall and the first and second regions of the third sheet are not contiguous. Aspect 167. The flexible material of any one of aspects 161 to 166, wherein the portion of the third sheet secured to the first sheet in the at least one wall region is separate from the portion of the third sheet secured to the first sheet in the opening panel region . Aspect 168. The flexible material of any of the foregoing aspects, further comprising at least one wall region and at least one fold region comprising the first sheet, wherein the at least one wall region is configured to define at least one wall. of the pack, the at least one fold region is adjacent to a boundary of the opening panel region and/or a boundary of at least one wall region and at least one of the fourth sheet secured to the first sheet in the at least one folding region. fold, wherein the at least one fold fold region is configured to be folded inward to define the edge of the package or the package panel at the boundary. Aspect 169. The flexible material of any of the foregoing aspects, wherein the second sheet comprises a pull tab region. Aspect 170. The flexible material of aspect 169, wherein the first or second sheet further comprises an erasing agent in the pull tab region such that the pull tab region is not secured to the first sheet. Aspect 171. The flexible material of any of the foregoing aspects, wherein at least a portion of the second sheet is releasably secured to at least a portion of the first sheet. Aspect 172. The flexible material of any of the foregoing aspects, wherein the opening panel region further comprises a reduced strength opening line defining the opening of the package. Aspect 173. The flexible material of any of the foregoing aspects, comprising a reduced strength hinge line configured to define a hinge around which a lid of a closure assembly hinges. Aspect 174. The flexible material of aspect 173, wherein the low strength hinge line does not overlap with the low strength opening line. Aspect 175. The flexible material of any one of aspects 155 to 174, wherein the third sheet is substantially permanently attached to the first sheet. Aspect 176. The flexible material of aspect 175, wherein the third sheet is secured to the first flexible sheet material with a permanent adhesive. Aspect 177. The flexible material of any one of aspects 155 to 176, wherein the first sheet is disposed between the second and third sheets. Aspect 178. The flexible material of any one of aspects 155 to 176, wherein the third sheet is secured to the first sheet and the second sheet is secured to the first sheet. Aspect 179. The flexible material of any one of aspects 155 to 177, wherein the third sheet comprises a material selected from the group consisting of PP, PET, PLA, OPS, PS, PETG, polyamide, PE and blend, copolymers, laminates and combinations thereof. Aspect 180. The flexible material of any of the foregoing aspects, wherein the second sheet has a thickness of at least 6 mils. Aspect 181. The flexible material of any of the foregoing aspects, wherein the second sheet comprises a material selected from the group consisting of PP, PET, PLA, OPS, PE, PS, polyamide, PETG, blends, copolymers, laminates and combinations thereof . Aspect 182. The flexible material of any of the foregoing aspects, wherein the first sheet comprises a material selected from the group consisting of PP, PE, NY, PET, PS, PLA, blends, copolymers, laminates and combinations thereof. Aspect 183. The flexible material of any of the foregoing aspects comprises a plurality of opening panel regions discretely spaced along a longitudinal length of the flexible material, the plurality of opening panel regions comprising the first sheet and a plurality of second sheets affixed to the first sheet in each of the plurality of opening panel regions. Aspect 184. The flexible material of aspect 183, further comprising a plurality of third sheets secured to the first sheet in each of the plurality of aperture panel regions. Aspect 185. A method of forming a flexible material comprising an opening panel region configured to define a panel of the package having an opening, the opening panel region comprising a first sheet and a second sheet secured to the first sheet in at least the first sheet. and second zones, the first zone comprising a region in which an opening is configured to be formed and the second zone adjacent to the first zone, the method comprising: applying an adhesive to the opening panel region at least the first and second zones zones; and applying an erasing agent to the second zone; and affixing the first sheet to the second sheet in the first and second zones, the first and second sheets having a first peel strength in the first region and a second peel strength in the second region, wherein the first peel strength is greater than the second stripping resistance in which the second zone is configured to be thermoformed. Aspect 186. The method of aspect 185, wherein the opening panel region further comprises a third region disposed between the first and second portions, and the method further comprises applying an erasing agent to the third attachment region and securing the first sheet to the second sheet in the third zone, wherein the first and second sheets have a third peel strength in the third zone, and the third peel strength is less than the first peel strength. Aspect 187. The method of aspect 185 or 186, wherein the opening panel region further comprises a pull tab region and the method further comprises applying an erasing agent to the pull tab region, wherein the erasing agent will have 100% coverage in the pull tab region. Aspect 188. The method of any one of aspects 185 to 187, comprising applying the erasing agent to have about 50% to about 100% coverage in the second zone. Aspect 189. The method of any one of aspects 185 to 188, further comprising forming a line of reduced strength on the first sheet in the opening panel region. Aspect 190. The method of aspect 189, wherein the first zone is limited by the line of reduced resistance. Aspect 191. The method of aspect 190, wherein the third zone is disposed between the line of reduced resistance and the second zone. Aspect 192. The method of aspect 189, wherein the first zone comprises the line of reduced resistance. Aspect 193. The method of any one of aspects 185 to 189, further comprising attaching a third sheet to the first sheet in the opening panel region. Aspect 194. The method of aspect 193, further comprising forming a line of reduced strength on the third sheet to define the