US20170081074A1 - Flexible film container and manufacturing method - Google Patents

Abstract

A self-supporting flexible film container is disclosed that includes a container base and a flexible film attached to the container base that forms a container wall and defines a packing region within the container. The container wall has at least one support column, such as a tubular support column, integrally formed therein. A method of conforming the container includes providing a web of flexible film, forming tubular support columns in the web of flexible film and forming a container from the web of flexible film containing the support columns. The support columns can be formed by ploughing and forming the web of flexible film.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• This application claims priority to and the benefit of U.S. App. No. 61/993,321 filed May 15, 2014 which is hereby incorporated by reference in its entirety.
FIELD
• This application is directed to flexible film containers and processes of manufacturing that include using flexible films. More particularly, this application relates to flexible films and containers having support columns and processes for manufacturing such flexible films and containers.
BACKGROUND
• Candy and other small or bite-size products like nuts, savory snacks, frozen heat-n-eat snacks, frozen heat-n-eat vegetables, ready-to-eat cereal, and mints are typically sold in multi-piece packages. In many cases, the package is designed for bulk sale of the product to the consumer rather than as a single serving size, although in some cases the individual product may still be separately wrapped prior to being placed in the package.
• Historically, the packaging of multi-piece units, particularly for candy, was primarily accomplished through the use of paper bags or metal tins. More recently, plastic bags, and more particularly the plastic bag often referred to as a pillow pack or a lay-down bag has become the industry standard. While pillow packs are advantageous because they are relatively easy and inexpensive to manufacture, they have numerous drawbacks for both the retailer and the consumer.
• Among the drawbacks faced by the retailer with pillow packs is that they are difficult to stack in a way that does not easily fall over in a retail setting where consumers are reaching in and out of shelves. Similar issues apply to gusseted bags and stand-up bags. As a result, it can be difficult for the retailer to present the product in a way that does not look disheveled and/or which does not require frequent attention by the retailer's staff. Furthermore, the portion most easily seen by the consumer can be narrow sides; the major surfaces of the package that provide the greatest area for graphics face toward the top of the shelf or being aligned to face away from a consumer. The reduced space for advertisements and branding can mean a lost opportunity to achieve a sale through brand recognition or a promotion advertised on the package. Likewise, the consumer must look more carefully to find his or her brand of choice on the store shelf, and may give up if the product cannot be found quickly.
• Among drawbacks faced by consumers with current packs is that the consumer faces many of the same problems regarding stackability and storage of the product on the pantry shelf that the retailer encounters with the store shelf. Other disadvantages faced by the consumer with the packs currently used for packaging include difficulty in opening the package and additional storage problems after the package is opened.
• A known process includes making containers that include pleats, which are folds in a film. Including pleats on the interior portions of a container with walls formed by a flexible film can increase strength and/or permit better display of packages than pillow packs. However, further improvements to strength and ability to display packages remain desirable, for example, to permit higher stacking of containers, to permit heavier contents to be placed in containers, and/or for larger walls capable of displaying more information.
• Improvements in flexible films, containers formed from flexible films, and processes of manufacturing that include using flexible films, in comparison to the prior art would be desirable.
• Other features and advantages of the present invention will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE INVENTION
• According to an embodiment, a container comprises a container base and a flexible film attached to the container base forming a container wall and defining a packing region within the container. The container wall has at least one tubular support column integrally formed therein.
• According to another embodiment, a manufacturing process comprises providing a web of flexible film, forming tubular support columns in the web of flexible film and forming a container from the web of flexible film containing the support columns.
• According to yet other embodiments, films, processes, and containers include that which is shown and described herein.
• Advantages that may be achieved with exemplary embodiments include providing films and containers that contain additional strength and/or rigidity, permit lower cost production of containers, permit increased visibility of graphics or other identifiable information on packaging, permit easier and quicker restocking in retail settings, permit easier and less costly transportation, and provide other advantages that will be evident from the present disclosure, or a combination thereof. Other features and advantages of the present invention will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 shows a perspective view of an embodiment of a flexible film within a film sheet having support columns for extending throughout the film sheet, according to the disclosure.
