US20120298663A1 - Flexible sturdy base container and method for making the same - Google Patents

Abstract

Flexible sturdy base containers and methods for manufacturing the same are provided. The flexible sturdy base container includes a rigid base element formed of a relatively rigid material. The rigid base element includes a bottom and a perimeter wall having an outward facing surface. The container also includes a flexible wall element formed of a relatively flexible material. The flexible wall element is affixed to the outward facing surface of the perimeter wall of the rigid base element and extends in a direction away from the bottom of the rigid base element. The flexible wall element and the bottom of the rigid base element together form an exterior of the flexible sturdy base container.

Description

FIELD
• The present disclose relates generally to flexible containers, and more particularly to a flexible container with a rigid base.
BACKGROUND
• Containers for foodstuffs and other bulk materials are made from various rigid or flexible materials in various configurations. Despite the availability of many different known flexible and rigid packaging designs, there remains a need for new containers for foodstuffs and other bulk materials that can be manufactured cost effectively and that can provide advantageous properties.
SUMMARY
• In one aspect, a flexible sturdy base container is provided. The flexible sturdy base container includes a rigid base element comprising a relatively rigid material. The rigid base element includes a bottom and a perimeter wall having an outward facing surface. The container also includes a flexible wall element comprising a relatively flexible material. The flexible wall element is affixed to the outward facing surface of the perimeter wall of the rigid base element and extends in a direction away from the bottom of the rigid base element. The flexible wall element and the bottom of the rigid base element together form an exterior of the flexible sturdy base container.
• In another aspect, a method of manufacturing a flexible sturdy base container is provided. The method includes transporting a rigid base element comprising a relatively rigid material to a flexible wall element application station. The rigid base element has a bottom and a perimeter wall having an outward facing surface. The method also includes applying a flexible wall element around the perimeter wall of the rigid base element at the flexible wall element application station without covering the bottom of the rigid base element. The flexible wall element comprises a relatively flexible material. The method also includes affixing the flexible wall element to the perimeter wall of the rigid base element to produce the flexible sturdy base container.
DRAWINGS
• FIG. 1 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.
• FIG. 2 is a side view, illustrating one of the flexible sturdy base containers ofFIG. 1.
• FIG. 3 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.
• FIG. 4 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.
• FIGS. 5A-C are perspective views, illustrating use of one of the flexible sturdy base containers ofFIG. 4.
• FIG. 6 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.
• FIGS. 7A-C are perspective views, illustrating use of one of the flexible sturdy base containers ofFIG. 6.
• FIG. 8 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.
• FIG. 9 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.
• FIG. 10 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.
• FIG. 11 is a perspective view, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.
• FIGS. 12A-C are perspective views, illustrating use of the flexible sturdy base container ofFIG. 11.
• FIG. 13 is a perspective view, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.
• FIGS. 14A and 14B are perspective views, illustrating use of the flexible sturdy base container ofFIG. 13.
• FIG. 15 is a side view, illustrating a method of manufacturing a sturdy base container in accordance with one or more embodiments of the present invention.
• FIGS. 16A and 16B are orthogonal views, illustrating a method of manufacturing a sturdy base container in accordance with one or more embodiments of the present invention.
• FIG. 17 is a side view, illustrating a method of filling and sealing a sturdy base container in accordance with one or more embodiments of the present invention.
• FIG. 18 is a perspective view, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.
• FIGS. 19A,19B, and19C are perspective views, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.
• FIGS. 20A and 20B, are a side view and a bottom view, respectively, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.
• FIGS. 21A and 21B, are a side view and a bottom view, respectively, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.
• FIGS. 21C and 21D, are perspective views, illustrating the flexible sturdy base container ofFIGS. 21A and 21B.
DETAILED DESCRIPTION
