US20100147724A1 - Tamper indicator for reclosable packages - Google Patents

Abstract

A reclosable package for storing and dispensing product. The package has a reclosable opening panel that can be selectively moved from a closed position where product contained within the package is retained to an open position where product contained within the package is exposed for dispensing. The package includes a tamper indicator that provides one or more of a visual, tactile, or auditory indication that the opening panel is being opened for the first time or has been previously opened.

Description

• The present invention relates to a reclosable product package for storing and dispensing products, particularly consumable products and more particularly confectionery products such as chewing gum and candy. In particular, the present invention relates to a tamper indicator for a reclosable package to provide an indication that the package is being opened for the first time and/or that the package has been previously opened.
• Certain consumable products are provided as individual pieces in a package. Oftentimes, it is desired to retain these products within the package yet when the package is opened, an individual piece can be exposed and removed from the package. In view of the fact that the package is reclosable, it would be desirable to provide some indication as part of the package that the package is being opened for the first time and/or has been previously opened.
SUMMARY
• The present invention therefore provides a package that includes, as part of the package, a tamper indicator that provides an indication that the package is being opened for the first time and/or has been previously opened. The package of the present invention is suitable for storing and dispensing individual pieces of edible product, particularly confectionery products such as candy and more particularly pieces of chewing gum. The tamper indicator of the present invention may also be used with a reclosable container that is configured to removably store one or more packages that, in turn, contain several individual pieces of edible product such as chewing gum or other confectionery products.
• The term reclosable as used herein refers to a package having an opening feature which may be repeatedly opened and securely reclosed for at least a sufficient number of times to permit consumption of the entire contents of the package, one piece at a time.
• In one embodiment, the reclosable package includes a laminated sheet having an inner layer and an outer layer. Each or both of the inner layer and the outer layer may be a single layer or may include a plurality of layers that act as a single layer for the purposes of the present invention. A first score line is created (for example, by a laser scoring operation) and extends at least substantially into the inner layer but does not extend into the outer layer. The term “score line” as used in the following specification and claims means a weakened line in the layer material that is intended to assist in separating the material along the score line. The score line may be a continuous line cut to full or partial depth of the layer or it may be a linear series of intermittent cuts to full or partial depth of the material. In any case, it is understood that the line may be straight, curved or some combination of these along its length. Due to the benefits of flexibility and precision, laser scoring is the preferred method of creating the score lines. In the case where the score line is created through the use of a laser, the score line may be referred to as a laser scored line.
• A second score line is created and extends at least substantially into the outer layer but does not extend into the inner layer. The second score line is laterally offset from the first score line to define a marginal region between the first and second score lines and to further define a surrounding region outside of the marginal region. The second score line also defines an opening panel for the package. A releasable adhesive may be provided between the inner and outer layers in at least a portion of the marginal region. A laminating adhesive is disposed between the inner and outer layers and it is provided substantially throughout the surrounding region such that the laminating adhesive is effective to bond the inner and outer layers together where it is applied. The package includes a tamper indicator that provides one or more of a visual, tactile, or auditory indication when the opening panel is first opened. The tamper indicator may further provide one or more of a visual or tactile indication that the opening panel has been previously opened.
• In one aspect, the tamper indicator includes printable ink underlying the opening panel that is revealed when the opening panel is opened. Alternatively, the printable ink (or printing) may be provided on the outer layer in a manner such that the printing traverses at least a portion of the second score line. As a result, when the opening panel is opened, the alignment of the word or at least a portion of it will be disturbed and when the opening panel is closed, alignment of the word or at least a portion of it will be disturbed.
• In another aspect, the tamper indicator includes a frangible link connected to a portion of the opening panel that, when lifted, provides an auditory and/or visual indication that the opening panel is being lifted. For example, the second score line may create a tab connected to the opening panel through a narrow conduit which constitutes the frangible link so that when the opening panel is opened for the first time, the frangible link is broken to allow access to the contents of the package. In one embodiment, a discontinuity in the second score line defines the frangible link. In further embodiments, the tamper indicator includes two or more frangible links located in key locations at the periphery of the opening panel. In an embodiment, two frangible links are located on opposite lateral sides of the opening panel.
• In other aspect, the opening panel may be configured such that upon first opening of the opening panel, a portion of the inner layer or outer layer is delaminated from a second portion of the same layer. In one embodiment, the laminating adhesive may be provided in a portion of the marginal region such that in that portion of the marginal region (i.e., where the laminating adhesive has been applied), a portion of the inner or outer layer is delaminated from a second portion of the same layer. In an embodiment, a tab defined by the second score line may have a portion that is permanently adhered to the package (for example, by application of the laminating adhesive) so that when a portion of the tab is moved away from the package, the score line will tear providing a visual and auditory indication that the seal has been broken and that the opening panel may have been opened. After the tab has been torn, evidence of such will be readily evident.
• In yet another aspect of the invention, the outer layer may be itself composed of two layers, a first opaque layer oriented toward the inner layer of the package and a second transparent layer oriented toward the outside of the package. In an embodiment, a laminating adhesive is applied (for example, as a pattern) within a portion of the marginal region. When the package is opened for the first time, the outer layer is delaminated where the laminating adhesive was applied, causing a pattern to be revealed in the second transparent layer where the opaque material was removed and on the inner layer where the first opaque layer material adheres to the inner layer of the package. Upon re-closure of the opening panel, it will be difficult or impossible to re-align the patterns thus providing an indication that the package was previously opened.
• For purposes of the present invention, “laminate” and “lamination” refer to any process which produces a multi-layer structure. In addition to traditional adhesive lamination, processes such as coextrusion and vacuum metallization are specifically contemplated.
• Also for purposes of the present invention, the term “delamination” refers to the complete or partial separation of layers that may occur between layers or within a given layer.
• In another aspect, a portion of the package that is covered by the opening panel may be provided with one or more of a light sensitive dye or other material such that when the opening panel is opened to expose the portion, the dye may cause a color change or other visual indication. In another aspect, the package may include a security tape located over at least a portion of the opening panel such that an expectation of the presence is created, which when the security tape is not present, or is torn, will provide an indication that the package has been previously opened. While particular examples of visual, tactile, and auditory indicators have been noted, the present invention is not limited to these specified examples. Rather, the invention includes any suitable visual, tactile, or auditory indicator that does not interfere with or inhibit the operation of the opening panel.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 shows an individual flexible product package according to one embodiment of the present invention with the reclosable opening panel in an open position to expose contents, which in this instance is chewing gum.
• FIG. 2 is a view of a portion of a first side of an outer layer for one embodiment of a package of the present invention showing a pattern of laminating adhesive applied to one side of the outer layer so that the outer layer can be adhered to a first side of an inner layer.
• FIG. 3 is a view of a portion of a first side of an outer layer for another embodiment of a package of the present invention showing a pattern of laminating adhesive applied to one side of the outer layer so that the outer layer can be adhered to a first side of an inner layer.
• FIG. 4 is a view of a portion of a second side of an inner layer, which will form the inner surfaces of the package and the other side of which is laminated onto a second side of the outer layer of any of the embodiments shown inFIGS. 2 and 3 to form a laminate roll stock.
• FIG. 5 is a view of a portion of the second side of the outer layer, which will form the outer surfaces of the package, the other side of which is laminated onto the second side of the inner layer to form a laminate roll stock.
• FIG. 6 is a partial cross sectional view of the laminate ofFIG. 5 with the adhesive pattern ofFIG. 2.
• FIG. 7 shows the package ofFIG. 1 with the reclosable opening panel in a closed position.
• FIG. 8 shows an embodiment of the package according to the present invention where the package is formed from a separate front and rear sheets.
• FIG. 9 shows an embodiment of the package according to the present invention where the package is formed with a rear side having a seal.
• FIG. 10aand10bshow the rear of the package ofFIG. 9 with two different rear seals.
• FIG. 11 is a diagrammatic depiction of a method for making a flexible package according to the present invention.
• FIG. 12 is a view of the outer layer structure before being laminated to the inner layer structure and after being scored.
• FIG. 13 is a cross-sectional view of a portion of one package, for example, a package made according to the process shown inFIG. 11 in a closed configuration.
• FIG. 14 is a cross-sectional view of a portion of the package ofFIG. 13 in an open configuration.
