Reclosable thermoformed flexible packages and method of making same

Abstract

A reclosable flexible package containing an article comprising a front flexible panel and a rear flexible panel. The reclosable flexible package has at least one panel comprising a thermoplastic film which is thermoformed; a reclosable fastener means; at least one line of structural weakness in the exterior surface of the front flexible panel and at least one line of structural weakness in the exterior surface of the rear flexible panel; and a tamper-evident structure. The tamper-evident structure includes a first portion comprising the front flexible panel extending from the at least one line of structural weakness in the exterior surface of the front flexible panel to a top seal (or top seal portion) and from the at least one line of structural weakness in the exterior surface of the rear flexible panel to a top seal (or top seal portion).

1 . A package containing an article, said package comprising: 
 (a) a front flexible panel comprising a first thermoplastic film, wherein said front flexible panel includes an interior surface and an exterior surface relative to said package;    (b) a rear flexible panel opposing said front flexible panel and comprising a second thermoplastic film, wherein said rear flexible panel includes an interior surface and an exterior surface relative to said package, wherein said second thermoplastic film is thermoformed,    (c) wherein said front flexible panel and said rear flexible panel each have a perimeter having a first peripheral side edge and an opposing second peripheral side edge, connected by a peripheral top edge, and an opposing peripheral bottom edge,    (d) wherein said interior surface of said front flexible panel is joined to said interior surface of said rear flexible panel by either a contiguous seal or a plurality of seals; wherein 
 (i) said contiguous seal comprises a first side seal portion, an opposing second side seal portion, and a top seal portion, an opposing bottom seal portion, wherein said seal portions are connected to form a seal perimeter between said front flexible panel and said rear flexible panel thereby forming a receptacle cavity;  
 (ii) said plurality of seals comprises a first side seal, an opposing second side seal, and a top seal, an opposing bottom seal, wherein said plurality of seals are connected to form a seal perimeter between said front flexible panel and said rear flexible panel thereby forming a receptacle cavity;  
   (e) a reclosable fastener means to provide an entree to said receptacle cavity, wherein said reclosable fastener means is positioned between said interior surface of said front flexible panel and said interior surface of said rear flexible panel;    (f) at least one line of structural weakness in said exterior surface of said front flexible panel extending transversely from said first peripheral side edge to said second peripheral side edge, positioned below and adjacent to said reclosable fastener means;    (g) at least one line of structural weakness in said exterior surface of said rear flexible panel extending transversely between said first peripheral side edge and said second peripheral side edge, positioned below and adjacent to said reclosable fastener means; and    (h) a tamper-evident structure having a first portion comprising said front flexible panel which extends from said at least one line of structural weakness in said exterior surface of said front flexible panel to either said top seal portion or said top seal, and a second portion comprising said rear flexible panel which extends from said at least one line of structural weakness in said exterior surface of said rear flexible panel to either said top seal portion or said top seal.    
     
     
         2 . A package containing an article according to  claim 1 , wherein 
 (a) said first side seal extends longitudinally between said peripheral top edge and said peripheral bottom edge and is positioned proximate to said first peripheral side edge;    (b) said second side seal is opposite to said first side seal and extends longitudinally from said peripheral top edge to said peripheral bottom edge and is positioned proximate to said second peripheral side edge;    (c) said top seal extends transversely from said first peripheral side edge to said second peripheral side edge and is positioned proximate to said peripheral top edge;    (d) said bottom seal is opposite to said top seal and extends transversely from said first peripheral side edge to said second peripheral side edge and is positioned proximate to said peripheral bottom edge.    
     
     
         3 . A package containing an article according to  claim 1 , wherein said package is hermetically sealed.  
     
     
         4 . A package containing an article according to  claim 1 , wherein said reclosable fastener means comprises a first interlocking member and a second interlocking member.  
     
     
         5 . A package containing an article according to  claim 4 , wherein said first interlocking member of said reclosable fastener means further comprises an attachment flange.  
     
     
         6 . A package containing an article according to  claim 5 , wherein said attachment flange of said first interlocking member is sealed to said interior surface of said front flexible panel.  
     
     
         7 . A package containing an article according to  claim 4 , wherein said second interlocking member of said reclosable fastener means further comprises an attachment flange.  
     
     
         8 . A package containing an article according to  claim 7 , wherein said attachment flange of said second interlocking member is sealed to said interior surface of said rear flexible panel.  
     
     
         9 . A package containing an article according to  claim 4 , wherein said first interlocking member of said reclosable fastener means and said second interlocking member of said reclosable fastener means are adapted to engage and disengage with each other.  
     
     
         10 . A package containing an article according to  claim 1 , wherein said reclosable fastener means further comprises a slider device connected to said first interlocking member and said second interlocking member.  
     
     
         11 . A package containing an article according to  claim 1 , wherein said reclosable fastener means is a peelable resealing strip.  
     
     
         12 . A package containing an article according to  claim 1 , wherein said at least one line of structural weakness in said exterior surface of said front panel has a depth of less than the entire thickness of said front panel.  
     
     
         13 . A package containing an article according to  claim 1 , wherein said at least one line of structural weakness in said exterior surface of said rear panel has a depth of less than the entire thickness of said rear panel.  
     
     
         14 . A package containing an article according to  claim 1 , wherein said tamper-evident structure covers a portion of said reclosable fastener means.  
     
     
         15 . A package containing an article according to  claim 14 , wherein said tamper-evident structure covers the entire said reclosable fastener means.  
     
     
         16 . A package containing an article according to  claim 1 , further comprising a frangible seal joining said interior surface of said front panel to said interior surface of said rear flexible panel and extends transversely from said first peripheral side edge to said second peripheral side edge, and is positioned below and adjacent to said at least one line of structural weakness in said exterior surface of said front flexible panel and at least one line of structural weakness in said exterior surface of said rear flexible panel.  
     
     
         17 . A package containing an article according to  claim 1 , wherein said contiguous seal is a heat-seal.  
     
     
         18 . A package containing an article according to  claim 1 , wherein said plurality of seals are each a heat-seal.  
     
     
         19 . A package containing an article according to  claim 1 , wherein said first thermoplastic film and said second thermoplastic film are the same thermoplastic film.  
     
     
         20 . A package containing an article comprising: 
 (a) a front flexible panel comprising a first thermoplastic film, wherein said front flexible panel includes an interior surface and an exterior surface relative to said package;    (b) a rear flexible panel opposing said front flexible panel and comprising a second thermoplastic film, wherein said rear flexible panel includes an interior surface and an exterior surface relative to said package, wherein said second thermoplastic film is thermoformed;    (c) wherein said front flexible panel and said rear flexible panel each have a perimeter having a first peripheral side edge and an opposing second peripheral side edge, connected by a peripheral top edge, and an opposing peripheral bottom edge,    (d) wherein said interior surface of said front flexible panel is joined to said interior surface of said rear flexible panel by a plurality of seals; wherein said plurality of seals comprises 
 (i) a first side seal extending longitudinally between said peripheral top edge and said peripheral bottom edge and positioned proximate to said first peripheral side edge;  
 (ii) a second side seal opposite to said first side seal and extending longitudinally from said peripheral top edge to said peripheral bottom edge and positioned proximate to said second peripheral side edge;  
 (iii) a top seal extending transversely from said first peripheral side edge to said second peripheral side edge and positioned proximate to said peripheral top edge;  
 (iv) a bottom seal opposite to said top seal and extending transversely from said first peripheral side edge to said second peripheral side edge and positioned proximate to said peripheral bottom edge;  
 (v) wherein said plurality of seals are connected to form a seal perimeter between said front flexible panel and said rear flexible panel thereby forming a receptacle cavity;  
   (e) a reclosable fastener means to provide an entree to said receptacle cavity, wherein said reclosable fastener means is positioned between said interior surface of said front flexible panel and said interior surface of said rear flexible panel and comprises a first interlocking member and a second interlocking member adapted to engage and disengage with each other;    (f) at least one line of structural weakness in said exterior surface of said front flexible panel extending transversely from said first peripheral side edge to said second peripheral side edge, positioned below and adjacent to said reclosable fastener means;    (g) at least one line of structural weakness in said exterior surface of said rear flexible panel extending transversely between said first peripheral side edge and said second peripheral side edge, positioned below and adjacent to said reclosable fastener means; and    (h) a tamper-evident structure having a first portion comprising said front flexible panel which extends from said at least one line of structural weakness in said exterior surface of said front flexible panel to said top seal and a second portion comprising said rear flexible panel which extends from said at least one line of structural weakness in said exterior surface of said rear flexible panel to said top seal.    
     
     
         21 . A package containing an article according to  claim 20 , wherein said first interlocking member of reclosable fastener means further comprises an attachment flange.  
     
     
         22 . A package containing an article according to  claim 21 , wherein said attachment flange of said first interlocking member is sealed to said interior surface of said front flexible panel.  
     
     
         23 . A package containing an article according to  claim 20 , wherein said second interlocking member of reclosable fastener means further comprises an attachment flange.  
     
     
         24 . A package containing an article according to  claim 23 , wherein said attachment flange of second interlocking member is sealed to said interior surface of said rear flexible panel.  
     
     
         25 . A package containing an article according to  claim 20 , wherein said at least one line of structural weakness in said exterior surface of said front flexible panel has a depth of less than the entire thickness of said front flexible panel.  
     
     
         26 . A package containing an article according to  claim 20 , wherein said at least one line of structural weakness in said exterior surface of said rear flexible panel has a depth of less than the entire thickness of said rear flexible panel.  
     
     
         27 . A package containing an article according to  claim 20 , further comprising a frangible seal joining said interior surface of said front panel to said interior surface of said rear panel and extending transversely from said first peripheral side edge to said second peripheral side edge, wherein said frangible seal is positioned below and adjacent to said at least one line of structural weakness in said exterior surface of said front flexible panel and at least one line of structural weakness in said exterior surface of said rear flexible panel.  
     
     
         28 . A package containing an article according to  claim 20 , wherein said plurality of seals are each a heat-seal.  
     
     
         29 . A package containing an article according to  claim 20 , wherein said first thermoplastic film and said second thermoplastic film are the same thermoplastic film.  
     
