CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application Serial No. 61/456785 filed November 12, 2010, the disclosure of which is incorporated herein by this reference.

BACKGROUND OF THE INVENTION

Field of the Invention

[0002] The present invention relates generally to packages particularly to packages having an aesthetic design and methods for producing such packages.

Description of Related Art

[0003] Many products today, including human and animal food products, are sold in packaging that is a flexible pouch or flexible container. Such packaging is frequently made by providing one or more pieces of an appropriate thermoset packaging material, such as a polyester film material, and using that thermoset packaging material to form a pouch-like shape by welding overlapping portions of the material. Such welds are often created by placing overlapped thermoset packaging material between a pair of heated plates, commonly called dies, jaws, or forming plates. Once the thermoset packaging material has been properly positioned, the plates are brought together such that they apply heat and pressure to the overlapped material. After an appropriate dwell time, the pressure is released and the thermoset packaging material is removed from the forming plates. This process partially melts the overlapped thermoset packaging material, causing the overlapped portions of material to adhere to one another, thereby forming a weld.

[0004] The forming plates used to produce this type of weld are typically designed so that the face of each member of the pair of plates is either flat or possesses longitudinal lines or grooves along the plate face, with the two plates being three-dimensional mirror images of one another so that, for example, the ridges of one plate fit within corresponding grooves of the other (see, e.g., PCT Published Application No. WO03/064260). The heated plates are also typically attached to a thermoforming device. Such devices are well known in the art and are readily available from a number of manufacturers.

[0005] In some cases, such as in a direct heat-sealing machine, the thermoforming device simply comprises forming plates attached to a means for delivering heat and pressure to those plates. In other cases, the thermoforming device comprises an apparatus that is able to automatically form the package, fill it with the desired material, and seal the package edges. Two common types of such thermoforming devices are the vertical and horizontal form-fill-seal (VFFS and HFFS) packaging machines. Such machines take a piece of thermoset packaging material and automatically 1) form it into an appropriate shape for a package, 2) fill the package with the desired material, and 3) weld the package edges together.

[0006] Though the welds created by such methods and devices are generally sufficiently strong and durable, they are not aesthetically pleasing or eye-catching. There is, therefore, a need for improved packages containing an aesthetic design in the package weld, as well as improved methods and apparatus for producing such packages.

SUMMARY OF THE INVENTION

[0007] It is, therefore, an object of the invention to provide methods for producing novel packaging, such as packages comprising an aesthetic design in the package weld.

[0008] It is another object of the invention to provide forming plates for producing packages in which an aesthetic design is present in at least a portion of a weld on the package.

[0009] It is another object of the invention to provide packages comprising an aesthetic design in the package weld.

[0010] One or more of these or other objects are achieved using novel methods and devices for producing packages having one or more aesthetic designs disposed on or along at least a portion of a weld in the package. The packages are formed through the use of forming plates in which the aesthetic designs are incorporated, such that formation of a weld using the forming plates results in the aesthetic design being embossed upon at least a portion of the weld. Thus, the invention encompasses methods, forming plates and packages produced by those methods, as well as other devices useful for automated and production- line forming of novel packages comprising the aesthetic designs, as well as multi-packs and displays for the novel packages.

[0011] Other and further objects, features, and advantages of the invention will be readily apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE FIGURES

[0012] FIG. 1 illustrates packages comprising an aesthetic design in the package weld. FIG. 1A is a top view of a package comprising a zig-zag shaped aesthetic design in the package weld along the edges of the package; FIG. IB is a top view of a package comprising a dog bone shaped aesthetic design in the package weld along the edges of the package.

[0013] FIG. 2 illustrates forming plates useful for producing welds comprising a zig-zag shaped aesthetic design. FIG. 2A illustrates an exploded view of an apparatus comprising a pair of forming plates. FIG. 2B illustrates a perspective side view of the same apparatus in its assembled and closed state. FIG. 2C illustrates a perspective front view of the same apparatus in its assembled and closed state.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

[0014] The terms "weldable packaging material" or "weldable material" refer to material that is amenable to being welded. Welding is understood in the art as a process for joining materials, usually metals or thermoplastics, by partial melting of the materials, which, upon cooling joins the materials together. Welding is accomplished through the application of heat or pressure, or both.

[0015] The terms "thermoset material," "thermoplastic material", "thermoset packaging," and "thermoset packaging material" are used interchangeably and refer to a piece of material that can be attached to a portion of the same piece or another piece of material through the application of appropriate heat and pressure to overlapped portions. In certain embodiments, such attachment is accomplished using a thermoforming device comprising forming plates. In other embodiments, the thermoforming device is contained within or is part of a vertical or horizontal form-fill-seal ( FS or HFFS) machine.

