JP2005514272A - Package for compressible product and method for manufacturing the package - Google Patents

Abstract

The present invention comprises a unitary flexible package (10) for enclosing and containing in a sealed condition one or more compressible products (100) in both a compressed and uncompressed condition. The package (10) comprises a first closure member (12) capable of sealing the package (10) in a first closed condition defining a first volume, and a second closure member (14) capable of sealing the package (10) in a second closed condition defining a second volume, the second volume being greater than the first volume. A method for making the package (10) of the present invention is also disclosed. <IMAGE>

Description

  The present invention relates to a package that can be used to effectively package and transport compressible products, and to a method of manufacturing such a package.

  When transporting a finished product from a point of manufacture to a point of sale or intermediate storage facility, it is often desirable to enclose multiple products in a larger, more durable package. This not only preserves the product in a desirable and marketable state, but also minimizes the number of individual items handled, and generally provides items of uniform shape through stacking and handling.

  Over time, such packages have dimensions suitable for enclosing a predetermined number of finished products made of corrugated or non-corrugated cardboard, many of which are rectangular rigid or semi-rigid It has often taken the form of a conventional package. For other products that require protection against contamination but do not require physical damage protection, "soft" flexible packaging materials such as polymer films and papers of various thicknesses are similar methods. Has been used in. Such a package has proven effective in protecting the finished product during transport and storage, but is required for transporting and storing a compressible product having a significant void volume inside. Is generally inefficient in terms of occupied space and material.

  To address this shortcoming, various package types have been devised to accommodate compressible products in a compressed state, i.e. under pressure. In addition, various methods have been devised to apply compressive pressure to the compressible product prior to packing into the package so that the package remains under tension until released. For example, one such package and method is disclosed in EP-A-0942881, which is a package for efficiently packaging and transporting a compressible product and a method for producing such a package. Disclosure.

  One drawback of current compressible packages for storing and transporting compressible products in a compressed state is that the compressible product is properly contained and / or stored after the transport package has been opened, for example, by a consumer. The large number of compressible products that are problems of the present invention exhibit sufficient recoverability, so after the release of the transport package, the compressible products in it tend to recover due to expansion, etc., so that the original package is no longer suitable Cannot accommodate the product. This raises the problem of the product in the package to the user. For example, if the compressible product requires sealed storage, the package can no longer be sealed against ambient conditions.

  Another problem associated with current compressible packages is that many are difficult to open. For example, compressible product packages are stressed on the seam so that there is little material to grip for opening. Opening with a sharp object such as a knife or scissors can damage the contents of the package.

  Another problem with current compressible packages, particularly for individually compressible articles, is that it is difficult to remove the first (or even more) articles in the package. Packed in a tightly compressed state, consumers often have to spend a significant amount of effort to remove the first item from the package.

  While not limited to such products, one representative segment of products that are often transported in a compressed state is disposable absorbent products. For example, disposable diapers can be highly compressed and packaged to minimize the required transportation and storage space. However, after the consumer opens the original package, the inner diaper can recover to a substantial percentage of the original pre-compression volume to the extent that it can no longer be properly closed again within the original package. This is problematic for consumers who want to re-seal diapers that remain against environmental dirt and moisture.

Therefore, it is desirable to have a compressible product containment package that can be packaged in a compressed low volume form and that can recover the compressible product therein and reseal it after opening.
In addition, it is desirable to have a compressible product containment package that can be easily opened.
In addition, it is desirable to have a package for transporting and storing compressible products that can be easily removed from the initial product in the package when the package is opened.
Finally, it is desirable to have a method for manufacturing such a package.

  The present invention includes an integral flexible package that encloses and houses one or more compressible products in a sealed state in both a compressed state and a compressed release state. The package includes a first closure member capable of sealing the package in a first closed state defining a first volume and a second closure member capable of sealing the package in a second closed state defining a second volume. A second volume is greater than the first volume. The package can have at least one flap for holding a portion of the package in a compact low volume package.

