Title of Invention

ELECTROLUMINESCENT FLEXIBLE FILM FOR PRODUCT PACKAGING

Abstract

A flexible electroluminescent film, and packaging material and packages made therefrom, that incorporates electroluminescent material within the polymer packaging film layers to enable the film to be illuminated without an external light source. The film may also comprise various thin-film items, such as power source, inverter, switch, integrated circuit, radio receiver, and speaker, all within the film layers. The film can be used in existing form and fill packaging machines without substantial modifications to the machines.

Full Text

FORM-2 THE PATENTS ACT, 1970 (39 of 1970) COMPLETE SPECIFICATION (See section 10; rule 13) 1. "ELECTROLUMINESCENT FLEXIBLE FILM FOR PRODUCT PACKAGING" 2. (a) Frito-Lay North America, Inc. (b) 7701 Legacy Drive, Piano, Texas 75024-4099, United States of America. (c) United States of America The following specification particularly describes the nature of the invention and the manner in which it is to be performed. The present invention relates to electroluminescent flexible films incorporated into food or other product packaging. This invention allows product packaging to be illuminated without substantially increasing film thickness or substantially decreasing the film flexibility necessary to conform to varying product shapes. More specifically, this invention can be used with existing product-packaging equipment, such as a vertical form, fill, and seal machine, to incorporate electroluminescent displays into product packaging. More generally, this invention can be used in any product requiring illuminated thin films or illuminated images on thin films. 1. Description of Related Art There are several examples of embodiments of illuminations on various containers in the prior art. Such designs allow for increased visibility of a design imprinted on the container in dark conditions. Further, illuminated containers are more likely to grab the viewer's attention than non-illuminated containers. Illuminating decorative designs helps emphasize illuminated parts, much like underlining helps emphasize marked text. Prior art devices typically utilize bulky light sources for illumination. For example, U.S. Pat. No. 5,567,054 uses a chemi luminescent "wand" disposed within a pouch at the base of a bag. The wand consists of two concentric tubes filled with two different chemicals that produce light when mixed. This wand illuminates the bag when the inner, frangible tube is broken to allow the two chemicals to interact. However, the bag requires an additional pouch to contain the wand. The manufacturing process for making the bag would thus require additional manufacturing steps for forming the pouch, placing the wand into the pouch, and heat-sealing the pouch.. A handbag with a removable electroluminescent lamp was disclosed in U.S. Patent Nos. 5,067,063 and 5,268,827. Electroluminescent technology is discussed in further detail below in reference to U.S. Patent No. 5,676,451. The electroluminescent lamp used in that invention can illuminate both inside and outside the bag. The lamp, however, must be manually attached to the inside wall of the bag 2 by some mechanical means, such as Velcro or clips. To mass-produce the handbags, additional labor steps would be required to attach the lamp to the inside wall. Alternatively, a separate machine would be needed to make the attachment. Furthermore, the bag requires a separate compartment to contain the battery and DC-to-AC converter. The attachment of an electroluminescent lamp and the addition of the batteries, a converter, a switch, the wiring, and containers to house those materials would unnecessarily decrease the amount of space available inside the bag. Similarly, U.S. Patent No. 4,926,296 discloses an illuminated carrying bag with a light bulb attached to a sidewall. Batteries contained in a pouch secured to that sidewall energize the light bulb. Like the invention disclosed in the '063 and '827 patents, the illuminating device in the '296 patent is bulky and requires extra labor and/or equipment to incorporate into existing bags. In another prior art reference, U.S. Patent No. 5,676,451, a fabric bag is illuminated with a flexible electroluminescent film strip attached to the exterior of the bag. Electroluminescence is a light emission phenomena resulting from the application of an electric field to prepared phosphor powders sandwiched between sheet-metal electrodes. Electroluminescent strips function with alternating current (AC). Voltage is applied between the front and the back electrode by way of an AC power source and the phosphor particles are excited by the electric field, thereby producing a luminescent energy. The film strip disclosed in the '451 Patent is energized by a battery and inverter (DC-to-AC