Mono-web package with tamper-evident tear strip and resealable flap portion

1. A method of making a package from a sheet of material comprising:

forming a first panel having an outer surface and an opposite, product-facing inner surface, the first panel extending between a top edge and an opposite folded bottom edge each extending in a transverse direction, and two opposing side edges each extending in a perpendicular longitudinal direction, between the top and bottom edges;

forming a second panel having an outer surface and an opposite, product-facing inner surface, the second panel extending between a top edge and the opposite folded bottom edge each extending in a transverse direction, and two opposing side edges each extending in a perpendicular longitudinal direction, between the top and bottom edges;

forming a layered structure on a first region of the inner surface of the first panel proximate the top edge thereof and extending substantially from one of the side edges to the other of the side edges, the layered structure comprising a pressure-sensitive adhesive (PSA) disposed on the first region of the first panel, and a non-tacky sealant coating selected from the group consisting of polyethylene (PE) emulsion, acrylic, urethane, and ethyl vinyl acetate, disposed over and covering the PSA such that the PSA is not exposed as long as the sealant coating is in place;

disposing a scalant material selected from the group consisting of polypropylene, polyethlene (HDPE, LDPE, LLDPE), polyethylene terephthalate, and nylon, on the iner surface of the first panel, directly adjhacent the PSA, at least in the first region and covers an area that is larger than the area on which the PSA and the sealant coating are disposed and wherein the sealant material is permanently sealed to the PSA,

disposing a sealant material selected form the group consisting of polypropylene, polyethylene (HDPE, LDPE, LLDPE), polyethylene terephthalate, and nylon, on the inner surface of the second panel at least in a second region corresponding to the first region of the first panel and the sealant material is permanently sealed to the sealant coating,

forming at least one line of weakness to define a removeable flap portion which is continuous with the top edge of the second panel, extend substantially form one of the side edges to the othere of the side edges, and comprises the second region and overlies the first region of the first panel;

sealing the first panel to the second panel, such that the first panel and the second panel are disposed with respective inner surfaces facing each other and the respective side and top edges being substantially aligned, wherein side seals are formed along at least the two pairs of opposing side edges of the first and second panels, such that a product placed between the first and second panels is enveloped thereby and the second region of the second panel overlies the first region of the first panel;

defining an inner reseal area on at least one of the inner surface of the first panel or the inner surface of the second panel between the folded bottom edge and a location of the at least one line of weakness, wherein the inner reseal area comprises at least one strip of PSA covered by polyethylene; and

selecting the sealant coating such that the permanent seal between the sealant material and the sealant coating in an area of the first and second regions has a bond strenght exceeding that existing between the sealant coating and the PSA, such that peeling back the removable flap portion causes the sealant coating to be lifted from the PSA and thereby exposes the PSA, creating a resealing flap portioin of the first panel that is configured to be folded over a new top edge of the second panel for resealing the package.

2. The method of claim 1 , wherein the sealant coating comprises a polyethylene (PE) emulsion.

3. The method of claim 1 , wherein forming the at least one line of weakness to define the removable flap portion comprises laser scoring the second panel to form a laser score line that extends partially through a thickness of the second panel.

4. The method of claim 1 , wherein forming the at least one line of weakness to define the removable flap portion comprises creating a perforation that extends from the outer surface of the second panel to the inner surface of the second panel.

5. The method of claim 4 wherein the inner reseal area, when sealed, is configured to maintain an integrity of the package interior prior to peeling of the removable flap portion.

6. The method of claim 1 , wherein at least one of the first or second panels comprises a mono-web, olefin-based film.

7. The method of claim 1 , wherein the first and second panels comprise a barrier layer.

8. The method of claim 1 further comprising creating an area of separation between the first panel and the second panel along opposing side edges of at least one of the pairs of opposing side edges in a location of the removable flap portion to facilitate peeling of the removable flap portion.

9. The method of claim 8 , wherein the area of separation is created using a pattern heat seal tool.

10. A package for holding a product, comprising:

a sheet of material, wherein the sheet defines:

a first panel having an outer surface and an opposite, product-facing inner surface, the first panel extending between a top edge and a folded edge forming an opposite bottom edge each extending in a transverse direction, and two opposing side edges each extending in a perpendicular longitudinal direction, between the top and bottom edges; and

a second panel having an outer surface and an opposite, product-facing inner surface, the second panel extending between a top edge and the folded edge forming an opposite bottom edge each extending in a transverse direction, and two opposing side edges each extending in a perpendicular longitudinal direction, between the top and bottom edges; and

a layered structure formed on a first region of the inner surface of the first panel proximate the top edge thereof and extending substantially from one of the side edges to the other of the side edges, the layered structure comprising a pressure-sensitive adhesive (PSA) disposed on the first region of the first panel, and a non-tacky sealant coating selected from the group consisting of polyethylene (PE) emulsion, acrylic, urethane, and ethyl vinyl acetate, wherein the sealant coating is disposed over and covering the PSA such that the PSA is not exposed as long as the sealant coating is in place;

wherein the first panel and the second panel are disposed such that the respective inner surfaces face each other and the respective side and top edges are substantially aligned, wherein side seals are formed along at least the two pairs of opposing side edges of the first and second panels, such that a product placed between the first and second panels is enveloped thereby,

