US20090094944A1

US20090094944A1 - Product Package

Info

Publication number: US20090094944A1
Application number: US11/871,608
Authority: US
Inventors: Steven G. Friedrich
Original assignee: Monosol LLC
Current assignee: Monosol LLC
Priority date: 2007-10-12
Filing date: 2007-10-12
Publication date: 2009-04-16
Also published as: WO2009048876A1

Abstract

A product package formed from a vertical form, fill, seal process includes a single piece of film arranged and configured to define a container portion. The container includes a top seal portion, a bottom seal portion, and one side seal portion. Additionally, the container includes at least one folded side edge. The top and bottom seal portions include concave edges defining convex profiles of the container portion. The convex profiles of the container portion intersect the side seals to advantageously blunt corners of the product package to advantageously reduce localized stresses.

Description

FIELD OF THE INVENTION

The present invention generally relates to product packages and, more particularly, to product packages constructed from plastic film.

BACKGROUND

Various small, granulated, or fluidic products are often sold or distributed in individual plastic packages resembling pouches, for example. Some such packages include transparent film such that consumers may readily identify the contents. Others may include labeling or other indicia for identifying the contents. Such plastic packages are conventionally formed and filled in an automated process. One conventional automated process includes a vertical form, fill, and seal (VFFS) process.
FIG. 1 depicts a conventional package 10 produced from a conventional VFFS process. The package 10 is constructed from a single piece of transparent plastic film, for example, and includes a container portion 12, a top seal 14, a bottom seal 16, and a side seal 18. The container portion 12 includes first and second side edges 12 a, 12 b, a top edge 12 c, and a bottom edge 12 d. The first side edge 12 a results from a fold in the plastic film.
One conventional VFFS process for producing the package 10 depicted in FIG. 1, for example, includes an apparatus such as an assembly machine that wraps a single piece of the plastic film around a vertically oriented feed tube. The machine heat seals or otherwise secures the opposing edges of the film together to create the side seal 18 and form a hollow tube of film. Subsequently, the machine heat seals or otherwise creates the bottom seal 16, which is disposed transverse to the longitudinal direction of the tube of film, thereby defining the container portion 12 with an open top where the top seal 14 will later be formed. The open top end, at this point, is disposed adjacent to an outlet of the feed tube. Thereafter, the machine introduces a specified amount of flowable product into the container portion 12 via the feed tube. Once the container portion 12 includes the desired amount of product, the machine advances the film to another heat sealing device, for example, to create the top seal 14. Finally, the machine advances the film to a cutter that cuts the film immediately above the top seal 14 to provide the filled package 10.
As illustrated in FIG. 1, the conventional package is generally rectangular in shape. Specifically, the top and bottom seals 14, 16, as well as the top and bottom edges 12 c, 12 d of the container portion 12, are generally linear and disposed substantially perpendicular to the side seal 18. The side edges 12 a, 12 b of the container portion 12, however, are slightly curved, or concave. This curvature is due to the container portion 12 containing product, and therefore expanding in a direction perpendicular to the side edges 12 a, 12 b, which draws the side edges 12 a, 12 b inward.
The conventional package 10 may be offered for distribution as a single unit (as shown in FIG. 1), or with a plurality of other similar packages in a bag or a box. Still further, a plurality of packages 10 may be offered for sale in a blister pack, where each blister stores a single package 10 containing product. Blister-packs may be beneficial for storing the packages 10 when the packages are constructed of a water-soluble film, for example. When being offered for sale or distribution, space may be limited for the storage of the package 10. Therefore, the top and bottom seals 14 and 16 may be folded over such as depicted in FIG. 2. The folded-over configuration of the package 10 may be especially beneficial for storing the packages in blisters of a blister-pack, which may have size constraints.
Whether the top and/or bottom seals 14, 16 are folded over or not, the conventional package 10 includes pointed corners 20 where the first and second side edges 12 a, 12 b meet the top and bottom edges 12 c, 12 d. In the conventional package 10 depicted in FIGS. 1 and 2, the first and second side edges 12 a, 12 b intersect the top and bottom edges 12 c, 12 d at angles β that are equal to or less than approximately ninety-degrees (90°).
One shortcoming of this conventional package 10 includes the concentration of stresses at the pointed corners 20 due to pressures generated within the container portion 12 of the package 10, especially when the package 10 stores a fluid product. Another shortcoming of the conventional package 10 is that the pointed corners 20 disposed along the first side edge 12 a of the container portion 12 are constantly exposed in a manner that increases their susceptibility to scraping against surfaces such as storage bins, counter tops, pocket liners, etc. Such scraping may cause the pointed corners 20 to tear, thereby leaking the contents of the container portion 12.

