Method for forming smooth walled flexible package

A method of fabricating a package and storing contents therein under vacuum, said method comprising the steps of:

• (a) providing a roll of a continuous, laminated web construction, said web construction including a first continuous flexible web formed of a gas barrier material adapted to form an inner bag of said package, and a second continuous flexible web adapted to form an outer bag of said package, said first and second continuous webs being adhered together by adhesive bonds to form said laminated web construction, said adhesive bonds including a discrete pattern of bonded areas which repeats in the machine-direction of the laminated web construction to define between discrete patterns of bonded areas a plurality of sequentially disposed, dual walled sheets, each of said dual walled sheets having a length required to form a package, each of said discrete patterns of bonded areas including discrete bonds which are spaced apart from each other in the cross-machine-direction of the roll to define between said discrete bonds at least one passageway between said first and second continuous webs, said first continuous flexible web and said second continuous flexible web of the laminated web construction being of different materials for precluding sealing of the at least one passageway when a bonding energy is applied to the dual walled sheets for sealing the package with contents in the inner bag of said package under vacuum, the machine-direction spacing between the discrete patterns of bonded areas permitting separation of the web construction through discrete patterns of bonded areas which are spaced apart from each other in the machine-direction to thereby form a plurality of said dual walled sheets;
• (b) forming said dual walled sheets into said tubular packages and sealing one opposed end of each of said tubular packages to form a closed bottom and a gas space between the inner and outer bags of each said tubular package without closing said at least one passageway located between the discrete bonds securing the walls of the dual walled sheet together adjacent said closed bottom, whereby the gas space between the inner bag and the outer bag remains in communication with the ambient atmosphere through said at least one passgaeway adjacent the closed bottom;
• (c) severing the sequentially disposed dual walled sheets in the cross-machine-direction through discrete patterns of bonded areas which are spaced-apart from each other in the machine-direction to separate the sequentially disposed dual walled sheets, with the walls thereof bonded together at opposed ends by two of said repeating, discrete patterns of bonded areas;
• (d) placing the contents to be packaged within the inner bag of each package;
• (e) creating a vacuum in the inner bag of each package;
• and
• (f) applying said bonding energy to the other of said opposed ends constituting an upper mouth of each of said packages for sealing together inner surfaces of the inner bag of each of said packages adjacent the upper mouth, to thereby seal the contents placed in the inner bag under vacuum, without closing said at least one passageway located between discrete bonds securing the walls of the dual walled sheet together adjacent the upper mouth, whereby the gas space between the inner bag and outer bag remains in communication with the ambient atmosphere through said at least one passageway adjacent the upper mouth, with the contents within the inner bag packaged under vacuum.