U.S. patent application number 12/794286 was filed with the patent office on 2010-12-09 for flexible to rigid packaging article and method of use and manufacture.
Invention is credited to Elie Helou, JR..
Application Number | 20100308062 12/794286 |
Document ID | / |
Family ID | 43298186 |
Filed Date | 2010-12-09 |
United States Patent
Application |
20100308062 |
Kind Code |
A1 |
Helou, JR.; Elie |
December 9, 2010 |
FLEXIBLE TO RIGID PACKAGING ARTICLE AND METHOD OF USE AND
MANUFACTURE
Abstract
In one embodiment, a flexible packaging system comprises a
flexible container and an inflatable hollow scaffolding component;
wherein the flexible packaging system may be made rigid or
semi-rigid by pressurizing the hollow scaffolding component. In
some aspects, the pressurizing is accomplished by filling the
hollow scaffolding component with gas or foam.
Inventors: |
Helou, JR.; Elie; (Santa
Barbara, CA) |
Correspondence
Address: |
PERKINS COIE LLP;Attn: Joseph P. Hamilton
P.O. Box 1208
Seattle
WA
98111-1208
US
|
Family ID: |
43298186 |
Appl. No.: |
12/794286 |
Filed: |
June 4, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61184777 |
Jun 5, 2009 |
|
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|
61218030 |
Jun 17, 2009 |
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Current U.S.
Class: |
220/660 ;
141/1 |
Current CPC
Class: |
B65D 81/052 20130101;
B65D 37/00 20130101 |
Class at
Publication: |
220/660 ;
141/1 |
International
Class: |
B65D 90/02 20060101
B65D090/02; B65B 3/04 20060101 B65B003/04 |
Claims
1. A flexible packaging system comprising: a flexible or
semi-flexible container; and an inflatable hollow scaffolding
component; wherein the flexible packaging system is configured to
be rigid or semi-rigid upon inflation of the hollow scaffolding
component by air, gas or foam.
2. The flexible packaging system of claim 1, wherein the hollow
scaffolding component is internally-associated with the flexible
container.
3. The flexible packaging system of claim 1, wherein the hollow
scaffolding component is externally-associated with the flexible
container.
4. The flexible packaging system of claim 1, wherein the hollow
scaffolding component includes a first opening for inflation or
deflation, and wherein the first opening can be permanently sealed
or releasable sealed.
5. The flexible packaging system of claim 1, wherein the hollow
scaffolding component is self-inflating.
6. The flexible packaging system of claim 5, wherein the hollow
scaffolding component is associated with two or more compartments
that contain two or more inflation components, that, when mixed,
form the necessary gas or foam to pressurize the hollow scaffolding
component.
7. The flexible packaging system of claim 5, wherein the hollow
scaffolding component contains pellets, capsules or beads that
contain two or more ingredients that, when mixed, form the
necessary gas or foam to inflate the hollow scaffolding
component.
8. The flexible packaging system of claim 1, wherein the flexible
packaging system further comprises one or more internal
supports.
9. The flexible packaging system of claim 8, wherein the internal
supports are comprised of ribbing or webbing.
10. The flexible packaging system of claim 1, wherein the flexible
packaging system is configured to be in a substantially flat
condition upon deflation of the scaffolding.
11. The flexible packaging system of claim 1, wherein the flexible
packaging system has an opening that allows for filling or pouring
products to be held within.
12. The flexible packaging system of claim 11, wherein the opening
is comprises with an integrated closure assembly.
13. The flexible packaging system of claim 11, wherein the opening
is configured to receive a separate closure assembly.
14. The flexible packaging system of claim 13, wherein the closure
assembly is selected from a resealable peel top, a screw top, a
snap top, a flip top, or a cork, press top, or plug-type
system.
15. The flexible packaging system of claim 1, wherein the hollow
scaffolding component includes one or more handle-like
appendages.
16. A flexible packaging system comprising: a flexible or
semi-flexible container; a hollow scaffolding component; and one or
more internal supports; wherein the flexible packaging system may
be made rigid or semi-rigid by inflation of the hollow scaffolding
component.
17. The flexible packaging system of claim 16, wherein the flexible
packaging system is made from a plastic component and formed into
thin sheets.
18. The flexible packaging system of claim 16, wherein the
container comprises a thin shell or film.
19. The flexible packaging system of claim 16, wherein the
container comprises an embedded fiber matrix.
20. The flexible packaging system of claim 16, wherein flexible
packaging system may be substantially flat or in a roll when in a
deflated state.
21. The flexible packaging system of claim 16, wherein the one or
more internal ribbing supports are selected from the group
consisting of string, webbing and membranes.
22. The flexible packaging system of claim 16, wherein the one or
more internal supports are inflatable.
23. A flexible packaging system of claim 16 further comprising an
expansion chamber in fluid connection with the scaffolding that
will expand and reduce in size to accommodate changes in
temperature after inflation of the scaffolding to maintain the
rigidity of the container for use.
