Flexible film packaging

Abstract

The invention relates to flexible film packaging comprising a bottom-gusset polyolefin film bag with welded side seams and a perforated pattern on the front surface that defines an opening. The packaging includes a polyolefin film label with a detachable pressure-sensitive adhesive on the rear surface, in contact with the front surface of the bag, covering the perforated pattern. The force used when removing the label from the bag is sufficient to initially separate the adhesive reverse side of the film of the bag and tear the film between the perforations, such that the label remains adhered to the torn film of the bag, forming a tearable flap. The exposed adhesive reverse side of the label, which projects from the film of the bag on the tearable flap, can be re-adhered to the front panel of the bag in order to reseal same. The bag film and the label film can be made of compatible polymers to allow recyclability in the same recycling category, which facilitates recycling of the packaging after use.

Description

[0001] A FLEXIBLE FILM PACKAGING

[0002] RELATED APPLICATIONS

[0003] This application claims the benefit of priority under 35 USC 119(e) for U.S. Provisional Application No. 63 / 655,438, filed on June 3, 2024, and for U.S. Provisional Application No. 63 / 697,178, filed on September 20, 2024, each of which is incorporated herein by reference in its entirety.

[0004] FIELD OF INVENTION

[0005] The present invention relates to resealable packaging, in particular to packaging having adhesive resealable openings for food products and consumer goods.

[0006] BACKGROUND OF THE INVENTION

[0007] Food and consumer goods are presented in a variety of packaging. Flexible polymer film packaging can be manufactured from various materials and in various ways. Flexible film packaging is typically pouch-shaped with an opening at one end. This packaging usually has a gusseted / folded or welded flap end that opens to access the contents, or an open end with a flange or clip to keep it closed. In the case of products with several pieces stacked in a pouch, the consumer can only select the pieces closest to the open end. It would be desirable to develop new flexible polymer film packaging that offers consumers additional options for selecting items from the pouch. It would also be desirable to develop pouches that meet the sustainability goals of consumers and / or businesses.

[0008] BRIEF DESCRIPTION OF THE INVENTION

[0009] A flexible film package consists of a bag made of polyolefin film with a perforation pattern on its front surface. A label may be made of polyolefin film with a pressure-sensitive peelable adhesive on its back surface. The label can be placed in contact with the front surface of the bag, covering the perforation pattern. When the label is removed from the bag, the pulling force may be sufficient to initially separate the adhesive from the bag film and subsequently tear the film between the perforations, so that the label remains adhered to the flap of the torn film, forming a peelable flap on the bag. The exposed adhesive of the label, protruding from the perforations that define the peelable flap, can be reattached to the front panel of the bag to reseal it.

[0010] BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 shows one embodiment of a polymer film sheet with a perforation pattern and a peelable label before being formed into a gusseted bag. Figure 2 shows another embodiment of a polymer film sheet with a perforation pattern before being formed into a gusseted bag.

[0012] FIG. 3 illustrates various styles of perforations to form a flap that can be torn and that may require different tearing forces and tearing speeds.

[0013] FIGS. 4A and 4B represent alternative embodiments of a gusseted bag with a tear-away front flap and a sealed end opening closed with gusseted folds and alternative visual appearances.

[0014] FIGS. 5A, 5B and 5C represent a prior art bag, a modality of a closed bag according to the present invention and a bag with the tear flap open according to the present invention, respectively.

[0015] Figures 6A, 6B and 6C represent three types of a label.

[0016] FIG. 7 shows a group of bags with folding labels stacked on a shelf.

[0017] FIG. 8 shows a sequence for using the label to open and close a type of bag according to the present invention.

[0018] The drawings are provided for illustrative purposes to facilitate understanding of various modalities and are not necessarily drawn to scale nor do they represent accurate representations of size and shape. The following detailed description illustrates the various modalities in more detail.

