U.S. patent application number 11/182685 was filed with the patent office on 2007-01-18 for process for manufacture of a flexible package.
Invention is credited to Heiner Bouten, Robert Paul Cassoni, Michael Joseph DiPaola, Peter John Whitlock.
Application Number | 20070012589 11/182685 |
Document ID | / |
Family ID | 37478835 |
Filed Date | 2007-01-18 |
United States Patent
Application |
20070012589 |
Kind Code |
A1 |
Cassoni; Robert Paul ; et
al. |
January 18, 2007 |
Process for manufacture of a flexible package
Abstract
A process for the manufacture of flexible packages. The process
may utilize a continuous flexible wall material sequentially
attached to a reinforcing member. The process may have the ability
to form multiple packages in a single moment.
Inventors: |
Cassoni; Robert Paul;
(Washington Twp., OH) ; DiPaola; Michael Joseph;
(Cincinnati, OH) ; Bouten; Heiner; (Zulpich,
DE) ; Whitlock; Peter John; (Warwick, GB) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY;INTELLECTUAL PROPERTY DIVISION
WINTON HILL BUSINESS CENTER - BOX 161
6110 CENTER HILL AVENUE
CINCINNATI
OH
45224
US
|
Family ID: |
37478835 |
Appl. No.: |
11/182685 |
Filed: |
July 15, 2005 |
Current U.S.
Class: |
206/494 ;
206/820 |
Current CPC
Class: |
B29C 66/432 20130101;
B29C 66/71 20130101; B29C 66/1122 20130101; B29K 2021/003 20130101;
B29K 2023/0625 20130101; B29K 2023/0633 20130101; B29K 2071/00
20130101; B29K 2077/00 20130101; B29K 2023/00 20130101; B29K
2023/083 20130101; B29K 2001/00 20130101; B29K 2023/12 20130101;
B29K 2023/06 20130101; B29K 2067/00 20130101; B29K 2033/12
20130101; B29K 2075/00 20130101; B29K 2023/065 20130101; B29K
2059/00 20130101; B29K 2025/08 20130101; B29C 65/02 20130101; B29K
2027/06 20130101; B29C 65/04 20130101; B29C 66/71 20130101; B29C
65/743 20130101; B29C 66/71 20130101; B29C 66/81422 20130101; B29C
66/71 20130101; B29C 66/71 20130101; B29C 66/71 20130101; B31B
2155/001 20170801; B29C 66/71 20130101; B29C 66/83513 20130101;
B31B 70/844 20170801; B29C 65/08 20130101; B31B 70/008 20170801;
B29K 2023/086 20130101; B29C 66/71 20130101; B29K 2033/08 20130101;
B29C 65/16 20130101; B29C 66/71 20130101; B29C 66/81427 20130101;
B31B 2155/00 20170801; B29C 66/72343 20130101; B29C 66/71 20130101;
B31B 2160/10 20170801; B29C 66/4312 20130101; B29C 66/71 20130101;
B29C 66/71 20130101; B29C 66/71 20130101; B31B 70/00 20170801; B29C
66/71 20130101; B29C 66/71 20130101; B29C 66/71 20130101; B29C
66/4322 20130101; B29C 66/71 20130101; B29C 66/83413 20130101; B29C
66/71 20130101; B31B 2155/0014 20170801; B29C 66/71 20130101; B29C
66/71 20130101 |
Class at
Publication: |
206/494 ;
206/820 |
International
Class: |
B65D 73/00 20060101
B65D073/00 |
Claims
1. A method for manufacturing a flexible package, the method
comprising the steps of: a) providing a continuous flexible wall
material, b) providing a reinforcing member, said reinforcing
member comprising a perimeter, c) attaching a first portion of said
flexible wall material to a first portion of said perimeter of said
reinforcing member, to provide a composite structure comprising an
attached first portion and an unattached second portion, d) cutting
said continuous flexible wall material to form a package pre-form,
e) attaching a second portion of said flexible wall material to
said unattached second portion.
2. The method of claim 1 wherein said perimeter of said reinforcing
member comprises a leading edge, a trailing edge, and opposed side
edges.
3. The method of claim 2 wherein said leading edge and said
trailing edge comprise hinge elements.
4. The method of claim 2 wherein said flexible wall material is
first attached to said opposed side edges of said perimeter of said
reinforcing member.
5. The method of claim 4 wherein said flexible wall material is
attached to said leading edge and said trailing edge of said
perimeter of said reinforcing member subsequent to said first
attachment.
6. The method of claim 1 wherein said perimeter of said reinforcing
member comprises a configuration selected from the group consisting
of square, rectangle, circle, ellipse, polygon and oval.
7. The method of claim 1 wherein attachment of said flexible wall
material to said remaining portion of said perimeter of said
reinforcing member occurs with said reinforcing member in a closed
or a partially closed configuration.
8. The method of claim 1 further comprising a step of forming a
package pre-form seal outboard of said reinforcing member, wherein
said package pre-form seal comprises opposed longitudinal side
edges.
9. The method of claim 8 wherein said package pre-form seal is cut
at a position intermediate to said side edges of said package
pre-form seal.
10. A method for manufacturing a flexible package, the method
comprising the steps of: a) providing a continuous flexible wall
material, b) providing a reinforcing member comprising opposed side
edges, a leading edge and a trailing edge opposed said leading edge
wherein said leading edge and said trailing edge comprise hinge
elements, c) attaching said flexible wall material to said opposed
side edges of said reinforcing member to provide a composite
structure, d) at least partially closing said reinforcing member,
e) forming a package pre-form seal outboard of said reinforcing
member, wherein said package pre-form seal comprises two opposed
longitudinal side edges, f) cutting said package pre-form seal at a
position intermediate to said side edges of said package pre-form
seal to form a package pre-form, g) at least partially opening said
reinforcing member, h) attaching said flexible wall material to
said leading edge and said trailing edge of said reinforcing
member.