24. A method for providing a flexible packaging system for holding
a product, wherein an unfilled flexible packaging system is
provided and utilized according to a method comprising: providing
at least two uninflated flexible packaging containers, wherein the
uninflated flexible packaging containers are substantially flat and
are provided in a stack or roll; inflating the one or more flexible
packaging containers prior to use; and wherein the flexible
packaging containers comprise a flexible container and a hollow
scaffolding component that may be made substantially rigid by
inflation of the hollow scaffolding component.
25. The method of claim 24, wherein each of the uninflated flexible
packaging containers is not attached to an adjacent flexible
packaging container.
26. The method of claim 24, wherein each of the uninflated flexible
packaging containers are separably attached to an adjacent flexible
packaging container.
27. The method of claim 24, wherein the uninflated flexible
packaging containers are self-inflating.
28. The flexible packaging system claim 16 wherein the scaffolding
is configured to be deflated following use.
29. The method of claim 24, wherein the stack or roll is comprised
of a matrix of individual uninflated containers for providing at
least two containers for substantially simultaneous inflation of
the at least two containers.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 61/184,777, filed Jun. 5, 2009, and of U.S.
Provisional Patent Application No. 61/218,030, filed Jun. 17, 2009,
both of which are incorporated herein by reference in their
entirety.
BACKGROUND
[0002] The global consumer packaging industry is estimated to be
worth over $400 billion and employs more than five million people
worldwide. Packaging allows marketing and product differentiation
and educates and informs the consumer. However, the procurement,
production, transport and disposal of packaging can have negative
consequences for both the environment and societies around the
globe. Thus, the consumer packaging industry is looking for new
ways to improve social or environmental consequences.
[0003] Moreover, there has been increased consumer demand for
sustainable packaging. Even in tough economic times, consumers
still demand improvements and more options in green purchasing.
According to recent studies, 44 percent of consumers say that their
green buying habits remain unchanged in a challenging economy, and
one third of consumers are more committed to buying green than they
were in the past. The use and development of sustainable packaging
is one way to support innovative, functional packaging materials
and systems that promote economic and environmental health.
[0004] To respond to consumer demand, many consumer goods companies
have committed to the redesign of traditional packaging methods in
order to make their products more sustainable. Over half of
consumer goods producers (55 percent) indicate their commitment to
sustainability initiatives do not change, even with economic
downturns, and that packaging is their top focus area (76 percent).
For example, the packaging industry is being pushed by customers,
for example, Wal-Mart, for source reduction (i.e., material
reduction).
[0005] Some of the factors that contribute to a sustainable design
of packaging include use of minimal materials (reduced packaging,
reduced layers of packaging, lower mass and volume), logistics
efficiency (ability to efficiently transport and utilize the
packaging), energy efficiency (total energy content and usage, use
of renewable energy), recycled content, ability to recycle and
reuse, use of renewable resources, use of biodegradable materials
when appropriate, avoidance of toxic materials, effects on the
atmosphere and climate, and any other environmentally-conscious
practice. At the same time, the packaging must be cost-effective,
and must meet market criteria for performance with respect to the
type of product to be packaged.
SUMMARY
[0006] In one embodiment, a flexible packaging system comprises a
flexible or semi-flexible container and an inflatable hollow
scaffolding component; wherein the flexible packaging system may be
made rigid or semi-rigid by inflation of the hollow scaffolding
component.
[0007] In some aspects, the flexible container is made from a
plastic component and formed into thin sheets or films. In other
aspects, the flexible container comprises an embedded fiber matrix.
In further aspects, the flexible container is an open top
container.
[0008] In some aspects, the hollow scaffolding component may be
internally-associated with the flexible container. In other
aspects, the hollow scaffolding component may be
externally-associated with the flexible container. In some
embodiments, the hollow scaffolding component is inflated by a
machine that pressurizes the hollow scaffolding component with air,
gas or foam. In other embodiments, the hollow scaffolding component
is self-inflating, wherein the hollow scaffolding component is
associated with two or more compartments that contain two or more
inflation components, that, when mixed, form the necessary gas,
foam, or liquid to pressurize the hollow scaffolding component.
Alternatively, in some aspects, the hollow scaffolding component
contains pellets, capsules or beads that contain two or more
ingredients that, when mixed, form the necessary gas or foam to
pressurize the hollow scaffolding component. In some aspects, the
hollow scaffolding component may include a handle-like
appendage.
[0009] In some embodiments, a flexible packaging system may further
comprise one or more internal or external ribbing supports. The
ribbing supports may be string, webbing, membranes, or one or more
inflatable supports that are associated with the hollow scaffolding
component.
[0010] In some embodiments, the flexible container, hollow
scaffolding component, or the flexible packaging system may be
compressed such that the system may be stored and transported flat
or in a roll.
