Note: Descriptions are shown in the official language in which they were submitted.
FLEXIBLE FILM CONTAINER AND MANUFACTURING METHOD
[0001] This application claims priority to and the benefit of U.S. App. No.
61/993,321 filed
May 15, 2014.
FIELD
[0002] 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
[0003] 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.
[0004] 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.
[0005] 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
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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.
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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
[0010] 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.
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[0011] 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.
[0012] According to yet other embodiments, films, processes, and containers
include that
which is shown and described herein.
[0013] 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
[0014] 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.
[0015] FIG. 2 shows a perspective view of an embodiment of a flexible film
having support
columns, according to the disclosure.
[0016] FIG. 3 shows a schematic view of an embodiment of a flexible film
having support
columns, according to the disclosure.
[0017] FIG. 4 shows a perspective view of an embodiment of a container
formed from a
flexible film having support columns, according to the disclosure.
[0018] FIGS. 5-6 show perspective views of an embodiment of a container
having a handle,
according to the disclosure.
[0019] FIGS. 7-8 show perspective views of an embodiment of a container
having pull-tabs,
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according to the disclosure.
[0020] FIG. 9 shows a perspective view of a container cover having a
bendable joint for an
embodiment of a container, according to the disclosure.
[0021] 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.
[0022] 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.
[0023] 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.
[0024] 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.
[0025] FIG. 14 shows a container cover having a flap for an embodiment of a
container,
according to the disclosure.
[0026] 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.
[0027] FIGS. 16-19 show perspective views of stacked containers, according
to an
embodiment of the disclosure.
[0028] FIG. 20 pictorially depicts an embodiment of a manufacturing
process, according to
the disclosure.
[0029] 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.
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[0030] 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.
[0031] FIG. 23 shows a perspective view of a column forming mechanism for
use in an
embodiment of a manufacturing process, according to the disclosure.
[0032] FIG. 24 shows a perspective view of a web spreading mechanism for
use in an
embodiment of a manufacturing process, according to the disclosure.
[0033] 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.
[0034] FIG. 26 shows a perspective view of a column flattening mechanism
for use in an
embodiment of a manufacturing process, according to the disclosure.
[0035] FIG. 27 shows a perspective view of a tension maintaining device for
use in an
embodiment of a manufacturing process, according to the disclosure.
[0036] 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.
[0037] FIG. 29 shows a perspective view of a welding system for use in an
embodiment of a
manufacturing process, according to the disclosure.
[0038] FIG. 30 shows a perspective view of a rotating weld head for use in
an embodiment
of a manufacturing process, according to the disclosure.
[0039] 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.
[0040] FIG. 32 shows a perspective view of a nesting system for use in an
embodiment of a
manufacturing process, according to the disclosure.
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[0041] FIG. 33 shows a diagrammatic view of loading of an embodiment of a
container,
according to the disclosure.
[0042] FIG. 34 illustrates a partial cross-sectional view of the column
forming mechanism of
FIG. 23.
[0043] FIG. 35 illustrates a support column in accordance with another
exemplary
embodiment of the disclosure.
[0044] Wherever possible, the same reference numbers will be used
throughout the drawings
to represent the same parts.
DETAILED DESCRIPTION OF THE INVENTION
[0045] 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.
[0046] FIG. 1 shows an embodiment of a flexible film 101. The flexible film
101 is shown
within a film sheet 100 having a plurality of the flexible films 101
adjacently arranged for the
manufacturing process, prior to cutting the plurality of the flexible films
101 to produce discrete
arrangements of the flexible films 101. The flexible film 101 permits
increased strength,
increased stackability, and easier display on a container 401 (see FIG. 4)
including the flexible
film 101. As shown in FIGS. 1-4, the flexible film 101 includes wall portions
103 in a flexible
film material 105 that are separated by support columns 107 in the flexible
film material 105, 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 to tubular
support columns 107, it will be appreciated that the invention is not so
limited and that the
support columns 107 may be formed in any suitable manner, including, for
example, one or more
z-folds as illustrated in FIG. 35 and discussed subsequently herein.
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[0047] The flexible film material 105 is any material that is generally
capable of being used
for packaging, with a general preference for two side sealable films. The
container 401, the
flexible film 101, and/or the film sheet 100 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).
[0048] 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. The flexible films 101 typically used in exemplary
embodiments have
a Gurley stiffness in the range of 80 to 140 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.
[0049] Any suitable number of the support columns 107 providing desired
strength is
capable of being used. For example, in various embodiments of the flexible
film 101, three, four,
five, or six of the support columns 107 are included in the flexible film 101.