[0019] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

[0020] In one embodiment, the flexible film packaging includes a bag configured for bulk placement over a window. The bag is made of a first polyolefin film and features a reinforced bottom, welded side seams, and several perforations on the front surface to define the edges of the opening. The packaging includes a label made of a second polyolefin film and adhesive covering virtually the entire back surface of the label. The label is placed on the bag with the adhesive on the back surface in contact with the front surface and is large enough to cover the perforations on the front surface and the opening defined by them.The label, adhesive, and perforations are configured so that when the label is removed from the bag to separate the adhesive from the back surface of a first portion of the film, the segment of film between the perforations tears away, leaving the label adhered to a second portion of the film to form a flap that opens the bag. The label and adhesive on the back surface of the label extend beyond the edge of the flap opening to allow the label to be resealed and re-adhered to the first portion of the bag film surrounding the opening.

[0021] In another embodiment, a food product packaged in flexible film packaging includes a bag made of a first polyolefin film with a reinforced bottom, a reinforced and sealed top, welded side seams, and several perforations on the front surface to define the edges of a tear-off opening. A food product in several pieces is placed inside the bag. A label, made of a second polyolefin film with adhesive covering virtually its entire back surface, is affixed to the bag. The adhesive on the back surface is in contact with the front surface of the bag and is large enough to cover and extend beyond the tear-off opening.The label, adhesive, and bag are configured so that when the label is removed from the bag with a specific force, this force is sufficient to separate the adhesive backing from the first portion of the bag film that protrudes from the tear-off flap opening and to tear the bag film between the perforations. The label remains adhered to the tear-off flap opening, which is large enough to allow the removal of a piece of the food contained in the bag. The adhesive on the back of the label covers a sufficient area and maintains the necessary adhesion to re-adhere to the first portion of the bag film.

[0022] In various forms of flexible film packaging, the plurality of perforations may define three sides of a substantially rectangular flap opening on the front surface of the bag. This plurality of perforations may include a first section of cuts with longer perforations, adjacent to a second section of cuts with shorter perforations. This plurality of perforations may also include a first section of cuts with perforations of varying lengths, adjacent to a second section of cuts with perforations of varying lengths. Furthermore, this plurality of perforations may include a first section of cuts that requires less tensile force to tear film segments between the cuts and a second section of cuts that requires greater tensile force to tear film segments between the cuts, relative to each section of cuts.The flexible film packaging may include perforations of varying lengths. The flexible film packaging may include a central perforation longer than the other perforations, located in the center of the plurality of perforations, below the label tab where the label initially separates from the bag. The flexible film packaging may include an entry lip at the top opening of the bag, which includes holes for inserting the bag and perforations for separating it from the lip. Preferably, both the first and second polyolefin films are composed of materials that meet the same recyclability category.Preferably, the adhesive exposed on the back surface of the label covers a sufficient area and has sufficient adhesion to allow the label to re-adhere to the first portion of the film when the flap is opened and closed at least 10 times, and more preferably at least 15 times.

[0023] In flexible film packaging containing a food product, the sealed top of the bag may preferably include a welded seam, with or without excess film extending beyond it. A portion of the label at one end, near the sealed, gusseted top of the bag, preferably has no adhesive so that the user can grasp and pull it.

[0024] In various implementations, the packaging is manufactured from a flexible film. This flexible film can be produced through a plastic film extrusion process and is typically made from raw granules. The manufacturing process involves superheating and pressurizing raw polyolefin plastic granules, such as LDPE, HDPE, or LLDPE, or blends thereof, to create a consistent molten liquid. Once the liquid is created, the resin is fed into a circular die. The heated resin is then expelled outward or upward to create a long, thin bubble or balloon of highly flexible plastic film. The plastic bubble cools as it expands and passes through several rollers that stretch it into very thin sheets, which will later become the bag walls. The sheets are wound onto two individual flatbeds and fed into the printing machine.

[0025] In this step, the film roll is unwound and cut to the desired size and shape, according to the bag's intended use. Special features can also be added at this stage to complete the plastic bags, such as a pre-cut pattern to be placed on the front panel of the bag. A sealing sticker can then be applied over the pre-cut pattern on the front panel.