[0011] In some embodiments, the flexible packaging system has an
opening that allows for filling or pouring contents to be held
within. The opening may be associated with an integrated closure
assembly, wherein the integrated closure assembly may be selected
from a resealable peel top, a screw top, a snap top, a flip top, or
a cork or plug-type system. Another embodiment is directed to a
packaging system comprising a semi-flexible container and an
associated scaffold component, wherein the container includes fiber
materials to provide additional stiffness and tension to help
define a desired shape, and the associated scaffold component
provides support for the fiber container.
[0012] In another embodiment, an unfilled flexible packaging system
described above is shipped, stored and utilized according to a
method comprising: providing one or more uninflated flexible
packaging systems; shipping and/or storing the one or more
uninflated flexible packaging systems; inflating the one or more
flexible packaging systems prior to use; and optionally deflating
the one or more flexible packaging systems after use.
[0013] In some aspects, the uninflated flexible packaging systems
are substantially flat and shipped and/or stored in a stack, or are
separably attached to each other and formed into a roll of stock
for shipping and/or storing.
[0014] In some aspects, the inflating may be accomplished by a
machine, and in other aspects, the uninflated flexible packaging
system is self-inflating. In one aspect, the hollow scaffolding
component of the self-inflating flexible packaging system is
associated with two or more compartments that contain two or more
inflation components, that, when mixed, form the necessary gas or
foam to pressurize the hollow scaffolding component. In another
aspect, the hollow scaffolding component of the self-inflating
flexible packaging system contains pellets, capsules or beads that
contain two or more ingredients that, when mixed, form the
necessary gas or foam to inflate the hollow scaffolding
component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a side view of a three-dimensional rendering of a
fully expanded flexible packaging system according to one
embodiment, having an internally-associated hollow scaffolding
component.
[0016] FIG. 2 is a cross-sectional view of a three-dimensional
rendering of a fully expanded flexible packaging system according
to one embodiment.
[0017] FIG. 3 is a series of line drawings (A, top view; B,
perspective view; and C, side view) illustrating a flexible
packaging system according to one embodiment, wherein the flexible
packaging system comprises an internally associated hollow
scaffolding component and an outer flexible container.
[0018] FIG. 4 is an exploded view of a line drawing illustrating a
flexible packaging system according to one embodiment, having an
internally-associated hollow scaffolding component.
[0019] FIGS. 5A and FIG. 5B are alternate side views of line
drawings illustrating a flexible packaging system according to one
embodiment, wherein the flexible packaging system comprises an
internally-associated hollow scaffolding component and a flexible
container providing a smooth outer surface.
[0020] FIG. 6 is a series of line drawings (A, side view; B,
perspective view; and C, top view) illustrating a fiber matrix that
can be imbedded into the packaging system according to one
embodiment.
[0021] FIG. 7 is a side view of a three-dimensional rendering of a
packaging system according to one embodiment, wherein the general
shape of the fully expanded packaging system is provided by
fiber-type materials and the hollow scaffolding system provides
tension against the fiber matrix.
[0022] FIG. 8A is a side view of a three-dimensional rendering of a
flexible packaging system according to one embodiment, having an
externally-associated hollow scaffolding component.
[0023] FIG. 8B is a side view of a three-dimensional rendering of a
flexible packaging system according to one embodiment, having an
externally-associated hollow scaffolding component. The externally
associated hollow scaffolding component is transparent for
visualization of the internal components.
[0024] FIG. 9 is a top view of a three-dimensional rendering of a
flexible packaging system according to one embodiment, having an
externally-associated hollow scaffolding component.
[0025] FIG. 10 is a series of line drawings (A and D, side views; B
and E, top views; and C perspective view) illustrating an alternate
way to make a flexible packaging system according to one
embodiment, having an externally-associated hollow scaffolding
component.
[0026] FIG. 11 illustrates a corner support structure according to
one embodiment, wherein the corner support structure is
incorporated into the flexible packaging system of FIG. 10 and FIG.
12.
[0027] FIG. 12 is an exploded view of a line drawing illustrating
the various components making up the design of a flexible packaging
system according to one embodiment, having an externally-associated
hollow scaffolding component.
[0028] FIG. 13 is a series of line drawings illustrating a tapered
flexible packaging system (A), having a flexible container (C) and
an externally-associated hollow scaffolding component (B) that is
integral with the bottom area according to one embodiment, wherein
the bottom area has 2 compartments that contain chemical reaction
components that, when mixed, may produce either gas or foam.
[0029] FIG. 14 is a side view of a three-dimensional rendering of a
bag-type flexible packaging system according to one embodiment,
having an internally-associated hollow scaffolding component and an
open top.
[0030] FIG. 15 is an exploded view of a three-dimensional rendering
of a bag-type flexible packaging system according to one
embodiment, having an internally-associated hollow scaffolding
component and an open top.
[0031] FIG. 16 is a series of line drawings (A, side view; B, top
view; C perspective view and D cross-sectional top view)
illustrating a open top, bag-type flexible packaging system
according to one embodiment, having an internally-associated hollow
scaffolding component and an open top.
[0032] FIG. 17 is a side view of a three-dimensional rendering of
an open top tray with an associated hollow scaffolding component
for support according to one embodiment.