• FIG. 2 shows a perspective view of an embodiment of a flexible film having support columns, according to the disclosure.
• FIG. 3 shows a schematic view of an embodiment of a flexible film having support columns, according to the disclosure.
• FIG. 4 shows a perspective view of an embodiment of a container formed from a flexible film having support columns, according to the disclosure.
• FIGS. 5-6 show perspective views of an embodiment of a container having a handle, according to the disclosure.
• FIGS. 7-8 show perspective views of an embodiment of a container having pull-tabs, according to the disclosure.
• FIG. 9 shows a perspective view of a container cover having a bendable joint for an embodiment of a container, according to the disclosure.
• FIG. 10 shows a perspective view of a container cover having externally-protruding pull tabs for an embodiment of a container, according to the disclosure.
• FIG. 11 shows a perspective view of a container cover having a two-piece arrangement of a lower rectangular recessed portion and an upper substantially planar rectangular portion for an embodiment of a container, according to the disclosure.
• FIG. 12 shows a perspective view of a container cover having a two-piece arrangement of a lower rectangular open portion and an upper rectangular substantially planar portion for an embodiment of a container, according to the disclosure.
• FIG. 13 shows a perspective view of a container cover having a two-piece arrangement of a lower circular open portion and an upper circular substantially planar portion for an embodiment of a container, according to the disclosure.
• FIG. 14 shows a container cover having a flap for an embodiment of a container, according to the disclosure.
• FIG. 15 shows an embodiment of a container with a container base and container cover positioned horizontally relative to a flexible film, according to the disclosure.
• FIGS. 16-19 show perspective views of stacked containers, according to an embodiment of the disclosure.
• FIG. 20 pictorially depicts an embodiment of a manufacturing process, according to the disclosure.
• FIG. 21 shows a perspective view of a roll connected to a web-tensioning mechanism that leads to a web steering system for use in an embodiment of a manufacturing process, according to the disclosure.
• FIG. 22 shows a perspective view of a first web guide, a column forming mechanism, and a second web guide for use in an embodiment of a manufacturing process, according to the disclosure.
• FIG. 23 shows a perspective view of a column forming mechanism for use in an embodiment of a manufacturing process, according to the disclosure.
• FIG. 24 shows a perspective view of a web spreading mechanism for use in an embodiment of a manufacturing process, according to the disclosure.
• FIG. 25 shows a section of a flexible film sheet having a support column with a second portion and a first portion on opposite sides of a centerline through the flexible film, according to an embodiment of the disclosure.
• FIG. 26 shows a perspective view of a column flattening mechanism for use in an embodiment of a manufacturing process, according to the disclosure.
• FIG. 27 shows a perspective view of a tension maintaining device for use in an embodiment of a manufacturing process, according to the disclosure.
• FIG. 28 shows a perspective view of a device that includes a first transformation mechanism, a tube welder, a second transformation mechanism, and a cutting mechanism for use in an embodiment of a manufacturing process, according to the disclosure.
• FIG. 29 shows a perspective view of a welding system for use in an embodiment of a manufacturing process, according to the disclosure.
• FIG. 30 shows a perspective view of a rotating weld head for use in an embodiment of a manufacturing process, according to the disclosure.
• FIG. 31 shows a perspective view of an expanding corner anvil head for use in an embodiment of a manufacturing process, according to the disclosure.
• FIG. 32 shows a perspective view of a nesting system for use in an embodiment of a manufacturing process, according to the disclosure.
• FIG. 33 shows a diagrammatic view of loading of an embodiment of a container, according to the disclosure.
• FIG. 34 illustrates a partial cross-sectional view of the column forming mechanism ofFIG. 23.
• FIG. 35 illustrates a support column in accordance with another exemplary embodiment of the disclosure.
• Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.
DETAILED DESCRIPTION OF THE INVENTION
• Provided are a flexible film, a container, and a manufacturing process. Embodiments of the present disclosure, for example, in comparison to similar concepts failing to include one or more of the features disclosed herein, provide additional strength and/or rigidity, permit lower cost production of containers, permit increased visibility of graphics or other identifiable information on packaging, permit easier and quicker restocking in retail settings, permit easier and less costly transportation, provide other advantages that will be evident from the present disclosure, or a combination thereof.
• FIG. 1 shows an embodiment of aflexible film101. Theflexible film101 is shown within afilm sheet100 having a plurality of theflexible films101 adjacently arranged for the manufacturing process, prior to cutting the plurality of theflexible films101 to produce discrete arrangements of theflexible films101. Theflexible film101 permits increased strength, increased stackability, and easier display on a container401 (seeFIG. 4) including theflexible film101. As shown inFIGS. 1-4, theflexible film101 includeswall portions103 in aflexible film material105 that are separated bysupport columns107 in theflexible film material105, the support columns being formed from the same web of flexible film as the container wall and thus being formed integral therewith. While primarily shown and described with respect totubular support columns107, it will be appreciated that the invention is not so limited and that thesupport columns107 may be formed in any suitable manner, including, for example, one or more z-folds as illustrated inFIG. 35 and discussed subsequently herein.