• FIG. 15 is a diagrammatic depiction of a method for making a flexible package according to the present invention, which contains features that can be used in the process depicted inFIG. 11.
• FIG. 16 shows a flexible container useful for storing and carrying a plurality of individual product packages such as those shown inFIGS. 1 and 7, each of which can contain a plurality of individual pieces of edible product, particularly chewing gum. The container is shown in an unopened position.
• FIG. 17 shows the container ofFIG. 16 in an open position.
• FIG. 18 shows a suitable configuration for a piece of gum that may be stored in the individual product packages.
• FIG. 19 shows a suitable configuration for a slab of gum that may be stored in the individual product packages.
• FIG. 20 is an alternative individual product package where the individual product package is in the form of a cylinder with a reclosable opening panel in a closed position.
• FIG. 21 shows the individual product package ofFIG. 19 with the reclosable opening panel in an open position to expose individual pieces of gum.
• FIG. 22 shows the individual product package ofFIG. 19 with the reclosable opening panel in an open position to expose a portion of a roll of gum that has a portion that has been scored.
• FIG. 23 shows an individual product package according to one embodiment of a tamper indicator.
• FIG. 24 shows an individual product package according to another embodiment of a tamper indicator.
• FIG. 25 shows an individual product package according to another embodiment of a tamper indicator
• FIG. 26 shows an individual product package according to another embodiment of a tamper indicator.
• FIG. 27 shows an individual product package according to another embodiment of a tamper indicator.
• FIG. 28 shows an individual product package according to another embodiment of a tamper indicator.
• FIG. 29 shows an individual product package according to another embodiment of a tamper indicator.
• FIG. 30 shows an individual product package according to another embodiment of a tamper indicator.
• FIG. 31 shows an individual product package according to another embodiment of a tamper indicator.
• FIG. 32 shows an individual product package according to another embodiment of a tamper indicator.
• FIG. 33 shows an individual product package according to another embodiment of a tamper indicator.
DETAILED DESCRIPTION
• The invention is described with reference to the drawings in which like elements are referred to by like numerals. The relationship and functioning of the various elements of this invention are better understood by the following description. Each aspect so defined may be combined with any other aspect or aspects unless clearly indicated to the contrary. The embodiments described below are by way of example only, and the invention is not limited to the embodiments illustrated in the drawings.
• Turning now toFIG. 1, areclosable package10 is shown with areclosable opening panel80 in an open position to expose thecontents2 of the package. The package includes opposedsurfaces12,14, an opposed top20 and bottom22, and opposed ends orsides24,26. One of the surfaces is scored to define areclosable opening panel80 that can be opened to expose thecontents2 stored within thepackage10. Thepackage10 is shown in a closed configuration inFIG. 7.
• In the description provided below, thepackage10 of the present invention is described as containing sticks (or tabs)2 of gum. It is to be understood, however, that the use of thepackage10 is not limited to gum, confections, or even consumable products, unless otherwise noted. For ease of description, however, the present invention will be described in connection with sticks of gum.
• Therefore, areclosable product package10 having an array ofgum sticks2 is shown inFIG. 1. Thepackage10 retains and encloses the array ofgum sticks2 as will be described below. Areclosable opening panel80 provides selective access to thecontents2 within thepackage10.
• As is known, gum sticks may be elongate rectangular shaped members that are individually wrapped with awrapper4 in a conventional fashion. Thewrapper4 may be a rectangular shaped member typically made of paper or foil. Typically, the longitudinal edges of the wrapper are overlapped and the ends of are turned over against the stick to enclose the stick.
• FIG. 1 showsgum sticks2 contained inwrappers4, where the gum sticks were individually wrapped prior to being placed in thepackage10. Thewrapper4 may be a single sheet or may include one or more sheets or layers. It is noted that the gum sticks2 can be placed in an array directly into the package, without being individually wrapped.
• WhileFIG. 1 shows thesticks2 oriented within thepackage10 in one direction, it is contemplated that the sticks could be oriented in a direction perpendicular to that shown inFIG. 1. Alternatively, thesticks2 may be oriented in another direction so long as when theopening panel80 is in an open position, access to the sticks is provided.
• FIG. 1 also shows the gum sticks2 aligned in a single row. It is to be understood that the gum sticks (wrapped or not) can be placed in a face-to-face manner, i.e., in two or more columns to form the array. When two or more columns are provided, each row may be encircled partially or completely by a wrapper to better contain the individual gum sticks. The array of gum sticks is placed in thepackage10 and are retained and enclosed. A portion of the inside of thepackage10 may contain an adhesive to releasably secure the gum sticks until the consumer removes them from thepackage10.
• Although it is not depicted, it is contemplated that one or more gum sticks may be contained within aflexible package10 and that one or moreflexible packages10 may be provided in acontainer800 as described below. Because thepackage10 and thecontainer800 are intended to be reclosable, as described in more detail below, the package is provided with atamper indicator950 that will provide an indication that thepackage10 has been first opened and/or has been previously opened.
• Thepackage10 is generally a parallelepiped shape and formed of any suitable material. Without being limited, it is contemplated that thepackage10 can be formed of a flexible plastic material, such as polyethylene (including but not limited to low density polyethylene and linear low-density polyethylene), polypropylene, mixtures or laminates of such, and other flexible plastics. The package could also be formed from metalized plastics, paper, laminated paper material, or other laminates. While it is contemplated that the package can be formed from a variety of suitable materials, for ease of understanding and description thepackage10 and its construction will be described as being formed from a flexible plastic material such as polypropylene.
• In general, the package is a laminated sheet having an inner layer and an outer layer. Each of the inner layer and outer layer or both may be a single layer or may include a plurality of layers that act as a single layer for purposes of the present invention. Accordingly, in one aspect, thepackage10 is formed from a laminate30 that includes a polypropylene film and optionally a polyethylene film. For example, thepackage10 may be formed from a laminate30 that includes ametal layer122 disposed between two layers ofpolypropylene42,120.
• Turning now toFIG. 2, one method of forming of one embodiment of thepackage10 will be explained. Briefly, this method includes creating a laminate from a first and second material, scoring each side of the laminate, cutting the laminate, filling the laminate with the desired contents, forming the package, and sealing appropriate areas to provide thepackage10. While several methods of forming thepackage10 are described below, each will produce a package having the features identified and shown inFIGS. 1 and 7.
• Accordingly, an outer layer ofmaterial40 may be unwound from a web (not shown). Theouter layer40 may be formed of polypropylene having afirst side44, asecond side46, alongitudinal direction48, and a lateral direction50 as shown inFIGS. 2 and 6. Desirably, the polypropylene is an oriented polypropylene with the orientation in the lateral direction50. As one skilled in the art will appreciate, orientation in this direction provides a higher resistance to tearing in thelongitudinal direction48 as compared to the lateral direction50. WhileFIG. 2 depicts a continuous layer of material, the figure also identifies afirst end52 and asecond end54, which when cut and joined to each other in a later operation will form the bottom22 of the package.
• Thefirst side44 of theouter layer40 is patterned with adhesive so that another layer may be adhered to thefirst side44 of theouter layer40. Thesecond side46 of theouter layer40 will form the outer surfaces of thepackage12 and14, as will become clear. Typically, theouter layer40 is patterned with apermanent laminating adhesive70 and a releasable adhesive72 (such as a pressure sensitive adhesive) as it is being unwound and before it is adhered to aninner layer100.
• FIG. 2 shows one pattern of adhesive application. As shown inFIG. 2, afold line60 is depicted at about the middle of the longitudinal length of theouter layer40. It is to be understood that thefold line60 is not provided on theouter layer40 but instead it represents the portion of theouter layer40 where the laminate30 will be folded in a later operation to create the top20 of thepackage10. Thefold line60 defines atop section62 and abottom section64 of theouter layer40 that will define aninner back surface18 and an inner front surface16 of thepackage10, respectively.
• In the embodiment shown inFIG. 2, apermanent laminating adhesive70 well known to those of skill in the art is applied to a sufficient portion of thetop section62 of theouter layer40 and only to a portion of thebottom section64. Thepermanent laminating adhesive70 may be applied to the entire portion of the top section, if desired. Put another way, thelaminating adhesive70 is distributed throughout a surrounding region63 (explained later in connection with the marginal region) to at least the extent necessary to effectively join theinner layer100 and theouter layer40 to allow thepackage10 to function as intended. Thelaminating adhesive70 may be applied evenly throughout the entirety of thesurrounding region63. Alternatively, it may be applied evenly to key areas where delamination could otherwise occur. It is also contemplated to provide thelaminating adhesive70 as a repeating or random pattern in discrete areas such as by using a dot matrix or cross hatch patterns. Of course, one or more combinations could also be used.
• In thebottom section64, afirst smile area82 is defined. Thefirst smile area82 includes a releasable adhesive72 such as a releasable pressure sensitive adhesive known to those of skill in the art. An adhesive-free area74 may be provided adjacent to at least a portion of the releasableadhesive area72. A releasable adhesive72 functions to join the outer40 and inner100 layers and it has a relatively low bond force to allow easy separation of the outer40 and inner100 layers. In addition, the releasable adhesive is capable of re-adhering the outer40 and inner100 layers a sufficient number of times (i.e., a sufficient number of iterations of joining and separating the layers). An adhesive-free area74 may be provided adjacent to at least a portion of the releasableadhesive area72. The adhesive-free area74 does not contain any adhesive, the reasons for which will become apparent upon further reading of the description.