[0033] FIG. 18 is an exploded view of a three-dimensional rendering
of an open top tray with an associated hollow scaffolding component
for support according to one embodiment.
[0034] FIG. 19 is a series of line drawings of an open top tray
with an associated hollow scaffolding component for support
according to one embodiment.
[0035] FIG. 20 is an exploded view of a line drawing of an open top
tray with an associated hollow scaffolding component for support
according to one embodiment. This view shows where welding or
gluing areas occur to provide association or attachment points
between the hollow scaffolding and the open top tray.
[0036] FIG. 21 is a side view of a line drawing of a lid that is
associated with an open top tray with an associated hollow
scaffolding component according to one embodiment.
[0037] FIG. 22 illustrates additional structures, such as webbing
that may be added to corners of an open top tray with an associated
hollow scaffolding component for support according to one
embodiment.
[0038] FIG. 23 is a bottom view of a three-dimensional rendering of
a fully expanded flexible packaging system according to one
embodiment, showing first and second compartments that contain
components that, when mixed, will produce the gas or foam needed to
fill the hollow scaffolding component.
[0039] FIG. 24 shows a roll of flat stock that can be made from
multi-laminated layers providing separable containers according to
one embodiment.
[0040] FIG. 25 is a three-dimensional rendering that illustrates
tension features, such as string, that constrain the container
expansion against the gas or foam-filled scaffolding pressures,
according to one embodiment.
[0041] FIG. 26 is a cross-sectional view of a line drawing that
illustrates tension features, such as string, that constrain the
container expansion against the gas or foam-filled scaffolding
pressures, according to one embodiment.
[0042] FIG. 27 is a three-dimensional rendering that illustrates
tension features, such as webbed structures, that provide tension
constraints against the pressure provided by the gas or foam-filled
scaffolding, according to one embodiment.
[0043] FIG. 28 is a cross-sectional view of a three-dimensional
rendering that illustrates tension features, such as webbed
structures, that provide tension constraints against the pressure
provided by the gas or foam-filled scaffolding, according to one
embodiment.
[0044] FIG. 29 is a cross-sectional view of a line drawing that
illustrates tension features, such as webbed structures, that
provide tension constraints against the pressure provided by the
gas or foam-filled scaffolding, according to one embodiment.
[0045] FIG. 30 is a three-dimensional rendering that illustrates
internal pressurized features that help create the final shape of
the expanded flexible packaging system according to one
embodiment.
[0046] FIG. 31 is a cross-sectional view of a line drawing that
illustrates internal pressurized features that help create the
final shape of the expanded flexible packaging system according to
one embodiment.
[0047] FIG. 32 is a series of line drawings (A, side view; B, top
view; C perspective view and D cross-sectional view) illustrating
internal pressurized features that help create the final shape of
the expanded flexible packaging system according to one
embodiment.
[0048] FIG. 33 is a front view of a line drawing that illustrates a
flexible packaging system having an externally-associated hollow
scaffolding component according to one embodiment, wherein the
externally-associated hollow scaffolding component contains
capsules or beads that that contain the necessary ingredients that
if mixed will generate the necessary gas or foam to fill the hollow
scaffolding component.
[0049] FIG. 34 illustrates a method of generating a flexible
packaging system according to one embodiment, wherein a single flat
sheet may be formed into a hollow scaffolding component that may be
formed into a tube. A bottom piece is then welded, glued, melted or
otherwise sealed to the bottom of the tube such that the hollow
scaffolding component is mated to the gas or foam creating
compartments and the remaining large cavity is self-closing. The
top is then closed off in one line and a closure assembly for
filling the system is mated to the bag assembly.
[0050] FIG. 35 illustrates a method of generating a flexible
packaging system according to one embodiment, wherein upper, lower
and middle film sheets are laminated together, forming an
integrated scaffolding component. The laminated sheets are then
formed into a tube, then a bottom cap is added and the top is
welded together and a pouring or access feature is added.
[0051] FIG. 36 is a three-dimensional rendering of a scaffolding
and thin shell system for use as a mail container with a top cover
that can be closed via a zipper, glue tabs or other means after the
inside contents have been filled with the item to be mailed.
[0052] FIG. 37 is a three-dimensional rendering of the scaffolding
and thin shell system of FIG. 36 that shows the scaffolding and
thin shell system separately.
[0053] FIG. 38 is a line drawing of the scaffolding and thin shell
system of FIG. 36.
[0054] FIG. 39 is a line drawing of the scaffolding and thin shell
system of FIG. 37.
[0055] FIG. 40 is an exploded view of three-dimensional rendering
of an unassembled scaffolding and thin shell system for use liquid
container with a sealed top cover and a bottom cover that can be
allow the container to stand upright.
[0056] FIG. 41 is a three-dimensional rendering of the scaffolding
and thin shell system of FIG. 40 showing the scaffolding and thin
shell system assembled.