• Theflexible film material105 is any material that is generally capable of being used for packaging, with a general preference for two side sealable films. Thecontainer401, theflexible film101, and/or thefilm sheet100 include materials that are microwaveable or are not suitable for microwaving and that contain vents for the release of pressure or do not contain vents for the release of pressure. Suitable materials include, but are not limited to, a single or multiple layer film, composite, or laminate, for example, including ethylene vinyl alcohol copolymer, polyamide, polyacrylonitrile, polyethylene terephthalate (PET), polyalkene (polyolefin), polyethylene, polypropylene, polylactic acid (PLA), cellophane, bioplastic-based film, any suitable polymer, or a combination thereof as well as metalized film, paper, or any other materials or laminates employing such materials. In one embodiment, the film comprises an oriented and/or cast polypropylene (OPP and CPP, respectively).
• Among the factors in film selection for a particular embodiment, aside from properties for containing a particular type of food, are those that impact the manufacture of the packaging, such as film stiffness. Films that are too stiff can result in large tension variations across a web of film during manufacture, as well as result in friction that can result in delamination or breakage. Theflexible films101 typically used in exemplary embodiments have a Gurley stiffness in the range of80 to140 mg (as measured using a standard Gurley-type stiffness tester). Film thickness to achieve the desired stiffness may vary depending upon the particular composition(s) of the flexible film material, but can range, by way of example, up to about 100 microns or greater.
• Any suitable number of thesupport columns107 providing desired strength is capable of being used. For example, in various embodiments of theflexible film101, three, four, five, or six of thesupport columns107 are included in theflexible film101. In one embodiment, thesupport columns107 are ultrasonically welded into form during the production of thefilm sheet100, for example, providing the increased strength for thecontainer401, permitting theflexible film101 to be self-supported, with or without rigid supports being positioned in thecontainer401 and/or theflexible film101. While one of the advantages of exemplary embodiments is the ability to provide a self-supported container without the use of rigid supports, they are not necessarily excluded and may be used in combination with thesupport columns107. Exemplary embodiments achieve a force load measurement—without relying on container contents and/or rigid supports—that is two to eight times stronger than conventional flexible packages.
• Additionally or alternatively, thesupport columns107 are formed during the production of thefilm sheet100 by adhesive, mechanical techniques, ultrasonic welding, cold seal, hot seal, or any other suitable technique of welding two or more surfaces to another. Additionally or alternatively, in one embodiment, thesupport columns107 enclose a gas (such as, air or an inert gas), for example, providing the increased strength for thecontainer401, permitting theflexible film101 to be self-supported, with or without rigid supports being positioned in thecontainer401 and/or theflexible film101.
• While primarily discussed herein as containing a gas, it will be appreciated that the invention is not so limited and that any fluid material (i.e., any flowable matter) may be contained within thesupport columns107, including a liquid, fine powder, etc. In some embodiments, for example, it may be desirable to fill one or more of thesupport columns107 itself with a food item such that the support column acts as a package within a package to separate contents within thecontainer401, such as nuts and candy or chips and dip, for example. As a result, exemplary embodiments permit a single web of flexible film to be used in making a multi-compartment container.
• To maintain tension, reduce friction, and result in a gradual narrowing of thefilm sheet100, in one embodiment, thesupport columns107 are produced in a staggered, sequential, or periodic manner. For example, in an embodiment, with four of thesupport columns107, one or two of thesupport columns107 are formed at a time. Thesupport columns107 are formed while thefilm sheet100 is static or as it moves.
• In the embodiment shown inFIG. 1, theflexible film101 includes thesupport columns107 enclosing the gas. Thesupport columns107 enclose the gas between flattenedregions109, for example, positioned along adirection111 for cutting thefilm sheet100 to discrete arrangements of theflexible film101, which are capable of being used to produce thecontainer401.FIGS. 2 and 3 show embodiments of theflexible film101 as such discrete arrangements capable of being used to produce thecontainer401. It will be appreciated that for embodiments which use one ormore support columns107 to also used as a storage area to contain a food or other item, that the support column to be filled is typically not permanently flattened during processing and at least one end is left unsealed to allow later filling. It will further be appreciated that the size of a column that is to subsequently be filled with a product to be consumed may be different (typically larger) than those used primarily to impart strength to thecontainer401.
