Reclosable Container with Resealable Flexible Cover and Method for Manufacturing the Same

Abstract

A reclosable container with a resealable, flexible cover portion that is easy to use and a method of manufacturing the same. The reclosable container comprises a container body having a storage space and an opening providing access to the storage space. The container body includes a base portion and a resealable cover portion having an inner layer, an outer layer, and a pressure-sensitive adhesive affixing the inner layer to the outer layer. The inner layer of the resealable cover portion is heat sealed to the base portion about the opening thereby forming a heat-sealed region where the inner layer contacts and is heat sealed to the base portion. The inner layer of the resealable cover portion has a cut inside the heat-sealed region such that when the resealable cover portion is pulled apart from the base portion, the inner layer, the outer layer, and the pressure-sensitive adhesive are together lifted away from the opening, but the inner layer remains attached to the base portion in and adjacent to the heat-sealed region such that the pressure-sensitive adhesive contacting the inner layer in and adjacent to the heat-sealed region is exposed.

1 . A reclosable container comprising:
 a container body having a storage space and an opening providing access to said storage space, the container body comprising a base portion and a resealable cover portion having an inner layer, an outer layer, and a pressure-sensitive adhesive affixing said inner layer to said outer layer;   wherein said inner layer of said resealable cover portion is heat sealed to said base portion about said opening thereby forming a heat-sealed region where said inner layer contacts and is heat sealed to said base portion, said inner layer of said resealable cover portion having a cut inside said heat-sealed region such that when said resealable cover portion is pulled apart from said base portion, said inner layer, said outer layer, and said pressure-sensitive adhesive are together lifted away from said opening, but said inner layer remains attached to said base portion in and adjacent to said heat-sealed region such that said pressure-sensitive adhesive contacting said inner layer in and adjacent to said heat-sealed region is exposed.   
     
     
         2 . The reclosable container of  claim 1 , wherein said resealable cover portion is a flexible laminate in which said inner layer, said outer layer, and said pressure-sensitive adhesive are continuous across said resealable cover portion. 
     
     
         3 . The reclosable container of  claim 1 , said resealable cover portion further comprising a pull tab, said pull tab formed by a second cut in said inner layer of said resealable cover portion, said second cut located outside of said heat sealed region. 
     
     
         4 . The reclosable container of  claim 1 , said resealable cover portion further comprising a pull tab, said pull tab formed by a second cut in said inner layer of said resealable cover portion and said container body, said second cut passing through a portion of said heat sealed region 
     
     
         5 . The reclosable container of  claim 1 , said inner layer comprising a thermoplastic material. 
     
     
         6 . The reclosable container of  claim 1 , said outer layer comprising a thermoplastic material. 
     
     
         7 . The reclosable container of  claim 1 , wherein said cut has an open geometry. 
     
     
         8 . The reclosable container of  claim 1 , wherein said inner layer has a gas permeability of less than 0.1 cc/100 in 2 /24 hrs. 
     
     
         9 . The reclosable container of  claim 1 , wherein the inner layer comprises ethylene vinyl alcohol. 
     
     
         10 . The reclosable container of  claim 1 , wherein said base portion comprises a substantially rigid material and said resealable cover portion comprises a flexible material. 
     
     
         11 . The reclosable container of  claim 1 , wherein said base portion and said resealable cover portion comprise a flexible material. 
     
     
         12 . A reclosable container comprising:
 a container body having a storage space and an opening providing access to said storage space, said container body comprising a base portion and a resealable cover portion having an inner layer, an outer layer, and a pressure-sensitive adhesive affixing said inner layer to said outer layer, said resealable cover portion being a flexible laminate in which said inner layer, said outer layer, and said pressure-sensitive adhesive are continuous across said resealable cover portion; said inner layer being sealed to said base portion along a sealed region about said opening of said container body; said resealable cover portion configured to separate, exposing said pressure-sensitive adhesive in and adjacent to said sealed region while covering said pressure-sensitive adhesive facing said opening with said inner layer when said resealable cover portion is lifted away from said base portion.   
     
     
         13 . The reclosable container of  claim 12 , said inner layer of said resealable cover portion having a cut inside said heat-sealed region. 
     
     
         14 . The reclosable container of  claim 13 , said resealable cover portion further comprising a pull tab, said pull tab formed by a second cut in said inner layer of said resealable cover portion, said second cut located outside of said heat sealed region. 
     
     
         15 . The reclosable container of  claim 13 , said resealable cover portion further comprising a pull tab, said pull tab formed by a second cut in said inner layer of said resealable cover portion and said base portion, said second cut passing through a portion of said heat sealed region 
     
     
         16 . The reclosable container of  claim 12 , said inner layer comprising a thermoplastic material. 
     
     
         17 . The reclosable container of  claim 12 , said outer layer comprising a thermoplastic material. 
     
     
         18 . The reclosable container of  claim 12 , wherein said inner layer is heat-sealed to said base portion along a sealed region about said opening of said container body. 
     
     
         19 . The reclosable container of  claim 13 , wherein said cut has an open geometry. 
     
     
         20 . A method of manufacturing a reclosable container comprising:
 providing a container body having a storage space and an opening providing access to said storage space;   loading a product into said storage space;   providing a flexible laminate having an inner layer, an outer layer, and a pressure-sensitive adhesive affixing said inner layer to said outer layer;   cutting said inner layer of said flexible laminate to form a separating cut, said separating cut passing through said inner layer but not through said outer layer; and   sealing said flexible laminate to said container body about said opening along a sealed region such that at least a portion of said separating cut lies inside said sealed region after said product is loaded into said storage space and said separating cut is cut into said inner layer.   
     
     
         21 . The method of  claim 20 , said inner layer comprising a thermoplastic material. 
     
     
         22 . The method of  claim 20 , said outer layer comprising a thermoplastic material. 
     
     
         23 . The method of  claim 20 , wherein said inner layer is sealed to said container body by a heat-sealing process. 
     
     
         24 . The method of  claim 20 , further comprising cutting said inner layer of said flexible laminate to form a second separating cut to form a pull tab, said second separating cut passing through said inner layer but not through said outer layer. 
     
     
         25 . The method of  claim 20 , wherein said separating cut has an open geometry. 
     
     
         26 . The method of  claim 20 , wherein said separating cut faces said container body inside said sealed region.