U.S. patent application number 13/014627 was filed with the patent office on 2011-07-28 for liner for use with flexible containers.
This patent application is currently assigned to Igloo Products Corp.. Invention is credited to Linda Baltus.
Application Number | 20110182532 13/014627 |
Document ID | / |
Family ID | 44308996 |
Filed Date | 2011-07-28 |
United States Patent
Application |
20110182532 |
Kind Code |
A1 |
Baltus; Linda |
July 28, 2011 |
LINER FOR USE WITH FLEXIBLE CONTAINERS
Abstract
A flexible liner has a planar base and multiple sides extending
up from the planar base. The base and sides of the flexible liner
define a cavity for receiving foodstuffs or other items. The
flexible liner is generally dimensioned to fit within a cavity of a
flexible container bag, such as a soft-sided cooler, duffle bag,
gym bag or reusable grocery tote bag. The flexible liner provides
increased rigidity and durability for the flexible container bag.
While manual force deforms the flexible liner from its original
shape, the liner is elastic and has shape memory such than when the
force is removed, the liner will return to its original shape. The
liner is made from a viscoelastic polymer material. Further, the
liner can be attached to or configured to be removable from the
flexible container bag.
Inventors: |
Baltus; Linda; (Houston,
TX) |
Assignee: |
Igloo Products Corp.
|
Family ID: |
44308996 |
Appl. No.: |
13/014627 |
Filed: |
January 26, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61298535 |
Jan 26, 2010 |
|
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Current U.S.
Class: |
383/109 |
Current CPC
Class: |
A45C 3/001 20130101;
A45C 13/10 20130101; A45C 11/20 20130101; A45C 13/008 20130101;
A45C 13/02 20130101; A45C 13/36 20130101; A45C 7/0059 20130101 |
Class at
Publication: |
383/109 |
International
Class: |
B65D 30/08 20060101
B65D030/08 |
Claims
1. A container system comprising: a flexible housing defining a
cavity; and a flexible, semi-rigid liner positioned within the
cavity, wherein the liner comprises at least one opening for
housing an item therein, wherein the liner deforms from an original
shape to a deformed shape when a force is applied to the liner, and
wherein the liner returns to the original shape when the force is
removed.
2. The container system of claim 1, wherein the liner comprises a
viscoelastic polymer.
3. The container system of claim 1, wherein the liner comprises one
of a thermoplastic and a thermoset material.
4. The container system of claim 1, wherein the liner comprises an
insulating material.
5. The container system of claim 1, wherein the liner comprises at
least one selected from the group consisting of styrenic block
copolymers, polyolefin blends, elastomeric alloys, thermoplastic
polyurethanes, thermoplastic copolyesters, thermoplastic
polyamides, silicone, latex, nitrile butadiene rubber,
ethylene-propylene terapolymers, fluorosilicone, and
polychloroprene.
6. The container system of claim 1, wherein the liner has a size
and shape substantially similar to a size and shape of the flexible
housing.
7. The container system of claim 1, wherein the flexible housing
comprises a material selected from the group consisting of
polyester, polychloroprene, nylon, cotton, polyethylene
terephthalate, leather, polyethylene, polyurethane, and canvas.
8. The container system of claim 1, wherein the liner comprises a
planar base having a perimeter, and one or more sidewalls extending
from the perimeter of the planar base, wherein the planar base and
the one or more sidewalls define the at least one opening.
9. The container system of claim 8, wherein the planar base is
rectangular, and the one or more sidewalls comprises four sidewalls
extending from the planar base in a direction substantially
orthogonal to the planar base.
10. The container system of claim 8, wherein the planar base is
circular, and the one or more sidewalls comprises one sidewall
extending from the planar base in a direction substantially
orthogonal to the planar base to form a substantially cylindrical
liner.
11. The container system of claim 8, wherein the liner comprises a
semi-rigid partition positioned within the at least one opening and
coupled to at least one of the planar base and one or more
sidewalls.
12. The container system of claim 1, wherein the liner is secured
to the flexible housing by at least one selected from the group
consisting of stitches, snaps, clips, and Velcro.RTM..