     
         30 . A package containing an article comprising: 
 (a) a front flexible panel comprising a first thermoplastic film, wherein said front flexible panel includes an interior surface and an exterior surface relative to said package;    (b) a rear flexible panel opposing said front flexible panel and comprising a second thermoplastic film, wherein said rear flexible panel includes an interior surface and an exterior surface relative to said package, wherein said second thermoplastic film is thermoformed;    (c) wherein said front flexible panel and said rear flexible panel each have a perimeter having a first peripheral side edge and an opposing second peripheral side edge, connected by a peripheral top edge, and an opposing peripheral bottom edge,    (d) wherein said interior surface of said front flexible panel is joined to said interior surface of said rear flexible panel by a plurality of seals; wherein said plurality of seals comprises: 
 (i) a first side seal extending longitudinally between said peripheral top edge and said peripheral bottom edge and positioned proximate to said first peripheral side edge;  
 (ii) a second side seal opposite to said first side seal and extending longitudinally from said peripheral top edge to said peripheral bottom edge and positioned proximate to said second peripheral side edge;  
 (iii) a top seal extending transversely from said first peripheral side edge to said second peripheral side edge and positioned proximate to said peripheral top edge;  
 (iv) a bottom seal opposite to said top seal and extending transversely from said first peripheral side edge to said second peripheral side edge and positioned proximate to said peripheral bottom edge;  
 (v) wherein said plurality of seals are connected to form a seal perimeter between said front flexible panel and said rear flexible panel thereby forming a receptacle cavity;  
   (e) a reclosable fastener means to provide an entree to said receptacle cavity, wherein said reclosable fastener means is positioned between said interior surface of said front flexible panel and said interior surface of said rear flexible panel and comprises 
 (i) a first interlocking member having an attachment flange,  
 (ii) a second interlocking member having an attachment flange,  
 (iii) wherein said attachment flange of said first interlocking member is sealed to said interior surface of said front flexible panel,  
 (iv) wherein said attachment flange of said second interlocking member is sealed to said interior surface of said rear flexible panel,  
 (v) a slider device connected to said first interlocking member and said second interlocking member,  
 (vi) wherein said first interlocking member and said second interlocking member are adapted to engage and disengage with each other;  
   (f) at least one line of structural weakness in said exterior surface of said front flexible panel extending transversely from said first peripheral side edge to said second peripheral side edge, positioned below and adjacent to said reclosable fastener means;    (g) at least one line of structural weakness in said exterior surface of said rear flexible panel extending transversely between said first peripheral side edge and said second peripheral side edge, positioned below and adjacent to said reclosable fastener means; and    (h) a tamper-evident structure having a first portion comprising said front flexible panel which extends from said at least one line of structural weakness in said exterior surface of said front flexible panel to said top seal and a second portion comprising said rear flexible panel which extends from said at least one line of structural weakness in said exterior surface of said rear flexible panel to said top seal.    
     
     
         31 . A package containing an article according to  claim 30 , further comprising a frangible seal joining said interior surface of said front flexible panel to said interior surface of said rear flexible panel and extending transversely from said first peripheral side edge to said second peripheral side edge, said frangible seal is positioned below and adjacent to said at least one line of structural weakness in said exterior surface of said front flexible panel and at least one line of structural weakness in said exterior surface of said rear flexible panel.  
     
     
         32 . (canceled)  
     
     
         33 . A method of manufacturing a reclosable thermoformed flexible package containing an article comprising: 
 (a) providing both a front flexible panel and a rear flexible panel, 
 (i) wherein said front flexible panel comprises a first thermoplastic film, an internal surface and an external surface and at least one line of structural weakness in said external surface,  
 (ii) wherein said rear flexible panel comprises a thermoformable second thermoplastic film, an internal surface and an external surface and at least one line of structural weakness in said external surface;  
   (b) dispensing a rear flexible panel from a first roll;    (c) providing a reclosable fastener means;    (d) tacking said reclosable fastener means to said interior surface of said rear flexible panel;    (e) thermoforming said rear flexible panel, wherein said thermoforming of said rear flexible panel is performed either after said dispensing said rear flexible panel from said first roll and before said providing said reclosable fastener means or after said tacking said reclosable fastener means to said interior surface of said rear flexible panel;    (f) placing an article onto said rear flexible panel;    (g) dispensing a front flexible panel from a second roll to cover said article, wherein said front flexible panel comprises;    (h) joining said reclosable fastener means to both said interior surface of said rear flexible panel and to said interior surface of said front flexible panel;    (i) joining said front flexible panel to said rear flexible panel to form a seal perimeter between said front flexible panel and said rear flexible panel thereby defining a receptacle cavity therewithin, such that an aperture is formed in said seal perimeter which is adapted to allow said receptacle cavity to communicate with the outside of said package;    j) modifying the atmosphere within said receptacle cavity through said aperture in said seal perimeter; and    (k) sealing said aperture of said seal perimeter.    
     
     
         34 . A package containing an article according to claims  1 ,  20  or  30 , wherein said at least one line of structural weakness in said external surface of both said front flexible panel and said rear flexible panel are each formed by a mechanical cutting device.