[0057] FIG. 42 is an exploded view of a line drawing of the
unassembled scaffolding and thin shell system of FIGS. 40 and
41.
[0058] FIG. 43 is a three-dimensional rendering of a flexible
packaging unit having a substantially ring-shaped base that can be
added to the scaffolding component so the flexible container is
able to rest on a flat surface according to one embodiment.
[0059] FIG. 44 is an exploded view of the three-dimensional
rendering of a flexible packaging unit of FIG. 43.
[0060] FIG. 45 is a series of line drawings (A, side view; B, top
view; C perspective view and D cross-sectional view) illustrating
the addition of a substantially ring-shaped base that can be added
to the scaffolding component of a flexible packaging unit according
to one embodiment.
[0061] FIG. 46 is an exploded view of a line drawing of a flexible
packaging unit of FIGS. 44 and 45.
DETAILED DESCRIPTION
[0062] In order to fully understand the manner in which the
above-recited details and other advantages and objects according to
the invention are obtained, a more detailed description of the
invention will be rendered by reference to specific embodiments
thereof. Other features and advantages of the present invention
will become apparent from the following detailed description. It
should be understood, however, that the detailed description and
the specific examples, while indicating the preferred embodiments
of the present invention, are given by way of illustration only,
since various changes and modifications within the spirit and scope
of the present invention will become apparent to those skilled in
the art from this detailed description.
[0063] In one embodiment, a flexible packaging system is provided.
Such a packaging system may be used as a source-reducing packaging
alternative. The flexible packaging system comprises a flexible
container and an associated inflatable scaffold or scaffolding
(such as a structural support or grid) component. The scaffolding
component may be hollow or not, and when inflated or pressurized,
provides the rigidity necessary to turn the flexible packaging
system into a rigid or semi-rigid packaging container.
Pressurization of the scaffolding may be accomplished, for example,
by inflating with gas, filling with foam or any other suitable
means to pressurize without adding excess weight to the packaging
system.
[0064] In some embodiments, the hollow scaffold component may be
independent from the flexible container. In some aspects, the
scaffold component is internally-associated and the flexible
container may act as a cover to the hollow scaffold component. The
flexible container may be removably or permanently attached to the
hollow scaffolding by an appropriate attaching means, for example,
Velcro.RTM., glue, snaps, zipper or welding.
[0065] In other embodiments, the scaffold component is externally
associated and the flexible container is held open by the
externally associated scaffold component. Such packaging systems
may compete with current cylindrical items, because round bottles
placed next to each other leave a space between them that can
accommodate corner-shaped scaffolding components. An externally
associated hollow scaffold component may comprise a flexible
container that has attached corners or other external components
that form the hollow scaffolding component. The hollow scaffolding
component may comprise of one or more compartments that may be
interconnected by way of one or more apertures between the
compartments, or may be inflated independently.
[0066] FIG. 3 shows a top view, side view, and a three-dimensional
view of a flexible packaging system 100, FIG. 4 shows an exploded
view of a flexible packaging system 100, and FIGS. 5A and 5B show
alternate views of a three-dimensional view of a flexible packaging
system 100 according to some embodiments. In such embodiments, a
flexible packaging system 100 has an internally associated
scaffolding component 105 and an outer flexible container 110. The
flexible packaging system 100 has a top that has a closure assembly
115, a bottom 120 that contains a separator 125 creating two
compartments that may contain components that, when mixed, will
create gas or foam to pressurize that internally associated
scaffolding component 105.
[0067] FIG. 10 shows a top view, side view and a three-dimensional
view of a flexible packaging system 100, FIG. 11 shows a corner
support structure 140 of a flexible packaging system 100, and FIG.
12 shows an exploded view of a flexible packaging system 100
according to some embodiments. In such embodiments, a flexible
packaging system 100 has an externally associated scaffolding
component 130 and an inner flexible container 135. The flexible
packaging system 100 has a top 150 that has a closure assembly 115,
and a bottom 120. The externally associated scaffolding component
130 comprises a corner support structure 140 and horizontal
supports 145. The corner support structure 140 and horizontal
supports may be connected via holes 155 (as shown in FIG. 12) in
order to create a continuous compartment.
[0068] In some embodiments, the hollow scaffold component may be
integrated into the flexible container such that the flexible
packaging system shape is formed by a single continuous component.
In one embodiment, a method for producing a flexible packaging
system is illustrated in FIG. 34, and comprises using a single
layer or sheet of flexible material, wherein a flat sheet 210 may
first be folded, forming enclosed cavities 215. Then, the folded
sheet may be formed into a tube 220. A bottom 225 is welded, glued
or melted to the bottom of the tube 220 such that the scaffolding
is mated to the gas or foam creating cavity and the remaining large
cavity is self-closing. The top is then closed off in one line and
a closure assembly 115 for filling is mated to the packaging system
assembly.
[0069] The term "weld," "welding," "welded" or the like as used
herein refers to melting the films together. In addition the films
and/or scaffolding could be joined by other means known in the art
including adhesives or other fastening means.