• FIG. 3 shows an alternative pattern of applying the adhesive to thefirst side44 of theouter layer40. This pattern is similar to that ofFIG. 2 except that the adhesive-free area74 is limited simply to atongue portion84.
• Turning now toFIG. 4, aninner layer100 is shown. The inner layer ofmaterial100 may be unwound from a web (not shown). Theinner layer100 may be formed from any suitable material as noted above. The material desirably is formed from a composite or laminate such that one layer can be scored with a laser while the other layer resists scoring. For example, the material may be a laminate of paper and metal or foil, or a laminate of a flexible plastic material and metal or foil. In one aspect of the present invention, theinner layer100 is a formed from metalized polypropylene, i.e., a layer ofpolypropylene120 and a layer ofmetal122 provided on one side of thepolypropylene120.
• Theinner layer100 has a first side102 (best seen inFIG. 6), a second side104 (best seen inFIG. 4), alongitudinal direction106 and alateral direction108. Desirably, the polypropylene is an oriented polypropylene with the orientation in thelateral direction108.
• As the inner layer ofmaterial100 is unwound, thefirst side102 of theinner layer100 is joined with thefirst side44 of theouter layer40. Theouter layer40 and theinner layer100 are laminated in a manner such that the layer of metal orfoil122 is disposed between the layers of thepolypropylene42 and120 and such that a laminate30 is formed. In other words, the layer ofmetal122 is in contact with the adhesive70,72 provided on thefirst side44 of thefirst layer40. Desirably, theinner layer100 is securely adhered to theouter layer40.
• Optionally, a heat-sealing layer124 such as a layer of polyethylene may be provided on thesecond side104 of theinner layer100. Alternatively, other layers may be provided on thesecond side104 or theinner layer100, as is known to those of skill in the art.
• FIG. 4 shows thesecond side104 of theinner layer100. It is to be understood thatFIG. 4 also shows the laminate30 with thesecond side104 of theinner layer100 visible. WhileFIG. 4 depicts a continuous layer of laminate, the figure also identifies afirst end103 and asecond end105, which, when cut and joined to each other by folding alongfold line110 in a later operation, will form the bottom22 of the package. It is to be understood that thefold line110 is not provided on theinner layer100 but instead it represents the portion of theinner layer100 where the laminate30 will be folded in a later operation to create the top20 of thepackage10. Thefold line110 defines atop section112 and abottom section114 of theinner layer100, which will form the rear14 andfront12 surfaces, respectively.
• As seen inFIG. 4, ascore line132 is created on thebottom section114 of thesecond side104 of theinner layer100. Desirably, the scoring may be performed after the laminate30 is formed. Alternatively, the scoring may be performed before theinner layer100 is laminated to theouter layer40. Desirably, thescore line132 is created by laser scoring and, as shown inFIG. 4, can be considered to define an inner smile cut132. The inner smile cut or scoreline132 will also define aninner smile area130, as will become clear upon reading the following description.
• The term score line is means a weakened line that is intended to assist the consumer in separating the material along the line. The score line may be a continuous line cut to partial depth of the layer or it may be a linear series of intermittent cuts to a full or partial depth of the layer. It is understood that the score line may be straight, curved, or a combination of these along the length of the score line.
• The scoring is on thepolypropylene layer120 only (or the polyethylene and heat seal layers, if a heat seal layer is present) and does not score beyond the metal layer122 (i.e., it does not score the first layer). The depth of the laser cut may be controlled in a manner known by those of skill in the art to provide such precision cutting. Specifically, the heat dissipation of the metal layer (or other laser scoring resistant material) reduces the likelihood that it is scored when the power of the laser is controlled for that purpose.
• Thescore line132 has afirst end131 and asecond end133 each of which is adjacent thefold line110. Desirably, thefirst end131 andsecond end133 terminate at substantially the same lateral location so that theinner smile area130 is substantially symmetric. Consistent with the objectives of the present invention, a localizedweak portion135 of thescore line132 may be provided between thefirst end131 and thesecond end133. The localizedweak portion135 has a break force that is less than the break force of the non-localized weak portion of thescore line132.
• The term break force is used to mean the force required to separate theinner smile area130 from thebottom section114 along the score line. The break force is dictated generally by the materials of construction, their orientation, and the score line itself, (i.e., how many “holes” and how big the “holes”, how far apart are the “holes”). One of skill in the art would understand that when laser scoring the material one or more operating parameters can be varied that will affect the break force. Accordingly, the localizedweak portion135 will have afirst end137 and asecond end139, each of which defines the end point of the localizedweak portion135 along thescore line132. The localizedweak portion135 is generally located at the tear propagation location which generally is located near thetongue84, as will become clear from the description below.
• Thetop section112 of thesecond side104 of theinner layer100 may include areleasable adhesive140 applied along a line or strip that runs in thelateral direction108. Thereleasable adhesive140 may be applied in a continuous or intermittent manner according to methods well known to those of skill in the art. Thisadhesive strip140 may engage some or all of the gum sticks2 or theirwrappers4 so that when thepackage10 is formed; the gum sticks2 are removably adhesively retained in the package. As a result, the gum sticks2 may remain positioned in thepackage10 even when one ormore gum sticks2 are removed. In addition, the adhesive140 may prevent the gum sticks from becoming inadvertently dislodged from thepackage10.
• Turning toFIG. 5, thesecond side46 of the laminate30 is shown. It will be understood thatFIG. 5 also shows the laminate30 with thesecond side46 of theouter layer40 visible. As seen inFIG. 5, anouter score line86 is created on thebottom section64 of thesecond side46 of theouter layer40. The scoring may be performed after the laminate30 is created and can be performed before, simultaneously with, or after the scoring is performed on thesecond side104 of theinner layer100. Alternatively, the scoring may be performed before the lamination process described above. Desirably, thescore line86 is created by laser scoring and, as shown inFIG. 6, can be considered to define an outer smile cut86. The outer smile cut orouter score line86 defines anouter smile area82 with atongue84. The scoring is on thepolypropylene layer42 only and does not score beyond the metal layer122 (i.e., it does not score the second polypropylene layer100). The depth of the laser cut may be controlled in a manner known by those of skill in the art to provide such precision cutting. Theouter smile area82 is larger than theinner smile area130.FIG. 6 shows a partial side cross sectional view of the portion of the laminate30 that has been score cut.
• In addition, as will be appreciated from the foregoing description, the first orinner score line132 and the second orouter score line86 are located in a manner with respect to each other (e.g. they are laterally offset) to define amarginal region73 between them and to also define asurrounding region63 which is the area other than themarginal region73.
• Thescore line86 has afirst end81 and asecond end83 each of which is adjacent thefold line60. Desirably, thefirst end81 andsecond end83 terminate at substantially the same lateral location so that theouter smile area82 is substantially symmetric. Consistent with the objectives of the present invention, a localizedweak portion85 of thescore line82 is provided between thefirst end81 and thesecond end83. The localizedweak portion85 has a break force that is less than the break force of the non-localized weak portion of thescore line86.
• The term break force is used to mean the force required to separate theouter smile area82 from thebottom section64 along thescore line86. The break force is dictated generally by the materials of construction, their orientation, and the score line it, (i.e., how many “holes” and how big the “holes”, how far apart are the “holes”). One of skill in the art would understand that when laser scoring the material one or more operating parameters can be varied which will affect the break force. Accordingly, the localizedweak portion85 will have afirst end87 and asecond end89, each of which defines the end point of the localizedweak portion85 along thescore line86. The localizedweak portion85 is generally located at the tear propagation location which generally is located near thetongue84.
• Referring back toFIG. 1, it is seen that one surface of thetongue84 may be printed or patterned with a rubberized or elastomeric material to provide a gripping surface. Advantageously, providing such a grip surface may also work to position the tongue in a position where it can be easily grasped by the user. For example, the additional weight caused by the presence of the rubberized or elastomeric material may work to cause the printed surface to lay adjacent thefront surface12. While a representative pattern of printed material is shown inFIG. 1, it is contemplated that the pattern could take any suitable and desired shape.
• After the laminate30 is formed and score cut, the laminate may be wound to form roll stock (not shown). During thepackage10 forming operation, the laminate30 is unwound from the roll stock. A portion of thesticks2 are placed adjacent thesecond side104 of theinner layer100 and the laminate30 is folded along thefold line110. The laminate30 is folded such that thetop section112 of thesecond side104 of theinner layer100 is juxtaposed with thebottom section114 of thesecond side104 of theinner layer100 and such that thetop section62 and thebottom section64 will form the rear14 andfront12 surfaces, respectively, of thepackage10. The laminate30 is then cut and sealed to create the bottom22 and ends24,26 of thepackage10. Of course, it is to be understood that these operations could take place in other sequences. For example, the laminate30 may be unwound and cut, after which the sticks are placed adjacent thesecond side104 of theinner layer100. Thereafter, the laminate30 is folded alongfold line110, cut, and then sealed to create the bottom22 and ends24,26 of thepackage10.
• Turning now toFIG. 7, thepackage10 is shown with the outer smile cut86 visible on the front12 surface. With the above in mind, when it is desired to open thepackage10, thetongue84 is lifted or pulled away from the front12 surface. Because of the scoring or inner smile cut132 on theinner layer100 and because themetal layer122 on theinner layer100 is adhered to theouter layer40, the inner smile cut132 of theinner layer100 tears together with the outer smile cut86 on theouter layer40. In addition, because theinner smile area130 is smaller than theouter smile area82, and because of the prior pattern application of releasable adhesive72 (as well as the provision of an adhesive-free area74), areclosable opening panel80 is defined with releasable adhesive72 provided adjacent theperimeter88 of the opening panel. Moreover, the portion of theopening panel88 that contains thereleasable adhesive72 is in contact with a portion of themetal layer122 to provide an effective reclosable seal.
