Easy Open Flexible Film Packaging Products and Methods of Manufacture

Abstract

Packages and methods having a flexible film ( 12 ) defining an interior contents cavity and having a first pair of opposing edge portions forming a first end seal ( 18 ), a second pair of opposing edge portions forming a second end seal ( 20 ), and a third pair of opposing edge portions forming a longitudinal fin seal ( 14 ) extending from the first end seal to the second end seal; the body having a first side portion having the longitudinal fin seal and a second side portion generally opposite the first side portion; a score ( 42 ) formed in the flexible film at the second side portion and defining an opening to the contents cavity upon initial rupturing and configured to propagate film tear longitudinally towards the second end-seal; a closure label ( 40 ) covering at least portion of the score, but less than the entire score; and a pressure sensitive adhesive being between the closure layer and the flexible film.

1 . A package, comprising:
 a flexible film defining an interior contents cavity and having a first pair of opposing edge portions forming a first end seal, a second pair of opposing edge portions forming a second end seal, and a third pair of opposing edge portions forming a longitudinal fin seal extending from the first end seal to the second end seal;   the body having a first side portion having the longitudinal fin seal and a second side portion generally opposite the first side portion;   a score formed in the flexible film at the second side portion and defining an opening to the contents cavity upon initial rupturing and configured to propagate film tear longitudinally towards the second end-seal;   a closure label covering at least portion of the score, but less than the entire score; and   a pressure sensitive adhesive being between the closure layer and the flexible film.   
     
     
         2 . The package of  claim 1 , wherein the pressure sensitive adhesive has a predetermined affinity between the closure layer and the flexible film such that the score ruptures upon removal of the closure layer from a portion of the second side portion. 
     
     
         3 . The package of  claim 1  wherein the score is closer to the first end seal than the second end seal. 
     
     
         4 . The package of  claim 3  wherein the score is arcuate. 
     
     
         5 . The package of  claim 4  wherein a concave side of the arcuate score faces the second end seal. 
     
     
         6 . The package of  claim 3  wherein the score is rectilinear. 
     
     
         7 . The package of  claim 3  wherein the score is pointed. 
     
     
         8 . The package of  claim 3  wherein the score includes a pair of terminal ends configured to resist further rupturing of the flexible film. 
     
     
         9 . The package of  claim 8  wherein the terminal ends are configured as hooks. 
     
     
         10 . The package of  claim 1  wherein the closure layer includes a tack free gripping portion to remove the closure layer from at least a portion of the second side. 
     
     
         11 . The package of  claim 1 , wherein the tack free gripping portion is an arcuate leading edge. 
     
     
         12 . The package of  claim 1 , wherein the closure layer extends beyond the score to cover sufficient marginal space around the score to effectively tack close the opening once the score has ruptured. 
     
     
         13 . The package of  claim 1 , wherein the flexible film is a laminate structure. 
     
     
         14 . The package of  claim 13 , wherein the laminate film structure is a co-extruded film structure. 
     
     
         15 . The flexible film package of  claim 13 , wherein the flexible film comprises a laminate of polyethylene terephthalate and oriented polypropylene having a thickness in the range of about 1.5 to 2.5 mils. 
     
     
         16 . The flexible film package of  claim 13 , wherein the flexible film comprises a laminate of polyethylene terephthalate having a thickness in the range of about 0.4 to 1.0 mill and oriented polypropylene having a thickness in the range of about 0.6 to 1.2 mils. 
     
     
         17 . The flexible film package of  claim 1 , wherein the closure layer is a bi-axially oriented polypropylene having a thickness in the range of about 1.2 mil to 5 mil. 
     
     
         18 . The flexible package of  claim 5 , wherein the score comprises a pair of parallel score lines extending from the arcuate leading edge beyond the closure layer. 
     
     
         19 . A laminate for producing flexible packages comprising:
 a continuous web of flexible film having a width and a longitudinal axis;   a discrete closure layer applied to at most half of the width of the continuous web of flexible film and along the longitudinal axis with pressure sensitive adhesive; and   the continuous web and the continuous closure layer configured to be formed into a series of identical package forming blanks, the flexible film of each identical package forming blank having a score formed therein that coincides with at least a portion of the closure layer, but not within all of the closure layer, and that subsequently forms a package opening when ruptured.   
     
     
         20 . The laminate of  claim 19  wherein:
 the closure layer is a bi-axially oriented polypropylene having a thickness in the range of about 1.2 mil to 5 mil; and 
 the continuous film is laminate in a range of about 1.5 to 2.5 mils having a polyethylene terephthalate layer and an oriented polypropylene layer. 
 
     
     
         21 . The laminate of  claim 20 , wherein film laminate can include ink and primer layer disposed between the polyethylene terephthalate layer and oriented polypropylene layer. 
     
     
         22 . A method of in-line packaging of products in a series of packages, comprising the steps of:
 merging a closure layer to a continuous film web having longitudinal edges spaced a predetermined width;   providing adhesive between the closure layer and the continuous film web across less than the predetermined width but more than half of the predetermined width;   scoring the continuous film web corresponding partially to the closure layer to define an opening in the continuous film web upon initial rupturing caused by removing the continuous substrate;   forming a longitudinal seal along the longitudinal edges;   forming a trailing end seal between adjacent packages of a series;   providing products in a series to be packaged; and   forming a leading end seal.