• New containers are disclosed that provide various advantages over presently-available container designs. Methods are also provided for manufacturing such containers. In one aspect, a flexible sturdy base container is provided that includes a rigid base element made from a relatively rigid material and a flexible wall element made from a relatively flexible material. As used herein the terms “relatively rigid material” and “relatively flexible material” are intended to denote that one material, i.e., the relatively rigid material, is more rigid than the other material, i.e., the relatively flexible material. The relatively rigid material may be any material suitable for providing structural integrity to the base of the container. For example, the material may be sufficiently rigid to allow the container to stand up vertically when placed on its base. In some embodiments, the material may be sufficiently rigid to prevent the container from tipping over when placed on its side.
• In some embodiments, the base is made of a rigid or semi-rigid material and the side wall is made of a flexible material. The term “rigid material,” as used herein, is used in the ordinary sense and refers to materials that are characterized by a degree of stiffness that would be considered rigid in the packaging and converting industry. Often these materials are made by blow molding, injection molding, or thermoforming processes. For example, the rigid base element may be made by thermoforming an extruded sheet. The term “flexible material,” as used herein, is used in the ordinary sense and refers to materials that are characterized by a degree of flexibility (e.g., to bending) that would be considered flexible in the packaging and converting industry. Often these materials are relatively thin webs or films produced by extrusion processes. The term “semi-rigid material,” as used herein, is used in the ordinary sense and refers to materials that are characterized by a degree of stiffness that would be considered semi-rigid in the packaging and converting industry. These materials may also be considered rigid or flexible. The terms “rigid” “semi-rigid” and “flexible” are extensive qualities that depend not only on the specific composition of the material but also the material's thickness, structure, and method of forming.
• The rigid base element may allow the container to stand vertically on its base or may allow the container to lay on its side without tipping over. Such a feature may be advantageous in retail settings where visible shelf space is limited. The rigid base may also provide protection for fragile dry products, e.g., it may reduce or prevent breaking of flakes. The rigid base may also allow for the container to stand up when it is partially filled. Thus, the container may be pantry, counter and table-top friendly. The rigid base may customized depending on the nature of the product and the needs of the customer and/or retailer. For example, the base can be formed in a shape consistent with ergonomic needs (e.g., it can be shaped to be easier to hold in the consumer's hand) or the base can be shaped such that the product stores better on a retailer shelf or is better for packing and/or shipping.
• The flexible wall element may occupy the majority of the exterior surface area of the package and/or a majority of the packaging material by mass, thereby making efficient use of the materials. The flexible wall element may also be made from thin films, thereby allowing for customizable barrier properties. Likewise, the rigid base may be thermoformed or co-injection molded for oxygen barrier properties if necessary. Such features may allow for customization of the barrier properties for different types of products (e.g., dry, frozen, fresh, oxygen sensitive, moisture sensitive, or respiring). The flexible wall material may be customizable in shape, providing excellent customization and product differentiation opportunities. The flexible wall element may also allow for various convenience features (such as easy-open or reclosable features) to be viewed. The flexible wall element may also include a product viewing window.
• The container, having a sturdy base and a flexible top, may also allow for open-top filling. Advantageously, in some embodiments, the container may be employed in high-speed filling and sealing systems. Moreover, the container may be made predominantly from a single polymer. For example, the container may be made predominantly of polypropylene, which is lightweight, cost effective, and recyclable. In some embodiments, the container may be made predominantly of polylactic acid, which is renewable and compostable.
• The container may be used to contain various food and other bulk products, such as granular products or products that can be gravity-fed. The bulk product can also include smaller packages, such as candy or individual servings of product. In some embodiments, the container may contain breakfast cereals, salty snacks, pasta, crackers, popcorn, nuts, dried fruits, confectionaries, chocolate, and other baked or fried goods and/or dry products. In some embodiments, the container may contain frozen food products, including frozen meat, seafood, vegetables, fruit, and combinations thereof. In other embodiments, the container may contain non-food items including laundry and dish-washing detergents, fertilizers, insecticides, pesticides and other granulated products.
Flexible Sturdy Base Container