11. The method of claim 10 wherein said flexible wall material is
provided into a trough wherein said trough comprises at least one
folding board, wherein said folding board allows said flexible wall
material to fold in an upward direction.
12. The method of claim 10 wherein closure is achieved by a method
selected from the group consisting of mechanical closure, closure
bars, magnetic force, air blasts, external pressure, and
combinations thereof.
13. The method of claim 10 wherein opening is achieved by a method
selected from the group consisting of suction cups, pry bars, flat
ploughs, tongs, magnetic force, air blasts, ploughs, and
combinations thereof.
14. The method of claim 10 wherein said hinge elements comprise
living hinges.
15. The method of claim 10 wherein more than one said package
pre-form seal is located outboard of at least one edge of said
reinforcing member, wherein said flexible wall material is unbonded
between said multiple package pre-form seals.
16. The method of claim 15 wherein said cutting occurs at a
position intermediate to said multiple package pre-form seals.
17. An intermediate product in a continuous manufacturing process
comprising: a) a continuous flexible wall material, b) a plurality
of reinforcing members attached to said flexible wall material at
spaced apart locations along said flexible wall material.
18. The intermediate product of claim 17 wherein said continuous
flexible wall material is partially attached to said reinforcing
members.
19. The intermediate product of claim 17 wherein said reinforcing
members are in either an open or partially open configuration.
20. The intermediate product of claim 17 wherein said reinforcing
members are in a closed or partially closed configuration.
21. The intermediate product of claim 17 comprising a package
pre-form seal between said reinforcing members.
Description
FIELD OF THE INVENTION
[0001] This invention relates to the process for the manufacture of
flexible packages. The packages may be suitable for a variety of
applications. The process may utilize a continuous flexible wall
material sequentially attached to a reinforcing member. The process
may have the ability to produce multiple flexible packages in a
continuous in-line production process.
BACKGROUND OF THE INVENTION
[0002] A wide variety of packages for articles of all different
types are known in the art. Many of the features of such packages
are dictated or influenced by the products or items they are
designed to hold or carry or the uses to which they are expected to
be put. For example, moisture containing cleansing articles such as
wet wipes (such as adult toilet wipes, cleaning wipes, and wet baby
wipes for the hands, face, or diaper change wiping) are often
packaged in either hard plastic "tubs" or smaller, often flexible
packages for more portable use. In the example of wet wipes, or
other moisture containing articles, the articles may be dispensed
with one hand (for example when holding a baby with the other
hand). In such a case, it may be desirable to be able to open the
package, dispense an article, and close the package with a single
hand. Other possible desired attributes of a package for articles
such as moisture containing cleansing articles are that it be
flexible, compact, and remain open or closed without further action
by the user. Of course some or all of these attributes may be
desired for packages for uses other than containing moisture
containing cleansing articles. These attributes and others may be
desired in any combination. Packages having some or all of these
attributes (and others not necessarily included on this list) may
be desired for a wide variety of applications.
[0003] In particular, there may be a desire to have flexible
packages which can store articles and be opened and closed with a
single hand. It may be desired that the package remains open once
opened by a user without further application of force and that when
closed by a user, the package remains closed. It may also be
desired that such packages be re-usable if desired, such as by
refilling them in whole or in part with additional articles such as
moisture containing cleansing implements. It may be desirable to
formulate a process which can produce flexible packages which can
store articles and be opened and closed with a single hand.
[0004] Processes known and used to assemble packages with the
desired attributes generally do not complete the package assembly
as a single process. Known processes may require some amount of
human manipulation during the process to complete assembly of the
packages.
[0005] Known processes which utilize some degree of human
manipulation to assemble single discrete packages may have limited
throughput of completed packages. There may also be lower
reliability of the process if human manipulation is required or if
each package is handled discretely by equipment. High costs
associated with package assembly may result from processes which
rely on human manipulation or single discrete package assembly.
[0006] It may be beneficial to provide new processes which can
manufacture flexible packages that can reduce or eliminate the need
for human manipulation of the packages. It may also be beneficial
to provide new processes in which an in-line continuous flexible
wall material is utilized rather than discrete pieces of flexible
wall material. The use of the continuous flexible wall material can
provide greater handling capability as well as greater control
capability. Both of these capabilities may result in higher
processing speed and less variance in the resulting flexible
packages. It may further be beneficial to provide new processes
that open up opportunities for producing new packages which allow
for an increased throughput and generate multiple packages. It may
be beneficial to provide new processes that reduce or eliminate
human error and allow for an increase in the quality of the package
that is assembled. It may further be beneficial to provide new
processes at reduced manufacturing cost.
SUMMARY OF THE INVENTION
[0007] The present invention relates to a process for making a
flexible package comprising the steps of providing a continuous
flexible wall material, providing a reinforcing member comprising a
perimeter of an opening, attaching the flexible wall material to a
first portion of the reinforcing member perimeter to provide a
composite structure comprising an attached first portion and an
unattached second portion, cutting the flexible wall material at
points beyond the reinforcing member to produce package pre-forms,
and attaching the remainder of the flexible wall material to the
remainder of the reinforcing member perimeter to fully form the
flexible package.
[0008] In certain embodiments of the present invention, the
reinforcing member may be in the shape of a square, rectangle,
circle, ellipse, polygon or oval.
[0009] In certain embodiments, the reinforcing member may comprise
a leading edge, a trailing edge, and opposed side edges. In such
embodiments, the flexible wall material may be first attached to
the opposed side edges. The flexible wall material may then be
attached to the leading and trailing edges.
[0010] In certain embodiments of the present invention, a package
pre-form seal may be created at a location external to the
perimeter of the reinforcing member. The package pre-form seal may
then be cut at a location intermediate to the edges of the package
pre-form seal to create discrete package pre-forms.
[0011] In certain embodiments of the present invention, the process
may comprise a further step of forming a gusset in the bottom of
the flexible package.
