AMENDED CLAIMS [received by the International Bureau on 20 December 2004 (20.12.2004); original claims 1, 29-32 and 36 amended; original claim 45 cancelled; remaining claims unchanged (6 pages)]
1. A release valve (10) for a flexible container (12) comprising: a vent layer (30) positioned over an opening (24) in a bag structure (13) of the flexible container (12), the vent layer (30) being pervious with respect to expected gasses and substantially impervious with respect to expected liquids; a sealable area (52) forforming a sealed passageway between the vent layer (30) and the bag structure (13), the area (52) having at least a portion positioned for alignment with the opening (24) in the bag structure (13); a cover layer (32) positioned over the vent layer (30) and attached thereto, the periphery of the cover layer (32) not extending beyond the periphery of the vent layer (30); a sealed area (56) forming a sealed passageway between the vent layer (30) and the cover layer (32), the sealed area (56) having a least a portion aligned with the sealable area (52); and at least one slit (42) through the cover layer (32) forming an exit from the sealed area (56), whereby released gas can pass from the area (52), through the vent layer (30) to the area (56), and exit the area (56) through the at least one slit (42).
2. A release valve (10) as set forth in the preceding claim, wherein the vent layer (30) and the cover layer (32) are of substantially the same shape and size, and are coextensive with each other.
3. A release valve (10) as set forth in either of the preceding claims, wherein the vent layer (30) and the cover layer (32) are each of a substantially circular shape. 4. A release valve (10) as set forth in any of the preceding claims, wherein the vent layer (30) comprises a non-woven polymer fabric.
5. A release valve (10) as set forth in any of the preceding claims, wherein the cover layer (32) comprises a polymer film.
20 AMENDED SHEET (ARTICLE, 19)
6. A release valve (10) as set forth in any of the preceding claims, wherein the sealable area (52) is formed by an adhesive area (50) on the inner surface (34) of the vent layer (30), the adhesive area (50) bordering the periphery of the inner surface (34) and surrounding, and sealing, the sealable area (52). 7. A release valve (10) as set forth in the preceding claim, wherein the adhesive area (50) can be used to attach the valve (10) to the bag structure (13).
8. A release valve (10) as set forth in either of the preceding two claims, wherein the adhesive area (50) is formed from a pressure-sensitive adhesive (62).
9. A release valve (10) as set forth in any of the preceding claims, wherein the sealed area (56) is formed by an adhesive area (54) bordering the periphery of the outer surface (36) of the vent layer (30).
10. A release valve (10) as set forth in the preceding claim, wherein the adhesive area (54) also attaches the cover layer (32) to the vent layer (30).
11. A release valve (10) as set forth in either of the two preceding claims, wherein the adhesive area (54) is formed from a curable adhesive (66).
12. A release valve (10) as set forth in any of the preceding claims, wherein the sealable area (52) and the sealed area (56) are of substantially the same size and shape, and wherein the sealable area (52) and the sealed area (56) are substantially aligned with each other. 13. A release valve (10) as set forth in any of the preceding claims, wherein the sealable area (52) and the sealed area (56) each have a substantially circular shape.
1 . A release valve (10) as set forth in any of claims 1 - 13, wherein the at least one slit (42) forms at least one flap (44) which lifts relative to the rest of the cover layer (32) when released gas passes through the slit (42).
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AMENDED SHEET (ARTICLE, 19)
15. A release valve (10) as set forth in the preceding claim, wherein the at least one slit (42) forms a plurality of flaps (44) which Irft relative to the rest of the cover layer (32) when released gas passes through the slit (42).
16. A release valve (10) as set forth in either of the preceding two claims, wherein the at least one slit (42) comprises a plurality of slits (42).
17. A release valve (10) as set forth in any of claims 1 - 13, wherein the at least one slit (42) is of a flapless design.
18. A release valve (10) as set forth in claim 17, wherein the at least one slit (42) comprises a plurality of perforations. 19. A release valve (10) as set forth in claim 17, wherein the at least one slit (42) comprises a plurality of linear cuts.
20. A web (80) comprises a plurality of the release valves (10) set forth in any of the preceding claims and a release liner (78) to which the valves (10) are temporarily attached for selective removal therefrom for integration into the bag structure (13).
21. A web (80) as set forth in claim 20 in a roll form.
22. A web (80) as set forth in claim 20 in a sheet form.
23. A web (80) as set forth in any of claims 20 - 22, when they depend from claim 6, wherein the adhesive area (50) temporarily attaches the valves (10) to the release liner (80).