A method of manufacturing a package of the present invention having at least one flap is disclosed, the method comprising:
Providing a continuous sleeve of material having an open first end and an open second end;
Coupling a second closure member to the opened first end;
Folding the open first end at a fold line to form a flap;
Coupling the flap to a continuous sleeve of material to form a first closure member at the closed first end;
Installing the product in a continuous sleeve of material;
Compressing the product;
Closing the second end of the sleeve of material and receiving the product in a compressed state.

  While the specification concludes with claims that particularly point out and distinctly claim the invention, the invention resides in conjunction with the specification, in which the components are given the same reference numerals, This can be better understood with reference to the drawings.

  As used herein, the term “coupled” refers to a configuration in which an element is secured directly to another element by securing it directly to another element, and an element is secured to the intermediate member and the intermediate member is secured to the other element. And a structure that is indirectly fixed to another element by being fixed to the element.

  As used herein, the term “monolithic” refers to a package that is formed from discrete pieces joined together to form a cooperating entity. For example, a package that includes a flexible polymer film that may be formed, folded, sealed, and coupled to other components, such as a closure mechanism, as a cooperating entity is “monolithic”. Similarly, packages such as plastic bags that are placed separately inside other packages, such as paperboard boxes, are not considered “integrated” together.

  FIG. 1 is a perspective view of one embodiment of an integrated flexible package 10 that encloses and encloses one or more compressible products 100 in a sealed state. As shown, the package 10 may be a parallelepiped that is generally rectangular in shape, although other shapes may be used, primarily in accordance with the compressible product 100 contained therein. Package 10 can be configured to any desired dimensions according to the particular product 100 contained therein.

  The package 10 of the present invention can be assembled from a wide variety of suitable materials, including but not limited to paper, woven fabrics, plastics including polymer films, and the like. The polymer film preferably has sufficient strength and creep deformation resistance to package the compressible article. Such polymeric materials are known in the art for compressible article packaging and include, for example, thermoplastic polymer films such as polyethylene, polyolefins, and polyesters. One preferred material for packaging articles such as disposable diapers is linear low density polyethylene (LLDPE) with a thickness of between about 5 μm and 5 mm. In general, the thickness of the package material depends on the product that is put into the package and the amount of pressure. Thermoplastic polymer films are facilitated by application of heat seams, pleats, and flaps, as is known in the art. Other means of fixing the various seams and flaps of the package 10 and fixing the pleats that reduce the volume in the assembled state can be used, such as tape, staples, and adhesives, among which hot melt bonding The material is currently preferred. Once the package 10 is formed, filled, and sealed by methods known in the art to form and fill a package of compressible products, the package is considered integral.

  The compressible product 100 can include solid individual compressible items, each enclosing the compressible product (s) in liquid, powder, granular, individual, or separable form. A separate compressible package may also be included. In the case of products in “loose” form such as liquids and particulates, suitable means should be used to keep the product during the compression process in order to prevent product loss. Thus, the package 10 of the present invention may contain a single individual product 100, such as a reusable product, such as a sponge, that can be resealed in the package 10 during use. However, the package 10 of the present invention is particularly suitable for housing a plurality of products 100, where individual product units themselves may be packages or transporters.

  Products 100 of particular interest in accordance with the present invention include products that are elastically compressible, i.e., can be compressed by a compressive force, but nevertheless fully conform to their initial volume and external dimensions when the compressive force is released. Includes products that tend to substantially or at least partially return. This type of product includes clothing, pillows, sponges, cotton stuffing, cotton balls, textile insulation stuff, and other disposable absorbent articles such as diapers, feminine hygiene products, and adult incontinence products, and paper towels, Paper and tissue products such as bathroom tissue, facial tissue, wipes, table napkins, and a wide variety of other products.

  The package 10 of the present invention can be transported in a compressed low volume form, but can still be easily opened, the product inside can be easily removed after being opened, and the product after being opened and taken out of the compressible product in it. Is a package for containing compressible products that can be properly contained and resealed. Accordingly, the package 10 can have two closing members 12 and 14 as shown in FIGS. As shown in FIGS. 1 and 2, the first closing member 12 closes and holds the package 10 in the first closed state, and FIG. 2 is a cross-sectional view of the package 10 in the first closed state. . In the first closed state, the package 10 defines a first volume V1, which means that the product therein is in a compressed state, such as a transported state, and the package 10 is secured by the first fastener 12. The volume of the closed interior space defined by the side wall 11 of the package 10 when closed in the closed state. Thus, in the first closed state, the package can contain at least one product 100 in a compressed reduced volume state.