• In one aspect, a flexible sturdy base container is provided that includes a rigid base element made from a relatively rigid material and a flexible wall element made from a relatively flexible material. In some embodiments, the rigid base element includes a bottom and a perimeter wall having an outward facing surface. In some embodiments, the flexible wall element is affixed to the outward facing surface of the perimeter wall of the rigid base element and extends in a direction away from the bottom of the rigid base element. In some embodiments, the flexible wall element and the bottom of the rigid base element together form an exterior of the flexible sturdy base container.
• An exemplary embodiment of a flexiblesturdy base container10 is illustrated inFIG. 1. The illustrated flexiblesturdy base container10 includes arigid base18 that forms the bottom14 of thecontainer10. Aflexible side wall16 is affixed to arigid base18. Theflexible side wall16 may extend from proximal to the bottom14 of thecontainer10 to the top12 of thecontainer10. At the top12 of thecontainer10 anend seal20 may be provided. The end seal may be, for example, a heat seal. In the illustrated embodiment, theend seal20 comprises a heat seal region that extends across the entirety of the top12 of thecontainer10 thereby sealing the end of theflexible side wall16 opposite therigid base18.
• The bottom14 may include areclosable lid22. Thereclosable lid22 may pivot with respect to the bottom14 by ahinge24, which may be a living hinge. As illustrated inFIG. 2, thereclosable lid22 may be selectively positionable in an open position and a closed position (FIG. 1). When thereclosable lid22 is positioned in the open position, aspout opening30 is uncovered, thereby allowing access to the contents of thecontainer10. Various locking features may be provided for retaining thereclosable lid22 in the closed position. For example, thespout opening30 may include anexternal rib28. Thereclosable lid22 may also include aninternal rib26 that mechanically engages theexternal rib28 when thereclosable lid22 is moved to the closed position. Engagement of theinternal rib26 andexternal rib28 may prevent thereclosable lid22 from opening inadvertently, such as when moving the container from one location to another.
• As illustrated inFIG. 2, theflexible side wall16 may be affixed to therigid base18 along aperimeter wall25 of therigid base18. Theflexible side wall16 may be affixed to theperimeter wall25, for example, by thermal, ultrasonic, RF or adhesive bonding. In the illustrated embodiment, theflexible side wall16 terminates proximal the bottom of therigid base14; however, an exposedportion27 of theperimeter wall25 is left uncovered by theflexible side wall16.
• In preferred embodiments, the flexible side wall material may be affixed to itself by a lap seam type seal that extends from the end of the flexible side wall proximal to the rigid base to the opposite end of the flexible side wall at the top of the container. The lap seam may be formed by sealing together, at respective edges, an outward-facing surface of the flexible side wall and an inward-facing surface of the flexible side wall. The seal may be created by thermal bonding, RF bonding, ultrasonic bonding, adhesive bonding, or a combination thereof. The lap seam not only provides an efficient use of material for flexible sturdy base container configurations but also provides improved structural strength and improved sealing relative to fin seals or butt seams. Specifically, it is noted that the lap seam induces an outward-exerting spring force within the flexible wall that provides natural resistance to folding. The lap seam also allows for the flexible material to be wrapped around the outward facing surface of the perimeter wall of the rigid base. This allows for a better seal to be formed between the flexible side wall and reduces or eliminates channels and wrinkling, which could compromise the sealing of the contents of the package.
• Another embodiment of a flexiblesturdy base container32 is illustrated inFIG. 3. Thecontainer32 includes arigid base36 at the bottom38 of thecontainer10 and aflexible side wall34 extending from proximal to the bottom38 of thecontainer10 to the top40 of thecontainer10. Therigid base36 may include a recessedpanel42 that is separated from bottom38 by astandoff44. Therigid base36 may also include areclosable lid46 that is attached to the recessedpanel42 by ahinge48, which may be a living hinge. Thereclosable lid46 may include atab50 that is elevated from the recessedpanel42 to facilitate opening.
• Another embodiment of a flexiblesturdy base container52 is illustrated inFIG. 4. The container includes a rigid base having an annular shaped bottom56. A recessedpanel54 is separated from bottom56 by astandoff60. As illustrated inFIG. 5A, thereclosable lid62 may be manipulated to the open position to reveal aremovable seal64. Theremovable seal64 may be a tamper-evident membrane that is configured to indicate to the user whether the container had previously been opened. The removable seal could be a lidding membrane that provides barrier properties as well as tamper evidency. Other tamper-evident features, including heat-shrunk bands placed over the lid, may be employed in addition to or in place of theremovable seal64.