[0026] This pre-cut pattern on the front panel can be created with a laser cutting tool, where a focused laser beam pierces and cuts the materials to cut patterns and geometries, or it can be done with a die-cutting machine.

[0027] Wheels can be used on the equipment to create the reinforcements. Dies can be used to cut the handles, if any. Seals can be formed by thermal or ultrasonic welding. Printing can be done before converting the bags from the film.

[0028] The final step involves pressing two printed sheets together or folding a sheet into two layers and sealing the edges to create the bag's sides. The plastic is then rolled and cut to the appropriate size and shape depending on the bag's intended use. These so-called "polyethylene bags" are either flat or have a gusset for extra space and are made from low- and high-density polyethylene. Additional customizations are available, such as perforations on flap bags, which are typically bundled and have a perforated edge for quick and easy tearing. Flap bags can be used to package a variety of products, including food, newspapers, clothing, hosiery, baked goods, and spare parts.

[0029] As mentioned previously, the bags may include perforations in the front panel that form a tear-away flap or an opening covered by a label with a pressure-sensitive adhesive backing that allows the consumer to peel the label back from the bag, tearing the perforations and forming the tear-away flap. The adhesive has enough tack to reseal the label and seal the package.

[0030] Some types of bags may be suitable for use with automatic packaging machines and for containing food and / or consumer goods. The label adhesive must retain its stickiness to allow the package to be resealed and reopened after the initial opening at least 10, 15, or even more times, depending on the number of product items in the bag, to ensure that the peel-and-reseal function is maintained throughout the product's use.

[0031] Bags or packages with tear-off flaps and resealable labels offer several advantages to the consumer. For example, a bread package with an opening in the front panel allows the consumer easier access to the product to choose the desired slice instead of having to search for the nearest one. The tear-off and resealable label helps the consumer remove internal air after consuming slices of bread, as the bag can be rolled or folded to seal it with the label at a size that better fits the remaining product, thus reducing the amount of air in the package and helping to maintain or prolong the product's freshness.

[0032] The packaging options available for bags or packages can offer various advantages to the supplier. Packaging improves sustainability by reducing plastic use, particularly by eliminating the excess plastic film required for snap closures, plastic or cardboard fasteners, or twist closures. Packaging can also enhance product safety throughout the supply chain and provide a better shelf presentation by having a tighter plastic film around the product and eliminating the creases associated with snap closures. Packaging can increase the shelf life of the products it contains compared to snap closures. Other advantages may become apparent to subject matter experts based on the information presented here.

[0033] In this document, the terms bag, packaging, and packing may be used interchangeably unless otherwise expressly indicated. Generally, "bag" refers to the empty package and, when describing the relationship between the two, may refer only to the bag's film and not the label film. Generally, "packaging" refers to the bag that is filled and sealed, or subsequently, during the product's life cycle.

[0034] In FIG. 1, a polymer sheet (10) is illustrated with a front panel (12), a back panel (14), a gusseted fold (16), a front label (18), a lip (20), and pass-through holes (22) before being folded and heat-sealed to form a bag. The pre-cut perforation pattern (24) in the front panel is indicated by the dashed or dotted line (24). The perforations define the edge of a tear-away flap (26) in the bag. The label (18) on the front panel (12) is indicated by the shaded area. The shaded area, which covers almost the entire label, has an adhesive on the back surface in contact with the front panel of the bag. The gusseted fold (16) optionally includes slits to facilitate folding the sheet and forming a gusseted bottom.