24. A method of making a plurality of the release valves (10) set forth in any of the preceding claims, said method comprising the steps of:
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AMENDED SHEET (ARTICLE, 19)
overlaying a vent material (70) and a cover material (60) so that an outer surface (74) of the vent material (70) is adjacent an inner surface (62) of the cover material (60); positioning an adhesive (68) between the outer surface (74) of the vent material (70) and the inner surface (62) of the cover material (60) in a pattern corresponding to the baffle areas (56); positioning an adhesive (76) on the inner surface (72) of the vent material (70) in a pattern corresponding to the sealable areas (52); cutting the cover material (60) and the vent material (70) into shapes corresponding to the overall shape of the valves (10); and cutting the cover material (60) with cuts corresponding to the slits (42).
25. A method as set forth in the preceding claim, wherein said step of positioning the adhesive (62) on the inner surface of the vent material (60) comprises the step of applying the adhesive (62) to the inner surface of the vent material (60).
26, A method as set forth in the preceding claim, further comprising the step of overlaying a release liner (64) over the adhesive (62) on the inner surface of the vent material (60). 27. A method as set forth in any of claims 24 - 26, wherein said step of overlaying the cover material (60) and the vent material (70) and said step of positioning the adhesive (76) between the cover material (60) and the vent material (70) comprises applying the adhesive (76) to the inner surface (62) of the cover material (60) and overlaying the vent material (70) over the adhesive (76).
28. A method as set forth in any of claims 24-27, wherein said slit-forming step is performed substantially simultaneously with said cutting step.
29. A flexible container (12) comprising a bag structure (13) having an opening (24) and the air release valve (10) set forth in any of claims 1 - 19, wherein the vent layer (30) is positioned so that the sealable area (52) has at least a portion
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aligned with the opening (24) in the bag structure (13) and wherein the vent layer (30) is attached to the bag structure (13) so that the sealable area (52) forms a sealed passageway between the vent layer (30) and the bag structure (13).
30. A flexible container (12) as set forth in the preceding claim, wherein the bag structure (13) includes a recloseable seam (22).
31. A flexible container (12) as set forth in the preceding claim, wherein the bag structure (13) comprises a plurality of thermoplastic panels (14, 16) and wherein the opening (24) is on one of the panels (14).
32. A method of using the flexible container (12) set forth in any of claims 29 - 31 » said method comprising the steps of: placing a portion of food (F) into the bag structure (13); closing the bag structure (13); and applying pressure to the bag structure (13) to release air from its interior cavity through the air release valve (10). 33. A method as set forth in the preceding claim, further comprising the step of placing the closed bag structure (13) in a freezer after performing said pressure-applying step.
34. A method as set forth in either of the preceding two claims, wherein said placing, closing, and pressure-applying steps are performed by a consumer when storing food for later consumption.
35. A method as set forth in any of the preceding three claims, wherein said pressure-applying step comprises pushing a portion of the bag structure (13).
36. A method of making a plurality of the flexible containers (12) set forth in any claims 29 - 31, said method comprising the steps of: manufacturing a plurality of the bag structures (13); separately manufacturing a plurality of the release valves (10);
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aligning the release valves (10) with the openings (24) in the bag structures (13) so that the sealable areas (52) will form sealed passageways between the vent layers (30) and the bag structures (13); securing the aligned release valves (10) to the bag structures (13).
g 37. A method as set forth in the preceding claim, wherein the bag- manufacturing step is performed at a bag-manufacturing location and the valve- manufacturing step is performed at a different valve-manufacturing location.
38. A method as set forth in either of the preceding claim, wherein saido valve-manufacturing step results in a web (80) comprising a plurality of the release valves (10) temporarily attached to a liner (78) for selective removal therefrom.
39. A method as set forth in the preceding claim, further comprising the step of removing the plurality of valves (10) from the liner (78) priorto said securing step. s 40. A method as set forth in claim 39, wherein said removing step is performed automatically by a machine.
41. A method as set forth in claim 39, wherein said removing step is performed by hand. 0 42. A method as set forth in any of claims 36 - 4 , wherein said aligning step and/or said securing step is performed automatically by a machine.
43. A method as set forth in any of claims 36 - 4 , wherein said aligning step and/or said securing step is performed by hand.
44. A release valve (10) for a flexible container (13) comprising a vent 25 layer (30), a cover layer (32), a passageway between the vent layer (30) and the cover layer (32), and an exit (42) for released gas; wherein the periphery of the cover layer (32) does not extend beyond the periphery of the vent layer (30).
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