• Referring back toFIG. 5A, theremovable seal64 may then be peeled or torn away to reveal anopening66, providing access to the contents of thecontainer52. With thereclosable lid62 in the open position, the contents of thecontainer52 may be poured out into a hand or acontainer65 as illustrated inFIG. 5B. As illustrated inFIG. 5C, thecontainer52 may be easily reclosed by pivoting thereclosable lid62 about thehinge58 untilreclosable lid62 snaps back into the closed position.
• Another embodiment of a flexiblesturdy base container70 is illustrated inFIG. 6. Thecontainer70 includes aflexible side wall72 and arigid base74. Areclosable lid78 is attached to the bottom76 of theridge base74 by ahinge80, which may be a living hinge. For additional security, therigid base74 further includes locking78 which securely engages thereclosable lid78 and maintains thereclosable lid78 in the closed position until thelocking tab80 is pulled away from thereclosable lid78. Arecess82 is provided in thereclosable lid82 to provide a space for inserting the end of a finger to pull away thelocking tab80 from the reclosable lid as illustrated inFIG. 7A. With thereclosable lid82 in the open position, the contents of thecontainer70 may be poured out into a hand or acontainer84 as illustrated inFIG. 7B. As illustrated inFIG. 7C, thecontainer70 may be reclosed by pivoting thereclosable lid78 back to the closed position and pressing thelocking tab80 back into position to secure thereclosable lid78.
• Another embodiment of a flexiblesturdy base container86 is illustrated inFIG. 8. Thecontainer86 includes aflexible side wall88 that is affixed to arigid base90. The rigid base may include a recessedpanel96 that is separated from the bottom92 of therigid base90 by a standoff95. The rigid base also includes areclosable lid98 that is attached to the recessedpanel96, for example, by a hinge. The embodiment illustrated inFIG. 8, like the embodiments ofFIGS. 1 and 6, has arigid base90 having a perimeter wall with flat, substantially planar portions on opposite sides of therigid base90. These flat, substantially planar portions may allow thecontainer86 to lay flat on its side with stability, i.e., without tipping over.
• Another embodiment of a flexiblesturdy base container100 is illustrated inFIG. 9. Thecontainer100 includes arigid base108 and aflexible side wall106 extending from proximal to thebottom104 of thecontainer100 to the top102 of thecontainer100. Therigid base108 includes areclosable lid110 that is attached to therigid base108 by a hinge. Therigid base108 also includes a perimeter wall having two pairs of opposing flat, substantiallyplanar portions114 and116. In this embodiment, thecontainer100 may rest stably on therigid base104 in the vertical orientation or may rest stably on any of its sides.
• Another embodiment of a flexiblesturdy base container120 is illustrated inFIG. 10. Thecontainer120 includes a rigid base129 and aflexible side wall126 extending from proximal to thebottom130 of thecontainer120 to the top122. The top122 of thecontainer120 may be heat sealed, and ahandle124 may be formed by a cutout within the heat seal region. Thehandle124 may be reinforced by the addition of a reinforcing layer. Areclosable lid132 is provided in therigid base128 at the bottom130.
• Another embodiment of a flexiblesturdy base container140 is illustrated inFIG. 11. Thecontainer140 includes arigid base152 and aflexible side wall150 extending from proximal to thebottom154 of thecontainer140 to the top146. Aheat seal region148 may also be provided along the top146, and astress riser144 may be provided in theflexible side wall150, for example, in theheat seal region148. Thestress riser144 may be configured to propagate atear145 when the user grasps a tear-awayportion142 and pulls as illustrated inFIG. 12A. When the tear-awayportion142 is torn from thecontainer140, anopening146 is formed as illustrated inFIG. 12B. Theopening146 may be used as a spout to pour the contents of thecontainer140 into a hand or acontainer152. Thecontainer140 then may be reclosed by folding a foldedportion150 over theopening146 and placing aclip148 over the fold as illustrated inFIG. 12C.
• Another embodiment of a flexiblesturdy base container160 is illustrated inFIG. 13. Thecontainer160 includes arigid base172 and aflexible side wall166. Theflexible side wall166 has a heat-seal region170 at the top168. The top168 may also include a tear-awayportion162 which, when removed, reveals aninternal locking feature164. As illustrated inFIG. 14A, thecontainer160 may be opened by tearing away tear-awayportion162 to produce anopening174 providing access to the contents of thecontainer160. As illustrated inFIG. 14B, thecontainer160 may then be closed by compressing theinternal locking feature164. Theinternal locking feature164 may be, for example, interlocking ribs, tabs, a zipper, hook and loop fasteners, or pressure sensitive adhesive.