In one embodiment,
the support columns 107 are ultrasonically welded into form during the
production of the film
sheet 100, for example, providing the increased strength for the container
401, permitting the
flexible film 101 to be self-supported, with or without rigid supports being
positioned in the
container 401 and/or the flexible film 101. 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 the support
columns 107. Exemplary embodiments achieve a force load measurement ¨ without
relying on
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container contents and/or rigid supports ¨ that is two to eight times stronger
than conventional
flexible packages.
[0050] Additionally or alternatively, the support columns 107 are folined
during the
production of the film sheet 100 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, the support columns 107
enclose a gas (such
as, air or an inert gas), for example, providing the increased strength for
the container 401,
permitting the flexible film 101 to be self-supported, with or without rigid
supports being
positioned in the container 401 and/or the flexible film 101.
[0051] 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 the support columns 107, including a liquid, fine powder,
etc. In some
embodiments, for example, it may be desirable to fill one or more of the
support columns 107
itself with a food item such that the support column acts as a package within
a package to
separate contents within the container 401, 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.
[0052] To maintain tension, reduce friction, and result in a gradual
narrowing of the film
sheet 100, in one embodiment, the support columns 107 are produced in a
staggered, sequential,
or periodic manner. For example, in an embodiment, with four of the support
columns 107, one
or two of the support columns 107 are formed at a time. The support columns
107 are formed
while the film sheet 100 is static or as it moves.
[0053] In the embodiment shown in FIG. 1, the flexible film 101 includes
the support
columns 107 enclosing the gas. The support columns 107 enclose the gas between
flattened
regions 109, for example, positioned along a direction 111 for cutting the
film sheet 100 to
discrete arrangements of the flexible film 101, which are capable of being
used to produce the
container 401. FIGS. 2 and 3 show embodiments of the flexible film 101 as such
discrete
arrangements capable of being used to produce the container 401. It will be
appreciated that for
embodiments which use one or more support columns 107 to also used as a
storage area to
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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
the container 401.
[0054] As shown in FIG. 2, in one embodiment, the support columns 107 are
arranged within
the flexible film 101, and the wall portions 103 abut each side of the support
columns 107. In this
embodiment, two of the wall portions 103 are capable of overlapping and/or
being fused together
to wrap the flexible film 101 in a continuous manner as is shown in FIG. 4 to
form the sidewall
of the container 401. Among the advantages of exemplary embodiments is that
the support
columns 107, formed integral from the same web of film 101 used to form the
container wall
portions 103, can each be formed on the same side of the web. Thus, when
wrapped and sealed
to form the continuous container wall, the support columns 107, and any
associated seams and/or
welds from their formation, are hidden from view within the interior of the
container 401. As a
result, an essentially continuous printable surface is provided on the
exterior of the container 401
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 the
container 401.
[0055] As shown in FIG. 3, the support columns 107 have a support column
width 301 that is
smaller than a wall portion width 303 for the wall portions 103 and a film
length 305 for the
flexible film 101. Suitable values for the support column width 301 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 the film length 305 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.
[0056] Suitable values for the wall portion width 303 include, but are not
limited to, being
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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 the wall portion width 303 in comparison to the support
column width 301 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, Ito 1, or
any suitable combination, sub-combination, range, or sub-range therein.
[0057] Suitable values for the column length 307 (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 the film length
305 in comparison to
the support column width 301 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.
[0058] Referring to FIG. 4, the container 401 formed from the flexible film
101 includes the
flexible film 101 affixed to a container base 403, for example, by heat
welding and/or ultrasonic
welding, to define a packing region 405 within the container 401. The packing
region 405 is any
suitable geometry capable of being formed with the flexible film 101 having
the support columns
107 (for example, in comers 407 of the container 401) and the wall portions
103. 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 the container 401 shown in FIG.
4 includes the
section profile being the square, the size of the wall portions 103 and/or the
support columns 107
are capable of being varied to produce a complex-shaped embodiment of the
container 401. The
packing region 405 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.
[0059] The container base 403 corresponds to the desired geometry for the
container 401.
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FIG. 4 shows the container base 403 corresponding to embodiments of the
container 401
generally having the sectional profile of the square. The container base 403
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, the container base 403 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. The container base 403 may be configured either in advance or
during container
manufacturing such that a surface portion of the container base 403 is in a
parallel plane with a
portion of the container wall portions 103 to create a sealable edge (as
shown, for example, in
FIG. 33).