opening. Aspect 195. The method of aspect 194, comprising forming the line of reduced strength simultaneously on the first and third sheets. Aspect 196. The method of any one of aspects 185 to 195, further comprising forming a line of reduced strength on the second sheet to define a hinge around which a lid of a closure assembly hinges. Aspect 197. The method of aspect 196, wherein the line of reduced strength to form the opening and the line of reduced strength to form the hinge do not overlap. Aspect 198. A reclosable package comprising: a container formed at least partially of a first sheet, the container having a plurality of walls cooperating to define an interior volume, the container having an opening through at least one of the plurality of walls; a second sheet secured to a portion of the first sheet in at least a portion of two walls of the pack, wherein a portion of the second sheet provides a resealable flap disposed along the resealable closure opening of the pack. Aspect 199. The reclosable pack of aspect 198, wherein the second sheet is disposed along a boundary of two adjacent ones, wherein the boundary defines the edge of the pack and the second sheet is marked or perforated in a region of the boundary. Aspect 200. The method or apparatus of any of the foregoing aspects, further comprising a conveyor having a racetrack type configuration. Aspect 201. The method or apparatus of any of the foregoing aspects, further comprising a package receiving element disposed on a conveyor for receiving a package after removal from the forming tube. Aspect 202. The method or apparatus of any of the foregoing aspects, further comprising a carrier, wherein the carrier comprises a heat element or glue for adhering a package leak seal to one side of the package. Aspect 203. The method or apparatus of aspect 202, further comprising a folding element for folding the pack leakage seal into contact with the side of the pack. Aspect 204. A reclosable package assembly in accordance with any of the foregoing aspects, wherein the lid assembly comprises a pull tab disposed at a corner of the lid assembly. Aspect 205. A reclosable package assembly in accordance with any of the foregoing aspects, wherein the lid assembly comprises a hinge adjacent an end of the opening panel region. Aspect 206: A flexible container comprising: a plurality of walls cooperating to define an interior volume, the plurality of walls being defined by a first sheet, the plurality of walls comprising: opposing side walls each having a seal disposed along a a portion of the side wall and one or more folds, the folds each comprising a portion of the first sheet folded towards the inner volume and disposed at least partially under the seal, at least one wall defining an opening panel comprising at least one portion of an opening to access the interior volume, a second sheet attached to at least a portion of the first sheet, the second sheet at least partially extending over at least three of the plurality of walls, each of the at least three of the plurality of walls is adjacent to at least one of the other at least three of the plurality of walls, one of the at least three of the plurality of walls is the at least one wall defining the opening panel and a portion of the second sheet defines a resealable tab disposed over the opening for resealable closure of the container, one of the at least three of the plurality of walls is a side wall, the second sheet comprises extends over boundaries between adjacent walls of the at least three of the plurality of walls and a portion of the second sheet extends to at least one ply and the second sheet includes a reduced strength line at or adjacent to a boundary between a portion of the second sheet and extending to the at least one ply and a portion of the second sheet extending through an adjacent wall of the at least three of the plurality of walls between the sidewall. Aspect 207. The flexible container of aspect 206, wherein the second sheet includes lines of reduced strength at each of the boundaries between adjacent walls of the at least three of the plurality of walls. Aspect 208. The flexible container of aspect 206 or 207, wherein the second sheet has a thickness of 10 mils or less, the reduced strength line comprises one or both of the perforations having at least 10% cut openings, crease lines and extending by at least 10% to the thickness of the second sheet. Aspect 209. The flexible container of aspect 207 or 209, wherein the second sheet is greater than 10 mils thick, wherein at least one of the lines of reduced strength comprises one or both of the perforations having at least 50% cut openings, lines of crease that extending for at least 50% to the thickness of the second sheet. Aspect 210. The flexible container of any of the foregoing aspects, wherein the at least one wall defining the opening panel includes four corners defined by the first sheet, the second sheet includes openings in portions of the second sheet extending through the corners, so that the corner extends through the opening. Aspect 211. The flexible container of aspect 206, wherein: the at least three of the plurality of walls comprise the at least one wall defining an opening panel, one of the side walls, and a third wall adjacent the at least one wall defining the panel of opening, the second sheet extends through the at least one wall defining the opening panel and over a first boundary disposed between the at least one wall defining the opening panel and the side wall, the second sheet having an extending portion. for the folds of the side wall, the second sheet further extends over a second boundary disposed between the at least one wall defining the opening panel and the third wall, the second sheet extends at least partially over the third wall, the second sheet includes a first line of reduced strength at or adjacent to the first boundary, and the second sheet includes a second line of reduced strength at or adjacent to the second boundary. and. Aspect 212. The flexible container of aspect 211, wherein the first and second lines of reduced strength comprise perforations and the first line of reduced strength has a greater percentage cut opening than the second line of reduced strength. Aspect 213. The flexible container of either aspect 211 or 212, wherein the first line of reduced strength has about 50% to about 100% cut openings and the second line of reduced strength has about 1% to about 50% of openings cut. Aspect 214. The flexible container of aspect 213, wherein the first and second lines of