Easy to Open Package and Method of Making Same

The present application is based upon and claims priority to U.S. Provisional Patent Application Ser. No. 63/574,924, having a filing date of Apr. 5, 2024, which is incorporated herein by reference in its entirety.

Many products, especially consumer products, are packaged in flexible bags made from a plastic or polymer film. Packages made from polymer films can offer various advantages. For instance, the polymer films can be wrapped tightly around the consumer products for eliminating void space. The resulting packages are not very bulky and are easy to handle. The polymer films can also be translucent, allowing a purchaser to view the contents prior to making the purchase. In addition, the polymer films can be printed with decorative graphics to make the product more attractive.

Although packages made from polymer films can provide various advantages, opening such packages can be quite difficult. For example, the polymer films must have sufficient strength to prevent against rupture during the packaging process and during subsequent transportation. Increasing the strength of the film or the seals that surround the content of the package, however, increases the difficulty in opening the package. For example, many such packages, such as packages that contain cereals, potato chips, and the like, do not include an easy opening feature. Thus, brute force or scissors need to be used in order to open the package.

In view of the above, those skilled in the art have attempted to make packages with easy to open features. For example, in the past, breachable bubbles have been placed in the tab region of the package that are designed to be popped by user applied pressure. Popping the breachable bubble can produce two opposing flaps that then can be used to open the package. For instance, various different types of breachable bubbles are disclosed in U.S. Pat. Nos. 9,365,339, 6,726,364, 6,938,394, 7,306,371, 7,644,821, U.S. Patent Publication No. 2007/0235369, U.S. Patent Publication No. 2007/0237431, U.S. Patent Publication No. 2007/0284375, U.S. Patent Publication No. 2007/0286535, U.S. Patent Publication No. 2007/0295766, U.S. Patent Publication No. 2008/0212904, U.S. Patent Publication No. 2010/0326989, and U.S. Patent Publication No. 2013/0118134, which are all incorporated herein by reference.

Although incorporating a breachable bubble into a package has provided great and meritorious advances in the art, further improvements are needed. For instance, when the breachable bubbles are created, air is trapped within the bubble that is typically at an elevated temperature due to the heat of the machinery or the temperature of the ambient environment. Once the package cools, the gas contained within the bubble cools causing a reduction in fluid pressure. Consequently, what is needed is a flexible, rigid, or semi-rigid package containing a breachable bubble in which the gas pressure in the bubble remains at an optimum level for accessing the popping functionality of the bubble without interior wrinkles and with an attractive, appealing surrounding perimeter girth.

In general, the present disclosure is directed to a package containing a breachable bubble that breaches upon application of minimal pressure by a user for facilitating the opening of the package. In particular, the breachable bubble is formed in accordance with the present disclosure in a manner that ensures that the bubble has adequate gas pressure and remains in a “plump” condition when shipped and sold to consumers.

For instance, in one embodiment, the present disclosure is directed to a package comprising a hollow enclosure configured to receive at least one product. The enclosure is sealed from the surrounding environment. The package includes at least one tab area. The tab area is formed by selectively sealing two opposing polymer films. At least one breachable bubble that is configured to be breached upon application of pressure by a user is located within the tab area. The breachable bubble is defined by an outer seal having a perimeter. In accordance with the present disclosure, the breachable bubble further comprises an inner seal that is located inside the perimeter of the outer seal. The inner seal extends along at least a portion of the perimeter of the outer seal. The inner seal reduces a volume of the breachable bubble. In this manner, gas contained within the bubble increases in pressure when the inner seal is formed. The breachable bubble can include a seal-breaking region located along the outer seal having a weaker seal strength than the remainder of the outer seal. The seal-breaking region can face an outer edge of the tab area. The seal-breaking region is configured to breach upon application of pressure to the breachable bubble by a user.

The outer seal can include a continuous perimeter. In one aspect, the inner seal extends over only a portion of the perimeter of the outer seal. For instance, the inner seal can be constructed such that it is not located along the seal-breaking region of the outer seal.

The seal-breaking region can have different configurations. In one embodiment, the seal-breaking region can comprise a notch or can have a zig-zag or sinusoidal pattern.

The two opposing polymer films used to form the package can comprise two separate pieces of film or can comprise a single piece of film folded over onto itself. The breachable bubble can be formed by trapping a gas, such as air, between the two opposing films. The breachable bubble can protrude from only one side of the package or can protrude from opposite sides of the tab area. Once the breachable bubble is breached, in one aspect, the opposing films become partially separated and may be used as flaps for a user to peel open the package.