  The first closure member 12 holds a portion of the package 10, such as the flap 16, in a closed state so that the first closure member 12 is released, loosened, removed, or otherwise opened. Any member capable of maintaining the first volume V1 can be used. Accordingly, the first closing member 12 can be any known closing means and includes mechanical fastening devices such as thermal fusion, ultrasonic fusion, and hook-and-loop fasteners. In one embodiment, as shown in FIGS. 1 to 3, the first closure member 12 can be an adhesive tape 18 that seals the folded flap 16 with an adhesive. The adhesive tape 18 can be any suitable adhesive tape known in the art, but is preferably a line of weakness 21 such as a perforation and / or that allows easy opening of the first closure member 12. Or a tape having a release strip 22 such as a tear string or tape (as shown in FIGS. 1 and 2). For example, the line of weakness 21 may or may not have an associated release strip 22 to help tear the tape into two portions 12a and 12b, as shown in FIG. Once teared in this manner, the first closure member 12 is not intended for reuse, but in some embodiments may have resealability.

  After the first closing member 12 is released, the flap 16 that can be formed on a part of the side wall 11 of the package 10 by a fold line 20 can be unfolded, for example, as shown in FIG. Unfolding the flap 16 creates an additional volume within the package 10. That is, once the flap is unfolded, an additional volume, shown as space 25 in FIG. Thereby, the compressible product 100 can expand | swell and return to the part of the volume before compression, still being accommodated in the package 10. FIG. The package 10 is then in a second state, and when closed with a second closing member, defines a second volume V2 that is greater than the first volume V1. In the second closed state, the package 10 defines a second volume V2, which is the volume of the closed interior space defined by the side wall 11 of the package 10 when the second closure is closed.

  The compressible product 100 can be compressed to a portion of the volume prior to compression, depending on what type of product. For example, certain sponges can be compressed to half their pre-compression volume. A disposable absorbent article such as a diaper having an absorbent core of cellulosic fluff can be folded and compressed to a thickness of 60% of the uncompressed thickness. In general, the package of the present invention may have a volume V1 that is 10% to 90% of the second volume V2. The package of the present invention may have a volume V1 that is 50% to 80% of the volume V2. The package of the present invention can have a volume V1 that is 60% to 70% of the volume V2 when used to package a disposable absorbent article. For highly compressible products, V2 can be 200% or more of V1.

  When the package 10 is in a second closed state that defines a second volume V2, the second closure member 14 can close and preferably seal the package 10. Accordingly, the second closure member 14 can be a slide lock closure, such as what is referred to in the art as a ziplock closure. The second closure member 14 can also be adhesively reclosable with a hot melt adhesive or the like or with an adhesive tape tab fastener. The second closure member 14 can also include a mechanical fastener such as a hook-and-loop fastener.

  If the second closing member 14 is intended to be hermetically sealed, the second closing member 14 can be in a non-hermetic state before the first closing member 12 is opened. That is, the second closure member 14 can be unclosed before releasing the first closure member so that the added volume can at least initially fill the air and the volume of the package 10. Can sufficiently expand from the first volume V1 to the second volume V2. Of course, the second closing member 14 can be in a closed sealing position, in which case partial opening is required to allow air to enter the package 10 for volume expansion.

  Thus, the package of the present invention is, in the most general sense, a one-piece flexible package 10 that encloses and houses one or more compressible products 100 in both a compressed state and a compressed release state. It can be described as being. The package can be produced and transported with the product in a compressed state. The package seals the package in a first closed state that defines a first volume so that the consumer of the product can easily open the package, for example, to allow reclosing after the initial opening. A possible first closure member 12 and a second closure member 14 capable of sealing the package in a second closed state defining a second volume, wherein the second volume is said first volume. It is larger than the volume. In this way, since the second volume is larger than the first volume, the enclosed product is no longer compressed and can be removed more easily.

