Reclosable flexible film packaging and methods of manufacture

Abstract

A reclosable flexible package can have a flexible film forming a body defining an interior contents cavity and having a first pair of opposing edge portions forming a first edge seal, a second pair of opposing edge portions forming a second edge seal, and a third pair of opposing edge portions forming a fin seal extending from the first edge seal to the second edge seal; the body having a first side portion having the 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 defining an opening to the contents cavity upon initial rupturing; a closure layer covering the score and a portion of the second side portion around the score; a resealable adhesive being between the closure layer and the flexible film; and the closure layer on the second side portion being capable of at least partial removal from the flexible film to rupture the score and form an opening.

1 . A package comprising:
 a flexible film forming a body defining an interior contents cavity and having a first pair of opposing edge portions forming a first edge seal, a second pair of opposing edge portions forming a second edge seal, and a third pair of opposing edge portions forming a longitudinal seal extending from the first edge seal to the second edge seal;   the body having a first side portion having the longitudinal seal and a second side portion generally opposite the first side portion;   a score formed in the flexible film at the second side portion defining an opening to the contents cavity upon initial rupturing;   a closure layer covering the score and a portion of the second side portion around the score;   a resealable adhesive being between the closure layer and the flexible film; and   the closure layer on the second side portion being capable of at least partial removal from the flexible film to rupture the score and form an opening.   
     
     
         2 . The package of  claim 1 , wherein the resealable 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 closure layer extends from the first edge seal to the second edge seal and generally parallel to the longitudinal seal. 
     
     
         4 . The package of  claim 1 , wherein the score is arcuate. 
     
     
         5 . The package of  claim 1 , wherein the score includes a pair of terminal ends configured to resist further rupturing of the flexible film. 
     
     
         6 . The package of  claim 5 , wherein the terminal ends are configured as ‘smiles’. 
     
     
         7 . 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. 
     
     
         8 . The package of  claim 7 , wherein the tack free gripping portion includes a deadener on the resealable adhesive. 
     
     
         9 . The package of  claim 7 , wherein the tack free gripping portion includes a portion of the closure layer adhered to itself with the resealable adhesive. 
     
     
         10 . The package of  claim 7 , wherein the tack free gripping portion is void of resealable adhesive. 
     
     
         11 . The package of  claim 1 , wherein the flexible film comprises a laminate structure. 
     
     
         12 . The package of  claim 11 , wherein the flexible film comprises a laminate of polyethylene terephthalate and oriented polypropylene having a thickness in a range of about 1.5 to 2.5 mils. 
     
     
         13 . The package of  claim 11 , wherein the flexible film comprises a laminate of polyethylene terephthalate having a thickness in a range of about 0.4 to 1.0 mils and oriented polypropylene having a thickness in a range of about 0.6 to 1.2 mils. 
     
     
         14 . The package of  claim 1 , wherein the closure layer is a bi-axially oriented polypropylene having a thickness in a range of about 1.2 mils to 5 mils. 
     
     
         15 . The package of  claim 1 , further including a gusset in a third edge of the film. 
     
     
         16 . The package of  claim 15 , wherein the score formed in the flexible film at the second side portion of the package is on a top half of the second side portion, and the third edge is on a bottom half of the second side portion. 
     
     
         17 . The package of  claim 15 , wherein the gusset is the flexible film folded into the interior contents cavity to form two opposing gusset sides extending inwardly from the first side portion and the second side portion toward the vertical center of the package. 
     
     
         18 . The package of  claim 1 , wherein the score is disposed partially through a thickness of the flexible film. 
     
     
         19 . The package of  claim 1 , wherein the score is disposed through an entire thickness of the flexible film. 
     
     
         20 . The package of  claim 1 , wherein the resealable adhesive is a pressure sensitive adhesive. 
     
     
         21 . A flexible film package comprising:
 a flexible film having two opposing edge portions forming a longitudinal seal extending from a first side seal to a second side seal, the side seals forming a front package panel and a rear package panel, the longitudinal seal disposed on the rear panel;   a score in the flexible film front panel oriented generally parallel to the longitudinal seal that defines a package opening upon initial rupturing;   an elongated closure layer extending within the edge portions from the first side seal to the second side seal and over the score;   a resealable adhesive being between the flexible film and the elongated closure layer;   the elongated closure layer having a tack free gripping portion to remove at least a portion of the elongated closure layer from the flexible film to form the package opening; and   the package having a blind fold to define a package top and a pair of folds directed to a package interior forming a gusset to define a package bottom.   
     
     
         22 . The package of  claim 21 , wherein the film is a printed laminate comprising a co-extruded polypropylene laminated to a heat sealable polypropylene; and the elongated closure layer is a BOPP bi-axially oriented polypropylene. 
     
     
         23 . A method for making a vertical stand-up pouch having a substantially symmetrical bottom gusset, comprising the steps of:
 tensioning a film roll;   continuously scoring the film roll on a surface directed to an interior the package;   laminating a continuous closure layer on an exterior surface of the package over the film with a resealable adhesive;   forming the film around a product delivery chamber;   sealing opposite longitudinal edges of the film to form a longitudinal seal;   forming a gusset to the film directed to a bottom of the package;   sealing the film to create a package side seal;   cutting the package side seal to separate the film; and   supplying product into the product delivery chamber into the unsealed film.   
     
     
         24 . The method of  claim 23 , further comprising the step of deadening a portion of the resealable adhesive before laminating to the film. 
     
     
         25 . The method of  claim 23 , wherein the longitudinal seal is a fin seal. 
     
     
         26 . The method of  claim 23 , wherein the step of sealing the film is performed by a pair of heated reciprocal heating bars to a film having a heat sealable layer on the interior surface of the film.