13. The container system of claim 1, further comprising an
insulation layer between the liner and the flexible housing.
14. A container bag comprising: a flexible housing comprising a
planar base having a first perimeter, at least one sidewall having
a first end and a second end, the first end of the at least one
sidewall coupled to the first perimeter of the planar base, a cover
having a second perimeter, the second end of the at least one
sidewall coupled to the second perimeter of the cover, wherein the
planar base, at least one sidewall, and cover define a cavity; and
a flexible liner positioned within the cavity, wherein the liner
comprises at least one opening for housing an item therein, wherein
the liner deforms from an original shape to a deformed shape when a
force is applied to the liner without damage to the liner, and
wherein the liner returns to the original shape when the force is
removed.
15. The container bag of claim 14, wherein the liner comprises a
viscoelastic polymer.
16. The container bag of claim 14, wherein the liner comprises one
of a thermoplastic and a thermoset material.
17. The container bag of claim 14, wherein the first perimeter is
substantially equal to the second perimeter.
18. A container bag comprising: a flexible housing comprising a
planar base having a first perimeter, at least one sidewall having
a first end and a second end, the first end of the at least one
sidewall coupled to the first perimeter of the planar base, a cover
having a second perimeter, the second end of the at least one
sidewall coupled to the second perimeter of the cover, wherein the
planar base, at least one sidewall, and cover define a cavity; and
a flexible, semi-rigid liner positioned within the cavity, the
liner comprising a liner base having a liner base perimeter, at
least one liner sidewall coupled to the liner base perimeter,
wherein the liner base and the at least one liner sidewall define
an opening for housing an item therein, wherein the liner deforms
from an original shape to a deformed shape when a force is applied
without damage to the liner, and wherein the liner returns to the
original shape when the force is removed.
19. The container bag of claim 18, wherein the liner comprises a
flexible, semi-rigid partition positioned within the opening to
form two compartments within the liner.
20. The container bag of claim 18, wherein the liner is secured to
the flexible housing by at least one selected from the group
consisting of stitches, snaps, clips, and Velcro.RTM..
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Patent Application No. 61/298,535,
titled "Flexible Liner Systems for Insulating Containers" filed on
Jan. 26, 2010, the entire disclosure of which is hereby fully
incorporated herein by reference.
TECHNICAL FIELD
[0002] The technical field relates generally to liners for flexible
containers, and more particularly, to flexible, semi-rigid liners
for soft-sided container bags.
BACKGROUND
[0003] Soft container bags are used for a number of applications.
For example, soft cooler bags, or cut-and-sew bags, are typically
used to store items that need to remain cool. Generally, a soft
cooler bag is lined with heat-sealed vinyl sheeting, such as
polyethylene vinyl acetate (PEVA) or polyvinyl chloride (PVC)
sheeting. The soft cooler bag may then be layered with foam
insulation to create an insulated bag. A number of problems have
been identified in the use of vinyl sheeting in coolers. The vinyl
sheeting is typically very thin and punctures relatively easily,
thereby creating leaks in the bag, which reduces the insulating
properties of the cooler. In addition, the seams of fabricated
liners tend to leak. To address this problem, manufacturers insert
a hard plastic liner, such as a rigid polypropylene bucket, into
the cooler bag to add strength and improve leak resistance.
However, the use of the hard plastic liner eliminates the benefits
of collapsibility and flexibility of the soft cooler bag.
[0004] Some other examples of soft container bags include duffel or
gym bags, and beach bags. Duffel bags and beach bags are typically
constructed from flexible materials, such as nylon and/or
polyester, that have a tendency to absorb moisture. In a number of
instances, users store damp or wet clothing or shoes in the bags,
for example, after working out or going swimming. Generally, the
material of the bag absorbs moisture from these items and creates
an unpleasant odor within the bag. In addition, the moisture
build-up can even lead to the formation of mildew in the bag. To
address this problem, manufacturers have typically used heat sealed
seams or sewn seams in fabricated non-woven plastic liners.