reduced strength comprise crease lines and the first line of reduced strength has crease lines that extend deeper into the thickness of the second sheet than the second sheet. line of reduced resistance. Aspect 215. The flexible container of aspect 213, wherein the first line of reduced strength comprises a crease line extending about 50% to about 100% of the thickness of the second sheet and the second line of reduced strength extends about from 1% to about 50% for the thickness of the second sheet. Aspect 216. The flexible container of any one of aspects 211 to 215, wherein the third wall is adjacent the side wall, the second sheet extends over a third boundary disposed between the third wall and the side wall, and the second sheet includes a third line of reduced resistance at or adjacent to the second boundary. Aspect 217. The flexible container of aspect 216, wherein the second sheet is less than 10 mils thick and the third line of reduced strength comprises perforations having from about 1% to about 60% of cut openings and/or crease lines that extend about 1% to about 60% to the thickness of the second sheet. Aspect 218. The flexible container of aspect 216, wherein the second sheet is greater than 10 mils thick and the third line of reduced strength comprises perforations having about 50% to about 100% cut openings and/or crease lines that extend about 50% to about 100% for the thickness of the second sheet. Aspect 219. The flexible container of any one of aspects 216 to 218, wherein the third line of reduced strength is substantially linear and an edge of the container defined at the third boundary is substantially linear. Aspect 220. The flexible container of any one of aspects 216 to 218, wherein the third line of reduced resistance is curved, thereby defining an edge of the container disposed at the third boundary to have a curvature corresponding to the curve of the third line of reduced resistance . Aspect 221. The flexible container of any one of aspects 220, wherein a portion of the second sheet extending to the sidewall of the third boundary comprises a contour line of reduced strength that is a mirror image of the third line of reduced strength. Aspect 222. The flexible container of aspect 221, wherein the reduced strength contour line comprises perforations having substantially the same percentage cut opening as the third reduced strength line and/or the reduced strength contour line comprises crease lines having substantially the same percentage penetration as the crease lines of the third line of reduced strength. Aspect 223. The flexible container of any one of aspects 216 to 222, wherein the third line of reduced strength has substantially the same percentage cut opening as the first line of reduced strength and/or the penetration of one or more crease lines of the third line of reduced strength is substantially equal to the penetration of one or more crease lines of the first line of reduced strength. Aspect 224. The flexible container of any one of aspects 221 to 223, wherein the first boundary extends between the first and second corners and the second sheet includes openings in each of the first and second corners. Aspect 225. The flexible container of any of the foregoing aspects, wherein the second sheet further comprises a hinge defined by a reduced line of resistance, the hinge is disposed at one end of the resealable tab, and the resealable tab is pivotable about the hinge. a closed position in which the resealable tab is in contact with the opening panel to releasably close the opening, and an open position in which the resealable tab is hinged away from the opening panel. Aspect 226. The flexible container of any of the foregoing aspects, wherein the second sheet further comprises first and second projections disposed at one end of the resealable tab, the first and second projections being pivotable from a first position, in which the first and second projections projections are in the same plane as at least one wall defining the opening panel and the resealable flap is in a closed position, and a second position in which the first and second projections are oblique to the at least one wall defining the opening panel and the resealable flap is in an open position. Aspect 227. The flexible container of aspect 226, wherein the second sheet further comprises a hinge around which the resealable flap hinges from the closed position to the open position and the first and second projections are disposed on opposite sides of the hinge. Aspect 228. The flexible container of aspect 226 or 227, wherein the first and second projections are disposed equidistant from the hinge. Aspect 229. The flexible container of any one of aspects 226 to 228, wherein the first and second projections are semicircular in shape. Aspect 230. The flexible container of any of the foregoing aspects, wherein the resealable tab comprises a pull tab for gripping the resealable tab. Aspect 231. The flexible container of aspect 230, wherein the tongue is disposed adjacent a boundary between adjacent walls and the pull tongue is spaced about 0.03 inch to about 0.1 inch from a reduced strength line in the or adjacent to the boundary adjacent to the pull tab. Aspect 232. The flexible container of aspect 230, wherein the pull tab extends to or along the line of reduced strength at or adjacent to the boundary adjacent the pull tab. Aspect 233. The flexible container of any of the foregoing aspects, wherein at least one of the first and second seals is secured to the sidewall. Aspect 234. The flexible container of any of the foregoing aspects, wherein at least one of the first and second seals extends substantially perpendicularly to the sidewall and comprises a handle opening in a portion of the seal to define a loop. Aspect 235. The flexible container of any of the foregoing aspects, wherein the second sheet has a thickness of about 2 mils to about 30 mils. Aspect 236. The flexible container of any of the foregoing aspects, wherein at least one of the plurality of walls defines a bottom container wall on which the flexible container rests, and the bottom wall comprises a corner seal. Aspect 237. The flexible container of aspect 236, wherein at least one of the plurality of walls defining the opening panel is adjacent the bottom wall, the opening comprises a pull tab at one end and the pull tab is disposed adjacent the corner seal. . Aspect 238. The flexible container of aspect 236, wherein the at least one of the plurality of walls defining the opening panel is opposite the bottom wall. Aspect 239. The flexible container of any of the foregoing aspects, wherein at least one of the plurality of walls defines a bottom wall of the container on which the flexible container rests, and a third sheet is secured to the first sheet on the bottom wall. Aspect 240. The flexible container of any of the foregoing aspects, wherein the opening extends through at least two adjacent walls of the plurality of walls. Aspect 241. A flexible container, comprising: opposite top and bottom walls, opposite side walls, each side wall comprising a seal and folds disposed adjacent the top and bottom walls, the folds comprising part of the first sheet folded inwardly and disposed under the seal ; opposite front and rear walls, wherein the top, bottom, opposite side, front and rear walls cooperate to define an interior volume of the container and are defined by a first sheet; an opening for accessing the interior volume defined in one or more of the top wall, front wall and rear wall, a second sheet attached to at least a portion of the first sheet, the second sheet comprising: a top wall portion extending through at least minus one top wall, fold portions extending to the folds of the opposite side wall disposed adjacent the top wall, wherein the top wall portion and the fold portions are connected such that the second sheet extends through the first and the second opposite boundaries disposed at an interface between the top wall and the opposite side walls, respectively, a first and second face portion extending through at least a portion of the front and rear walls, respectively, wherein the top wall portion and the first and second face portions are connected such that the second sheet extends across the third and fourth opposite boundaries of each other. placed at an interface between the top wall portion and the first and second face portions, respectively; and side wall portions extending through at least a portion of each of the side walls, away from the seal, the side wall portions being connected to adjacent face portions such that the second sheet extends through a fifth, sixth , seventh and eighth boundaries arranged at respective interfaces between adjacent side wall portions and face portions, first, second, third, fourth, fifth, sixth, seventh and eighth lines of reduced strength disposed on the second sheet at or adjacent to the first, second , third, fourth, fifth, sixth, seventh and eighth thresholds, and a resealable flap defined in one or more of the top wall portions and in face portions and arranged to releasably cover the opening. Aspect 242. The flexible container of aspect 241, wherein the opening is defined in the top wall. Aspect 243. The flexible container of aspect 242, wherein the resealable tab comprises a pull tab and the pull tab has an end edge extending upwardly or across the first line of reduced strength. Aspect 244. The flexible container of aspect 242, wherein the resealable tab comprises a pull tab and an end edge of the pull tab is spaced at least 0.03 inch from the first line of reduced strength. Aspect 245. The flexible container of aspect 241, wherein the opening is defined in the front panel. Aspect 246. The flexible container of aspect 245, wherein the resealable tab comprises a pull tab, the bottom wall comprises a corner seal, and an end end of the pull tab extends into the corner seal. Aspect 247. The flexible container of aspect 241, wherein the opening is defined in the top wall and front panel. Aspect 248. The flexible container of any one of aspects 241 to 247, wherein the top wall comprises four corners and the top wall portion comprises a corner relief opening at the corners so that the second sheet is disposed around the corners. . Aspect 249. The flexible container of any one of aspects 241 to 248, wherein the first, second, fifth, sixth, seventh, and eighth lines of reduced strength comprise perforations having about 1% to about 50% cut openings. Aspect 250. The flexible container of any one of aspects 241 to 249, wherein the third and fourth lines of reduced strength comprise perforations having about 60% to about 99% cut openings. Aspect 251. The flexible container of any one of aspects 241 to 250, further comprising a third sheet attached to the bottom wall. Aspect 252. The flexible container of any one of aspects 241 to 251, wherein each seal is folded over and secured to the respective sidewall. Aspect 253. The flexible container of aspect 252, wherein each seal is heat sealed to the portion of the first sheet defining the sidewall. Aspect 254. The flexible container of aspect 252, wherein the side wall portions comprise first and second side wall portions, the first and second side wall portions extending through the side wall to the seal disposed on the respective side wall, each seal is folded over and sealed to the respective first or second sidewall portion. Aspect 255. A contoured flexible container, comprising: opposite top and bottom walls, opposite side walls, each side wall comprising a seal and folds disposed adjacent the top and bottom walls, the folds comprising part of the inwardly folded first sheet and disposed under the fence; opposite front and rear walls, wherein the top, bottom, opposite side, front and rear walls cooperate to define an interior volume of the container and are defined by a first sheet; an opening for accessing the interior volume defined in one or more of the top wall, front wall and rear wall, a second sheet attached to at least a portion of the first sheet, the second sheet comprising: a top wall portion extending through at least minus one top wall, fold portions extending to the folds of the opposite side wall disposed adjacent the top wall, wherein the top wall portion and the fold portions are connected such that the second sheet extends through the first and the second opposite boundaries disposed at an interface between the top wall and the opposite side walls, respectively, face portions extending through at least a portion of the front and rear walls, respectively, wherein the top wall portion and the face portions are connected such that the second sheet extends through the third and fourth opposite edges disposed at an interface between the wall portion. top and face portions, respectively; and side wall portions extending through at least a portion of each of the side walls, away from the seal, the side wall portions being connected to adjacent face portions such that the second sheet extends through a fifth, sixth , seventh and eighth boundaries arranged at respective interfaces between adjacent side wall