• The embodiments illustrated inFIGS. 1-14 are intended to be illustrative of the various features and configurations possible for flexible sturdy base containers according to one or more embodiments of the present invention. It should be appreciated that the various features that are illustrated in one embodiment (including shapes of the rigid base, the presence or absence of a recessed panel, handle, reclosable feature, locking tab, stress riser or tear-way portion) may be incorporated and used in each of the other illustrated embodiments. For example, as illustrated inFIG. 18, a flexiblesturdy base container500 may include a top54, an internal reclose feature502 proximal the top504, and a flat rectangular shapedbase506. In another example, as illustrated inFIGS. 19A-C, a flexiblesturdy base container600 may include ahandle604, a tear awayportion602, and aninternal locking feature606 all located in a top portion of thecontainer600. In yet another example, as illustrated inFIGS. 20A and 20B, a flexiblesturdy base container700 can include a substantially triangular-shapedbottom702 having areclosable lid704 integrated to the bottom702 by ahinge706. In yet another example, a flexiblesturdy base container800 may have a substantially triangular-shapedbottom802 and agusset804 on one side with aninternal locking feature806 within a folded portion of the gusset. Thegusset804 may be opened (i.e., unfolded) to create an opening or pour spout for providing access to the contents of thecontainer800.
• Flexible Wall Element
• The flexible wall element may be made of a relatively flexible material, which may be a flexible material. In some embodiments, the relatively flexible material is sufficiently flexible to allow the top of the container to be rolled or folded over. In some embodiments, the relatively flexible material comprises a polymeric material. For example, the relatively flexible material may comprise a relatively thin polymeric film or web.
• In certain embodiments, the relatively flexible material may be a multilayer laminate structure. In an exemplary embodiment, the multilayer laminate structure may include one or more of a heat-sealable inner layer, an oxygen and/or a vapor barrier layer, and a print layer. Other layers serving other functions may also be employed.
• The heat-sealable inner layer may comprise any heat-sealable material. Exemplary heat-sealable materials include, but are not limited to, thermoplastic polymeric materials, such as polypropylene, polyethylene, polylactic acid, copolymers of polypropylene, copolymers of polyethylene, heat sealable PET, PET copolymers, and biodegradable and compostable thermoplastics.
• The oxygen and/or vapor barrier layer may comprises any material suitable for provided the desired oxygen and/or vapor barrier performance qualities. In some embodiments, the multilayer laminate structure provides a gas permeability of less than 100 cc/100 in²/24 hrs, or more preferably less than 10 cc/100 in²/24 hrs, or most preferably less than 0.1 cc/100 in²/24 hrs. Exemplary barrier layer materials include metal films (e.g., aluminum films), metalized polyolefin films, and copolymers of vinyl alcohol (EVOH, PVOH), metalized PLA, aluminum oxide coated PET, silicon oxide coated PET, nylon, metalized nylon, and polyglycolic acid (PGA) films.
• In some embodiments, the flexible wall element extends from approximately the bottom of the container to the top of the container. In certain embodiments, a portion of the rigid base is exposed between the top and the bottom of the container. In such embodiments, the flexible wall element, an exposed portion of the perimeter wall of the rigid base element, and the bottom of the rigid base element together form an exterior of the flexible sturdy base container. In other embodiments, the flexible wall element may extend from the top of the container to the bottom of the container without covering the bottom. In such embodiments, no portion of the perimeter wall of the rigid base may form the exterior of the container, i.e., the entirety of the perimeter wall may be covered by the flexible wall element.
• In some embodiments, the top of the flexible wall includes a heat seal region in which opposite sides of the flexible wall are heat-sealed together. Alternatively, in some embodiments, the heat seal region may be a bonding region in which the opposite sides of the flexible wall are bonded by ultrasonic bonding or RF bonding. In some embodiments, the heat seal or bonding region may extend across the entirety of the top of the container, thereby hermetically sealing the container and its contents. In some embodiments, the container may include a stress riser placed in the heat seal or bonding region that is designed to propagate a tear when a tear away portion is pulled by a user to provide access to the contents of the container.
• In some embodiments, the container may include a reclosable element integrated or attached to the flexible wall element. The reclosable element may allow for the selective closure of an end of the flexible wall element. Various reclosable elements may be employed including, but not limited to, interlocking ribs, tabs, zippers, hook and loop fasteners, or pressure sensitive adhesive.
• Rigid Base Element
• The rigid base element may be made of a relatively rigid material, which may be a rigid material. In some embodiments, the rigid base element may be a molded or thermoformed article. For example, the relatively rigid material may be formed of a plastic material. Exemplary materials for forming the rigid base include polypropylene, polyethylene, polyethylene teraphthalate, copolymers of polypropylene, copolymers of polyethylene, EVOH, styrene, ABS, PVC, PVDC, copolymers of styrene, multilayer materials, composite materials, and bioderived materials.
