U.S. patent application number 14/243816 was filed with the patent office on 2015-10-08 for flexible package with a stable structure.
The applicant listed for this patent is Dave Dytchkowskyj. Invention is credited to Dave Dytchkowskyj.
Application Number | 20150284144 14/243816 |
Document ID | / |
Family ID | 54209090 |
Filed Date | 2015-10-08 |
United States Patent
Application |
20150284144 |
Kind Code |
A1 |
Dytchkowskyj; Dave |
October 8, 2015 |
Flexible Package With A Stable Structure
Abstract
A packaging for containing fluids or other pourable materials is
described. The packaging includes contoured sides that experience
an outward force due to the gravitational forces of the fluid
contained in the package thereby helping the package to remain
upright. The package may include a bottom gusset that rests on the
surface to provide stability. The package may include strengthening
ribs.
Inventors: |
Dytchkowskyj; Dave;
(Hartford, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dytchkowskyj; Dave |
Hartford |
WI |
US |
|
|
Family ID: |
54209090 |
Appl. No.: |
14/243816 |
Filed: |
April 2, 2014 |
Current U.S.
Class: |
383/6 ; 383/119;
383/120 |
Current CPC
Class: |
B65D 75/5877 20130101;
B65D 33/02 20130101; B65D 75/008 20130101; B65D 33/06 20130101 |
International
Class: |
B65D 33/06 20060101
B65D033/06; B65D 33/02 20060101 B65D033/02 |
Claims
1. A package for containing a fluid, comprising: a front panel and
a rear panel joined along at least a portion of their sides by a
seal having an inwardly extending contoured section located at or
about the packages midsection; wherein when the package contains
the fluid, the fluid exerts an outward force against the contoured
section thereby facilitating the package to stand upright.
2. The package of claim 1, wherein one or more strengthening ribs
are included in the seal.
3. The package of claim 2, wherein the one or more strengthening
ribs extend to correspond to the shape of the contoured
section.
4. The package of claim 1, wherein the inwardly extending contoured
section includes a vertex and an upper curved section above the
vertex and a lower curved section below the vertex.
5. The package of claim 1, wherein the inwardly extending contoured
section includes a vertex and a convex upper curved section above
the vertex and a lower convex section below the vertex.
6. The package of claim 1, wherein the inwardly extending contoured
section includes a vertex and a concave upper curved section above
the vertex and a lower concave section below the vertex
7. The package of claim 1, wherein the gravitational force of the
fluid above the contoured section exerts a downward force on the
upper curved section, which results in an outward force against the
contoured section.
8. The package of claim 1, wherein the inwardly extending contoured
section comprises a baffle to restrict the volume of fluid flowing
up or down past the contoured section.
9. The package of claim 1, further comprising a bottom gusset
having a bottom point that is positioned to engage a surface on
which the package rests.
10. The package of claim 9, further comprising a bottom skirt that
substantially surrounds the bottom gusset.
11. The package of claim 10, wherein the bottom skirt is configured
to engage the surface on which the package rests.
12. The package of claim 1, wherein the contoured section is
parabolic.
13. The package of claim 1, wherein the contoured section is
curved.
14. The package of claim 1, further comprising a top skirt attached
to the front panel and rear panel.
15. The package of claim 12, wherein the top skirt includes a
handle.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to packaging that
may contain fluids and other pourable materials, including
packaging made of flexible material in a configuration that allows
the packaging to remain stable and/or in an upright position. The
present invention also relates to such packaging used to contain
larger volumes of fluids or other pourable materials.
BACKGROUND OF THE INVENTION
[0002] Fluids and other pourable materials are frequently contained
in packaging that allows the user to dispense the contents. Such
packaging has been made of rigid and flexible materials, but
flexible packaging has a number of advantages over rigid
packaging.
[0003] For example, flexible packaging may be made from a roll of
material having sections that may be joined together. As such,
flexible packaging may be manufactured using a variety of
cost-efficient materials, and may allow for simpler manufacturing
and lower cost. Flexible packaging may also comprise materials that
allow the packaging to be refilled and reused. Flexible packaging
may also be efficiently stored between uses and require less shelf
space in the retail setting. Rigid packages, on the other hand,
often involve additional expense and manufacturing effort.
Additionally, rigid packages often consume more space when stored
or placed on retail shelves. Rigid packaging also provides fewer
options for customization and brand recognition.
[0004] Despite the benefits of flexible packaging, however, there
are shortcomings. Among them is the inability for the flexible
packaging to retain stability and remain upright or stand in a
vertical position. Many existing flexible packages tend to fold
over due to the weight of the fluid contained therein and/or the
top-heavy nature of the packaging. This typically occurs in the
middle portion of the flexible package where the sides would kink
inward due to the liquid weight. Once filled with liquid, many
flexible packages have a weak area around the middle of the pouch
that promotes bending or collapsing. This inability to remain
upright is a significant drawback.
[0005] For example, it is important for the packaging to look
enticing in the retail environment in order to encourage consumers
to buy the product contained therein. Indeed, the manner in which a
package appears on the shelf serves a significant promotional
purpose. And where a flexible package cannot remain upright on a
shelf and serve that promotional purpose, sales may be hurt and
retailers may discontinue buying the product.