portions and face portions, first, second, third, fourth, fifth, sixth, seventh and eighth lines of reduced strength disposed on the second sheet at or adjacent to the first, second , third, fourth, fifth, sixth, seventh and eighth limits, the fifth, sixth, seventh and eighth lines of reduced strength have a curved shape so that package edges defined between the side walls and the adjacent front and/or back panel have a curved shape, and a resealable tab defined in one or more of the top wall portion and face portions and arranged to releasably cover the opening. Aspect 256. The contoured flexible container of aspect 255, wherein the fifth, sixth, seventh and eighth lines of reduced resistance curve away from the fifth, sixth, seventh and eighth boundaries and into the face portions. Aspect 257. The contoured flexible container of aspect 255 or 256, wherein the side wall portion comprises a contoured line of reduced strength on the second sheet, the contour line of reduced strength being a mirror image. Aspect 258. The container flexible in contour of any of the aspects 255 to 257, where the opening is defined in the top wall. Aspect 259. The contoured flexible container of aspect 258, wherein the resealable tab comprises a pull tab and the pull tab has an end edge extending upwardly or along the first line of reduced strength. Aspect 260. The contoured flexible container of aspect 258, wherein the resealable tab comprises a pull tab and an end edge of the pull tab is spaced at least 0.03 inch from the first line of reduced strength. Aspect 261. The contoured flexible container of any one of aspects 255 to 257, wherein the opening is defined in the front panel. Aspect 262. The contoured flexible container of aspect 261, wherein the resealable tab comprises a pull tab, the bottom wall comprises a corner seal, and an end end of the pull tab extends into the corner seal. Aspect 263. The contoured flexible container of any one of aspects 255 to 257, wherein the opening is defined in the top wall and front panel. Aspect 264. The flexible container of any of the foregoing aspects, wherein further comprises a third sheet secured to the first sheet at least in the opening panel region. Aspect 265. A method of forming a sealable package, comprising: providing a web comprising a first sheet having a second sheet secured to a portion of the first sheet, the first sheet comprising an aperture defined therein; and bending the web to define a plurality of walls which cooperate to define an interior volume of the container, the interior volume being accessible through the opening; sealing the edges of the web to define first and second seals, thereby defining the first and second side walls, wherein: the plurality of walls comprises: opposite first and second side walls having first and second seals, respectively, disposed along a side wall portion and a fold portion, the fold portion comprising a portion of the first sheet folded towards the inner volume and disposed at least partially under the seal, at least one wall defining an opening panel comprising at least a portion of the opening, the second sheet extends at least partially over at least three of the plurality of walls, each of the at least three of the plurality of walls being adjacent to at least one of the other at least three of the plurality of walls, one of the at least three of the plurality of walls is the at least one wall defining the opening panel and a portion of the second sheet defines a resealable tab. 1 disposed over the opening for resealable closure of the container, one of the at least three of the plurality of walls is a side wall, the second sheet extends over boundaries between adjacent walls of the at least three of the plurality of walls and a portion of the second sheet is extends to at least one ply, and the second sheet includes a line of reduced strength at or adjacent to a boundary between a portion of the second sheet extending into the at least one ply and a portion of the second sheet extending through an adjacent wall. of at least three of the plurality of walls. Aspect 266. The method of aspect 265, wherein the web is folded around a forming tube, the forming tube comprises an outer extension on at least one side and a plate for creasing the web around the outer extension. Aspect 267. The method of aspect 265 or 266, the method further comprising folding over at least one of the first and second seals and securing the seal to the respective sidewall. Aspect 268. The method of aspect 267, wherein folding over at least one of the first and second seals comprises arranging the pack in a holder having a size and shape corresponding to the flexible container, actuating a first plate against a portion of the sidewall, not including the seal, and actuating a second plate against a remaining portion of the side wall including the seal, the second plate providing the seal against the side wall to secure the seal to the side wall. Aspect 269. A method of forming a contoured flexible container, the method comprising: providing a web comprising a first sheet having a second sheet secured to a portion of the first sheet, folding the first sheet to define a plurality of cooperating walls to define an interior volume of the container, the plurality of walls comprising opposite top and bottom walls, opposite front and rear walls, and opposite first and second side walls, wherein: the container comprises a first edge between the first side wall and the front wall, a second edge between the first side wall and the rear wall, a third edge between the second side wall and the front wall, and a fourth edge between the second side wall and the rear wall, at least one of the top wall, front wall and Bottom wall has at least part of an opening defined therein, the second sheet extends at least partially over the walls. On the front and rear and first and second side walls, the second sheet comprises first, second, third and fourth lines of reduced strength on or adjacent to the first, second, third and fourth edges of the container, respectively, the first, second, third and fourth lines of reduced strength are each curved in shape, and upon folding of the first sheet, the first sheet defines first, second, third and fourth edges resulting from the first, second, third and fourth lines of reduced strength being curved. Although various embodiments have been described above, this disclosure is not intended to be limited thereto. Variations can be made in the described modalities that are still within the scope of the attached aspects.