SUMMARY

One embodiment of the present invention includes a product package constructed from a single sheet of film. The single sheet of film is arranged and configured to comprise a container portion. The container portion includes a side edge and opposing end edges. The end edges are disposed transverse to the side edge. At least one of the end edges of the container portion comprises a convex profile.
Another embodiment of the present invention includes a method of forming a package from a single sheet of film. The method comprises wrapping the single sheet of film about a longitudinal axis of the film. Then, opposing sidewalls of the wrapped film are sealed together along a first path that is transverse to the longitudinal axis to form a first end seal portion. The first end seal portion comprises an edge having a concave profile. Then, the opposing sidewalls of the wrapped film are scaled together along a second path that is transverse to the longitudinal axis of the film to form a second end seal portion. The second end seal portion is longitudinally spaced from the first end seal portion. The first and second end seal portions at least partly define a container portion that is adapted to contain a substance.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a conventional package constructed by a conventional vertical form, fill, seal process;

FIG. 2 is a front view of the conventional package of FIG. 1 configured with its top and bottom seals folded;

FIG. 3 is a front view of a first embodiment of a package constructed in accordance with the principles of the present invention;

FIG. 4 is a front view of the package of FIG. 3 configured with its top and bottom seals folded;

FIG. 5 is a front view of an alternative embodiment of a package constructed in accordance with the principles of the present invention;

FIG. 6 is a perspective schematic view of one embodiment of a vertical form, fill, seal machine for producing the package of FIGS. 3 and 4 in accordance with the principles of the present invention;

FIG. 7 is a partial schematic view of one embodiment of a vertical form, fill, seal machine for producing the package of FIG. 5 in accordance with the principles of the present invention, and taken from circle VII from FIG. 6;

FIG. 8 is a front view of another alternative embodiment of a package constructed in accordance with the principles of the present invention; and

FIG. 9 is a front view of yet another alternative embodiment of a package constructed in accordance with the principles of the present invention.