converter), both of which are contained in a pouch. Although the electroluminescent film strip is flexible in the preferred embodiment of the '451 patent and can conform to the changing shape of the bag walls, the electroluminescent film strip still is not part of the wall itself; it still must be mechanically attached. Furthermore, the power source requires its own pouch. Prior to the current invention, no other invention incorporated electroluminescent materials into self-contained, flexible packaging films for use with product packaged in flexible film packages, such as snack food packaged using a vertical form, fill, and seal machine. Consequently, a need exists for flexible electroluminescent films suitable for use with existing film-packaging equipment or 3 other uses requiring flexible electroluminescent films, such as packaging for chips and other snack food products. Such films should be easily manufactured and readily adaptable to existing form and fill machines. Further, such invention should save space and reduce the necessary amount of raw materials by eliminating the need to attach a separate, exterior light source to the packaging film. Prior art methods utilized attached light sources that were prone to detachment from shifting container contents or rough handling. Consequently, a need exists for a light source for containers that is not prone to detachment. By incorporating the light source within the packaging film instead of merely attaching it onto the film, such invention would prevent the light source from being knocked loose during shipping or handling. The invention should also be flexible in order to withstand the deformation of containers that occurs during normal shipping and handling. SUMMARY OF THE INVENTION The proposed invention comprises a flexible electroluminescent film, and packaging derived therefrom, in combination with other elements capable of illuminating graphic designs contained within the film layers. The invention can be used as flexible packaging material and can be used in traditional packaging devices. All the necessary components for illumination are incorporated within a thin film sheet. In one embodiment of the invention, the flexible electroluminescent film is incorporated within the layers of a bag used to hold chips or other snack food products. Electroluminescent material is sandwiched within various polymer, ink, and moisture-absorbing layers. A thin-film DC power source, a thin-film current inverter, and a thin-film touch-sensitive switch ("power system") are all incorporated within the layers of the packaging material. Thus, a single sheet of film incorporating all these features can be fed into a vertical form, fill, and seal machine. The electroluminescent material, various ink layers, and opaque mask layers are arranged in such a manner as to illuminate a graphics image on the formed bag when the power system is activated. The invention is a great improvement over the prior art for a number of reasons. Incorporating the light source into the enclosure material itself instead of attaching a separate light source saves interior space and leaves more room for product to be enclosed. Having the packaging and light source all in one piece also avoids the problem of having attachments that can be knocked loose during shipping or handling. It also avoids the problem of enclosed items snagging or catching onto the light and/or the power system. Importantly, having the light source and power system already incorporated into a film sheet saves time and expense for packaging facilities. Whereas prior art solutions required extra machinery and/or labor to attach electroluminescent lamps, no such additions are necessary with this invention. The sheet comprising the flexible electroluminescent film can be assembled on a film converter and used in existing form, filling, and sealing packaging systems for existing product lines. Incorporating the electroluminescent layers into the packaging layers saves raw material costs by preventing the duplication of materials. In prior art systems involving electroluminescent lamps separately attached to packaging walls, both the lamp and the packaging walls required their own moisture-trapping layers. Because the electroluminescent layers are within the packaging layers, only one set of moisture-trapping layers is necessary. The above as well as additional features and advantages of the present invention will become apparent in the following written detailed description. BRIEF DESCRIPTION OF THE DRAWINGS The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein: Figure 1 is a schematic view of flexible electroluminescent film components in one embodiment of the invention; Figures 2a and 2b are perspective views of the flexible electroluminescent film of one embodiment of the present invention