[0060] In one embodiment, the strength-enhancing design and/or the
container base 403 in
general decrease(s) the amount of deformation within the wall portions 103
during stacking of
the containers 401. Other suitable features capable of being included in the
container base 403 to
provide strength include, but are not limited to, raised edges 411 or chamfers
for nesting and/or
stacking containers 401 on top of one other. In embodiments in which the
container base 403 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 the container 401.
[0061] In addition to the container base 403 being affixed to the flexible
film 101, in one
embodiment, a container cover 409 is affixed to the flexible film 101 to form
the container 401.
The container cover 409 is affixed to the flexible film 101 by ultrasonic
welding, adhesive,
mechanical techniques, cold seal, hot seal, or any other suitable technique.
[0062] The container cover 409 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 in FIG. 4, the
container cover 409
is substantially planar and rigid. In one embodiment, as shown in FIGS. 5-6,
the container cover
409 includes a handle 501 and vent holes 601 exposed by repositioning the
handle 501 in a
direction 603 from the orientation in FIG. 5 to the orientation in FIG. 6. In
some embodiments,
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the vent holes 601 (see FIG. 6) may instead be formed as a plurality of small
holes or other
punctures in the cover 409 that may be sized to allow some pressurization when
the container's
contents are heated (for example during microwaving of a container 401
containing a food
product), which in some embodiments is accomplished by the vent holes 601
being configured to
achieve a vent pressure of 0.5 psig or less.
[0063] In another embodiment, as shown in FIGS. 7-8, the container cover
409 includes pull-
tabs 701 capable of opening and/or tearing a portion 801 of the container
cover 409 when pulled
in a direction 703 from the position in FIG. 7 to the position in FIG. 8.
Other embodiments
include, but are not limited to, the container cover 409 having a bendable
joint 901 positioned
substantially in the center of the container cover 409 (see FIG. 9), having
externally-protruding
pull tabs 1001 that extend beyond the profile of the container cover 409 upon
being adjusted (see
FIG. 10), having a two-piece arrangement of a lower rectangular recessed
portion 1101 and an
upper substantially planar rectangular portion 1103 configured to be secured
within the lower
rectangular recessed portion 1101 (see FIG. 11), having a two-piece
arrangement of a lower
rectangular open portion 1201 and an upper rectangular substantially planar
portion 1203
configured to cover an open rectangular portion 1205 of the lower rectangular
open portion 1201
upon being secured to the lower rectangular open portion 1201 (see FIG. 12),
having a two-piece
arrangement of a lower open portion 1301 and an upper circular substantially
planar portion
1303 configured to cover an open circular portion 1305 of the lower open
portion 1301 upon
being secured to the lower open portion 1301 (see FIG. 13), the container
cover 409 having a
flap 1401 or pealable portion capable of being opened upon bending at edge
1403 or otherwise
ripping,/tearing of the container cover 409 (see FIG. 14), a feature within
the container cover 409
being arranged as or in conjunction with a vent, or a combination thereof
[0064] As will be appreciated, the container base 403 and/or the container
cover 409 are
capable of being arranged in any orientation with respect to the flexible film
101. For example,
as shown in FIG. 15, in one embodiment, the container base 403 and the
container cover 409 are
positioned horizontally relative to the flexible film 101, with the term
horizontal representing a
direction perpendicular or substantially perpendicular to the direction of
gravity. In a further
embodiment, the container cover 409 includes a seal portion 1501 and a cover
portion 1503 for
covering the seal portion 1501, the cover portion 1503 having a removable
region 1505 or spout,
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allowing access to the seal portion 1501, which is capable of being punctured
to allow fluid
contents to exit the container 401.
100651 Referring to FIG. 16, the containers 401 are capable of being
stacked with or without
other structures, such as trays or cartons, with the containers 401 in some
embodiments being
stacked in a nestable fashion, with the base 403 of one container 401 being
nested by the cover
409 of a second container on which it is stacked. In the illustrated
embodiment, one or more
stacks 1601 of the containers 401 is/are positioned within a tray 1603, such
as a corrugated
and/or die cut material. In a further embodiment, the stacks 1601 are
positioned adjacent and
within recesses 1605 having a die cut 1609 and geometry corresponding with the
container base
403 for each of the containers 401 positioned on the bottom of the stacks
1601. The stacks 1601
are capable of including any suitable number of the containers 401, for
example, two of the
containers 401, three of the containers 401, four of the containers 401, or
more of the containers
401, so long as the containers 401 positioned on the bottom of the stacks 1601
are not crushed or
damaged by the containers positioned above them. In one embodiment, a covering
1607, such as
a card hood, is capable of being positioned on the stacks 1601, thereby
enclosing them in
conjunction with the tray 1603, 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.