DETAILED DESCRIPTION

FIG. 3 depicts one embodiment of a product package 100 constructed in accordance with the principles of the present invention. The package 100 is constructed from a single piece of transparent plastic film such as a non-water-soluble film, a water-soluble film, or an edible water-soluble film, for example. In general, the single piece of film includes opposing film portions 102 a, 102 b folded to define a first side edge 110 a of the package 100. The package 100 includes a container portion 102, a top seal portion 104, a bottom seal portion 106, and a side seal portion 108. The container portion 102 defines an internal cavity, or containment cavity defined between the opposing folded over film portions 102 a, 102 b. The container portion 102 is therefore adapted to accommodate a substance (not shown) such as fluid, granulated matters candy, etc. For the sake of description, the container portion 102 includes the first side edge 110 a, a second side edge 110 b, a top edge 110 c, and a bottom edge 110 d. As mentioned, the first side edge 110 a includes a folded edge of the plastic film and, in one embodiment, can be creased. The second side edge 110 b abuts the side seal portion 108. In the disclosed embodiment, the top edge 110 c includes a convex profile and abuts the top seal portion 104. Similarly, the bottom edge 110 d of the disclosed embodiment includes a convex profile and abuts the bottom seal portion 106. The top and bottom edges 110 c, 110 d intersect the first and second side edges 110 a, 110 b at corners 112 having angles α that are greater than ninety-degrees (90°) due to the convex curvature of the top and bottom edges 110 c, 110 d. In the disclosed embodiment, the top and bottom edges 110 c, 110 d may intersect the side edges 110 a, 111 b at angles α of approximately one-hundred and thirty-five degrees (135°), for example. Accordingly, the corners 112 also include angular dimensions a of approximately one hundred and thirty-five degrees (135°). However, in alternative embodiments, the top and bottom edges 110 c, 110 d may intersect the side edges 110 a, 110 b at generally any angle α greater than ninety-degrees (90°) depending on the radius of convex curvature, or other configuration, of the top and bottom edges 110 c, 110 d.
As mentioned, the package 100 further includes the top seal portion 104, the bottom seal portion 106, and the side seal portion 108. In the disclosed embodiment, the top, bottom, and side seal portions 104, 106, 108 include portions of the folded, opposing film portions 102 a, 102 b adhered together by heat sealing, for example, or some other fashion.
For the purposes of description, the top seal portion 104 includes a mating edge 104 a and a free edge 104 b. The mating edge 104 a is located proximal to the container portion 102. The free edge 104 b is spaced from the mating edge 104 a and located distal to the container portion 102. The mating edge 104 a includes a concave profile abutting the convex top edge 110 c of the container portion 102. The free edge 104 b includes a linear profile and is disposed substantially perpendicular to the side edges 110 a, 110 b of the container portion 102.
Similarly, the bottom seal portion 106 includes a mating edge 106 a and a free edge 106 b. The mating edge 106 a is located proximal to the container portion 102. The free edge 106 b is spaced from the mating edge 106 a and located distal to the container portion 102. The mating edge 106 a includes a concave profile abutting the convex bottom edge 110 d of the container portion 102. The free edge 106 b includes a linear profile and is disposed substantially perpendicular to the side edge 110 b of the container portion 102.
Finally, the side seal portion 108 also includes a mating edge 108 a and a free edge 108 b. The mating edge 108 a is located proximal to the container portion 102. The free edge 108 b is located distal to the container portion 102. The mating edge 108 a includes a linear profile defined by the second side edge 110 b of the container portion 102. The free edge 108 b includes a linear profile spaced from the mating edge 108 a and disposed substantially parallel to the second side edge 110 b of the container portion 102.
Thus, the container portion 102 of the package 100 depicted in FIG. 3 includes a generally rectangular profile having convex-shaped top and bottom edges 110 c, 110 d. Similarly, the entire package 100 includes a generally rectangular profile. The rectangular profile of the package 100 is defined by the free edges 104 b, 106 b, 108 b of the seal portions 104, 106, 108 and the first side edge 110 a of the container portion 102.
Although depicted and described as generally linear, the first and second side edges 110 a, 110 b of the container portion 102 may alternatively include slightly curved concave profiles. Such curvature may be the result of the container portion 102 containing a substance or other product. Specifically, the substance may expand the container portion 102 in a direction perpendicular to the side edges 110 a, 110 b, thereby drawing the side edges 110 a, 110 b inward.
Similar to the conventional package 10 discussed above with reference to FIGS. 1 and 2, the package 100 may be distributed as a single unit (as shown in FIG. 3), or with a plurality of other similar packages in a bag or a box, for example. Still further, a plurality of packages 100 may be distributed or offered for sale in a blister-pack, wherein each blister stores a single package 100 containing product. Blister-packs may be beneficial for storing the packages 100 when the packages are constructed of a water-soluble film or an edible water-soluble film. Additionally, when offered for sale or distribution, space may be limited for the storage of the package 100. Therefore, the top and bottom seal portions 104 and 106 may be folded over such as depicted in FIG. 4. The folded-over configuration of the package 100 may be especially beneficial for storing the packages in blisters of a blister-pack, which may have size constraints or contoured sidewalls. Additionally, the folded over configuration can protect the corners 112 of the package 100, as described below.