• As shown inFIG. 2, in one embodiment, thesupport columns107 are arranged within theflexible film101, and thewall portions103 abut each side of thesupport columns107. In this embodiment, two of thewall portions103 are capable of overlapping and/or being fused together to wrap theflexible film101 in a continuous manner as is shown inFIG. 4 to form the sidewall of thecontainer401. Among the advantages of exemplary embodiments is that thesupport columns107, formed integral from the same web offilm101 used to form thecontainer wall portions103, can each be formed on the same side of the web. Thus, when wrapped and sealed to form the continuous container wall, thesupport columns107, and any associated seams and/or welds from their formation, are hidden from view within the interior of thecontainer401. As a result, an essentially continuous printable surface is provided on the exterior of thecontainer401 for presenting graphics or other text or branding without multiple visible seals or seams that could otherwise interrupt and/or make printing graphics (or aligning pre-printed graphics) more difficult, with only the single seam joining the two ends of the film visible on the exterior of thecontainer401.
• As shown inFIG. 3, thesupport columns107 have asupport column width301 that is smaller than awall portion width303 for thewall portions103 and afilm length305 for theflexible film101. Suitable values for thesupport column width301 include, but are not limited to, being less than 50 millimeters, being less than 40 millimeters, being less than 30 millimeters, being between 20 and 30 millimeters, or any suitable combination, sub-combination, range, or sub-range therein. Suitable values for thefilm length305 range include, but are not limited to being greater than 100 mm, being less than 1000 mm, being between 100 and 1000 mm, such as 200, 300, 400, 500, 600, 700, 800, or 900 mm or any suitable combination, sub-combination, range, or sub-range therein.
• Suitable values for thewall portion width303 include, but are not limited to, being greater than 50 millimeters, being less than 200 millimeters, being between 50 and 200 millimeters, such as 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, or 190 mm or any suitable combination, sub-combination, range, or sub-range therein. In one embodiment, the relative value of thewall portion width303 in comparison to thesupport column width301 is at a ratio, for example, of 10 to 1, 9 to 1, 8 to 1, 7 to 1, 6 to 1, 5 to 1, 4 to 1, 3 to 1, 2 to 1, 1 to 1, or any suitable combination, sub-combination, range, or sub-range therein.
• Suitable values for the column length307 (also generally corresponding to container height) include, but are not limited to, being greater than 50 millimeters, being less than 200 millimeters, being between 50 and 200 millimeters, such as 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, or 190 mm, or any suitable combination, sub-combination, range, or sub-range therein. In one embodiment, the relative value of thefilm length305 in comparison to thesupport column width301 is at a ratio, for example, of 10 to 1, 9 to 1, 8 to 1, 7 to 1, 6 to 1, 5 to 1, 4 to 1, 3 to 1, 2 to 1, 1 to 1, or any suitable combination, sub-combination, range, or sub-range therein.
• Referring toFIG. 4, thecontainer401 formed from theflexible film101 includes theflexible film101 affixed to acontainer base403, for example, by heat welding and/or ultrasonic welding, to define apacking region405 within thecontainer401. Thepacking region405 is any suitable geometry capable of being formed with theflexible film101 having the support columns107 (for example, incorners407 of the container401) and thewall portions103. Suitable geometries, include, but are not limited to, generally having a sectional profile of a triangle, a square, a rectangle, a pentagon, a hexagon, or any other polygon, although it will be appreciated that exemplary embodiments also include geometries with rounded sides, such as cylindrical (both round and ovular, for example). Although thecontainer401 shown inFIG. 4 includes the section profile being the square, the size of thewall portions103 and/or thesupport columns107 are capable of being varied to produce a complex-shaped embodiment of thecontainer401. Thepacking region405 is capable of being used for storing any collection of small articles such as food (for example, candy, nuts, mints, and/or pasta), spices, seeds/bulbs, or fasteners, all by way of example.
• Thecontainer base403 corresponds to the desired geometry for thecontainer401.FIG. 4 shows thecontainer base403 corresponding to embodiments of thecontainer401 generally having the sectional profile of the square. Thecontainer base403 shown is a strengthened base having a strength-enhancing design, for example, a rigid thermoplastic having a pre-determined defined shape such as those produced during cold-forming, thermoforming, or a combination thereof. In other embodiments, thecontainer base403 is a flexible film that is formed to a pre-determined defined shape, such as just mentioned with respect to rigid thermoplastics and/or which is formed into its shape as part of container manufacturing operations. Thecontainer base403 may be configured either in advance or during container manufacturing such that a surface portion of thecontainer base403 is in a parallel plane with a portion of thecontainer wall portions103 to create a sealable edge (as shown, for example, inFIG. 33).
• In one embodiment, the strength-enhancing design and/or thecontainer base403 in general decrease(s) the amount of deformation within thewall portions103 during stacking of thecontainers401. Other suitable features capable of being included in thecontainer base403 to provide strength include, but are not limited to, raisededges411 or chamfers for nesting and/or stackingcontainers401 on top of one other. In embodiments in which thecontainer base403 is itself formed of a flexible film material, that material may be of the same or a different material from that used to form the side walls of thecontainer401.