权利要求:
Claims (16)
[0001]
1. Flexible package (12), comprising: a plurality of panels cooperating to define an interior volume (18) of the package (12), the plurality of panels being defined by a first sheet (14) and comprising: a first panel disposed between and adjacent to second and third panels disposed transversely to the first panel; a first boundary line defined by an intersection between the first and second panels; and a second boundary line defined by an intersection between the first and third panels; an aperture (20) defined in at least one of the first panel, the second panel or the third panel of the first sheet (14); a second sheet (24) secured to the first sheet (14) at (i) at least one of the first panel, the second panel, and the third panel in which the opening (20) is defined and (ii) a panel adjacent to at least one of the first panel, the second panel or the third panel in which the opening (20) is defined; CHARACTERIZED in that the second sheet (24) comprises a reduced strength line (653) defining a reclosable tab (623) formed by a portion of the second sheet (24) which is separable from a remaining portion of the second sheet (24) , the resealable tab (623) is pivotable between a first position in which the resealable tab (623) overlaps the opening (20) in the first sheet (14) and a second position in which the resealable tab (623) is disposed separate from the opening (20) in the first sheet (14), so that the opening (20) is exposed, and wherein the second sheet (24) is attached to less than a whole of the first sheet (14) and the second sheet (24). ) has a width that is greater than a width of the resealable tab (623) and the resealable tab (623) has a width that is greater than a width of the opening (20) in the first sheet (14); and one or more corners formed by the first sheet (14) at one or more end ends of at least one of the first boundary line and the second boundary line, and one or more corner reliefs defined by the second sheet (24), each the one or more corner reliefs receiving the one or more corners.
[0002]
2. Flexible material (400) for a flexible package, comprising: a first sheet (414) comprising a plurality of panel regions comprising a first panel region disposed between the second and third panel regions, and one or more corner regions; a second sheet (416) secured to the first sheet (414) in at least a portion of the first panel region and a portion of the second panel region, wherein the second sheet (416) comprises one or more corner reliefs disposed in regions. corner so that when configured for a flexible package, portions of the first sheet (414) in one or more corner regions define one or more corners that extend through the corner reliefs; CHARACTERIZED in that it further comprises a third sheet (418) attached to the second sheet (416) in at least a portion of the first panel region and attached to the first sheet (414) in at least a portion of the third panel region, at that the flexible material comprises an opening region defined in the first sheet (414) and the second sheet (416) in at least the first panel region, and a tab is defined in the third sheet in the first panel region and overlapping the region of opening, the flap having a width greater than the opening region.
[0003]
3. Flexible package (12) according to claim 1, CHARACTERIZED by the fact that the plurality of panels further comprises: a first side wall and a second opposite side wall, each side wall comprising a seal disposed along a portion of the side wall and one or more folds, each of the folds comprising part of the first sheet (14) folded towards the interior volume (18) and disposed at least under the seal; the second sheet (24) secured to at least a portion of the first sheet (14), the second sheet (24) at least partially extending over at least three of the plurality of panels, wherein: each of the at least three of the the plurality of panels is adjacent to at least one of the other at least three of the plurality of panels, and the at least three of the plurality of walls (16) comprises the at least one of the first panel, the second panel or the third panel in where the opening is defined, the first panel, and the third panel adjacent to at least one of the first panel, the second panel or the third panel in which the opening is defined, a portion of the second sheet (24) defines a resealable tab disposed over the opening for resealable closure of the package, the second sheet (24) extends over a boundary disposed between the at least one of the first panel, the second panel or the third panel in which the opening is defined and the first wall laterally, a portion of the second sheet (24) extends to the at least one ply, the second sheet (24) includes a first line of reduced strength at or adjacent to the boundary disposed between the at least one of the first panel of the second panel or of the third panel in which the opening is defined, the second sheet (24) additionally extends over the second boundary, the second sheet (24) extends at least partially over the third panel, the second sheet (24) includes a second line of reduced strength at or adjacent to the second edge, the third wall is adjacent to the first side panel, the second sheet (24) extends over a third edge disposed between the third panel and the first side panel, the second sheet ( 24) includes a third line of reduced strength at or adjacent to the third boundary, the third line of reduced strength is curved, thereby defining an edge of the container disposed at the third boundary to have a corresponding curvature. plummeting to the curve of the third line of reduced strength, and a portion of the second sheet (24) extending to the first sidewall of the third boundary comprising a contour line of reduced strength that is a mirror image of the third line of reduced strength.