  As used herein with respect to the first and second closure members 12, 14, the term “sealing” refers to “closing” the product to be contained within the package. The term can refer to a hermetic or watertight seal, but is not limited to such a seal.

  Various other package configurations can be implemented without departing from the above description. For example, two or more fold lines 16 can be used, depending on when it is desired to place the first closure member on the finished package of the compressible product. In one embodiment, a fan fold line can be used to achieve the function of the fold line 16. In another embodiment, two or more first closure members 12 can be used to associate one or more with each fold line 16. In general, the greater the difference between V1 and V2, the greater the number of fold lines 16 to effectively and cleverly wrap the remaining sidewall material 11 of the package before opening the first closure member 12. Is required.

  In another variation, the first closure member 12 may be as shown in FIG. 4 where the flap 16 is secured by a line of adhesive such as a hot melt adhesive. The flap 16 can be secured in the first closed state by heat-sealing a portion of the thermoplastic polymer packaging material on the side wall 11 in the region of the first closing member 12 rather than attaching an adhesive.

  In another variation, also shown in FIG. 4, a compression resistant seal 24 can be provided adjacent to the fold line 16. In this manner, the first closure member 12 can be released and the flap 16 can be unfolded before releasing the pressure exerted by the compressible product 100. In order to release the pressure exerted by the compressible product 100 and expand the package 10 to the second volume V1, the seal 24 must first be broken. One method of creating the seal 24 is a peelable adhesive, ie, sufficient adhesion that is compression resistant, but nevertheless separates the parts of the package material that are bonded together. This is possible with an adhesive having a sufficiently low peel force. The compression resistant seal 24 is shown in connection with the configuration shown in FIG. 4, but can be used in combination with other configurations such as that shown in FIG.

  The present invention is disclosed herein primarily in an embodiment having flap (s) 16 because such a configuration represents the current best method for commercial viability. is there. That is, the flap 16 is a convenient way of constructing the package 10 compactly for transport without the excess material being left loose. However, certain embodiments are contemplated where there is no flap 16 folded at the fold line 20 as shown. For example, the embodiment shown in FIG. 4 can be reconfigured so that there are no fold lines 20 or flaps 16 in the finished package. In that case, the sealing portion 24 becomes the first closing member 12 having release means by, for example, pulling off the seam of the pressure-sensitive adhesive. Therefore, the package material between the sealing portion 24 and the second closing member 14 does not need to be folded and closed as a flap, and can simply remain unsealed in the package. Such a configuration may be advantageous in packages that require little difference between the first volume V1 and the second volume V2.

  FIG. 5 illustrates another embodiment of the package 10 of the present invention having an optional handle 26 on one side that can be integrally formed with the package. The package 10 is formed of a flexible packaging material such as polymer film or kraft paper so that various fold lines and pleats can be easily created during high speed production as is known in the art. .

  Known methods for packaging compressible products into flexible packages can be used to make the packages of the present invention. Such methods can include “online” continuous processes and “offline” batch processes. For example, the known “flow wrap” technique uses a continuous web of polymer film formed into a sleeve of continuous material along the X axis to form a compressible package, as shown in FIG. Can be adapted. The material can subsequently be formed at the two open ends, folded and / or pleated and heat sealed to form a closed monolithic package 10. Since the material is formable / deformable and flexible, the pleats may optionally be preformed or formed from a sheet of material during the product compression process.

  The product 100 in the package shown in FIG. 5 is a plurality of folded disposable diapers that are compressed, for example, in the direction indicated by the X axis during final assembly of the package. The packaging process, for example, in either a batch or continuous process, heat-seals a sleeve of material 30 that is continuous in the Z-Y axis (ie, the opposite edge of a material web, for example as known in the art) Forming a tube material, such as a flexible, formable cylindrical tube. The sleeve of material 30 can be cut to length to open two ends facing the X axis, one of the ends referred to herein as the first end (eg, FIG. 5). And the right hand end in FIG. 6) may have a second closure member applied thereto. Next, the first end is folded at a fold line 20 to form a flap 16. The first end is formed in a finished package by coupling the flap 16 to the package material 30 to form the first closure member 12 as described above with respect to FIGS.