[0006] Other drawbacks include the following. A flexible package
that is prone to folding over or collapsing may lack product
integrity during the shipping and distribution cycle. In
particular, such a package could develop flexing or flex cracks
during transit cycles where the package may experience a high
degree of vibration leading to degradation of the film integrity
and cause leaks. In addition, flexible package that is prone to
folding over or collapsing may be difficult to store or otherwise
handle. Furthermore, the end consumer may have difficulty
dispensing fluid from a folded-over package leading to spillage and
lack of repeat purchases. Still further, because an unstable
flexible package would tend to fold over at the same area, that
area would tend to become an area of flex cracking in the film
during distribution where handling and/or vibration would weaken
the seals or film structures in those areas to cause leaks or pin
holes.
[0007] The foregoing problems may not be a major concern with small
packages that simply do not contain enough fluid to become
top-heavy or otherwise unstable so as to fold over. Indeed, small
packages containing juice for children may be relatively stable
because they are small.
[0008] However, the foregoing problems are exacerbated for flexible
packaging as the size or volume of the package increases. This
generally occurs because as the package increases in size or
volume, the increased volume of fluid weighs more, which may lead
to instability. Furthermore, larger packages may become top heavy
because of the weight of the fluid at or near the top of the
packaging. This in turn causes the instability problems described
above because the package is more susceptible to fold over at or
near its middle portion.
[0009] Instability problems may especially arise when the package
experiences a perturbation or indentation that may occur when the
package is moved or bumped. For example, when the package is in the
transit cycle, or when the package is placed on a retail shelf, the
forces it experiences from this movement may cause it to fold over.
Repeat folding can lead to cracking in the flexible film material.
Alternatively, if a consumer opens a fitment to dispense the fluid,
this perturbation may cause the package to fold over. As another
alternative, if a prospective consumer touches a package on a
retail shelf, this indentation force may cause the package to fold
over.
[0010] The stability problems referenced above are common in
packaging having straight side edges such as in U.S. Design Pat.
No. D582,788 to Smith. With such designs having straight edges, the
top-heavy nature of the design and/or the weight of the liquid may
cause the package to fold over or collapse as discussed above.
[0011] Accordingly, there is a need for a package designed to
counteract or otherwise address the gravitational or other forces
exerted by the liquid in the package. This need is increased for
larger packages. This need has recently become more acute because
recent advancement in spouts, closures and film structures that are
strong enough to support fluids in larger format packages bring
more robust options and cost savings to be able to produce large
format packages. Indeed, large flexible packages that stand upright
on retail shelves have significant shelf presence. But despite
these advances in packaging technology and the potential benefits,
the inability for flexible packages, especially large packages, to
remain stable and upright still exists.
[0012] There are existing packages that have non-linear side edges,
such as those with an hourglass shape. However, the hourglass
shapes used with these packages do not appear to be designed to
address the instability issues discussed above, such as the
gravitational or other forces associated with the fluid contained
in the package. Indeed, most of these packages are small and thus
do not have significant issues regarding instability. Furthermore,
the hourglass shape used in some of these packages appears intended
for consumer recognition, or to allow the user to more easily grip
the package. In sum, the hourglass sides of existing packages do
not appear to be designed to address forces and improve stability
of the package so that it remains upright.
[0013] There are also existing large flexible pouches that contain
fluids that have been sold at retail. However, these larger pouches
are often found in corrugated boxes where the box provides the
stability and the flexible film structure is solely for containment
within the box, and the graphics are on the exterior of the box and
not the flexible pouch itself. This has been a common format in
wine and/or other liquids of larger format packaging.
[0014] Accordingly, despite the existence of small,
hourglass-shaped packages and pouch-in-box packages, the need for
flexible packaging that is stable and that may remain upright
certainly exists. This is especially so to avoid collapse when the
package is moved or experiences perturbations. To this end, there
is a need for a flexible package having an interior containment
area and an exterior surface both made of a flexible film structure
for ease of manufacturing, shipping, handling and storage, and
greater customization.
[0015] Another drawback of existing flexible packaging arises from
the fact that the package has to be sufficiently wide in relation
to its height such that the overall stability of the packaging is
maintained. But current linear or non-linear package designs do not
allow for various package shapes and designs. Accordingly, there is
a need for increasing the number of shape options available in
order to customize packaging and to increase shipping and storage
efficiency. There is also a need for reducing the weight of the
package and reduce manufacturing costs by reducing the overall
amount of material used.
[0016] To address stability issues, some existing packages use
strengthening ribs. However, the ribs in existing packaging are
typically not constructed to withstand the forces of increased
fluid volumes for larger size packaging. Accordingly, there is a
need for strengthening ribs that address the fluid forces to
protect the packaging against fold-over. Moreover, the rib
construction in existing packaging may be complex and require
additional manufacturing steps or materials. Accordingly, there is
a need for strengthening ribs that are easily formed during the
manufacturing process and/or do not involve extra materials.