[0035] With reference to FIG. 2, another embodiment of a polymer sheet (28) without the adhesive label affixed to the front panel is illustrated. The pre-cut perforation pattern (24) can be indicated by dashed or dotted lines (24) on the front surface of the sheet to be formed into the bag. The perforation pattern (24) is U-shaped, but can have various shapes and dimensions to allow the removal of one or more pieces of product from the bag. As shown, only the three sides of the tear-off flap include perforations, so that the pre-cut perforation pattern can be torn to form the tear-off flap and create an opening when the label is removed from the bag. The perforations or cuts can be made, for example, by laser cutting or with a die-cutting roller.The terms "perforations" and "cuts" may be used interchangeably unless otherwise specified herein in connection with specific modalities. 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 neither circular nor triangular. The flap may have four sides and rounded corners, or one or more rounded sides, as when the perforations are U-shaped, but its overall appearance resembles that of a rectangle or a square. The flap may have other shapes provided its function is similar to that described herein.Various configurations may include a longer cut (25) in the center section of the pattern, shorter cuts on either side of the longer central cut, medium-length cuts at the shoulder (29) of the pattern, longer cuts along the sides, and small dots or holes (27) at the ends of the perforation pattern. The cuts or perforations can range from small holes to 1 mm cuts, up to approximately 10 mm in length or more, and various intermediate lengths, depending on the desired tear strength or the tensile force required to tear the perforation pattern.

[0036] Figure 3 illustrates examples of various perforation styles that can be useful in providing different tear characteristics on the flap of a finished bag. Style A 30 features long perforations or cuts with short lengths of plastic film in between, which should exhibit a fast tear rate. Style B 32 features short perforations or cuts with short lengths of plastic film in between, which should exhibit a relatively slower tear rate compared to Style A, as more portions of plastic film must be torn per unit of linear dimension along the perforation line. Style C 34 features long perforations with long lengths of plastic film in between, which should exhibit a slow tear rate compared to Style A and may also require greater pulling force to tear longer lengths of plastic film in between.Style D 36 features short perforations with large expanses of plastic film between them, which should have a relatively slower tearing speed compared to Style C, since more portions of plastic film are required per unit of linear dimension along the perforation line. As a person skilled in the art will understand from this description, the perforation can be selected to create a tearable flap with the desired pull strength and tearing speed. Perforation styles can be combined on the front panel to create areas of easy or fast tearing and areas of more difficult or slow tearing.For example, Style E 38 illustrates another form of a pre-cut perforation pattern with a combination of short, medium, and long perforations, as shown separately in Styles A through D, which can provide a range of pulling forces and tearing speeds when the consumer initially opens the label and tears the plastic film along the perforations.

[0037] The pre-cut perforation pattern may combine different styles in different sections to provide varying amounts of pulling force required to tear the flap. Some perforation sections may have longer cuts, while others may have shorter cuts. Sections may include a mix of both. Instead of cuts, some 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 less pulling force to tear, while sections with shorter cuts require more pulling force.The perforations must also match the characteristics of the plastic film used to create the bag, because some films may have greater tear resistance than others of the same thickness, and thicker films may also have greater tear resistance than thinner films of the same material. If the film offers greater tear resistance, it is recommended to add a longer cut (25) in the center of the pre-cut pattern, as shown in Figure 2. The longer center cut is preferably located below the label tab to facilitate the initial tear of the flap. For example, the tear characteristics should be selected so that the front panel flap is relatively easy to open, but not so easy as to prevent the consumer from accidentally opening it or during handling of the package.For example, the flap may have a zone where the perforations are relatively easy to tear when initially opened (i.e., requiring less pulling force and lower tear resistance), and a zone that is more difficult to tear (i.e., requiring greater pulling force and higher tear resistance), so that the user does not inadvertently tear it completely off the bag. A zone of high tear resistance can be achieved by a section of closely spaced dots or holes at the end 27 of the precut pattern, as shown in FIG. 2.

[0038] Figures 4A and 4B show alternative embodiments of a gusseted bag or package filled with product, with a tear-away front flap, where the top opening is sealed with seals and side pleats that provide an alternative visual appearance. The closing and sealing process of the filled package involves the machine first creating a gusset fold 42 at the top, sealing the bag opening, and then removing some or all of the excess trim. As illustrated, the package (40) in Figure 4A exhibits excess trim remnants 44 extending from the weld line (46), which can alternatively be made as a flap seal. In contrast, the package (46) illustrated in Figure 4B...4B eliminates almost all excess trimming by cutting the plastic film at or very close to the weld line 48 to leave a sealed and gusseted end 42 that fits better to the contents of the filled bag, which can provide a more attractive and tidy appearance for the consumer.