• In addition to thecontainer base403 being affixed to theflexible film101, in one embodiment, acontainer cover409 is affixed to theflexible film101 to form thecontainer401. Thecontainer cover409 is affixed to theflexible film101 by ultrasonic welding, adhesive, mechanical techniques, cold seal, hot seal, or any other suitable technique.
• Thecontainer cover409 is any suitable design meeting the desired end use, such as, but not limited to, being microwavable, having instructions for use, being sealed, being re-sealable, allowing hot gases to vent, allowing pouring, and/or having heating/cooling packs and/or insulation. For example, in one embodiment, as shown inFIG. 4, thecontainer cover409 is substantially planar and rigid. In one embodiment, as shown inFIGS. 5-6, thecontainer cover409 includes ahandle501 and ventholes601 exposed by repositioning thehandle501 in adirection603 from the orientation inFIG. 5 to the orientation inFIG. 6. In some embodiments, the vent holes601 (seeFIG. 6) may instead be formed as a plurality of small holes or other punctures in thecover409 that may be sized to allow some pressurization when the container's contents are heated (for example during microwaving of acontainer401 containing a food product), which in some embodiments is accomplished by the vent holes601 being configured to achieve a vent pressure of 0.5 psig or less.
• In another embodiment, as shown inFIGS. 7-8, thecontainer cover409 includes pull-tabs701 capable of opening and/or tearing aportion801 of thecontainer cover409 when pulled in adirection703 from the position inFIG. 7 to the position inFIG. 8. Other embodiments include, but are not limited to, the container cover409 having a bendable joint901 positioned substantially in the center of the container cover409 (seeFIG. 9), having externally-protruding pull tabs1001 that extend beyond the profile of the container cover409 upon being adjusted (seeFIG. 10), having a two-piece arrangement of a lower rectangular recessed portion1101 and an upper substantially planar rectangular portion1103 configured to be secured within the lower rectangular recessed portion1101 (seeFIG. 11), having a two-piece arrangement of a lower rectangular open portion1201 and an upper rectangular substantially planar portion1203 configured to cover an open rectangular portion1205 of the lower rectangular open portion1201 upon being secured to the lower rectangular open portion1201 (seeFIG. 12), having a two-piece arrangement of a lower open portion1301 and an upper circular substantially planar portion1303 configured to cover an open circular portion1305 of the lower open portion1301 upon being secured to the lower open portion1301 (seeFIG. 13), the container cover409 having a flap1401 or pealable portion capable of being opened upon bending at edge1403 or otherwise ripping/tearing of the container cover409 (seeFIG. 14), a feature within the container cover409 being arranged as or in conjunction with a vent, or a combination thereof.
• As will be appreciated, thecontainer base403 and/or thecontainer cover409 are capable of being arranged in any orientation with respect to theflexible film101. For example, as shown inFIG. 15, in one embodiment, thecontainer base403 and thecontainer cover409 are positioned horizontally relative to theflexible film101, with the term horizontal representing a direction perpendicular or substantially perpendicular to the direction of gravity. In a further embodiment, thecontainer cover409 includes aseal portion1501 and acover portion1503 for covering theseal portion1501, thecover portion1503 having aremovable region1505 or spout, allowing access to theseal portion1501, which is capable of being punctured to allow fluid contents to exit thecontainer401.
• Referring toFIG. 16, thecontainers401 are capable of being stacked with or without other structures, such as trays or cartons, with thecontainers401 in some embodiments being stacked in a nestable fashion, with thebase403 of onecontainer401 being nested by thecover409 of a second container on which it is stacked. In the illustrated embodiment, one ormore stacks1601 of thecontainers401 is/are positioned within atray1603, such as a corrugated and/or die cut material. In a further embodiment, thestacks1601 are positioned adjacent and withinrecesses1605 having adie cut1609 and geometry corresponding with thecontainer base403 for each of thecontainers401 positioned on the bottom of thestacks1601. Thestacks1601 are capable of including any suitable number of thecontainers401, for example, two of thecontainers401, three of thecontainers401, four of thecontainers401, or more of thecontainers401, so long as thecontainers401 positioned on the bottom of thestacks1601 are not crushed or damaged by the containers positioned above them. In one embodiment, a covering1607, such as a card hood, is capable of being positioned on thestacks1601, thereby enclosing them in conjunction with thetray1603, providing protection (for example, from debris, damage, early-display, or a combination thereof), providing a display arrangement that decreases the duration of time for replenishment, providing simpler transportation and/or storage, providing increased freshness of contents, or a combination thereof.
• Referring toFIGS. 17 through 19, in one embodiment, thestacks1601 are wrapped with acollation wrap1701 to provide structural support within thestacks1601 and/or to prevent damage to thecontainers401. Thecollation wrap1701 reduces or eliminates movement and/or damage of thecontainers401 by securing them together. Thecollation wrap1701 is capable of extending around one of thestacks1601 or a plurality of thestacks1601 and/or is capable of being wrapped with afilm wrap1703. In one embodiment, as shown inFIGS. 18 and 19, thefilm wrap1703 includes alip1801 for retaining thestacks1601 within thecollation wrap1701 inside of thefilm wrap1703. As shown inFIG. 19, in one embodiment, thelip1801 is capable of being folded to open or close anaccess region1901 for accessing thestacks1601 and/or thecontainers401.