[0017] The manner in which many existing flexible packages engage
the ground or surface on which they rest also contributes to their
instability problems. The bottoms of many existing flexible
packages include a bottom skirt that has an oval or circular cross
section after the package is filled. Such packages also often
include a bottom gusset that are located within this skirt and that
allows the fluid-containing pouch of the packaging to expand as the
package is filled with fluid.
[0018] However, such bottom gussets tend to be located above the
horizontal surface on which the package rests. So instead of the
bottom gusset engaging the surface, only the bottom skirt typically
engages the surface and thus supports the entire weight of the
package and its contents. Because typical existing bottom skirts
are thin, i.e., they generally have the thickness of the material
used to make the package itself, such bottom skirts do not provide
much stability and are prone to buckling. This problem is
exacerbated for larger packages containing more fluid, which
imparts more weight on the bottom skirt. Accordingly, there is a
need for an improved package where the bottom gusset may engage the
surface to provide stability so that the package may remain in a
vertical position as the weight of the fluid in the packaging
increases.
SUMMARY OF THE INVENTION
[0019] The flexible packaging of the current invention addresses
the foregoing and other issues and drawbacks of existing packages.
In general, the current invention provides a flexible package for
containing fluids or other pourable materials, which retains its
stability, even for larger packages with increased volumes of
fluid.
[0020] An aspect of the current invention regards a flexible
packaging with contoured sides designed to improve stability. The
contoured sides of the present invention may include a narrowed or
hourglass portion at or near the middle of the package, and curved
or convex upper and lower sections. The contoured sides may be
parabolic, with either concave and/or convex sections, or of
another curve or shape. With this configuration, it is preferred
that due to the gravitational force of the fluid contents, an
outward hydrostatic force may be exerted on the narrowed section of
the hourglass shape when the pouch is at rest. This in turn may
result in vertical forces that extend upward on the upper curved
section and downward forces on the lower curved section, which in
turn help the package retain an upright standing position.
[0021] In another aspect of the invention, the contoured sides may
help the package withstand perturbations such as indentations that
may occur in the dispensing process or in the process of moving the
package. As described below, minor perturbations in a container
having this geometry preferably results in less displacement of the
center of mass, and therefore less torque on the container. The
reduced torque allows the container to remain upright during normal
use and storage.
[0022] In another aspect of the invention, the contoured section or
hourglass shape may also serve as a baffle that reduces the forces
of downward-moving liquid if the package is dropped. The baffle
effect may be created by the contour's narrowing of the passage for
the liquid above and below the contour. Therefore, the fluid is
slowed as it travels downward and the amount of fluid traveling
downward is constricted and thus reduced. This helps prevent a
blowout of the seal, which could otherwise occur with a more sudden
increase in force on a particular part of the seal. To this end,
the seal of the package may also have a contoured shape that
conforms to the shape of the flexible package. The parabolic seal
further reduces the chance of a blow out on the bottom or sides of
the container if the container is dropped, given that the force
from the liquid will be diffused during a drop.
[0023] In another aspect of the invention, the width of the seal
that if formed when joining the front and rear panels may be
increased to provide greater beam strength to the sides of the
contoured shape. To this end, the outer side edges of the package
may be contoured to follow the hourglass shape of the interior side
edge (that interfaces with the contained fluid) and the width of
this contoured seal may be varied to provide the desired beam
strength. Alternatively, the outer side edge may be straight while
the interior side is contoured there providing increased seal
width.
[0024] In another aspect of the invention, the bottom portion of
the pouch containing the fluid may contact the surface on which the
package rests, such that the weight of the package is not entirely
borne by the bottom skirt or other bottom feature of the package.
This feature provides further stability for the package to remain
upright.
[0025] Another aspect of the invention regards one or more
strengthening ribs. In a preferred embodiment, the ribs may be
positioned within the seal area. For example, the ribs may be
embedded in the seal during manufacture of the package. The ribs
may be vertical, follow the contour of the side edges or have some
other configuration. The ribs may provide additional structural
support by supplying rigidity while allowing the overall packaging
to remain flexible. As described below, the ribs may be constructed
along with the packaging sides during the manufacturing process
thereby avoiding complex designs or extra materials.
[0026] In another aspect of the invention, the packaging may be
used to contain large volumes of fluids. In this aspect of the
invention, it is preferred that rigid structures, that may be used
to support flexible pouches, e.g., as in the box-of-wine context,
may be avoided. In this aspect of the invention, the larger volumes
also preferably provide a greater surface area for marketing,
promotional, branding or other graphics or information.
[0027] The packaging of the current invention may include fitments
for pouring or dispensing, may be refillable and may accommodate
various fluids and other materials such as soaps, detergents,
conditioners, liquor, water, honey, oil, shampoo, or any other
viscosity that can be pourable or dispensed out of a fitment that
is either face mounted or top mounted either corner or center.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a front view of a package.
[0029] FIG. 2 is a top rear perspective view of a package.
[0030] FIG. 3 is a side view of a package.
[0031] FIG. 4 is a bottom perspective view of a package.