However, the seams in these liners eventually leak, thus causing
moisture to contaminate the fabric of the bag.
[0005] Another example of a soft container bag is a tote bag or a
carry bag, such as a grocery tote. Tote bags are typically
constructed from a flexible cloth material, such as canvas, nylon
or other easy-care synthetics, recycled matter, or
minimally-processed natural fibers. When a user stores a cold item,
such as cold milk from the grocery store, in the tote bag,
condensation forms and makes the interior of the tote bag wet. In
some instances, moisture exposure compromises the fabric of the
tote bag, and causes the tote bag to stretch or tear. In some other
cases, the fabric of the tote bag absorbs the condensation and
causes the exterior of the bag to become undesirably wet. In
addition, condensation from the cold item may cause other dry items
in the tote bag to also become wet.
[0006] Therefore, a need exists for a system to address the
problems associated with various soft container bags.
SUMMARY
[0007] The present invention provides soft container bags having a
flexible liner that can generally insulate items stored therein,
while providing strength and flexibility, as well as improved leak
resistance over conventional soft container bags. An example of a
soft material is one that is pliable, bendable, or gives way easily
under pressure. An example of a flexible material is one that is
capable of being bent or flexed repeatedly without significant
damage. In one aspect of the invention, a container system can
include a flexible housing or bag having a cavity, and a flexible,
semi-rigid liner positioned within the cavity. An example of a
semi-rigid material is one that is partly or moderately rigid, and
can maintain its shape. The liner can be the same size and shape as
the cavity, or be sized to fit in a portion of the cavity. The
liner can include one or more openings for storage or insulation
purposes. Generally, the liner has shape memory, such that it can
deform when a force is applied thereon, and resume its original
shape without being damaged when the deforming force is removed.
The liner can be manufactured from a viscoelastic polymer, such as
a thermoplastic or a thermoset material. The liner can be secured
to the flexible housing by stitches, snaps, clips, and the like, or
remain removable from the flexible housing.
[0008] In another aspect of the invention, a container bag can
include a flexible housing having a flexible liner. The flexible
housing has a base having a first perimeter, a cover having a
second perimeter, and one or more sidewalls extending between the
first perimeter and the second perimeter. The first perimeter can
be the same size as the second perimeter. The cover can be secured
to the one or more sidewalls using a zipper, clip, or other
fastening device. The base, one or more sidewalls, and cover define
an interior cavity in which the liner can be housed. The liner has
one or more openings, and readily deforms from its original shape
to a deformed shape when a force is applied to the liner without
damage to the liner. When the force is removed from the liner, the
liner returns to the original shape.
[0009] In yet another aspect of the invention, a container bag can
include a flexible housing having a flexible, semi-rigid liner. The
flexible housing has a base having a first perimeter, a cover
having a second perimeter, and one or more sidewalls extending
between the first perimeter and the second perimeter. The first
perimeter can be the same size as the second perimeter. The cover
can be secured to the one or more sidewalls using a zipper, clip,
or other fastening device. The base, one or more sidewalls, and
cover define an interior cavity in which the liner can be housed.
The liner has a base and one or more sidewalls extending from a
perimeter of the base to define an opening for housing a item. The
liner readily deforms from its original shape to a deformed shape
when a force is applied to the liner without damage to the liner.
When the force is removed from the liner, the liner returns to the
original shape. The liner can also include a flexible, semi-rigid
partition positioned within the opening to form two compartments
within the liner. The liner can be secured to the flexible housing
by stitches, snaps, clips, Velcro.RTM., and other fastening
devices.
[0010] These and other aspects, objects, features, and embodiments
of the present invention will become apparent to those having
ordinary skill in the art upon consideration of the following
detailed description of illustrative embodiments exemplifying the
best mode for carrying out the invention as presently
perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a more complete understanding of the exemplary
embodiments of the present invention and the advantages thereof,
reference is now made to the following description in conjunction
with the accompanying drawings, which are described below.
[0012] FIG. 1A is a perspective view of a soft cooler bag having a
semi-rigid liner therein, according to an exemplary embodiment.
