U.S. patent application number 16/313303 was filed with the patent office on 2019-05-23 for flexible container.
This patent application is currently assigned to Dow Global Technologies LLC. The applicant listed for this patent is Dow Global Technologies LLC. Invention is credited to Lamy J. Chopin, III, Muhammad Ali Siddiqui, Rashi Tiwari.
Application Number | 20190152669 16/313303 |
Document ID | / |
Family ID | 59325651 |
Filed Date | 2019-05-23 |
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United States Patent
Application |
20190152669 |
Kind Code |
A1 |
Tiwari; Rashi ; et
al. |
May 23, 2019 |
Flexible Container
Abstract
The present disclosure provides a flexible container. In an
embodiment, the flexible container includes (A) a front panel, a
rear panel, a first gusseted side panel, and a second gusseted side
panel. The gusseted side panels adjoin the front panel and the rear
panel along peripheral seals to form a chamber. The flexible
container includes (B) each peripheral seal having (i) a body seal
inner edge (BSIE) with opposing ends, (ii) a tapered seal inner
edge (TSIE) extending from each end of the body seal, and (iii) an
inner arc where each tapered seal inner edge extends from a
respective BSIE end. The flexible container includes (C) at least
one inner arc having a radius of curvature, Rc, from greater than
3.18 mm to 7.95 mm.
Inventors: |
Tiwari; Rashi; (Missouri
City, TX) ; Chopin, III; Lamy J.; (Missouri City,
TX) ; Siddiqui; Muhammad Ali; (Waedenswil,
CH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dow Global Technologies LLC |
Midland |
MI |
US |
|
|
Assignee: |
Dow Global Technologies LLC
Midland
MI
|
Family ID: |
59325651 |
Appl. No.: |
16/313303 |
Filed: |
June 15, 2017 |
PCT Filed: |
June 15, 2017 |
PCT NO: |
PCT/US2017/037712 |
371 Date: |
December 26, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62356776 |
Jun 30, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 75/008 20130101;
B65D 75/5883 20130101; B65D 75/563 20130101 |
International
Class: |
B65D 75/58 20060101
B65D075/58; B65D 75/56 20060101 B65D075/56 |
Claims
1. A flexible container comprising: A. a front panel, a rear panel,
a first gusseted side panel, and a second gusseted side panel, the
gusseted side panels adjoining the front panel and the rear panel
along peripheral seals to form a chamber; B. each peripheral seal
having (i) a body seal inner edge (BSIE) with opposing ends, (ii) a
tapered seal inner edge (TSIE) extending from each end of the body
seal; (iii) an inner arc where each tapered seal inner edge extends
from a respective BSIE end; and C. the container comprises at least
one inner arc having a radius of curvature, Rc, from greater than
3.18 mm to 7.95 mm.
2. The flexible container of claim 1 comprising four bottom inner
arcs (b-IAs), each b-IA having a Rc from greater than 3.18 mm to
7.95 mm.
3. The flexible container of claim 2 wherein the flexible container
exhibits a greater than 20 hours time to failure when subjected to
a modified ISTA 1E vibration test.
4. The flexible container of claim 1 comprising four top inner arcs
(t-IAs), each t-IA having a radius of clearance from greater than
3.18 mm to 7.95 mm.
5. The flexible container of claim 4 comprising at least one bottom
inner arc and at least one top inner arc, each inner arc having a
radius of curvature from greater than 3.18 mm to 7.95 mm.
6. The flexible container of claim 1 comprising four bottom inner
arcs and four top inner arcs, each inner arc having a radius of
curvature from greater than 3.18 mm to 7.95 mm.
7. The flexible container of claim 1 comprising a bottom apex and
an overseal in the apex.
8. The flexible container of claim 1 comprising a handle.
9. The flexible container of claim 1 wherein a portion of a top end
section of each panel is sealed to a spout.
10. The flexible container of claim 9 wherein each panel is sealed
to a base of the spout, the base having a circular cross-sectional
shape.
Description
BACKGROUND
[0001] The present disclosure is directed to a flexible container
for dispensing a flowable material.
[0002] Known are flexible containers with a gusseted body section.
These gusseted flexible containers are currently produced using
flexible films which are folded to form gussets and heat sealed in
a perimeter shape. The gusseted body section opens to form a
flexible container with a square cross section or a rectangular
cross section. The gussets are terminated at the bottom of the
container to form a substantially flat base, providing stability
when the container is partially or wholly filled.
[0003] When a filled gusseted flexible container is handled,
transported, or dropped, burst or leakage may occur, resulting in
lost product, waste, spill damage, and clean-up cost. Desired is a
gusseted flexible container with improved drop strength, improved
compression strength, and/or improved vibration strength.
SUMMARY
[0004] The present disclosure provides a flexible container. In an
embodiment, the flexible container includes (A) a front panel, a
rear panel, a first gusseted side panel, and a second gusseted side
panel. The gusseted side panels adjoin the front panel and the rear
panel along peripheral seals to form a chamber. The flexible
container includes (B) each peripheral seal having (i) a body seal
inner edge (BSIE) with opposing ends, (ii) a tapered seal inner
edge (TSIE) extending from each end of the body seal, and (iii) an
inner arc where each tapered seal inner edge extends from a
respective BSIE end. The flexible container includes (C) at least
one inner arc having a radius of curvature, Rc from greater than
3.18 mm to 7.95 mm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of a filled flexible container
having top and bottom flexible handles in a rest position.
[0006] FIG. 2 is a bottom plan view of the flexible container of
FIG. 1
[0007] FIG. 3 is a perspective view of the flexible container of
FIG. 1 shown with its top and bottom handles extended.
[0008] FIG. 4 is a top plan view of the flexible container of FIG.
1.
[0009] FIG. 5 is a side plan view of the flexible container of FIG.
11 in an inverted position for transferring the contents.
[0010] FIG. 6 is a cross-sectional view taken along the line 6-6 of
FIG. 1.
[0011] FIG. 7 is a perspective view of the container of FIG. 1 in a
collapsed configuration.
[0012] FIG. 8 is an enlarged view of the bottom seal area of FIG.
7.
[0013] FIG. 9 is a top plan view of a flexible container in the
collapsed configuration in accordance with an embodiment of the
present disclosure.
[0014] FIG. 9A is an enlarged view of Area 9A of FIG. 9.
[0015] FIG. 10 is a perspective view of the flexible container of
FIG. 9, partially expanded to show the inner arcs.
[0016] FIG. 11 is a perspective view of the flexible container of
FIG. 9, partially expanded to show the inner arcs.
[0017] FIG. 12 is a perspective view of a die plate used to produce
the flexible container of FIG. 9.
DETAILED DESCRIPTION
[0018] The present disclosure provides a flexible container. The
flexible container includes:
[0019] A. A front panel, a rear panel, a first gusseted side panel,
and a second gusseted side panel, the gusseted side panels
adjoining the front panel and the rear panel along peripheral seals
to form a chamber.
[0020] B. Each panel includes a bottom segment comprising two
opposing peripheral tapered seals, each peripheral tapered seal
extending from a respective peripheral seal, each peripheral
tapered seal comprising an inner edge, the peripheral tapered seals
converging at a bottom seal area.
[0021] C. The front panel bottom segment includes a first line
defined by the inner edge of the first peripheral tapered seal and
a second line defined by the inner edge of the second peripheral
tapered seal, the first line intersecting the second line at an
apex point in the bottom seal area.
[0022] D. The front panel bottom segment has a bottom distalmost
inner seal point on the inner edge.
[0023] E. The apex point is separated from the bottom distalmost
inner seal point by a distance from 0 mm to less than 8.0 mm.
[0024] FIGS. 1-2 show a flexible container 10 having a flexible top
12 and a bottom 14. The flexible container 10 has four panels, a
front panel 22, a back panel 24, a first gusset panel 18 and a
second gusset panel 20. The four panels 18, 20, 22, and 24 extend
toward a top end 44 and a bottom end 46 of the container 10 to form
the top segment 28 and bottom segment 26, respectively. When the
container 10 is inverted, the top and bottom positions in relation
to the container 10 change. However, for consistency the handle
adjacent the spout 30 will be called the top or upper handle 12 and
the opposite handle will be called the bottom or lower handle 14.