[0032] FIG. 5 is a front or rear cross-section view of a package in
an unfilled state.
[0033] FIGS. 6A and 6B are front or rear views of a package
including dashed lines to show an expanded bottom gusset located at
the level of the flat bottom of the bottom section of a package.
FIG. 6A shows a straight outer edge. FIG. 6B shows a contoured
outer edge.
[0034] FIG. 7 is a plan view of a package showing a front panel and
a rear panel before they have been folded and sealed together.
[0035] FIG. 8 depicts a roll of material for use during the
manufacturing process.
[0036] FIG. 9a depicts the hydrostatic forces existing in a package
when at rest.
[0037] FIG. 9b depicts the hydrostatic forces existing in an
alternative package when at rest.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] In general, the flexible packaging of the current invention
may contain liquids or other pourable material, and is preferably
stable and may stand up or otherwise retain its vertical
orientation when filled, when its contents are dispensed, when the
package is at rest and/or when the package is moved or experiences
a perturbation. The current invention also preferably avoids
expensive or labor intensive manufacturing processes. The current
invention may also provide marketing functions and may provide a
packaging with dimensions that may be customized.
[0039] The current invention is now described with reference to the
figures. Components appearing in more than one figure bear the same
or similar reference numerals.
[0040] Package or packaging 10 is first generally described with
reference to FIGS. 1-4. Packaging 10 may be 12'' tall or taller,
though other heights may be used and the invention is not limited
to this example. Packaging 10 may be approximately 7'' wide or
wider, though other widths may be used and the invention is not
limited to this example. As shown, packaging 10 may include pouch
section 20 that may contain the fluid or other contents of package
10. Pouch section 20 may be approximately 10'' tall or taller,
though other heights may be used and the invention is not limited
to this example. Package 10 may also include top section 30 and
bottom section 40, which may each include a gusset that may expand
as pouch section 20 is filled.
[0041] Top section 30 may include expandable top gusset 32 and top
skirt 34. Top skirt 34 may be approximately 2'' tall, though other
heights are also contemplated and the invention is not limited to
this example. Top skirt 34 may extend upward from pouch section 20
and may generally surround top gusset 32. Top skirt 34 may also
include handles 15 so that package 10 may be easily carried or
moved.
[0042] Similarly, bottom section 40 may include expandable bottom
gusset 42 and bottom skirt 44. Bottom skirt 44 may extend downward
from pouch section 20 and may generally surround bottom gusset 42.
Bottom skirt may be approximately 2'' tall or taller, though other
heights are also contemplated and the invention is not limited to
this example. Bottom skirt 44 may include a bottom surface 47,
which rests upon the surface supporting package 10.
[0043] As shown in FIG. 4, bottom gusset 42 may include a bottom
point 46 that may reside above bottom surface 47 when pouch 20 is
not filled. But as shown in FIGS. 6A and 6B, when pouch 20 is
filled, bottom gusset 42 may expand downward so that its bottom
surface 47 extends down to the same plane as the bottom surface 47.
As discussed later in more detail, this allows both bottom gusset
42 and bottom skirt 44 to rest on the surface to support the weight
of the liquid contents and to provide stability.
[0044] Package 10 may also include fitment 17 that may be used to
pour or otherwise dispense the contents of package 10. Fitment 17
may be attached to package through a hole.
[0045] As indicated several times above, the dimensions of package
10 may vary. To this end, it is preferred that the dimensions
provide for the package to remain stable, especially for larger
volumes of fluid or other contents.
[0046] Package 10 may generally be formed by joining front panel 70
and rear panel 80 around their peripheries or outer edges, as well
as the areas between pouch 20 and top section 30, and between pouch
20 and bottom sections 40. The areas in which front and rear panels
70, 80 are joined may form seal 50 thereby creating pouch section
20.
[0047] As discussed in more detail later, package 10, and more
specifically, pouch section 20, may include contoured section 90
that may provide stability and serve as a baffle against
hydrostatic forces if package 10 is dropped. Contoured section 90
may generally be curved to form a parabolic or hourglass shape.
However, other shapes may be used.
[0048] The different components of package 10 as well as its
manufacturing process are now described with reference to FIGS. 7
and 8. Packaging 10 may preferably be manufactured using an
automated process. At the start of the manufacturing process, the
flexible material that ultimately comprises package 10 may
initially be rolled up in roll 11 as shown in FIG. 8. Each segment
of roll 11 that is fed into the manufacturing machinery may include
front panel 70 and rear panel 80 connected as one sheet.
[0049] The materials used may comprise any flexible material,
including but limited to laminations of the following materials, to
include polyethylene (PE), low density polyethylene (LDPE), linear
low density polyethylene (LLDPE), medium density polyethylene
(MDPE), high density polyethylene (HDPE), polypropylene (PP), cast
polypropylene (CPP), oriented polypropylene (OPP), metalized
polyester (mPET), metalized oriented polypropylene (mOPP),
polyester (PET), nylon or biaxially oriented nylons (BON), paper
poly (extrusion coated PE), foil poly, or film foil laminations.
Additional flexible materials are also contemplated.
