Flexible package and methods of making same

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.

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.

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.