• The rigid base element may include a bottom and a perimeter wall having an outward facing surface for mating with and bonding with the flexible wall element. The outward-facing surface may include ribs, etching, or other surface characteristics to improve manufacturing or the consumer experience. In some embodiments, the bottom of the rigid base may comprise a flat, substantially planar surface covering the area circumscribed by the perimeter wall. In other embodiments, the bottom of the rigid base may comprise a recessed panel that is separated from the bottom by a standoff.
• In some embodiments, the rigid base element may include a reclosable lid that selectively covers a spout opening through which the contents of the container may be accessed. The reclosable lid may be integral with the rigid base or it may be a separate component that is attached to the rigid base. The reclosable lid may be joined to the rigid base by a hinge, such as a living hinge. Thus, the lid may be selectively positioned in an open position and a closed position. In some embodiments, the spout opening has an external rib and the reclosable lid has an internal rib that engages the external rib when the reclosable lid is positioned in the closed position.
• In some embodiments, the rigid base element further includes a locking tab for locking the reclosable lid in a closed position. In certain embodiments, the locking tab is moveable between a unlocked position and a locked position in which the reclosable lid is secured in the closed position.
• Advantageously, in some embodiments, the rigid base and its associated components may be formed of a single, integral, and contiguous material. For example, the reclosable lid may be integral with the base, such as, by the use of a living hinge, and the locking feature, if present, may be similarly integrally formed with and a part of the rigid base. Such a feature may allow for the rigid base and its components to be manufactured economically and efficiently.
• The rigid base may be formed in various shapes and sizes, including any polygonal, curvilinear or hybrid polygonal-curvilinear shape, including, but not limited to, triangular, quadrilateral, rectangular, square, trapezoidal, rhomboidal, pentagonal, hexagonal, heptagonal, octagonal, nonagonal, decagonal, circular, oval, elliptical, Reuleaux polygonal, or combination of any number of the foregoing. Moreover, the shape may comprise one or more other features such as a fillet or a chamfer. In certain embodiments, the perimeter wall has at least one flat, substantially planar portion. The flat, substantially planar portion may be sufficiently large in area to allow the container to rest stably on a side without tipping over.
Methods of Manufacturing a Sturdy Base Container
• In another aspect, a method of manufacturing a flexible sturdy base container is provided. The method may include transporting a rigid base element made of a relatively rigid material to a flexible wall element application station. The rigid base element may include a bottom and a perimeter wall having an outward facing surface. The method may further include applying a flexible wall element around the perimeter wall of the rigid base element at the flexible wall element application station without covering the bottom of the rigid base element. The flexible wall element may be made of a relatively flexible material. The method may further include affixing the flexible wall element to the perimeter wall of the rigid base element to produce the flexible sturdy base container. The method may further include forming an overlap of the flexible wall element in which the flexible wall element overlaps itself to form a lap seam. The method may further include affixing an outward-facing surface of the flexible wall element to an inward-facing surface of the flexible wall element at the lap seam.
• In some embodiments, the method further includes transporting the flexible sturdy base container to a filling station, and filling the flexible sturdy base container with a bulk product while the flexible sturdy base container is at the filling station. In some embodiments, after being filled, the container may then be transported to a sealing station where an open end of the flexible wall element is sealed. For example, the open end may be sealed by heat sealing the flexible wall element to form a heat seal region. In certain embodiments, the step of sealing the open end of the flexible wall element comprises bonding opposite sides of the flexible wall element to form a bonding region. In certain embodiments, the open end of the flexible wall element may be sealed by compressing opposing reclosable elements together.