[0050] Roll 11 may be unrolled during the manufacturing process as
depicted in FIG. 8. Front and rear panels 70, 80 may undergo
several folding operations to engage each other such that a pair of
front and rear opposing package panels 70, 80 is formed. At this
point, the outer edges of front and rear panels 70, 80 may be
joined together, such as by using a heat bar. Where panels 70, 80
are so joined, seal 50 may be formed. Seal 50 may be approximately
0.375'' in width, or more, though other widths are contemplated and
the invention is not limited to this example. The seal width may be
varied to increase beam strength as desired.
[0051] As shown in FIGS. 7 and 8, front and rear panels may have
the same or similar configuration so that they match up when folded
to engage each other. To this end, front and rear panels 70, 80 may
each include pouch portion 72, 82 that ultimately form pouch 20 as
shown in FIGS. 1-4. Panels 70, 80 may each also include top section
74, 84 and bottom section 76, 86. When panels 70, 80 are joined,
top sections 74, 84 may be folded and joined to form top skirt 34.
Similarly, bottom sections 76, 86 may be joined to form bottom
skirt 44. As shown, part of the bottom section 76 that is
ultimately located in the front of package 10 may initially be part
of back panel 80 prior to manufacture.
[0052] Top gusset 32 and bottom gusset 42 may be formed as part of
front and rear panels 70, 80. As noted above, when pouch 20 is
filled with a liquid or another substance, gussets 32, 42 may
expand and bottom gusset may extend downward to help stabilize
package 10.
[0053] Bottom skirt 44 may have a flat bottom such that the entire
lower surface 47 of bottom skirt 44 may rest upon the surface on
which package 10 is placed. Bottom skirt 44 may optionally include
perforations 45 in front and rear panels 70, 80 to reduce the
overall weight of package 10 and to allow for customization. FIGS.
5, 7 and 8 depict examples of circular and rectangular
perforations. The perforations, if present, may comprise any
combination of shapes or may comprise a single shape.
[0054] Top skirt 34 may include upper perforations 35 in front and
rear panels 70, 80 to reduce the overall weight of the package and
allow for customization. Upper perforations 35 are depicted in
FIGS. 7 and 8 as triangles, though the perforations, if present,
may comprise any combination of shapes, or may comprise a single
shape. Several of the upper perforations may form handles 15. These
may be cut during the manufacturing process in order to facilitate
transportation of package 10. Handles 15 may be rectangular in
shape, though other shapes are contemplated, including circular or
arc-shaped handles.
[0055] During the manufacturing process, panels 70, 80 may be
sealed together around their peripheries and other locations with a
heat bar to create seal 50. However, other methods of joining
panels 70, 80 may be used. Seal 50 may have a contoured shape that
preferably conforms to the shape of front and rear panels 70, 80 of
package 10. The width of seal 50 may be varied to provide the
desired beam strength. When the seal is wider, beam strength is
increased. Increasing beam strength in this manner preferably
allows package 10 to be constructed in a larger format and contain
a larger volume of contents.
[0056] After the seal 50 is formed, a die-cut operation may occur
to stamp out and/or otherwise remove portions of the packaging
material along sections of seal 50. For example, the die-cut
operation may remove material along the outer vertical edges of
package 10 thereby creating the curved or contoured shape as
mentioned above.
[0057] The packages 10 that are formed from the roll 11 may still
be interconnected after seal 50 is formed, through solid film
portions that remain joined in the upper section of the packages.
Individual packages may subsequently be formed by cutting through
the upper sections. A different order of manufacturing steps may
also be used.
[0058] Pouch 20 may be filled as a part of the manufacturing
process. For example, pouch 20 may be filled after front and rear
panels 70, 80 are sealed together. Alternatively, package 10 may be
shipped with an empty pouch 20, and be filled by a retailer or
end-user.
[0059] The aspect of the invention relating to the contoured side
edges and the manner in which this helps package 10 remain upright
and stable are now further described with reference to FIGS. 1, 2,
5, 7, 8, 9A and 9B. As shown in FIGS. 1-2, package 10 may include a
contoured section 90 on its vertical side. Contour 90 may be in the
form of an hourglass shape, a parabola, other curved or non-linear
shape or other configuration. Accordingly, the current invention is
not limited to the contour shape shown in the figures.
[0060] As shown in FIG. 5, contour 90 may include vertex 92 which
may represent the narrowest point of contour 90 and thus package
10. Vertex 92 may be approximately 0.4'' closer to the central axis
of pouch 20, though other vertex locations and/or curvatures are
contemplated and the invention is not limited to this example.
Upper curved section 94 and lower curved section 96 may reside
above and below vertex 92, respectively. In a preferred embodiment,
upper and lower curved sections 94, 96 may be convex sections which
are joined by concave vertex 92 at or around the middle portion of
pouch 20 and/or package 10. The curvature of contour 90 may vary,
and different curvatures may result from the desired die-cut or
other manufacturing operation. Accordingly, vertex 92 may be
located at, above or below the middle portion of pouch 20 and/or
package 10.
[0061] In general, it is preferred that contour 90 be shaped to
distribute, direct or otherwise address the hydrostatic forces of
package 10 when it is at rest to help the package remain in a
standing or otherwise upright position. It is also preferred that
contour 90 be shaped to help address any hydrodynamic forces that
may arise when package 10 is moved, such as when it is shipped, if
it is dropped or experiences some other type of disturbance or
perturbation. This may generally occur in both static and dynamic
conditions by the gravitational or downward forces of the fluid
above the contour resulting in an outward force against the
narrowed section of contour 90 that tends to expand the narrowed
section and straighten the curved shape of contour 90 such that the
vertical edges of package 10 are urged to remain upright.
[0062] The foregoing is further discussed with reference to FIG.
5a. As shown, when pouch 20 is filled, the weight of the contents
exerts a downward hydrostatic force 97. Due to the curvature of
upper curved section 94 and the lower curved section 96, the weight
of the contents also exerts an outer force 98 that is normal to the
walls of the package. Because the outer normal forces 98 on the
upper and lower curved sections 94, 96 may balance each other,
there is a resultant force 99 in the outward direction. Force 99
results from the normal force on the vertex 92. That resultant
force 99 allows the package 10 to retain its structural stability
and its vertical position, even when constructed in a larger size
format, and filled with larger volumes of contents. In general, the
contoured nature of package 10 enables the contents to press
outward on the inside of the seal radius, preferably forcing
package 10 to stand erect.
[0063] The use of this type of contour represents a departure from
prior art packages which include straight vertical edges. This is
because such straight edges do not experience the type of outward
resultant force as does the narrow section of contour 90.
Accordingly, packages having straight vertical edges are more
susceptible to folding over and collapsing which may lead to
cracking of the flexible film. And even in prior art packages that
include an hourglass shape, such packages are typically small and
any hourglass shape they may include is not directed to address
hydrostatic and/or hydrodynamic forces as discussed above.
[0064] Referring to FIGS. 7-8, the contour shapes that may exist in
front and rear panels 70, 80 are now further described. As noted
above, panels 70, 80 may have similar configurations. To this end,
front panel 70 may include contours 78 that may have inner and
outer edges 77, 79. Similarly, back panel 80 may include contours
88 that may have inner and outer edges 87, 89. When front and back
panels 70, 80 are joined and seal 50 is formed, these contours 78,
88 may also be joined so that front and back pouch sections 72, 82
form pouch 20 of package 10. To this end, inner edges 77, 87 may be
joined to form inner edge 27 of pouch 20. Similarly, outer edges
79, 89 may be joined to form outer edge 29 of pouch 20. Front and
rear panels 70, 80 may be die-cut to provide contoured sections 78,
88.
[0065] Another configuration for contour 90 is shown in FIG. 9B.
Here, upper curved section 94 and lower curved section 96 may each
comprise a convex curve. Where a curved surface is above or outside
of a liquid, as in FIG. 9B, the weight of the liquid or other
viscous material and the vertical component of the hydrostatic
force may act in opposite directions. To this end, the contents of
pouch 20 may exert a force normal to each segment of the pouch
inner wall 27. In the convex sections 94, 96, that force may be
directed radially outward. In the area of the narrowed vertex 92,
the hydrostatic force is in an outward direction because the
pressure forces are normal to the surface. Therefore, there is a
resultant outward force in the narrowed section of the package. The
result of that outward force is that the package retains its
structural stability rather than bending inward, which would result
in a collapse.
[0066] Alternative variations on the above-described geometry are
also contemplated. For example, lower curved section 96 need not
have a larger radius than upper curved section 94 in order to
remain stable. This in turn allows the base of package 10 to be
relatively narrow which may reduce manufacturing costs, increases
storage efficiency and increase consumer appeal on the retail
shelf.
[0067] The manner in which contour 90 may provide stability for
packaging 10 when it experiences movements or perturbations is now
further discussed. Under various scenarios, the flexible material
comprising package 10 will experience slight disturbances or
perturbations. For example, the material may be slightly indented
as the package is moved or as contents are poured or otherwise
dispensed from the package. Alternatively, a consumer may touch the
package when it is on the retail shelf. In prior art packaging,
that indentation, regardless of how small, may cause the package to
fold over. This is because an indentation, however small, may
result in a bulge above the indented area. The fluid inside the
package will then be displaced into that bulge, which will change
the center of gravity of the package. Without anything to
counteract that shift in the center of gravity, a torque is created
and acts on the container with the result that the package will
fold over toward the side in which the indentation occurred.
[0068] In sharp contrast, however, contour 90 of the current
invention helps package 10 withstand perturbations and retain its
vertical position. First, the volume of the fluid in either the
upper or lower portions of the container, e.g., above or below
vertex 92, is less than the overall volume of fluid. Accordingly,
with any perturbation, there will be less fluid displaced, and the
displacement in the center of mass will be minor. Second, in the
case where contour 90 is shaped as an hourglass, the overall
hourglass shape may be relatively large, compared to the curved
portions of the hourglass. As a result, there is a restoring moment
arm provided by the geometry, and the change in center of gravity
due to perturbations is preferably minimized. The resulting torque
is therefore minimized as well, and the package will remain in an
upright position.