[0004]
4. Flexible package (12), according to any one of claims 1 to 3, CHARACTERIZED by the fact that the resealable flap (623) is pivotable around a hinge (28), and the package additionally comprises: one or more projections extending from one end of the resealable tab (623) at a location adjacent to the hinge (28), the one or more projections having distal ends spaced apart from the resealable tab (623) and being movable with the resealable tabs (623) between : a passive position in which the one or more projections generally occupy the same plane as at least one of the first, second and third panels in which the opening is defined, and an active position in which the one or more projections are angled relative to at least one of the first, second and third panels in which the opening is defined and the distal ends of the one or more projections contact at least one of the first, second and third panels in which the opening is defined to hold the flap retracted movable (623) in the second position, the one or more projections optionally comprising first and second projections disposed on opposite sides of the hinge (28).
[0005]
5. Flexible package (12), comprising: a first panel disposed between the second and third panels that are transverse to the first panel; a first boundary line defined by an intersection between the first and second panels; a second boundary line defined by an intersection between the first and third panels; fourth and fifth panels disposed adjacent opposite ends of the first panel and extending between the second and third panels, wherein the fourth panel comprises a lead seal and the fifth panel comprises a leak seal and the first, second, third panels. , fourth and fifth panels are formed from a first sheet (14); a third boundary line defined by an intersection between the first and fourth panels; a fourth boundary line defined by an intersection between the first and fifth panels; CHARACTERIZED by the fact that it further comprises a first and a second ply disposed adjacent to the third and fourth boundary lines, respectively, the first and second plies defined by portions of the first sheet (14) that are folded inwardly towards the interior of the package ( 12) and arranged behind the fourth and fifth panels, respectively; a second sheet (24) comprising a first portion attached to the first sheet (14) in at least a portion of the first panel, and at least a second portion attached to the first sheet (14) in at least a portion of at least one of the first panel. and second folds, wherein at least a second portion has a first end disposed adjacent a boundary between the first panel and at least one of the fourth and fifth panels and a second end opposite the first end, wherein a width of at least one second portion at the first end is greater than a width of at least one second portion at the second end.
[0006]
6. Flexible package (12), according to claim 5, CHARACTERIZED in that it further comprises a line of reduced strength (653) disposed on the second sheet (24) at or adjacent to one or both of the third and fourth boundary lines.
[0007]
7. Flexible package (12) according to claim 5, CHARACTERIZED by the fact that the fourth panel comprises an attack seal and the fifth panel comprises a leakage seal, wherein the second sheet (24) is not attached to the first sheet (14) on the attack and escape seals.
[0008]
8. Flexible package (12), according to any one of the preceding claims, CHARACTERIZED by the fact that it comprises: one or more corners formed by the first sheet (14) at one or more end ends of at least one of the first row limit and the second limit line; and one or more openings in the second sheet (24) defining one or more corner reliefs, each of the one or more corner reliefs having a corner extending through the opening (20).
[0009]
9. Flexible package (12), according to any one of the preceding claims, CHARACTERIZED by the fact that it comprises one or more lines of reduced strength arranged on the second sheet (24) at or adjacent to at least one of the first and second boundary lines of the first sheet (14).
[0010]
10. Flexible package (12), according to any one of the preceding claims, CHARACTERIZED by the fact that the second sheet (24) is fixed to the first sheet (14) in at least a portion of the first panel, at least one portion of the second panel, and at least a portion of the third panel.
[0011]
11. Flexible package (12), according to any one of the preceding claims, CHARACTERIZED by the fact that the second sheet (24) is fixed to the first sheet (14) in at least portions of the first panel and the second panel and the reclosable tab (623) extends through at least a portion of the first panel and at least a portion of the second panel.
[0012]