[0039] Figures 5A, 5B, and 5C show a prior art bag (50), a embodiment of a closed bag 52 according to the present invention, and a bag 54 with the detachable flap open according to the present invention, respectively, each containing food products, such as sliced ​​bread. The removal of the Kwik Lok® twist closure (56) and the drawstring (58), as shown in Figure 5A, reduces the amount of plastic film used in the bag and provides a cleaner appearance for product presentation, as shown in Figure 5B. The removal of the Kwik Lok® twist closure (56) and the drawstring (58) also reduces the product's shelf space and the bulk packaging space required for transport.Preferably, the printed graphic design area (51) of the packaging in the prior art (50) includes direct printing onto the bag film, which can be used to determine the outline of the printed label (53) used on the bags (52) according to this invention. This allows the bags (52) to include tear-off labels with printed graphics similar to those on the film of the bags in the prior art (50). In this way, to facilitate consumer acceptance, it is preferred that the consumer recognize the packaging with the tear-off, resealable opening, since the tear-off label uses a graphic print similar to that of the conventional packaging. In use, as shown in FIG. 5C, the consumer can open the packaging from the center of the front panel using a tear-off flap / label (60) to offer a selection of products from the center (62) of the packaging, away from the ends (64) and (66).In the case of sliced ​​bread, the slices at or near the ends are generally less desirable to consumers. In traditional bread bag packages with openings at the ends, the end pieces make it difficult to select the center slices. Therefore, bread bags manufactured according to this invention could be preferred by consumers.

[0040] As shown in FIG. 5C, the consumer can grasp the top (68), or free end, of the label (60) and pull down, as indicated by the arrow (70). The adhesive on the back (72) of the label (60) has sufficient tack to adhere to the front surface (74) of the package (54) until sufficient force is applied to separate it. The force required to separate the adhered label from the bag film is preferably greater than the tear strength of the perforated portions of the plastic film. Thus, when the label (60) is separated from the package, as the pulling force is transferred to the front panel (74) of the bag along the perforations, the plastic film of the front panel tears along or between the perforations, creating an opening in the package. The tear-off flap (76) of the bag film remains adhered to the back (72) of the label.The label with exposed adhesive extends beyond the edge of the flap that can be opened, thus creating a flap that can be resealed and resealed over the opening.

[0041] Ideally, the size, length, and number of perforations in the pre-cut pattern defining the opening flap are selected (depending on the type of bread, its dimensions, and the bag material [tear resistance]) to allow the consumer to apply a reasonable pulling force to the label to tear the film between the perforations and form the flap opening. The dimensions and shape of the perforations may vary along their length, so that a different force is required to initiate the tear than to complete it. As mentioned earlier with reference to Figure 3, this can be achieved by modifying the length and spacing of the perforations. Specifically, the more widely spaced the perforations, the easier it is to tear the bag film (i.e., less force is required).For example, when the perforations are U-shaped, using more widely spaced perforations will reduce the length of film required, so the force needed to open the flap will be less than the force needed to tear the longer sections of plastic film between the more widely spaced perforations. The dimensions, shape, and spacing of the perforations can be designed to achieve the desired characteristics, taking into account the tear resistance of the bag film, which can vary depending on its thickness.

[0042] In one embodiment, a bread bag is made of polyethylene or a mixture of polyolefins with a thickness of between 0.0254 and 0.0381 millimeters (1 and 1.5 thousandths of an inch) and may have a tear resistance; Tear test (Elmendorf) of between 60 and 180 grams molecular weight (MD), according to ASTM D-1922 test methods. Therefore, the adhesive strength on the back or rear surface of the label may have to exceed the tear strength (Elmendorf) of the film for the initial opening of the bag along the perforations. In other bag configurations with different tear strengths (Elmendorf), the adhesive strength on the back of the label may also have to exceed the tear strength (Elmendorf) of the film for the initial opening of the bag along the perforations.