incorporated into a snack food bag; Figure 3 is a cross-section view of a prior art flexible electroluminescent film incorporated in one embodiment of the present invention; Figure 4 is a perspective view of the flexible electroluminescent film of one embodiment of the present invention incorporated into a snack food bag showing several components attached to the packaging walls; Figure 5a is a perspective view of a display shelf with several snack food bags that incorporate one embodiment of the flexible electroluminescent film of the present invention arranged in a collage presentation; Figure 5b is a perspective view of one of the bags in Figure 5a with a section of the first few layers of the film removed, along the line (5b-5b) indicated on Figure 5a, to show various components; and Figure 6 is a schematic view of the flexible electroluminescent film of one embodiment of the present invention with an integrated chip and speaker included. 6. The flexible film sheet of Claim 2 wherein the flexible film further comprises a thin-film radio receiver electrically connected to said DC power source and located between said first polymer layer and said second polymer layer. 7. A flexible package for containing a product, said package comprising: a first polymer layer; a second polymer layer; an electroluminescent thin film sandwiched between said first polymer layer and said second polymer layer; a power source electrically connected to said electroluminescent thin film; and wherein said first polymer layer, second polymer layer, and electroluminescent film are bound together and arranged to form said flexible package. 8. The flexible package of Claim 10 wherein the power source comprises a thin-film DC power source electrically connected to an inverter. 9. The flexible package of Claim 10 further comprising a switch electrically connected to said power source, whereby such switch controls the input of power into the electroluminescent film. 10. The flexible package of Claim 10 wherein said package comprises a bag for containing a snack food product. 11. A method for producing a flexible package, said package comprising two polymer film layers, said method comprising the steps of: a) placing between the two polymer film layers an electroluminescent film and a thin film power supply, wherein said electroluminescent film and power supply are electrically connected; b) sealing the two polymer film layers together, thereby encasing the electroluminescent film and power supply within the two layers and forming a sheet of thin-film, flexible material; c) feeding said sheet of thin-film, flexible material into a form, fill, and seal machine; and d) forming a package from said sheet of thin-film, flexible material. 12. The flexible film sheet of Claim 2 further comprising a thin-film speaker electrically connected to said DC power source and located between said first polymer layer and said second polymer layer. 13. The flexible package of Claim 10 further comprising an integrated circuit electrically connected to the power source. 14. The flexible package of Claim 10 further comprising a radio receiver electrically connected to the power source. 15. The flexible package of Claim 10 further comprising a speaker electrically connected to the power source. 16. The method for producing a flexible package of Claim 14 wherein step d) further comprises forming a snack food product package. 17. The method for producing a flexible package of Claim 14 wherein step a) further comprises placing between the two polymer film layers an integrated circuit electrically connected to the electroluminescent film and power supply. 18. The method for producing a flexible package of Claim 14 wherein step a) further comprises placing between the two polymer film layers a thin-film switch electrically connected to the electroluminescent film and power supply. 19. The method for producing a flexible package of Claim 14 wherein step a) further comprises placing between the two polymer film layers a thin-film radio receiver electrically connected to the electroluminescent film and power supply. 20. The method for producing a flexible package of Claim 14 wherein step a) further comprises placing between the two polymer film layers a thin-film speaker electrically connected to the electroluminescent film and power supply. CLAIMS: We claims 2. A flexible film sheet comprising: a first polymer film layer; a first electrode film layer bound to said first polymer film layer; an electroluminescent material layer bound to said first electrode film 5 layer; a second electrode film layer bound to said electroluminescent material layer; a second polymer film layer bound to said second electrode layer; a power source electrically connected to said electroluminescent 10 material; and wherein said flexible film sheet is suitable for use in a vertical form, fill, and seal packaging machine, and the power source further comprises a thin-film DC power source. 