[0013] FIG. 1B is a perspective view of the soft cooler bag of FIG.
1A, with the semi-rigid liner removed, according to an exemplary
embodiment.
[0014] FIG. 1C is a perspective view of the soft cooler bag of FIG.
1A, with the semi-rigid liner removed and partially compressed,
according to an exemplary embodiment.
[0015] FIG. 2A is a top perspective view of another soft cooler bag
having a semi-rigid liner therein, according to another exemplary
embodiment.
[0016] FIG. 2B is a top perspective view of the soft cooler bag of
FIG. 2A, being partially deformed, according to an exemplary
embodiment.
[0017] FIG. 3 is a perspective view of a duffel bag having
semi-rigid liners therein, according to yet another exemplary
embodiment.
[0018] FIG. 4 is a top perspective view of a tote-bag having a
semi-rigid liner therein, according to yet another exemplary
embodiment.
[0019] FIG. 5 is a flow diagram illustrating an exemplary method
for manufacturing a semi-rigid liner, according to an exemplary
embodiment.
[0020] FIG. 6 is a flow diagram illustrating an exemplary method
for manufacturing a semi-rigid liner, according to another
exemplary embodiment.
[0021] FIG. 7 is a flow diagram illustrating an exemplary method
for manufacturing a soft container bag having a semi-rigid liner,
according to an exemplary embodiment.
[0022] The drawings illustrate only exemplary embodiments of the
invention and are therefore not to be considered limiting of its
scope, as the invention may admit to other equally effective
embodiments. The elements and features shown in the drawings are
not necessarily drawn to scale, emphasis instead being placed upon
clearly illustrating the principles of exemplary embodiments of the
present invention. Additionally, certain dimensions may be
exaggerated to help visually convey such principles. In the
drawings, reference numerals designate like or corresponding, but
not necessarily identical, elements.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The exemplary soft container bags generally include a
semi-rigid liner or a semi-rigid compartment to provide insulation
to items placed therein and/or to contain moisture therein. The
semi-rigid liner or compartment can be bent or bent or flexed
repeatedly without being damaged, and is effective in adding
strength and durability to the soft container bag without the
confinements of conventional hard plastic inserts. The semi-rigid
liner or compartment also provides improved leak resistance over
conventional soft container bags without the inclusion of rigid
interior parts. The invention may be better understood by reading
the following description of non-limiting, exemplary embodiments
with reference to the attached drawings.
[0024] FIG. 1A is a perspective view of a soft cooler bag 100
according to an exemplary embodiment. The soft cooler bag 100
includes a flexible bag 102 and a removable liner 104 positioned
within an interior cavity 112 of the flexible bag 102. FIG. 1B is
another perspective view of the soft cooler bag 100 showing the
liner 104 removed from the interior cavity 112 of the flexible bag
102. FIG. 1C is yet another perspective view of the soft cooler bag
100 showing the liner 104 removed from the interior cavity 112 of
the flexible bag 102 and partially compressed. In certain exemplary
embodiments, the soft cooler bag 100 is a lunch bag or a bag used
to store drinks, such as cans of soda or bottles of water.
[0025] Referring to FIGS. 1A-C, the flexible bag 102 includes a
rectangular base 108 and four sidewalls 110a, 110b, 110c, 110d,
collectively referred to herein as sidewalls 110, and a cover or
lid 116. In one exemplary embodiment, the base 108 includes a top
planar surface, an opposing bottom planar surface, and four side
edges. The sidewalls 110 are coupled to and extend up from each of
the sides of the base 108 in a direction generally orthogonal to
the base 108. In certain embodiments, the sidewalls 110 extend at
an angle less than about 135 degrees from the base 108. The base
108 and the sidewalls 110 form the cavity 112 within the bag 102
that is configured to receive the liner 104. In certain exemplary
embodiments, the flexible bag 102 also includes the cover 116 for
covering the cavity 112. The cover 116 can be coupled to the
sidewalls 110 by any number of securing means, such as a zipper 118
or other fastener. The flexible bag 102 can be constructed from a
wide range of woven and non-woven textiles and materials including,
but not limited to, polyester, neoprene or polychloroprene, nylon,
cotton, polyethylene terephthalate (PET) such as Dacron.TM.,
recycled polyethylene terephthalate (RPET), leather, polyethylene,
polyurethane, and canvas. In certain embodiments, the flexible bag
102 is constructed from soft materials and/or foam, and includes
any combination of soft materials arranged in layers with foam
therebetween. In one exemplary embodiment, the flexible bag 102 is
an insulating, soft-sided cooler.