[0043] In a preferred configuration 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 closer together than the perforations on the sides of the U. This can 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 package label, as it will require more force to tear the label as it approaches the ends of the U-shaped perforation. This slows the rate at which the bag film tears along the perforations with the same applied pulling force, providing a physical feedback to the consumer.The selected perforation pattern may depend on several factors, including, but not limited to, the tear strength of the bag film and the anticipated consumer preference for the tensile force required to tear the label flap on the package.

[0044] The opening can be resealed by placing the tear-off flap back in its original position on the front panel of the bag. Alternatively, if enough product has been removed from the bag, the opening can be resealed by first rolling or folding the top edge, or sealed end, over the front surface of the package. The portion of the back surface of the label that protrudes from the torn flap of the bag film, with the adhesive exposed, will then contact the roll-off or fold-off top of the package to re-adhere the label to the bag film. It is preferred that the adhesive be provided in sufficient quantities, with adequate retention or tack, to allow the label to be peeled off and resealed at least 10 times, preferably at least 12 times, and optionally 15 or more.Ideally, when packaging is used with food products, such as sliced ​​bread, the adhesive should be provided in sufficient quantities and with adequate retention or adhesion to allow the label to be peeled off and resealed throughout the product's shelf life. Upon opening and resealing the flap for the first time, it will be visible that the package has been opened, providing an inherent safety indication, unlike a drawstring bag with a plastic seal, where it is not possible to see that the bag has been opened. Optionally, the label, bag, or package may include other security features, such as those known in the art, that visually indicate when the label has been removed for the first time to open it.

[0045] Figures 6A, 6B, and 6C illustrate other embodiments of peel-off and resealable labels without printing on most or all of their surface. Figures 6A and 6B illustrate two embodiments of labels (80) and (82), with only the peel-off tab areas (84) and (86) printed, and a typical label shape used for a gusseted bread bag, according to the embodiments of the present invention. Virtually the entire underside of the label may be coated with an adhesive. In some embodiments, the upper portion of the label with the peel-off tab may not have adhesive on its back surface so that the consumer can more easily grasp the unattached or "free" edge of the label and peel it away from the bag film. Figure 6C is an example of a label 88 with a different shape that may vary depending on the product brand.The shape of the label can be determined according to the graphic design of the printing on the label and the functionality of the package, in such a way that the packaging of the product with the tear-open flap on the front panel looks similar to the previous packaging configuration, as can be seen by comparing FIGS. 5A and 5B.

[0046] Figure 7 shows a label (90) similar to that in Figure 6A on the surface (92) of a transparent plastic or polymer film formed into gusseted bags (94), which are supplied in bulk in a slot 96. The product manufacturer or packer may use automated packaging equipment to introduce the products into the bags. After filling the bag, the sealing equipment may fold the open end to form a gusset and seal the open end or the top of the bags, and trim off the excess plastic film, thus forming the sealed food packaging.

[0047] With reference to FIG. 8, a panel (100) of images illustrates the use of the packaging according to the present embodiments. Step 1 (102): The consumer lowers the label tab to tear the perforations and create an opening in the front surface of the package. Step 2 (104): The consumer can remove a product through the opening. Step 3 (106): As the contents are removed from the package, the top of the package can be rolled up to remove air. Step 4 (108): If enough contents have been removed, before closing the label, the top of the package can be rolled up toward the opening area on the front surface, and then the label can be folded closed, covering the rolled-up top of the package under the adhesive side to keep it sealed. This resealable label food packaging configuration can increase the shelf life of stored food products.

