Die Cut Package Integrity Feature With Neck Region
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Solution Overview
Problem
Conventional package integrity features for flexible film-based packages are inconsistent in manufacturing and performance, leading to unreliable tamper-evident indications.
Innovation Solution
A package integrity feature defined by an inner film layer with a main die cut portion and continuous first and second die cut portions, forming a neck region that tears upon opening force, and an anchor region that resists the opening force to ensure consistent tearing at the neck region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional package integrity features are used, then tamper-evident indication is provided, but manufacturing consistency and performance reliability are poor
Solution Approach 1:
The package integrity feature is segmented into distinct functional regions: a tear initiation region with reduced width that concentrates stress, and anchor regions with increased width that distribute and resist opening forces. This segmentation ensures predictable tearing at the narrow region while maintaining manufacturing consistency through defined geometric parameters.
Solution Approach 2:
Different regions of the package integrity feature are given different local properties: the tear initiation region has reduced width (5-15 mm) to facilitate controlled tearing, while the anchor regions have increased width (20-50 mm) to provide structural support and resist opening forces. This local differentiation resolves the contradiction by optimizing each region for its specific function.
2Ease of manufacture
If a simple die cut design is used, then ease of manufacture is improved, but functional reliability of the tamper-evident feature deteriorates
Solution Approach 1:
The package integrity feature is pre-formed during the die cutting process with built-in geometric features (narrow tear initiation region, wide anchor regions) that predetermined the tearing behavior. This preliminary action ensures functional reliability is achieved through design rather than post-manufacturing adjustments, maintaining ease of manufacture.
Solution Approach 2:
The width parameter of the package integrity feature is strategically varied along its length: reduced to 5-15 mm at the tear initiation region and increased to 20-50 mm at the anchor regions. This parameter change within a single die cut process achieves both ease of manufacture and functional reliability through controlled geometric variation.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2~3
AI summary
A package integrity feature (50) defined by a film laminate comprises an outer film layer (30); an inner film (25) layer adhered to the outer film layer in an area within a peelable flap portion (20) of the laminate, wherein the inner film layer comprises a package integrity feature comprising: a first die cut portion (52) extending from a main die cut portion (40), wherein the main die cut portion at least partially defines an opening (45) of the laminate; and a second die cut portion (54) extending from the main die cut portion, wherein the first and second die cut portions are continuous with each other and with the main die cut portion, and wherein the first and second die cut portions define: a neck region (56) of the package integrity feature having a reduced width and configured to tear as an opening force is applied to the laminate by a user, wherein tearing of the neck region provides access, via the opening, to contents stored within the laminate in a tamper evident manner, and an anchor region ((58) configured to resist the opening force applied by the user such that the neck region tears in response to application of the opening force, wherein the anchor region is configured to have sufficient surface area to remain secured to the peelable flap such that tearing of the package integrity feature occurs at the neck region.