FIG. 5 depicts an alternative embodiment of a product package 200 constructed in accordance with the principles of the present invention. The product package 200 is generally similar to the package 100 depicted in FIGS. 3 and 4.
Specifically, the package 200 includes a container portion 202, a top seal portion 204, a bottom seal portion 206, and a side seal portion 208. Identical to the container portion 102 of the package 100 described above with reference to FIGS. 3 and 4, the container portion 202 of the package 200 in FIG. 5 includes generally linear first and second side edges 210 a, 210 b and convex top and bottom edges 210 c, 210 d. Therefore, the convex top and bottom edges 210 c, 210 d intersect the side edges 210 a, 210 b at angles α that are greater than ninety-degrees (90). At least in one embodiment, the convex top and bottom edges 210 c, 210 d may intersect the side edges 210 a, 210 b at angles α of approximately one-hundred and thirty-five degrees (135°). Accordingly, the container portion 202 also includes corners 212 having angular dimensions a of approximately one-hundred and thirty-five degrees (135°).
Moreover, the top and bottom seal portions 204, 206 include respective mating edges 204 a, 206 a and free edges 204 b, 206 b. Identical to the package 100 discussed above with reference to FIGS. 3 and 4, the mating edges 204 a, 206 a of the package 200 depicted in FIG. 5 include concave profiles defined by the convex top and bottom edges 210 c, 210 d of the container portion 202. In contrast to the previous embodiment of the package 100, however, the free edges 204 b, 206 b of the top and bottom seal portions 204, 206 of the package 200 depicted in FIG. 5 also include convex profiles. In the embodiment disclosed in FIG. 5, the convex free edges 204 b, 206 b of the top and bottom seal portions 204, 206 are disposed concentric with the convex top and bottom edges 210 c, 210 d of the container portion 202, respectively. In alternative embodiments, however, the convex free edges 204 b, 206 b of the top and bottom seal portions 204, 206 may not be disposed concentric with the convex top and bottom edges 210 c, 210 d of the container portion 202. Furthermore, this alternative embodiment of the package 200 may be distributed to consumers, for example, as a single unit (as shown in FIG. 5), as a plurality of units in a bag or a box, or in blister-packs. Thus, as discussed above, it may be beneficial to fold the top and bottom seal portions 204, 206 to conserve space in a manner similar to that disclosed with reference to the package 100 depicted in FIG. 4.
As mentioned above, the various embodiments of the packages 100, 200 of the present invention may be constructed with a single piece of transparent film such as a non-water-soluble film, a water-soluble film, or an edible water-soluble film, for example. The packages 100, 200 may also be constructed of other films and materials, whether transparent, or not. Construction of the packages 100, 200 may be achieved through various methods. One method that may be utilized to construct the packages 100, 200 includes a vertical form, fill, seal (VFFS) process.
FIG. 6 schematically illustrates a portion of a VFFS machine 300 for performing a process and constructing a plurality of packages 100 in accordance with the present invention. The machine 300 depicted in FIG. 6 is specifically designed to form a plurality of the packages 100 depicted in FIGS. 3 and 4. The machine 300, however, may be adapted to form a plurality of the packages 200 depicted in FIG. 5, as will be described below.
FIG. 6 illustrates the machine 300 as generally including a feed tube 302, a longitudinal sealer 304, a transverse sealer 306, and a cutter 308. In the disclosed embodiment, the longitudinal sealer is disposed adjacent the feed tube 302; the transverse sealer 306 is disposed downstream from the longitudinal sealer 304; and the cutter 308 is disposed downstream from the transverse sealer 306. The machine 300 is adapted to form a plurality of packages 100 from a single piece of film 310, which may be supplied from a single roll of film (not shown). The film 310 preferably comprises an elongated film having a longitudinal axis. The feed tube 302 includes an elongated hollow cylindrical tube oriented generally vertically. The feed tube 302 includes a top end 302 a and a bottom end 302 b. The top end 302 a is in communication with a product source (not shown) such as a hopper containing a substance or product to be delivered to the package 100 and combined therein. The bottom end 302 b is disposed within the package 100 during an intermediate forming stage, as will be described. The longitudinal and transverse sealers 304, 306 each include, at least in one embodiment, a heat sealer. The longitudinal sealer 304 includes a pair of identical rectangular sealing irons 304 a for being compressed together, only one of which is illustrated in FIG. 6. The longitudinal sealer 304 is thus arranged to create the side seal portion 108 on the packages 100. The transverse sealer 306 also includes a pair of identical sealing irons 306 a for being compressed together, only one of which is illustrated in FIG. 6. The sealing irons 306 a of the transverse sealer 306 include opposing top and bottom concave edges 307 a, 307 b for forming a combination seal 107, as will be described. The cutter 308 includes a pair of cutting members 308 a, only one of which is depicted in FIG. 6. At least one of the cutting members 308 a includes a linear cutting blade 308 b, which is shown in phantom, for cutting the film 310. In alternative embodiments, however, the cutter 308 can include a hot wire, or some other device capable of cutting the film 310 as desired.
During operation, the machine 300 initially advances the film 310 from the roll and wraps, or otherwise folds, the film 310 about its longitudinal axis and around the vertically oriented feed tube 302. As the film 310 advances downward, opposing longitudinal side edges 310 a, 310 b of the film 310 move between the pair of sealing irons 304 a of the longitudinal sealer 304. The machine 300 moves the sealing irons 304 a together to seal the side edges 310 a, 310 b of the film 310 together to form the side seal portion 108 of the package 100. At this point, the side seal portion 108 of the package 108 extends outward from the remainder of the film 310, as illustrated in FIG. 6. As mentioned, in one embodiment, the longitudinal sealer 304 includes a heat sealer such that the sealing irons 304 a of the longitudinal sealer 304 simultaneously apply a compressive force and heat energy to the side edges 310 a, 310 b to form the side seal portion 108. At this stage of the forming process, the film 310 takes the shape of a hollow tube disposed about the bottom end 302 b of the feed tube 302.
Subsequently, the machine 300 advances the hollow tube of film 310 between the sealing irons 306 a of the transverse sealer 306. The sealing irons 306 a of the transverse sealer 306 compress the tube of film 310 and seal opposing sidewalls together to form the combination seal 107. As mentioned, in one embodiment, the transverse sealer 306 includes a heat sealer such that the sealing irons 306 a of the transverse sealer 306 simultaneously apply a compressive force and heat energy to the sidewalls of the tube of film 310 to form the combination seal 107. As illustrated in FIG. 6, the combination seal 107 includes the top seal portion 104 of a completely formed, filled, and sealed package 100 a and the bottom seal portion 106 of a partially formed intermediate package 100 b.
Accordingly, the intermediate package 100 b includes the side seal portion 108, the bottom seal portion 106, and the folded side edge 110 a. The intermediate package 100 b thus defines an open container in communication with the bottom end 302 b of the feed tube 302. The machine 300 then delivers a desired amount of product to the intermediate package 100 b. Delivering the product can comprise filling the intermediate package 100 b with a flowable substance such as a granulated substance, a fluid, etc. Once the product has been delivered, the machine 300 advances the film 310 such that the combined seal 107 is disposed between the cutting members 308 a of the cutter 308. So disposed, the machine 300 moves at least one of the cutting members 308 a toward the other such that the linear cutting blade 308 b cuts the film 310 at the combination seal 107, as depicted in FIG. 6, thereby detaching a completely formed, filled, and sealed package 100 c from the remainder of the film 310.
Based on the foregoing, the geometrical configuration of the sealing irons 306 a of the transverse sealer 306 define the profiles of the top and bottom edges 110 c, 110 d of the container portion 102 of the package 100. Moreover, the geometrical configuration of the cutter blade 308 b of the cutter 308 defines the profiles of the free edges 104 b, 106 b of the top and bottom seals 104, 106 of the package 100. Thus, to form the alternative package 200 depicted in FIG. 5, the machine 300 may have to be modified.
For example, the cutter 308 would require one or more cutting blades or one or more hot wires having a curved configuration, as depicted in FIG. 7. Specifically, FIG. 7 depicts an alternative cutter 408 for use with the machine 300 for forming packages 200 in accordance with the embodiment of depicted in FIG. 5. Similar to the cutter 308 described above with reference to FIG. 6, the cutter 408 includes a pair of cutting members 408 a, only one of which is depicted. At least one of the cutting members 408 a includes a pair of curved cutting blades 410, 412, which are depicted in phantom in FIG. 7. Specifically, the cutting blades 410, 412 are curved away from each other along radiuses that are similar or identical to the radiuses of the respective free edges 204 b, 206 b of the top and bottom seals 204, 206 of the package 200, as well as the top and bottom concave edges 307 a, 307 b of the sealing irons 306 a of the transverse sealer 306 depicted in FIG. 6. So configured, at least one of the cutting members 408 a is movable toward the film 310 as it passes therebetween to cut the film 310 and detach a completely formed, filled, and sealed package 200. Thus, the machine 300 and process performed, at least partly by the machine 300, may be adapted and customized to provide packages of various configuration and designs.
While the product packages 100, 200 of the present invention have thus far been described as including side seal portions 108, 208 that are located adjacent to the second side edges 110 b, 210 b of the respective packages 100, 200, alternative embodiments can include side seal portions located elsewhere. For example, FIGS. 8 and 9 depict alternative packages 400, 500 that include side seal portions 415, 515 that are located along a mid-portion of respective container portions 402, 502 of the packages 400, 500. In one embodiment, the side seal portions 415, 515 can include lap seals, as will be described.
More specifically, FIG. 8 depicts one alternative package 400 that comprises a single sheet of film 401 having opposing film portions 402 a, 402 b folded along a first side edge 410 a and a second side edge 410 b to define the container portion 402. The container portion 402 also includes a top edge 410 c and a bottom edge 410 d. In addition to the side seal portion 415, the package 400 includes a top seal portion 404 and a bottom seal portion 406. The side seal portion 415 extends from a mid-point A of the top seal portion 404 to a mid-point B of the bottom seal portion 406.
The top seal portion 404 includes a mating edge 404 a and a free edge 404 b, and the bottom seal portion 406 includes a mating edge 406 a and a free edge 406 b. In the embodiment depicted in FIG. 8, the top and bottom seal portions 404, 406 are generally identical to the top and bottom seal portions 104, 106 of the package 100 described above with reference to FIGS. 3 and 4. That is, the mating edges 404 a, 406 a of the top and bottom seal portions 404, 406 include smooth, curved, concave profiles that mate with smooth, curved, convex profiles of the respective top and bottom edges 410 c, 410 d of the container portion 402. Thus, the mating edges 404 a, 406 a intersect with the first and second side edges 410 a, 410 b at corners 412 disposed at angles α that are greater than ninety degrees (90°) and, in one embodiment, approximately one-hundred and thirty-five degrees (135°). Moreover, the free edges 404 b, 406 b of the top and bottom seal portions 404, 406 include linear profiles. Thus, other than the location and construction, which will be described below, of the side seal portion 415, the package 400 depicted in FIG. 8 is generally similar to the package 100 depicted in FIGS. 3 and 4.
As mentioned, the embodiment of the side seal portion 415 depicted in FIG. 8 includes a lap seal, and thus, its construction is different from the side seal portions 108, 208 of the packages 100, 200 described above. For example, as mentioned, the package 400 comprises a single sheet of film 401. The sheet of film 401 includes opposing first and second longitudinal side edges 401 a, 401 b, which combine to form the side seal portion 415. More specifically, the first longitudinal side edge 401 a of the film 401 overlaps the second longitudinal side edge 401 b of the film 401. The overlapping portions of the first and second longitudinal side edges 401 a, 401 b are sealed together with heat sealing, ultrasonic sealing, vibrational sealing, or otherwise, as described herein. Thus, the side seal portion 415 constitutes a lap seal that is disposed within generally the same plane as one of the opposing film portions 402 a, 402 b of the completed container portion 402 of the package 400. In the embodiment depicted in FIG. 8, the side seal portion 415 is disposed in a plane in common with the forward-most film portion 402 a.
The manufacturing process for forming the package 400 is slightly different from the manufacturing process described above for the packages 100, 200. Specifically, the package 400 can be constructed utilizing a vertical form, fill, seal process similar to that which is performed by the VFFS machine 300 described above with reference to FIG. 6, however, the structure and function of various components would slightly be changed. As described above, the longitudinal scaler 304 of FIG. 6 comprises a pair of sealing irons 304 a that compress opposing longitudinal side edges 310 a, 310 b of the film 310 together to form a side seal portion 108 that extends outward from the remainder of the film 310 as it travels along the vertical feed tube 302. The side seal portion 415 of the package 400 depicted in FIG. 8, however, must be formed to be in the same plane as the remainder of the film 401. That is, as the film 401 is wrapped around the feed tube 302 depicted in FIG. 6, the longitudinal side edges 401 a, 401 b of the film 401 are overlapped, such that the film 410 forms a complete cylinder, without any appendages. Thereafter, the longitudinal sealer 304 would compress, or otherwise, seal the longitudinal edges 401 a, 401 b together. In one embodiment, the longitudinal sealer 304 can comprise a single scaling iron 304 a adapted to compress the overlapping longitudinal side edges 401 a, 401 b of the film 401 together against the feed tube 302. Thereafter, the film 401 continues through the machine 300 to the transverse sealer 306 and cutter 308. However, because the side seal portion 415 of the completed package 400 depicted in FIG. 8 extends from the mid-point A of the top seal 404 to the mid-point B of the bottom seal 406, the transverse sealer 306 and cutter 308 would be positioned ninety-degrees (90°) offset from the position depicted in FIG. 6, relative to the longitudinal sealer 304. Nevertheless, the manufacturing process proceeds in a manner generally similar to that described above to form the top and bottom seal portions 404, 406, and subsequently cut a completed package 400 from the remainder of the film 401. One advantage of utilizing the lap seal 415 extending through a mid-portion of the container portion 402 of the package 400 is that it can decrease the exposure of the corner 412 to foreign surfaces that may cause tearing.
While the top and bottom edges 110 c, 210, 410 c and 110 d, 210 d, 410 d of the container portions 102, 202, 400 of the packages 100, 200, 400 and the top and bottom seal portions 104, 204, 404 and 106, 206, 406 of the packages 100, 200, 400 have been depicted and described herein as including smoothly curved concave or convex profiles, alternative embodiments of the packages may not include such simple concave or convex profiles. For example, in alternative embodiments, the concave or convex profiles may be constructed of two or more linear sections arranged end-to-end, for example, to generally define a curved, concave, or convex profile in accordance with the principles of the present invention. FIG. 9 depicts one such alternative embodiment that includes a product package 500 having a container portion 502 with convex top and bottom edges 510 c, 510 constructed of a plurality of linear sections. Accordingly, the package 500 also includes top and bottom seal portions 504, 506 having concave mating edges 504 a, 506 a constructed of complementary linear sections. Otherwise, the package 500 depicted in FIG. 9 is identical to the package 400 depicted in FIG. 8.