12. Flexible material for a flexible package (12) as defined in claim 1, CHARACTERIZED in that it comprises: said first sheet (14) comprising a plurality of panel regions comprising a first panel region disposed between the second and third panel regions, and one or more corner regions, wherein the first sheet (14) comprises an opening region disposed in at least one of the first, second, or third panel regions, and said second sheet (24) is attached. to the first sheet (14) in (i) at least a portion of at least one of the first, second and third panel regions in which the opening region is defined, and (ii) at least a portion of a panel region adjacent to at least one of the first, second or third panel region, wherein a portion of the second sheet (24) overlaps the opening region and comprises a reduced strength line (653) defining a reclosable tab (623) which is with Figured to partially detach from a remaining portion of the second sheet (24) along the line of reduced strength (653) to expose the opening region, the reclosable tab (623) is integral with the remaining portion of which it is partially detached. , the second sheet (24) has a width that is greater than a width of the reclosable flap (623), and the second sheet (24) is secured to less than a whole of the first sheet (14), and wherein the second sheet sheet (24) comprises one or more corner reliefs disposed in the one or more corner regions so that when configured for a flexible package (12), portions of the first sheet (14) in the one or more corner regions define one or more corners that extend through the corner reliefs.
[0013]
13. Flexible material according to claim 12, CHARACTERIZED in that the tab (623) has a length extending between a first end and an oppositely disposed second end, the tab (623) comprises one or more projections extending to outside the second end of the tab, the tab (623) being configured to detach from a remaining portion of the second sheet (24) and pivot so that the one or more projections are in the same plane as the first sheet (14) when the tab (623) is in the first position, and are angled relative to the remaining portion of the second sheet (24) when tab (623) is in the second position.
[0014]
14. Flexible material according to claim 12, CHARACTERIZED in that the first sheet (14) further comprises: oppositely disposed fourth and fifth panel regions, and adjacently disposed to opposite ends of the second panel region; and oppositely disposed sixth and seventh panel regions and adjacently disposed opposite ends of the third panel region; and wherein the second sheet (24) is secured to at least one of: (ii) at least a portion of the second panel region and at least a portion of one or both of the fourth and fifth panel regions, and (iii) by the at least a portion of the third panel region and at least a portion of one or both of the sixth and seventh panel regions.
[0015]
15. Flexible material according to any one of claims 11 to 13, CHARACTERIZED by the fact that the first sheet (14) comprises one or more corner zones in which a corner defined by the flexible material is formed in the form of a package, and the second sheet (24) comprises one or more openings defining one or more corner reliefs disposed in one or more corner zones.
[0016]
16. Method for manufacturing the reclosable package assembly as defined in claim 1, the method being CHARACTERIZED in that it comprises: securing the second sheet (24) to a first portion of the first sheet (14); forming the cap element (26) of a closure assembly (22) from the second sheet (24); and thermoforming the first sheet (14) to define the first engagement feature (36) which is disposed adjacent to and at least partially surrounding the opening, wherein the first sheet (14) and the first engagement feature (36) are a single-piece unitary structure; thermoforming the second sheet (24) to define the second engaging feature (38) disposed on the cap element of the closure assembly (22), wherein the second sheet (24) and the second engaging feature (38) are a unitary structure one-piece.

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法律状态:
2018-05-29| B25A| Requested transfer of rights approved|Owner name: PRIMAPAK, LLC (US) |

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2018-11-21| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

---

2019-12-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

---

2020-11-17| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

---

2021-04-06| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

---

2021-07-20| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-08-17| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 25/10/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201261719340P| true| 2012-10-26|2012-10-26|

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US61/719,340|2012-10-26|

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US201261739535P| true| 2012-12-19|2012-12-19|

---

US61/739,535|2012-12-19|

---

US201361769168P| true| 2013-02-25|2013-02-25|

---

US61/769,168|2013-02-25|

---

US201361801186P| true| 2013-03-15|2013-03-15|

---

US61/801,186|2013-03-15|

---

US201361860233P| true| 2013-07-30|2013-07-30|

---

US61/860,233|2013-07-30|

---

PCT/US2013/066985|WO2014066867A1|2012-10-26|2013-10-25|Flexible package and method of making the same|

---