Likewise, the top or upper portion, segment or panel will be the
surface adjacent the spout 30, and the bottom or lower portion,
segment, or panel will be the surface opposite the top segment.
[0025] The four panels 18, 20, 22 and 24 can each be composed of a
separate web of film. The composition and structure for each web of
film can be the same or different. Alternatively, one web of film
may also be used to make all four panels and the top and bottom
segments. In a further embodiment, two or more webs can be used to
make each panel.
[0026] In an embodiment, four webs of film are provided, one web of
film for each respective panel 18, 20, 22, and 24. The edges of
each film are sealed to the adjacent web of film to form peripheral
seals 41 (FIG. 1). The peripheral tapered seals 40a-40d are located
on the bottom segment 26 of the container as shown in FIG. 2. The
peripheral seals 41 are located on the side edges of the container
10.
[0027] To form the top segment 28 and the bottom segment 26, the
four webs of film converge together at the respective end and are
sealed together. For instance, the top segment 28 can be defined by
extensions of the panels sealed together at the top end 44 and when
the container 10 is in a rest position it can have four top panels
28a-28d (FIG. 4) of film that define the top segment 28. The bottom
segment 26 can also have four bottom panels 26a-26d of film sealed
together and can also be defined by extensions of the panels at the
opposite end 46 as shown in FIG. 2.
[0028] In an embodiment, a portion of the four webs of film that
make up the top segment 28 terminate at a spout 30. A portion of a
top end section of each of the four webs of film is sealed, or
otherwise welded, to an outer, lower rim 52 of the spout 30 to form
a tight seal. The spout is sealed to the flexible container by way
of compression heat seal, ultrasonic seal, and combinations thereof
Although the base of spout 30 has a circular cross-sectional shape,
it is understood that the base of spout 30 can have other
cross-sectional shapes such as a polygonal cross-sectional shape,
for example. The base with circular cross-sectional shape is
distinct from fitments with canoe-shaped bases used for
conventional two-panel flexible pouches.
[0029] In an embodiment, the outer surface of the base of spout 30
has surface texture. The surface texture can include embossment and
a plurality of radial ridges to promote sealing to the inner
surface of the top segment 28.
[0030] In an embodiment, the spout 30 excludes fitments with oval,
wing-shaped, eye-shaped, or canoe-shaped bases.
[0031] Furthermore, the spout 30 can contain a removable closure
32. The spout 30 has an access opening 50 through the top segment
28 to the interior as shown in FIGS. 5-6. Alternatively, the spout
30 can be positioned on one of the panels, where the top segment
would then be defined as an upper seal area defined by the joining
together of at least two panel ends. In a further embodiment, the
spout 30 is positioned at generally a midpoint of the top segment
28 and can be sized smaller than a width of the container 10, such
that the access opening 50 of the spout 30 can have an area that is
less than a total area of the top segment 28. In yet a further
embodiment, the spout area is not more than 20% of the total top
segment area. This can ensure that the spout 30 and its associated
access opening 50 will not be large enough to insert a hand
therethrough, thus avoiding any unintentional contact with the
product 58 stored therein.
[0032] The spout 30 can be made of a rigid construction and can be
formed of any appropriate plastic, such as high density
polyethylene (HDPE), low density polyethylene (LDPE), polypropylene
(PP), and combinations thereof. The location of the spout 30 can be
anywhere on the top segment 28 of the container 10. In an
embodiment the spout 30 is located at the center or midpoint of the
top segment 28. The closure 32 covers the access opening 50 and
prevents the product from spilling out of the container 10. The cap
32 may be a screw-on cap, a flip-top cap or other types of
removable (and optionally reclosable) closures.
[0033] In an embodiment, the container does not have a rigid spout
and the panels are across the neck, by way of a releasable seal
(tear seal), for example.
[0034] As shown in FIGS. 1-2, the flexible bottom handle 14 can be
positioned at a bottom end 46 of the container 10 such that the
bottom handle 14 is an extension of the bottom segment 26.
[0035] Each panel includes a respective bottom face. FIG. 2 shows
four triangle-shaped bottom faces 26a, 26b, 26c, 26d, each bottom
face being an extension of a respective film panel. The bottom
faces 26a-26d make up the bottom segment 26. The four panels
26a-26d come together at a midpoint of the bottom segment 26. The
bottom faces 26a-26d are sealed together, such as by using a
heat-sealing technology, to form the bottom handle 14. For
instance, a weld can be made to form the bottom handle 14, and to
seal the edges of the bottom segment 26 together. Nonlimiting
examples of suitable heat-sealing technologies include hot bar
sealing, hot die sealing, impulse sealing, high frequency sealing,
or ultrasonic sealing methods.
[0036] FIG. 2 shows bottom segment 26. Each panel 18, 20, 22, 24
has a respective bottom face 26a-26d that is present in the bottom
segment 26. Each bottom face is bordered by two opposing peripheral
tapered seals 40a, 40b, 40c, 40d. Each peripheral tapered seal
40a-40d extends from a respective peripheral seal 41. The
peripheral tapered seals for the front panel 22 and the rear panel
24 have an inner edge 29a-29d (FIG. 2) and an outer edge 31 (FIG.
8). The peripheral tapered seals 40a-40d converge at a bottom seal
area 33 (FIG. 2, FIG. 7, FIG. 8).
[0037] The front panel bottom face 26a includes a first line A
defined by the inner edge 29a of the first peripheral tapered seal
40a and a second line B defined by the inner edge 29b of the second
peripheral tapered seal 40b. The first line A intersects the second
line B at an apex point 35a in the bottom seal area 33. The front
panel bottom face 26a has a bottom distalmost inner seal point 37a
("BDISP 37a"). The BDISP 37a is located on an inner seal edge
defined by inner edge 29a and inner edge 29b.
[0038] The apex point 35a is separated from the BDISP 37a by a
distance S from 0 millimeter (mm) to less than 8.0 mm.
[0039] In an embodiment, the rear panel bottom face 26c includes an
apex point similar to the apex point on the front panel bottom
face. The rear panel bottom face 26c includes a first line C
defined by the inner edge of the 29c first peripheral tapered seal
40c and a second line D defined by the inner edge 29d of the second
peripheral tapered seal 40d. The first line C intersects the second
line D at an apex point 35c in the bottom seal area 33. The rear
panel bottom face 26c has a bottom distalmost inner seal point 37c
("BDISP 37c"). The BDISP 37c is located on an inner seal edge
defined by inner edge 29c and inner edge 29d. The apex point 35c is
separated from the BDISP 37c by a distance T from 0 millimeter (mm)
to less than 8.0 mm.
[0040] It is understood the following description to the front
panel bottom face applies equally to the rear panel bottom face,
with reference numerals to the rear panel bottom face shown in
adjacent closed parentheses.
[0041] In an embodiment, the BDISP 37a (37c) is located where the
inner edges 29a (29c) and 29b (29d) intersect. The distance between
the BDISP 37a (37c) and the apex point 35a (35c) is 0 mm.
[0042] In an embodiment, the inner seal edge diverges from the
inner edges 29a, 29b (29c, 29d), to form a distal inner seal arc
39a (front panel) a distal inner seal arc 39c (rear panel) as shown
in FIGS. 2 and 8. The BDISP 37a (37c) is located on the inner seal
arc 39a (39c). The apex point 35a (apex point 35c) is separated
from the BDISP 37a (BDISP 37c) by the distance S (distance T) which
is from greater than 0 mm, or 1.0 mm, or 2.0 mm, or 2.6 mm, or 3.0
mm, or 3.5 mm, or 3.9 mm, to 4.0 mm, or 4.5 mm, or 5.0 mm, or 5.2
mm, or 5.3 mm, or 5.5 mm, or 6.0 mm, or 6.5 mm, or 7.0 mm, or 7.5
mm, or 7.9 mm.
[0043] In an embodiment, apex point 35a (35c) is separated from the
BDISP 37a (37c) by the distance S (distance T) which is from
greater than 0 mm to less than 6.0 mm.
[0044] In an embodiment, the distance from S (distance T) from the
apex point 35a (35c) to the BDISP 37a (37c) is from greater than 0
mm, or 0.5 mm, or 1.0 mm, or 2.0 mm to 4.0 mm, or 5.0 mm, or less
than 5.5 mm.
[0045] In an embodiment, apex point 35a (apex point 35c) is
separated from the BDISP 37a (BDISP 37c) by the distance S
(distance T) which is from 3.0 mm, or 3.5 mm, or 3.9 mm to 4.0 mm,
or 4.5 mm, or 5.0 mm, or 5.2 mm, or 5.3 mm, or 5.5 mm.
[0046] In an embodiment, the distal inner seal arc 39a (39c) has a
radius of curvature from 0 mm, or greater than 0 mm, or 1.0 mm to
19.0 mm, or 20.0 mm.
[0047] In an embodiment, each peripheral tapered seal 40a-40d
(outside edge) and an extended line from respective peripheral seal
41 (outside edge) form an angle G as shown in FIG. 7. The angle G
is from 40.degree., or 42.degree., or 44.degree., or 45.degree. to
46.degree., or 48, or 50.degree.. In an embodiment, angle G is
45.degree..
[0048] The bottom segment 26 includes a pair of gussets 54 and 56
formed thereat, which are essentially extensions of the bottom
faces 26a-26d. The gussets 54 and 56 can facilitate the ability of
the flexible container 10 to stand upright. These gussets 54 and 56
are formed from excess material from each bottom face 26a-26d that
are joined together to form the gussets 54 and 56. The triangular
portions of the gussets 54 and 56 comprise two adjacent bottom
segment panels sealed together and extending into its respective
gusset. For example, adjacent bottom faces 26a and 26d extend
beyond the plane of their bottom surface along an intersecting edge
and are sealed together to form one side of a first gusset 54.
Similarly, adjacent bottom faces 26c and 26d extend beyond the
plane of their bottom surface along an intersecting edge and are
sealed together to form the other side of the first gusset 54.
Likewise, a second gusset 56 is similarly formed from adjacent
bottom faces 26a-26b and 26b-26c. The gussets 54 and 56 can contact
a portion of the bottom segment 26, where the gussets 54 and 56 can
contact bottom faces 26b and 26d covering them, while bottom
segment panels 26a and 26c remain exposed at the bottom end 46.
[0049] As shown in FIGS. 1-2, the gussets 54 and 56 of the flexible
container 10 can further extend into the bottom handle 14. In the
aspect where the gussets 54 and 56 are positioned adjacent bottom
segment panels 26b and 26d, the bottom handle 14 can also extend
across bottom faces 26b and 26d, extending between the pair of
panels 18 and 20. The bottom handle 14 can be positioned along a
center portion or midpoint of the bottom segment 26 between the
front panel 22 and the rear panel 24.
[0050] The bottom handle 14 can comprise up to four layers of film
sealed together when four webs of film are used to make the
container 10. When more than four webs are used to make the
container, the handle will include the same number of webs used to
produce the container. Any portion of the bottom handle 14 where
all four layers are not completely sealed together by the
heat-sealing method, can be adhered together in any appropriate
manner, such as by a tack seal to form a fully-sealed multi-layer
bottom handle 14. The bottom handle 14 can have any suitable shape
and generally will take the shape of the film end. For example,
typically the web of film has a rectangular shape when unwound,
such that its ends have a straight edge. Therefore, the bottom
handle 14 would also have a rectangular shape.
[0051] Additionally, the bottom handle 14 can contain a handle
opening 16 or cutout section therein sized to fit a user's hand, as
can be seen in FIG. 3. The opening 16 can be any shape that is
convenient to fit the hand and, in one aspect, the opening 16 can
have a generally oval shape. In another aspect, the opening 16 can
have a generally rectangular shape. Additionally, the opening 16 of
the bottom handle 14 can also have a flap 38 that comprises the cut
material that forms the opening 16. To define the opening 16, the
handle 14 can have a section that is cut out of the multilayer
handle 14 along three sides or portions while remaining attached at
a fourth side or lower portion. This provides a flap of material 38
that can be pushed through the opening 16 by the user and folded
over an edge of the opening 16 to provide a relatively smooth
gripping surface at an edge that contacts the user's hand. If the
flap of material were completely cut out, this would leave an
exposed fourth side or lower edge that could be relatively sharp
and could possibly cut or scratch the hand when placed there.
[0052] Furthermore, a portion of the bottom handle 14 attached to
the bottom segment 26 can contain a dead machine fold 42 or a score
line that provides for the handle 14 to consistently fold in the
same direction, as illustrated in FIGS. 1 and 3. The machine fold
42 can comprise a fold line that permits folding in a first
direction toward the front side panel 22 and restricts folding in a
second direction toward the rear panel 24. The term "restricts" as
used throughout this application can mean that it is easier to move
in one direction, or the first direction, than in an opposite
direction, such as the second direction. The machine fold 42 can
cause the handle 14 to consistently fold in the first direction
because it can be thought of as providing a generally permanent
fold line in the handle that is predisposed to fold in the first
direction X, rather than in the second direction Y. This machine
fold 42 of the bottom handle 14 can serve multiple purposes, one
being that when a user is transferring the product from the
container 10 they can grasp the bottom handle 14 and it will easily
bend in the first direction X to assist in pouring. Secondly, when
the flexible container 10 is stored in an upright position, the
machine fold 42 in the bottom handle 14 encourages the handle 14 to
fold in the first direction X along the machine fold 42, such that
the bottom handle 14 can fold underneath the container 10 adjacent
one of the bottom segment panels 26a, as shown in FIG. 6. The
weight of the product can also apply a force to the bottom handle
14, such that the weight of the product can further press on the
handle 14 and maintain the handle 14 in the folded position in the
first direction X. As will be discussed herein, the top handle 12
can also contain a similar machine fold 34a-34b that also allows it
to fold consistently in the same first direction X as the bottom
handle 14.
[0053] Additionally, as the flexible container 10 is evacuated and
less product remains, the bottom handle 14 can continue to provide
support to help the flexible container 10 to remain standing
upright unsupported and without tipping over. Because the bottom
handle 14 is sealed generally along its entire length extending
between the pair of side panels 18 and 20, it can help to keep the
gussets 54 and 56 (FIG. 1, FIG. 3) together and continue to provide
support to stand the container 10 upright even as the container 10
is emptied.
[0054] As seen in FIGS. 3-4, the top handle 12 can extend from the
top segment 28 and, in particular, can extend from the four panels
28a-28d that make up the top segment 28. The four panels 28a-28d of
film that extend into the top handle 12 are all sealed together to
form a multi-layer top handle 12. The top handle 12 can have a
U-shape and, in particular, an upside down U-shape with a
horizontal upper handle portion 12a having a pair of spaced legs 13
and 15 extending therefrom. The legs 13 and 15 extend from the top
segment 28, adjacent the spout 30 with one 13 on one side of the
spout 30 and other leg 15 on the other side of the spout 30, with
each leg 13, 15 extending from opposite portions of the top segment
28.
[0055] The bottommost edge of the upper handle portion 12a when
extended in a position above the spout 30, can be just tall enough
to clear the uppermost edge of the spout 30. A portion of the top
handle 12 can extend above the spout 30 and above the top segment
28 when the handle 12 is extended in a position perpendicular to
the top segment 28 and, in particular, the entire upper handle
portion 12a can be above the spout 30 and the top segment 28. The
two pairs of legs 13 and 15 along with the upper handle portion 12a
together make up the handle 12 surrounding a handle opening that
allows a user to place her hand therethrough and grasp the upper
handle portion 12a of the handle 12.
[0056] As with the bottom handle 14, the top handle 12 also can
have a dead machine fold 34a-34b that permits folding in a first
direction toward the front side panel 22 and restricts folding in a
second direction toward the rear side panel 24. The machine fold
34a-34b can be located in each leg 13, 15 at a location where the
seal begins. The handle 12 can be adhered together, such as with a
tack adhesive, beginning from the machine folded portion 34a-34b up
to and including the horizontal upper handle portion 12a of the
handle 12. The positioning of the machine fold 34a-34b can be in
the same latitude plane as the spout 30 and, in particular, as the
bottommost portion of the spout 30. The two machine folds 34a-34b
in the handle 12 can allow for the handle 12 to be inclined to fold
or bend consistently in the same first direction X as the bottom
handle 14, rather than in the second direction Y. As shown in FIGS.
1 and 3, the handle 12 can likewise contain a flap portion 36, that
folds upwards toward the upper handle portion 12a of the handle 12
to create a smooth gripping surface of the handle 12, as with the
bottom handle 14, such that the handle material is not sharp and
can protect the user's hand from getting cut on any sharp edges of
the handle 12.
[0057] When the container 10 is in a rest position, such as when it
is standing upright on its bottom segment 26, as shown in FIG. 1,
the bottom handle 14 can be folded underneath the container 10
along the bottom machine fold 42 in the first direction X, so that
it is parallel to the bottom segment 26 and adjacent bottom panel
26a, and the top handle 12 will automatically fold along its
machine fold 34a-34b in the same first direction X, with a front
surface of the handle 12 parallel to a top section or panel 28a of
the top segment 28. The top handle 12 folds in the first direction
X, rather than extending straight up, perpendicular to the top
segment 28, because of the machine folds 34a-34b. Both handles 12
and 14 are inclined to fold in the same direction X, such that upon
dispensing the handles can fold the same direction, relatively
parallel to its respective end panel or end segment, to make
dispensing easier and more controlled. Therefore, in a rest
position, the handles 12 and 14 are both folded generally parallel
to one another. Additionally, the flexible container 10 can stand
upright even with the bottom handle 14 positioned underneath the
upright flexible container 10.
[0058] Alternatively, in another aspect the flexible container can
contain a fitment or pour spout positioned on a sidewall, where the
top handle is essentially formed in and from the top portion or
segment. The top handle can be formed from the four webs of film,
each extending from its respective sidewall, extending into a
sidewall or flap positioned at the top end of the container, such
that the top segment of the container converges into the handle and
they are one and the same, with the spout to the side of the
extended handles, rather than underneath.
[0059] The material of construction of the flexible container 10
can comprise a food-grade plastic. For instance, nylon,
polypropylene, polyethylene such as high density polyethylene
(HDPE) and/or low density polyethylene (LDPE) may be used as
discussed later. The film of the flexible container 10 can have a
thickness that is adequate to maintain product and package
integrity during manufacturing, distribution, product shelf life
and customer usage. In an embodiment, the flexible multilayer film
has a thickness from 100 micrometers, or 200 micrometers, or 250
micrometers to 300 micrometers, or 350 micrometers, or 400
micrometers. The film material can also be such that it provides
the appropriate atmosphere within the flexible container 10 to
maintain the product shelf life of at least about 180 days. Such
films can comprise an oxygen barrier film, such as a film having a
low oxygen transmission rate (OTR) from 0, or greater than 0 to
0.4, or 1.0 cc/m.sup.2/24 hrs/atm) at 23.degree. C. and 80%
relative humidity (RH). Additionally, the flexible multilayer film
can also comprise a water vapor barrier film, such as a film having
a low water vapor transmission rate (WVTR) from 0, or greater than
0, or 0.2, or 1.0 to 5.0, or 10.0, or 15.0 g/m.sup.2/24 hrs at
38.degree. C. and 90% RH. Moreover, it may be desirable to use
materials of construction having oil and/or chemical resistance
particularly in the seal layer, but not limited to just the seal
layer. The flexible multilayer film can be either printable or
compatible to receive a pressure sensitive label or other type of
label for displaying of indicia on the flexible container 10.
[0060] In an embodiment, each panel is made from a flexible
multilayer film having at least one, or at least two, or at least
three layers. The flexible multilayer film is resilient, flexible,
deformable, and pliable. The structure and composition of the
flexible multilayer film for each panel may be the same or
different. For example, each of the four panels can be made from a
separate web, each web having a unique structure and/or unique
composition, finish, or print. Alternatively, each of the four
panels can be the same structure and the same composition.
[0061] In an embodiment, each panel 18, 20, 22, 24 is a flexible
multilayer film having the same structure and the same
composition.
[0062] The flexible multilayer film may be (i) a coextruded
multilayer structure or (ii) a laminate, or (iii) a combination of
(i) and (ii). In an embodiment, the flexible multilayer film has at
least three layers: a seal layer, an outer layer, and a tie layer
between. The tie layer adjoins the seal layer to the outer layer.
The flexible multilayer film may include one or more optional inner
layers disposed between the seal layer and the outer layer.
[0063] In an embodiment, the flexible multilayer film is a
coextruded film having at least two, or three, or four, or five, or
six, or seven to eight, or nine, or 10, or 11, or more layers. Some
methods, for example, used to construct films are by cast
co-extrusion or blown co-extrusion methods, adhesive lamination,
extrusion lamination, thermal lamination, and coatings such as
vapor deposition. Combinations of these methods are also possible.
Film layers can comprise, in addition to the polymeric materials,
additives such as stabilizers, slip additives, antiblocking
additives, process aids, clarifiers, nucleators, pigments or
colorants, fillers and reinforcing agents, and the like as commonly
used in the packaging industry. It is particularly useful to choose
additives and polymeric materials that have suitable organoleptic
and or optical properties.
[0064] In another embodiment, the flexible multilayer film can
comprise a bladder wherein two or more films that are adhered in
such a manner as to allow some delamination of one or more plies to
occur during a significant impact such that the inside film
maintains integrity and continues to hold contents of the
container.
[0065] Nonlimiting examples of suitable polymeric materials for the
seal layer include olefin-based polymer (including any
ethylene/C.sub.3-C.sub.10 .alpha.-olefin copolymers linear or
branched), propylene-based polymer (including plastomer and
elastomer, random propylene copolymer, propylene homopolymer, and
propylene impact copolymer), ethylene-based polymer (including
plastomer and elastomer, high density polyethylene ("HDPE"), low
density polyethylene ("LDPE"), linear low density polyethylene
("LLDPE"), medium density polyethylene ("MDPE"), ethylene-acrylic
acid or ethylene-methacrylic acid and their ionomers with zinc,
sodium, lithium, potassium, magnesium salts, ethylene vinyl acetate
copolymers and blends thereof.
[0066] Nonlimiting examples of suitable polymeric material for the
outer layer include those used to make biaxially or monoaxially
oriented films for lamination as well as coextruded films. Some
nonlimiting polymeric material examples are biaxially oriented
polyethylene terephthalate (OPET), monoaxially oriented nylon
(MON), biaxially oriented nylon (BON), and biaxially oriented
polypropylene (BOPP). Other polymeric materials useful in
constructing film layers for structural benefit are polypropylenes
(such as propylene homopolymer, random propylene copolymer,
propylene impact copolymer, thermoplastic polypropylene (TPO) and
the like, propylene-based plastomers (e.g., VERSIFY.TM. or
VISTAMAX.TM.)), polyamides (such as Nylon 6, Nylon 6,6, Nylon 6,66,
Nylon 6,12, Nylon 12 etc.), polyethylene norbornene, cyclic olefin
copolymers, polyacrylonitrile, polyesters, copolyesters (such as
PETG), cellulose esters, polyethylene and copolymers of ethylene
(e.g., LLDPE based on ethylene octene copolymer such as DOWLEX.TM.,
blends thereof, and multilayer combinations thereof.
[0067] Nonlimiting examples of suitable polymeric materials for the
tie layer include functionalized ethylene-based polymers such as
ethylene-vinyl acetate ("EVA"), polymers with maleic
anhydride-grafted to polyolefins such as any polyethylene,
ethylene-copolymers, or polypropylene, and ethylene acrylate
copolymers such an ethylene methyl acrylate ("EMA"), glycidyl
containing ethylene copolymers, propylene and ethylene based olefin
block copolymers (OBC) such as INTUNE.TM. (PP-OBC) and INFUSE.TM.
(PE-OBC) both available from The Dow Chemical Company, and blends
thereof.
[0068] The flexible multilayer film may include additional layers
which may contribute to the structural integrity or provide
specific properties. The additional layers may be added by direct
means or by using appropriate tie layers to the adjacent polymer
layers. Polymers which may provide additional mechanical
performance such as stiffness or opacity, as well polymers which
may offer gas barrier properties or chemical resistance can be
added to the structure.
