Method and Apparatus for Laser Scored Packaging

Abstract

A package formed via a vertical-form-fill-and-seal process includes a web material with edge portions sealed to create a vertical sleeve. The package also includes a first sealed end and a second sealed end at either end of the vertical sleeve to create a sealed package. The package includes a laser scribed ablation pattern extending across the web material with ablated portions having an about one to about three millimeter length separated by non-ablated portions of about 0.25 and about 0.75 millimeter length. The package has increased tensile strength to avoid breaking during the vertical-form-fill-and-seal process and provides a high likelihood that an outer edge and vertical seal of the package include ablated portions to provide an easy-to-start tear area to open the package. Also, the short spaces between ablated portions increase the likelihood of tear propagation along the ablation pattern, all the way across the package.

1 . A package formed via a vertical-form-fill-and-seal process comprising:
 a web material with a first edge portion and a second edge portion opposite the first edge portion sealed together in a seal with a first sealed end at a first end of the seal and a second sealed end at a second end of the seal;   wherein the first sealed end and the second sealed end define a first package side edge and a second package side edge wherein the first package side edge and the second package side edge comprise folded web material;   an ablation pattern extending across the web material between the first edge portion and the second edge portion wherein the ablation pattern comprises a series of ablated portions about 1 millimeter to about 3 millimeters in length separated by non-ablated portions about 0.25 millimeters to about 0.75 millimeters in length such that the ablation pattern defines a tear line across the package such that the package substantially tears along the along tear line and across the seal when a separating force is applied by a user at the first package side edge or the second package side edge and such that the web material maintains sufficient tensile strength to withstand the vertical-form-fill-and-seal process substantially without breaking.   
     
     
         2 . The package of  claim 1  wherein the package has a length from the first sealed end to the second sealed end of about 75 millimeters to about 200 millimeters. 
     
     
         3 . The package of  claim 1  wherein the web material comprises at least two layers. 
     
     
         4 . The package of  claim 1  wherein the web material comprises:
 an outer layer comprising at least one of a group comprising PET (polyethylene terephthalate) and OPP (oriented polypropylene film); and   at least a second layer comprising at least one of a group comprising PET, OPP, and foil.   
     
     
         5 . The package of  claim 1  wherein the ablated portions have a depth less than a thickness of an outer layer of the package. 
     
     
         6 . The package of  claim 1  wherein the ablation pattern is non-uniform. 
     
     
         7 . The package of  claim 1  wherein the first package side edge, the second package side edge, and an edge of the seal have ablated portions. 
     
     
         8 . The package of  claim 1  further comprising a second ablation pattern disposed on a web material side opposite and substantially in line with the ablation pattern. 
     
     
         9 . The package of  claim 1  wherein the seal comprises at least one of a group comprising a fin-type seal and an overlap seal. 
     
     
         10 . A method of manufacturing a package comprising:
 laser scoring an ablation pattern across a web material between a first edge portion and a second edge portion of the web material wherein the ablation pattern comprises a series of ablated portions about 1 millimeter to about 3 millimeters in length separated by non-ablated portions about 0.25 millimeters to about 0.75 millimeters in length;   feeding the web material into a vertical-form-fill-and-seal-process device;   sealing the web material along a vertical direction to form at least one seal;   advancing the web material within the vertical-form-fill-and-seal-process device;   sealing and cutting the web material horizontally across the at least one seal at a first end of the package;   cutting the web material at a second end of the package with the ablation pattern between the first end and the second end.   
     
     
         11 . The method of  claim 10  wherein the step of laser scoring an ablation pattern extending across a web material between a first edge portion and a second edge portion of the web material wherein the ablation pattern comprises a series of ablated portions about 1 millimeter to about 3 millimeters in length separated by non-ablated portions about 0.25 millimeters to about 0.75 millimeters in length further comprises ablating the web material to a depth less than a thickness of an outer layer of the package. 
     
     
         12 . The method of  claim 10  wherein the step of laser scoring an ablation pattern extending across a web material between a first edge portion and a second edge portion of the web material wherein the ablation pattern comprises a series of ablated portions about 1 millimeter to about 3 millimeters in length separated by non-ablated portions about 0.25 millimeters to about 0.75 millimeters in length further comprises ablating the web material on two sides of the web material. 
     
     
         13 . The method of  claim 10  wherein the step of laser scoring an ablation pattern extending across a web material between a first edge portion and a second edge portion of the web material is performed after the step of feeding the web material into a vertical-form-fill-and-seal-process device. 
     
     
         14 . The method of  claim 10  wherein the step of cutting the web material at a second position with the ablation pattern between the first position and the second position further comprises cutting the web material with a length from the first end to the second end of about 75 millimeters to about 200 millimeters. 
     
     
         15 . The method of  claim 10  wherein the ablation pattern is non-uniform. 
     
     
         16 . The method of  claim 10  further comprising laser scoring a second ablation pattern disposed on a web material side opposite and substantially in line with the ablation pattern. 
     
     
         17 . The method of  claim 10  wherein the step of sealing the web material along a vertical direction to form at least one seal comprises sealing the web material to a second web material. 
     
     
         18 . The method of  claim 17  further comprising laser scoring a second ablation pattern extending across the second web material wherein the ablation pattern comprises a series of ablated portions about 1 millimeter to about 3 millimeters in length separated by non-ablated portions about 0.25 millimeters to about 0.75 millimeters in length. 
     
     
         19 . A package formed via a vertical-form-fill-and-seal process comprising:
 a first web material sealed to a second web material at a first side edge along a first side edge seal and at a second side edge along a second side edge seal;   a first sealed end sealing the package between the first side edge seal and the second side edge seal;   a second sealed end sealing the package between the first side edge seal and the second side edge seal;   an ablation pattern extending across at least the first web material between the first side edge and the second side edge wherein the ablation pattern comprises a series of ablated portions about 1 millimeter to about 3 millimeters in length separated by non-ablated portions about 0.25 millimeters to about 0.75 millimeters in length such that the ablation pattern defines a tear line across the package such that the package substantially tears along the along tear line and across the first side edge seal and the second side edge seal when a separating force is applied by a user at the first side edge or the second side edge and such that the web material maintains sufficient tensile strength to withstand the vertical-form-fill-and-seal process substantially without breaking.   
     
     
         20 . The package of  claim 19  further comprising a second ablation pattern extending across the second web material between the first side edge and the second side edge substantially in line with the ablation pattern on the first web material. 
     
     
         21 . The package of  claim 19  wherein the package has a length from the first sealed end to the second sealed end of about 75 millimeters to about 200 millimeters. 
     
     
         22 . The package of  claim 19  wherein the first web material and the second web material comprises:
 an outer layer comprising at least one of a group comprising PET (polyethylene terephthalate) and OPP (oriented polypropylene film); and   at least a second layer comprising at least one of a group comprising PET, OPP, and foil.   
     
     
         23 . The package of  claim 19  wherein the ablated portions have a depth less than a thickness of an outer layer of the package. 
     
     
         24 . The package of  claim 19  wherein the ablation pattern is non-uniform. 
     
     
         25 . The package of  claim 19  wherein the first side edge and the second side edge have ablated portions.