[0066] Referring to FIGS. 17 through 19, in one embodiment, the stacks 1601
are wrapped
with a collation wrap 1701 to provide structural support within the stacks
1601 and/or to prevent
damage to the containers 401. The collation wrap 1701 reduces or eliminates
movement and/or
damage of the containers 401 by securing them together. The collation wrap
1701 is capable of
extending around one of the stacks 1601 or a plurality of the stacks 1601
and/or is capable of
being wrapped with a film wrap 1703. In one embodiment, as shown in FIGS. 18
and 19, the
film wrap 1703 includes a lip 1801 for retaining the stacks 1601 within the
collation wrap 1701
inside of the film wrap 1703. As shown in FIG. 19, in one embodiment, the lip
1801 is capable
of being folded to open or close an access region 1901 for accessing the
stacks 1601 and/or the
containers 401.
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[0067] FIG. 20 shows an embodiment of a manufacturing process 2000 for
producing the
flexible film 101 and/or the container 401. The flexible film 101 is formed by
forming the
support columns 107 (step 2002) and forming the wall portions 103 (step 2004).
The container
401 is formed by attaching the container base 403 (step 2006) and, in a
further embodiment,
attaching the container cover 409 (step 2008).
[0068] Referring to FIG. 21, in one embodiment, the forming of the support
columns 107
(step 2002) includes unwinding a roll 2102 connected to a web-tensioning
mechanism 2103 that
leads to a web steering system 2105 to produce the film sheet 100. 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.
[0069] Referring to FIG. 22, in one embodiment, the forming of the support
columns 107
(step 2002) includes the film sheet 100 entering a first web guide 2201, prior
to the film sheet
100 travelling to a column forming mechanism 2203 that produces the support
columns 107 in
the film sheet 100 after exiting a second web guide 2201. In a further
embodiment, the film sheet
100 then travels through a web spreading mechanism 2205 and a column
flattening mechanism
2207, where the support columns 107 are flattened. In one embodiment, the
forming of the
support columns 107 (step 2002) is adjustably controlled by a hitch fixed
clamp 2209, a hitch
index 2211, and a hitch moving clamp 2213.
[0070] As shown in FIG. 23, in one embodiment, the column forming mechanism
2203
ploughs/forms and seams/welds the flexible film material 105 in the film sheet
100 to produce
the tubular support columns 107 integral with the web, thereby laterally
defining the wall
portions 103. The forming includes guiding the film sheet 100 through the
column forming
mechanism 2203, integration and seaming by the column forming mechanism 2203,
inflation of
the support column 107 (for example, with compressed air, ambient/entrained
air, or another
suitable inert gas to increase the structural integrity of the support column
107) by the column
forming mechanism 2203, or a combination thereof. FIG. 34 illustrates a
partial cross-sectional
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view of the column forming mechanism 2203 including a ploughing tool 3401,
plough mandrel
3407 and weld tool 3403. As shown, the plough mandrel has an interior chamber
that provides a
gas inflation channel 3405 for embodiments in which air or another gas is
optionally introduced
into the column 107 during formation.
[0071] The column forming mechanism 2203 moves relative to the web of
flexible film
material 105 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 the
column forming mechanism 2203 relative to the web while the web remains
temporarily
stationary.
[0072] As shown in FIG. 24, in one embodiment, the web spreading mechanism
2205
spreads the film sheet 100 after the column forming mechanism ploughs/forms
and seams/welds
the flexible film material 105 in the film sheet 100 to produce the support
columns 107. The web
spreading mechanism 2205 spreads the film sheet 100 to align the support
columns 107 for
flattening. For example, referring to FIG. 25, in one embodiment, a first
portion 2501 of the
support column 107 and a second portion 2503 of the support column 107 are
aligned such that
each of the first portion 2501 and the second portion 2503 are on opposite
sides of a centerline
2505 that is perpendicular, or substantially perpendicular, to the film sheet
100. In a further
embodiment, the first portion 2501 has a first volume that is within a
selected relative range of a
second volume of the second portion 2503, 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, the
support column 107 is
preferably flattened evenly so that there is an equal or approximately equal
amount of the
material forming the support column 107 on both sides of the centerline 2505.
[0073] As shown in FIG. 26, in one embodiment, the column flattening
mechanism 2207
applies pressure to one or more of the support columns 107 in the film sheet
100, for example, on
both the first portion 2501 and the second portion 2503 of the support columns
107. The pressure
adjusts the geometry of at least a portion of the support columns 107, for
example, from having a
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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 the
support columns 107
are sealed by the flattening, thereby defining a region where the support
columns 107 are capable
of being cut without allowing the gas to escape from within the support
columns 107. In another
embodiment, the entire support column 107 is flattened, either partially or
entirely, with
entrained air able to escape by sealing one end of the support column 107
followed by sealing
the opposite end after flattening.