[0069] Nonlimiting examples of suitable material for the optional
barrier layer include copolymers of vinylidene chloride and methyl
acrylate, methyl methacrylate or vinyl chloride (e.g., SARAN resins
available from The Dow Chemical Company); vinylethylene vinyl
alcohol (EVOH), metal foil (such as aluminum foil). Alternatively,
modified polymeric films such as vapor deposited aluminum or
silicon oxide on such films as BON, OPET, or OPP, can be used to
obtain barrier properties when used in laminate multilayer
film.
[0070] In an embodiment, the flexible multilayer film includes a
seal layer selected from LLDPE (sold under the trade name
DOWLEX.TM. (The Dow Chemical Company)), single-site LLDPE
(substantially linear, or linear, olefin polymers, including
polymers sold under the trade name AFFINITY.TM. or ELITE.TM. (The
Dow Chemical Company) for example, propylene-based plastomers or
elastomers such as VERSIFY.TM. (The Dow Chemical Company), and
blends thereof. An optional tie layer is selected from either
ethylene-based olefin block copolymer PE-OBC (sold as INFUSE.TM.)
or propylene-based olefin block copolymer PP-OBC (sold as
INTUNE.TM.). The outer layer includes greater than 50 wt % of
resin(s) having a melting point, Tm, that is from 25.degree. C., to
30.degree. C., or 40.degree. C. or higher than the melting point of
the polymer in the seal layer wherein the outer layer polymer is
selected from resins such as VERSIFY or VISTAMAX, ELITE.TM., HDPE
or a propylene-based polymer such as propylene homopolymer,
propylene impact copolymer or TPO.
[0071] In an embodiment, the flexible multilayer film is
co-extruded.
[0072] In an embodiment, flexible multilayer film includes a seal
layer selected from LLDPE (sold under the trade name DOWLEX.TM.
(The Dow Chemical Company)), single-site LLDPE (substantially
linear, or linear, olefin polymers, including polymers sold under
the trade name AFFINITY.TM. or ELITE.TM. (The Dow Chemical Company)
for example, propylene-based plastomers or elastomers such as
VERSIFY.TM. (The Dow Chemical Company), and blends thereof. The
flexible multilayer film also includes an outer layer that is a
polyamide.
[0073] In an embodiment, the flexible multilayer film is a
coextruded film and includes: [0074] (i) a seal layer composed of
an olefin-based polymer having a first melt temperature less than
105.degree. C., (Tm1); and [0075] (ii) an outer layer composed of a
polymeric material having a second melt temperature, (Tm2), [0076]
wherein Tm2-Tm1>40.degree. C.
[0077] The term "Tm2-Tm1" is the difference between the melt
temperature of the polymer in the outer layer and the melt
temperature of the polymer in the seal layer, and is also referred
to as ".DELTA.Tm." In an embodiment, the .DELTA.Tm is from
41.degree. C., or 50.degree. C., or 75.degree. C., or 100.degree.
C., to 125.degree. C., or 150.degree. C., or 175.degree. C., or
200.degree. C.
[0078] In an embodiment, the flexible multilayer film is a
coextruded film, the seal layer is composed of an ethylene-based
polymer, such as a linear or a substantially linear polymer, or a
single-site catalyzed linear or substantially linear polymer of
ethylene and an alpha-olefin monomer such as 1-butene, 1-hexene or
1-octene, having a Tm from 55.degree. C. to 115.degree. C. and a
density from 0.865 to 0.925 g/cm.sup.3, or from 0.875 to 0.910
g/cm.sup.3, or from 0.888 to 0.900 g/cm.sup.3 and the outer layer
is composed of a polyamide having a Tm from 170.degree. C. to
270.degree. C.
[0079] In an embodiment, the flexible multilayer film is a
coextruded film having at least five layers, the coextruded film
having a seal layer composed of an ethylene-based polymer, such as
a linear or substantially linear polymer, or a single-site
catalyzed linear or substantially linear polymer of ethylene and an
alpha-olefin comonomer such as 1-butene, 1-hexene or 1-octene, the
ethylene-based polymer having a Tm from 55.degree. C. to
115.degree. C. and density from 0.865 to 0.925 g/cm.sup.3, or from
0.875 to 0.910 g/cm.sup.3, or from 0.888 to 0.900 g/cm.sup.3 and an
outermost layer composed of a polyamide having a Tm from
170.degree. C. to 270.degree. C.
[0080] In an embodiment, the flexible multilayer film is a
coextruded film having at least seven layers. The seal layer is
composed of an ethylene-based polymer, such as a linear or
substantially linear polymer, or a single-site catalyzed linear or
substantially linear polymer of ethylene and an alpha-olefin
comonomer such as 1-butene, 1-hexene or 1-octene, the
ethylene-based polymer having a Tm from 55.degree. C. to
115.degree. C. and density from 0.865 to 0.925 g/cm.sup.3, or from
0.875 to 0.910 g/cm.sup.3, or from 0.888 to 0.900 g/cm.sup.3. The
outer layer is a polyamide having a Tm from 170.degree. C. to
270.degree. C.
[0081] In an embodiment, the flexible multilayer film includes a
seal layer composed of an ethylene-based polymer, or a linear or
substantially linear polymer, or a single-site catalyzed linear or
substantially linear polymer of ethylene and an alpha-olefin
monomer such as 1-butene, 1-hexene or 1-octene, having a heat seal
initiation temperature (HSIT) from 65.degree. C. to less than
125.degree. C. In a further embodiment, the seal layer of the
flexible multilayer film has an HSIT from 65.degree. C., or
70.degree. C., or 75.degree. C., or 80.degree. C., or 85.degree.
C., or 90.degree. C., or 95.degree. C., or 100.degree. C. to
105.degree. C., or 110.degree. C., or 115.degree. C., or
120.degree. C., or less than 125.degree. C. Applicant discovered
that the seal layer with an ethylene-based polymer with a HSIT from
65.degree. C. to less than 125.degree. C. advantageously enables
the formation of secure seals and secure sealed edges around the
complex perimeter of the flexible container. The ethylene-based
polymer with HSIT from 65.degree. C. to less than 125.degree. C. is
a robust sealant which also allows for better sealing to the rigid
fitment which is prone to failure. The ethylene-based polymer with
HSIT from 65.degree. C. to 125.degree. C. enables lower heat
sealing pressure/temperature during container fabrication. Lower
heat seal pressure/temperature results in lower stress at the fold
points of the gusset, and lower stress at the union of the films in
the top segment and in the bottom segment. This improves film
integrity by reducing wrinkling during the container fabrication.
Reducing stresses at the folds and seams improves the finished
container mechanical performance. The low HSIT ethylene-based
polymer seals at a temperature below what would cause the outer
layer to be compromised.
[0082] In an embodiment, the flexible multilayer film is a
coextruded five layer film, or a coextruded seven layer film having
at least two layers containing an ethylene-based polymer. The
ethylene-based polymer may be the same or different in each
layer.
[0083] In an embodiment, the flexible multilayer film is a
coextruded five layer, or a coextruded seven layer film having at
least two layers containing a polyamide polymer.
[0084] In an embodiment, the flexible multilayer film is a
seven-layer coextruded film with a seal layer composed of an
ethylene-based polymer, or a linear or substantially linear
polymer, or a single-site catalyzed linear or substantially linear
polymer of ethylene and an alpha-olefin monomer such as 1-butene,
1-hexene or 1-octene, having a Tm from 90.degree. C. to 104.degree.
C. The outer layer is a polyamide having a Tm from 170.degree. C.
to 270.degree. C. The film has a .DELTA.Tm from 40.degree. C. to
200.degree. C. The film has an inner layer (first inner layer)
composed of a second ethylene-based polymer, different than the
ethylene-based polymer in the seal layer. The film has an inner
layer (second inner layer) composed of a polyamide the same or
different to the polyamide in the outer layer. The seven layer film
has a thickness from 100 micrometers to 250 micrometers.
[0085] Flexible container 10 has an expanded configuration (shown
in FIGS. 1-6) and a collapsed configuration as shown in FIG. 7.
When the container 10 is in the collapsed configuration, the
flexible container is in a flattened, or in an otherwise evacuated
state. The gusset panels 18, 20 fold inwardly (dotted lines of FIG.
7) and are sandwiched by the front panel 22 and the rear panel
24.
[0086] FIG. 8 shows an enlarged view of the bottom seal area 33 of
FIG. 7 and the front panel 26a. The fold lines 60 and 62 of
respective gusset panels 18, 20 are separated by a distance U that
is from 0 mm, or 0.5 mm, or 1.0 mm, or 2.0 mm to 12.0 mm, or 60 mm,
or greater than 60 mm. In an embodiment, distance U varies based on
the size and volume of the flexible container 10. For example, the
flexible container 10 may have a distance U (in mm) that is from
greater than 0 mm to three times the volume (in liters) of the
container. For example, a 2-liter flexible container can have a
distance U from greater than 0 to less than or equal to 6.0 mm. In
another example, a 20-liter flexible container 10 has a distance U
that is from greater than 0 mm to less than or equal to 60 mm.
[0087] FIG. 8 shows line A (defined by inner edge 29a) intersecting
line B (defined by inner edge 29b) at apex point 35a. BDISP 37a is
on the distal inner seal arc 39a. Apex point 35a is separated from
BDISP 37a by distance S having a length from greater than 0 mm, or
1.0 mm, or 2.0 mm, or 2.6 mm, or 3.0 mm, or 3.5 mm, or 3.9 mm to
4.0 mm, or 4.5 mm, or 5.0 mm, or 5.2 mm, or 5.5 mm, or 6.0 mm, or
6.5 mm, or 7.0 mm, or 7.5 mm, or 7.9 mm.
[0088] In FIG. 8, an overseal 64 is formed where the four
peripheral tapered seals 40a-40d converge in the bottom seal area.
The overseal 64 includes 4-ply portions 66, where a portion of each
panel (18, 20, 22, 24) is heat sealed to a portion of every other
panel. Each panel represents 1-ply in the 4-ply heat seal. The
overseal 64 also includes a 2-ply portion 68 where two panels
(front panel 22 and rear panel 24) are sealed together.
Consequently, the "overseal," as used herein, is the area where the
peripheral tapered seals converge and that is subjected to a
subsequent heat seal operation (and subjected to at least two heat
seal operations altogether). The overseal 64 is located in the
peripheral tapered seals and does not extend into the chamber of
the flexible container 10.
[0089] In an embodiment, the apex point 35a is located above the
overseal 64. The apex point 35a is separated from, and does not
contact the overseal 64. The BDISP 37a is located above the
overseal 64. The BDISP 37a is separated from and does not contact
the overseal 64.
[0090] In an embodiment, the apex point 35a is located between the
BDISP 37a and the overseal 64, wherein the overseal 64 does not
contact the apex point 35a and the overseal 64 does not contact the
BDISP 37a.
[0091] The distance between the apex point 35a to the top edge of
the overseal 64 is defined as distance W shown in FIG. 8. In an
embodiment, the distance W has a length from 0 mm, or greater than
0 mm, or 2.0 mm, or 4.0 mm to 6.0 mm, or 8.0 mm, or 10.0 mm or 15.0
mm.
[0092] When more than four webs are used to produce the container,
the portion 68 of the overseal 64 may be a 4-ply, or a 6-ply, or an
8-ply portion.
[0093] In an embodiment, the flexible container 10 has a vertical
drop test pass rate from 90%, or 95% to 100%. The vertical drop
test is conducted as follows. The container is filled with tap
water to its nominal capacity, conditioned at 25.degree. C. for at
least 3 hours, held in an upright position from its upper handle at
1.5 m height (from the base or side of the container to the
ground), and released to a free fall drop onto a concrete slab
floor. If any leak is detected immediately after the drop, the test
is recorded as a failure. If no leak is detected immediately after
the drop, the test is recorded as a success or "pass." A minimum of
twenty flexible containers are tested. A percentage for pass/fail
containers is then calculated.
[0094] In an embodiment, the flexible container 10 has a side drop
pass rate from 90%, or 95% to 100%. This side drop test is
conducted as follows. The container is filled with tap water to its
nominal capacity, conditioned at 25.degree. C. for at least 3
hours, held in upright position from its upper handle. The flexible
container is released on its side from a 1.5 m height to a free
fall drop onto a concrete slab floor. If any leak is detected
immediately after the drop, the test is recorded as failure. If no
leak is detected immediately after the drop, the test is recorded
as a success or "pass." A minimum of twenty flexible containers are
tested. A percentage for pass/fail containers is then
calculated.
[0095] In an embodiment, the flexible container 10 passes the
stand-up test where the package is filled with water at ambient
temperature and placed on a flat surface for seven days. The
flexible container remains in the same position, with unaltered
shape or position for the seven days.
1. Flexible Container with Inner Arc
[0096] The present disclosure provides another container. In an
embodiment, a flexible container is provided and includes: (A) a
front panel, a rear panel, a first gusseted side panel, and a
second gusseted side panel, the gusseted side panels adjoining the
front panel and the rear panel along peripheral seals to form a
chamber. (B) Each peripheral seal has (i) a body seal inner edge
(BSIE) with opposing ends, (ii) a tapered seal inner edge (TSIE)
extending from each end of the body seal, between each BSIE and
TSIE. Each TSIE extends from a respective BSIE end. An inner arc is
present between each BSIE and TSIE. The flexible container includes
at least one inner arc having a radius of curvature, Rc, from
greater than 3.18 mm to 7.95 mm.
[0097] FIGS. 9-11 show a flexible container 110. Flexible container
110 may include, one, some, or all of the features of flexible
container 10. The flexible container 110 may optionally include one
or more handles. In an embodiment, the flexible container 110
includes a top handle 112 and a bottom handle 114. It is understood
that flexible container 110 may contain only one of handles 112,
114.
[0098] The flexible container 110 has four panels, a front panel
122, a rear panel 124, a first gusset panel 118, and a second
gusset panel 120. The flexible container 110 includes a bottom
segment 126, a top segment 128, and a spout 130. The spout may
include a closure, such as a cap, for example.
[0099] Each panel 118-124 is made of a flexible multilayer film.
The flexible multilayer film can be any flexible multilayer film as
disclosed above. The gusseted side panels 118, 120 adjoin the front
panel 122 and the rear panel 124 along peripheral seals 132a, 132b,
132c, and 132d shown in FIGS. 10-11. The sealed panels from an
interior chamber.
[0100] Each peripheral seal 132a-132d has opposing ends, a top end
and a bottom end. Each peripheral seal 132a-132d includes a
respective body seal inner edge (BSIE) 134a, 134b, 134c, and 134d.
Each peripheral seal 132a-132d further includes a respective
tapered seal inner edge (TSIE) extending from the bottom end and
from the top end of each respective BSIE. TSIEs 136a, 136b, 136c,
136d extend from the bottom end of each respective BSIE 134a-134d
and are hereafter collectively referred to as "b-TSIE." TSIEs 138a,
138b, 138c, and 138d extend from the top end of each respective
BSIE and are hereafter collectively referred to "t-TSIE."
[0101] An inner arc 140a-140h (or "IA 140a-140h") extends between
each BSIE and TSIE to connect, or otherwise adjoin, each TSIE to
its respective BSIE end (top end or bottom end). The flexible
container 110 has eight inner arcs (or IAs), 140a-140h. As best
shown in FIGS. 9 and 9A, IA 140a extends between BSIE 134a and
b-TSIE 136a. IA 140a connects BSIE 134a to b-TSIE 136a. It is
understood that IAs 140b-140h connect respective BSIEs and TSIEs in
a similar manner as shown and described with respect to IA 140a. It
is further understood that inner arcs 140a-140h are distinct from
the distal inner seal arcs 39a, 39c in the bottom seal area.
[0102] Each inner arc defines a radius of curvature, Rc. As
flexible container 110 has eight inner arcs (IAs 140a-140h), the
flexible container 110 has eight radii of curvature, Rc. The radii
of curvature for the AIs may be the same or different.
[0103] The "radius of curvature," or "Rc," as used herein, is the
radius of a circle that fits the inner arc for flexible container
110 (or fits the inner seal arc for flexible container 10, FIG. 8).
The radius of curvature is measured when the flexible container 110
is in its collapsed configuration. As best shown in FIG. 9A, inner
arc 140a has a radius of curvature, Rc. It is understood that IAs
140b-140h each has a similar respective radius of curvature, Rc, as
described for inner arc 140a.
[0104] In an embodiment, at least one of the inner arcs 140a-140h,
(IAs), has a radius of curvature from greater than 3.18 millimeter
(mm) to 7.95 mm. In an further embodiment, at least one of the IAs
has a radius of curvature, Rc, from greater than 3.18 mm, or 3.30
mm, or 3.81 mm, or 4.32 mm, or 4.77 mm, or 5.08 mm, or 5.33 mm, or
5.59 mm, or 5.84 mm, or 6.10 mm, or 6.35 mm to 6.60 mm, or 6.86 mm,
or 7.11 mm, or 7.36 mm, or 7.62 mm, or 7.95 mm.
[0105] In an embodiment, at least two of the inner arcs 140a-140h
have a radius of curvature from greater than 3.18 millimeter (mm)
to 7.95 mm.
[0106] Inner arcs 140a-140d are hereafter collectively referred to
as bottom inner arcs, or "b-IAs." Inner arcs 140e-140h are
hereafter collectively referred to as top inner arcs, or
"t-IAs."
[0107] In an embodiment, at least one b-IA and at least one t-IA
has a radius of curvature from greater than 3.18 mm to 7.95 mm.
[0108] In an embodiment, each of the four b-IAs of flexible
container 110 (IAs 140a-140d) has a radius of curvature from
greater than 3.18 mm to 7.95 mm. In a further embodiment, each of
the four b-IAs has the same radius of curvature in the range from
4.78 mm to 7.95 mm.
[0109] In an embodiment, each of the four t-IAs of flexible
container 110 (IAs 140e-140h) has a radius of curvature from
greater than 3.18 mm to 7.95 mm. In a further embodiment, each of
the four t-IAs have the same radius of curvature in the range from
4.78 mm to 7.95 mm.
[0110] In an embodiment, each of the four b-IAs and each of the
four t-IAs of flexible container 110 (IAs 140a-140h) has a radius
of curvature from greater than 3.18 mm to 7.95 mm. In a further
embodiment, each of the four b-IAs and each of the four t-IAs has
the same radius of curvature in the range from greater than 4.78 mm
to 7.95 mm.
[0111] In an embodiment, the b-IAs and/or the t-IAs have a radius
of curvature from greater than 3.18 mm to 7.95 mm, and the flexible
container 110 exhibits greater than 20 hours time to failure when
subjected to a modified ISTA 1E vibration test. In an embodiment,
the b-IAs and/or the t-IAs have a radius of curvature from 4.78 mm
to 7.95 mm and the flexible container 110 exhibits a time to
failure from greater than 20 hours, or 25 hours, or 30 hours, or 40
hours, or 50 hours to 60 hours, or 70 hours, or 80 hours when
subjected to the modified ISTA 1E vibration test.
[0112] In an embodiment, the flexible container 110 has the
geometry and structure of flexible container 10 in addition to the
one or more inner arcs 140a-140h with Rc from greater than 3.18 mm
to 7.95 mm and shown in FIGS. 9-11. In a further embodiment, the
flexible container 110 has a bottom apex and an overseal 242. The
bottom apex and the overseal 242 of the flexible container 110 have
the same geometry as shown in FIGS. 2 and 8 (and supporting text)
as disclosed above.
[0113] The flexible container 110 can be produced by way of hot die
sealing. The four panels (or four webs) are sandwiched between
opposing die plates under heat and pressure to seal the panels to
each other. In an embodiment, a die plate 210 shown in FIG. 12 is
used to form the seals of the flexible container 110. It is
understood that an opposing die plate that is a mirror image of die
plate 210 is used in the hot die sealing.
[0114] The die plate 210 includes peripheral seal segments 232 and
tapered seal segments 233 which respectively form the peripheral
seals and the tapered seals of the flexible container 110. The die
plate 210 includes body seal inner edge 234 which forms the body
seal inner edges 134a-134d in the flexible container 110. The die
plate 210 includes bottom tapered seal inner edge 236 which forms
the bottom tapered seal inner edges 136a-136d in the flexible
container 110. The die plate 210 includes top tapered seal inner
edges 238 which form the bottom tapered seal inner edges 138a-138d
in flexible container 110. The die plate 210 includes inner arcs
240a-240d with form the inner arcs 140a-140h in the flexible
container 110. The die plate 210 can be produced so that one, some,
or all of the inner arcs 240a-240d has/have an Rc from greater than
3.18 mm to 7.95 mm.
[0115] In an embodiment, the flexible container 10 and/or flexible
container 110 has a volume from 0.25 liters (L), or 0.5 L, or 0.75
L, or 1.0 L, or 1.5 L, or 2.5 L, or 3 L, or 3.5 L, or 4.0 L, or 4.5
L, or 5.0 L to 6.0 L, or 7.0 L, or 8.0 L, or 9.0 L, or 10.0 L, or
20 L, or 30 L.
[0116] The flexible container 10 and/or flexible container 110 can
be used to store any number of flowable substances therein. In
particular, a flowable food product can be stored within the
flexible container 10. In one aspect, flowable food products such
as salad dressings, sauces, dairy products, mayonnaise, mustard,
ketchup, other condiments, beverages such as water, juice, milk, or
syrup, carbonated beverages, beer, wine, animal feed, pet feed, and
the like can be stored inside of the flexible container 10.
[0117] The flexible container 10 and/or flexible container 110 is
suitable for storage of other flowable substances including, but
not limited to, oil, paint, grease, chemicals, cleaning solutions,
washing fluids, suspensions of solids in liquid, and solid
particulate matter (powders, grains, granular solids).
[0118] The flexible container 10 and/or flexible container 110 is
suitable for storage of flowable substances with higher viscosity
and requiring application of a squeezing force to the container in
order to discharge. Nonlimiting examples of such squeezable and
flowable substances include grease, butter, margarine, soap,
shampoo, animal feed, sauces, and baby food.
Definitions and Test Methods
[0119] The numerical ranges disclosed herein include all values
from, and including, the lower value and the upper value. For
ranges containing explicit values (e.g., 1, or 2, or 3 to 5, or 6,
or 7) any subrange between any two explicit values is included
(e.g., 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.).
[0120] Unless stated to the contrary, implicit from the context, or
customary in the art, all parts and percents are based on weight,
and all test methods are current as of the filing date of this
disclosure.
[0121] The term "composition," as used herein, refers to a mixture
of materials which comprise the composition, as well as reaction
products and decomposition products formed from the materials of
the composition.
[0122] The terms "comprising," "including," "having," and their
derivatives, are not intended to exclude the presence of any
additional component, step or procedure, whether or not the same is
specifically disclosed. In order to avoid any doubt, all
compositions claimed through use of the term "comprising" may
include any additional additive, adjuvant, or compound, whether
polymeric or otherwise, unless stated to the contrary. In contrast,
the term, "consisting essentially of" excludes from the scope of
any succeeding recitation any other component, step or procedure,
excepting those that are not essential to operability. The term
"consisting of" excludes any component, step or procedure not
specifically delineated or listed.
[0123] An "ethylene-based polymer," as used herein is a polymer
that contains more than 50 mole percent polymerized ethylene
monomer (based on the total amount of polymerizable monomers) and,
optionally, may contain at least one comonomer.
[0124] The term "heat seal initiation temperature," is minimum
sealing temperature required to form a seal of significant
strength, in this case, 2 lb/in (8.8 N/25.4 mm). The seal is
performed in a Topwave HT tester with 0.5 seconds dwell time at 2.7
bar (40 psi) seal bar pressure. The sealed specimen is tested in an
Instron Tensiomer at 10 in/min (4.2 mm/sec or 250 mm/min).
[0125] Tm or "melting point" as used herein (also referred to as a
melting peak in reference to the shape of the plotted DSC curve) is
typically measured by the DSC (Differential Scanning Calorimetry)
technique for measuring the melting points or peaks of polyolefins
as described in U.S. Pat. No. 5,783,638. It should be noted that
many blends comprising two or more polyolefins will have more than
one melting point or peak, many individual polyolefins will
comprise only one melting point or peak.
[0126] Moisture permeability is a normalized calculation performed
by first measuring Water Vapor Transmission Rate (WVTR) of the film
and then multiplying WVTR by the film thickness (usually thickness
in units of mil). WVTR is measured at 38.degree. C., 100% relative
humidity and 1 atm pressure with a MOCON Permatran-W 3/31. For
values of WVTR at 90% relative humidity the measured WVTR (at 100%
relative humidity) is multiplied by 0.90. The instrument is
calibrated with National Institute of Standards and Technology
certified 25 .mu.m-thick polyester film of known water vapor
transport characteristics. The specimens are prepared and the WVTR
is performed according to ASTM F1249. WVTR units are g/m.sup.2/24
hr.
[0127] An "olefin-based polymer," as used herein is a polymer that
contains more than 50 mole percent polymerized olefin monomer
(based on total amount of polymerizable monomers), and optionally,
may contain at least one comonomer. Nonlimiting examples of
olefin-based polymer include ethylene-based polymer and
propylene-based polymer.
[0128] Oxygen permeability is a normalized calculation performed by
first measuring Oxygen Transmission Rate (OTR) for a given film
thickness and then multiplying this measured OTR by the film
thickness (usually thickness in units of mil). OTR is measured at
23.degree. C., 50% relative humidity and 1 atm pressure with a
MOCON OX-TRAN 2/20. The instrument is calibrated with National
Institute of Standards and Technology certified Mylar film of known
O.sub.2 transport characteristics. The specimens are prepared and
the OTR is performed according to ASTM D 3985. Typical OTR units
are cc/m.sup.2/24 hr/atm.
[0129] A "polymer" is a compound prepared by polymerizing monomers,
whether of the same or a different type, that in polymerized form
provide the multiple and/or repeating "units" or "mer units" that
make up a polymer. The generic term polymer thus embraces the term
homopolymer, usually employed to refer to polymers prepared from
only one type of monomer, and the term copolymer, usually employed
to refer to polymers prepared from at least two types of monomers.
It also embraces all forms of copolymer, e.g., random, block, etc.
The terms "ethylene/.alpha.-olefin polymer" and
"propylene/.alpha.-olefin polymer" are indicative of copolymer as
described above prepared from polymerizing ethylene or propylene
respectively and one or more additional, polymerizable
.alpha.-olefin monomer. It is noted that although a polymer is
often referred to as being "made of" one or more specified
monomers, "based on" a specified monomer or monomer type,
"containing" a specified monomer content, or the like, in this
context the term "monomer" is understood to be referring to the
polymerized remnant of the specified monomer and not to the
unpolymerized species. In general, polymers herein are referred to
has being based on "units" that are the polymerized form of a
corresponding monomer.
[0130] A "propylene-based polymer" is a polymer that contains more
than 50 mole percent polymerized propylene monomer (based on the
total amount of polymerizable monomers) and, optionally, may
contain at least one comonomer.
[0131] By way of example, and not by limitation, some embodiments
of the present disclosure will now be described in detail in the
following Examples.
EXAMPLES
1. Materials for Composition of the Flexible Multilayer Film--for
Example 1 (7 Layer Co-Extruded Flexible Multilayer Film)
TABLE-US-00001 [0132] TABLE 1 152.4 micron-extruded film structure
used for making flexible containers for Example 1 (Example 1 film)
Overall % Thickness Weight % Layer Density ULTRAMID C33L01 13.0%
15.3% 1 1.12 AMPLIFY TY1352 12.0% 11.6% 2 0.922 ELITE 5400G 20.0%
19.2% 3 0.916 AMPLIFY TY1352 12.0% 11.6% 4 0.922 ULTRAMID C33L01
6.0% 7.0% 5 1.12 AMPLIFY TY1352 12.0% 11.6% 6 0.922 AFFINITY
PF1146G 23.6% 22.3% 7 0.899 AMPACET 1.0% 1.0% 7 0.92 10090(Slip)
AMPACET 10063 0.4% 0.4% 7 1.05 (Antiblock) Total 100.0% 100.0%
[0133] Layer 7 of the film structure is a three-component blend of
AFFINITY PF1146G, AMPACET 10090(Slip agent), and AMPACET 10063
(Antiblock agent).
2. Vibration Testing
[0134] The standard International Safe Transit Association (ISTA)
1E procedure is a `non-simulation` integrity test designed for
unitized loads. The ISTA series 1 tests are primarily intended to
accelerate improvements in package development, and therefore do
not simulate actual transportation conditions. The 1E tests consist
of four parts: 1) atmospheric preconditioning, 2) vibration testing
at pallet resonance (G.sub.rms of 1.15G, 3) shock testing via
horizontal impact at 1.7 m/s, and 4) shock testing via rotational
edge drop at a height of 200 mm. The test is cumulative, with a
passing package proceeding through each of the 4 stages. Pallet
resonance in the vibration test is considered as the lowest
frequency vibration at which it is possible to pass a metal shim
under the pallet (indicating the pallet is completely leaving the
vibration table during each displacement cycle).
[0135] Applicant utilized a modified ISTA 1E (hereafter "modified
ISTA 1E test") that is a prolonged vibration test. A vibration
table is driven at 4.625 Hz and the amplitude is adjusted until a
distinct change in the response of the flexible containers is
observed, indicating that the flexible containers are in resonance
and a timer is started. The vibration test is continued until the
first failure is observed for each respective flexible container,
which stops the timer. The results are measured in "time to
failure" (hours, or hrs). Failure is defined as visually observed
leakage from the flexible containers being tested.
[0136] Four flexible containers with a volume of 3.875L (1 gallon)
are made using the Example 1 film shown in Table 1 above. The
flexible containers for Example 1 have the container geometry shown
in FIGS. 1-8 (i.e., the overseal) and also include the geometry
shown in FIGS. 9-11. Each of the four flexible containers (flexible
containers 1, 2, 3, 4) is made with a different radius of curvature
for its respective four b-IAs. For each flexible container 1-4, the
four t-IAs each has a radius of curvature of 3.18 mm.
[0137] The flexible containers 1-4 are subjected to the modified
ISTA 1E test described above. Each of the four 1-gallon (3.875 L)
flexible containers is filled with water. The four flexible
containers are placed into a corrugated box. The corrugated box is
subsequently placed on a vibration table. Each flexible container
has a different Rc for its respective bIAs as set forth in Table 2
below. The vibration table is driven at 4.625 Hz and the amplitude
is adjusted until a distinct change in the response of the bottles
is observed, indicating that the packages are in resonance and the
timer is started. The vibration test is continued until the first
failure for each respective flexible container is observed. The
timer is stopped when a failure in a flexible container is observed
and the time is recorded. The results are measured in hours as time
to failure. Table 2 below shows the hours to failure as related to
Rc for the b-IAs for each flexible container.
3. Results
TABLE-US-00002 [0138] TABLE 2 Rc and modified ISTA IE failure rates
Flexible Radius of Radius of Hours to failure container Corner
Radius curvature curvature (modified ISTA ID Increase Factor (inch)
(mm) IE test) 1* 1.0 (Control) 0.125 3.18 19.5 2 1.5 0.188 4.78
42.5 3 2.0 0.250 6.48 45.3 4 2.5 0.313 7.95 70.4 *comparative
sample
[0139] Flexible container 1 is a control/comparative sample and
flexible containers 2, 3, 4 are examples of the present flexible
container. Applicant discovered that flexible container with
geometry in FIGS. 1-11 and b-IAs with Rc from greater than 3.18 mm
to 7.95 mm show improved strength (improved vibration strength)
compared to flexible container of same geometry and having b-IA Rc
less than or equal to 3.18 mm. Each flexible container 2-4, with
respective b-IA Rc's from greater than 3.18 mm to 7.95 mm show
improved strength (i.e., improved vibration resistance) compared to
control flexible container 1 (comparative sample) container 1 which
has b-IAs with Rc of 3.18 mm.
[0140] Flexible containers 2-3 each shows a greater than two-fold
improvement in vibration strength (42.5/45.3 vs 19.5 hrs time to
failure) over flexible container 1. Flexible container 4 shows a
greater than three-fold improvement in vibration strength (70.4 vs
19.5 hrs to failure) compared to control container 1.
[0141] It is specifically intended that the present disclosure not
be limited to the embodiments and illustrations contained herein,
but include modified forms of those embodiments including portions
of the embodiments and combinations of elements of different
embodiments as come with the scope of the following claims.
* * * * *