• FIG. 20 shows an embodiment of amanufacturing process2000 for producing theflexible film101 and/or thecontainer401. Theflexible film101 is formed by forming the support columns107 (step2002) and forming the wall portions103 (step2004). Thecontainer401 is formed by attaching the container base403 (step2006) and, in a further embodiment, attaching the container cover409 (step2008).
• Referring toFIG. 21, in one embodiment, the forming of the support columns107 (step2002) includes unwinding aroll2102 connected to a web-tensioning mechanism2103 that leads to aweb steering system2105 to produce thefilm sheet100. In a further embodiment, the unwinding further includes splicing of the film sheet, for example, with an automatic splicing system. In some embodiments, a turner bar may be employed to flip the film sheet, isolating a bow wave formed in the web by column forming from the steering system. This can help overcome misalignments between unwinding of the film and the column formation, as well as helping to overcome tracking effects of column formation.
• Referring toFIG. 22, in one embodiment, the forming of the support columns107 (step2002) includes thefilm sheet100 entering afirst web guide2201, prior to thefilm sheet100 travelling to acolumn forming mechanism2203 that produces thesupport columns107 in thefilm sheet100 after exiting asecond web guide2201. In a further embodiment, thefilm sheet100 then travels through aweb spreading mechanism2205 and acolumn flattening mechanism2207, where thesupport columns107 are flattened. In one embodiment, the forming of the support columns107 (step2002) is adjustably controlled by a hitch fixedclamp2209, ahitch index2211, and ahitch moving clamp2213.
• As shown inFIG. 23, in one embodiment, thecolumn forming mechanism2203 ploughs/forms and seams/welds theflexible film material105 in thefilm sheet100 to produce thetubular support columns107 integral with the web, thereby laterally defining thewall portions103. The forming includes guiding thefilm sheet100 through thecolumn forming mechanism2203, integration and seaming by thecolumn forming mechanism2203, inflation of the support column107 (for example, with compressed air, ambient/entrained air, or another suitable inert gas to increase the structural integrity of the support column107) by thecolumn forming mechanism2203, or a combination thereof.FIG. 34 illustrates a partial cross-sectional view of thecolumn forming mechanism2203 including a ploughing tool3401, plough mandrel3407 and weld tool3403. As shown, the plough mandrel has an interior chamber that provides a gas inflation channel3405 for embodiments in which air or another gas is optionally introduced into thecolumn107 during formation.
• Thecolumn forming mechanism2203 moves relative to the web offlexible film material105 which may be accomplished either by continuous flow of the web through the mechanism or, more typically, incremental movement of the web, followed by movement of thecolumn forming mechanism2203 relative to the web while the web remains temporarily stationary.
• As shown inFIG. 24, in one embodiment, theweb spreading mechanism2205 spreads thefilm sheet100 after the column forming mechanism ploughs/forms and seams/welds theflexible film material105 in thefilm sheet100 to produce thesupport columns107. Theweb spreading mechanism2205 spreads thefilm sheet100 to align thesupport columns107 for flattening. For example, referring toFIG. 25, in one embodiment, afirst portion2501 of thesupport column107 and asecond portion2503 of thesupport column107 are aligned such that each of thefirst portion2501 and thesecond portion2503 are on opposite sides of acenterline2505 that is perpendicular, or substantially perpendicular, to thefilm sheet100. In a further embodiment, thefirst portion2501 has a first volume that is within a selected relative range of a second volume of thesecond portion2503, for example, the first volume being within 20% of the second volume, the first volume being within 10% of the second volume, the first volume being within 8% of the second volume, within 5% of the second volume, the first volume being within 3% of the second volume, being within 1% of the second volume, or any suitable combination, sub-combination, range, or sub-range therein. That is, thesupport column107 is preferably flattened evenly so that there is an equal or approximately equal amount of the material forming thesupport column107 on both sides of thecenterline2505.
• As shown inFIG. 26, in one embodiment, thecolumn flattening mechanism2207 applies pressure to one or more of thesupport columns107 in thefilm sheet100, for example, on both thefirst portion2501 and thesecond portion2503 of thesupport columns107. The pressure adjusts the geometry of at least a portion of thesupport columns107, for example, from having a circular profile to a rectangular profile. Flattening in conjunction with a lower volume variation of the first volume and the second volume provides additional strength in comparison to flattening with a higher volume variation. In one embodiment, ends of thesupport columns107 are sealed by the flattening, thereby defining a region where thesupport columns107 are capable of being cut without allowing the gas to escape from within thesupport columns107. In another embodiment, theentire support column107 is flattened, either partially or entirely, with entrained air able to escape by sealing one end of thesupport column107 followed by sealing the opposite end after flattening.