• It is understood that the releasable adhesive72 will have a delamination force, by which is meant the force required to separate theopening panel80 from the package along the releasable adhesive72 portion. The delamination force should have a strength suitable to repeatedly maintain the opening panel in a closed position yet not be so strong as to be an impediment to the opening of the opening panel.
• In one aspect a localizedweak portion85 may be provided adjacent thetongue84. Thus, when thetongue84 is lifted or moved away from the front12 surface, the initial tear propagation point will be in the area of the localizedweak portion85 between theends87 and89 so that as thetongue84 is moved away from the front12 surface, theopening panel80 will tear along thescore line86 starting at the localizedweak portion85 and terminating at theends81 and83. Because theinner score line132 is constructed in a similar fashion as theouter score line86, the inner score line will operate in a similar manner.
• In addition, it is desirable to provide a delamination force of the releasable adhesive72 that is greater than the localizedweak portion85 break force and/or the break force of thescore line86,132. In this instance, a portion of theopening panel80 will begin to separate from thepackage10 along the localizedweak portions85,135 and then along the score lines86,132 before theopening panel80 separates from thepackage10 along the releasable adhesive72 location. It is also desirable to provide thelaminating adhesive70 with a bond strength that defines the amount of force necessary to separate the inner100 and outer40 layer such that the bond strength of thelaminating adhesive70 is greater than the break force of thefirst score line132. In this way, as theopening panel80 is moved away from thepackage10, theinner layer100 is carried with theouter layer40 in thesurrounding region63 of theopening panel80.
• Turning now toFIG. 8, another method of making thepackage10 is shown. In this embodiment, a first laminate150 is formed to define afront surface152. The first laminate150 may be formed in the same manner described above in connection with the formation of the laminate30, except that the laminate will not be folded. Instead, asecond material154 will be used or formed to define a back156 surface. Thesecond material154 may be formed from any suitable material such as polypropylene, polyethylene, laminates, or other materials that can effectively seal with the first laminate150 to provide aclosed package10 according to the present invention.
• The first laminate150 will be scored in the manner described above to provide areclosable opening panel80 in the same manner as described above. Thereafter, each of the edges of the first laminate150 and thesecond material154 are sealed to create aclosed package10.
• Turning now toFIG. 9, another method of making thepackage10 is shown. In this embodiment, a laminate330 is made in the same manner as described above, except, as seen inFIG. 9, the laminate will have threesections302,304,306 with twofold lines308,310. In addition, thefirst section302 has a peripheral edge320 that will join with aperipheral edge334 provided on thethird section306. To finish thepackage10, thefirst section302 and thethird section306 are folded away from the outer smile cut86 and toward each other after the product has been inserted. Theperipheral edges320 and334 are sealed, such as by heat sealing or other suitable means. Alternatively, afin seal350 as shown inFIG. 10aor alap seal360 as shown inFIG. 10bmay be created at the rear of thepackage10. Of course, other known seals may be created as is known to those of skill in the art.
• Turning now toFIG. 11, another embodiment of the manufacturing process of the present invention is depicted. Afirst structure440 is formed by joining afirst layer442 with asecond layer446. Thefirst layer442 may be advanced from asupply roll444 and thesecond layer446 may be advanced from adifferent supply roll448. Adhesive450 may be applied to thefirst layer442, thesecond layer446, or both. Thereafter, thefirst layer442 and thesecond layer446 may be joined in alaminating station452 to form thefirst structure440.
• Alternatively, thefirst structure440 may be supplied from a roll of preformed first structure laminate600 (as best seen inFIG. 15). In addition, whileFIG. 11 shows thefirst structure440 being formed from two film layers, it is contemplated that thefirst structure440 could be formed from more than two layers, e.g., from three or more layers. In addition, the formedfirst structure440 could be rolled up on aspool600 for later processing, as described below.
• Various materials can be used for the layer(s) of thefirst structure440, including polymers such polyesters, polyolefins (including homopolymers and copolymers), polyamides, and others; paper; metal foil; and the like. Advantageously, when metal foil is used as an inner layer, it allows partial scoring through the outer layer while maintaining structural integrity for later operations such as scoring, batch rolling, transporting, batch unrolling, and the like.
• Thefirst structure440 may then be advanced by suitable web driving and handling equipment (not shown) to anoptional print station480 comprising a printing apparatus, such as a rotogravure printer or the like, for printing graphics and/or indicia on the first structure by applying inks to a surface of thefirst structure440. In one embodiment of the invention, thefirst structure440 includes an outer layer that is substantially transparent and may be reverse-printed in the print station so that the inks will be visible through thefirst structure440. The inks may be applied to the surface of thefirst structure440 that is subsequently laminated to another structure, as described below; from the opposite side of the first structure, which will form an exterior of apackage10 constructed from the laminate430 created according to this embodiment.
• Prior to printing thefirst structure440 at theprint station480, the surface of thefirst structure440 to be printed can be treated by a corona discharge orflame treatment apparatus482 to render the surface more-receptive to the inks and/or to render the surface more-readily bondable to the pressure-sensitive adhesive that is subsequently pattern-applied to the surface as described below.
• Following the optional corona/flame treatment and/or optional printing operation, thefirst structure440 may be advanced to the next processing stage or it may be rolled up onto a spool602 (as best seen inFIG. 15) and stored for subsequent processing operations.
• Thefirst structure440 either from the previous processing step or fromroll602 is advanced to ascoring station520 where a first score line86 (FIG. 7 andFIG. 13) is formed through the thickness of thefirst structure440. Thefirst score line86 is in registration with (i.e., coincides with) the printing of the graphics or indicia or other features. Thefirst score line86 extends substantially through the thickness of thefirst structure440.
• Thefirst scoring station520 can comprise a laser. The use of lasers for scoring through flexible materials is generally known, for example as described in U.S. Pat. Nos. 3,909,582 and 5,229,180, the contents of which are incorporated herein by reference. The depth of the score line formed by the laser can be regulated by regulating the power output or beam intensity of the laser beam, the width or spot size of the laser beam, and the amount of time a given spot on the film surface is irradiated by the beam. These factors generally are selected based on the characteristics of the material being scored. Some materials are more readily scored by lasers than other materials, as known in the art.
• As noted, thefirst score line86 should be in registration with one or more features such as printing, indicia marks, the location of the outer perimeter of the pressure-sensitive strip492 (and the outer perimeter of thetongue84 orthumb tab500, if present). To accomplish this registration, the operation of the laser is controlled to be synchronized with the advancement of the first structure. A sensor disposed adjacent the first structure can be used to detect a feature on the first structure (such as printing) whose location in relation to the strip of pressure-sensitive adhesive492 is known, and the sensor's output signal can be used by a suitable controller (not shown) for controlling the laser. Subsequent to the scoring, thefirst structure440 may be rolled ontospool604 for subsequent processing (as best seen inFIG. 15).
• After scoring, thefirst structure440 may be advanced (either fromspool604 or from the previous continuous scoring station520) to a firstadhesive application station490 at which a pressure-sensitive adhesive492 (releasable adhesive) may be applied to thefirst structure440 in a predetermined pattern that recurs at regular intervals along the lengthwise direction of thefirst structure440. The predetermined pattern may be in the form of a strip of various forms or shapes. As illustrated, one shape for the strip pattern may be generally U-shaped or smile shaped, for reasons that will become apparent. Other shapes for the pattern can be used. The pattern can include a region that is free of adhesive500 and that will ultimately form a thumb tab or grasping portion of thefirst structure440 as further described below.
• The pressure-sensitive adhesive492 can comprise various compositions. Pressure-sensitive adhesives form viscoelastic bonds that are aggressively and permanently tacky, adhere without the need of more than a finger or hand pressure, and require no activation by water, solvent or heat. Pressure-sensitive adhesives are often based on non-crosslinked rubber adhesives in a latex emulsion or solvent-borne form, or can comprise acrylic and methacrylate adhesives, styrene copolymers (SIS/SBS), and silicones. Acrylic adhesives are known for excellent environmental resistance and fast-setting time when compared with other resin systems. Acrylic pressure-sensitive adhesives often use an acrylate system. Natural rubber, synthetic rubber or elastomer sealants and adhesives can be based on a variety of systems such as silicone, polyurethane, chloroprene, butyl, polybutadiene, isoprene, or neoprene. When the packaging laminate of the invention is to be used for food packaging, the pressure-sensitive adhesive generally must be a food-grade composition. Various pressure-sensitive adhesives are approved by the U.S. Food and Drug Administration for use in direct food contact, as regulated by 21 CFR Part 175.300. Food-grade pressure-sensitive adhesives are preferred for use in the present invention. Additives (e.g., particulates or the like) can be added to the pressure-sensitive adhesive to reduce the tenacity of the bond to thesecond structure460, if necessary, so that the pressure-sensitive adhesive492 readily detaches from thesecond structure460 on opening (particularly on the very first opening).
