Easy-open peel pouch

Abstract

A package for containing and dispensing a product is disclosed. The package has a first layer, a second layer, and at least a first seal zone where the first layer is joined to the second layer by a peelable seal. The first seal zone has an inner perimeter that defines an unsealed pouch area for containing the sheet product. A tab cut is defined in the first layer that divides the package into a package zone and a tab zone. A method and relevant manufacturing equipment are also disclosed.

We claim: 
     
         1 . A package for containing and dispensing a product, comprising:
 a first layer;   a second layer;   at least a first seal zone where the first layer is joined to the second layer by a peelable seal, the first seal zone having an inner perimeter that defines an unsealed pouch area for containing the product and an outer perimeter; and   an unsealed header zone adjacent to the outer perimeter of the first seal zone, wherein the first layer is not joined to the second layer in the unsealed header zone; and   a first tab cut in the first layer within the unsealed header zone, wherein the first tab cut divides the package into a package zone and a first tab zone.   
     
     
         2 . The package of  claim 1  wherein the first layer is coextensive with the second layer so that the first layer and second layer share a common outer perimeter. 
     
     
         3 . The package of  claim 1  wherein the unsealed header zone is positioned substantially along one side of the package. 
     
     
         4 . The package of  claim 1  further comprising a second seal zone where the first layer is joined to the second layer, wherein the second seal zone is within the first tab zone, wherein the second seal zone is separated from the first seal zone by a portion of the unsealed header zone. 
     
     
         5 . The package of  claim 4 , wherein the first tab zone is located in a corner of the package, further comprising:
 a second tab cut in the first layer within the unsealed header zone, wherein the second tab cut defines the boundary of a second tab zone located in a corner of the package; and   a third seal zone where the first layer is joined to the second layer, wherein the third seal zone is within the second tab zone.   
     
     
         6 . The package of  claim 1  wherein the package is substantially rectangular and wherein the unsealed header zone is positioned substantially along one side of the package. 
     
     
         7 . The package of  claim 1  wherein there is no cut in the second layer at a location corresponding to the first tab cut on the first layer. 
     
     
         8 . The package of  claim 1  wherein the product is a sheet product. 
     
     
         9 . The package of  claim 1  wherein the package is substantially rectangular and the unsealed header zone is substantially rectangular and is located along one side of the package, and wherein the first tab zone is defined at a corner of the package. 
     
     
         10 . The package of  claim 1  wherein the package is substantially rectangular and the unsealed header zone is substantially rectangular and is located along one side of the package, and wherein the first tab cut is curved. 
     
     
         11 . A method of forming a package for containing and dispensing a product comprising:
 providing a first layer web and a second layer web;   placing a product on at least one pouch area of one of the first and second layer webs;   forming a combined web by sealing the first layer web to the second layer web at least at a first seal zone so that the first layer is joined to the second layer by a peelable seal surrounding the at least one pouch area, and leaving an unsealed header zone adjacent to an outer perimeter of the first seal zone where the first layer web is not sealed to the second layer web; and   cutting at least one individual package around an outer package perimeter to separate the individual package from the combined web, wherein cutting further comprises cutting the first layer of the package at a first tab cut location within the unsealed header zone to define a boundary of the first tab zone in the package.   
     
     
         12 . The method of  claim 11  wherein forming a combined web further comprises sealing the first layer web to the second layer web at a second seal zone which is within the tab zone. 
     
     
         13 . The method of  claim 11  wherein cutting the individual package comprises die cutting. 
     
     
         14 . The method of  claim 13  wherein cutting the individual package comprises rotary die cutting. 
     
     
         15 . The method of  claim 11  further comprising forming a second seal zone where the first layer is joined to the second layer, wherein the second seal zone is within the first tab zone, wherein the second seal zone is separated from the first seal zone by a portion of the unsealed header zone. 
     
     
         16 . The method of  claim 11 , wherein the first tab zone is located in a corner of the package, further comprising:
 cutting a second tab cut in the first layer within the unsealed header zone, wherein the second tab cut defines the boundary of a second tab zone located in a corner of the package; and   forming a third seal zone where the first layer is joined to the second layer, wherein the third seal zone is within the second tab zone.   
     
     
         17 . The method of  claim 11  wherein there is no cut in the second layer at a location corresponding to the first tab cut on the first layer. 
     
     
         18 . A device for forming a package for containing and dispensing a sheet product comprising:
 a heat seal plate for joining a first layer web and a second layer web with a heat seal at first seal zones to form a combined web, wherein the seal plate defines at least one first seal zone having an inner perimeter and an outer perimeter; and   a cutting die for cutting the combined web to form at least one individual package and for cutting through only the first layer at a tab cut location, where the first tab cut location is not within any of the first seal zones on the combined web.   
     
     
         19 . The device of  claim 18  wherein the cutting die is a rotary cutting die.