  Product 100 can be placed in continuous sleeve 30 in any suitable manner according to the particular product being packaged. For example, in the case of the diapers shown in FIGS. 5 and 6, each diaper can be supplied in a predetermined number of folded and stacked diapers and introduced into the sleeve 30 in a manner known in the art. After the product 100 is installed in the sleeve 30, a compressive force can be applied in the X-axis direction, as indicated by the external force line F in FIG. The external force F can be applied by a plunger or other means known in the art while constraining the package. After fully compressing the product 100, the pleats 32 are formed by folding the sleeve material 30 inwardly at the open second end of the package under compression. In one suitable process, a separate end piece 34 of the packaging material 30 is compressed with the product 100. The pleat 32 is bent and sealed onto the end piece 34 by heat sealing or the like to form a closed integrated package 10. In some embodiments, for example, if the folded and fused pleats 32 are strong enough to hold the product 100 in a compressed state, the end piece 34 need not be included. There is. Either way, the open second end of the sleeve of material 30 is closed to fully accommodate the product 30 in a compressed state.

  In another process, the product 100 is first compressed, for example in an off-line process, introduced into the package material in a compressed state, and then closed in an integral package.

  Once sufficient formation and thermal fusion of the pleats 32 and / or end pieces 34 is complete, the external force F can be removed and sealed with a plurality of compressible products 100 sealed in the first volume V1. The finished integrated flexible package 10 is obtained.

  Various modifications of the described method can be employed without departing from the scope of the present invention. For example, product 100 can be placed into a continuous sleeve of material 30 before either the first or second end of package 10 is closed. Similarly, the second end can be closed first (without the first and second closure members 12, 14 associated therewith) and then the first end can be closed.

  While particular embodiments of the present invention have been shown and described, it would be obvious to those skilled in the art that various other combinations and modifications can be made without departing from the scope of the invention. Accordingly, all such combinations and modifications that are within the scope of this invention are intended to be included within the scope of the appended claims.

The perspective view of one Embodiment of the package of this invention. Sectional drawing before opening the 1st closing member of the package shown in FIG. FIG. 3 is a cross-sectional view of a package similar to that shown in FIG. 2 after opening the first closing member. The partial notch perspective view of one Embodiment of the package of this invention. FIG. 5 is a partially cutaway perspective view of the embodiment shown in FIG. 4 showing compressive force.

Claims (10)

  In an integrated flexible package (10) that encloses and encloses one or more compressible products (100) in both a compressed state and a compressed release state, the package defines a first volume. A first closure member (12) capable of sealing the package (10) in a first closed state and a second closure member (12) capable of sealing the package (10) in a second closed state defining a second volume. The integrated flexible package (10), wherein the second volume is greater than the first volume.   The flexible package (10) of claim 1, wherein the package (10) comprises a polymeric material, preferably low density polyethylene.   The flexible package (10) of claim 1, wherein the first closure member (12) comprises an adhesive.   The flexible package (10) of claim 3, wherein the adhesive is in the form of an adhesive tape (18).   The flexible package (10) of claim 4, wherein the adhesive tape (18) includes a line of weakness (21) for tearing and releasing the first closure member (12).   The flexible package (10) of claim 5, wherein the adhesive tape (18) comprises a release strip (22).   The flexible package (10) of claim 1, wherein the second closure member (14) is resealable and includes a hermetic sealing member.   The flexible package (10) of claim 1, wherein the first volume is between 10% and 90% of the second volume. In the manufacturing method of the flexible package (10) for accommodating the product (100) in a compressed state,
a. Providing a continuous sleeve of material (30) having an open first end and an open second end;
b. Coupling a second closure member (14) to the opened first end;
c. Folding the open first end at a fold line (20) to form a flap (16);
d. Coupling the flap (16) to a continuous sleeve of the material (30) to form a first closure member (12) at a closed first end;
e. Installing the product (100) in a continuous sleeve of the material;
f. Compressing the product (100);
g. Closing the second end of the sleeve of material (30) and receiving the product (100) in a compressed state, the method of manufacturing a flexible package (10).   The method of claim 9 wherein step (e) and step (f) are reversed.

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