[0026] The liner 104 is configured to be placed in (FIG. 1A) and
removed from (FIG. 1B) the cavity 112 of the flexible bag 102. In
certain exemplary embodiments, the liner 104 includes a rectangular
base 120 and four sidewalls 122a, 122b, 122c, 122d, collectively
referred to herein as sidewalls 122. The rectangular base 120 has a
substantially planar top surface, an opposing substantially planar
bottom surface, and multiple sides defining the outer edges of the
base 120. Each sidewall 122 is coupled to or integral with and
extend from at least one of the sides of the base 120 in a
direction generally orthogonal to the planar surface of the base
120. The base 120 and the sidewalls 122 define a cavity 126 within
which items, such as food and beverages, are stored. In certain
exemplary embodiments, the general dimensions of the liner 104 and
the volume of the cavity 126 is sized to fit within the cavity 112.
When the liner 104 is placed within the cavity 112, the sidewalls
122 typically contact the sidewalls 110 of the flexible bag 102. In
certain alternative embodiments, the general dimensions of the
liner 104 and the overall volume of the cavity 126 of the liner 104
are smaller than those of the cavity 112. In this alternative
embodiment, items such as food and beverages, can be isolated from
other items stored in the cavity 112 of the flexible bag 102. In
certain other embodiments, the liner 104 has a substantially
cylindrical shape and is capable of receiving cylindrical container
within the cavity 126, such as a water bottle or can of soda. In
certain embodiments, multiple liners 104 are placed within the
cavity 112 to create separate compartments within the flexible bag
102. In certain exemplary embodiments, the general dimensions of
the liner 104 and the volume of the cavity 126 are sized to carry
nine standard twelve-ounce beverage cans. In certain other
embodiments, the general dimensions of the liner 104 and the volume
of the cavity 126 are sized to carry eighteen standard twelve-ounce
beverage cans. In certain other embodiments, the general dimensions
of the liner 104 and the volume of the cavity 126 are sized to
carry forty-eight standard twelve-ounce beverage cans. One having
ordinary skill in the art will recognize that the soft cooler bags
of the present invention can be sized any number of ways to
accommodate any desired number of drink containers or food
items.
[0027] The exemplary liner 104 is flexible and semi-rigid, and is
constructed from any viscoelastic polymer generally having a
notably low Young's modulus and a high yield strain when compared
with other materials used in constructing conventional soft-sided
collapsible container bags. The polymers typically includes
thermoplastic (TPE) or thermoset (TSE) materials that resemble
rubber, whereby the material resumes its original shape when a
deforming force F1 (FIG. 1C) is removed. The amount of force
required to cause a deflection or deformation in the material
depends upon the type of material and the thickness of the
material, and is generally very small. In certain exemplary
embodiments, the amount of force required to cause a deflection is
less than about one Newton. In certain exemplary embodiments, the
liner 104 is insulating. In certain exemplary embodiments, the
liner 104 provides a waterproof barrier between items stored within
the cavity 126 and the flexible bag 102. Generally, the strength of
the liner 104 is not compromised upon exposure to moisture. In
certain exemplary embodiments, the liner 104 does not absorb
moisture or condensation. Suitable examples of materials of
construction include, but are not limited to styrenic block
copolymers, polyolefin blends, elastomeric alloys such as
thermoplastic elastomer vulcanizates (TPE-v or TPV), thermoplastic
polyurethanes, thermoplastic copolyesters, thermoplastic
polyamides, silicone, latex, nitrile butadiene rubber,
ethylene-propylene terapolymers, fluorosilicone, and
polychloroprene or neoprene. The liner 104 can be constructed using
a number of manufacturing processes. Suitable examples of
manufacturing processes include, but are not limited to, injection
molding, rotational molding, blow molding, dip molding, casting,
compression molding, reaction injection molding (RIM), vacuum
casting, and transfer molding.
[0028] FIG. 2A is a perspective view of a soft cooler bag 200, and
FIG. 2B is a perspective view of the soft cooler bag 200 having a
deforming force F.sub.2 applied thereon, according to another
exemplary embodiment. The soft cooler bag 200 is similar to the
soft cooler bag 100, the difference being in the dimensions of the
soft cooler bags and in the removability of the liner 104.
Referring to FIGS. 2A-B, the soft cooler bag 200 includes a liner
204 that is coupled to an interior of a flexible bag 202. The liner
204 can be coupled to the flexible bag 202 by any suitable means
known to one having ordinary skill in the art, including securing
the liner 204 to the flexible bag 202 with threads or stitches 230.
In certain alternative embodiments, the liner 204 is secured to the
flexible bag 202 by clips, Velcro.RTM., and other mechanical
fasteners.
[0029] In certain exemplary embodiments, the liner 204 includes
grooves or ridges 232 for added structural strength. The grooves or
ridges 232 extend longitudinally along the top planar surface of
the base of the liner 204. In the exemplary embodiment containing
grooves, the grooves are generally an elongated linear depression
in the top planar surface of the base of the liner 204. In the
exemplary embodiment containing ridges 232, the ridges 232 are
generally a linear raised surface extending up from the top planar
surface of the base of the liner 204.
[0030] FIG. 3 is a perspective view of a duffel bag 300, according
to an exemplary embodiment. In certain exemplary embodiments, the
duffel bag 300 is a gym bag or a beach bag used to store clothing,
shoes, towels, drink containers, and any other items typically used
at the gym, pool, or beach. The duffel bag 300 includes a flexible
exterior bag 302. The flexible exterior bag 302 can be constructed
from a wide range of woven and non-woven textiles and materials
including, but not limited to, polyester, neoprene,
polychloroprene, nylon, cotton, polyethylene terephthalate (PET)
such as Dacron.TM., recycled polyethylene terephthalate (RPET),
leather, polyethylene, polyurethane, and canvas. In certain
embodiments, the flexible exterior bag 302 is constructed from soft
materials and/or foam, and can include any combination of soft
materials arranged in layers with foam therebetween. The exemplary
flexible exterior bag 302 includes a central or main compartment
302a and two smaller side compartments 302b, 302c positioned on
opposite ends of the main compartment 302a. The main compartment
302a and the side compartments 302b, 302c include openings or
apertures 312a, 312c to allow users access to an interior cavity
326a, 326c of each of the compartments 302a-c. The openings can be
closed using any suitable closure means known to one having
ordinary skill in the art, such as zippers 318a, 318c, collectively
referred to herein as zippers 318, snaps or the like. The main
compartment 302a and the side compartments 302b, 302c can be any
geometric and non-geometric shape suitable for storing items,
including, but not limited to, cylindrical, cubic, spherical,
rectangular, oval, and trapezoidal. In certain embodiments, the
duffel bag 300 includes a rigid or semi-rigid base for support.
[0031] The duffel bag 300 also includes a liner 304a that is
positioned within the interior cavity 326a of the main compartment
302a, a liner (not shown) that is positioned within an interior
cavity (not shown) of the side compartment 302b, and a liner 304c
that is positioned within an interior cavity 326c of the side
compartment 302c. The liners 304a, 304c are collectively referred
to herein as liners 304, and can be constructed from any of the
materials described with respect to the liner 104. In certain
exemplary embodiments, the liners 304 are sized and shaped to
correspond to the interior cavities of the compartments 302a-c. In
certain exemplary embodiments, the liners 304 are secured to the
interior of the compartments 302a-c by any means known to one
having ordinary skill in the art, such as by stitches, clips,
Velcro.RTM., or other fasteners. In alternative embodiments, the
liners 304 are removable from the flexible exterior bag 302 and are
sized smaller than the compartments 302a-c to allow separation of
items stored within a single compartment. In exemplary embodiments,
a flexible, semi-rigid separator 324 is included in the main
compartment 302a to separate the interior cavity 326a into two
sections.
[0032] FIG. 4 is a top perspective view of a tote bag 400,
according to an exemplary embodiment. The exemplary tote bag 400
is, for example, an open beach bag or a grocery tote, typically
used to store different items, including drinks, such as cans of
soda or bottles of water, therein. The tote bag 400 includes a
flexible bag 402 having a liner 404 therein. The flexible bag 402
includes a rectangular base 408 having a generally planar top
surface, an opposing substantially planar bottom surface and four
sides that define the perimeter of the base 408. The tote bag 400
also includes four sidewalls 410a-d, collectively referred to
herein as sidewalls 410. One or more sidewalls 410 are coupled to
or are integrally formed with and extend from each of the sides of
the base 408 in a direction generally orthogonal to the top planar
surface. In certain embodiments, the base 408 is rigid or
semi-rigid to provide added strength or support. The base 408 and
the sidewalls 410 form a cavity 412 configured to receive the liner
404. The exemplary flexible bag 402 can be constructed from a wide
range of woven and non-woven textiles and materials, including, but
not limited to, canvas, nylon or other easy-care synthetics,
recycled matter, and minimally-processed natural fibers.
[0033] In one exemplary embodiment, the liner 404 is coupled to the
interior of the flexible bag 402 by stitches, clips, Velcro.RTM.,
or other fasteners. Alternatively, the liner 404 is removable from
the flexible bag 402. The liner 404 is constructed from any of the
materials described with respect to the liner 104. In certain
exemplary embodiments, the liner 404 includes a rectangular base
(not shown) having substantially planar top surface, an opposing
substantially planar bottom surface and multiple sides defining the
perimeter of the base, four exterior sidewalls 422a-c (fourth
sidewall not shown) (collectively referred to herein as sidewalls
422), and at least one separator 424 extending up from the base and
extending between at least two of the sidewalls 422 to create
separate compartments within a cavity 426 of the liner 404. In one
exemplary embodiment, one or more sidewalls 422 extend from each of
the sides of the base in a direction generally orthogonal to the
planar top surface of the base. The base, the sidewalls 422, and
the separator 424 define cavities 426a, 426b, collectively referred
to herein as cavities 426, within which items, such as a beverage
carton 440 and dry food containers 442, are stored. Generally, the
dimensions of the liner 404 and the volume of the cavity 426 are
sized to fit within the cavity 412 of the flexible tote bag 402.
When the liner 404 is positioned within the cavity 412 of the bag
402, the sidewalls 422 contact the sidewalls 410 of the flexible
bag 402 and the substantially planar bottom surface of the base 420
contacts the substantially planar top surface of the base 408. In
certain alternative embodiments, the general dimensions of the
liner 404 and the volume of the cavities 426 are sized
substantially smaller than the cavity 412, so that items stored
within the liner 404 are separated from other items stored in the
cavity 412 of the flexible bag 402. In certain other embodiments,
the liner 404 is cylindrically-shaped and dimensioned to house a
single cylindrical container, such as a water bottle or standard
twelve-ounce aluminum beverage container. In certain embodiments,
multiple liners 404 are placed within the cavity 412. One having
ordinary skill in the art will recognize that the liners of the
present invention can be sized and configured any number of ways to
accommodate any desired number of sections within the tote bag
400.