The present disclosure is also directed to a process for forming a package. The process includes forming a hollow enclosure between two polymer film layers. The hollow enclosure is configured to receive at least one product. The polymer film layers are sealed together by applying heat and pressure to form a package having perimeter edges in a manner such that the hollow enclosure is sealed from the surrounding environment. At least one breachable bubble is formed adjacent to a perimeter edge. The breachable bubble is defined by a continuous outer seal formed by attaching the polymer film layers together. The breachable bubble has a volume and contains a gas, such as air, at a pressure. In accordance with the present disclosure, the process further includes forming an inner seal within the outer seal in a manner that reduces the volume of the breachable bubble and increases the gas pressure within the breachable bubble. In this manner, the breachable bubble is configured to be breached upon application of pressure by a user.

Other features and aspects of the present disclosure are discussed in greater detail below.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present disclosure.

In general, the present disclosure is directed to a package having a unique opening device and to a process for making the package. In particular, the package includes a breachable bubble that, when popped by a user, facilitates opening of the package. In one aspect, the breachable bubble can be formed between two polymer film layers and can be located along an edge of the package.

The breachable bubble can be formed using different methods and techniques. In one aspect, for instance, the breachable bubble can be formed during a thermoforming process in which two seal bars are brought together using vacuum and pressure. During the process, the bubble can be filled with any suitable fluid, such as air, another gas, or a liquid, such as liquid nitrogen. One problem that has been experienced in the past in producing breachable bubbles is that the fluid or gas inside the bubble cools after the bubble is formed. As the fluid or gas inside the bubble cools, fluid pressure is reduced which changes the look and appearance of the bubble. In particular, the bubble can assume a somewhat deflated appearance and may begin to show film dents or small areas where the film has collapsed or wrinkled. Partially deflated bubbles are not aesthetically attractive and may not perform as intended. In particular, breachable bubbles for opening packages work optimally when the bubbles are fully inflated and have a “plump” appearance. When completely inflated, for instance, less pressure may be needed in order to breach the bubble. In addition, inflated bubbles can be designed to produce a “pop” sound that is not only consumer preferred but also indicates to the user that the bubble has not been breached.

The present disclosure is directed to producing breachable bubbles that remain inflated and have optimum fluid pressure. The bubbles, for instance, can be created by using two different sealing stations. The first sealing station can form an outer seal that is used to form the bubble. The second sealing station, on the other hand, can be used to form a seal inside the perimeter of the outer seal for reducing the volume of the bubble and thereby increasing fluid pressure. For instance, in one application, the second sealing station or mechanism can create an overlap/perimeter seal around the bubble shape which can overlap, or seal inside, the outer seal or first perimeter seal of the bubble. The second seal can also be used to further define the shape of the bubble and to create a breaching point where the bubble breaches when pressed.

The process of the present disclosure produces breachable bubbles with many advantages and benefits. In one aspect, for instance, a cold seal can be created that overlaps a heat seal which eliminates wrinkles surrounding the formed bubble. The second seal can also create a stronger seal around the bubble perimeter, except in areas where the bubble is to burst or breach. This results in a more controlled, precision sealing process to ensure hermetic seals and strong seals where desired. The process of the present disclosure can also optimize machine line speeds while producing highly functional breachable bubbles. In this regard, the overall process can increase the bubble bursting consistency, sealing integrity of the package, and increase the dispensing performance accuracy of the finished product.

Referring to, reference numeralgenerally indicates a package in accordance with one embodiment of the present invention. The packagemay include a first flexible polymer filmand a second flexible polymer film(see). In one embodiment of the present invention, the first filmand the second filmare portions of a singular sheet of flexible polymer film. In another embodiment, the first filmand the second filmare separate sheets of flexible polymer film. It should be understood that the packagecan have any suitable shape depending upon various factors including the type of product contained in or to be received in the package.

The first flexible polymer filmand the second flexible polymer filmcan be made from any suitable polymer. Polymers that may be used to form the package include, for instance, polyolefins such as polyethylene and polypropylene, polyesters, polyamides, polyvinyl chloride, mixtures thereof, copolymers thereof, terpolymers thereof, and the like. In addition, the package can also be made from any suitable elastomeric polymer.

The first flexible polymer filmand the second flexible polymer filmcan each comprise a single layer of material or can comprise multiple layers. For instance, the first filmand the second filmcan each include a core layer of polymeric material coated on one or both sides with other functional polymeric layers. The other functional polymeric layers may include, for instance, an oxygen barrier layer, an ultraviolet filter layer, an anti-blocking layer, a printed layer, and the like.

The first flexible polymer filmand the second flexible polymer filmcan each be translucent or transparent. If translucent or transparent, for instance, the contents of the packagecan be viewed from the outside. In another embodiment, however, the first flexible polymer filmand the second flexible polymer filmcan each be opaque. For instance, in one embodiment, the packagecan display various graphics that identify, for instance, the brand and the description of the product inside. In other embodiments, the first flexible polymer filmcan be translucent or transparent while the second flexible polymer filmis opaque, and the first flexible polymer filmcan be opaque while the second flexible polymer filmis translucent or transparent.