[0070] In other embodiments, the hollow scaffold component may be
formed from two or more film sheets forming a ribbing system
integrated within the flexible container walls. In one embodiment,
a method for producing a flexible packaging system is illustrated
in FIG. 35, and comprises using upper 230, lower 235 and middle 240
film sheets that are laminated together with different patterns. In
some aspects, the upper 230 and lower 235 sheets do not stick to
each other but the middle sheet 240 does laminate to the lower 235
and upper 230 sheets. The result creates a sheet assembly 245 that
has a natural pocket or pockets 250 between the lower 235 and upper
230 sheets that form the hollow scaffolding component that contains
any necessary properties for its function, such as raw components
contained by compartments, beads, or capsules (as discussed below)
to create gas or foam, or a valve for inflation. Alternatively the
valve for inflation may be formed from the sheets, which can be
welded or sealed after inflation. In some embodiments, the valve
for inflation is one-way valve. In other embodiments, the valve for
inflation may be a two-way valve to allow for deflation, refilling
and/or reuse of the packaging system. The sheet assembly 245 is
then laminated into a tube 220 with a bottom 225 added. The bottom
225 may contain the necessary components to form a gas or foam to
pressurize and fill the scaffolding component. The top may be
welded or glued together, and includes a spout 255 or other closure
means to access to the materials contained in the packaging
system.
[0071] The flexible packaging system may take the form of any shape
beneficial to efficient storage, trademark design, or other
marketing strategies. In some aspects, the flexible packaging
system is in the shape of a bottle, cup, tray, cylinder, tapered
cylinder or bag to be used for holding food and drink products,
personal hygiene products, detergents and soap, and any other
suitable household or commercial products, or consumer, industrial
or military products that require rigid or semi-rigid storage, for
example, for liquids, gels, powders, fragile contents, and food
products.
[0072] FIG. 13 shows a three-dimensional side view and an exploded
view of a flexible packaging system, 100 according to one
embodiment. Such an embodiment has an externally associated tapered
scaffolding system 310 and an inner tapered flexible container 300.
There is also a bottom 120 with a separator 125, and a top 330 with
an incorporated closure assembly 115.
[0073] The flexible container and the hollow scaffolding component
may be made of any substance or substances suitable for packaging
materials, and may be associated with sustainable packaging. Such
substances include, but are not limited to any flexible plastic
material or a combination thereof, for example, rubbers,
polyesters, nylons, mylars, Saran Wrap.RTM., PETE, cellophane,
polyethylene, PVC, LDPE, Polypropylene, and EVA that may be formed
into thin sheets or films, thereby producing a packaging container
that is light, thin and easily stored or transported in a very
small area when deflated. The materials may be recyclable,
biodegradable, compostable, or any combination thereof, and may
also include aluminized or other treated films.
[0074] Another embodiment is directed to a semi-flexible container
that has an embedded fiber matrix that assists in providing the
shape of the packaging system. FIG. 6 illustrates a fiber matrix
130 that can be imbedded into the packaging system according to one
embodiment. Suitable fiber materials may include, but are not
limited to plastic fibers, or any other material that can provide
stiffness and tension. A hollow scaffolding component that is
associated with a fiber matrix embedded flexible container pushes
against the fiber matrix to provide support for the structure. The
fiber matrix provides one way to increase the stability of the
packaging without substantially increasing the volume, or weight of
the packaging system.
[0075] The ability to transform uninflated thin films or shells
into inflated rigid or semi-rigid containers allows the packaging
to remain functional while reducing the environmental costs of
other traditional packaging. Thus, the flexible packaging system
described herein may be suitable for replacement of glass jars,
metal cans, and rigid plastic bottles such as for shampoo or
household goods. In one embodiment, the uninflated flexible
packaging system may be transported in a flat or substantially flat
state, wherein one or more flat or substantially flat packaging
systems are stacked on top of each other. In another embodiment, a
plurality of uninflated flexible packaging system units may
separably attached to each other and formed into a roll of stock.
FIG. 24 shows a roll of stock 600 according to one embodiment.
[0076] The ability to transport and store flexible packaging
systems in an uninflated state as described herein conveys
substantial benefits to a user of such packaging systems with
respect to the transport and storage of the flexible packaging
system. For example, one truckload of unfilled, flat or rolled
flexible packaging system is equivalent to approximately 25
truckloads of unfilled glass jars. Therefore, the uninflated
flexible packaging systems may be economically shipped to users,
stored in a smaller storage space, and may be inflated prior to
use, deflated after use, or both. In one embodiment, the uninflated
flexible packaging system may be kept in storage until needed, and
inflation of a flexible packaging system may occur immediately
prior to use. In other embodiments, the inflation may occur at a
predetermined time, prior to use.
[0077] The use of a thin, flexible container also reduces the
chance of damage to the packaging system. Traditional rigid
containers such as thick plastic, metal, or glass may be dented,
punctured or broken at the local force application point during an
impact event that may occur in transit or other handling. The
flexible packaging system described herein retains semi-flexibility
such that upon impact, the shape of the container will be retained
after a load is removed.
[0078] In some embodiments, the flexible packaging system may
include additional inflatable or foam-filled appendages to provide
a handle or other carrying means for use in applications such as
soups, coffee cups and other applications that require mitigation
of heat transfer to the person handling the system.
[0079] In some embodiments, internal ribbing supports may be
included to add tension features that would constrain the container
expansion against the scaffolding pressures and/or to help create
the final shape of an expanded flexible packaging system. In some
aspects, as shown in FIG. 26, the internal ribbing supports may be
strings 190. In other aspects, as shown in FIG. 29, the internal
ribbing supports may be webbing 195. Other internal ribbing
supports may include membranes or other similar internal structures
that are suitable to provide tension against the scaffolding
pressures. The webbing, ribs, filaments or other supports may be
internal, external, or both, of either the scaffolding or flexible
container portion.
[0080] In other aspects, the internal ribbing supports are
pressurized. As shown in FIGS. 31 and 32, pressurized internal
ribbing supports 700 may be integrated with the hollow scaffolding
component and may be filled with air or foam in the same manner as
the scaffolding component. In other aspects, the supports may be
external.
[0081] In some embodiments, the flexible packaging system may
comprise an open-top container such as a cup, a bag, a tray, or
another container that can be used to hold liquids, creams, gels,
powders or other products or materials. In some aspects the hollow
scaffolding component may be enlarged or thickened to provide
insulation for heated products, such as for hot drinking cups or
food trays to be used in the microwave. An open-top container may
also include an associated lid, such as a lid to cover a food tray
or a cup to allow for more efficient transport when full.
[0082] FIG. 16 shows a side view, three-dimensional view and top
views of an open-top flexible packaging system 400 according to one
embodiment. The open-top flexible packaging system described in
this embodiment has an open top 165, an internally associated
scaffolding component 105, an outer flexible container 110 and a
bottom 120 with a separator 125.
[0083] FIGS. 19, 20, 21 and 22 show multiple views of an open top
tray flexible packaging system 500 according to some embodiments.
The open top tray flexible packaging system 500 described in this
embodiment comprises an open tray liner 170 and a tray scaffold
system 175. Optionally included is a lid 180 as shown in FIG. 21,
and a webbing 185 to provide further support.
[0084] In some embodiments, the flexible packaging system is a
closed system, for a one-time use. In other embodiments, the
flexible packaging system includes an integrated closure assembly
that allows a packaging system to be opened and closed multiple
times. The closure assembly may comprise a removable and resealable
peel-top portion of the flexible container or may comprise a
separate opening system such as a screw top, a snap-cap top, a flip
top, a cork or plug-type system, or any other suitable recloseable
independent closure assembly.
[0085] In some embodiments, inflation of the flexible container
system may be accomplished by a machine that fills the inflatable
hollow scaffolding component with air, gas, foam, or any other
suitable substance to pressurize the scaffolding component. In
other embodiments, the flexible container system may be
self-inflating. In one embodiment, a self inflatable system
includes two or more compartments, each compartment filled with
components that, when mixed, will form the gas or foam necessary to
fill the hollow scaffolding component. Suitable components that can
form gas include, but are not limited to any acid mixed with a form
of carbonate, such as citric acid and sodium bicarbonate, will
produce carbon dioxide that may pressurize the hollow scaffolding
component. Alternatively, the gas may be produced by blowing agents
used in the plastics industry such as Ezio di Carbonamides that
produce carbon dioxide when heated. The components may be in the
form of liquids, solids, powders or any combination thereof.
Suitable components that can form the foam include, but are not
limited to compounds such as mixtures of isocyanates and
polyols.
[0086] In another embodiment, the hollow scaffolding system may
contain beads, capsules, small bags, or other means to hold the
necessary ingredients that, if mixed, will generate the gas or foam
required to fill the hollow scaffolding component. FIG. 33 shows a
flexible packaging system 100 with beads 205 in an externally
associated scaffold system 310. Suitable components that can form
gas include, but are not limited to any acid mixed with a form of
carbonate, such as citric acid and sodium bicarbonate, will produce
carbon dioxide that may pressurize the hollow scaffolding
component. Alternatively, the gas may be produced by blowing agents
used in the plastics industry such as Ezio di Carbonamides that
produce carbon dioxide when heated. The components may be in the
form of liquids, solids, powders or any combination thereof.
Suitable components that can form the foam include, but are not
limited to compounds such as mixtures of isocyanates and
polyols.
[0087] In one aspect, the beads or capsules may be activated by
palpating their location and squeezing the scaffolding component,
causing them to break open, releasing their contents. In another
aspect, the beads may be placed in an area of the scaffolding
wherein the act of filling the container with the product or
products it was designed to hold will break the beads such that the
gas or foam released will cause the scaffolding to be filled
simultaneously with the flexible container. In another aspect, the
beads may be broken upon quick freezing or flash heating. In
another aspect, extra beads or capsules may be added such that if a
container starts to lose rigidity due to loss of gas over time, the
extra beads could be squeezed to release additional gas.