[0016] As used herein with reference to thermoset or thermoplastic materials, the term "weld" means an attachment between two overlapped portions of the packaging material, the attachment resulting from the application of sufficient heat and pressure to the overlapped thermoset packaging material to cause the portions to partially melt and thus adhere to one another. A weld can either form a complete seal along the welded portion or can contain gaps within the weld such that a seal is not created. In certain embodiments, a thermoforming device comprising one or more heated forming plates produces the weld. In other embodiments, the thermoforming device is contained within or is part of a VFFS or HFFS machine.

[0017] The term "aesthetic design" means a design that has been selected because of its artistic or decorative appearance, attractiveness, beauty, eye-catching quality, or the like. Aesthetic designs useful in the present invention include any desired design that lends itself to inclusion on a forming plate. Such designs include, but are not limited to, a zig-zag pattern; a repeating shape pattern, such as a repeating circle or oval pattern; a partem incorporating a corporate symbol, product symbol, trademark, or the like; an animal shape pattern, such as a paw-print, cat face shape, or animal silhouette; a bone shape pattern; or a feeding bowl pattern.

The Invention

[0018] In one aspect, the invention provides methods for producing packages comprising one or more aesthetic designs in the package weld. The methods comprise providing a weldable material, such as a thermoset packaging material, and welding that material to form a package in which the aesthetic design is embossed on at least a portion of the weld. In certain other embodiments, the welding is accomplished by a thermoforming device comprising forming plates, the forming plates comprising the aesthetic design incorporated into the contact faces of the plates. The thermoforming device can be a form- fill device that forms the package and fills it with a product in an automated fashion. Such devices can be incorporated into production lines, in some embodiments.

[0019] In another aspect, the invention provides packages produced according to the methods of the invention.

[0020] In another aspect, the invention provides forming plates useful for producing welds comprising an aesthetic design. The forming plates comprise the aesthetic design incorporated into the contact faces of the plates. In certain embodiments, the forming plates are within or are part of a thermoforming device. In other embodiments, the thermoforming device comprises a form-fill device such as a VFFS or HFFS. The thermoforming device can be incorporated into a production line.

[0021] In yet another aspect, the invention provides packages. The packages comprise an aesthetic design embossed in at least a portion of the package weld. In certain embodiments, a product is contained within the package. Useful products include both comestible compositions, such as human or pet foods or pet treats, and non-comestible compositions, such as cleaning products, detergents, litters, fertilizers, and the like.

[0022] In another aspect, the invention provides multi-pack packages. The multi-pack packages comprise a plurality of packages comprising an aesthetic design in the package weld of the invention arranged in an array and one or more devices for retaining the containers in the array. In some embodiments, the multi-pack packages have one or more handles affixed to the packages to facilitate handling and transporting the packages. In various embodiments, the devices are boxes made from paper, plastic, polymers, and combinations thereof. In others, the devices are systems of connected plastic rings affixed to each of the containers. In still others, the devices are wrappings of plastic of similar materials, e.g., twelve cans stacked in an array and wrapped in plastic. In preferred embodiments, the multi-pack packages further comprise one or more indicia describing the contents of the containers in the packages, e.g., labels, printing on the packages, stickers, and the like. In other embodiments, the devices further comprise one or more windows that permit the package contents to be viewed without opening the multi-pack package. In some embodiments, the windows are a transparent portion of the devices. In others, the windows are missing portions of the devices that permit the containers to be viewed without opening the multi-pack package.

[0023J One method of producing a weld comprising an aesthetic design comprises placing an overlapped portion of a weldable packaging material between two forming plates. Each of the forming plates comprises a contact face that contacts the packaging material during the weld process, with the three-dimensional shape of the contact face of each of the two forming plates being a mirror image of that of the other forming plate such that the two plates comprise a mated pair. The contact faces may be generally flat, or ridged, or comprising any configuration conducive to forming a weld or seal. The contact faces of the forming plates contain the desired aesthetic design incorporated therein, again with the two plates possessing three-dimensional mirror image versions of the aesthetic design. The incorporation of the aesthetic design may be accomplished by etching, carving, molding, or any other means well known in the art and suitable for the particular material of which the forming plates are made. Thus, for example, if one of the plates has a dog bone-shaped aesthetic design molded onto it in a particular location on the contact face and is raised above the plate face, the other plate will possess the same dog bone shape etched in the same location of the plate, but the etching will be done such that the dog bone is carved into the plate face. After placement of the packaging material, the forming plates are moved toward the packaging material until the material is pressed between the forming plates. One or both of the forming plates are heated to an appropriate temperature to create a weld between the overlapped pieces of material either prior to or during the period of contact with the thermoset packaging material. Additionally, the forming plates provide an appropriate amount of pressure to create the desired weld. After an appropriate dwell time has elapsed to allow the weld to form, the forming plates are moved away from the packaging material, thus releasing the packaging material from the apparatus. Because of the aesthetic design present on the contact faces of the forming plates, this process produces a weld between the overlapped portions which comprises the aesthetic design within or along the weld. This process is sometimes referred to herein as embossing.

[0024] As will be understood by the skilled artisan, weldable packaging materials useful in the present invention can be any suitable material known to persons skilled in the art. The packaging material preferably is a thermoset material, also referred to in the art as a thermoplastic material. Either a single material type or more than one material type, e.g., two sheets of different types of packaging material, may be employed. Preferably, the material(s) will be flexible but will be capable of maintaining the shape of the aesthetic design after the pouch material cools. The thermoset packaging material(s) also will preferably be from 0.5 to 10 mils thick, more preferably from 0.75 to 8 mils thick, most preferably from 2 to 4 mils thick. Additionally, the packaging material(s) may be mono or multi-laminated materials.

[0025] Choice of material(s) will also depend in part upon the composition that the package is to ultimately contain. For example, thermoset materials useful for the packaging of human and animal products include, but are not limited to, low density polyethylene (LDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), linear low-density polyethylene (LLDPE), metallocene polymer, ethylene vinyl acetate (EVA), ethylene methacrylic acid (EMAA), cast polypropylene (CPP), oriented polypropylene (OPP), polyester (PET), nylon/polyamide (ON), polyvinyl alcohol (PVA), ethylene vinyl alcohol copolymer (EVOH), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), cellophane, polystyrene (PS), and plastics not derived from petrochemicals, i.e., bio-plastics such as polylactic acid (PLA). More particularly, such materials are useful in combination/lamination with aluminum foil (AL), vacuum metalized film, AlOx metalized, SiOx metalized (VM Films), paper contained film, glassine paper, Rayon paper, and non- woven materials. Even more particularly as single-layer films or through the co-extrusion or lamination processes.

[0026] With regard to the amount of pressure to be applied, suitable temperatures to employ, and appropriate dwell times to use during the weld process, useful ranges of these variables and methods for determining the proper value to employ to create a suitable weld are well known to the skilled artisan. These variables are interdependent and their adjustment depends on multiple factors well known to the skilled artisan, including the type of packaging material being employed, the type of material from which the forming plates were made, and the shape of the aesthetic design being used.

[0027] Typical pressure applied during a weld procedure for thermoset packaging material is at least about 40 psi and typically not more than about 80 psi. Preferably, the pressure is greater than about 50 psi and less than about 70 psi. More preferably, the pressure is greater than about 55 psi and less than about 65 psi. Most preferably, the pressure is between 58.1 and 60.0 psi.

[0028] Typical temperature to employ for welding thermoset packaging material is between about 200°F (93°C) and about 450°F (232°C). Preferably, the temperature is between about 250°F (121°C) and about 400°F (204°C). More preferably, the temperature is between about 280°F (138°C) and about 380°F (193°C). Most preferably, the temperature is between 310°F (154°C) and 350°F (177°C). The temperature being employed can be measured as either the temperature of the forming plate(s) or the temperature to which the thermoset packaging material is heated

[0029] Typical dwell time to employ for welding thermoset packaging material is between about 0.1 and about 2.5 seconds. Preferably, the dwell time is between about 0.2 and about 2.0 seconds. More preferably, the dwell time is between about 0.4 and about 1.5 seconds. Most preferably, the dwell time is between 0.5 and 1.0 seconds.

[0030] Particularly preferred conditions to employ when using forming plates made of stainless steel, e.g. stainless steel 304, and thermoset packaging material comprising LDPE, MDPE, HDPE, or LLDPE are a pressure of 58.1 to 60.0 psi, a temperature of 310 to 350°F (154 to 177°C), and a dwell time of between 0.5 and 1.0 seconds.

[0031] As stated above, forming plates useful in the present invention will possess an aesthetic design incorporated into the contact face of each forming plate, with the three- dimensional shape of the contact face of each forming plate being a mirror image of that of the other forming plate such that the two plates form a mated pair. The aesthetic design can be any suitable size and shape. Preferably, the aesthetic design will be sized and located on the forming plates in such a way as to permit the weld formed by the forming plates to be a complete seal.

[0032] Forming plates useful to produce welds containing aesthetic designs can be made of any suitable material. Such materials are well known to the skilled artisan. Choice of forming plate material may depend on numerous factors well known to the skilled artisan. Preferably, the forming plates are made of a steel or rubber material. Suitable types of steels include 304, 316, and Nitronic 30 stainless steels. A preferred steel material is 304 stainless steel. Suitable types of rubbers include silicon rubbers having acceptable compression recovery, finish, Durometer rating, and Food & Drug Administration (FDA) approval. Criteria that may be important in selecting a suitable steel material include machinability, hardness, corrosion resistance, and heat transfer characteristics of the steel. Criteria that may be important in selecting a suitable rubber material include moldability, surface finish, Durometer rating, temperature rating, impact resistance, FDA specification, closed cell construction, and chemical resistance of the rubber. Additional factors to consider include the type of thermoset packaging material being welded, type of apparatus being used to create the weld, and the shape of the aesthetic design. The skilled artisan will be able to analyze important criteria and select an appropriate material from which to make the forming plates.

[0033] In certain embodiments, the forming plates are within or are part of a thermoforming device. Various types of suitable devices exist and are readily available from a number of manufacturers, and such devices are well known in the art. One example of a suitable device is a direct heat-sealing machine, which merely comprises forming plates attached to a means for delivering heat and pressure to those plates. Such devices can be manually controlled or can be automatic. In other embodiments, the thermoforming device is a part of an apparatus that is able to automatically form the package, fill it with the desired material, and seal the package edges. Two common types of such thermoforming devices are the vertical and horizontal form-fill-seal (VFFS and HFFS) packaging machines, each of which is capable of taking a piece of thermoset packaging material and automatically 1) forming it into an appropriate shape for a package, 2) filling the package with the desired material, and 3) welding the package edges together using a thermoforming device.

[0034] Examples of suitable aesthetic designs and forming plates can be found in FIGS. 1 and 2. Referring to FIGS. 2A-2C, forming plates 20 are attached to mounting plates 23 via a plurality of attachment screws 24. Mounting plates 23 could in turn be attached to a thermoforming device. Though such mounting plates are not necessary and are not always employed in the methods and apparatus of the present invention, they can be used, for example, to simplify the attachment of the forming plates to the thermoforming device or to allow the forming plates to be made of a material that is not suitable for direct attachment to the thermoforming device. Each forming plate 20 possesses a contact face 22, each of which possesses a zig-zag pattern 22 incorporated therein. As can be seen in FIGS. 2B and 2C, the zig-zag patterns 21 of the two forming plates 20 are three-dimensional mirror image versions of one another such that they form a mating pair when brought together.

[0035] The forming plates of FIG. 2 can be used to produce, for example, the package of FIG. 1A. Referring to FIG. 1A, package 10 possesses a plurality of welded edges 1 1, which possess a zig-zag pattern aesthetic design 12 embossed in the edge weld, which in this embodiment form a complete seal for the package. Forming plates similar to those of FIG. 2, but which possess a dog bone aesthetic design on the contact faces (as opposed to a zig-zag pattern) could be used, for example, to produce the package of FIG. IB. Referring to FIG. IB, package 13 possesses a plurality of welded edges 14, which possess a dog bone pattern aesthetic design 15 embossed in the edge weld.

[0036] A desirable weld of the present invention will possess one or more, and preferably all, of the following characteristics: (1) the aesthetic design is readily recognizable; (2) there are few or no stretch marks emanating from the aesthetic design; (3) the edges of the aesthetic design are sharp versus erratic; and (4) the thermoset packaging material is free from discoloration. As discussed above, producing the desired weld may require the adjustment of multiple variables, which are well known to the skilled artisan.

[0037] In the specification, there have been disclosed typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation. Obviously many modifications and variations of the invention are possible in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described.

[0038] Unless defined otherwise, all technical and scientific terms and any acronyms used herein have the same meanings as commonly understood by one of ordinary skill in the art in the field of this invention. Although any compositions, methods, and means for communicating information similar or equivalent to those described herein can be used to practice this invention, the preferred compositions, methods, and means for communicating information are described herein.

[0039] As used herein "comprising" is to be interpreted as specifying the presence of the stated features, integers, steps, or components as referred to, but does not preclude the presence or addition of one or more features, integers, steps, or components, or groups thereof. Thus, for example, a package comprising one weld comprising an aesthetic design may have two or three welds with an aesthetic design. Additionally, the term "comprising" is intended to include embodiments encompassed by the terms "consisting essentially of and "consisting of." Similarly, the term "consisting essentially of is intended to include embodiments encompassed by the term "consisting of."

[0040] All references cited above are incorporated herein by reference to the extent allowed by law. The discussion of those references is intended merely to summarize the assertions made by their authors. No admission is made that any reference (or a portion of any reference) is relevant prior art. Applicants reserve the right to challenge the accuracy and pertinence of any cited reference.