[0048] Bags may be made of any polymer film suitable for the products for which they are designed. For example, bags for containing food products must use materials certified for food contact 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 specified, 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 that includes at least one layer comprising linear low-density polyethylene (LLDPE) and low-density polyethylene (LDPE), as typically used for food packaging. Preferably, at least one layer of the multilayer film includes high-density polyethylene (HDPE) for increased film strength to withstand the tearing stress of the resealable label flap. Preferably, the film is not heat-shrinkable. The multilayer film may include an oxygen or moisture barrier layer, such as ethylene vinyl alcohol (EVOH), vinylidene chloride (PVDC) copolymers, or copolymers thereof. One layer of the multilayer film may include nylon or other amides. The film is preferably transparent and flexible.The film layers may also include small amounts of other known film-making additives, such as antistatic, antiblocking, slip, processing, compatibilizer, or pigment agents.

[0049] The label can 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 (melt polypropylene), or a mixture of polyolefins and other components suitable for processability or film characteristics, such as strength. For example, it would be undesirable for the label to stretch when pulled. Resealable labels can be made of a polymer film that is similar to the polymer film of the bag, so that the bag and label are classified in the same category of recyclable materials. For example, low-density polyethylene is a Category 4 material according to the U.S. Department of Energy.However, a plastic film containing both high-density polyethylene and low-density polyethylene can be accepted as compatible materials for recycling together. It may be preferable for the label to be made of low-density polyethylene when the bag is made of low-density polyethylene, so that the bag and label can be recycled together in the same Category 4 recycling stream. Films may include other compatible polymers, such as nylon and EVOH. However, plastic films with certain components to increase strength and block light, such as films with a metallized coating, are generally not considered recyclable and would not be suitable if the bag and label are to be recycled together.

[0050] Labels may have a pressure-sensitive, peelable adhesive on the back surface for affixing to the front surface of the bag, which has been perforated to create the tear-off flap opening. It is preferable that the adhesive be compatible with the bag's contents. For example, a suitable adhesive for packaging bakery products might be a removable acrylic certified for indirect food contact. Under 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 where: (1) it is separated from the food by a functional barrier that will prevent migration of any of the adhesive components into the food, or (2) it has incidental contact with the food limited to traces at the seams or edges of the label.

[0051] It is preferable to apply only pressure-sensitive peelable adhesive to the back surface of the label. Furthermore, it is preferable to use only one type of pressure-sensitive peelable adhesive. While a permanent adhesive may be used on the non-resealable portion of the label, it is preferable not to use permanent adhesive anywhere on the back surface.

[0052] The products can be packaged in bags, according to this invention, by various methods. For example, one method may consist of manufacturing the bag by placing a perforation pattern on a polyethylene film, where the pattern is positioned to form a tear-away flap on the front panel of the bag. A polyethylene label with a pressure-sensitive, peelable adhesive on the back can be placed over the perforation pattern, in the area where the front panel of the bag would be located. The film can then be cut to the desired size and shape to form the bag. The cut film can be folded almost in half and welded to form a gusseted bottom. The side seams are then welded, leaving an opening at the top of the bag, with a grooved flange adjacent to the top opening, so that the perforation pattern with the label is on the front panel.The bag can be placed in a slot alongside other bags. A bag containing bags can be placed in equipment that automatically inserts a food product through the top opening and separates it from the rim. The equipment folds the film near the top opening, forming a gusset fold, welds or seals the top opening, and trims off the excess film. This creates a food package filled with a resealable label that can be pulled from the bag with sufficient force to separate the adhesive from the film and tear the film between the perforations, so that the label adheres to the torn film of the bag to form the tear flap. To clarify the use and notify the public, the Applicant defines the phrases “at least one of…” , , ... y <n>" or "at least one of< / n> , , ... o <n> " or "at least one of< / n> , , ... o <n> , or combinations of these" or "< / n> , , ... I <n>"In the broadest sense, superseding any prior or subsequent implied definition, unless expressly stated otherwise by the Applicant, the term 'a' refers to one or more selected elements from the group comprising A, B, ... and N. In other words, the phrases refer to any combination of one or more of the elements A, B, ... or N, including any one element alone or in combination with one or more of the other elements, which may also include, in combination, additional elements not listed. Unless otherwise stated or the context suggests otherwise, as used herein, 'a' or 'an' means 'at least one' or 'one or more'. While various modalities have been described, it will be evident to those skilled in the art that many more are possible. Accordingly, the modalities described herein are examples, not the only possibilities."