[0088] In other embodiments, other means known in the art may be
employed to inflate or fill the scaffolding component of the
flexible packaging system including heating or cooling, localized
laser or radiation means, for example microwaves to activate
release of foam or gas. In other embodiments, other means may be
employed to fill or inflate the scaffolding such as explosives or
similar. For example, a pellet of sodium azide (NaN.sub.3) may be
ignited causing a rapid reaction generating nitrogen gas (N.sub.2)
to fill the scaffolding. Potassium nitrate and silicon dioxide can
be used in secondary and tertiary reactions to deal with the
liberated sodium.
[0089] In another embodiment, small chambers are provided that may
act as expansion chambers. Such expansion chambers may be necessary
to avoid explosion of the scaffolding component due to expansion of
the gas or foam that may occur due to heating or shipping by plane
or other means of shipping that requires travel through high
altitude regions.
[0090] In another embodiment, the flexible container and associated
hollow scaffolding component may be manufactured from the same,
substantially the same, similar materials, or any combination
thereof that would allow recycling of the both the flexible
container and associated hollow scaffolding component together.
[0091] Referring to FIGS. 36-39, a flexible packaging system 800
including a scaffolding component 810 and a shell 805 for use as a
mail container is shown. The system includes a top cover 815 that
can be closed by a zipper, glue tabs, adhesives, or other means
(not shown) after the inside contents have been filled with the
item to be mailed. In one aspect of this embodiment the scaffolding
805 may keep the package rigid or semi rigid, protect the contents
of the container system 800, or both. Further, the system may
include additional or less scaffolding 805 to provide more or less
protection as required. In another aspect, the container system 800
may be provided uninflated, such that the container is flat or
substantially flat, and then the scaffolding may be inflated
immediately prior to use, deflated after use, or both.
[0092] Referring to FIGS. 40-42, a flexible packaging system 900 is
shown having a scaffolding component 910 and thin shell 905 for use
as a flexible container with a sealed top cover 915 and a openable
bottom cover 920 to allow the container to stand upright. This
embodiment can be used with viscous liquids to allow a user easy
access to the contents by permitting the contents to move toward
the openable bottom cover 920 of the container 900 when not in use.
This embodiment can be used as a container for shampoos, lotions,
ketchup or other similar viscous product contents or with powders,
gels, or other products or materials.
[0093] Referring to FIGS. 43-46, a flexible packaging system 1000
according to some embodiments is shown. When a flexible container
1010 is filled, it may tend to form a bowed or substantially
rounded bottom 1040, which may affect the flexible packaging
system's ability to rest upright on a flat surface. Therefore, a
flexible container 1010 may be associated with a scaffolding
component 1020 that includes a substantially ring-shaped base 1030
to assure that the flexible container has a substantially flat
bottom. The substantially ring-shaped base 1030 may be added as
part of the scaffolding component 1010. In an alternative
embodiment, the scaffolding may include a plurality of legs that
extend therefrom such that they provide support for the flexible
container to stand upright (not shown). In one aspect, the
scaffolding includes at least three legs for support.
[0094] In another aspect of any of the previous embodiments, the
flexible packaging system including a scaffolding component and
flexible container or shell can be formed from two or more bonded
sheets wherein one or more of the sheets includes weak areas, for
example, areas with reduced or no bonding between the sheets, at
which the scaffolding would expand upon inflation. The weak areas
can be designed into the one or more sheets prior to manufacture or
modified, after the two or more sheets are bonded, by a secondary
process wherein when the scaffolding is pressurized, the expansion
occurs at the weakest areas in the one or more sheets. The weak
areas can be of any configuration, for example, a configuration to
form any container system set forth herein.
[0095] In other aspects of the previous embodiments, the container
system may include an internal reservoir or weak area that is
designed to expand if over-pressurization occurs due to altitude
changes or temperature changes or pressure changes, or the
container system may include several laminated layers so that
different properties can be created, for example, to hold modified
atmosphere or oxygen scavenging systems.
[0096] In other embodiments, the container may be configured such
that the gas or other material used to inflate or fill the
scaffolding diffuses out of the scaffolding over time such that the
gas or other material used to inflate or fill the scaffolding
diffuses to the interior of the container, the exterior of the
container, or both. Such embodiments can be configured to indicate
the expiration or "shelf life" of the contents of the container by,
for example, deflating the scaffolding after a predetermined time.
In other aspects of these embodiments, the diffusion may be used to
provide a particular gas or other material to the interior of the
container over time to, for example, preserve the contents of the
container or for other purposes.
[0097] Although the invention has been described with respect to
specific embodiments, it will be readily appreciated by those
skilled in the art that modifications and adaptations of the
invention are possible without deviation from the spirit and scope
of the invention. Accordingly, the scope of the present invention
is limited only by the following claims.
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