[0012] In certain embodiments of the present invention, the process
for making a flexible package may comprise the steps of providing a
continuous flexible wall material, providing a reinforcing member
comprising a perimeter, attaching the flexible wall material to a
portion of the reinforcing member perimeter, closing the
reinforcing member, forming a package pre-form seal outboard of the
perimeter of the reinforcing member, cutting along a line at a
position intermediary to the seal edges to create discrete segments
of flexible packages, opening the reinforcing member and attaching
the flexible wall material to the remaining portion of the
reinforcing member perimeter.
[0013] In certain embodiments of the present invention, attachment
of the flexible wall material to a portion of the reinforcing
member perimeter may occur while the reinforcing member is in a
closed or sufficiently closed configuration.
[0014] In other embodiments of the present invention, attachment of
the flexible wall material to a portion of the reinforcing member
perimeter may occur while the reinforcing member is in an open or
sufficiently open configuration.
[0015] In certain embodiments of the present invention, the process
for making a flexible package may comprise the steps of providing a
continuous flexible wall material, providing a reinforcing member
comprising a perimeter, attaching the flexible wall material to a
portion of the reinforcing member perimeter, closing the
reinforcing member, forming a pre-form seal outboard of the
perimeter of the reinforcing member, opening the reinforcing member
and attaching the flexible wall material to the remaining portion
of the reinforcing member perimeter, and cutting along a line at a
position intermediate to the seal edges to create discrete
packages.
[0016] The present invention may also relate to the production of
multiple package pre-forms continuously attached to each other
prior to separation into discrete packages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] While the specification concludes with claims particularly
pointing out and distinctly claiming the subject matter which is
regarded as forming the present invention, it is believed that the
invention will be better understood from the following and
foregoing description taken in conjunction with the accompanying
drawings, in which:
[0018] FIG. 1 is a plan view of an exemplary flexible package,
which can be produced by the production line of the present
invention.
[0019] FIG. 2 is a plan view of exemplary reinforcing member
shapes.
[0020] FIG. 3 is a plan view of multiple composite structures and
package pre-forms made according to the present invention.
[0021] FIG. 4 is a schematic diagram of one embodiment of the
production line of the present invention in which the reinforcing
member experiences both closed and open configurations.
[0022] FIG. 5 is a schematic diagram of one embodiment of the
production line of the present invention for producing flexible
packages in which the reinforcing member remains in an open
configuration.
[0023] FIG. 6 is a schematic diagram of one embodiment of the
production line of the present invention for producing flexible
packages in which the reinforcing member is in a partially closed
configuration.
[0024] FIG. 7 is a schematic diagram of one embodiment of the
production line of the present invention for producing flexible
packages with an optional gusset.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention may reduce or eliminate the need for
discrete pieces of flexible wall material and human manipulation.
The present invention can combine the use of a continuous flexible
wall material with a fully automated system into a continuous
process for assembling flexible packages. In one embodiment, the
package can be opened or closed with one hand.
Terminology
[0026] The term "continuous process" refers herein to an in-line
production process that may produce multiple packages without
stopping. The continuous process may comprise providing a plurality
of reinforcing members, providing a supply of flexible wall
material and aligning the reinforcing members and the flexible wall
material in a spaced-apart relationship on an assembly line. The
reinforcing members and flexible wall material may be attached to
form composite structures, package pre-forms and further processed
into packages.
[0027] The term "continuous flexible wall material" refers herein
to a component of a package made according to the process of the
present invention that is sufficiently long so as to produce
multiple packages from that component.
[0028] The term "material" refers herein to include either a
natural or synthetic material or any combination thereof, including
films, film laminates, non-woven laminates, sponges, non-woven
webs, woven webs, knitted fabrics, foams, natural materials, and
any combination thereof, or dry lap materials including wood pulp,
and the like, having a single layer or multiple layers.
[0029] The term "non-woven fabric" or "non-woven material" or
"non-woven web" or "non-woven" refers herein to a material made
from continuous filaments and/or discontinuous fibers, without
weaving or knitting by processes such as spun-bonding and
melt-blowing. The non-woven material can comprise one or more
layers of the non-woven material, wherein each layer can include
continuous filaments or discontinuous fibers.
[0030] The term "foam" refers herein to any material comprising a
solid, liquid crystalline, or liquid continuous phase and a gaseous
dispersed phase. Because of the dispersed gaseous phase, foam has a
density less than the density of the continuous phase.
[0031] The term "film" refers herein to any polymeric sheet made by
a process such as, but not limited to, extrusion of a polymeric
material through a narrow slot of a die. The polymeric sheet can
optionally be impervious to a liquid and pervious to an air
vapor.
[0032] The term "polymer" or "polymeric" refers herein to
thermosetting and/or thermoplastic compositions, including but not
limited to, polyolefins, including polyethylene, polypropylene,
linear low density polyethylene, low density polyethylene, low
density polypropylene, high density polyethylene, high density
polypropylene, polyesters, polyamides, polyacetals, polyethers,
poly (meth) acrylates, thermoplastic elastomers, styrenic block
copolymers, metallocene-catalyzed polyolefins, polyether amides,
polyurethanes, polyvinylchloride, superabsorbent materials, rayon,
ethylene vinyl acetate, ethylene vinyl alcohol, and blends and
copolymers, filled polymers, biconstituent or bicomponent mixtures
thereof and combinations thereof. The polymeric material can also
include various pigments to provide desired colors and/or visual
effects and other components such as antioxidants, fillers (such as
magnetoplumbite-structure ferrite particles), processing aids and
the like.
[0033] A "natural material" means herein a material derived from
plants, animals, insects or byproducts of plants, animals, and
insects. Non-limiting examples of natural materials include
cellulosic fibers, cotton fibers, keratin fibers, silk fibers and
the like. Non-limiting examples of cellulosic fibers include wood
pulp fibers, hemp fibers, jute fibers, and the like. Non-limiting
examples of keratin fibers include wool fibers, camel hair fibers
and the like.
[0034] The term "attach" herein refers to a component of a flexible
package is at least partially secured directly or indirectly (by
one or more intermediate members) to another component of the
flexible package. Attachment may be relatively continuous or
intermittent. Relatively continuous attachment may imply that the
components are bonded together over substantially all of one or
more dimensions of a common interface between the components.
Intermittent attachment may imply that the components are bonded
together with one or more individual, discrete bonds that are not
continuous or bond patterns having open areas free of bonds.
Attachment may be conducted by a variety of methods well known in
the art such as adhesive bonding, thermal bonding, mechanical
bonding, ultrasonic bonding, heat bonding, pressure bonding,
stitching, induction bonding, RF bonding, microwave bonding, laser
bonding, and the like. If the attachment is performed by an
adhesive applicator, the adhesive applicator may apply an effective
amount of adhesive so as to make the attachment.
[0035] The term "flexible" or "flexible" means herein that the
material out of which the package walls are constructed will tend
to conform or deform in the presence of externally applied forces.
As measured under the Stiffness of Fabric test, the flexible wall
material may have a peak load of less than about 1000 g.sub.f.
[0036] The term "reinforcing member" means herein a component of
the package which offers more resistance to bending or deformation
than the flexible packaging material as a whole.
Exemplary Flexible Package
[0037] The following description describes, in detail, features of
flexible packages which may be produced according to the present
invention. It should be noted that the design elements and
attributes described herein are exemplary and the scope of the
invention is determined solely by the appended claims. One example
of a flexible package that can be produced by the process of the
present invention is illustrated in FIG. 1. FIG. 1 shows a flexible
package 20 made according to the present invention in an open
configuration.
[0038] The package 20 may comprise as its basic components a
flexible wall material 40 and a reinforcing member 50. These basic
components may provide primary functions of a package for a wide
variety of moisture containing articles, and also normally define
the size, shape and the perimeter of a particular package. These
basic components may also be combined to produce a flexible package
which can store articles (not shown). Further the package 20 may be
opened and closed with a single hand. As shown in FIG. 1, the basic
arrangement of the flexible wall material 40 of the package 20 may
be such that the flexible wall material 40 surrounds the articles
to be contained and dispensed. In this exemplary configuration, the
flexible wall material 40 may define a flexible package having four
side walls, such as side walls 80 and 81, bottom wall 82, and an
opening 70. The package 20 may also comprise an end seal 30 formed
according to the present invention. The package 20 shown in FIG. 1
may also comprise a reinforcing member 50 defining a perimeter of
the opening 70 of the package 20.
[0039] The bottom wall 82 of the package 20 may be formed by a
single sheet of continuous flexible wall material 40 or by multiple
sheets of flexible wall material 40. A single sheet of flexible
wall material 40 inserted into a production line of the present
invention may be folded or otherwise configured to provide two
opposing panels 42 and 44 (shown in FIG. 5). The opposing panels 42
and 44 may be attached to the reinforcing member 50 to form a
continuous bottom wall 82 of a package 20 and two opposing side
walls (such as side wall 81). In another embodiment, separate
opposing sheets of flexible wall material 40 may also be used to
form a bottom wall 82. In this embodiment, the separate, opposing
sheets of flexible wall material 40 may each have an upper end (not
shown) and a distal end (not shown). The upper ends of the sheets
of flexible wall material 40 may be attached to opposing sides of
the reinforcing member 50. The free distal ends of the sheets may
be attached together to provide a sealed bottom wall 82.
[0040] The package 20 may take on various overall shapes. As
exemplified in FIG. 1, the package 20 may be in a substantially
parallelepiped configuration. Alternative shapes of the package 20
may also include, but are not limited to, tubular, square, V-shape,
U-shape, gusseted, and non-gusseted. The package 20 may contain a
reinforcing member 50 comprising a perimeter. The perimeter may
initially serve as the border of the reinforcing member 50 and
provide a structure on which to attach the flexible wall material
40. The perimeter may be discernible as any pathway or portion
along the reinforcing member 50 that may form a closed loop. Once
the package 20 of the current invention has been produced, the
perimeter of the reinforcing member 50 may also define the opening
70 of the package 20. The reinforcing member 50 may comprise hinge
elements 15 so as to enable the package 20 to open and close.
[0041] As shown in FIG. 1 the overall dimensions of package 20 may
be selected to result in a configuration useful for containing
various articles. For example, in the configuration shown in FIG.
1, the package 20 may have an overall length dimension L of from
about 70 to about 600 mm. In another embodiment, the overall length
dimension L may be from about 70 mm to about 450 mm and from about
70 mm to about 300 mm in yet another embodiment. Similarly, the
width dimension W may be from about 30 mm to about 400 mm. In yet
another embodiment, the width dimension W may be from about 30 mm
to about 300 mm and may be from about 30 mm to about 200 mm in yet
another embodiment. The height dimension of the package 20 in the
closed configuration H.sub.c may be from about 30 mm to about 300
mm. In yet another embodiment, the height dimension in the closed
configuration may be from about 30 mm to about 750 mm and from
about 30 mm to about 1450 mm. The height of the package 20 when in
the open configuration H.sub.o may be greater than the height of
the package 20 when in the closed configuration H.sub.c. The height
dimension of the package 20 in the open configuration H.sub.o may
be from about 40 mm to about 400 mm. In another embodiment, the
height dimension of the package in an open configuration may be
from about 40 mm to about 800 mm and from about 40 mm to about 1500
mm in yet another embodiment.
[0042] As exemplified in FIG. 2, the shape of the reinforcing
member 50 may be in the shape of, but not limited to, rectangular,
square, circular, ovoid, polygonal and elliptical. Hinge elements
15 may be located at an axis point of the reinforcing member 50 and
may generally be provided as an opposing pair. The resulting
finished package 20 may generally assume the overall shape of the
reinforcing member 50 e.g., a circular reinforcing member 50 may
yield a generally cylindrical package; an ovoid reinforcing member
50 may yield a tubular ovoid package, etc.
[0043] Further discussion of an exemplary flexible package may be
found in U.S. patent application Ser. No. 10/971,636 filed in the
name of Saggar et al. entitled Flexible Stable Easily Opened
Package (P&G Case No. 9809).
Exemplary Package Pre-Form Chain
[0044] The production line 100 of the present invention corresponds
to a continuous process of an in-line assembly of the package 20.
FIG. 3 exemplifies that the flexible wall material 40 may be
introduced into the production line 100 in such a manner as to form
opposing side panels A and A'. This may be by folding the flexible
wall material 40 into a U- or V-shaped formation as shown in FIG.
3. A composite structure 16 may exist after initial attachment of
the flexible wall material 40 to a reinforcing member 50. The
composite structure 16 may comprise the flexible wall material 40
in an unattached state outboard of the leading edge 51 and trailing
edge 52 of the reinforcing member 50 of the composite structure 16.
Opposing side panels B and B' of the flexible wall material 40 may
be situated between sequentially attached reinforcing members 50
which comprise composite structures 16. Creating package pre-form
seals 34 in the flexible wall material 40 outboard of the
reinforcing member 50 may convert the composite structure 16 into a
package pre-form 17. The package pre-form seal 34 may comprise two
longitudinal edges 31 and 32. Multiple package pre-forms 17
connected to each other may form a package pre-form chain 25
comprising a series of package pre-forms 17 linked together. Each
of the package pre-forms 17 of the chain 25 may have a reinforcing
member 50 in either a closed or open configuration. Opposing side
panels C and C' of the flexible wall material 40 may be situated
between the package pre-form seals 34 and the reinforcing member 50
which together may comprise a package pre-form 17. The package
pre-form seal 34 may be cut, at a location intermediate to the two
longitudinal edges 31 and 32, to produce an end seal 30 of a
package pre-form 17. Opposing side panels D and D' of the flexible
wall material 40 may be situated between the reinforcing member 50
and the end seal 30. The area of flexible wall material 40
characterized by D and D' may generally be termed a flap 35.
Production Line
[0045] The production line 100 may be an in-line assembly of the
package 20. The production line 100, depending on the complexity of
the flexible package 20, can include any number of stations,
wherein each station may provide either a particular component of
the flexible package for attaching to the rest of the components
into a final product or may manipulate the provided components to
further manufacture the final package. In addition, the sequential
order of the stations can vary depending upon the type of flexible
package 20 being produced, its particular design, as well as many
other processes and production considerations. Further, the
production line 100 can be configured to form any suitable
configuration of the stations on the production floor. The
production line 100 may have a linear configuration of the
stations, however, the configuration may also be curvilinear,
circular, rectilinear, U-shape, C-shape, X-shape, cross-shape, or
any combination thereof. Further, several production lines 100 can
be situated in any suitable relation to each other to form any
suitable arrangement on the production floor.
[0046] The production line 100 may comprise one or more stations,
such as assembly stations, cutting stations, closing stations,
opening stations, and gusseting stations. The stations may be
placed in any order and some or all stations may be utilized for
the production of a flexible package.
[0047] It may be desired to advance the package chain in a stepwise
manner, bringing various portions of the package chain to
appropriate workstations as exemplified below. It may be desired to
produce a package of the present invention in the machine direction
(MD). The machine direction may be the designated direction of flow
of workpieces from the beginning of the process to the final
product. It should be understood that any or all steps may be
performed in the cross direction (CD). The cross direction may be
designated as a direction perpendicular to the machine
direction.
[0048] FIG. 4 depicts a schematic diagram of one embodiment of a
composite structure 16 being processed into a package pre-form 17
and further processed in the production line 100 of the present
invention to produce a flexible package 20 such as shown in FIG. 1.
A reinforcing member 50 may be partially attached to the flexible
wall material 40 forming a composite structure 16. The reinforcing
member 50 may be in a sufficiently open configuration during
attachment. The reinforcing member 50 may be positioned into a
sufficiently closed configuration following the initial attachment
of the flexible wall material 40 to the reinforcing member 50.
[0049] A package pre-form seal 34 may be cut (as discussed above)
to produce a package pre-form 17 comprising at least one end seal
30. It has now been discovered that if the reinforcing member 50
was positioned in a sufficiently closed configuration, the
reinforcing member 50 may be reopened to allow the flap 35
comprising the flexible wall material 40 and the end seal 30 to be
naturally drawn into position for attachment of the flexible wall
material 40 to the remainder of the reinforcing member 50 to
transform the package pre-form 17 into a package 20. Without being
bound by theory, this may be a natural result of an appropriately
selected relationship between the overall size of the package 20
and the size of the reinforcing member 50.
[0050] FIG. 5 depicts a production line of an in-line assembly of a
package 20. An assembly station 75 may receive both the flexible
wall material 40 (such as from a continuous supply) and the
reinforcing member 50 (as a series of discrete parts). The
reinforcing member 50 may be positioned to accept the attachment of
e portion of the flexible wall material 40 on portions of the
reinforcing member 50 perimeter to produce a composite structure
16. Package pre-form seals 34 may then be formed outboard of the
reinforcing member 50 to create a package pre-form 17. Multiple
package pre-forms 17 may remain connected to form a package
pre-form chain 25 (as shown in FIG. 3) or the package pre-form
seals 34 may be cut at a location intermediate to the package
pre-form seal edges, such as edges 31 and 32, to produce a cut edge
33 thereby further producing individual package pre-forms 17.
[0051] The reinforcing member 50 may be at least partially attached
to the flexible wall material 40 in the assembly station 75. In the
context of the present invention, the assembly station 75 may be
provided with the ability to detect any loss of synchronization
between the flexible wall material 40 and the reinforcing member
50. The detection means for detecting loss of synchronization may
be implemented in a wide variety of ways. The detection means may
be optical cells or mechanical feelers situated at a measured and
known fixed distance from the points of attachment. The detection
means may be adapted to ensure synchronization relative to
detection marks applied to the flexible wall material 40 and/or the
reinforcing member 50.
Providing a Flexible Wall Material
[0052] As may be seen in FIG. 5, a flexible wall material 40 may be
provided in a substantially continuous manner (i.e., the flexible
wall material may be supplied continuously during the normal
operation of the process) such as from a bulk supply roll (not
shown). Suitable flexible wall materials may include either a
natural or synthetic material or any combination thereof, including
films, film laminates, non-woven laminates, sponges, non-woven
webs, woven webs, knitted fabrics, foams, natural materials, and
any combination thereof, or dry lap materials including wood pulp,
and the like, having a single layer or multiple layers and any
combination thereof. Additional suitable flexible wall materials
may be found as disclosed in U.S. Pat. Nos. 5,006,380, 5,205,650,
5,518,801, 5,650,214, 5,691,035, 5,723,087, 6,394,652. In some
embodiments, the flexible wall material 40 may include a fibrous
substrate such as an extensible non-woven web that comprises
polyolefin fibers and/or filaments. In some embodiments, the
flexible wall material 40 may have a peak load in grams-force
(g.sub.f) as measured under the Stiffness of Fabric Test of less
than about 250 g.sub.f, or less than about 500 g.sub.f, or less
than about 1000 g.sub.f. It will be appreciated, by those of skill
in the art, that the Stiffness of Fabric Test can be employed on
materials not commonly thought of as "fabrics" such as leather,
synthetic leather, plastics, and other materials from which
packages can be made.
[0053] The flexible wall material 40 may be provided by bulk supply
roll or on-line formation. In such an embodiment, the process may
be equipped with a formation station where the flexible wall
material 40 may be created. Methods for creating a flexible wall
material 40 such as, for example, films, knitted fabrics, woven
fibrous webs, non-woven fibrous webs, laminates or combinations
thereof are well known in the art.
[0054] As shown in FIG. 5, the flexible wall material 40 may be fed
into a trough 55 to allow for a general U-shape of the flexible
wall material 40 to form opposing panels 42 and 44 situated on
either side of the reinforcing member 50. As previously stated, a
single sheet of flexible wall material 40 may be fed into a trough
55 to form a continuous bottom wall 82. In another embodiment,
multiple sheets of flexible wall material 40 may be fed into a
trough 55. The distal ends of the sheets (not shown) may then be
attached together to form a bottom wall 82. The uppermost portion
of the trough 55 may comprise a guide track 60 for receiving items
such as reinforcing members 50.
Providing Reinforcing Members
[0055] As may be seen in FIG. 5, a plurality of reinforcing members
50 may be provided in a substantially sequential manner (i.e., the
reinforcing member may be supplied in a pattern of one reinforcing
member following another reinforcing member at specified intervals
during the normal operation of the process). In some embodiments,
the reinforcing members 50 may be dropped onto a guide track 60 by
a mandrel 65 (shown in FIG. 7). In other embodiments, the
reinforcing member 50 may be placed into the track 60 from the same
directional plane. The reinforcing member 50 may be provided to the
production line 100 in such a manner as to have a leading edge 51,
trailing edge 52, and two opposing side edges 53 and 54.
[0056] The reinforcing member 50 may be of any convenient and
desired configuration. It may be useful to provide a reinforcing
member 50 comprising a perimeter. It may also be useful to provide
a reinforcing member 50 which provides a defined perimeter of the
opening 70 of the package 20. The perimeter may be in the shape of
a square, rectangle, circle, elliptical, polygon or oval
configuration. The package 20 may be formed into the same perimeter
shape of the reinforcing member, but the overall shape of the
package 20 should not be so limited.
[0057] It may also be useful to provide the reinforcing member 50
with a pair of hinge elements 15. The hinge elements 15 may be
located on the leading edge 51 and trailing edge 52 of the
reinforcing member 50. Such a hinge element 15 could be an area of
weakness, reduced diameter, or the like within the reinforcing
member 50 providing a defined location where the reinforcing member
50 can bend about a folding axis. The hinge elements 15 can be
actual hinge structures such as a pinned structure. The hinge
elements 15 may also be so called "living hinges" in which joints
are created by an area or zone of weakness in the reinforcing
member 50 as a whole. The hinge elements 15 designed as "living
hinges" are areas of less material and preferred bending and
weakness designed to allow the reinforcing member 50 to be opened
and closed multiple times throughout its life. It may be desired to
design the reinforcing member 50 and the hinge elements 15 such
that the reinforcing member tends to be stable in at least a closed
and near full open position. Thus, it may be desired that when the
reinforcing member 50 is in the open configuration (as shown in
FIG. 1), it does not tend to close on its own in the absence of
externally applied forces. This may allow the reinforcing member 50
to hold the opening 70 of the package 20 open for article retrieval
and use.
[0058] The reinforcing member 50 may be composed of a variety of
materials including, but not limited to, cardboard, corrugated
paper, wood, metal, cardstock, thermoplastic material,
non-thermoplastic material (i.e., plastic), paper, ceramic, bone,
thermosetting polymers and combinations thereof. The reinforcing
member 50 may be, but need not be, comprised of a thermoplastic
material. For example, the reinforcing member 50 may be comprised
of a high density polyethylene injection molded frame. The
reinforcing member 50 may also be comprised of polypropylene,
polyethylene, and combinations thereof. The reinforcing member 50
may be of a thickness sufficient to provide some degree of rigidity
as compared with the flexible wall material 40. The materials of
the reinforcing member 50 and the flexible wall material 40 may be
the same or similar and may be selected to be compatible with the
method of attachment utilized to attach the reinforcing member 50
to the flexible wall material 40.
Attaching the Flexible Wall Material to the Reinforcing Member
[0059] The flexible wall material 40 may be attached to at least a
portion of the perimeter of the reinforcing member 50. As shown in
FIG. 5, attachment of the flexible wall material 40 to the
reinforcing member 50 may occur more than once during production.
The term "attach" is not limited to securing the flexible wall
material 40 to the entire perimeter of the reinforcing member 50.
Rather, attachment may occur multiple times to various portions of
the perimeter. The flexible wall material 40 may be partially
attached to a first portion of the perimeter of the reinforcing
member 50 in an assembly station 75. The first partial attachment
of the flexible wall material 40 to a first portion of the
perimeter of the reinforcing member 50 may occur in the machine
direction. In another embodiment, the flexible wall material 40 may
also be attached to the opposing side edges 53 and 54 of the
reinforcing member 50. The composite structure 16 may then be in
either a closed or open configuration. The flexible wall material
40 may be cut prior to any further attachment of the flexible wall
material 40 to the reinforcing member 50.
[0060] Attachment of the flexible wall material 40 to the remainder
of the perimeter may occur following the initial attachment or may
occur prior to or following the opening and/or closing of the
reinforcing member 50 and/or cutting of the flexible wall material
40. The attachment of the flexible wall material 40 to the
remainder of the perimeter of the reinforcing member 50 may occur
in the cross direction. In another embodiment, attachment of the
remainder of the flexible wall material 40 may also occur to the
leading edge 51 and trailing edge 52 of the reinforcing member
50.
[0061] As shown in FIG. 5, the flexible wall material 40 and the
reinforcing member 50 may be brought together in a face-to-face
relationship by way of bonding rolls 77. The bonding rolls 77 may
form a bonding nip whereby the flexible wall material 40 and the
reinforcing member 50 may be brought into contact and may be
compressed. In the case of adhesive attachment, compression may
improve adhesive spread and/or penetration into the flexible wall
material 40 and/or the reinforcing member 50 thus providing for a
stronger adhesive bond. In the case of thermo-mechanical bonding,
the bonding rolls may impart bonding by heat and/or pressure so as
to fuse the flexible wall material 40 and the reinforcing member
50.
Forming a Package Pre-Form Seal
[0062] As may be seen in FIG. 5, the flexible wall material 40
extending outboard of the reinforcing member 50 may be attached
together to form a package pre-form seal 34.
[0063] If the attachment is performed by an adhesive applicator
(not shown), the adhesive applicator may apply an effective amount
of adhesive so as to attach the flexible wall material 40 together.
The opposing flexible wall material panels 42 and 44 may be brought
together in a face-to-face relationship by way of a profile sealer
37. The profile sealer 37 may form a package pre-form seal 34
whereby the opposing panels 42 and 44 may be brought into contact
with each other and pressed together. In the case of an adhesive
sealing, compression may improve adhesive spread and/or penetration
into the flexible wall material 40 thus providing for a stronger
adhesive bond. In the case of thermo-mechanical bonding, the
profile sealer 37 may impart bonding by heat and/or pressure so as
to fuse the flexible wall material 40.
[0064] The profile sealer 37 may include multiple seal bars 38 and
supply heat in a conventional manner. The profile sealer 37 may
supply the fusion energy necessary to adhere the flexible wall
material 40 together. The seal bars 38 of the profile sealer 37 may
be positioned on opposite sides of the production line and, when
actuated, seal the flexible wall material 40 creating a package
pre-form seal 34. The seal bars 38 may exert an external pressure
along the longitudinal length of the flexible wall material 40 to
form a package pre-form seal 34.
[0065] The package pre-form seals 34 may be formed at time
intervals according to the overall size of the package 20.
Optionally, the spacing between the package pre-form seals 34 may
be varied according to specifications of the desired package 20.
The package pre-form seal 34 may have two longitudinal edges 31 and
32 delineating the boundary of the package pre-form seal 34. The
package pre-form seals 34 may have a generally constant width
throughout the package pre-form seal 34.
Cutting Said Flexible Wall Material
[0066] As may be seen in FIG. 5, the package pre-form seals 34 of
the flexible wall material 40 may be severed to create discrete
segments of package pre-forms 17. Cutting may occur by various
cutters, including but not limited to, knives and lasers. In one
embodiment, a series of guillotine-type cutters (not shown) may be
employed to sever the package pre-form chain 25 (as shown in FIG.
3) into package pre-forms 17. The cutters may be aligned so as to
sever the package pre-form seals 34. Cutting of the package
pre-form seal 34 may generally occur at a position intermediate to
the two longitudinal edges 31 and 32 of the package pre-form seal
34. In another embodiment, two package pre-form seals 34 may be
formed external to either the leading edge 51 or trailing edge 52
of the reinforcing member 50 prior to cutting the flexible wall
material 40. In this embodiment, cutting may generally occur in the
area of the unattached flexible wall material 40 situated between
the two package pre-form seals 34.
[0067] In another embodiment, the cutting of the flexible wall
material 40 may occur immediately following, or in conjunction
with, the formation of the package pre-form seals 34. In this
alternate embodiment, the cutters may be located within the profile
sealer 37 and upon activation, the cutters may extend beyond the
seal bars 38 to create the cuts which would separate the package
pre-forms 17.
[0068] It may be desirable to support the segments of the package
chain prior to the severing operation so as to maintain positional
control of the severed flexible packages. Any of a number of
conventional supports, such as vacuum operated suction cups can be
employed for this purpose. If suction cups are utilized, they may
be located on opposite sides of the flexible packages so that, by
withdrawing the suction cups away from one another, the reinforcing
member may be opened.
Opening the Reinforcing Member
[0069] As shown in FIG. 5, the reinforcing member 50 may be in an
open configuration at any point in the production line 100. The
reinforcing member 50 may be provided to the production line 100 in
an open configuration. The reinforcing member 50 may also be placed
into an open configuration at any point during production.
[0070] Opening of the reinforcing member 50 may be done in a
variety of ways. The reinforcing member 50 may be formed by
injection molding in an open configuration. The reinforcing member
50 may also be opened by mechanical means. Methods that may be used
to open the reinforcing member 50 may include, but are not limited
to, suction cups, pry bars, flat ploughs, tongs, magnetic force,
air blasts, ploughs, and combinations thereof.
Closing the Reinforcing Member
[0071] As shown in FIG. 6, the reinforcing member 50 may be in a
closed configuration at any point in the production line 100. The
reinforcing member 50 may be provided to the production line 100 in
a closed configuration. The reinforcing member 50 may also be
placed into a closed configuration while moving through the
production line 100, such as prior to reaching an assembly station
75. The reinforcing member 50 may also be placed into a closed
configuration after passing through an assembly station 75 (as
shown in FIG. 7).
[0072] Closure of the reinforcing member 50 may be conducted in a
variety of ways. The reinforcing member 50 may be formed by
injection molding in a closed configuration. The reinforcing member
50 may also be closed by any mechanical means such as closure bars
95 placed along the production line 100 or by magnetic force or air
blasts and combinations thereof. FIG. 6 exemplifies that closure
bars 95 may also be located along the topside of the production
line 100 and placed into the hinge elements 15 of the reinforcing
member 50 in order to close the reinforcing member 50 (also shown
in FIG. 7). The reinforcing member 50 may also be closed by
pressure exerted by the flexible wall material 40 following
attachment.
Forming an Optional Bottom Gusset in the Flexible Wall Material
[0073] As shown in FIG. 7, it may be desirable to form a bottom
upward fold in the flexible wall material 40 forming a gusset in
order to facilitate the formation of a flat bottom 82 in the
flexible package 20 (as shown in FIG. 1). The flexible wall
material 40 may be fed into a trough 55 in the production line 100.
The trough 55 may further comprise at least one folding board 90.
The flexible wall material 40 may be passed through the trough 55
in such a manner as to follow the shape of the folding board 90
thus allowing the flexible wall material 40 to fold in an upward
direction forming a gusset.
Test Method
Stiffness of Fabric Test
[0074] The Stiffness of Fabric Test is run for purpose of the
present specification is a modification of the Stiffness of Fabric
Test by Circular bend as described in the ASTM D 4032-94. (hereby
incorporated by reference). The Stiffness of Fabric Test for
purposes of the present specification is conducted as follows:
Summary of Test Method
[0075] A pusher-ball forces a swatch of material through an orifice
in a platform. The maximum force required to push the fabric
through the orifice is an indication of the material's stiffness
(resistance to bending).
Apparatus
[0076] Circular Bend Stiffness Tester, having the following parts:
[0077] Platform, 102 by 102 by 6 mm smooth-polished chrome-plated
steel plate with a 38.1-mm diameter orifice. The lap edge of the
orifice should be at a 45.degree. angle to a depth of 4.8 mm.
[0078] Pusher-Ball, 6mm diameter steel spherical ball, mounted
concentric with orifice, 16 mm clearance on all sides. The bottom
of the pusher-ball plunger should be set at 3 mm above the top of
the orifice plate. From this position, the downward stroke length
is 57 mm. [0079] Force-Measurement Gage, dial or digital type Dial
gages with maximum reading pointer in different capacities ranging
from 1 to 50 lbf, 0.5 to 25 kgf, or 5 to 200 N with 100 graduations
minimum; or Digital gage with maximum reading "hold" feature and
capacity of 100 lbf, 50 kgf, or 500 N, with 1000 graduations
minimum. [0080] Actuator, manual or pneumatic. [0081] Specimen
Marking Template, 102 by 102 mm. [0082] Stop Watch, for checking
stroke speed. Number and Preparation of Test Specimens
[0083] Using the specimen marking template specified above mark and
cut five test specimens from staggered areas of each swatch of
material to be tested. It will be appreciated that it may not be
practical or possible to obtain all samples from a particular
swatch (or particular product if the material is only available as
incorporated into a product). In such a case, it is acceptable to
take samples from multiple products or swatches. Samples with
bonded, seals, seams or the like should be avoided. Lay each
specimen flat to form a square 102 by 102 mm. Handling of specimens
should be kept to a minimum and to the edges to avoid affecting
stiffness properties.
Conditioning
[0084] Store the samples for 8 hours or more at 23.degree. C and
50% relative humidity.
Procedure
[0085] Set the tester on a flat surface with dial at eye level.
[0086] Select a gage with a capacity in which results will fall
within 15 to 100 % of dial gage force or 1.5 to 100 % of digital
gage force. [0087] Check tester pusher-ball speed control for full
stroke length. [0088] Pneumatic Actuator--Set the air pressure
control to the actuator at 324 kPa. Using a stop-watch, adjust the
pneumatics to provide plunger speed of 1.7.+-.0.15 s under no load
conditions. [0089] Manual Actuator--Using a stop-watch, establish
and confirm a plunger speed of 1.7.+-.0.3 s. [0090] Center a
specimen on the orifice platform below the pusher-ball. If 3.2 mm
clearance under pusher-ball prevents ease of entry of specimen due
to sample thickness, the clearance may be increased to 6.3 mm
maximum. In reporting, the results should indicate the pusher-ball
clearance, if not standard. [0091] Check the gage zero and adjust,
if necessary. [0092] Set the maximum force reading switch. [0093]
Actuate the pusher-ball for the full stroke length. Avoid touching
the specimen during testing. [0094] Record maximum force reading to
nearest gage graduation. [0095] Continue as directed above until
all specimens have been tested. Calculation [0096] Average the
individual specimen readings and round to the nearest gage
increment. [0097] Report [0098] Report the Average force in gage
units. End of Test
[0099] All documents cited in the Detailed Description of the
Invention are, in relevant part, incorporated herein by reference;
the citation of any document is not to be construed as an admission
that it is prior art with respect to the present invention. To the
extent that any meaning or definition of a term in this written
document conflicts with any meaning or definition of the term in a
document incorporated by reference, the meaning or definition
assigned to the term in this written document shall govern.
[0100] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *