U.S. patent application number 13/116216 was filed with the patent office on 2012-11-29 for flexible sturdy base container and method for making the same.
This patent application is currently assigned to PRINTPACK ILLINOIS, INC.. Invention is credited to William Ben Bower, Hwan Koo Cho, Karen Lynn English, David James Kessler, JR., Gray McCalley, JR., Thomas P. Seidel, Hannah C Smith, James Douglas Taylor.
Application Number | 20120298663 13/116216 |
Document ID | / |
Family ID | 46246208 |
Filed Date | 2012-11-29 |
United States Patent
Application |
20120298663 |
Kind Code |
A1 |
Seidel; Thomas P. ; et
al. |
November 29, 2012 |
FLEXIBLE STURDY BASE CONTAINER AND METHOD FOR MAKING THE SAME
Abstract
Flexible sturdy base containers and methods for manufacturing
the same are provided. The flexible sturdy base container includes
a rigid base element formed of a relatively rigid material. The
rigid base element includes a bottom and a perimeter wall having an
outward facing surface. The container also includes a flexible wall
element formed of a relatively flexible material. The flexible wall
element is affixed to the outward facing surface of the perimeter
wall of the rigid base element and extends in a direction away from
the bottom of the rigid base element. The flexible wall element and
the bottom of the rigid base element together form an exterior of
the flexible sturdy base container.
Inventors: |
Seidel; Thomas P.; (Smyrna,
GA) ; Taylor; James Douglas; (Johns Creek, GA)
; Cho; Hwan Koo; (Williamsburg, VA) ; Bower;
William Ben; (Palo Alto, CA) ; Kessler, JR.; David
James; (Atlanta, GA) ; Smith; Hannah C;
(Smyrna, GA) ; English; Karen Lynn; (Alpharetta,
GA) ; McCalley, JR.; Gray; (Atlanta, GA) |
Assignee: |
PRINTPACK ILLINOIS, INC.
Elgin
IL
|
Family ID: |
46246208 |
Appl. No.: |
13/116216 |
Filed: |
May 26, 2011 |
Current U.S.
Class: |
220/212 ;
220/628 |
Current CPC
Class: |
B65D 75/5816 20130101;
B65D 2207/00 20130101; B65D 3/12 20130101; B65D 77/12 20130101;
B65D 3/08 20130101; B65D 47/0847 20130101 |
Class at
Publication: |
220/212 ;
220/628 |
International
Class: |
B65D 51/00 20060101
B65D051/00; B65D 25/20 20060101 B65D025/20 |
Claims
1. A flexible sturdy base container comprising: a rigid base
element comprising a relatively rigid material, the rigid base
element comprising a bottom and a perimeter wall having an outward
facing surface; and a flexible wall element comprising a relatively
flexible material; wherein the flexible wall element is affixed to
the outward facing surface of the perimeter wall of the rigid base
element and extends in a direction away from the bottom of the
rigid base element; and wherein the flexible wall element and the
bottom of the rigid base element together form an exterior of the
flexible sturdy base container.
2. The flexible sturdy base container of claim 1, wherein the
flexible wall element overlaps itself along a portion of the
perimeter wall to form a lap seam.
3. The flexible sturdy base container of claim 2, wherein an
inward-facing surface of the flexible wall element is bonded to an
outward-facing surface of the flexible wall element where the
flexible wall element overlaps itself at the lap seam.
4. The flexible sturdy base container of claim 1, the rigid base
element further comprising a reclosable lid.
5. The flexible sturdy base container of claim 4, further
comprising a hinge connecting the reclosable lid to the rigid base
element.
6. The flexible sturdy base container of claim 5, wherein the hinge
is a living hinge.
7. The flexible sturdy base container of claim 4, the rigid base
element further comprising a spout opening providing access to an
interior of the container, the spout opening being selectively
closable with the reclosable lid.
8. The flexible sturdy base container of claim 7, the reclosable
lid comprising an internal rib and the spout opening comprising an
external rib, and wherein the internal rib engages the external rib
when the reclosable lid is positioned in a closed position.
9. The flexible sturdy base container of claim 1, wherein the
flexible wall element covers only a first portion of the perimeter
wall of the rigid base element thereby leaving a second portion of
the perimeter wall exposed proximal the bottom of the rigid base
element.
10. The flexible sturdy base container of claim 1, wherein rigid
base element comprises a molded or thermoformed article.
11. The flexible sturdy base container of claim 1, wherein the
relatively rigid material comprises a plastic material.
12. The flexible sturdy base container of claim 1, wherein the
rigid base element comprises a recessed panel and a standoff
extending between the recessed panel and the bottom of the rigid
base element.
13. The flexible sturdy base container of claim 12, further
comprising a reclosable lid attached to the recessed panel.
14. The flexible sturdy base container of claim 1, wherein the
perimeter wall has at least one flat, substantially planar
portion.
15. The flexible sturdy base container of claim 4, further
comprising a locking tab for locking the reclosable lid in a closed
position, the locking tab moveable between a unlocked position and
a locked position.
16. The flexible sturdy base container of claim 1, wherein the
relatively flexible material comprises a polymeric material.
17. The flexible sturdy base container of claim 1, wherein the
relatively flexible material comprises a multilayer laminate
structure.
18. The flexible sturdy base container of claim 17, wherein the
multilayer laminate structure comprises a heat-sealable inner layer
comprising a heat sealable material.
19. The flexible sturdy base container of claim 17, wherein the
multilayer laminate structure comprises an oxygen and/or vapor
barrier layer.
20. The flexible sturdy base container of claim 17, wherein the
multilayer laminate structure comprises a print layer.
21. The flexible sturdy base container of claim 1, wherein the
flexible wall element comprises a first end proximal to the bottom
of the rigid base element and a second end distal to the bottom of
the rigid base element, and wherein the second end of the flexible
wall element comprises a heat seal region, the heat seal region
hermetically sealing the container.
22. The flexible sturdy base container of claim 21, wherein the
flexible wall element further comprises a tear-away portion and a
stress riser that facilitates the tearing away of the tear away
portion.
23. The flexible sturdy base container of claim 1, wherein the
flexible wall element comprises a first end proximal to the bottom
of the rigid base element and a second end distal to the bottom of
the rigid base element, and wherein the second end of the flexible
wall element comprises a reclosable element, the reclosable element
allowing selective closure of the second end of the flexible wall
element.
24. The flexible sturdy base container of claim 1, wherein the
container contains a bulk product.
Description
FIELD
[0001] The present disclose relates generally to flexible
containers, and more particularly to a flexible container with a
rigid base.
BACKGROUND
[0002] Containers for foodstuffs and other bulk materials are made
from various rigid or flexible materials in various configurations.
Despite the availability of many different known flexible and rigid
packaging designs, there remains a need for new containers for
foodstuffs and other bulk materials that can be manufactured cost
effectively and that can provide advantageous properties.
SUMMARY
[0003] In one aspect, a flexible sturdy base container is provided.
The flexible sturdy base container includes a rigid base element
comprising a relatively rigid material. The rigid base element
includes a bottom and a perimeter wall having an outward facing
surface. The container also includes a flexible wall element
comprising a relatively flexible material. The flexible wall
element is affixed to the outward facing surface of the perimeter
wall of the rigid base element and extends in a direction away from
the bottom of the rigid base element. The flexible wall element and
the bottom of the rigid base element together form an exterior of
the flexible sturdy base container.
[0004] In another aspect, a method of manufacturing a flexible
sturdy base container is provided. The method includes transporting
a rigid base element comprising a relatively rigid material to a
flexible wall element application station. The rigid base element
has a bottom and a perimeter wall having an outward facing surface.
The method also includes applying a flexible wall element around
the perimeter wall of the rigid base element at the flexible wall
element application station without covering the bottom of the
rigid base element. The flexible wall element comprises a
relatively flexible material. The method also includes affixing the
flexible wall element to the perimeter wall of the rigid base
element to produce the flexible sturdy base container.
DRAWINGS
[0005] FIG. 1 is a perspective view, illustrating two flexible
sturdy base containers made in accordance with one or more
embodiments of the present invention.
[0006] FIG. 2 is a side view, illustrating one of the flexible
sturdy base containers of FIG. 1.
[0007] FIG. 3 is a perspective view, illustrating two flexible
sturdy base containers made in accordance with one or more
embodiments of the present invention.
[0008] FIG. 4 is a perspective view, illustrating two flexible
sturdy base containers made in accordance with one or more
embodiments of the present invention.
[0009] FIGS. 5A-C are perspective views, illustrating use of one of
the flexible sturdy base containers of FIG. 4.
[0010] FIG. 6 is a perspective view, illustrating two flexible
sturdy base containers made in accordance with one or more
embodiments of the present invention.
[0011] FIGS. 7A-C are perspective views, illustrating use of one of
the flexible sturdy base containers of FIG. 6.
[0012] FIG. 8 is a perspective view, illustrating two flexible
sturdy base containers made in accordance with one or more
embodiments of the present invention.
[0013] FIG. 9 is a perspective view, illustrating two flexible
sturdy base containers made in accordance with one or more
embodiments of the present invention.
[0014] FIG. 10 is a perspective view, illustrating two flexible
sturdy base containers made in accordance with one or more
embodiments of the present invention.
[0015] FIG. 11 is a perspective view, illustrating a flexible
sturdy base container made in accordance with one or more
embodiments of the present invention.
[0016] FIGS. 12A-C are perspective views, illustrating use of the
flexible sturdy base container of FIG. 11.
[0017] FIG. 13 is a perspective view, illustrating a flexible
sturdy base container made in accordance with one or more
embodiments of the present invention.
[0018] FIGS. 14A and 14B are perspective views, illustrating use of
the flexible sturdy base container of FIG. 13.
[0019] FIG. 15 is a side view, illustrating a method of
manufacturing a sturdy base container in accordance with one or
more embodiments of the present invention.
[0020] FIGS. 16A and 16B are orthogonal views, illustrating a
method of manufacturing a sturdy base container in accordance with
one or more embodiments of the present invention.
[0021] FIG. 17 is a side view, illustrating a method of filling and
sealing a sturdy base container in accordance with one or more
embodiments of the present invention.
[0022] FIG. 18 is a perspective view, illustrating a flexible
sturdy base container made in accordance with one or more
embodiments of the present invention.
[0023] FIGS. 19A, 19B, and 19C are perspective views, illustrating
a flexible sturdy base container made in accordance with one or
more embodiments of the present invention.
[0024] FIGS. 20A and 20B, are a side view and a bottom view,
respectively, illustrating a flexible sturdy base container made in
accordance with one or more embodiments of the present
invention.
[0025] FIGS. 21A and 21B, are a side view and a bottom view,
respectively, illustrating a flexible sturdy base container made in
accordance with one or more embodiments of the present
invention.
[0026] FIGS. 21C and 21D, are perspective views, illustrating the
flexible sturdy base container of FIGS. 21A and 21B.
DETAILED DESCRIPTION
[0027] New containers are disclosed that provide various advantages
over presently-available container designs. Methods are also
provided for manufacturing such containers. In one aspect, a
flexible sturdy base container is provided that includes a rigid
base element made from a relatively rigid material and a flexible
wall element made from a relatively flexible material. As used
herein the terms "relatively rigid material" and "relatively
flexible material" are intended to denote that one material, i.e.,
the relatively rigid material, is more rigid than the other
material, i.e., the relatively flexible material. The relatively
rigid material may be any material suitable for providing
structural integrity to the base of the container. For example, the
material may be sufficiently rigid to allow the container to stand
up vertically when placed on its base. In some embodiments, the
material may be sufficiently rigid to prevent the container from
tipping over when placed on its side.
[0028] In some embodiments, the base is made of a rigid or
semi-rigid material and the side wall is made of a flexible
material. The term "rigid material," as used herein, is used in the
ordinary sense and refers to materials that are characterized by a
degree of stiffness that would be considered rigid in the packaging
and converting industry. Often these materials are made by blow
molding, injection molding, or thermoforming processes. For
example, the rigid base element may be made by thermoforming an
extruded sheet. The term "flexible material," as used herein, is
used in the ordinary sense and refers to materials that are
characterized by a degree of flexibility (e.g., to bending) that
would be considered flexible in the packaging and converting
industry. Often these materials are relatively thin webs or films
produced by extrusion processes. The term "semi-rigid material," as
used herein, is used in the ordinary sense and refers to materials
that are characterized by a degree of stiffness that would be
considered semi-rigid in the packaging and converting industry.
These materials may also be considered rigid or flexible. The terms
"rigid" "semi-rigid" and "flexible" are extensive qualities that
depend not only on the specific composition of the material but
also the material's thickness, structure, and method of
forming.
[0029] The rigid base element may allow the container to stand
vertically on its base or may allow the container to lay on its
side without tipping over. Such a feature may be advantageous in
retail settings where visible shelf space is limited. The rigid
base may also provide protection for fragile dry products, e.g., it
may reduce or prevent breaking of flakes. The rigid base may also
allow for the container to stand up when it is partially filled.
Thus, the container may be pantry, counter and table-top friendly.
The rigid base may customized depending on the nature of the
product and the needs of the customer and/or retailer. For example,
the base can be formed in a shape consistent with ergonomic needs
(e.g., it can be shaped to be easier to hold in the consumer's
hand) or the base can be shaped such that the product stores better
on a retailer shelf or is better for packing and/or shipping.
[0030] The flexible wall element may occupy the majority of the
exterior surface area of the package and/or a majority of the
packaging material by mass, thereby making efficient use of the
materials. The flexible wall element may also be made from thin
films, thereby allowing for customizable barrier properties.
Likewise, the rigid base may be thermoformed or co-injection molded
for oxygen barrier properties if necessary. Such features may allow
for customization of the barrier properties for different types of
products (e.g., dry, frozen, fresh, oxygen sensitive, moisture
sensitive, or respiring). The flexible wall material may be
customizable in shape, providing excellent customization and
product differentiation opportunities. The flexible wall element
may also allow for various convenience features (such as easy-open
or reclosable features) to be viewed. The flexible wall element may
also include a product viewing window.
[0031] The container, having a sturdy base and a flexible top, may
also allow for open-top filling. Advantageously, in some
embodiments, the container may be employed in high-speed filling
and sealing systems. Moreover, the container may be made
predominantly from a single polymer. For example, the container may
be made predominantly of polypropylene, which is lightweight, cost
effective, and recyclable. In some embodiments, the container may
be made predominantly of polylactic acid, which is renewable and
compostable.
[0032] The container may be used to contain various food and other
bulk products, such as granular products or products that can be
gravity-fed. The bulk product can also include smaller packages,
such as candy or individual servings of product. In some
embodiments, the container may contain breakfast cereals, salty
snacks, pasta, crackers, popcorn, nuts, dried fruits,
confectionaries, chocolate, and other baked or fried goods and/or
dry products. In some embodiments, the container may contain frozen
food products, including frozen meat, seafood, vegetables, fruit,
and combinations thereof. In other embodiments, the container may
contain non-food items including laundry and dish-washing
detergents, fertilizers, insecticides, pesticides and other
granulated products.
Flexible Sturdy Base Container
[0033] In one aspect, a flexible sturdy base container is provided
that includes a rigid base element made from a relatively rigid
material and a flexible wall element made from a relatively
flexible material. In some embodiments, the rigid base element
includes a bottom and a perimeter wall having an outward facing
surface. In some embodiments, the flexible wall element is affixed
to the outward facing surface of the perimeter wall of the rigid
base element and extends in a direction away from the bottom of the
rigid base element. In some embodiments, the flexible wall element
and the bottom of the rigid base element together form an exterior
of the flexible sturdy base container.
[0034] An exemplary embodiment of a flexible sturdy base container
10 is illustrated in FIG. 1. The illustrated flexible sturdy base
container 10 includes a rigid base 18 that forms the bottom 14 of
the container 10. A flexible side wall 16 is affixed to a rigid
base 18. The flexible side wall 16 may extend from proximal to the
bottom 14 of the container 10 to the top 12 of the container 10. At
the top 12 of the container 10 an end seal 20 may be provided. The
end seal may be, for example, a heat seal. In the illustrated
embodiment, the end seal 20 comprises a heat seal region that
extends across the entirety of the top 12 of the container 10
thereby sealing the end of the flexible side wall 16 opposite the
rigid base 18.
[0035] The bottom 14 may include a reclosable lid 22. The
reclosable lid 22 may pivot with respect to the bottom 14 by a
hinge 24, which may be a living hinge. As illustrated in FIG. 2,
the reclosable lid 22 may be selectively positionable in an open
position and a closed position (FIG. 1). When the reclosable lid 22
is positioned in the open position, a spout opening 30 is
uncovered, thereby allowing access to the contents of the container
10. Various locking features may be provided for retaining the
reclosable lid 22 in the closed position. For example, the spout
opening 30 may include an external rib 28. The reclosable lid 22
may also include an internal rib 26 that mechanically engages the
external rib 28 when the reclosable lid 22 is moved to the closed
position. Engagement of the internal rib 26 and external rib 28 may
prevent the reclosable lid 22 from opening inadvertently, such as
when moving the container from one location to another.
[0036] As illustrated in FIG. 2, the flexible side wall 16 may be
affixed to the rigid base 18 along a perimeter wall 25 of the rigid
base 18. The flexible side wall 16 may be affixed to the perimeter
wall 25, for example, by thermal, ultrasonic, RF or adhesive
bonding. In the illustrated embodiment, the flexible side wall 16
terminates proximal the bottom of the rigid base 14; however, an
exposed portion 27 of the perimeter wall 25 is left uncovered by
the flexible side wall 16.
[0037] In preferred embodiments, the flexible side wall material
may be affixed to itself by a lap seam type seal that extends from
the end of the flexible side wall proximal to the rigid base to the
opposite end of the flexible side wall at the top of the container.
The lap seam may be formed by sealing together, at respective
edges, an outward-facing surface of the flexible side wall and an
inward-facing surface of the flexible side wall. The seal may be
created by thermal bonding, RF bonding, ultrasonic bonding,
adhesive bonding, or a combination thereof. The lap seam not only
provides an efficient use of material for flexible sturdy base
container configurations but also provides improved structural
strength and improved sealing relative to fin seals or butt seams.
Specifically, it is noted that the lap seam induces an
outward-exerting spring force within the flexible wall that
provides natural resistance to folding. The lap seam also allows
for the flexible material to be wrapped around the outward facing
surface of the perimeter wall of the rigid base. This allows for a
better seal to be formed between the flexible side wall and reduces
or eliminates channels and wrinkling, which could compromise the
sealing of the contents of the package.
[0038] Another embodiment of a flexible sturdy base container 32 is
illustrated in FIG. 3. The container 32 includes a rigid base 36 at
the bottom 38 of the container 10 and a flexible side wall 34
extending from proximal to the bottom 38 of the container 10 to the
top 40 of the container 10. The rigid base 36 may include a
recessed panel 42 that is separated from bottom 38 by a standoff
44. The rigid base 36 may also include a reclosable lid 46 that is
attached to the recessed panel 42 by a hinge 48, which may be a
living hinge. The reclosable lid 46 may include a tab 50 that is
elevated from the recessed panel 42 to facilitate opening.
[0039] Another embodiment of a flexible sturdy base container 52 is
illustrated in FIG. 4. The container includes a rigid base having
an annular shaped bottom 56. A recessed panel 54 is separated from
bottom 56 by a standoff 60. As illustrated in FIG. 5A, the
reclosable lid 62 may be manipulated to the open position to reveal
a removable seal 64. The removable seal 64 may be a tamper-evident
membrane that is configured to indicate to the user whether the
container had previously been opened. The removable seal could be a
lidding membrane that provides barrier properties as well as tamper
evidency. Other tamper-evident features, including heat-shrunk
bands placed over the lid, may be employed in addition to or in
place of the removable seal 64.
[0040] Referring back to FIG. 5A, the removable seal 64 may then be
peeled or torn away to reveal an opening 66, providing access to
the contents of the container 52. With the reclosable lid 62 in the
open position, the contents of the container 52 may be poured out
into a hand or a container 65 as illustrated in FIG. 5B. As
illustrated in FIG. 5C, the container 52 may be easily reclosed by
pivoting the reclosable lid 62 about the hinge 58 until reclosable
lid 62 snaps back into the closed position.
[0041] Another embodiment of a flexible sturdy base container 70 is
illustrated in FIG. 6. The container 70 includes a flexible side
wall 72 and a rigid base 74. A reclosable lid 78 is attached to the
bottom 76 of the ridge base 74 by a hinge 80, which may be a living
hinge. For additional security, the rigid base 74 further includes
locking 78 which securely engages the reclosable lid 78 and
maintains the reclosable lid 78 in the closed position until the
locking tab 80 is pulled away from the reclosable lid 78. A recess
82 is provided in the reclosable lid 82 to provide a space for
inserting the end of a finger to pull away the locking tab 80 from
the reclosable lid as illustrated in FIG. 7A. With the reclosable
lid 82 in the open position, the contents of the container 70 may
be poured out into a hand or a container 84 as illustrated in FIG.
7B. As illustrated in FIG. 7C, the container 70 may be reclosed by
pivoting the reclosable lid 78 back to the closed position and
pressing the locking tab 80 back into position to secure the
reclosable lid 78.
[0042] Another embodiment of a flexible sturdy base container 86 is
illustrated in FIG. 8. The container 86 includes a flexible side
wall 88 that is affixed to a rigid base 90. The rigid base may
include a recessed panel 96 that is separated from the bottom 92 of
the rigid base 90 by a standoff 95. The rigid base also includes a
reclosable lid 98 that is attached to the recessed panel 96, for
example, by a hinge. The embodiment illustrated in FIG. 8, like the
embodiments of FIGS. 1 and 6, has a rigid base 90 having a
perimeter wall with flat, substantially planar portions on opposite
sides of the rigid base 90. These flat, substantially planar
portions may allow the container 86 to lay flat on its side with
stability, i.e., without tipping over.
[0043] Another embodiment of a flexible sturdy base container 100
is illustrated in FIG. 9. The container 100 includes a rigid base
108 and a flexible side wall 106 extending from proximal to the
bottom 104 of the container 100 to the top 102 of the container
100. The rigid base 108 includes a reclosable lid 110 that is
attached to the rigid base 108 by a hinge. The rigid base 108 also
includes a perimeter wall having two pairs of opposing flat,
substantially planar portions 114 and 116. In this embodiment, the
container 100 may rest stably on the rigid base 104 in the vertical
orientation or may rest stably on any of its sides.
[0044] Another embodiment of a flexible sturdy base container 120
is illustrated in FIG. 10. The container 120 includes a rigid base
129 and a flexible side wall 126 extending from proximal to the
bottom 130 of the container 120 to the top 122. The top 122 of the
container 120 may be heat sealed, and a handle 124 may be formed by
a cutout within the heat seal region. The handle 124 may be
reinforced by the addition of a reinforcing layer. A reclosable lid
132 is provided in the rigid base 128 at the bottom 130.
[0045] Another embodiment of a flexible sturdy base container 140
is illustrated in FIG. 11. The container 140 includes a rigid base
152 and a flexible side wall 150 extending from proximal to the
bottom 154 of the container 140 to the top 146. A heat seal region
148 may also be provided along the top 146, and a stress riser 144
may be provided in the flexible side wall 150, for example, in the
heat seal region 148. The stress riser 144 may be configured to
propagate a tear 145 when the user grasps a tear-away portion 142
and pulls as illustrated in FIG. 12A. When the tear-away portion
142 is torn from the container 140, an opening 146 is formed as
illustrated in FIG. 12B. The opening 146 may be used as a spout to
pour the contents of the container 140 into a hand or a container
152. The container 140 then may be reclosed by folding a folded
portion 150 over the opening 146 and placing a clip 148 over the
fold as illustrated in FIG. 12C.
[0046] Another embodiment of a flexible sturdy base container 160
is illustrated in FIG. 13. The container 160 includes a rigid base
172 and a flexible side wall 166. The flexible side wall 166 has a
heat-seal region 170 at the top 168. The top 168 may also include a
tear-away portion 162 which, when removed, reveals an internal
locking feature 164. As illustrated in FIG. 14A, the container 160
may be opened by tearing away tear-away portion 162 to produce an
opening 174 providing access to the contents of the container 160.
As illustrated in FIG. 14B, the container 160 may then be closed by
compressing the internal locking feature 164. The internal locking
feature 164 may be, for example, interlocking ribs, tabs, a zipper,
hook and loop fasteners, or pressure sensitive adhesive.
[0047] The embodiments illustrated in FIGS. 1-14 are intended to be
illustrative of the various features and configurations possible
for flexible sturdy base containers according to one or more
embodiments of the present invention. It should be appreciated that
the various features that are illustrated in one embodiment
(including shapes of the rigid base, the presence or absence of a
recessed panel, handle, reclosable feature, locking tab, stress
riser or tear-way portion) may be incorporated and used in each of
the other illustrated embodiments. For example, as illustrated in
FIG. 18, a flexible sturdy base container 500 may include a top 54,
an internal reclose feature 502 proximal the top 504, and a flat
rectangular shaped base 506. In another example, as illustrated in
FIGS. 19A-C, a flexible sturdy base container 600 may include a
handle 604, a tear away portion 602, and an internal locking
feature 606 all located in a top portion of the container 600. In
yet another example, as illustrated in FIGS. 20A and 20B, a
flexible sturdy base container 700 can include a substantially
triangular-shaped bottom 702 having a reclosable lid 704 integrated
to the bottom 702 by a hinge 706. In yet another example, a
flexible sturdy base container 800 may have a substantially
triangular-shaped bottom 802 and a gusset 804 on one side with an
internal locking feature 806 within a folded portion of the gusset.
The gusset 804 may be opened (i.e., unfolded) to create an opening
or pour spout for providing access to the contents of the container
800.
[0048] Flexible Wall Element
[0049] The flexible wall element may be made of a relatively
flexible material, which may be a flexible material. In some
embodiments, the relatively flexible material is sufficiently
flexible to allow the top of the container to be rolled or folded
over. In some embodiments, the relatively flexible material
comprises a polymeric material. For example, the relatively
flexible material may comprise a relatively thin polymeric film or
web.
[0050] In certain embodiments, the relatively flexible material may
be a multilayer laminate structure. In an exemplary embodiment, the
multilayer laminate structure may include one or more of a
heat-sealable inner layer, an oxygen and/or a vapor barrier layer,
and a print layer. Other layers serving other functions may also be
employed.
[0051] The heat-sealable inner layer may comprise any heat-sealable
material. Exemplary heat-sealable materials include, but are not
limited to, thermoplastic polymeric materials, such as
polypropylene, polyethylene, polylactic acid, copolymers of
polypropylene, copolymers of polyethylene, heat sealable PET, PET
copolymers, and biodegradable and compostable thermoplastics.
[0052] The oxygen and/or vapor barrier layer may comprises any
material suitable for provided the desired oxygen and/or vapor
barrier performance qualities. In some embodiments, the multilayer
laminate structure provides a gas permeability of less than 100
cc/100 in.sup.2/24 hrs, or more preferably less than 10 cc/100
in.sup.2/24 hrs, or most preferably less than 0.1 cc/100
in.sup.2/24 hrs. Exemplary barrier layer materials include metal
films (e.g., aluminum films), metalized polyolefin films, and
copolymers of vinyl alcohol (EVOH, PVOH), metalized PLA, aluminum
oxide coated PET, silicon oxide coated PET, nylon, metalized nylon,
and polyglycolic acid (PGA) films.
[0053] In some embodiments, the flexible wall element extends from
approximately the bottom of the container to the top of the
container. In certain embodiments, a portion of the rigid base is
exposed between the top and the bottom of the container. In such
embodiments, the flexible wall element, an exposed portion of the
perimeter wall of the rigid base element, and the bottom of the
rigid base element together form an exterior of the flexible sturdy
base container. In other embodiments, the flexible wall element may
extend from the top of the container to the bottom of the container
without covering the bottom. In such embodiments, no portion of the
perimeter wall of the rigid base may form the exterior of the
container, i.e., the entirety of the perimeter wall may be covered
by the flexible wall element.
[0054] In some embodiments, the top of the flexible wall includes a
heat seal region in which opposite sides of the flexible wall are
heat-sealed together. Alternatively, in some embodiments, the heat
seal region may be a bonding region in which the opposite sides of
the flexible wall are bonded by ultrasonic bonding or RF bonding.
In some embodiments, the heat seal or bonding region may extend
across the entirety of the top of the container, thereby
hermetically sealing the container and its contents. In some
embodiments, the container may include a stress riser placed in the
heat seal or bonding region that is designed to propagate a tear
when a tear away portion is pulled by a user to provide access to
the contents of the container.
[0055] In some embodiments, the container may include a reclosable
element integrated or attached to the flexible wall element. The
reclosable element may allow for the selective closure of an end of
the flexible wall element. Various reclosable elements may be
employed including, but not limited to, interlocking ribs, tabs,
zippers, hook and loop fasteners, or pressure sensitive
adhesive.
[0056] Rigid Base Element
[0057] The rigid base element may be made of a relatively rigid
material, which may be a rigid material. In some embodiments, the
rigid base element may be a molded or thermoformed article. For
example, the relatively rigid material may be formed of a plastic
material. Exemplary materials for forming the rigid base include
polypropylene, polyethylene, polyethylene teraphthalate, copolymers
of polypropylene, copolymers of polyethylene, EVOH, styrene, ABS,
PVC, PVDC, copolymers of styrene, multilayer materials, composite
materials, and bioderived materials.
[0058] The rigid base element may include a bottom and a perimeter
wall having an outward facing surface for mating with and bonding
with the flexible wall element. The outward-facing surface may
include ribs, etching, or other surface characteristics to improve
manufacturing or the consumer experience. In some embodiments, the
bottom of the rigid base may comprise a flat, substantially planar
surface covering the area circumscribed by the perimeter wall. In
other embodiments, the bottom of the rigid base may comprise a
recessed panel that is separated from the bottom by a standoff.
[0059] In some embodiments, the rigid base element may include a
reclosable lid that selectively covers a spout opening through
which the contents of the container may be accessed. The reclosable
lid may be integral with the rigid base or it may be a separate
component that is attached to the rigid base. The reclosable lid
may be joined to the rigid base by a hinge, such as a living hinge.
Thus, the lid may be selectively positioned in an open position and
a closed position. In some embodiments, the spout opening has an
external rib and the reclosable lid has an internal rib that
engages the external rib when the reclosable lid is positioned in
the closed position.
[0060] In some embodiments, the rigid base element further includes
a locking tab for locking the reclosable lid in a closed position.
In certain embodiments, the locking tab is moveable between a
unlocked position and a locked position in which the reclosable lid
is secured in the closed position.
[0061] Advantageously, in some embodiments, the rigid base and its
associated components may be formed of a single, integral, and
contiguous material. For example, the reclosable lid may be
integral with the base, such as, by the use of a living hinge, and
the locking feature, if present, may be similarly integrally formed
with and a part of the rigid base. Such a feature may allow for the
rigid base and its components to be manufactured economically and
efficiently.
[0062] The rigid base may be formed in various shapes and sizes,
including any polygonal, curvilinear or hybrid
polygonal-curvilinear shape, including, but not limited to,
triangular, quadrilateral, rectangular, square, trapezoidal,
rhomboidal, pentagonal, hexagonal, heptagonal, octagonal,
nonagonal, decagonal, circular, oval, elliptical, Reuleaux
polygonal, or combination of any number of the foregoing. Moreover,
the shape may comprise one or more other features such as a fillet
or a chamfer. In certain embodiments, the perimeter wall has at
least one flat, substantially planar portion. The flat,
substantially planar portion may be sufficiently large in area to
allow the container to rest stably on a side without tipping
over.
Methods of Manufacturing a Sturdy Base Container
[0063] In another aspect, a method of manufacturing a flexible
sturdy base container is provided. The method may include
transporting a rigid base element made of a relatively rigid
material to a flexible wall element application station. The rigid
base element may include a bottom and a perimeter wall having an
outward facing surface. The method may further include applying a
flexible wall element around the perimeter wall of the rigid base
element at the flexible wall element application station without
covering the bottom of the rigid base element. The flexible wall
element may be made of a relatively flexible material. The method
may further include affixing the flexible wall element to the
perimeter wall of the rigid base element to produce the flexible
sturdy base container. The method may further include forming an
overlap of the flexible wall element in which the flexible wall
element overlaps itself to form a lap seam. The method may further
include affixing an outward-facing surface of the flexible wall
element to an inward-facing surface of the flexible wall element at
the lap seam.
[0064] In some embodiments, the method further includes
transporting the flexible sturdy base container to a filling
station, and filling the flexible sturdy base container with a bulk
product while the flexible sturdy base container is at the filling
station. In some embodiments, after being filled, the container may
then be transported to a sealing station where an open end of the
flexible wall element is sealed. For example, the open end may be
sealed by heat sealing the flexible wall element to form a heat
seal region. In certain embodiments, the step of sealing the open
end of the flexible wall element comprises bonding opposite sides
of the flexible wall element to form a bonding region. In certain
embodiments, the open end of the flexible wall element may be
sealed by compressing opposing reclosable elements together.
[0065] Various methods may be employed to apply the flexible wall
element to the rigid base element. For example, in some
embodiments, an open end of a tube of a relatively flexible
material may be placed around the perimeter wall of the rigid base
element. In other embodiments, the flexible wall element may be
applied to the rigid base element by wrapping a sheet of a
relatively flexible material around the perimeter wall of the rigid
base element. The flexible wall element may be affixed to the
perimeter wall by applying heat and/or pressure to the flexible
wall element. The flexible wall element may be affixed to the rigid
base element by various methods of affixing, including heat
sealing, RF bonding, ultrasonic bonding, or adhesive bonding. For
example, the flexible wall element may be bound to the perimeter
wall by applying heat, pressure, ultrasonic energy, RF energy, or a
combination thereof to the flexible wall element.
[0066] An embodiment of a system 200 and method for affixing a
flexible wall element to a rigid base element is illustrated in
FIG. 15. The rigid base 202 may be transported via a conveyor 204
to a tube application position 205. In embodiments of the flexible
sturdy base container that include a recessed panel and standoff,
the conveyor 204 may include gripping elements that insert into the
space between the recessed panel and standoff to maintain positive
control of the rigid base 202 as it is transported on the conveyor
202.
[0067] At the tube application position 205, an open end 208 of a
tube 206 of flexible material is placed over the rigid base 202 and
slid down the perimeter wall of the rigid base 202. The tube 206
may be formed as part of an inline process with the tube
application process. For example, the tube 206 may be formed as
part of a vertical form-fill-and-seal process on a production line.
In other embodiments, the tube may be made prior to and independent
of the application process. The tube 206 may include a series of
reclosable elements 212 and/or easy open features 210, such as
perforations or scores. The tube 206 may then be sealed to the
rigid base 202, such as by applying heat and/or pressure. The top
214 of the flexible wall element may then be formed by cutting the
tube 206 at the desired length.
[0068] Another embodiment of a system 300 and method for affixing a
flexible wall element to a rigid bas element is illustrated in
FIGS. 16A and 16B. The system 300 includes a rotating former 302,
which includes a plurality of forming mandrels 316. At one
position, a rigid base 320 is placed at one end of the mandrel 316,
and the former 302 may then rotate so that the mandrel 316 is moved
to a second position.
[0069] At the second position, a flexible wall element may be
affixed to the rigid base by feeding a sheet of flexible packaging
material 306 to the mandrel 316 while the mandrel 316 rotates about
a longitudinal axis. While the flexible packaging material is
wrapped around the mandrel 316, a heated roller 318 may apply heat
and/or pressure to the flexible packaging material 306 so that the
flexible packaging material bonds to the rigid base 320. In
embodiments of the flexible sturdy base container that include a
reclosable feature, a reclose material 308 may be fed from a
reclose material roll 310 and joined to a flexible packaging
material 306 fed from a flexible packaging roll 304 by a pressure
roll 312 which applies heat and/or pressure to the reclose material
308 and/or flexible packaging material 306 as the two components
pass across a guide roll 314. The reclose material 30 may be
affixed to the flexible packaging material 306 by various methods
of affixing, including heat sealing, RF bonding, ultrasonic
bonding, or adhesive bonding. The flexible packaging material 306
may be cut to a length that will allow the flexible packaging
material 306 to wrap completely around the mandrel 316 with an
overlap.
[0070] The former 302 may then rotate to move the mandrel 316 to a
third position. At the third position, a side sealing roll 324 may
seal the flexible side wall element to itself from the top of the
container to the bottom of the flexible side wall element. The
container may then be discharged from the mandrel at the third
position or at another position. In some embodiments, the container
may discharged onto another conveyor that transports the container
to a filling and/or sealing system.
[0071] An embodiment of a filling and sealing system 400 is
illustrated in FIG. 17. The container 404 may be transported by a
conveyor 408 to a fill position 406 where a fill tube 402 may be
inserted through the open top of the container 404. The fill tube
402 may fill the container 404 with a product 410. The container
402 may then be transported by the conveyor 408 to a seal position
412. During the transport, the product 410 may be allowed to settle
in the container 404. At the seal position, a heat seal 414 may be
formed across the previously-open top of the container 404. The
conveyor 408 may then transport the container 404 to another
location for inspection and/or boxing or palletizing.
[0072] In some embodiments, a flexible sturdy base package forming
system may be easily and quickly changed between forming and
optionally, filling and sealing, containers of two or more
different configurations. For example, the flexible sturdy base
package forming system may first operate to form, fill, and seal a
first container that is customized for a first product and then may
be converted to operate to form, fill, and seal a second container
that is customized for a second product with minimal equipment
modification and downtime.
[0073] It will be appreciated that various of the above-disclosed
and other feature and functions, or alternatives thereof, may be
desirably combined into many other different systems or
applications. Various presently unforeseen or unanticipated
alternatives, modifications, variations, or improvements therein
may be subsequently made by those skilled in the art which are also
intended to be encompassed by the following claims.
* * * * *