In accordance with the present disclosure, the first filmand the second filmmay be sealed together to form an enclosureand at least one tab area. The enclosuremay define an interior volume configured to receive a consumer product. In one embodiment, a consumer product may be situated in the interior volume. The consumer product may be, for example, a food product. The food product, for instance, can be a snack food, a condiment, a beverage, or the like. In one aspect, the food product can comprise a cereal. The package of the present disclosure, for instance, can be designed to hold solids, liquids, or gel. In addition to food products, the package of the present disclosure can also be designed to hold personal care products. Such products include shampoos, conditioners, body washes, and the like. The package can also be designed to hold hardware items or any suitable consumer item.

In one embodiment, the tab areamay be located near the periphery of the first filmand the second film. In another embodiment, the tab areamay be a plurality of tab areas. The tab areamay include a breachable bubble. The breachable bubblemay be formed in a discrete portion of the tab area. Sufficient fluid may be trapped within the breachable bubblesuch that the bubblebreaches upon application of minimal pressure by a user, separating a sealed portion of the first filmfrom the second film. The fluid may be, for example, a liquid or a gas. In one embodiment, the fluid may be air. In one embodiment, the tab areamay include a breach pointthat is generally oriented towards the periphery of the package. The breach pointrepresents a sealed portion of the first filmand the second filmthat more easily separates than the remainder of the sealed first filmand second filmwhen the breachable bubbleis breached.

The breachable bubblemay provide a distinct breaching sound when the bubbleis breached. The breaching sound may be caused by the trapped fluid escaping from the discrete portion of the tab areawhen the bubbleis breached. For example, in one embodiment, the breachable bubblemay provide a popping sound, similar to a small balloon popping, when the bubbleis breached. In other embodiments, the breachable bubblemay provide, for example, a peeping sound, a snapping sound, or a whistling sound.

Referring to, the bubblemade in accordance with the present disclosure is shown in greater detail. Through the process of the present disclosure, the bubbleis created with optimal air pressure without displaying interior wrinkles and with an overall attractive, appealing appearance. In one aspect, for instance, the bubbleis created by applying an outer sealto the tab area. The outer sealcan be made using various methods and techniques. In one embodiment, for instance, the outer seal is formed using heat and pressure to form thermal bonds between the first film layerand the second film layer. While the outer sealis being formed, a gas, such as air, can be trapped inside the bubble. In the embodiment illustrated in, for instance, the outer sealhas a ribbed-like appearance and not only seals the film layersandtogether but also can improve the overall appearance of the package.

In one embodiment, for instance, two heated seal bars can come together that simultaneously draw vacuum where the bubbleis to be formed and apply heat and pressure to form the outer seal. The seal bars, for instance, can include at least one, such as two opposing sealing cups. After the film layersandare drawn into the sealing cups, the sealing bar plates come together to apply heat and pressure, thus sealing the package together in forming the bubble.

Alternatively, the outer sealcan be formed using adhesives, such as cold seal adhesives. The adhesive, for instance, may be a rubber-based adhesive, a synthetic polymer-based adhesive, or a natural rubber and synthetic polymer-based adhesive.

As shown in, the outer sealcan be continuous and can form an initial perimeter of the bubble. The outer sealcan be applied to the package such that the bubblehas any suitable shape. For instance, as shown in, the bubble can, in one embodiment, have a circular shape or oval shape. In the embodiments illustrated in, on the other hand, the bubblecan have a semi-circular shape. Alternatively, the bubble can have a triangular shape, can be in the shape of a rectangle, can have a fanciful shape, or can be in the shape of a polygon, such as a pentagon.

In accordance with the present disclosure, the packagefurther includes an inner sealthat is applied inside the perimeter of the outer seal. In one aspect, the inner sealcan be applied to the package after the bubblehas been formed. The inner sealcan be formed using thermal bonding, ultrasonic bonding, or can be formed through the use of an adhesive as described above. The inner seal, in one aspect, decreases the volume of the bubbleand thereby increases fluid pressure within the bubble.

For example, during initial formation of the bubble, the fluid pressure may be relatively low due to process constraints. In addition, the bubblemay be formed at an elevated temperature and, as the package cools, the air pressure within the bubbledecreases. The inner seal, however, is used in order to ensure that the bubble pressureis optimum and that a “plump” bubble is formed that does not contain interior wrinkles and can breach or pop with minimal pressure.

The inner sealcan have any suitable shape depending upon the particular application. In one aspect, the inner sealcan also be continuous and follow the entire perimeter of the outer seal. Alternatively, as shown in, the inner sealcan extend over only a portion of the perimeter of the outer seal. For example, as shown in, the inner sealcan include a gap that forms a seal breaking region. When pressure is applied to the bubble, for instance, the bubble can breach along the seal breaking regionfor opening the package. The seal breaking region, for instance, can be placed adjacent to an outer edge of the package as shown in. In this regard, the inner sealmay have greater seal strength than the outer seal. In this manner, breaching of the bubble occurs within the gap formed by the inner seal.

Alternatively, the outer sealcan have a seal strength that is the same or greater than the inner seal. In this embodiment, the seal breaking regioncan be formed by producing a weakened seal within the outer seal.

In the embodiment illustrated in, the inner sealis placed adjacent to the outer seal. Alternatively, the inner sealcan be spaced a distance from the outer seal. In still another embodiment, the inner sealcan overlap the outer seal. Having the seals overlap, for instance, may facilitate forming of the package without having to rely on exact placement of the inner seal.

Through the process of the present disclosure, sufficient pressure is maintained within the bubblesuch that the bubble can be breached with minimal pressure. Breaching the bubblecan cause a sealed portion of the layers of the polymer film to separate. The layers of the polymer film can then be peeled away from each other until the package is opened and the contents accessible. In other constructions, however, the bubbleonce breached can create fluid channels within the package for producing a passageway from enclosurethrough an edge of the package to the outside environment.

Referring to, another embodiment of a packagemade in accordance with the present disclosure is shown. Like reference numerals have been used to indicate similar elements. As shown, the packageis made from polymer films that form an enclosurefor holding a product. The packageincludes a tab area. Located within the tab areais a bubblethat is positioned adjacent an outer edge of the package. In accordance with the present disclosure, the bubbleis formed from an outer sealand an inner seal. The inner seal, for instance, can be formed after the outer sealis formed. The inner sealdecreases the volume of the bubbleand increases fluid pressure within the bubble. In this embodiment, the inner sealis positioned around the lower end of the outer sealand has a tapering width. The inner sealcan overlap with the outer sealor can be positioned adjacent to the outer seal.

In the embodiment illustrated in, the seal breaking regionextends the entire width of the bubble. Producing an enlarged seal breaking region, for instance, may later facilitate opening of the package when the bubbleis breached.

In certain embodiments, the package is formed from a single film layer that is attached together to form a fin sealas shown in. The fin seal, for instance, can be located on the back of the package.

Referring to, another embodiment of a packagemade in accordance with the present disclosure is shown. The packageillustrated inis very similar to the package illustrated in. The package is formed from a polymer film and includes an enclosureand a tab area. Within the tab areais a bubbleformed by a first outer sealand a second inner seal. In this embodiment, the inner sealhas a uniform width along the perimeter of the outer seal. The inner sealprovides a reinforcement seal which offers greater seal strength and sealing controls in designated areas surrounding the bubble. As shown, the inner sealonly extends along a portion of the outer seal. The inner sealcan, in one embodiment, overlap the outer seal.

The inner sealcan control the direction and width of the seal breaking region. For instance, the inner sealcan be narrower or wider to control and reinforce the sealing areas. In this manner, the inner sealprovides greater control over bursting performance of the bubbleand improves the appearance of the bubble.

One particular advantage is that the outer sealand the inner sealcan both be made with the same seal strength instead of having to create a weakened area when applying only a single seal to the package. In this manner, the packages may be formed at greater speeds with greater control over bubble performance.

Referring to, still another embodiment of a packagemade in accordance with the present disclosure is shown. The packageincludes an enclosureseparated from a tab area. The packagecan be made from a single piece of film that is sealed together to form a fin seal. In accordance with the present disclosure, the packageincludes a bubblesurrounded by an inner sealand an outer seal. The packageillustrated inis very similar to the package illustrated in. In the embodiment illustrated in, however, the outer sealis applied to the package to form a unique bubble edgethat forms the seal breaking region. In the embodiment illustrated in, the bubble edgehas a zig-zag shape. The zig-zag shape can assist with the bursting of the bubblewhen pressure is applied. The bubble edge, for instance, can be used to more fully and more easily open the full width of the bubble. The zig-zag pattern, for instance, can cause multiple air bursting points across the horizontal seal. The zig-zag pattern creates areas where there is a smaller distance between sealed areas and unsealed areas, making the package weak seal areas easier to open for the consumer.

The zig-zag pattern of the bubble edgecan vary depending upon the particular application. For instance, the zig-zag pattern can be scaled to be much smaller or larger than illustrated. The zig-zag pattern can also be curved or include other line patterns and shapes. For instance, alternatively, the bubble edgemay include a single notch, may have a sinusoidal shape, or can have any other suitable shape.

These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims.