Bottom gusseted bag with resealable closure label

Abstract

A flexible film package comprises a bag made from a polyolefin film with a gusseted bottom, welded side seams and a pattern of perforations in a front surface defining an opening. The package includes a label made from a polyolefin film with a releasable pressure sensitive adhesive on a back surface positioned in contact with the front surface of the bag covering the pattern of perforations. When the label is pulled away from the bag, the force is sufficient to initially separate the adhesive backing of the label from the film of the bag and to tear the film of the bag between the perforations such that the label remains adhered to the torn bag film forming a tear open flap in the bag. The exposed adhesive backing on the label extending beyond the film of the bag on the tear open flap may be re-adhered to the front panel of the bag to reclose the bag. The bag film and label film may be made from polymers that are compatible for recyclability in the same recycle category for ease of recycling the package after use.

Description

RELATED APPLICATIONS

[0001] The present application claims the benefit of priority under 35 USC 119 (e) to U.S. Provisional Application No. 63 / 655,438, filed on Jun. 3, 2024, and to U.S. Provisional Application No. 63 / 697,178, filed on Sep. 20, 2024, each of which are hereby incorporated by reference in their entirety herein.TECHNICAL FIELD

[0002] The present disclosure relates to resealable packaging, in particular, packaging having adhesive resealable openings for foodstuffs and consumer items.BACKGROUND

[0003] Foodstuffs and consumer items come in a variety of packages. Packages made of flexible polymer films may be manufactured from a variety of materials in a variety of ways. Flexible film packages are often in the form of a bag with an opening at one end. Such packages may often have a gusseted / folded or fin-welded end that may be opened to access the contents, or may have a ponytail open end with a wire tie or clip to keep it closed. For products comprising numerous pieces in a stacked arrangement in a bag, a consumer is limited to selecting the pieces closest to the opened end of the bag. It would be desirable to develop new forms of packaging made from flexible polymer films that allow consumers additional options for selecting product pieces from the bag. It would also be desirable to develop bags that meet consumer and / or corporate goals for sustainability.BRIEF SUMMARY

[0004] A flexible film package comprises a bag made from a polyolefin film with a pattern of perforations in a front surface. A label may be made from a polyolefin film with a releasable pressure sensitive adhesive on a back surface. The label may be positioned in contact with the front surface of the bag covering the pattern of perforations. When the label is pulled away from the bag, the pull force may be sufficient to initially separate the adhesive backing of the label from the film of the bag and to then tear the film of the bag between the perforations such that the label remains adhered to the flap of torn film which forms a tear open flap in the bag. The exposed adhesive backing on the label extending beyond the perforations defining the tear open flap of the bag may be re-adhered to the front panel of the bag to reclose and reseal the bag.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 depicts one embodiment of a sheet of polymer film with a pattern of perforations and a peelable label before being formed into a gusseted bag.

[0006] FIG. 2 depicts another embodiment of a sheet of polymer film with a pattern of perforations before being formed into a gusseted bag.

[0007] FIG. 3 illustrates various styles of perforations to form a tear open flap that may require different forces for tearing and rates of tearing.

[0008] FIGS. 4A and 4B depict alternative embodiments of a gusseted bag with the front panel tear open flap and the end opening sealed closed with gusseted folds and alternative visual appearances.

[0009] FIGS. 5A, 5B and 5C depict a prior art bag, an embodiment of a closed bag according to the present disclosure, and a bag with the tear flap opened according to the present disclosure, respectively.

[0010] FIGS. 6A, 6B, and 6C depict three embodiments of a label.

[0011] FIG. 7 depicts a group of bags with peelable labels stacked on a wicket.

[0012] FIG. 8 depicts a sequence for using the label to open and close an embodiment of a bag according to the present disclosure.

[0013] The drawings are provided for illustrative purposes to aid in the understanding of several embodiments, and are not necessarily drawn to scale or accurate representations as to size and shape. The following detailed description further illustrate the several embodiments.DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0014] In one embodiment, the flexible film package includes a bag configured for bulk placement on a wicket, the bag is made from a first polyolefin film and has a gusseted bottom, welded side seams, and a plurality of perforations on a front surface of the bag to define edges of an opening of the bag. The film package includes a label made from a second polyolefin film and an adhesive on substantially all of a back surface of the label, the label being disposed on the bag with the adhesive on the back surface of the label in contact with the front surface of the bag and of sufficient size to cover the perforations in the front surface of the bag and the opening defined by the perforations. The label, adhesive and plurality of perforations are configured such that when the label is pulled away from the bag to separate the adhesive on a back surface of the label from a first portion of the film of the bag, the segment of the film of the bag between the perforations tears such that the label remains adhered to a second portion of the film of the bag to form a flap opening the bag. The label and the adhesive on the back surface of the label extends past the edge of the flap opening to allow the label to be reclosed and re-adhere to the first portion of the film of the bag surrounding the opening.

[0015] In yet another embodiment, a packaged foodstuff in a flexible film package includes a bag made from a first polyolefin film having a gusseted bottom, a gusseted and sealed top, welded side seams, and a plurality of perforations on a front surface of the bag to define edges of a tear flap opening of the bag. A foodstuff item having multiple pieces is disposed in the bag. A label made from a second polyolefin film and having an adhesive on substantially all of a back surface of the label is disposed on the bag with the adhesive on the back surface of the label in contact with the front surface of the bag and of sufficient size to cover and extend beyond the tear flap opening in the front surface of the bag. The label, adhesive and bag are configured such that when the label is pulled away from the bag with a specified force, the force is sufficient to separate the adhesive backing of the label from a first portion of the film of the bag extending beyond the tear flap opening and to tear the film of the bag between the perforations such that the label remains adhered to the tear flap opening in the bag, and the opening is of sufficient size to allow the removal of a piece of the foodstuff contained in the bag. The adhesive on the portion of the back surface of the label covers sufficient area and retains sufficient tack to re-adhere to the first portion of the film of the bag.

[0016] In various embodiments of the flexible film package, the plurality of perforations may define three sides of a substantially rectangular flap opening on the front surface of the bag. The plurality of perforations may include a first section of cuts that include perforations with a longer length adjacent to a second section of cuts that include perforations with a shorter length. The plurality of perforations may include a first section of cuts that include perforations with a mix of a shorter and longer length adjacent to a second section of cuts that include perforations with a shorter and longer length. The plurality of perforations may include a first section of cuts that require a lower pull force to tear segments of film between the cuts and a second section of cuts that require a higher pull force to tear segments of film between the cuts, relative to each of the section of cuts. The flexible film package may include perforations that are not uniform in length. The flexible film package may include a central perforation with a length longer than the length of all other perforations, where the central perforation is positioned at a central location of the plurality of perforations under a pull tab of the label where the label is initially pulled away from the bag. The flexible film package may include a wicket lip at the top opening of the bag, where the wicket lip including holes for placement of the bag on the wicket and perforations to separate the bag from the wicket lip. Preferably, the first polyolefin film and the second polyolefin film each comprise materials that meet the same recyclable category. Preferably, the exposed adhesive on the back surface of the label covers sufficient area and has sufficient tack to allow the label to re-adhere to the first portion of the film when the flap opening is opened and closed at least 10 times, and more preferably at least 15 times.

[0017] In embodiments of the flexible film package filled with a foodstuff, the sealed top of the bag preferably may include a weld seam with or without excess film extending beyond the weld seam. A portion of the label at one end of the label nearest the gusseted and sealed top of the bag preferably has no adhesive so as to provide a free end of the label for a user to grasp to pull the label.

[0018] In various embodiments, the package is made from a flexible film. The flexible film may be made by a plastic film extrusion process and typically manufactured from raw pellets. The manufacturing process involves superheating and pressurizing raw polyolefin plastic pellets, such as LDPE, HDPE, or LLDPE, or blends thereof, to create a consistent molten liquid. Once the liquid is created, the resin is forced into a circular die. Then the hot resin is blown outward or upward to create a thin, long balloon or bubble of very pliable plastic film.

[0019] The plastic bubble cools as it further expands, and it encounters several rollers that stretch it into very thin sheets, which will later become the bag walls. The sheets are then rolled onto two individual flat beds and moved into the printing machine.

[0020] In this step, the roll of film is unwrapped and cut into a desired size and shape depending on the commercial intent for the bag. This stage can also add special characteristics required to complete the plastic bags like a pre-cut pattern that will be on the front panel of a bag formed from the film. An adhesive sealing label may be placed over and cover the precut pattern on the front panel.

[0021] This pre-cut pattern on the front panel may be created by a laser cutting tool where a focused laser beam pierces and cuts through materials to cut out patterns and geometries, or may be done by die-cutting equipment.

[0022] Wheels may be used on the equipment to create the gussets. Dies may be used to cut out the handles, if any. Seals may be formed by heat or ultrasonic welding. Printing may be performed before the bags have been converted from the film.

[0023] The last step starts with pressing two printed sheets together or folding over one sheet into two layers and sealing the edges of the sheets to create the sides of the bag. The plastic can then be wound and cut to a suitable size and shape based on the actual use or application for the bag. So-called “Poly bags” are either flat or have a bottom gusset to provide extra space and are made from low-and high-density polyethylene. Additional customizations can be added, such as perforations on wicket poly bags that are often bundled together and have a perforated lip so they tear off quickly and easily. Wicketed bags may be used for packaging a variety of products, such as, but not limited to, food products, newspapers, apparel, hosiery, bakeries, and parts.

[0024] As noted above, the bags may include perforations on the front panel that form a tear open flap or a flap opening covered by a label with a pressure sensitive adhesive backing that allows a consumer to pull the label away from the bag thereby tearing the perforations and forming the tear open flap. The adhesive has sufficient tack that permits the label to be reclosed and to reseal the package closed.

[0025] Embodiments of the bag may be suitable for use with automatic packaging machines and to contain food and / or consumer items. The adhesive on the label preferably has the capacity to retain its adhesiveness or tackiness for closing and reopening the package with the label after the initial opening a minimum of about 10 times, or 15 times, or preferably more times, depending on the number of product pieces in the bag, to ensure the peel and reseal feature lasts for full use of the product contained in the package made from the bag.

[0026] Embodiments of the bags or packages with the tear open flaps and resealable closure labels may have several advantages for the consumer. For example, a bread package with an opening on the front panel may allow the consumer better product accessibility to pick the slice they want instead of reaching for the closest one. The peel-and-reseal label will help the consumer eliminate the internal air after consuming some bread slides, because the bag can be rolled or folded to close it with the label to a size more closely fitting the remaining product inside, thus reducing the amount of air in the package to help maintain or extend product freshness for a longer period.

[0027] Embodiments of the bags or packages may have several advantages for the supplier. The packaging improves sustainability by plastic reduction particularly by eliminating excess plastic film required for the ponytail, eliminating the plastic or cardboard quick lock, or eliminating the twist tie. The packaging also may enhance product safety through the supply chain, and may provide better presentation on the shelf by having tighter plastic film around the product and elimination of the wrinkles / folds associated with the ponytail. The packaging may increase shelf life of the contained products relative to the ponytail closure. Other advantages may be apparent to those of ordinary skill in the art based on the teachings herein.

[0028] As used herein, the terms bag, package and packaging may be used interchangeably unless specifically noted. Generally, the bag refers to the unfilled package, and may refer to only the bag film material and not the label film material when the relationship of the two elements are described. Generally, the package or packaging refers to the bag that is filled and sealed or thereafter during the product lifecycle.

[0029] Referring to FIG. 1, a polymer film blank 10 is illustrated with a front panel 12, a back panel 14, a gusseted fold area 16, front panel label 18, lip 20 and wicket holes 22 prior to being folded and heat sealed to form a bag. The pre-cut pattern of perforations 24 on the front panel is indicated by the dashed or dotted line 24. The perforations define the edge of a tear open flap 26 in the bag. The label 18 in the front panel 12 is indicated by the shaded area. The shaded area over substantially the entire label has an adhesive on the back surface in contact with the front panel of the bag. The gusseted fold area 16 optionally includes scores for facilitating the folding of the film to form a gusseted bottom.

[0030] Referring to FIG. 2, another embodiment of a polymer film blank 28 is illustrated without the adhesive label adhered to the front panel. The pre-cut pattern of perforations 24 may be indicated by the dashed or dotted lines 24 on the front surface of the film blank to be formed into a bag. The pattern of perforations 24 is illustrated as a generally u-shaped form but may have a variety of shapes and dimensions suitable to allow one or more pieces of product in the bag to be removed. As shown, only the three-sides of the tear open flap area include perforations, such that the pre-cut pattern of perforations may be torn to form the tear open flap and create an opening when the label is pulled away from the bag. The perforations or cuts may be made by laser cutting or with a die-cut roller, for example. The terms perforations and cuts may be used interchangeably, unless specifically described otherwise herein in connection with specific embodiments. Preferably, the shape defined by the perforations on three sides of the flap may be considered substantially rectangular, that is, the shape of the flap is not circular or triangular. The flap may be substantially four-sided and may have rounded corners or one of more rounded sides, such as when the perforations are in a u-shape, yet overall in appearance resembles a rectangle or square. The flap may be other shapes provided the function is similar as described herein. Various embodiments may include a longer or longest cut 25 at the center section of the pattern, shorter length cuts on either side of the center longest cut, medium length cuts at the shoulder 29 of the pattern, longer cuts along the sides, and small dots or holes 27 at the terminal ends of the pattern of perforations. The cuts or perforations may range from small holes to 1 mm cuts, to about 10 mm long or longer, and various lengths inbetween depending on the desired tear resistance or pull force required to tear through the pattern of perforations.

[0031] Referring to FIG. 3, examples of a variety of perforation styles are illustrated that may be useful for providing different tear-opening characteristics for the tear-open flap in a finished bag. Style A 30 illustrates long perforations or cuts with short spans of plastic film between the perforations, which should exhibit a fast rate of being torn open. Style B 32 illustrates short perforations or cuts with short spans of plastic firm between the perforations, which should exhibit a relatively slower rate of being torn open compared to Style A since more portions of plastic film need to be torn for each unit of linear dimension along the perforation line. Style C 34 illustrates long perforations with long spans of plastic film between the perforations, which should exhibit slow rate of being torn compared to style A and also may require greater pull force to tear through longer spans of plastic film between the perforations. Style D 36 illustrates short perforations with long spans of plastic film between the perforations, which should exhibit a relatively slower rate of being torn open compared to Style C since more portions of plastic film need to be torn for each unit of linear dimension along the perforation line. As may be understood by one of ordinary skill in the art based on this disclosure, the perforation may be selected to create a tear open flap with the desired pull force and rate of being torn open by a consumer. The styles of perforations may be combined in the front panel to create zones of easy or faster tearing and zones of harder or slower tearing. For example, Style E 38 illustrates another embodiment of a pre-cut pattern of perforations with a combination of short, medium and long perforations, as shown separately in Styles A through D, which may provide a range of pull forces and tear rates as a consumer initially pulls open the label and tears the plastic film along the perforations.

[0032] The pre-cut pattern of perforations may combine different styles in different sections of the pattern to provide different amounts of pull force required to tear open the flap through the different sections. Sections of the perforations may have longer cuts, other sections may have shorter cuts. Sections may include a mix of shorter and longer cuts. Instead of cuts, other sections may have a line of dots or holes perforated through the film. A single section may have a combination of various perforation shapes and sizes as described herein. Generally, sections with longer cuts require a lower pull force to tear open, and sections with shorter cuts require a high pull force to tear open. The perforations should also be matched to the characteristics of the plastic film used to create the bag, because some films may have a higher resistance to tearing than other films of the same thickness, and thicker films may also have a higher resistance to tearing than thinner films of the same material. If the film has a higher resistance to tearing, it is recommended to add a longer cut 25 in the center area of the precut pattern, as shown in FIG. 2. The longer central cut is preferably positioned under the location of the label pull tab to facilitate the initial tearing of the tear flap opening. For example, the tear-open characteristics should be selected to make it somewhat easy to tear open the front panel flap but not too easy to prevent the front panel tear open flap from being accidentally opened by the consumer or during handling of the packaging. As another example, the flap may have a zone where the perforations are somewhat easy to tear when initially opening the flap, i.e., requiring lower pull force, lower tear resistance, and a zone that gets harder to tear, i.e., requiring higher pull force, higher tear resistance, so the user will not inadvertently tear the flap completely from the bag. A high tear resistance zone may be implemented by a section of closely spaced dots or holes at the terminal end 27 of the pre-cut pattern, as shown in FIG. 2.

[0033] FIGS. 4A and 4B depict alternative embodiments of a gusseted bag or package filled with product with a front panel tear-open flap, where the top end opening is sealed closed with seals and side tuckers that provide alternative visual appearances. The filled package closing and sealing process will involve the machine first creating a gusset fold 42 in the top, sealing the bag opening, and then removing some or all of the excess trim. As illustrated, the package 40 in FIG. 4A has some remnants of excess trim 44 extending from the sealing weld line 46, which alternatively may be made as a fin seal. In contrast, the package 46 illustrated in FIG. 4B has nearly all excess trim removed by cutting the plastic film at or very close to the seal weld line 48 to leave a sealed, gusseted end 42 more tightly conforming to the contents of the filled bag, which may provide a more visually appealing neat appearance to the consumer.

[0034] FIGS. 5A, 5B and 5C depict a prior art bag 50, an embodiment of a closed bag 52 according to the present disclosure, and a bag 54 with the tear open flap opened according to the present disclosure, respectively, each of which are filled with foodstuff items, such as sliced bread. Eliminating the twist tie / Kwik Lok 56 and ponytail 58 shown in FIG. 5A reduces the amount of plastic film used in the bag, and provides a cleaner appearance for product presentation, as shown in FIG. 5B. Eliminating the twist tie / Kwik Lok 56 and the ponytail 58 also reduces the amount of shelf storage space for the product as well as the amount of bulk packaging space required for transportation of the product. Preferably, the printed graphic design area 51 of the prior art packaging 50 includes printing directly on the film of the bag, which may be used to determine the outline of the printed label 53 used in bags 52 according to this disclosure, with the result that the bags 52 may include pull-away labels with printed graphics that resemble the printed graphics on the film of the prior art bags 50. In this manner, for easy consumer acceptance, it is preferred for consumers to recognize the packaging of the packaging with the tear-open recloseable, resealable opening because the tear open label uses graphic printing similar to the printing in the same area of the conventional packaging. In use, as shown in FIG. 5C, the consumer may open the package from the middle of the front panel using a tear-open flap / label 60 to provide the consumer a selection of choice product from the center 62 of the package away from the ends 64, 66. In the context of sliced bread, the slices of bread on or near the ends are typically less desired by the consumer. In traditional bread bag packages with openings in the end, the end pieces impede the consumer's selection of the center slices. Accordingly, bread bags made in accordance with this disclosure may be preferred by consumers.

[0035] As shown in FIG. 5C, the top 68, or free end, of the label 60 may be grasped by the consumer and pulled down as indicated by the arrow 70. The adhesive on the reverse side 72 of the label 60 has a suitable amount of stickiness or adhesiveness to adhere to the front surface 74 of the package 54 until sufficient force is applied to pull the label away from the front surface. The amount of force required to pull away the adhered label from the bag film is preferably greater than the tear resistance of the perforated portions of the plastic bag film. In this way, as the label 60 is pulled away from the package when the pull force is transferred to the front panel 74 of the bag along the perforations, the front panel plastic film tears away along or between the perforations to create an opening in the package. The tear open flap portion 76 of the bag film remains adhered to the reverse side 72 of the label. The label with exposed adhesive extends beyond the edge of the tear open flap, thus creating a recloseable, resealable flap over the opening.

[0036] Preferably, the size, length and number of perforations in the pre-cut pattern of perforations that define the tear-open flap are selected (depending on the loave of bread type, dimensions, as well as the bread bag material (tear strength)) to allow a reasonable pull force on the label by a consumer to tear the film between the perforations to form the tear flap opening. The perforation dimensions and shape may vary along the length of the perforations such that a different amount of force is required to initiate the tearing as compared to the amount of force required to complete the tearing along the perforations. As discussed above with reference to FIG. 3, this may be accomplished by changing the length and spacing of the perforations. Specifically, the closer the perforations are spaced, the easier the bag film should be to tear (i.e., less force required). For example, when the perforations are in a U-shaped pattern, if closer spaced perforations are used, the length of film will be shorter such that the force required to tear the flap open will be less than the force required to tear the longer spans of plastic film between perforations that are farther apart. The dimensions, shape and spacing of the perforations may be designed to obtain desired characteristics considering the tear strength of the bag film, which may vary based on its thickness.

[0037] In one embodiment, a bread bag is made of polyethylene or a mix of polyolefins with a thickness of between about 1 to 1.5 mil and may have an Elmendorf tear strength of about 60 to about 180 grams MD, as measured under ASTM D-1922 test methods. Accordingly, the strength of the adhesive on the reverse side or back surface of the label may need to exceed the film Elmendorf tear strength for the initial tearing open of the bag along the perforations. For other bag embodiments with different Elmendorf tear strengths, the strength of the adhesive on the back of the label may likewise need to exceed the film Elmendorf tear strength for the initial tearing open of the bag along the perforations.

[0038] In a preferred embodiment of a U-shaped perforation pattern, the perforations at or near the base of the U (i.e., near the top of the opening illustrated in FIG. 5C) may be longer or spaced closer together than the perforations of the sides of the U-shape. This may create a zone of lower tear resistance near the base of the U-shaped flap. This configuration will help prevent the user from tearing the label off the package because the user will need greater force to tear the label as it gets closer to the end points of the U-shaped perforation, thus slowing down the rate at which the film of the bag is torn along the perforations with the same pull force applied giving a physical feedback to the consumer. The selected perforation pattern may depend on several factors, including among other things, the bag's film tear strength and anticipated consumer preference for needed pull force to tear open the label flap on the package.

[0039] The opening may be reclosed by replacing the tear-open flap to its original position on the front panel of the bag. Alternatively, if sufficient product has been removed from the bag, the opening may be reclosed by first rolling or folding the top edge, or sealed end, onto the front surface of the package. The portion of the back surface of the label extending beyond the torn flap portion of the bag film having the exposed adhesive thereupon will recontact the rolling or folding top of the package to re-adhere the label to the bag film. It is preferred that the adhesive be provided in suitable amounts, with suitable adhesive retention or tackiness to allow the label to be peeled and reclosed at least about 10 times, and preferably at least about 12 times, and optionally 15 or more times. Most preferably, when the package is used with food products, e.g., sliced bread, the adhesive is provided in suitable amounts, with suitable adhesive retention to allow the label to be peeled and reclosed for the useful life of the product. After the flap is torn open for the first time and then reclosed, it may be observable that the package had been opened, which may offer an inherent tamper evident indication, in contrast to a bag with a pony tail closure and twist tie or clip where it is not possible to see that the bag had been opened. Optionally, the label, bag and / or package may include other tamper evident features, such as known in the art, that visually depict when the label has been pulled away the first time to create the opening.

[0040] Referring to FIGS. 6A, 6B, and 6C, other embodiments of a peelable, resealable label are illustrated without printing over most or all of the surface area. In FIG. 6A and 6B, two embodiments of labels 80 and 82 are illustrated with only the lift tab areas 84 and 86 printed on the label, and a typical shape of the label used for a gusseted bread bag in accordance with embodiments of the present disclosure. Substantially all of the underside surface of the label may be coated with an adhesive. In some embodiments, the top of the label with a lift tab area may not have an adhesive on its back surface to permit a consumer to more easily grasp the unadhered or “free” edge of the label and pull it away from the bag film. FIG. 6C is an example of a label 88 with a different label shape that may vary for different brands of product. The label shape may be determined according to the graphic design of the printing on the label and package functionality, such that the packaging of the product with the tear open flap on the front panel appears similar to the prior configuration of packaging, as may be observed comparing FIGS. 5A and 5B.

[0041] Referring to FIG. 7, a label 90 similar to the shape depicted in FIG. 6A is shown on the surface 92 of a clear plastic or polymer film formed into gusseted bags 94, which are supplied in bulk on a wicket 96. The product manufacturer or packer may use automated packaging equipment to insert the products into the bags. After filling the bag, the seal equipment may fold the open end into a gusset and seal the open end or top of the bags, and trim off excess plastic film, thereby forming the sealed food package.

[0042] Referring to FIG. 8, a panel 100 of images is shown depicting use of the package according to the present embodiments. Step 1 (102): A consumer will pull down the tab on the label to tear the perforations and create a flapped opening on the front surface of the package. Step 2 (104): A consumer may remove a product piece through the opening. Step 3 (106): As the contents of the package are removed, the top of the package may be rolled down to eliminate air space. Step 4 (108): If sufficient contents are removed, before closing the label, the top of the package may be rolled down into the area of the opening on the front surface, and then the label may be folded to a closed position and cover the top rolled portion of the package under the adhesive side of the label to retain the package in a smaller closed form. This food package configuration with a resealable label may increase the shelf life and useful life of the food products stored therein.

[0043] The bags may be made of any polymer film suitable for the products for which it is designed to contained. For example, bags for containing food products should use materials certified for use with food according to FDA regulations. Preferably the film is a polyolefin film, or more preferably, a polyethylene film, which is heat sealable. As used herein, unless otherwise indicated, the term “polyethylene” includes polyethylene, high density polyethylene (HDPE), medium density polyethylene (MDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), very low density polyethylene (VLDPE), ultra low density polyethylene (ULDPE), ethylene / α-olefin copolymers, and combinations thereof. Preferably, the film is a multilayer film including at least one layer comprising linear low density polyethylene (LLDPE) and low density polyethylene (LDPE), as may typically be used for packaging food products. Preferably, at least one layer of the multilayer film includes high density polyethylene (HDPE) for increased film strength to accommodate the stress from tearing open the resealable label flap. Preferably the film is not heat shrinkable. The multilayer film may include an oxygen or moisture barrier layer, such as comprising ethyl vinyl alcohol (EVOH), vinylidene chloride copolymers (PVDC), or copolymers thereof. A layer of the multilayer film may include nylon or other amides. The film is preferably transparent and flexible. The layers of the film may also include small amounts of other well-known additives for the film manufacture, such as antistatic, antiblocking, slip, processing, compatibilizer agents, or pigments.

[0044] The label may be made of any polymer, such as polyolefins, including polyethylene and polypropylene, or other suitable polyolefins, such as LDPE, HDPE, LLDPE, BOPP (biaxially oriented polypropylene), CPP (cast polypropylene), or a mix of polyolefins and other suitable components for processability or film characteristics, such as strength. For example, it would be undesirable for the label to stretch when being pulled. The resealable labels may be made from a polymer film that is of a similar material as the bag polymer film such that the bag and the label are categorized in the same recyclable materials category. For example, low density polyethylene is a category 4 material according to the U.S. Dept. of Energy. However, a plastic film containing both high density polyethylene and low density polyethylene may be accepted as compatible materials to recycle together. It may be preferred that the label be made from low density polyethylene when the bag is made from low density polyethylene, such that the bag and the label may be recycled together in the same category 4 recycle stream. The films may include other compatible polymers such as nylon and EVOH. However, plastic films with certain components to enhance strength and block light, such as films with a metallized layer, are not generally considered recyclable, and would not be suitable if recycling the bag and the label together is desired.

[0045] The labels may have a releasable, pressure sensitive adhesive on the back surface of the label to adhere the label to the area on the front surface of the bag that has been perforated to create the tear flap bag opening when the label is pulled away from the bag. It is preferred that the adhesive be compatible with the contents packaged by the bag. For example, one suitable adhesive for packaging bread products may be a removable acrylic certified for indirect food contact. According to Title 21, Section 175.105 of the Code of Federal Regulations (21 CFR 175.105), this regulation permits the use of this adhesive in applications for which the adhesive either (1) is separated from the food by a functional barrier, which will prevent the migration of any of the adhesive components to the food, or (2) has incidental contact with food limited to the trace amount at the seams or the edges of the label.

[0046] It is preferred that only releasable pressure sensitive adhesive is applied across the back surface of the label. It is further preferred that only a single type of releasable pressure sensitive adhesive is applied. While a permanent adhesive can be used on the non-resealable portion of the label, it is preferred that a permanent adhesive is not used on any portion of the back surface of the label.

[0047] Products may be packaged in bags in accordance with this disclosure by various methods. For example, one method may include making the bag by placing a pattern of perforations on a sheet of polyethylene film, where the pattern is in a position on the film capable of forming a tear open flap on a front panel of the bag formed from the sheet of polyethylene film. A label comprising polyethylene film with a releasable, pressure sensitive adhesive on a back surface of the label may be positioned over the pattern of perforations on the film in the area where the front panel of the bag would be located. The film may be cut to the desired size and shape to be formed into the bag. The cut film may be folded nearly in half and welded to form a gusseted bottom, then the side seams are welded, leaving an opening at the top of the bag, with a wicket lip at the top of the bag adjacent the top opening, such that the pattern of perforations with the label end up on the front panel of the bag. The bag may be placed on a wicket with other bags. A wicket loaded with bags may be placed in equipment that automatically inserts a food product into the bag through the top opening and separates the bag with the food product inside from the wicket lip. The equipment then folds the film near the top opening into a gusseted fold, welds or seals closed the opening at the top of the bag, and trims any excess film. Thereby, a filled food package may be formed that has a resealable label that may be pulled away from the bag with a force sufficient to separate the adhesive backing of the label from the film of the bag and to tear the film of the bag between the perforations such that the label is adhered to the torn bag film to form the tear opening flap.

[0048] To clarify the use of and to hereby provide notice to the public, the phrases “at least one of , , . . . and <N>” or “at least one of , , . . . or <N>” or “at least one of , , . . . <N>, or combinations thereof” or “, , . . . and / or <N>” are defined by the Applicant in the broadest sense, superseding any other implied definitions hereinbefore or hereinafter unless expressly asserted by the Applicant to the contrary, to mean one or more elements selected from the group comprising A, B, . . . and N. In other words, the phrases mean any combination of one or more of the elements A, B, . . . or N including any one element alone or the one element in combination with one or more of the other elements which may also include, in combination, additional elements not listed. Unless otherwise indicated or the context suggests otherwise, as used herein, “a” or “an” means “at least one” or “one or more.”

[0049] While various embodiments have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible. Accordingly, the embodiments described herein are examples, not the only possible embodiments and implementations.

[0050] In addition to the features mentioned in each of the independent aspects enumerated above, some examples may show, alone or in combination, the optional features mentioned in the dependent aspects and / or as disclosed in the description above and shown in the figures.

Examples

Embodiment Construction

[0014]In one embodiment, the flexible film package includes a bag configured for bulk placement on a wicket, the bag is made from a first polyolefin film and has a gusseted bottom, welded side seams, and a plurality of perforations on a front surface of the bag to define edges of an opening of the bag. The film package includes a label made from a second polyolefin film and an adhesive on substantially all of a back surface of the label, the label being disposed on the bag with the adhesive on the back surface of the label in contact with the front surface of the bag and of sufficient size to cover the perforations in the front surface of the bag and the opening defined by the perforations. The label, adhesive and plurality of perforations are configured such that when the label is pulled away from the bag to separate the adhesive on a back surface of the label from a first portion of the film of the bag, the segment of the film of the bag between the perforations tears such that th...

RELATED APPLICATIONS

[0001] The present application claims the benefit of priority under 35 USC 119 (e) to U.S. Provisional Application No. 63 / 655,438, filed on Jun. 3, 2024, and to U.S. Provisional Application No. 63 / 697,178, filed on Sep. 20, 2024, each of which are hereby incorporated by reference in their entirety herein.TECHNICAL FIELD

[0002] The present disclosure relates to resealable packaging, in particular, packaging having adhesive resealable openings for foodstuffs and consumer items.BACKGROUND

[0003] Foodstuffs and consumer items come in a variety of packages. Packages made of flexible polymer films may be manufactured from a variety of materials in a variety of ways. Flexible film packages are often in the form of a bag with an opening at one end. Such packages may often have a gusseted / folded or fin-welded end that may be opened to access the contents, or may have a ponytail open end with a wire tie or clip to keep it closed. For products comprising numerous pieces in a stacked arrangement in a bag, a consumer is limited to selecting the pieces closest to the opened end of the bag. It would be desirable to develop new forms of packaging made from flexible polymer films that allow consumers additional options for selecting product pieces from the bag. It would also be desirable to develop bags that meet consumer and / or corporate goals for sustainability.BRIEF SUMMARY

[0004] A flexible film package comprises a bag made from a polyolefin film with a pattern of perforations in a front surface. A label may be made from a polyolefin film with a releasable pressure sensitive adhesive on a back surface. The label may be positioned in contact with the front surface of the bag covering the pattern of perforations. When the label is pulled away from the bag, the pull force may be sufficient to initially separate the adhesive backing of the label from the film of the bag and to then tear the film of the bag between the perforations such that the label remains adhered to the flap of torn film which forms a tear open flap in the bag. The exposed adhesive backing on the label extending beyond the perforations defining the tear open flap of the bag may be re-adhered to the front panel of the bag to reclose and reseal the bag.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 depicts one embodiment of a sheet of polymer film with a pattern of perforations and a peelable label before being formed into a gusseted bag.

[0006] FIG. 2 depicts another embodiment of a sheet of polymer film with a pattern of perforations before being formed into a gusseted bag.

[0007] FIG. 3 illustrates various styles of perforations to form a tear open flap that may require different forces for tearing and rates of tearing.

[0008] FIGS. 4A and 4B depict alternative embodiments of a gusseted bag with the front panel tear open flap and the end opening sealed closed with gusseted folds and alternative visual appearances.

[0009] FIGS. 5A, 5B and 5C depict a prior art bag, an embodiment of a closed bag according to the present disclosure, and a bag with the tear flap opened according to the present disclosure, respectively.

[0010] FIGS. 6A, 6B, and 6C depict three embodiments of a label.

[0011] FIG. 7 depicts a group of bags with peelable labels stacked on a wicket.

[0012] FIG. 8 depicts a sequence for using the label to open and close an embodiment of a bag according to the present disclosure.

[0013] The drawings are provided for illustrative purposes to aid in the understanding of several embodiments, and are not necessarily drawn to scale or accurate representations as to size and shape. The following detailed description further illustrate the several embodiments.DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0014] In one embodiment, the flexible film package includes a bag configured for bulk placement on a wicket, the bag is made from a first polyolefin film and has a gusseted bottom, welded side seams, and a plurality of perforations on a front surface of the bag to define edges of an opening of the bag. The film package includes a label made from a second polyolefin film and an adhesive on substantially all of a back surface of the label, the label being disposed on the bag with the adhesive on the back surface of the label in contact with the front surface of the bag and of sufficient size to cover the perforations in the front surface of the bag and the opening defined by the perforations. The label, adhesive and plurality of perforations are configured such that when the label is pulled away from the bag to separate the adhesive on a back surface of the label from a first portion of the film of the bag, the segment of the film of the bag between the perforations tears such that the label remains adhered to a second portion of the film of the bag to form a flap opening the bag. The label and the adhesive on the back surface of the label extends past the edge of the flap opening to allow the label to be reclosed and re-adhere to the first portion of the film of the bag surrounding the opening.

[0015] In yet another embodiment, a packaged foodstuff in a flexible film package includes a bag made from a first polyolefin film having a gusseted bottom, a gusseted and sealed top, welded side seams, and a plurality of perforations on a front surface of the bag to define edges of a tear flap opening of the bag. A foodstuff item having multiple pieces is disposed in the bag. A label made from a second polyolefin film and having an adhesive on substantially all of a back surface of the label is disposed on the bag with the adhesive on the back surface of the label in contact with the front surface of the bag and of sufficient size to cover and extend beyond the tear flap opening in the front surface of the bag. The label, adhesive and bag are configured such that when the label is pulled away from the bag with a specified force, the force is sufficient to separate the adhesive backing of the label from a first portion of the film of the bag extending beyond the tear flap opening and to tear the film of the bag between the perforations such that the label remains adhered to the tear flap opening in the bag, and the opening is of sufficient size to allow the removal of a piece of the foodstuff contained in the bag. The adhesive on the portion of the back surface of the label covers sufficient area and retains sufficient tack to re-adhere to the first portion of the film of the bag.

[0016] In various embodiments of the flexible film package, the plurality of perforations may define three sides of a substantially rectangular flap opening on the front surface of the bag. The plurality of perforations may include a first section of cuts that include perforations with a longer length adjacent to a second section of cuts that include perforations with a shorter length. The plurality of perforations may include a first section of cuts that include perforations with a mix of a shorter and longer length adjacent to a second section of cuts that include perforations with a shorter and longer length. The plurality of perforations may include a first section of cuts that require a lower pull force to tear segments of film between the cuts and a second section of cuts that require a higher pull force to tear segments of film between the cuts, relative to each of the section of cuts. The flexible film package may include perforations that are not uniform in length. The flexible film package may include a central perforation with a length longer than the length of all other perforations, where the central perforation is positioned at a central location of the plurality of perforations under a pull tab of the label where the label is initially pulled away from the bag. The flexible film package may include a wicket lip at the top opening of the bag, where the wicket lip including holes for placement of the bag on the wicket and perforations to separate the bag from the wicket lip. Preferably, the first polyolefin film and the second polyolefin film each comprise materials that meet the same recyclable category. Preferably, the exposed adhesive on the back surface of the label covers sufficient area and has sufficient tack to allow the label to re-adhere to the first portion of the film when the flap opening is opened and closed at least 10 times, and more preferably at least 15 times.

[0017] In embodiments of the flexible film package filled with a foodstuff, the sealed top of the bag preferably may include a weld seam with or without excess film extending beyond the weld seam. A portion of the label at one end of the label nearest the gusseted and sealed top of the bag preferably has no adhesive so as to provide a free end of the label for a user to grasp to pull the label.

[0018] In various embodiments, the package is made from a flexible film. The flexible film may be made by a plastic film extrusion process and typically manufactured from raw pellets. The manufacturing process involves superheating and pressurizing raw polyolefin plastic pellets, such as LDPE, HDPE, or LLDPE, or blends thereof, to create a consistent molten liquid. Once the liquid is created, the resin is forced into a circular die. Then the hot resin is blown outward or upward to create a thin, long balloon or bubble of very pliable plastic film.

[0019] The plastic bubble cools as it further expands, and it encounters several rollers that stretch it into very thin sheets, which will later become the bag walls. The sheets are then rolled onto two individual flat beds and moved into the printing machine.

[0020] In this step, the roll of film is unwrapped and cut into a desired size and shape depending on the commercial intent for the bag. This stage can also add special characteristics required to complete the plastic bags like a pre-cut pattern that will be on the front panel of a bag formed from the film. An adhesive sealing label may be placed over and cover the precut pattern on the front panel.

[0021] This pre-cut pattern on the front panel may be created by a laser cutting tool where a focused laser beam pierces and cuts through materials to cut out patterns and geometries, or may be done by die-cutting equipment.

[0022] Wheels may be used on the equipment to create the gussets. Dies may be used to cut out the handles, if any. Seals may be formed by heat or ultrasonic welding. Printing may be performed before the bags have been converted from the film.

[0023] The last step starts with pressing two printed sheets together or folding over one sheet into two layers and sealing the edges of the sheets to create the sides of the bag. The plastic can then be wound and cut to a suitable size and shape based on the actual use or application for the bag. So-called “Poly bags” are either flat or have a bottom gusset to provide extra space and are made from low-and high-density polyethylene. Additional customizations can be added, such as perforations on wicket poly bags that are often bundled together and have a perforated lip so they tear off quickly and easily. Wicketed bags may be used for packaging a variety of products, such as, but not limited to, food products, newspapers, apparel, hosiery, bakeries, and parts.

[0024] As noted above, the bags may include perforations on the front panel that form a tear open flap or a flap opening covered by a label with a pressure sensitive adhesive backing that allows a consumer to pull the label away from the bag thereby tearing the perforations and forming the tear open flap. The adhesive has sufficient tack that permits the label to be reclosed and to reseal the package closed.

[0025] Embodiments of the bag may be suitable for use with automatic packaging machines and to contain food and / or consumer items. The adhesive on the label preferably has the capacity to retain its adhesiveness or tackiness for closing and reopening the package with the label after the initial opening a minimum of about 10 times, or 15 times, or preferably more times, depending on the number of product pieces in the bag, to ensure the peel and reseal feature lasts for full use of the product contained in the package made from the bag.

[0026] Embodiments of the bags or packages with the tear open flaps and resealable closure labels may have several advantages for the consumer. For example, a bread package with an opening on the front panel may allow the consumer better product accessibility to pick the slice they want instead of reaching for the closest one. The peel-and-reseal label will help the consumer eliminate the internal air after consuming some bread slides, because the bag can be rolled or folded to close it with the label to a size more closely fitting the remaining product inside, thus reducing the amount of air in the package to help maintain or extend product freshness for a longer period.

[0027] Embodiments of the bags or packages may have several advantages for the supplier. The packaging improves sustainability by plastic reduction particularly by eliminating excess plastic film required for the ponytail, eliminating the plastic or cardboard quick lock, or eliminating the twist tie. The packaging also may enhance product safety through the supply chain, and may provide better presentation on the shelf by having tighter plastic film around the product and elimination of the wrinkles / folds associated with the ponytail. The packaging may increase shelf life of the contained products relative to the ponytail closure. Other advantages may be apparent to those of ordinary skill in the art based on the teachings herein.

[0028] As used herein, the terms bag, package and packaging may be used interchangeably unless specifically noted. Generally, the bag refers to the unfilled package, and may refer to only the bag film material and not the label film material when the relationship of the two elements are described. Generally, the package or packaging refers to the bag that is filled and sealed or thereafter during the product lifecycle.

[0029] Referring to FIG. 1, a polymer film blank 10 is illustrated with a front panel 12, a back panel 14, a gusseted fold area 16, front panel label 18, lip 20 and wicket holes 22 prior to being folded and heat sealed to form a bag. The pre-cut pattern of perforations 24 on the front panel is indicated by the dashed or dotted line 24. The perforations define the edge of a tear open flap 26 in the bag. The label 18 in the front panel 12 is indicated by the shaded area. The shaded area over substantially the entire label has an adhesive on the back surface in contact with the front panel of the bag. The gusseted fold area 16 optionally includes scores for facilitating the folding of the film to form a gusseted bottom.

[0030] Referring to FIG. 2, another embodiment of a polymer film blank 28 is illustrated without the adhesive label adhered to the front panel. The pre-cut pattern of perforations 24 may be indicated by the dashed or dotted lines 24 on the front surface of the film blank to be formed into a bag. The pattern of perforations 24 is illustrated as a generally u-shaped form but may have a variety of shapes and dimensions suitable to allow one or more pieces of product in the bag to be removed. As shown, only the three-sides of the tear open flap area include perforations, such that the pre-cut pattern of perforations may be torn to form the tear open flap and create an opening when the label is pulled away from the bag. The perforations or cuts may be made by laser cutting or with a die-cut roller, for example. The terms perforations and cuts may be used interchangeably, unless specifically described otherwise herein in connection with specific embodiments. Preferably, the shape defined by the perforations on three sides of the flap may be considered substantially rectangular, that is, the shape of the flap is not circular or triangular. The flap may be substantially four-sided and may have rounded corners or one of more rounded sides, such as when the perforations are in a u-shape, yet overall in appearance resembles a rectangle or square. The flap may be other shapes provided the function is similar as described herein. Various embodiments may include a longer or longest cut 25 at the center section of the pattern, shorter length cuts on either side of the center longest cut, medium length cuts at the shoulder 29 of the pattern, longer cuts along the sides, and small dots or holes 27 at the terminal ends of the pattern of perforations. The cuts or perforations may range from small holes to 1 mm cuts, to about 10 mm long or longer, and various lengths inbetween depending on the desired tear resistance or pull force required to tear through the pattern of perforations.

[0031] Referring to FIG. 3, examples of a variety of perforation styles are illustrated that may be useful for providing different tear-opening characteristics for the tear-open flap in a finished bag. Style A 30 illustrates long perforations or cuts with short spans of plastic film between the perforations, which should exhibit a fast rate of being torn open. Style B 32 illustrates short perforations or cuts with short spans of plastic firm between the perforations, which should exhibit a relatively slower rate of being torn open compared to Style A since more portions of plastic film need to be torn for each unit of linear dimension along the perforation line. Style C 34 illustrates long perforations with long spans of plastic film between the perforations, which should exhibit slow rate of being torn compared to style A and also may require greater pull force to tear through longer spans of plastic film between the perforations. Style D 36 illustrates short perforations with long spans of plastic film between the perforations, which should exhibit a relatively slower rate of being torn open compared to Style C since more portions of plastic film need to be torn for each unit of linear dimension along the perforation line. As may be understood by one of ordinary skill in the art based on this disclosure, the perforation may be selected to create a tear open flap with the desired pull force and rate of being torn open by a consumer. The styles of perforations may be combined in the front panel to create zones of easy or faster tearing and zones of harder or slower tearing. For example, Style E 38 illustrates another embodiment of a pre-cut pattern of perforations with a combination of short, medium and long perforations, as shown separately in Styles A through D, which may provide a range of pull forces and tear rates as a consumer initially pulls open the label and tears the plastic film along the perforations.

[0032] The pre-cut pattern of perforations may combine different styles in different sections of the pattern to provide different amounts of pull force required to tear open the flap through the different sections. Sections of the perforations may have longer cuts, other sections may have shorter cuts. Sections may include a mix of shorter and longer cuts. Instead of cuts, other sections may have a line of dots or holes perforated through the film. A single section may have a combination of various perforation shapes and sizes as described herein. Generally, sections with longer cuts require a lower pull force to tear open, and sections with shorter cuts require a high pull force to tear open. The perforations should also be matched to the characteristics of the plastic film used to create the bag, because some films may have a higher resistance to tearing than other films of the same thickness, and thicker films may also have a higher resistance to tearing than thinner films of the same material. If the film has a higher resistance to tearing, it is recommended to add a longer cut 25 in the center area of the precut pattern, as shown in FIG. 2. The longer central cut is preferably positioned under the location of the label pull tab to facilitate the initial tearing of the tear flap opening. For example, the tear-open characteristics should be selected to make it somewhat easy to tear open the front panel flap but not too easy to prevent the front panel tear open flap from being accidentally opened by the consumer or during handling of the packaging. As another example, the flap may have a zone where the perforations are somewhat easy to tear when initially opening the flap, i.e., requiring lower pull force, lower tear resistance, and a zone that gets harder to tear, i.e., requiring higher pull force, higher tear resistance, so the user will not inadvertently tear the flap completely from the bag. A high tear resistance zone may be implemented by a section of closely spaced dots or holes at the terminal end 27 of the pre-cut pattern, as shown in FIG. 2.

[0033] FIGS. 4A and 4B depict alternative embodiments of a gusseted bag or package filled with product with a front panel tear-open flap, where the top end opening is sealed closed with seals and side tuckers that provide alternative visual appearances. The filled package closing and sealing process will involve the machine first creating a gusset fold 42 in the top, sealing the bag opening, and then removing some or all of the excess trim. As illustrated, the package 40 in FIG. 4A has some remnants of excess trim 44 extending from the sealing weld line 46, which alternatively may be made as a fin seal. In contrast, the package 46 illustrated in FIG. 4B has nearly all excess trim removed by cutting the plastic film at or very close to the seal weld line 48 to leave a sealed, gusseted end 42 more tightly conforming to the contents of the filled bag, which may provide a more visually appealing neat appearance to the consumer.

[0034] FIGS. 5A, 5B and 5C depict a prior art bag 50, an embodiment of a closed bag 52 according to the present disclosure, and a bag 54 with the tear open flap opened according to the present disclosure, respectively, each of which are filled with foodstuff items, such as sliced bread. Eliminating the twist tie / Kwik Lok 56 and ponytail 58 shown in FIG. 5A reduces the amount of plastic film used in the bag, and provides a cleaner appearance for product presentation, as shown in FIG. 5B. Eliminating the twist tie / Kwik Lok 56 and the ponytail 58 also reduces the amount of shelf storage space for the product as well as the amount of bulk packaging space required for transportation of the product. Preferably, the printed graphic design area 51 of the prior art packaging 50 includes printing directly on the film of the bag, which may be used to determine the outline of the printed label 53 used in bags 52 according to this disclosure, with the result that the bags 52 may include pull-away labels with printed graphics that resemble the printed graphics on the film of the prior art bags 50. In this manner, for easy consumer acceptance, it is preferred for consumers to recognize the packaging of the packaging with the tear-open recloseable, resealable opening because the tear open label uses graphic printing similar to the printing in the same area of the conventional packaging. In use, as shown in FIG. 5C, the consumer may open the package from the middle of the front panel using a tear-open flap / label 60 to provide the consumer a selection of choice product from the center 62 of the package away from the ends 64, 66. In the context of sliced bread, the slices of bread on or near the ends are typically less desired by the consumer. In traditional bread bag packages with openings in the end, the end pieces impede the consumer's selection of the center slices. Accordingly, bread bags made in accordance with this disclosure may be preferred by consumers.

[0035] As shown in FIG. 5C, the top 68, or free end, of the label 60 may be grasped by the consumer and pulled down as indicated by the arrow 70. The adhesive on the reverse side 72 of the label 60 has a suitable amount of stickiness or adhesiveness to adhere to the front surface 74 of the package 54 until sufficient force is applied to pull the label away from the front surface. The amount of force required to pull away the adhered label from the bag film is preferably greater than the tear resistance of the perforated portions of the plastic bag film. In this way, as the label 60 is pulled away from the package when the pull force is transferred to the front panel 74 of the bag along the perforations, the front panel plastic film tears away along or between the perforations to create an opening in the package. The tear open flap portion 76 of the bag film remains adhered to the reverse side 72 of the label. The label with exposed adhesive extends beyond the edge of the tear open flap, thus creating a recloseable, resealable flap over the opening.

[0036] Preferably, the size, length and number of perforations in the pre-cut pattern of perforations that define the tear-open flap are selected (depending on the loave of bread type, dimensions, as well as the bread bag material (tear strength)) to allow a reasonable pull force on the label by a consumer to tear the film between the perforations to form the tear flap opening. The perforation dimensions and shape may vary along the length of the perforations such that a different amount of force is required to initiate the tearing as compared to the amount of force required to complete the tearing along the perforations. As discussed above with reference to FIG. 3, this may be accomplished by changing the length and spacing of the perforations. Specifically, the closer the perforations are spaced, the easier the bag film should be to tear (i.e., less force required). For example, when the perforations are in a U-shaped pattern, if closer spaced perforations are used, the length of film will be shorter such that the force required to tear the flap open will be less than the force required to tear the longer spans of plastic film between perforations that are farther apart. The dimensions, shape and spacing of the perforations may be designed to obtain desired characteristics considering the tear strength of the bag film, which may vary based on its thickness.

[0037] In one embodiment, a bread bag is made of polyethylene or a mix of polyolefins with a thickness of between about 1 to 1.5 mil and may have an Elmendorf tear strength of about 60 to about 180 grams MD, as measured under ASTM D-1922 test methods. Accordingly, the strength of the adhesive on the reverse side or back surface of the label may need to exceed the film Elmendorf tear strength for the initial tearing open of the bag along the perforations. For other bag embodiments with different Elmendorf tear strengths, the strength of the adhesive on the back of the label may likewise need to exceed the film Elmendorf tear strength for the initial tearing open of the bag along the perforations.

[0038] In a preferred embodiment of a U-shaped perforation pattern, the perforations at or near the base of the U (i.e., near the top of the opening illustrated in FIG. 5C) may be longer or spaced closer together than the perforations of the sides of the U-shape. This may create a zone of lower tear resistance near the base of the U-shaped flap. This configuration will help prevent the user from tearing the label off the package because the user will need greater force to tear the label as it gets closer to the end points of the U-shaped perforation, thus slowing down the rate at which the film of the bag is torn along the perforations with the same pull force applied giving a physical feedback to the consumer. The selected perforation pattern may depend on several factors, including among other things, the bag's film tear strength and anticipated consumer preference for needed pull force to tear open the label flap on the package.

[0039] The opening may be reclosed by replacing the tear-open flap to its original position on the front panel of the bag. Alternatively, if sufficient product has been removed from the bag, the opening may be reclosed by first rolling or folding the top edge, or sealed end, onto the front surface of the package. The portion of the back surface of the label extending beyond the torn flap portion of the bag film having the exposed adhesive thereupon will recontact the rolling or folding top of the package to re-adhere the label to the bag film. It is preferred that the adhesive be provided in suitable amounts, with suitable adhesive retention or tackiness to allow the label to be peeled and reclosed at least about 10 times, and preferably at least about 12 times, and optionally 15 or more times. Most preferably, when the package is used with food products, e.g., sliced bread, the adhesive is provided in suitable amounts, with suitable adhesive retention to allow the label to be peeled and reclosed for the useful life of the product. After the flap is torn open for the first time and then reclosed, it may be observable that the package had been opened, which may offer an inherent tamper evident indication, in contrast to a bag with a pony tail closure and twist tie or clip where it is not possible to see that the bag had been opened. Optionally, the label, bag and / or package may include other tamper evident features, such as known in the art, that visually depict when the label has been pulled away the first time to create the opening.

[0040] Referring to FIGS. 6A, 6B, and 6C, other embodiments of a peelable, resealable label are illustrated without printing over most or all of the surface area. In FIG. 6A and 6B, two embodiments of labels 80 and 82 are illustrated with only the lift tab areas 84 and 86 printed on the label, and a typical shape of the label used for a gusseted bread bag in accordance with embodiments of the present disclosure. Substantially all of the underside surface of the label may be coated with an adhesive. In some embodiments, the top of the label with a lift tab area may not have an adhesive on its back surface to permit a consumer to more easily grasp the unadhered or “free” edge of the label and pull it away from the bag film. FIG. 6C is an example of a label 88 with a different label shape that may vary for different brands of product. The label shape may be determined according to the graphic design of the printing on the label and package functionality, such that the packaging of the product with the tear open flap on the front panel appears similar to the prior configuration of packaging, as may be observed comparing FIGS. 5A and 5B.

[0041] Referring to FIG. 7, a label 90 similar to the shape depicted in FIG. 6A is shown on the surface 92 of a clear plastic or polymer film formed into gusseted bags 94, which are supplied in bulk on a wicket 96. The product manufacturer or packer may use automated packaging equipment to insert the products into the bags. After filling the bag, the seal equipment may fold the open end into a gusset and seal the open end or top of the bags, and trim off excess plastic film, thereby forming the sealed food package.

[0042] Referring to FIG. 8, a panel 100 of images is shown depicting use of the package according to the present embodiments. Step 1 (102): A consumer will pull down the tab on the label to tear the perforations and create a flapped opening on the front surface of the package. Step 2 (104): A consumer may remove a product piece through the opening. Step 3 (106): As the contents of the package are removed, the top of the package may be rolled down to eliminate air space. Step 4 (108): If sufficient contents are removed, before closing the label, the top of the package may be rolled down into the area of the opening on the front surface, and then the label may be folded to a closed position and cover the top rolled portion of the package under the adhesive side of the label to retain the package in a smaller closed form. This food package configuration with a resealable label may increase the shelf life and useful life of the food products stored therein.

[0043] The bags may be made of any polymer film suitable for the products for which it is designed to contained. For example, bags for containing food products should use materials certified for use with food according to FDA regulations. Preferably the film is a polyolefin film, or more preferably, a polyethylene film, which is heat sealable. As used herein, unless otherwise indicated, the term “polyethylene” includes polyethylene, high density polyethylene (HDPE), medium density polyethylene (MDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), very low density polyethylene (VLDPE), ultra low density polyethylene (ULDPE), ethylene / α-olefin copolymers, and combinations thereof. Preferably, the film is a multilayer film including at least one layer comprising linear low density polyethylene (LLDPE) and low density polyethylene (LDPE), as may typically be used for packaging food products. Preferably, at least one layer of the multilayer film includes high density polyethylene (HDPE) for increased film strength to accommodate the stress from tearing open the resealable label flap. Preferably the film is not heat shrinkable. The multilayer film may include an oxygen or moisture barrier layer, such as comprising ethyl vinyl alcohol (EVOH), vinylidene chloride copolymers (PVDC), or copolymers thereof. A layer of the multilayer film may include nylon or other amides. The film is preferably transparent and flexible. The layers of the film may also include small amounts of other well-known additives for the film manufacture, such as antistatic, antiblocking, slip, processing, compatibilizer agents, or pigments.

[0044] The label may be made of any polymer, such as polyolefins, including polyethylene and polypropylene, or other suitable polyolefins, such as LDPE, HDPE, LLDPE, BOPP (biaxially oriented polypropylene), CPP (cast polypropylene), or a mix of polyolefins and other suitable components for processability or film characteristics, such as strength. For example, it would be undesirable for the label to stretch when being pulled. The resealable labels may be made from a polymer film that is of a similar material as the bag polymer film such that the bag and the label are categorized in the same recyclable materials category. For example, low density polyethylene is a category 4 material according to the U.S. Dept. of Energy. However, a plastic film containing both high density polyethylene and low density polyethylene may be accepted as compatible materials to recycle together. It may be preferred that the label be made from low density polyethylene when the bag is made from low density polyethylene, such that the bag and the label may be recycled together in the same category 4 recycle stream. The films may include other compatible polymers such as nylon and EVOH. However, plastic films with certain components to enhance strength and block light, such as films with a metallized layer, are not generally considered recyclable, and would not be suitable if recycling the bag and the label together is desired.

[0045] The labels may have a releasable, pressure sensitive adhesive on the back surface of the label to adhere the label to the area on the front surface of the bag that has been perforated to create the tear flap bag opening when the label is pulled away from the bag. It is preferred that the adhesive be compatible with the contents packaged by the bag. For example, one suitable adhesive for packaging bread products may be a removable acrylic certified for indirect food contact. According to Title 21, Section 175.105 of the Code of Federal Regulations (21 CFR 175.105), this regulation permits the use of this adhesive in applications for which the adhesive either (1) is separated from the food by a functional barrier, which will prevent the migration of any of the adhesive components to the food, or (2) has incidental contact with food limited to the trace amount at the seams or the edges of the label.

[0046] It is preferred that only releasable pressure sensitive adhesive is applied across the back surface of the label. It is further preferred that only a single type of releasable pressure sensitive adhesive is applied. While a permanent adhesive can be used on the non-resealable portion of the label, it is preferred that a permanent adhesive is not used on any portion of the back surface of the label.

[0047] Products may be packaged in bags in accordance with this disclosure by various methods. For example, one method may include making the bag by placing a pattern of perforations on a sheet of polyethylene film, where the pattern is in a position on the film capable of forming a tear open flap on a front panel of the bag formed from the sheet of polyethylene film. A label comprising polyethylene film with a releasable, pressure sensitive adhesive on a back surface of the label may be positioned over the pattern of perforations on the film in the area where the front panel of the bag would be located. The film may be cut to the desired size and shape to be formed into the bag. The cut film may be folded nearly in half and welded to form a gusseted bottom, then the side seams are welded, leaving an opening at the top of the bag, with a wicket lip at the top of the bag adjacent the top opening, such that the pattern of perforations with the label end up on the front panel of the bag. The bag may be placed on a wicket with other bags. A wicket loaded with bags may be placed in equipment that automatically inserts a food product into the bag through the top opening and separates the bag with the food product inside from the wicket lip. The equipment then folds the film near the top opening into a gusseted fold, welds or seals closed the opening at the top of the bag, and trims any excess film. Thereby, a filled food package may be formed that has a resealable label that may be pulled away from the bag with a force sufficient to separate the adhesive backing of the label from the film of the bag and to tear the film of the bag between the perforations such that the label is adhered to the torn bag film to form the tear opening flap.

[0048] To clarify the use of and to hereby provide notice to the public, the phrases “at least one of , , . . . and <N>” or “at least one of , , . . . or <N>” or “at least one of , , . . . <N>, or combinations thereof” or “, , . . . and / or <N>” are defined by the Applicant in the broadest sense, superseding any other implied definitions hereinbefore or hereinafter unless expressly asserted by the Applicant to the contrary, to mean one or more elements selected from the group comprising A, B, . . . and N. In other words, the phrases mean any combination of one or more of the elements A, B, . . . or N including any one element alone or the one element in combination with one or more of the other elements which may also include, in combination, additional elements not listed. Unless otherwise indicated or the context suggests otherwise, as used herein, “a” or “an” means “at least one” or “one or more.”

[0049] While various embodiments have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible. Accordingly, the embodiments described herein are examples, not the only possible embodiments and implementations.

[0050] In addition to the features mentioned in each of the independent aspects enumerated above, some examples may show, alone or in combination, the optional features mentioned in the dependent aspects and / or as disclosed in the description above and shown in the figures.

Examples

Embodiment Construction

[0014]In one embodiment, the flexible film package includes a bag configured for bulk placement on a wicket, the bag is made from a first polyolefin film and has a gusseted bottom, welded side seams, and a plurality of perforations on a front surface of the bag to define edges of an opening of the bag. The film package includes a label made from a second polyolefin film and an adhesive on substantially all of a back surface of the label, the label being disposed on the bag with the adhesive on the back surface of the label in contact with the front surface of the bag and of sufficient size to cover the perforations in the front surface of the bag and the opening defined by the perforations. The label, adhesive and plurality of perforations are configured such that when the label is pulled away from the bag to separate the adhesive on a back surface of the label from a first portion of the film of the bag, the segment of the film of the bag between the perforations tears such that th...

Claims

1. A flexible film package comprising:a bag configured for bulk placement on a wicket, the bag comprising a first polyolefin film and having a gusseted bottom, welded side seams, and a plurality of perforations on a front surface of the bag to define edges of an opening of the bag; anda label comprising a second polyolefin film and an adhesive on substantially all of a back surface of the label, the label being disposed on the bag with the adhesive on the back surface of the label in contact with the front surface of the bag and of sufficient size to cover the perforations in the front surface of the bag and the opening defined by the perforations,wherein the label, adhesive and plurality of perforations are configured such that when the label is pulled away from the bag to separate the adhesive on a back surface of the label from a first portion of the film of the bag, a segment of the film of the bag between the perforations tears such that the label remains adhered to a second portion of the film of the bag to form a flap opening the bag,wherein the label and the adhesive on the back surface of the label extends past the edge of the flap opening to allow the label to be reclosed and re-adhere to the first portion of the film of the bag surrounding the opening.

2. The flexible film package of claim 1, wherein the plurality of perforations define three sides of a substantially rectangular flap opening on the front surface of the bag.

3. The flexible film package of claim 1, wherein the plurality of perforations comprise a first section of cuts that include perforations with a mix of shorter and longer length adjacent to a second section of cuts that include perforations with a mix of longer and shorter length.

4. The flexible film package of claim 1, wherein the plurality of perforations include perforations that are not uniform in length.

5. The flexible film package of claim 1, wherein the plurality of perforations comprise a first section of cuts that require a lower pull force to tear segments of film between the cuts and a second section of cuts that require a higher pull force to tear segments of film between the cuts, relative to each of the section of cuts.

6. The flexible film package of claim 1, wherein the plurality of perforations include a central perforation with a length longer than the length of all other perforations, where the central perforation is disposed at a central location of the plurality of perforations under a pull tab of the label where the label is initially pulled away from the bag.

7. The flexible film package of claim 1, further comprising a wicket lip at a top opening of the bag, the wicket lip including holes for placement of the bag on the wicket and perforations to separate the bag from the wicket lip.

8. The flexible film package of claim 1, wherein the first polyolefin film and the second polyolefin film each comprise materials that meet a same recyclable category.

9. The flexible film package of claim 1, wherein the adhesive on the back surface of the label has sufficient tack to allow the label to re-adhere to the first portion of the film when the flap opening is opened and closed at least 10 times.

10. The flexible film package of claim 1, wherein the adhesive on the back surface of the label has sufficient tack to allow the label to re-adhere to the first portion of the film when the flap opening is opened and closed at least 15 times.

11. A packaged foodstuff in a flexible film package comprising:a bag comprising a first polyolefin film having a gusseted bottom, a gusseted and sealed top, welded side seams, and a plurality of perforations on a front surface of the bag to define edges of a tear flap opening of the bag;a foodstuff item comprising multiple pieces disposed in the bag; anda label comprising a second polyolefin film and an adhesive on substantially all of a back surface of the label, the label being disposed on the bag with the adhesive on the back surface of the label in contact with the front surface of the bag and of sufficient size to cover and extend beyond the tear flap opening in the front surface of the bag; andwherein the label, adhesive and bag are configured such that when the label is pulled away from the bag with a specified force, the force is sufficient to separate the adhesive backing of the label from a first portion of the film of the bag extending beyond the tear flap opening and to tear the film of the bag between the perforations such that the label remains adhered to the tear flap opening in the bag, and the opening is of sufficient size to allow removal of a piece of the foodstuff contained in the bag, andwherein the adhesive on a portion of the back surface of the label retains sufficient tack to re-adhere to the first portion of the film of the bag.

12. The packaged foodstuff in a flexible film package of claim 11, wherein the plurality of perforations define three sides of a substantially rectangular flap on the front surface of the bag.

13. The packaged foodstuff in a flexible film package of claim 11, wherein the plurality of perforations comprise a first section of cuts that include perforations with a shorter and longer length adjacent to a second section of cuts that have perforations with a shorter and longer length.

14. The packaged foodstuff in a flexible film package of claim 11, wherein the plurality of perforations include perforations that are not uniform in length.

15. The packaged foodstuff in a flexible film package of claim 11, wherein the plurality of perforations comprise a first section of cuts that require a lower pull force to tear segments of film between the cuts and a second section of cuts that require a higher pull force to tear segments of film between the cuts, relative to each of the section of cuts.

16. The packaged foodstuff in a flexible film package of claim 11, wherein the plurality of perforations include a central perforation with a length longer than the length of all other perforations, where the central perforation is disposed at a central location of the plurality of perforations under a pull tab of the label where the label is initially pulled away from the bag.

17. The flexible film package of claim 11, wherein the first polyolefin film and the second polyolefin film each comprise materials that meet a same recyclable category.

18. The packaged foodstuff in a flexible film package of claim 11, wherein the sealed top comprises a weld seam without excess film extending beyond the weld seam.

19. The packaged foodstuff in a flexible film package of claim 11, wherein a portion of the label at one end of the label nearest the gusseted and sealed top has no adhesive to provide a free end of the label for a user to grasp to pull the label.

20. The packaged foodstuff in flexible film package of claim 11, wherein the adhesive is of sufficient tack and covers a sufficient area of the label beyond the tear flap to permit the label to be peeled and resealed at least 10 times.

Images