Flexible package and methods of making same

Abstract

A flexible package being capable and being adapted for accommodating a multiplicity of compressed articles is provided. The package has a substantially parallelepiped-shape. A flexible package having a substantially folded flat-shape able to be converted into the unfolded flexible package is provided. Methods of manufacturing the flexible packages are also provided.

What is claimed is: 
     
         1 . A flexible package for accommodating a multiplicity of compressed articles, having a substantially parallelepiped-shape comprising:
 a front wall, a rear wall, a first and second opposite side wall, a third and fourth opposite side wall and a pair of gussets;   a first panel, the first panel forming the front wall, a portion of each of the first and second opposite side wall and a portion of the fourth side wall;   a second panel, the second panel forming the rear wall, a portion of each of the first and second opposite side wall and a portion of the fourth side wall; wherein the first and the second panel are connected to each other at the first and second opposite side wall along first and second side seam;   a third panel, the third panel forming the third side wall;   wherein the third panel comprises the pair of gussets;   wherein each gusset is located at the respective first or second side wall;   wherein each gusset comprises an internal panel and an external panel;   wherein the internal panel and external panel of each gusset are made of triangular portions of the third panel;   wherein the internal and external panel of each gusset are coextensive at a first and second fold line to form a pocket;   wherein the first and second fold line of the pocket of each gusset converge and meet at a vertex;   wherein the vertex of each gusset is joined to the respective first or second side seam at the first or second side wall;   wherein the internal panel of each gusset comprises an altitude extending from the vertex of each gusset towards the third side wall;   wherein the altitude of the internal panel of each gusset has a length (L);   wherein the internal panel of each gusset comprises a triangular area which starts from the vertex of each gusset towards the third side wall;   wherein the triangular area of the internal panel of each gusset has an altitude which coincides with the altitude of the internal panel of each gusset;   wherein the altitude of the triangular area of the internal panel of each gusset has a length (l) which is from 1% to 30% of the length (L) of the altitude of the internal panel of each gusset; and   wherein at least one gusset comprises an area of weakness located at least in the internal panel of the at least one gusset within the triangular area of the internal panel of the at least one gusset; and   wherein the area of weakness is located at or adjacent to the altitude of the internal panel of the at least one gusset.   
     
     
         2 . The flexible package of  claim 1  wherein each gusset comprises an area of weakness located at least within the triangular area of the internal panel of each gusset,
 wherein the area of weakness is located at or adjacent to the altitude of the internal panel of each gusset. 
 
     
     
         3 . The flexible package of  claim 1  wherein the area of weakness has a pattern selected from the group consisting of a straight line, a wavy line, a zigzag, a circle and combinations thereof. 
     
     
         4 . The flexible package of  claim 1  wherein the area of weakness is not a continuous slit. 
     
     
         5 . The flexible package of  claim 1  wherein the flexible package is made of a film having a thickness, wherein the area of weakness comprises a plurality of straight lines where the thickness of the film is reduced or where the film is perforated, wherein the plurality of straight lines alternates with a plurality of solid straight lines, wherein each straight line has a length and each solid straight line has a length, wherein the ratio between the length of each straight line and the length of each solid straight line is from 1:6 to 1:2. 
     
     
         6 . The flexible package of  claim 1  wherein the area of weakness is a straight line of weakness which intersects the altitude of the internal panel of the at least one gusset and forms an angle (α) ranging from 1 degree to 179 degrees with respect with the altitude of the internal panel of the at least one gusset. 
     
     
         7 . The flexible package of  claim 6  wherein the area of weakness starts from the altitude of the internal panel of the at least one gusset and extends towards the front or rear wall. 
     
     
         8 . The flexible package of  claim 1  wherein the area of weakness comprises a first and second portion of weakness which converge at an end point, wherein the end point is located at or adjacent to the altitude of the internal panel of the at least one gusset, wherein each of the first and second portion of weakness forms a first and second angle (β 1 , β 2 ) with respect to the altitude of the internal panel of the at least one gusset,
 wherein, with respect to the altitude of the internal panel of the at least one gusset, the first and second angle (β 1 , β 2 ) are angles adjacent to each other and are each from 1 degree to 179 degrees. 
 
     
     
         9 . The flexible package of  claim 1  wherein the area of weakness is selected from the group consisting of a straight line of weakness, a wavy line of weakness, a zigzag, a straight line of weakness where the thickness of the film is reduced or where the film is perforated and combinations thereof; and wherein the area of weakness has a length which is from 2 mm to 20 mm or wherein the area of weakness is a circle having a diameter, wherein the diameter of the circle is from 2 mm to 20 mm. 
     
     
         10 . A flexible package for accommodating a multiplicity of compressed articles, having a substantially folded flat-shape able to be converted into an unfolded flexible package having a substantially parallelepiped-shape comprising:
 a front wall, a rear wall, a first and second opposite side wall, a third and fourth opposite side wall and a pair of gussets when the flexible package is converted into the unfolded flexible package;   a first panel, the first panel forming the front wall, a portion of each of the first and second opposite side wall and a portion of the fourth side wall when the flexible package is converted into the unfolded flexible package;   a second panel, the second panel forming the rear wall, a portion of each of the first and second opposite side wall and a portion of the fourth side wall when the flexible package is converted into the unfolded flexible package;   wherein the first and the second panel are connected to each other along first and second side seam which are located at the first and second opposite side wall when the flexible package is converted into the unfolded flexible package;   a third panel, the third panel forming the third side wall when the flexible package is converted into the unfolded flexible package;   wherein the third panel comprises the pair of gussets;   wherein each gusset is located at the respective first or second side wall when the flexible package is converted into the unfolded flexible package;   wherein the flexible package comprises a film comprising a twofold portion and a fourfold portion, the twofold portion of the film comprising first and second layers and the fourfold portion of the film comprising first and second outer layers and first and second inner layers, wherein the first and second outer layers of the fourfold portion are coextensive with the first and second layers of the twofold portion of the film;   wherein the first layer of the twofold portion of the film forms the first panel;   wherein the second layer of the twofold portion of the film forms the second panel;   wherein the first and second outer layers and the first and second inner layers of the fourfold portion of the film form the third panel;   wherein the first and second inner layers of the fourfold portion of the film mutually merge at a medial fold line, wherein the medial fold line of the third panel has a length (D) from the first side seam to the second side seam;   wherein the third panel comprises a first area spaced inboard from the first side seam towards the second side seam and a second area spaced inboard from the second side seam towards the first side seam and wherein each of the first and second area of the third panel has a length (d) which is from 1% to 25% of the length (D) of the medial fold line of the third panel;   wherein the flexible package comprises an area of weakness located in at least one of the first or second area of the third panel and in at least one of the first or second inner layers of the fourfold portion of the film; and wherein the area of weakness is located at or adjacent the medial fold line of the third panel.   
     
     
         11 . The flexible package of  claim 10  wherein the flexible package comprises an area of weakness located in each of the first and second inner layers of the fourfold portion of the film. 
     
     
         12 . The flexible package of  claim 10  wherein the flexible package comprises an area of weakness located in each of the first and second areas of the third panel. 
     
     
         13 . A method of manufacturing a flexible package for accommodating a multiplicity of compressed articles, having a substantially folded flat-shape able to be converted into an unfolded flexible package configuration having a substantially parallelepiped-shape comprising, in said unfolded flexible package configuration:
 a front wall, a rear wall, a first and second opposite side wall, a third and fourth opposite side wall and a pair of gussets;   a first panel forming the front wall, a portion of each of the first and second opposite side wall and a portion of the fourth side wall;   a second panel forming the rear wall, a portion of each of the first and second opposite side wall and a portion of the fourth side wall;   wherein the first and the second panel are connected to each other along first and second side seam which are located at the first and second opposite side walls respectively;   a third panel forming the third side wall;   wherein the third panel comprises the pair of gussets;   wherein each gusset is located at the respective first or second side wall;   the method comprising the steps of:   (a) providing a film in the form of an endless sheet travelling in a machine direction and comprising in a cross machine direction a twofold portion and a fourfold portion, the twofold portion of the film comprising first and second layers and the fourfold portion of the film comprising first and second outer layers and first and second inner layers, wherein the first and second outer layers of the fourfold portion are coextensive with the first and second layers of the twofold portion of the film;   wherein the first layer of the twofold portion of the film forms the first panel of the flexible package;   wherein the second layer of the twofold portion of the film forms the second panel of the flexible package;   wherein the first and second outer layers and the first and second inner layers of the fourfold portion of the film form the third panel of the flexible package;   wherein the first and second inner layers of the fourfold portion of the film mutually merge at a medial fold line;   (b) introducing areas of weakness at least at one of the first or second inner layer of the fourfold portion of the film, wherein the areas of weakness are located at or adjacent the medial fold line and in an area at or adjacent where the first and/or second side seam are formed; and   (c) sealing and cutting the first and second layers of the twofold portion of the film and the outer and inner layers of the fourfold portion of the film along a continuous straight line in the cross machine direction to form the first and second side seam of each flexible package.   
     
     
         14 . The method according to  claim 13 , wherein the step (b) further comprises introducing areas of weakness at the first and second inner layers of the fourfold portion of the film, wherein the areas of weakness are located at or adjacent the medial fold line and in an area at or adjacent where the first and second side seam are formed. 
     
     
         15 . A method of manufacturing a flexible package for accommodating a multiplicity of compressed articles, having a substantially folded flat-shape able to be converted into an unfolded flexible package configuration having a substantially parallelepiped-shape comprising, in said unfolded flexible package configuration:
 a front wall, a rear wall, a first and second opposite side wall, a third and fourth opposite side wall and a pair of gussets;   a first panel, the first panel forming the front wall, a portion of each of the first and second opposite side wall and a portion of the fourth side wall;   a second panel, the second panel forming the rear wall, a portion of each of the first and second opposite side wall and a portion of the fourth side wall;   wherein the first and the second panel are connected to each other along first and second side seam which are located at the first and second opposite side wall;   a third panel, the third panel forming the third side wall;   wherein the third panel comprises the pair of gussets;   wherein each gusset is located at the respective first or second side wall;   the method comprising the steps of:   (a) providing a film in the form of an endless sheet travelling in a machine direction, the film comprising a first, second and medial fold line extending in the machine direction, wherein the third panel is delimited by the first and second fold line, wherein the medial fold line is centered between the first and second fold line in the machine direction and divides the third panel in a first and second half in the machine direction,   (b) introducing areas of weakness at least at one of the first or second half of the third panel, wherein the areas of weakness are located at or adjacent the medial fold line and in an area at or adjacent where the first and/or second side seam are formed; and   (c) folding the film in the cross machine direction to provide the film comprising a twofold portion and a fourfold portion, the twofold portion of the film comprising first and second layers and the fourfold portion of the film comprising first and second outer layers and first and second inner layers, wherein the first and second outer layers of the fourfold portion are coextensive with the first and second layers of the twofold portion of the film;   wherein the first layer of the twofold portion of the film forms the first panel;   wherein the second layer of the twofold portion of the film forms the second panel;   wherein the first and second outer layers and the first and second inner layers of the fourfold portion of the film forms the third panel;   wherein the first and second inner layers of the fourfold portion of the film mutually merge at the medial fold line; and   (d) sealing and cutting the first and second layers of the twofold portion of the film and the outer and inner layers of the fourfold portion of the film along a continuous straight line in the cross machine direction to form the first and second side seam of each flexible package.   
     
     
         16 . The method according to  claim 15 , wherein the step (b) further comprises introducing areas of weakness at the first and second half of the third panel, wherein the areas of weakness are located at or adjacent the medial fold line and in an area at or adjacent where the first and second side seam are formed.