• In still another embodiment of the invention, illustrated inFIG. 35, thesupport column107 is formed as a series of overlappingfolds3503, such as one or more z-folds. In this embodiment, rather than forming a tube, the plowing and forming step includes one or more additional folds in the web to form thesupport column107. Depending on the number of folds and/or the order and direction of sealing operations, gas may or may not still be trapped within thesupport column107. In some embodiments in which thesupport column107 is a folded column, thesupport column107 is entirely flattened and then welded over its full width and/or length.
• As shown inFIG. 27, in one embodiment, the forming of the wall portions103 (step2004) includes use of atension maintaining device2701. In one embodiment, the tension maintaining device has a receivingroller2703 for receiving thefilm sheet100, adancing arm2705 positioned to receive thefilm sheet100 from the receivingroller2703 and to maintain tension of thefilm sheet100 despite adjustments in the rate of movement after thetension maintaining device2701, and aroller2707 positioned proximal to aguide roller2709, where the film sheet exits thetension maintaining device2701. The rollers are any suitable geometry capable of supporting thefilm sheet100. The rollers are triangular, square, pentagonal, hexagonal, or any other suitable geometry. In one embodiment, the rollers haveplanar portions2711 of equal or slightly smaller size than thewall portions103 andcorner portions2713 separating theplanar portions2711. In one embodiment, the rollers are designed to accommodate a change in direction of thefilm sheet100, for example, while prohibiting bending within thesupport columns107.
• As shown inFIG. 28, in one embodiment, the forming of the wall portions103 (step2004) is achieved by adevice2800 that includes a first transformation mechanism2801 (for example, to transform thefilm sheet100 from planar to round), a tube welder2803 (for example, to weld thefilm sheet100 from the round geometry into a tube), a second transformation mechanism2805 (for example, to transform thefilm sheet100 from being round to being square or another suitable geometry for the flexible film101), and acutting mechanism2807 used for cutting thefilm sheet100 into discrete units of theflexible film101 capable of being used to form thecontainer401, for example, in a circular fashion around the perimeter of theflexible film101. Cutting of the polygonal perimeter in a circular or arc like fashion results in the cutting occurring with a slicing action in contrast to stabbing or square pecking found in conventional cutting operations. In a further embodiment, the movement of thefilm sheet100 through thedevice2800 is performed by an urging force applied by atube drive2809, for example, positioned between thesecond transformation mechanism2805 and thecutting mechanism2807. In one embodiment, one or more of the components of thedevice2800 are held under vacuum to provide additional stability for thefilm sheet100 during the transformation, welding, and/or cutting.
• Forming of thecontainer401 from theflexible film101 begins with the attaching of the container base403 (step2006) or the attaching of the container cover409 (step2008) to one or more of thewall portions103 of theflexible film101, for example, using awelding system2901 as is shown inFIG. 29. An embodiment of thewelding system2901 includes a nesting system2903 (seeFIG. 32) for receiving the wall portion(s)103 and aninsertion head2905 for receiving thecontainer base403 and/or thecontainer cover409. Thenesting system2903 is a precision-machined part providing location accuracy, having avacuum plenum3201 capable of temporarily holding the wall portion(s)103 (for example, during re-referencing), and having interchangeable geometry-definingelements3203, permitting use with different sized-parts.
• Thecontainer base403 and/or thecontainer cover409 are welded to the wall portion(s)103 by any suitable technique. Suitable techniques include, but are not limited to, being ultrasonically welded and/or being heat-welded. In one embodiment, the welding begins with a tack weld to hold thecontainer base403 or thecontainer cover409 in position and is followed by a finish weld for complete attachment to be achieved. The welding is achieved by using any suitable devices, such as, rotating weld heads2907 (seeFIG. 30), an expanding corner anvil head2909 (seeFIG. 31), and/or anenergy chain tray2911. The rotating weld heads2907 have a tool geometry configured to the desired end-product, such as thecontainer401. The expandingcorner anvil head2909 is an expanding mechanism configured to stretch out theflexible film101 during the welding, for example, by being pre-heated to reduce welding times.
• Referring toFIG. 33, in one embodiment, after the positioning of thewall portions103 and the attaching of thecontainer base403 within thenesting system2903, thepacking region405 is loaded with aproduct3301 prior to the attaching of thecontainer cover409 and the completion of thecontainer401. In this embodiment, thecontainer base403 is shown as a sheet of flexible film that is pushed through what will become the top of the container and then sealed at its edges, the sheet used for the container base being wider than the space defined by thewall portions103, leaving selvedge that folds against the inner wall that forms an overlapping surface for sealing. Alternatively, thecontainer cover409 is attached prior to the loading of theproduct3301 and thecontainer base403 is attached afterward. In either case, in some embodiments in may be desirable to introduce air or another gas (such as nitrogen in the case of most food products) to fill head space over the container contents and optionally to pressurize thecontainer401.
• While the invention has been described with reference to one or more embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims (36)