wherein the first panel comprises a sealant material selected form the group consisting of polypropylene, polyethylene (HDPE, LDPE, LLDPE), polyethylene terephthalate, and nylon, wherein the sealant material is disposed on the inner surface of the first panel at least in the first region and covers an area that is larger that the area on which the PSA and the sealant coating are disposed and wherein the sealant material is permanently sealed to the PSA,

wherein the sealant material disposed on the inner surface of the first panel is directly adjacent the PSA,

wherein the second panel comprises a sealant material selected from the group consisting of polypropylene, polyethylene (HDPE, LDPE, LLDPE), polyethylene terephthalate, and nylon, wherein the sealant material is disposed on the inner surface of the second panel at least in a second region correspoinding to the first region of the first panel and the sealant material is pernamently sealed to the sealant coating,

wherein the second panel further comprises at least one line of weakness comprising a perforation that etends from the outer surface of the second panel to the inner surface of the second panel, defining a removable flap portion which is continuous with the top edge of the second panel, extends substantially from one of the side edges to the other of the side edges, and comprises the second region and overlies the first region of the first panel,

wherein the sealant coating is selected such that the permanent seal between the sealant material and the sealant coating in an area of the first and second regions has a bond strength exceeding that existing between the sealant coating and the PSA, such that peeling back the removable flap portion causes the sealant coating to be separated from the PSA, and thereby exposes the PSA, creating a resealing flap portion of the first panel that is configured to be folded over and adhered to the second panel for resealing the package, and

an inner reseal area defined on at least one of the inner surface of the first panel or the inner surface of the second panel between the folded bottom edge and a location of the at least one line of weakness, wherein the inner reseal area comprises at least one strip of PSA covered by polyethylene.

11. A package for holding a product, comprising:

a sheet of material, wherein the sheet defines:

a first panel having an outer surface and an opposite, product-facing inner surface, the first panel extending between a top edge and a folded edge forming an opposite bottom edge each extending in a transverse direction, and two opposing side edges each extending in a perpendicular longitudinal direction, between the top and bottom edges; and

a second panel having an outer surface and an opposite, product-facing inner surface, the second panel extending between a top edge and the folded edge forming an oppostie bottom edge each extending in a transverse direction, and two opposing side edges each extending in a perpendicular longitudinal direction, between the top and bottom edges; and

a layered structure formed on a first region of the inner surface of the first panel proximate the top edge thereof and extending substantially from one of the side edges to the other of the side edges, the layered structure comprising a pressure-sensitive adhesive (PSA) disposed on the first region of the first panel, and a non-tacky sealant coating selected from the group consisting of polyethylene (PE) emulsion, acrylic, urethane, and ethyl vinyl acetate, wherein the sealant coating is disposed over and covering the PSA such that the PSA is not exposed as long as the sealant coating is in place;

wherein the first panel and the second panel are disposed such that the respective inner surfaces face each other and the respective side and top edges are substantially aligned, wherein side seals are formed along at least the two pairs of opposing side edges of the first and second panels, such that a product placed between the first and second panels is enveloped thereby,

wherein the first panel comprises a sealant material selected from the group consisting of polypropylene, polyethylene (HDPE, LDPE, LLDPE), polyethylene terephthalate, and nylon, wherein the sealant material is disposed on the inner surface of the first panel at least in the first region and covers an area that is larger than the area on which the PSA and the sealant coating is disposed and wherein the sealant material is pernamently sealed to the PSA,

wherein the sealant material disposed on the inner surface of the first panel is in direct contact with the PSA,

wherein the second panel comprises a sealant material selected from the group consisting of polypropylene, polyethylene, (HDPE, LDPE, LLDPE), polyethylene terephthalate, and nylon, wherein the sealant material is disposed on the inner surface of the secnd panel at least in a second region corresponding to the first region of the first panel and the sealant material is permanently sealed to the sealant coating,

wherein the second panel further comprises at least one line of weakness comprising a perforation that extends from the outer surface of the second panel to the inner surface of the second panel, defining a removable flap portion which is continuous with the top edge of the second panel, extends substantially from one of the dise edges to the other of the side edges, and comprises the second region and overlies the first region of the first panel,

wherein the sealant coating is selected such that the permanent seal between the sealant material and the sealant coating in an area of the first and second regions has a bond strength exceeding that existing between the sealant coating and the PSA, such that peeling back the removable flap portion causes the sealant coating to be separated from the PSA, and thereby exposes the PSA, creating a resealing flap portion of the first panel that is configured to be folded over and adhered to the secoond panel for resealing the package, and

an inner reseal area defined on at least on of the inner surface of the first panel or the inner surface of the second panel between the folded bottom edge and a location of the at least one line of weakness, wherein the inner reseal area comprises at least one strip of PSA covered by polyethylene.

12. The package of claim 10 or 11 , wherein at least one of the first or second panels comprises a mono-web, olefin-based film.

13. The package of claim 10 or 11 , wherein the first and second panels comprise a barrier layer.

14. The package of claim 10 or 11 wherein the first panel and the second panel comprise polyethylene terephthalate, the sealant material comprises polyethylene, and the sealant coating comprises a polyethylene emulsion.

15. The package of claim 10 or 11 additionally comprising an area of separation between the first panel and the second panel in a location of the removable flap portion to facilitate peeling of the removable flap portion.

16. The package of claim 10 or 11 wherein the layered structure is bounded at an upper boundary by the top edge of the first panel.