Flexible packaging structure with a built-in opening and reclose feature, and method for making same

A package for products, comprising:

• a flexible wrapper for enveloping the products, the wrapper having a width and being formed as a flexible packaging laminate having opposite longitudinal edges, the laminate being formed by an outer structure and an inner structure each having a width equal to the width of the wrapper, the outer structure being adhesively joined in face-to-face relation to the inner structure such that respective opposite longitudinal edges of the outer and inner structures are substantially coincident with each other and define the longitudinal edges of the laminate, substantially the entire surfaces of the inner and outer structures being adhesively laminated to each other by pattern-applied permanent laminating adhesive and pattern-applied pressure-sensitive adhesive, the pattern-applied pressure-sensitive adhesive being disposed in a predetermined pattern and the pattern-applied permanent laminating adhesive being disposed in a predetermined pattern not covering the predetermined pattern of pressure-sensitive adhesive, the outer structure forming an outer surface of the wrapper and comprising at least one layer of flexible material, the inner structure comprising at least a flexible barrier layer facing the outer structure and a polymer sealant layer forming an inner surface of the wrapper;
• and
• an opening and reclose feature formed in the laminate, and comprising an outer flap portion formed by scoring through the outer structure along a generally U-shaped outer score line, and an inner flap portion formed by scoring through the inner structure along a generally U-shaped inner score line, the inner score line creating an opening into the wrapper when the flap portions are peeled back, a marginal region of the outer flap portion extending beyond an edge of the inner flap portion and overlying an underlying surface of the inner structure, the flap portions being joined with the pattern-applied permanent adhesive, and the pattern-applied pressure-sensitive adhesive being disposed between the marginal region of the outer flap portion and the underlying surface of the inner structure for attaching and re-attaching the outer flap portion to the underlying surface.

A flexible lid for attachment to an open end of a container, the lid comprising:

• a laminate having a width defined between opposite longitudinal edges of the laminate, the laminate being formed by an outer structure and an inner structure each having a width equal to the width of the laminate, the outer structure being adhesively joined in face-to-face relation to the inner structure such that respective opposite longitudinal edges of the outer and inner structures are substantially coincident with each other and define the longitudinal edges of the laminate, the outer structure comprising at least one layer of flexible material and the inner structure comprising at least one layer of flexible material, substantially the entire surfaces of the inner and outer structures being adhesively joined to each other by pattern-applied permanent laminating adhesive and pattern-applied pressure-sensitive adhesive, the pattern-applied pressure-sensitive adhesive being disposed in a predetermined pattern and the pattern-applied permanent laminating adhesive being disposed in a predetermined pattern not covering the predetermined pattern of pressure-sensitive adhesive;
• an outer score line formed through the outer structure, the outer score line delineating an outer opening portion that is separable from the outer structure along the outer score line;
• an inner score line formed through the inner structure, the inner score line delineating an inner opening portion that is separable from the inner structure along the inner score line;
• wherein the inner opening portion is joined to the outer opening portion by the pattern-applied permanent laminating adhesive such that lifting the outer opening portion out of the plane of the lid causes the inner opening portion to be lifted along with the outer opening portion so as to create an opening through the flexible lid;
• and
• wherein a marginal region of the outer opening portion extends beyond an edge of the inner opening portion and overlies an underlying surface of the inner structure, and wherein the pattern-applied pressure-sensitive adhesive is disposed on one of the marginal region of the outer structure and the underlying surface of the inner structure for re-adhering the marginal region to the underlying surface after initial opening.