Thus, it should be appreciated that the terms concave and convex, as used herein, are not intended to be limited to simple, smooth curves, but rather, may include variations thereon including, but not limited to, a plurality of linear sections combined to generally represent a convex or concave profile. In one alternative embodiment, the profiles may not include curves at all, but may merely include two linear sections generally defining a V-shaped profile, for example. In another alternative embodiment, the convex profiles of the top and bottom edges 110 c, 210 c, 410, 510 c and 110 d, 210, 410 d, 510 d of the container portions 102, 202, 402, 502 of the packages 100, 200, 400, 500 may comprise a plurality of convex segments arranged to define the overall convex profile. For example, in such a configuration the convex segments may have a radius of curvature that is smaller than or greater than a radius of curvature of the overall top and bottom edges 110 c, 210 c, 410 c, 510 c and 110 d, 210 d, 410 d, 510 d.
Furthermore, while the corners 112, 212, 412, 512 of the container portions 102, 202, 402, 502 of the packages 100, 200, 400, 500 of the present invention have thus far been disclosed as being approximately one-hundred and thirty-five degrees (135°), alternative embodiments may include corners 112, 212, 412, 512 of generally any angle and, preferably any angle greater than ninety-degrees (90°). For example, the corners 112, 212, 412, 512 can be any angle in the range of approximately ninety-five degrees (95°) to approximately one-hundred and seventy-five degrees (175°).
Further still, while the longitudinal sealer 304 and the transverse sealer 306 have been disclosed herein as comprising sealing irons 304 a, 306 a that operate as heat sealers, for example, alternative embodiments of the sealers 304, 306 may include sealing irons 304 a, 306 a that operate as vibrational and/or ultrasonic sealers. In yet other alternative embodiments, the sealing irons 304 a, 306 a may not provide any energy other than compressive forces, for example, and the side seal portions 108, 415, 515 and combination seals 107 may be created with a water seal, or some other adhesive. Thus, the sealing irons 304 a, 306 a of the present disclosure are not intended to be limited to heat sealing irons, but rather, any type of sealing iron capable of at least assisting in the creation of the seals.
In light of the foregoing, one advantage of the curved top and bottom edges 110 c, 210, 410 c, 510 c and 110 d, 210 d, 410 d, 510 d of the container portions 102, 202, 402, 502 of the packages 100, 200, 400, 500 of the present invention includes the resultant obtuse configuration of the corners 112, 212, 412, 512 of the container portions 102, 202, 402, 502. Specifically, the obtuse angles of intersection between the top and bottom edges 110 c, 210, 410 c, 510 e and 110 d, 210 d, 410 d, 510 d of the container portions 102, 202, 402, 502 and the side edges 110 a, 210 a, 410 a, 510 a, and 110 b, 210 b, 410 b, 510 b of the container portions 102, 202, 402, 502 decreases the stresses otherwise present at the acute corners 20 of the container portion 12 of the conventional package 10 depicted in FIGS. 1 and 2. This reduction in stress thereby reduces the tendency for the container portions 102, 202, 402, 503 of the packages 100, 200, 400, 500 of the present invention to fail.
Another advantage of the curved top and bottom edges 110 c, 210, 410 c, 510 c and 110 d, 210 d, 410 d, 510 d of the packages 100, 200, 400, 500 of the present invention includes the ability of the packages 100, 200, 400, 500 to more closely conform to secondary packaging constraints. For example, as mentioned, the primary packages 100, 200, 400, 500 disclosed herein may be offered for distribution or sale in blister-packs. Blister-packs typically include a plurality of blisters having rounded sidewalls. The curved nature of the top and bottom edges 110 c, 210, 410 c, 510 c and 110 d, 210 d, 410 d, 510 d of the container portions 102, 202, 402, 502 of the packages 100, 200, 400, 500 of the present invention may therefore more closely conform to rounded sidewalls, thereby reducing wasted space in the blister and enabling more product to be stored and delivered.
A still further advantage of the packages 100, 200, 400, 500 of the present invention includes increased aesthetic appeal and unique packaging, which allows consumers to readily identify the contents and/or the source of the product.
Yet another advantage of the packages 100, 200, 400, 500 of the present invention includes the fact that the corners 112, 212, 412, 512 include angular dimensions a that are greater than ninety degrees such that the corners 112, 212, 412, 512 are more blunt than the corners 20 of the conventional package 10 depicted in FIGS. 1 and 2. The corners 112, 212, 412, 512 of the packages 100, 200 of the present invention therefore do not protrude from the packages 100, 200, 400, 500 as abruptly as the corners 20 of the conventional package 10, thereby reducing the degree to which the corners 112, 212, 412, 512 frictionally engage surfaces such as container walls, for example, which tends to cause tearing and failure of the conventional packages 10.
It should be appreciated that the foregoing description merely provides examples and embodiments of the present invention and the present invention is not intended to be limited thereby. Rather, the present invention is defined by the following claims and intended to include subject matter falling within the scope and spirit thereof.

Claims

1. A product package, comprising:

a single sheet of film, the single sheet of film arranged and configured to comprise:

a container portion including a side edge, and opposing end edges disposed transverse to the side edge, at least one of the opposing end edges comprising a convex profile.

2. The product package of claim 1, wherein the convex end edge comprising the convex profile intersects the side edge at an angle that is greater than ninety degrees.

3. The product package of claim 1, wherein the single sheet of film further comprises opposing end seal portions disposed adjacent to the opposing end edges of the container portion.

4. The product package of claim 3, wherein at least one of the opposing end seal portions comprises a concave edge mating with the end edge of the container portion comprising a convex profile.

5. The product package of claim 3, wherein each of the opposing end edges of the container portion comprises a convex profile.

6. The product package of claim 5, wherein each of the opposing end seal portions comprises a concave edge abutting corresponding opposing convex end edges of the container portion.

7. The product package of claim 6, wherein each of the opposing end seal portions further comprises a linear edge spaced from the concave edge.

8. The product package of claim 6, wherein each of the opposing end seal portions further comprises a convex edge spaced from the concave edge.

9. The product package of claim 1, wherein the single sheet of film comprises a water-soluble film.

10. A product, comprising:

a single sheet of film arranged and configured to comprise:

a container portion for accommodating a substance, the container portion comprising first and second end edges, and first and second side edges, each of the first and second end edges comprising a convex profile,

first and second end seal portions, the first end seal portion comprising a concave edge abutting the first end edge of the container portion, the second end seal portion comprising a concave edge abutting the second end edge of the container portion, and

at least one of the first and second side edges of the container portion comprising a folded edge.

11. The product of claim 10, wherein the first and second end edges of the container portion intersect at least one of the first and second side edges of the container portion at an angle greater than ninety degrees.

12. The product of claim 10, wherein each of the first and second end seal portions further comprise a linear edge spaced from the concave edge.

13. The product of claim 10, wherein each of the first and second end seal portions further comprise a convex edge spaced from the concave edge.

14. The product of claim 10, wherein the single sheet of film comprises a water-soluble film.

15. A method of forming a package, comprising:

wrapping a single sheet of film about a longitudinal axis of the film;

sealing opposing sidewalls of the wrapped film together along a first path that is transverse to the longitudinal axis of the film to form a first end seal portion, the first end seal portion comprising a concave edge; and

sealing opposing sidewalls of the wrapped film together along a second path that is transverse to the longitudinal axis of the film to form a second end seal portion, the second end seal portion longitudinally spaced from the first end seal portion, thereby defining a container portion disposed between the first and second end seal portions, the container portion adapted to contain a substance.

16. The method of claim 15, wherein wrapping the single sheet of film comprises at least partly wrapping the single sheet of film around a vertical feed tube.

17. The method of claim 16, further comprising sealing opposing longitudinal edges of the wrapped film together to form a tube of film prior to forming the first and second end seal portions.

18. The method of claim 17, further comprising filling the container portion with a flowable substance prior to forming the second end seal portion.

19. The method of claim 15, wherein the second end seal portion comprises a concave edge.

20. The method of claim 15, further comprising cutting the film adjacent to the second end seal portion to define a linear edge of the package.

21. The method of claim 15, further comprising cutting the film adjacent to the second end seal portion to define a convex edge of the package.

22. A product package constructed in accordance with the method of claim 15.

23. An apparatus for manufacturing a product package from a single sheet of film, the product package comprising a container portion with at least one end edge having a convex profile, the apparatus comprising:

a sealing iron having a first concave edge, the sealing iron adapted to engage the sheet of film such that the first concave edge forms the end edge of the container portion having the convex profile; and

a cutter located downstream of the sealing iron for cutting the sheet of film adjacent to the end edge of the container portion having the convex profile.

24. The apparatus of claim 23, wherein the cutter comprises a curved cutter to define an edge of the product package having a convex profile.

25. The apparatus of claim 24, wherein the curved cutter comprises a radius equal to a radius of the first concave edge of the sealing iron.