• Various methods may be employed to apply the flexible wall element to the rigid base element. For example, in some embodiments, an open end of a tube of a relatively flexible material may be placed around the perimeter wall of the rigid base element. In other embodiments, the flexible wall element may be applied to the rigid base element by wrapping a sheet of a relatively flexible material around the perimeter wall of the rigid base element. The flexible wall element may be affixed to the perimeter wall by applying heat and/or pressure to the flexible wall element. The flexible wall element may be affixed to the rigid base element by various methods of affixing, including heat sealing, RF bonding, ultrasonic bonding, or adhesive bonding. For example, the flexible wall element may be bound to the perimeter wall by applying heat, pressure, ultrasonic energy, RF energy, or a combination thereof to the flexible wall element.
• An embodiment of asystem200 and method for affixing a flexible wall element to a rigid base element is illustrated inFIG. 15. Therigid base202 may be transported via aconveyor204 to atube application position205. In embodiments of the flexible sturdy base container that include a recessed panel and standoff, theconveyor204 may include gripping elements that insert into the space between the recessed panel and standoff to maintain positive control of therigid base202 as it is transported on theconveyor202.
• At thetube application position205, anopen end208 of atube206 of flexible material is placed over therigid base202 and slid down the perimeter wall of therigid base202. Thetube206 may be formed as part of an inline process with the tube application process. For example, thetube206 may be formed as part of a vertical form-fill-and-seal process on a production line. In other embodiments, the tube may be made prior to and independent of the application process. Thetube206 may include a series ofreclosable elements212 and/or easyopen features210, such as perforations or scores. Thetube206 may then be sealed to therigid base202, such as by applying heat and/or pressure. The top214 of the flexible wall element may then be formed by cutting thetube206 at the desired length.
• Another embodiment of asystem300 and method for affixing a flexible wall element to a rigid bas element is illustrated inFIGS. 16A and 16B. Thesystem300 includes a rotating former302, which includes a plurality of formingmandrels316. At one position, arigid base320 is placed at one end of themandrel316, and the former302 may then rotate so that themandrel316 is moved to a second position.
• At the second position, a flexible wall element may be affixed to the rigid base by feeding a sheet offlexible packaging material306 to themandrel316 while themandrel316 rotates about a longitudinal axis. While the flexible packaging material is wrapped around themandrel316, aheated roller318 may apply heat and/or pressure to theflexible packaging material306 so that the flexible packaging material bonds to therigid base320. In embodiments of the flexible sturdy base container that include a reclosable feature, areclose material308 may be fed from areclose material roll310 and joined to aflexible packaging material306 fed from aflexible packaging roll304 by apressure roll312 which applies heat and/or pressure to thereclose material308 and/orflexible packaging material306 as the two components pass across aguide roll314. Thereclose material30 may be affixed to theflexible packaging material306 by various methods of affixing, including heat sealing, RF bonding, ultrasonic bonding, or adhesive bonding. Theflexible packaging material306 may be cut to a length that will allow theflexible packaging material306 to wrap completely around themandrel316 with an overlap.
• The former302 may then rotate to move themandrel316 to a third position. At the third position, aside sealing roll324 may seal the flexible side wall element to itself from the top of the container to the bottom of the flexible side wall element. The container may then be discharged from the mandrel at the third position or at another position. In some embodiments, the container may discharged onto another conveyor that transports the container to a filling and/or sealing system.
• An embodiment of a filling and sealingsystem400 is illustrated inFIG. 17. Thecontainer404 may be transported by aconveyor408 to afill position406 where afill tube402 may be inserted through the open top of thecontainer404. Thefill tube402 may fill thecontainer404 with aproduct410. Thecontainer402 may then be transported by theconveyor408 to aseal position412. During the transport, theproduct410 may be allowed to settle in thecontainer404. At the seal position, aheat seal414 may be formed across the previously-open top of thecontainer404. Theconveyor408 may then transport thecontainer404 to another location for inspection and/or boxing or palletizing.
• In some embodiments, a flexible sturdy base package forming system may be easily and quickly changed between forming and optionally, filling and sealing, containers of two or more different configurations. For example, the flexible sturdy base package forming system may first operate to form, fill, and seal a first container that is customized for a first product and then may be converted to operate to form, fill, and seal a second container that is customized for a second product with minimal equipment modification and downtime.
• It will be appreciated that various of the above-disclosed and other feature and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Claims (24)

1. A flexible sturdy base container comprising:

a rigid base element comprising a relatively rigid material, the rigid base element comprising a bottom and a perimeter wall having an outward facing surface; and

a flexible wall element comprising a relatively flexible material;

wherein the flexible wall element is affixed to the outward facing surface of the perimeter wall of the rigid base element and extends in a direction away from the bottom of the rigid base element; and

wherein the flexible wall element and the bottom of the rigid base element together form an exterior of the flexible sturdy base container.

2. The flexible sturdy base container ofclaim 1, wherein the flexible wall element overlaps itself along a portion of the perimeter wall to form a lap seam.

3. The flexible sturdy base container ofclaim 2, wherein an inward-facing surface of the flexible wall element is bonded to an outward-facing surface of the flexible wall element where the flexible wall element overlaps itself at the lap seam.

4. The flexible sturdy base container ofclaim 1, the rigid base element further comprising a reclosable lid.

5. The flexible sturdy base container ofclaim 4, further comprising a hinge connecting the reclosable lid to the rigid base element.

6. The flexible sturdy base container ofclaim 5, wherein the hinge is a living hinge.

7. The flexible sturdy base container ofclaim 4, the rigid base element further comprising a spout opening providing access to an interior of the container, the spout opening being selectively closable with the reclosable lid.

8. The flexible sturdy base container ofclaim 7, the reclosable lid comprising an internal rib and the spout opening comprising an external rib, and wherein the internal rib engages the external rib when the reclosable lid is positioned in a closed position.

9. The flexible sturdy base container ofclaim 1, wherein the flexible wall element covers only a first portion of the perimeter wall of the rigid base element thereby leaving a second portion of the perimeter wall exposed proximal the bottom of the rigid base element.

10. The flexible sturdy base container ofclaim 1, wherein rigid base element comprises a molded or thermoformed article.

11. The flexible sturdy base container ofclaim 1, wherein the relatively rigid material comprises a plastic material.

12. The flexible sturdy base container ofclaim 1, wherein the rigid base element comprises a recessed panel and a standoff extending between the recessed panel and the bottom of the rigid base element.

13. The flexible sturdy base container ofclaim 12, further comprising a reclosable lid attached to the recessed panel.

14. The flexible sturdy base container ofclaim 1, wherein the perimeter wall has at least one flat, substantially planar portion.

15. The flexible sturdy base container ofclaim 4, further comprising a locking tab for locking the reclosable lid in a closed position, the locking tab moveable between a unlocked position and a locked position.

16. The flexible sturdy base container ofclaim 1, wherein the relatively flexible material comprises a polymeric material.

17. The flexible sturdy base container ofclaim 1, wherein the relatively flexible material comprises a multilayer laminate structure.

18. The flexible sturdy base container ofclaim 17, wherein the multilayer laminate structure comprises a heat-sealable inner layer comprising a heat sealable material.

19. The flexible sturdy base container ofclaim 17, wherein the multilayer laminate structure comprises an oxygen and/or vapor barrier layer.

20. The flexible sturdy base container ofclaim 17, wherein the multilayer laminate structure comprises a print layer.

21. The flexible sturdy base container ofclaim 1, wherein the flexible wall element comprises a first end proximal to the bottom of the rigid base element and a second end distal to the bottom of the rigid base element, and wherein the second end of the flexible wall element comprises a heat seal region, the heat seal region hermetically sealing the container.

22. The flexible sturdy base container ofclaim 21, wherein the flexible wall element further comprises a tear-away portion and a stress riser that facilitates the tearing away of the tear away portion.

23. The flexible sturdy base container ofclaim 1, wherein the flexible wall element comprises a first end proximal to the bottom of the rigid base element and a second end distal to the bottom of the rigid base element, and wherein the second end of the flexible wall element comprises a reclosable element, the reclosable element allowing selective closure of the second end of the flexible wall element.

24. The flexible sturdy base container ofclaim 1, wherein the container contains a bulk product.

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