• While denoted as a pressure-sensitive adhesive, the use of a cohesive is also contemplated. In this regard, the term “cohesive” refers to a material that is an adhesive that only sticks to a cohesive surface, most commonly to another layer of itself. Cohesives are commercially available from a supplier such as Henkel and the particular cohesive composition is not a feature of the present invention. Typically, the cohesive is applied to thefirst structure440. The desired cohesive is such that, although it is applied to thefirst structure440, a portion of the cohesive is transferred to the portion of theouter structure460 juxtaposed with the area on which the cohesive is applied. In addition, the cohesive is formulated such that the bonding affinity between the cohesive and either of thefirst structure440 and thesecond structure460 is greater than the bonding affinity between the cohesive on each of the first and second structure so that the portions containing the cohesive are rebondable or reclosable.
• The pattern of pressure-sensitive adhesive492 is applied to thefirst structure440 at regular intervals along thefirst structure440. The spacing or index distance d between the patterns can correspond to a dimension, such as a length, ofpackages10 to be produced from thelaminate430.
• Theadhesive application station490 can comprise any suitable device capable of accurately applying the pressure-sensitive adhesive492 to thefirst structure440 in the desired pattern at regular intervals along thefirst structure440. For example, theadhesive application station490 can comprise one or more gravure rolls that pick up the pressure-sensitive adhesive492 from a reservoir on the outer surface of the roll such that the adhesive fills one or more recessed areas in the surface. A doctor blade may then be used to scrape off excess adhesive so that it remains essentially only in the recessed area(s). Thefirst structure440 may be contacted by the gravure roll with a backing roll that may be used to provide support on the opposite side of thefirst structure440.
• After application of the pressure-sensitive adhesive492, thefirst structure440 may be advanced to adryer496 such as an oven or the like, to dry the pressure-sensitive adhesive492. Thefirst structure440 may then advanced to a secondadhesive application station510 at which apermanent laminating adhesive512 is applied to thefirst structure440 in such a manner that a sufficiently large proportion of the surface is covered by thepermanent laminating adhesive512 to permit thefirst structure440 to be adhesively attached to asecond structure460 at adownstream laminating station530. Alternatively, thefirst structure440 may be advanced to the secondadhesive application station510 before being advanced to thedryer496. Thereafter, thefirst structure440, which contains both the pressure-sensitive adhesive492 and thepermanent laminating adhesive512, is advanced to thedryer516 to dry the adhesives.
• Thepermanent laminating adhesive512 does not cover the pressure-sensitive adhesive492. Furthermore, when the pattern of pressure-sensitive adhesive492 includes an adhesive-free region500 (74) to form a thumb tab or grasping portion as previously noted, the pattern of thepermanent laminating adhesive512 also does not cover the adhesive-free region500 (74). Thus, thepermanent laminating adhesive512 should be applied by an apparatus capable of accurately applying thepermanent laminating adhesive512 in a predetermined pattern, in registration with the pressure-sensitive adhesive492 but not covering it or the adhesive-free region500 (74), if present. A suitable adhesive application device can be a gravure roll of the type previously described.
• Thepermanent laminating adhesive512 can comprise various compositions. Suitable examples include two-component polyurethane adhesive systems, such as Tycel 7900/7283 available from Henkel.
• WhileFIG. 11 depicts a certain order of processing of thefirst structure440, it is contemplated that the various processing steps can be varied according to manufacturing and processing desires. Thus, for example, it may be desirable to apply adhesives prior to scoring.
• After application of the adhesives and any optional drying, thefirst structure440 is advanced to alaminating station530 that can include a pair of rolls forming a nip therebetween. Thefirst structure440 is passed through the nip along with asecond structure460 that is separately advanced, and thefirst structure440 is laminated to thesecond structure460.
• As noted above, thesecond structure460 is advanced separately from thefirst structure440 to thelaminating station530. Thesecond structure460 may be formed from one or more layers. Thesecond structure460 may be coextensive with thefirst structure440, i.e., the width of thesecond structure460 may be substantially equal to the width of thefirst structure440 and the longitudinal edges of thesecond structure460 substantially coincide with the longitudinal edges of thefirst structure440.
• As shown inFIG. 11, thesecond structure460 may be formed from two layers. Accordingly, thesecond structure460 is formed by joining afirst layer462 with asecond layer466. Thefirst layer462 may be advanced from asupply roll464 and thesecond layer466 may be advanced from adifferent supply roll468. Adhesive470 may be applied to thefirst layer462, thesecond layer466, or both. Thereafter, thefirst layer462 and thesecond layer466 may be joined in alaminating station472 to form thesecond structure460.
• Alternatively, thesecond structure460 may be supplied from a roll of preformed second structure laminate. In addition, whileFIG. 11 shows thesecond structure460 being formed from two film layers, it is contemplated that thesecond structure460 could be formed from more than two layers, e.g., from three or more layers.
• After the laminate430 is formed, the laminate430 may be rolled up on roll606 for storage and later processing as shown inFIG. 15. Alternatively, as shown inFIG. 11, the laminate430 is advanced to asecond scoring station540 at which a second score line542 is formed through the thickness of thesecond structure460. The second score line542 is in registration with (i.e., coincides with) the inner perimeter of the strip-shaped pattern of pressure-sensitive adhesive492. The second score line542 extends substantially through the thickness of thesecond structure460, but preferably does not extend to any substantial extent into thefirst structure440, as illustrated inFIG. 13 and 14.
• Thesecond scoring station540 can comprise a laser. The operation of the laser is synchronized with the advancement of the laminate430. A sensor can detect a feature, such as an eye mark or printing, on the laminate430 whose location in relation to the pressure-sensitiveadhesive strip492 is known, and the sensor output can be used for regulating the laser operation so that the second score line542 is in registration with the inner perimeter of the pressure-sensitiveadhesive strip492.
• As an alternative to the use of lasers for scoring the laminate, the score lines can be formed by mechanical scoring or cutting. For instance, thefirst scoring station520 can comprise a kiss roll and backing roll that form a nip through which the first structure is passed. The kiss roll may include a rotary cutting die defining a cutting edge (not shown). The kiss roll acts in conjunction with the backing roll to cut partially through the thickness of thefirst structure440 starting from the outer surface of the first structure, such that thefirst structure440 is substantially scored through. Thesecond scoring station540 may likewise comprise a kiss roll and backing roll for scoring through thesecond structure460. The kiss roll acts in conjunction with the backing roll to cut partially through the thickness of thesecond structure460 starting from the outer surface of thesecond structure460, such that thesecond structure460 is substantially scored through while thefirst structure440 is left intact.
• Additionally, it is within the scope of the invention to laser-score one of the first structure or the second structure and to kiss cut or otherwise mechanically scores the other. This can be advantageous, for example, when one of the structures making up the laminate430 is readily scored by a laser but the other structure is not. For instance, when thefirst structure440 is a polyester such as PET, it can readily be scored with a laser, but if a polyethylene heat seal layer is employed on thesecond structure460, laser scoring may not be the best choice because polyethylene does not score well with a laser. In this case, kiss cutting or other mechanical scoring can be used to score thesecond structure460.
• It is also within the scope of the present invention to conduct the each of the scoring operations after the laminate430 has been formed. For example, thefirst scoring station520 may be adjacent, opposite, or near thesecond scoring station540 so that each of the first and second scoring operations take place either simultaneously or relatively soon after each other.
• As noted above, thescore line86 and132 are located in relationship to each other to define amarginal region73 between thescore line86 and132 and to define asurrounding region63 located outside of themarginal region73.
• After the scoring operation, the laminate430 can be sent to a reel-up or take up roll550 and wound into a roll for subsequent processing. Alternatively, it is possible for the reel-up operation to be omitted, such that the laminate430 is directly advanced to a fill and seal station.
• The laminate430 can also be slit into a plurality of partial widths and wound into multiple rolls. In this latter instance, each partial width would have the recurring patterns of pressure-sensitive and permanent adhesives applied with suitably configured adhesive applicators to the full-width material, and would have the recurring score lines formed by suitably configured scoring devices acting on either the full-width laminate prior to slitting or acting on each partial-width portion after slitting.
• FIG. 7 shows aflexible package10 in a closed position made according to the process described above. Thepackage10 includes an outer portion that envelopes the package contents and is sealed to enclose the contents. The outer portion comprises a laminate430 made by a method in accordance with the invention, such as the laminate previously described. The outer portion is manipulated and sealed along seal lines.
• In the illustrated package, the score lines86,132 are provided to be on afront surface12 of thepackage10. The area of thepackage10 bounded by the score lines can constitute any fraction of the total front surface of the package, but advantageously the area is a majority of the total surface area offront surface12.
• As noted above, it is desirable to provide a releasable adhesive72 on least a portion of themarginal region73 to provide areclosable opening panel80. In this regard, it is desirable to provide a sufficient amount of releasable adhesive72 as well as provide the releasable adhesive72 on a sufficient area of themarginal region73 so that the opening panel will function to open and close a desired number of times but also will effectively close theopening panel80 when theopening panel80 is in the closed position. Thus, the ratio of the area of themarginal region73 containing releasable adhesive to the area of the opening panel is from about 1:10 to about 10:1, and may be from about 1:5 to about 5:1, or may be from about 1.2 to about 2:1. Alternatively or simultaneously, the ratio of the area of the opening panel to the area of the front is from about 1:10 to about 10:1, and may be from about 1:5 to about 5:1, or may be from about 1.2 to about 2:1. By providing a relatively larger opening panel and/ormarginal region73, the area of themarginal region73 containing releasable adhesive can be larger and thus provide more surface area for adhering.
• Based on the previous description of the laminate430 and its formation process, it will be appreciated that the presence of the score lines has little or no impact on the barrier function of thepackage10 because eachscore line86,132 extends only partially through the total thickness and the score lines are not aligned with each other. Additionally, the pressure-sensitive adhesive492 fills the space between the score lines so that even if the score lines overlap somewhat in the thickness direction, there is still no open route between them. Furthermore, the score lines typically have a small width, on the order of a few thousandths of an inch.
• Various materials can be used for the construction of thepackage10. As noted above, thefirst structure440 that forms the outer surface of thepackage10 may comprise a single layer of flexible material or several layers of various materials. One material is a polyester such as polyethylene terephthalate (PET). As noted, the PET layer can be reverse-printed if desired, although alternatively it can be printed on its exterior and covered by an over-lacquer (not shown). Thesecond structure460 forming the inner surface of thepackage10 may comprise a barrier layer and a sealant layer. The sealant layer constitutes the innermost surface of and can comprise various sealant materials such as heat seals or cold seals. Heat seals generally are preferred because they provide stronger seals than cold seals typically are capable of achieving. Any suitable heat seal material can be employed, such as polyethylene, polypropylene, ionomer resins such as SURLYN®, or others.
• The barrier layer can comprise any of various barrier materials including barrier polymer films such as: ethylene vinyl alcohol copolymer (EVOH), polyamide, and the like; metallized polyolefin films such as polyethylene, polypropylene, oriented polypropylene, and the like; AlOx-coated polymer films; SiOx-coated polymer films; metal foil; and others. The barrier layer and sealant layer can be joined in various ways, including adhesive lamination, extrusion lamination, or coextrusion.
• The laminate430 may also include a metallization layer or a metal foil layer between thefirst structure440 and thesecond structure460, for example by providing a metallization layer on the surface that faces thefirst structure440. This is beneficial in enhancing the barrier performance of the laminate430. The metallization layer or metal foil layer can also be helpful when a laser is used for scoring thesecond structure460. In particular, when the sealant layer comprises polyethylene, which is not as readily scored by laser as some other materials such as polyester, it can be difficult to employ a sufficiently high laser energy to score through the polyethylene sealant layer without scoring through the laminate430 more deeply than desired. In particular, it is undesirable to score the entire thickness of the laminate. The metallization layer or metal foil layer can be helpful in “tuning” the laser to penetrate only up to the metallization layer or foil layer.
• The function of the reclosable opening panel provided by the pattern-applied adhesives and the score lines is described with respect toFIGS. 1 and 7. Thepackage10 is shown in a closed condition (FIG. 7), for example as initially filled and sealed in a packaging plant. Thepackage10 hasedges22,24,26, that are sealed to each other with atop edge20 that may be formed by folding the laminate430 on itself. On thefront surface12, the first or outer structure is adhesively joined to the second or inner structure via the permanent adhesive. Theouter score line86 bounds an outer opening portion of the outer structure. In this embodiment, the outer opening portion has a generally U-shaped or smile shaped perimeter having three sides defined by thescore line86, and is attached to the remainder of the outer wrapper along a fourth side (i.e., an imaginary line extending between the free ends of the two legs of the U-shaped score line). Theinner score line132 is also generally U-shaped or smile shaped with its portions parallel to adjacent portions of theouter score line86, but is spaced inwardly of theouter score line86 so as to define an inner opening portion of smaller area than the outer opening portion. Accordingly, there is a marginal region of the outer opening portion that extends beyond the edge of the inner opening portion. The pressure-sensitive adhesive72,492 is disposed between this marginal region and an underlying surface of the inner structure. The outer opening portion and inner opening portion are permanently joined by the permanent adhesive.
• Consequently, when the outer opening portion is detached from the outer wrapper along theouter score line86 and is peeled back as depicted inFIG. 1, the inner opening portion remains affixed to the outer opening portion and comes with it, thereby creating an opening in thefront surface12 as defined by theinner score line132. The outer and inner opening portions essentially form apanel80 that remains attached along a hinge line defined between the free ends of the two legs of the U-shaped score lines.
• In one embodiment, the outer structure has a greater affinity for bonding with the pressure-sensitive adhesive72,492 than does the surface of the inner structure, and hence the pressure-sensitive adhesive72,492 is detached from the surface and remains attached to the marginal region of the outer opening portion. Thepackage10 is reclosable by re-attaching the pressure-sensitive adhesive72,492 to the surface of the inner structure to restore thepackage10 to the condition shown inFIG. 7.
• The greater bonding affinity of the outer structure can be achieved in various ways. When the outer structure comprises a layer of PET and the layer of the inner structure to which the pressure-sensitive adhesive72,492 is attached comprises a polyolefin such as polypropylene, oriented polypropylene, or metallized oriented polypropylene, the PET will naturally have a greater affinity for bonding to the adhesive than will the polyolefin layer. Additionally or alternatively, the surface of the outer structure can be treated, as previously noted, by corona discharge or flame treatment, to increase the surface energy and enhance the bonding affinity. It is also possible, as already noted, to control the bond strength of the pressure-sensitive adhesive to the layer by including an additive in the adhesive to reduce the bond strength, if desired.
• Although the pressure-sensitive adhesive72,492 may be applied to the outer structure and to remain on the outer structure upon opening, it is also within the scope of the invention to apply the pressure-sensitive adhesive to the inner structure and to remain on the inner structure upon opening.
• In addition, the pressure-sensitive adhesive (releasable adhesive)72,492 has a delamination force that is greater than the break force of each of the localizedweak portions85,135 and the score lines86,132 so that theopening panel80 tears from the surface before the pressuresensitive adhesive72,492 allows the desired portion of theopening panel80 to be detached. In another embodiment, particularly where a cohesive is used, a portion of the cohesive is transferred from the surface to which it was initially applied to the other surface and because the cohesive is formulated in a desired manner, the marginal region containing the cohesive is rebondable and reclosable. A cohesive may be desired since it does not exhibit adhesive properties to structures that do not also contain a cohesive. Thus, during processing or use, undesired material will not stick to those areas containing the cohesive; yet, those areas containing the cohesive will readily stick to each other.
• It should be noted that the terms “line of weakness” and “score line” as used herein refer either to a complete cutting through of one or more layers of the laminate or to a weakening of such layer(s) allowing the layer(s) to be severed along the score line.
• Referring back toFIG. 1, thepackage10 of the present invention is shown with thereclosable opening panel80 in an open position to expose the contents of thepackage10. Thepackage10 includes opposed surfaces only one of which is shown, an opposed top and bottom, and opposed ends or sides. One of the surfaces is scored to define areclosable opening panel80 that can be opened to expose the contents stored within the package.
• The package of the present invention is shown as containing sticks ofgum2. It is to be understood, however, that the use of thepackage10 is not limited to gum but also includes other confectionery products. Therefore, as is known and shown inFIG. 18, agum stick2 may be elongate rectangular shaped member having afirst face702, asecond face704 opposite the first face, afirst end710 and asecond end712 opposite the first end, and athird end706 with a fourth end708 opposite the third end. The gum stick also has athickness714. Specifically, the thickness is substantially smaller than the width (the distance between706 and708), which itself is substantially smaller than the length (the distance between710 and712). In other words, [L>W>T].
• Referring back toFIG. 1, theindividual product package10 will contain one or more sticks ofgum2. As shown inFIG. 1, the sticks ofgum2 may be oriented so that one of thethird end706 and fourth end708 and one of thefirst face702 andsecond face704 of the stick ofgum2 are exposed when theopening panel80 is in an open orientation. In this orientation, one of thefirst face702 andsecond face704 of the stick ofgum2 is juxtaposed with one of the inner front surface16 or innerrear surface18. Also, it will be appreciated that a plane of one of thethird end706 or fourth end708 is parallel to a plane defined byfirst side20 andsecond side22 of thepackage10 and that a plane of one of thefirst face702 and thesecond face704 is parallel to the a plane of one of thefront surface12 or the innerrear surface18 of the package. Of course, it is contemplated that the sticks ofgum2 can be oriented in other directions. Advantageously, in each of these orientations, when thepackage10 is opened, only one or a few sticks are exposed for easy removal.
• Turning toFIG. 19, an alternative form of a gum product that can be usefully stored and dispensed from theindividual product package10 according to the present invention is shown. In this alternative form, the gum is in the form of aslab720 that is shaped and sized to be complementary to the shape and size of theproduct package10, for example, generally rectangular. The slab may have a first face722, asecond face724 opposite the first face722, afirst end730 and asecond end732 opposite thefirst end730, athird end726 and fourth end728 opposite thethird end726. Theslab720 also has athickness734. Specifically, the thickness is substantially smaller than the width (the distance between726 and728) and the length (the distance between730 and732). Theslab720 may be provided with at least one and desirably more than onescore line736, which will allow the consumer to easily break a portion of the slab from the remaining portion along thescore line736. Theslab720 is desirably oriented within thepackage10 such that thethird end726 or fourth end728 is parallel to the plane defining the opening of thepackage10. In other words, thethird end726 or fourth end728 is parallel to the plane defined by thefirst side20 of the package. Put another way, theslab720 is oriented such that one or both of thefirst end710 and thesecond end712 are in a plane substantially perpendicular to the opening or a plane defined by thefirst side20 of the package. Desirably, when provided, thescore line736 orlines736 are oriented such that they are parallel to the plane defining the opening of the package or by thefirst side20 of the package. Put yet another way, the first face722 of the slab is juxtaposed with one of the inner front surface16 orinner back surface18 of thepackage10. Likewise, the second side of theslab724 is juxtaposed with one of the inner front surface16 orinner back surface18 of thepackage10.
• While it is contemplated that asingle package10 may be sold or otherwise provided to a consumer, it is also contemplated that two or more individual packages may be bundled together in a suitable fashion. For example, two or more individual packages may be wrapped with suitable wrapping to provide a multiplicity of individual packages. It is also contemplated to provide aflexible container800, as shown inFIGS. 16 and 17, which can be made using the same material described above for thepackages10 and can be made by any of the processes described above and which can resealably store and contain two or more individual product packages10. Theflexible container800 is similar to thepackage10 described above except that it is wider, i.e., configured such that the distance between its front812 and rear814 is can be greater that the distance between the front12 and14 rear of theindividual package10 so that two or moreindividual packages10 can be stored within thecontainer800.
• Inasmuch as thecontainer800 shares common characteristics of theflexible package10 described above, such as the opening panel, the scoring, the releasable adhesive, etc. Suffice to say, thecontainer800 includes a front812, a rear814 opposite the front, a top820, a bottom822, opposite the top, afirst side824 and asecond side826 opposite the first side. Anopening panel880 is provided monolithically with the rear814 and is configured to fold over and resealably join to the front812, in a manner similar to that described above for the individual package. Advantageously, because thecontainer800 is flexible, when anindividual package10 is removed from the container, the size of the package can be reduced by, for example pushing the front812 toward the rear814.
• Turning now toFIGS. 20-22, an alternativeindividual package900 is shown. This alternativeindividual package900 is in the form of a cylinder having afirst end902 and asecond end904 disposed between asurface906 that is cylindrically shaped. Anouter score line910 is provided so that anopening panel912 is defined. Thepackage900 may be made from the same material described above for thepackages10 and can be made by the processes described above for thepackage10. Therefore, one of skill in the art will understand that the construction, manufacture, and operation of thepackage900 are understood from a review of such with respect to thepackage10. As shown inFIG. 21, the sticks ofgum2 are oriented in the same direction as shown inFIG. 1. In other words, the ends of the sticks of gum are oriented perpendicular to the opening of thepackage900.FIG. 22 shows the container ofFIG. 20 but with a slab ofgum720. Theslab720 may be rolled to conform to the shape of the cylinder.
• It will be appreciated from the above description that laminates made in accordance with the invention may provide a tamper-evidence function for a package because after opening it is very difficult to replace the opening portions in such a way as to achieve a completely smooth, flush condition with the surrounding portion of the laminate. It tends to be readily ascertainable that the package has been opened. When printing is included on the laminate, it is even more noticeable when the package has been opened because it is difficult to achieve perfect registration of the printed matter across the score line when reclosing the package.
• Notwithstanding the ability of the package itself to provide tamper evidence, it may be desirable to provide other tamper evident features. For example, when the outer structure is reverse-printed with ink, an area on the marginal region of the outer opening portion can first be treated (such as by applying a release coating or the like) to reduce the adherence of the ink so that when the package is first opened, the ink on the area of the marginal region detaches from the marginal region of the outer opening portion and remains with the pressure-sensitive adhesive on the inner structure adjacent the package opening. The release coating can be applied in a pattern (e.g., spelling out a word such as “Opened” or the like). Other types of tamper-evidence features can be included.
• Referring toFIGS. 23 and 24, one form of atamper indicator950 is shown. In this embodiment, thetamper indicator950 includes anopening tab952 that, as shown inFIG. 23, is connected to theopening panel80 by afrangible link954. Thefrangible link954 is configured such that when theopening tab952 is moved in a direction away from thepackage10, thefrangible link954 will break causing theopening tab952 to be separated from theopening panel80. Thefrangible link954 may be defined by anarrow conduit956 created by the pattern of thesecond score line86. By providing anarrow conduit956 to define thefrangible link954, a sufficient area adjacent thefrangible link954 will contain thelaminating adhesive70,512, which will provide resistance to the moving of theopening tab952 away from thepackage10 and assist in the breaking of thefrangible link954. The breaking of thefrangible link954 may provide an auditory, visual, and tactile indication that theopening panel80 is being opened for the first time.
• After theopening tab952 is separated from theopening panel80 by virtue of the breaking of thefrangible link954, it will be apparent from viewing thepackage10 that theopening tab952 has been removed and thus, that thepackage10 has been previously opened. The underside of theopening tab952 is generally free of adhesive. In addition, as seen inFIGS. 23 and 24, the shape of thesecond score line86 within the area of theopening tab952 may have any suitable shape so that theopening tab952 may be easily separated from the package and so that thefrangible link954 is defined in a manner to allow thefrangible link954 to break when theopening tab952 is moved away from thepackage10. It is also contemplated that theopening tab952 will have any suitable shape, even though a rectangular shape is shown inFIGS. 23 and 24.
• It is possible to increase the effectiveness of thetamper indicator950 by using two or morefrangible links954 placed in key locations on the periphery of theopening panel80. In general, it will be advantageous to position twofrangible links954 on opposite lateral sides of theopening panel80. Such a configuration increases the difficulty of partially opening theopening panel80 to gain access to the contents without breaking at least one of thefrangible links954. An example of such a configuration is shown inFIG. 25 where eachfrangible link954 includes anarrow conduit956. Lifting or moving theopening panel80 away from the package will cause thefrangible links954 to break and also cause the material encircled by thefrangible links954 to remain laminated or attached and thus provide a visual indication that thepackage10 has been opened. It will also be appreciated that, when theopening panel80 is moved to a closed position after the initial opening, it will be evident that the frangible link has been previously broken and that the package has been previously opened.
• Alternatively, as seen inFIGS. 26-30, the tamper indicator50 includes configuring theopening panel80, thescore line86 and thelaminating adhesive70,512 in a manner such that upon first opening theopening panel80, a portion of the outer layer is delaminated from another portion of the outer layer. For example, as shown inFIG. 25, thescore line86 is configured to provide a pair ofwings970 that extend beyond the outer periphery of theopening panel80 and between which laminatingadhesive70 is present. Put another way, laminating adhesive is present not only in thesurrounding region63 but also in a portion of themarginal region73. As a result, as theopening panel80 is lifted (moved away from the package), the area within the wings delaminates a portion of theouter layer40 from another portion of the outer layer. As a further example, where theouter layer40 includes two layers (such as a plastic layer laminated with a metal layer) in the wing area, the metal layer is lifted with theopening panel80.
• FIG. 27 shows another configuration where theopening panel80 has a shape such that a portion of themarginal region73 containslaminating adhesive70. Thescore line86 in the area of theopening panel80 may have a “boot shape”, with the heel of the boot containing a laminating adhesive, which when theopening panel80 is lifted, will cause a portion of theouter layer40 to delaminate from another portion of the outer layer.FIGS. 28-30 show other configurations to provide delamination of one portion of the outer layer from another portion of the outer layer. In each instance, once the openingpanel80 has been opened for the first time, it will be evident that a portion of the outer layer has been delaminated from another portion of the outer layer.
• In each ofFIGS. 27-30, certain configurations of the delamination portion are shown. It is contemplated that, instead of the shapes shown, letters or words may be created by the patterning of the laminating adhesive. For example, as illustrated inFIG. 33, words such as OPENED, ENJOY, or the like may be used. In addition, in each of these embodiments and configurations, theouter layer40 could include a laminate formed of an opaque first layer and a transparent second layer. Desirably, the transparent second layer is oriented toward the outside of thepackage10. In other words, the transparent second layer may be the outermost layer. Accordingly, as theopening panel80 is lifted the first time, a portion of the opaque first layer will be delaminated from the transparent second layer. As a result, not only will the package contain evidence of the delamination but theopening panel80 will also contain evidence of the delamination (i.e., the portion that has been delaminated will be transparent).
• Turning toFIG. 31, another form of atamper indicator950 is shown. In this form, thetamper indicator950 includes printing980 on or in theouter layer40 such that the printing traverses at least a portion of thescore line86. In this way, when theopening panel80 is opened for the first time and it is later closed, it is likely that each of the portions of the letters forming the line will not be aligned, which will provide a visual indication that theopening panel80 has been opened.
• Turning toFIG. 32, another embodiment of atamper indicator950 is illustrated. In this embodiment, asecurity tape990 is provided to overlap at least a portion of theopening panel80. Thesecurity tape990 is removably adhered to theouter layer40 of the package and may or may not contain printing992. The printing992 may be incorporated with thesecurity tape990 through a permanent adhesive so that when thesecurity tape990 is removed, the printing992 remains on theouter layer40 of the package.
• The foregoing detailed description has described only a few of the many forms that this invention can take. For this reason, this detailed description is intended by way of illustration, and not by way of limitation. It is only the following claims, including all equivalents that are intended to define the scope of this invention.

Claims (27)

1.-9. (canceled)

10. A reclosable package for consumable products comprising:

a. a laminated sheet comprising an inner layer and an outer layer wherein the inner layer is oriented toward an inside of the package and the outer layer is oriented toward an outside of the package;

b. a first laser scored line extending at least substantially into the inner layer but not extending into the outer layer;

c. a second laser scored line extending at least substantially into the outer layer but not extending into inner layer, and being laterally offset from the first laser scored line to define an opening panel in the package and a marginal region between the first and second laser scored lines and further defining a surrounding region of the sheet outside of the marginal region; and

d. a tamper indicator that provides an indication that the opening panel is being opened for a first time and includes at least one of a frangible link that breaks when the opening panel is being opened for the first time and a configuration which causes partial delamination of the inner or outer layer when the opening panel is opened for the first time.

11. The reclosable package ofclaim 10 wherein the second laser scored line has a configuration such that at least a portion of the second laser scored line defines the frangible link.

12. The reclosable package ofclaim 11 wherein the configuration of the second laser scored line defines a narrow conduit within the outer layer.

13. The reclosable package ofclaim 10 wherein, the tamper indicator includes at least two frangible links located on opposite lateral sides of the opening panel.

14. The reclosable package of claim1 wherein the inner layer is a laminated sheet and the tamper indicator comprises a configuration of the opening panel such that upon first opening of the opening panel a portion of the inner layer is at least partially delaminated.

15. The reclosable package ofclaim 14 wherein the configuration includes laminating adhesive applied to a portion of the marginal region.

16. (canceled)

17. The reclosable package ofclaim 10 wherein the tamper indicator further comprises a security tape located over at least a portion of the opening panel.

18. The reclosable package ofclaim 17 wherein the security tape includes printing.

19.-25. (canceled)

26. A package for consumable products comprising:

a. a laminated sheet comprising an inner layer and an opaque outer layer wherein the inner layer is oriented toward the inside of the package and the opaque outer layer is oriented toward the outside of the package;

b. a first score line extending at least substantially into the inner layer but not extending into the opaque outer layer;

c. a second score line laterally offset from the first score line and extending at least substantially into the opaque outer layer but not extending into the inner layer, the second score line defining an opening panel in the package and further defining a marginal region in the laminated sheet between the first and second score lines and further defining a surrounding region that extends throughout the laminated sheet outside of the marginal region;

d. a releasable adhesive disposed between the inner layer and opaque outer layer in at least a portion of the marginal region;

e. a laminating adhesive disposed between the inner layer and opaque outer layer and extending substantially throughout the surrounding region such that the laminating adhesive is effective to bond the inner layer and opaque outer layer together where it is applied; and,

f. a tamper indicator that provides a visual indication that the opening panel has been previously opened and comprises at least one of a frangible link which is broken when the opening panel is opened for the first time and a configuration which causes partial delamination of the inner or outer layer when the opening panel is opened for the first time.

27. The package ofclaim 26 wherein the frangible link is located within the outer layer.

28. The package ofclaim 27, wherein the second score line defines a narrow conduit within the outer layer.

29. The package ofclaim 26 wherein a discontinuity in the second line defines the frangible link.

30. (canceled)

31. The package ofclaim 26 wherein the opaque outer layer comprises a laminate of a opaque first layer and a transparent second layer wherein the transparent second layer is oriented toward the outside of the package and the tamper indicator comprises laminating adhesive applied to a portion of the marginal region between the inner layer and opaque outer layer, wherein the opaque first layer is delaminated from the transparent second layer in the portion of the marginal region where the laminating adhesive has been applied when the opening panel is opened for the first time.

32. A package for consumable products comprising:

a. a laminated sheet comprising an inner layer and an outer layer wherein the inner layer is oriented toward the inside of the package and the outer layer is oriented toward the outside of the package;

b. a first score line extending at least substantially into the inner layer but not extending into the outer layer;

c. a second score line extending at least substantially into the outer layer but not extending into inner layer, and being laterally offset from the first score line to define an opening panel in the package and a marginal region between the first and second score lines and further defining a surrounding region of the sheet outside of the marginal region; and

d. a tamper indicator that provides an indication that the opening panel has previously been opened;

wherein the tamper indicator is selected from the group consisting of a frangible link in the outer layer, a configuration which causes partial delamination of the inner or outer layer when the package is opened for the first time, and a security tape applied across the second score line.

33. The package ofclaim 32 wherein the tamper indicator consists of a frangible link in the outer layer.

34. The package ofclaim 33 wherein the tamper indicator consists of at least two frangible links located on opposite lateral sides of the opening panel.

35. The package ofclaim 32 wherein the tamper indicator consists of a configuration which causes partial delamination of the inner or outer layer when the package is opened for the first time.

36. The package ofclaim 32 wherein the tamper indicator consists of a security tape applied across the second score line.

37. The package ofclaim 32 wherein the tamper indicator provides a tactile indication that the package is being opened for the first time.

38. The package ofclaim 32 wherein the tamper indicator provides an auditory indication that the package is being opened for the first time.

39. The package ofclaim 32 wherein the tamper indicator provides a tactile indication that the package is being opened for the first time.

40. (canceled)

41. (canceled)

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