[0053] In addition to the features mentioned in each of the independent aspects listed 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 (FIGS).< / n>

Claims

CLAIMS 1. A flexible film package comprising: a bag configured for bulk placement in a window, the bag comprising a first polyolefin film and having a reinforced bottom, welded side seams, and a plurality of perforations in a front surface of the bag to define the edges of a bag opening; and a label comprising a second polyolefin film and an adhesive over substantially the entire 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,The adhesive and the plurality of perforations are configured such that when the label is removed from the bag to separate the adhesive on a back surface of the label from a first portion of the bag film, a segment of the bag film between the perforations tears away so that the label remains adhered to a second portion of the bag film to form a flap that opens the bag, wherein the label and the adhesive on the back surface of the label extend beyond the edge of the flap opening to allow the label to be resealed and re-adhered to the first portion of the bag film surrounding the opening.

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

3. The flexible film packaging of claim 1, wherein the plurality of perforations comprises a first section of cuts including perforations with a mixture of shorter and longer lengths adjacent to a second section of cuts including perforations with a mixture of longer and shorter lengths.

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

5. The flexible film packaging of claim 1, wherein the plurality of perforations comprises a first section of cuts requiring a lesser pulling force to tear film segments between the cuts and a second section of cuts requiring a greater pulling force to tear film segments between the cuts, relative to each of the cut sections.

6. The flexible film packaging of claim 1, wherein the plurality of perforations includes a central perforation having a length greater than that of all other perforations, wherein the central perforation is arranged in a central location of the plurality of perforations below a label pull tab where the label is initially removed from the bag.

7. The flexible film packaging of claim 1, further comprising a porthole lip in an upper opening of the bag, the porthole lip including holes for placing the bag in the porthole and perforations for separating the bag from the porthole lip.

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

9. The flexible film packaging of claim 1, wherein the adhesive on the back surface of the label has sufficient adhesion 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 packaging of claim 1, wherein the adhesive on the back surface of the label has sufficient adhesion 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 food product packaged in a flexible film package comprising: a bag comprising a first polyolefin film having a reinforced bottom, a reinforced and sealed top, welded side seams, and a plurality of perforations on a front surface of the bag to define the edges of a tear-flap opening of the bag; a food product comprising multiple pieces arranged in the bag; and a label comprising a second polyolefin film and an adhesive on substantially the entire back surface of the label, the label being arranged 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 on the front surface of the bag;and wherein the label, adhesive, and bag are configured in such a way that when the label is removed 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 bag film extending beyond the tear-off flap opening and to tear the bag film between the perforations in such a way that the label remains adhered to the tear-off flap opening in the bag, and the opening is of sufficient size to permit the removal of a piece of the food product contained in the bag, and wherein the adhesive on a portion of the back surface of the label retains sufficient adhesion to re-adhere to the first portion of the bag film.

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

13. The food product packaged in a flexible film package of claim 11, wherein the plurality of perforations comprises a first section of cuts including perforations of a shorter and longer length adjacent to a second section of cuts having perforations of a shorter and longer length.

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

15. The food product packaged in a flexible film package of claim 11, wherein the plurality of perforations comprises a first section of cuts that require less pulling force to tear film segments between the cuts and a second section of cuts that They require a greater pulling force to tear film segments between cuts, in relation to each of the cut sections.

16. The food product packaged in a flexible film package of claim 11, wherein the plurality of perforations includes a central perforation with a length greater than that of all other perforations, wherein the central perforation is arranged in a central location of the plurality of perforations below a tab of the label where it is initially removed from the bag.

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

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

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

20. The food product packaged in a flexible film package of claim 11, wherein the adhesive has sufficient adhesion and covers a sufficient area of ​​the label beyond the tear flap to allow the label to be peeled off and resealed at least 10 times.

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