What is claimed is:

1. A container, comprising:

a container base; and

a flexible film attached to the container base forming a container wall and defining a packing region within the container, the container wall having at least one support column integrally formed therein.

2. The container ofclaim 1, wherein the support column is a tubular support column.

3. The container ofclaim 1, wherein the support column comprises one or more overlapping folds.

4. The container ofclaim 1, wherein the support column is oriented perpendicular to the container base.

5. The container ofclaim 4, wherein the support column extends from a bottom of the container to a top of the container.

6. The container ofclaim 1, wherein the support column is a flattened support column.

7. The container ofclaim 1, wherein the container wall is a polygon having at least three sides.

8. The container ofclaim 7, wherein the support column is formed in a corner of the container wall.

9. The container ofclaim 8, comprising support columns in each corner of the container wall.

10. The container ofclaim 7, wherein the container wall has four wall portions and four corners.

11. The container ofclaim 1, wherein the support column encloses a fluid material, the support column being welded at opposing ends.

12. The container ofclaim 11, wherein the support column encloses a gas.

13. The container ofclaim 1, wherein the flexible film comprises a material selected from the group consisting of ethylene vinyl alcohol copolymer, polyamide, polyacrylonitrile, polyethylene terephthalate (PET), polyethylene, polypropylene, polyalkene (polyolefin), polylactic acid (PLA), cellophane, bioplastic-based film, metallized film, paper and combinations thereof.

14. The container ofclaim 11, wherein the flexible film comprises polypropylene and wherein the polypropylene is oriented polypropylene or cast polypropylene.

15. The container ofclaim 1, wherein the flexible film has a Gurley stiffness of 80 to 140 mg.

16. The container ofclaim 1, wherein the container base is a flexible film material.

17. The container ofclaim 16, wherein a portion of the flexible film container base is configured to be a plane parallel to a portion of the container wall.

18. The container ofclaim 1, further comprising a container cover attached to the container wall at an opposite end of the container as the container base.

19. The container ofclaim 18, wherein the container cover comprises a handle.

20. The container ofclaim 18, wherein the container cover comprises a spout.

21. The container ofclaim 18, wherein the container comprises a vent.

22. The container ofclaim 18, wherein the container has a pressurized interior.

23. The container ofclaim 1, wherein the container wall is cylindrical, triangular, rectangular or square.

24. A manufacturing process, comprising:

providing a web of flexible film;

forming support columns in the web of flexible film; and

forming a container from the web of flexible film containing the support columns.

25. The process ofclaim 24, wherein forming support columns further comprises forming at least two substantially parallel rows of support columns in the web of flexible film.

26. The process ofclaim 24, wherein the support columns are formed by ploughing and forming the web of flexible film.

27. The process ofclaim 24, wherein forming support columns further comprises forming tubular support columns.

28. The process ofclaim 27, further comprising enclosing a fluid material within the tubular support columns.

29. The process ofclaim 28, comprising enclosing air as the fluid material within the tubular support columns.

30. The process ofclaim 28, further comprising enclosing the fluid material by welding the support columns at opposing ends.

31. The process ofclaim 30, wherein the welding is accomplished by ultrasonic welding.

32. The process ofclaim 24, wherein forming support columns further comprises flattening the support columns against the web of flexible film.

33. The process ofclaim 24, wherein forming a container further comprises transforming the web of flexible film into a polygon to form a container wall and attaching a container base to the container wall.

34. The process ofclaim 33, wherein attaching the container base comprises welding a flexible film container base to the container wall.

35. The process ofclaim 33, further comprising attaching a container cover to the container wall an opposite end of the container wall from the container base.

36. The process ofclaim 33, wherein the transforming of the web into a polygon comprises transforming the flexible film using a vacuum plenum to temporarily hold the container wall in position during welding operations.

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