[0069] In sum, contour 90 of the current invention preferably helps
package 10 remain upright when experiencing hydrostatic forces when
at rest, as well as hydrodynamic forces that may arise during
perturbations or other movement.
[0070] Beyond the foregoing, contour 90 may also serve as a baffle
to lessen the impact of hydrodynamic forces if package 10 is
dropped. This aspect of the current invention relating to the
baffle effects of contour 90 that guard against a seal blow-out is
now further described with reference to FIGS. 9A-9B.
[0071] If a prior art package having straight edges is dropped, it
will typically either land on an edge or on a flat side. In either
scenario, there is nothing to ameliorate the force exerted against
the seal, and the package may rupture. For example, if a prior art,
linear package falls and lands on an edge, there will be a downward
component to the force, as well as components of the force that
push down and out on each edge. In that scenario, the only force to
counteract the fall, is the upwardly directed force at the point of
contact. Accordingly, the outwardly directed forces are likely to
exceed that single upward force, and the seal will rupture.
[0072] With the current invention, however, if package 10 is
dropped and the fluid inside pouch 20 moves as a result, the fluid
will be slowed as it passes through vertex 92. Furthermore, the
constriction provided by vertex 92 preferably allows less fluid to
move between the upper and lower sections of pouch 20. Accordingly,
the amount of force exerted on seal 50 will be lessened. This will
be the case regardless of whether package 10 lands on its bottom
skirt 44 or on its curved side.
[0073] Moreover, where package 10 lands on either of its curved
sides, the surface area of package 10 hitting the ground will be
maximized due to the curvature thereby maximizing the length of
seal 50 that interacts with the surface on which package 10 is
dropped. By contrast, the prior art packaging can land on a corner,
with a minimum surface area. As a result of the relatively larger
and curved surface area, the downward and outward forces exerted on
the packaged by the liquid will be counteracted by the upward and
inward normal forces exerted on the package by the surface. The
force is therefore less likely to exert enough pressure on a single
portion of the seal such that it will rupture.
[0074] The aspect of the current invention regarding strengthening
ribs is now further discussed with reference to FIG. 5. As shown,
seal section 50 may include strengthening ribs 53, which preferably
impart additional vertical stiffness. Ribs 53 may be formed during
the manufacturing process, such as during an embossing process
without heat for minimum depth ribs. As another example, a heated
bar with male and female patterns may be used to create an
impression zone imparting the rib features. In this example, the
heat bar used to create seal 50 may be further embossed with
grooves or other pattern(s) that allow material in the contoured
sections 78, 88 of front and/or back panels 70, 80 to flow therein
during the sealing process. Ribs 53 may either be smooth or may be
formed of additional patterns such as a crosshatch pattern or small
linear detents. Ribs 53 may be between a width of 2 mm to 6 mm, at
a depth of 1 mm to 3 mm, based on the material composition and the
width of the overall pouch seal. However, other dimensions and
locations are also contemplated and the invention is not limited to
this example.
[0075] In this manner, strengthening rib 53 may be formed at the
same time as seal 50. This represents an advance over prior art in
that the strengthening ribs in existing packages may be separate
components that require additional materials and/or additional
manufacturing steps to install on the package. The increased cost
and design complexity associated with these existing packages is
thus avoided by the current invention.
[0076] As shown in FIG. 5, seal 50 may include two ribs on either
side of pouch 20. However, other numbers of ribs may be used. To
this end, the heat bar used to create seal 50 may be embossed such
that a single rib is created, or multiple ribs are created. The
configuration of the ribs may also vary. For example, ribs 53 shown
in FIG. 5 follow the curve of contour 90 and the two ribs shown on
each side run alongside each other. However, ribs 53 may be
straight, spaced in a staggered fashion, have different lengths or
may otherwise vary.
[0077] Strengthening ribs 53 preferably increase the beam strength
of package 10 by providing structural rigidity. Ribs 53 therefore
contribute to the overall ability of package 10 to remain in a
vertical position, even when the package is manufactured in a large
format, and filled with larger volumes of fluids or other
materials. And the ability to increase beam strength by readily
creating strengthening ribs 53 during the manufacturing process is
an advantage of the current invention.
[0078] The manner in which beam strength may be increased by the
current invention is now further described with reference to FIGS.
6A-6B. As shown in FIG. 6B, inner edge 27 of pouch 20 may generally
follow outer edge 29 of package 10 in contoured section 90. This
may provide a seal 50 having a desired width and associated beam
strength. The seal width 50 may be altered depending on the volume
of package 10 and other factors.
[0079] Alternatively, as shown in FIG. 6A, outer edge 29 may remain
straight while inner edge 27 may be contoured as discussed above.
In this configuration, the width of seal 50 is increased, thereby
providing additional beam strength. Again, the width of seal 50 may
be adjusted to suit the dimensions and other characteristics of
package 10.
[0080] The aspect of the current invention relating to the
additional stability provided by bottom gusset 42 engaging the
surface on which packaging 10 rests is now further described with
reference to various figures. As shown in, e.g., FIG. 4, when pouch
20 and package 10 are filled with a liquid or other pourable
material, bottom gusset 42 may expand and drop down so that its
lowest point 46 may generally be on the same plane as the bottom 47
of bottom skirt 44. In this manner, both bottom skirt 44 and bottom
gusset 42 may engage the surface on which package 10 rests. As a
result, the weight of package 10 and its contents are distributed
between the bottom skirt 44 and bottom gusset 42.
[0081] This represents a significant departure from existing
packaging art and enables package 10 of the current invention to be
manufactured in larger formats and accommodate large volumes of
fluids and other pourable materials. In existing packaging where
the bottom gusset does not drop down to become flush with
horizontal resting surface, only the bottom skirt supports the
weight of the package and its contents. That configuration tends to
result in buckling of the skirt, because the thickness of the skirt
is oftentimes only as thick as the rest of the material used to
form the pouch aspect of the packaging. Even where existing bottom
skirts have increased thickness due to folding operations, its
thickness and associated strength is relatively low. As such,
existing bottom skirts are prone to buckling, particularly as the
size of the package increases and/or the volume of the contents
increases.
[0082] In such prior art packaging, the weight of the product
applies a downward force on the bottom gusset. That force exerts
strain on the side seal. In particular, the side seal will
experience an inward normal force as a result of the outwardly
directed force from the weight of the product. That force tends to
result in collapse of the vertical seal where the bottom gusset
meets the side seal.
[0083] For example, in typical prior art packaging, the bottom
point of the bottom gusset is either designed to be rounded or
parabolic at the bottom, or it becomes slightly rounded or
parabolic at the bottom due to the weight of the contents pushing
against the flexible bottom panel. As a result of that curvature,
the force of the contents will have both a downward and an outward
component. The downward component of the force can be counteracted
by the upwardly directed normal force exerted on the bottom skirt
by the horizontal surface. However, there is no force to oppose the
outward components of the force from the weight of the liquid. This
outward component of force generally extends in the direction of
the thin bottom skirt's weakest aspect. As a result, the bottom
skirt will eventually buckle.
[0084] In the current invention, however, bottom gusset 42 expands
downward to rest flush against the surface along with bottom skirt
44. In this manner, any outward components of force of the fluid
are counteracted by the inward normal force from the skirt, and the
geometry remains stable, even as the package size and fluid weight
increases. It should be noted that bottom gusset shown in FIG. 5 is
shown at a time before the pouch 20 is filled with fluid and before
any downward force causes bottom gusset 42 to expand downward.
However, FIGS. 6A, 6B, 9A and 9B show how the bottommost point 46
of bottom gusset 42 may expand downward so that it is flush with
the bottom 47 of bottom skirt 44.
[0085] Another benefit of the engagement between bottom gusset 42
and the surface is as follows. Existing bottom gussets sometimes
include bottom baffles to increase the structural integrity of the
package. However, package 10 of the current present invention
eliminates the need for bottom baffles, and allows for less
expensive material cost and more efficient manufacturing.
[0086] The aspect of the invention relating to flexible packaging
containing larger volumes of fluids or other materials is now
further discussed. Generally, the foregoing aspects of the
invention such as the hourglass shape, the bottom gusset contacting
a surface, strengthening ribs and other aspects discussed above
allow the packaging of the current invention to hold larger volumes
while still remaining upright and/or otherwise stable. In a
preferred embodiment, the packaging of the current invention may
remain stable while containing volumes such as one quart to three
gallons or more. However, the stable containment of smaller volumes
such as volumes above twelve or sixteen ounces, are also
contemplated by the current invention. In any event, the current
invention is not limited to these particular volumes.
[0087] The ability to provide stability with larger volumes is an
advance for several reasons such as avoiding the need for boxes or
other rigid components. For example, existing box-of-wine and other
boxed packages typically include a flexible pouch contained in and
supported by a box or other rigid container. These packages often
hold volumes from one quart to two gallons and the flexible
interior pouch would not stand up on its own. With the current
invention, however, boxes and other rigid containers are preferably
avoided which may reduce cost, save space, save weight and ease
manufacture.
[0088] The ability of package 10 to remain upright or otherwise
stable has benefits beyond those described above. For example,
package 10 will exhibit structural integrity that allows for good
shelf presence in the retail setting. To this end, package 10 may
appear attractive and enticing to consumers. The ability to keep
the package upright also provides ample space for marketing
opportunity given that the front and rear-facing sides of the
panels are relatively flat and thus visible to consumers. For
example, as shown in FIG. 8, the pouch areas 72, 82 of front and
rear panels 70, 80 may also serve as areas on which to print text,
graphics or other items on the front and rear of package 10. To
this end, various types of print copy or graphics relating to
branding or marketing can be placed during the manufacturing
process.
[0089] Although certain presently preferred embodiments of the
invention have been described herein, it will be apparent to those
skilled in the art to which the invention pertains that variations
and modifications of the described embodiments may be made without
departing from the spirit and scope of the invention.
* * * * *