[0034] The liners 104, 204, 304, and 404 can be manufactured a
number of ways, including using compression molding. FIG. 5 is a
flow diagram illustrating an exemplary method 500 for manufacturing
a liner. The exemplary method 500 begins at step 502, where heaters
in a molding machine heat a mixture having a viscoelastic polymer
to form a preheated viscoelastic polymer material. Any of the
various exemplary viscoelastic polymer materials described
previously can be used. In step 504, an extruder of the molding
machine places the preheated viscoelastic polymer material into a
heated mold for a liner. In an exemplary embodiment, the size,
shape, dimension, and configuration of the mold is selected based
upon the desired size, shape, dimension, and configuration of the
liner. The mold is closed with a top force or a plug member in step
506. In step 508, molding machine platens apply pressure and heat
until the viscoelastic polymer material has cured or solidified.
The liner is removed from the mold in step 510. In step 512, an
inquiry is conducted to determine if the liner has fully hardened.
In one exemplary embodiment, determining if the liner has fully
hardened is completed by a machine operator. If the liner has not
completely hardened, the "No" branch is followed to step 514, where
an oven or a heated conveyer further heats the liner using a
post-cure process until fully cured. Otherwise, the "Yes" branch is
followed to the End step.
[0035] Referring now to FIG. 6, the liners 104, 204, 304, and 404
can be manufactured using transfer molding. FIG. 6 is a flow
diagram illustrating an exemplary method 600 for manufacturing a
liner, according to another exemplary embodiment. The exemplary
method 600 begins at step 602, where heaters in a molding machine
heat a mixture having viscoelastic polymer materials in a chamber,
or transfer pot. Any of the various exemplary viscoelastic polymer
materials described previously can be used. In step 604, a plunger
is used to force the preheated viscoelastic polymers from the pot
through channels known as a sprue into a heated mold for a liner.
In step 606, molding machine platens apply pressure and heat until
the materials in the mold has cured or solidified. The liner is
removed from the mold in step 608. In step 610, an inquiry is
conducted to determine if the liner has fully hardened. In one
exemplary embodiment, determining if the liner has fully hardened
is completed by a machine operator or inspector. If the liner has
not completely hardened, the "No" branch is followed to step 612,
where an oven or a heated conveyer further heats the liner using a
post-cure process until fully cured. Otherwise, the "Yes" branch is
followed to the End step.
[0036] FIG. 7 is a flow diagram illustrating an exemplary method
700 for manufacturing a soft-sided container bag having a flexible,
semi-rigid liner, according to an exemplary embodiment. The liner
can be manufactured using injection molding. The exemplary method
700 begins at step 702, where a user feeds viscoelastic polymer
resin into a heated barrel of an injection molding machine. The
heated barrel heats and mixes the viscoelastic polymer resin. Any
of the various exemplary viscoelastic polymer materials described
previously can be used. In step 704, an extruder of the molding
machine forces the heated mixture through a screw or a ramming
device into a mold for a liner. In step 706, molding machine
platens apply pressure and chilled fluids flowing through the mold
cools the liner until the liner is hardened to the configuration of
the mold. The liner is removed from the mold in step 708. The liner
is placed into a flexible bag in step 710. In step 712, an inquiry
is conducted to determine if the liner is to remain removable from
the flexible bag. If the liner is coupled to the flexible bag, the
"No" branch is followed to step 714, where the liner is secured to
the interior of the flexible bag. In certain exemplary embodiments,
the liner is sewn to the flexible bag. Otherwise, the "Yes" branch
is followed to the End step.
[0037] Therefore, the semi-rigid liners for soft container bags
described herein are adapted to attain the ends and advantages
mentioned as well as those that are inherent therein. The
particular embodiments disclosed above are illustrative only, as
the present invention may be modified and practiced in different
but equivalent manners apparent to those having ordinary skill in
the art having the benefit of the teachings herein. Having
described some exemplary embodiments of the present invention, it
is believed that the use of alternate liner configurations is
within the purview of those having ordinary skill in the art. In
addition, the liner and/or soft container bag is not limited to
having a rectangular shape or a cylindrical shape. While numerous
changes may be made by those having ordinary skill in the art, such
changes are encompassed within the spirit of this invention as
defined by the appended claims. It is therefore evident that the
particular illustrative embodiments disclosed above may be altered
or modified and all such variations are considered within the scope
and spirit of the present invention.
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