3. The flexible film sheet of Claim 2 wherein the power source further comprises a thin-film current inverter electrically connected to the DC power source and the electroluminescent material layer. Docket No- CFLAY.00040PCT R-17' The flexible film sheet of Claim 3 wherein the film further comprises a circuit said circuit located between said first polymer layer and said second polymer layer, for conducting a current from the DC power source, through the inverter, to the electroluminescent material, and back to the DC power source. The flexible film sheet of Claim 2 wherein the flexible film further comprises a thin-film switch electrically connected to said DC power source and located between said first polymer layer and said second polymer layer. The flexible film sheet of Claim 2 wherein the flexible film further comprises an integrated circuit electrically connected to said DC power source and located within said film layers. The flexible film sheet of Claim 2 wherein the flexible film further comprises a thin-film radio receiver electrically connected to said DC power source and located between said first polymer layer and said second polymer layer. 10. A flexible package for containing a product, said package comprising: a first polymer layer; a second polymer layer; an electroluminescent thin film sandwiched between said first polymer 5 layer and said second polymer layer; a power source electrically connected to said electroluminescent thin film; and wherein said first polymer layer, second polymer layer, and 10 electroluminescent film are bound together and arranged to form said flexible package. 11. The flexible package of Claim 10 wherein the power source comprises a thin-film DC power source electrically connected to an inverter. 12. The flexible package of Claim 10 further comprising a switch electrically connected to said power source, whereby such switch controls the input of power into the electroluminescent film. 13. The flexible package of Claim 10 wherein said package comprises a bag for containing a snack food product. 14. A method for producing a flexible package, said package eompiising two polymer film layers, said method comprising the steps of: a) placing between the two polymer film layers an electroluminescent film and a thin film power supply, wherein said 5 electroluminescent film and power supply are electrically connected; b) sealing the two polymer film layers together, thereby encasing the electroluminescent film and power supply within the two layers and forming a sheet of thin-film, flexible material; c) feeding said sheet of thin-film, flexible material into a form, 10 fill, and seal machine; and d) forming a package from said sheet of thin-film, flexible material. Docket No. CFLAY.00040PCT R-201 15. The flexible film sheet of Claim 2 further comprising a thin-film speaker electrically coimected to said DC power source and located between said first polymer layer and said second polymer layer. 19. The flexible package of Claim 10 further comprising an integrated circuit electrically connected to the power source. 20. The flexible package of Claim 10 further comprising a radio receiver electrically connected to the power source. 21. The flexible package of Claim 10 further comprising a speaker electrically connected to the power source. 22. The method for producing a flexible package of Claim 14 wherein step d) further comprises forming a snack food product package. 23. The method for producing a flexible package of Claim 14 wherein step a) further comprises placing between the two polymer film layers an integrated circuit electrically connected to the electroluminescent film and power supply. 24. The method for producing a flexible package of Claim 14 wherein step a) further comprises placing between the two polymer film layers a thin-film switch electrically connected to the electroluminescent film and power supply. Docket No. CFLAY.00040PCT R-2l '

Documents:

00123-mumnp-2004-abstract(14-02-2004).doc

00123-mumnp-2004-abstract(14-02-2004).pdf

00123-mumnp-2004-abstract1.jpg

00123-mumnp-2004-claims(granted)-(14-02-2004).pdf

00123-mumnp-2004-correspondence(16-09-2004).pdf

00123-mumnp-2004-correspondence(ipo)-(29-09-2006).pdf

00123-mumnp-2004-drawing(14-02-2004).pdf

00123-mumnp-2004-form 19(23-02-2004).pdf

00123-mumnp-2004-form 1a(17-02-2004).pdf

00123-mumnp-2004-form 2(granted)-(14-02-2004).doc

00123-mumnp-2004-form 2(granted)-(14-02-2004).pdf

00123-mumnp-2004-form 26(14-02-2004).pdf

00123-mumnp-2004-form 3(07-09-2004).pdf

00123-mumnp-2004-form 3(14-03-2004).pdf

00123-mumnp-2004-pct-ipea-409(14-02-2004).pdf

00123-mumnp-2004-pct-isa-210(14-02-2004).pdf

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