[0074] In still another embodiment of the invention, illustrated in FIG.
35, the support
column 107 is formed as a series of overlapping folds 3503, 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 the support column 107. Depending on the
number of folds
and/or the order and direction of sealing operations, gas may or may not still
be trapped within
the support column 107. In some embodiments in which the support column 107 is
a folded
column, the support column 107 is entirely flattened and then welded over its
full width and/or
length.
[0075] As shown in FIG. 27, in one embodiment, the forming of the wall
portions 103 (step
2004) includes use of a tension maintaining device 2701. In one embodiment,
the tension
maintaining device has a receiving roller 2703 for receiving the film sheet
100, a dancing arm
2705 positioned to receive the film sheet 100 from the receiving roller 2703
and to maintain
tension of the film sheet 100 despite adjustments in the rate of movement
after the tension
maintaining device 2701, and a roller 2707 positioned proximal to a guide
roller 2709, where the
film sheet exits the tension maintaining device 2701. The rollers are any
suitable geometry
capable of supporting the film sheet 100. The rollers are triangular, square,
pentagonal,
hexagonal, or any other suitable geometry. In one embodiment, the rollers have
planar portions
2711 of equal or slightly smaller size than the wall portions 103 and corner
portions 2713
separating the planar portions 2711. In one embodiment, the rollers are
designed to
accommodate a change in direction of the film sheet 100, for example, while
prohibiting bending
within the support columns 107.
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[0076] As shown in FIG. 28, in one embodiment, the forming of the wall
portions 103 (step
2004) is achieved by a device 2800 that includes a first transformation
mechanism 2801 (for
example, to transform the film sheet 100 from planar to round), a tube welder
2803 (for example,
to weld the film sheet 100 from the round geometry into a tube), a second
transformation
mechanism 2805 (for example, to transform the film sheet 100 from being round
to being square
or another suitable geometry for the flexible film 101), and a cutting
mechanism 2807 used for
cutting the film sheet 100 into discrete units of the flexible film 101
capable of being used to
form the container 401, for example, in a circular fashion around the
perimeter of the flexible
film 101. 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 the film sheet
100 through the
device 2800 is performed by an urging force applied by a tube drive 2809, for
example,
positioned between the second transformation mechanism 2805 and the cutting
mechanism 2807.
In one embodiment, one or more of the components of the device 2800 are held
under vacuum to
provide additional stability for the film sheet 100 during the transformation,
welding, and/or
cutting.
100771 Forming of the container 401 from the flexible film 101 begins with
the attaching of
the container base 403 (step 2006) or the attaching of the container cover 409
(step 2008) to one
or more of the wall portions 103 of the flexible film 101, for example, using
a welding system
2901 as is shown in FIG. 29. An embodiment of the welding system 2901 includes
a nesting
system 2903 (see FIG. 32) for receiving the wall portion(s) 103 and an
insertion head 2905 for
receiving the container base 403 and/or the container cover 409. The nesting
system 2903 is a
precision-machined part providing location accuracy, having a vacuum plenum
3201 capable of
temporarily holding the wall portion(s) 103 (for example, during re-
referencing), and having
interchangeable geometry-defining elements 3203, permitting use with different
sized-parts.
[0078] The container base 403 and/or the container cover 409 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 the container base 403 or the container cover 409 in
position and is
followed by a finish weld for complete attachment to be achieved. The welding
is achieved by
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using any suitable devices, such as, rotating weld heads 2907 (see FIG. 30),
an expanding corner
anvil head 2909 (see FIG. 31), and/or an energy chain tray 2911. The rotating
weld heads 2907
have a tool geometry configured to the desired end-product, such as the
container 401. The
expanding corner anvil head 2909 is an expanding mechanism configured to
stretch out the
flexible film 101 during the welding, for example, by being pre-heated to
reduce welding times.
[0079] Referring to FIG. 33, in one embodiment, after the positioning of
the wall portions
103 and the attaching of the container base 403 within the nesting system
2903, the packing
region 405 is loaded with a product 3301 prior to the attaching of the
container cover 409 and the
completion of the container 401. In this embodiment, the container base 403 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 the wall
portions 103, leaving selvedge that folds against the inner wall that forms an
overlapping surface
for sealing. Alternatively, the container cover 409 is attached prior to the
loading of the product
3301 and the container base 403 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 the container
401.
[0080] 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.
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