Patent Application
20180079573
The present disclosure is directed to a flexible container with a dispensing fitment and a standup flexible container with a dispensing fitment in particular.
Flexible packaging is known to offer significant value and sustainability benefits to product manufacturers, retailers and consumers as compared to solid, molded plastic packaging containers. Flexible packaging provides many consumer conveniences and benefits, including extended shelf life, easy storage, microwavability and refillability. Flexible packaging has proven to require less energy for creation and creates fewer emissions during disposal.
Flexible packaging includes flexible containers with a gusseted body section. These gusseted flexible containers are currently produced using flexible films which are folded to form gussets and heat sealed in a perimeter shape. The gusseted body section opens to form a flexible container with a square cross section or a rectangular cross section. The gussets are terminated at the bottom of the container to form a substantially flat base, providing stability when the container is partially or wholly filled. The gussets are also terminated at the top of the container to form an open neck for receiving a rigid fitment and closure.
Conventional procedures for fabricating gusseted flexible containers with a rigid fitment have shortcomings. The fitment requires a material and a thickness strong enough to withstand the heat and compression force imparted by opposing seal bars during the sealing process. This requirement constrains the diameter of the fitment base. The fitment material must also be compatible with the container film material in order to form a heat seal weld.
Fitments with a canoe-shaped base or a base with extended radial fins oriented 180° apart, are not practical for flexible containers with more than two panels because the base geometry of these fitments does not match the geometry of containers with three, four, or more panels.
A need exists for a gusseted flexible container having an enlarged fitment base diameter. A need further exists for a gusseted flexible container having a thin-wall fitment, alone or in combination with, an enlarged fitment base diameter.
The present disclosure provides a flexible container. In an embodiment, the flexible container includes (A) four panels, each panel comprising a flexible multilayer film. The flexible multilayer film includes a polymeric material. The four panels form (i) a body and (ii) a neck. The flexible container includes (B) a fitment having a top portion and a base. The fitment is composed of a polymeric material. The base is sealed in the neck. The base has (C) a cross-sectional shape with a diameter (d), and the base has a wall thickness (WT). The base has a d/WT ratio, wherein the d/WT ratio (in mm) is from 35 to 800.
An advantage of the present disclosure is a flexible container with improved seal strength between the fitment and the flexible container panels.
An advantage of the present disclosure is a flexible container with a transparent fitment through which the material being dispensed from the flexible container can be seen.
An advantage of the present disclosure is a flexible container with a fitment made with a reduced amount of polymeric material.
An advantage of the present disclosure is a flexible container with a thin-wall fitment.
An advantage of the present disclosure is a flexible container with a flexible fitment.
An advantage of the present disclosure is a flexible container with a fitment made from a polymeric material having a low modulus.
The present disclosure provides a flexible container. In an embodiment, the flexible container includes (A) four panels. Each panel includes a flexible multilayer film. The flexible multilayer film includes a polymeric material. The four panels form (i) a body and (ii) a neck. The flexible container includes (B) a fitment. The fitment has a top portion and a base. The fitment is composed of a polymeric material. The base is sealed in the neck. The base has (C) a cross sectional shape with a diameter (d), and the base has a wall thickness (WT).
1. Flexible Container
The flexible container includes panels, each panel composed of a flexible multilayer film. The flexible container can be made from two, three, four, five, six, or more panels. In an embodiment, the flexible container 10 has a collapsed configuration (as shown in
In an embodiment, the flexible container 10 is made from four panels, as shown in
As shown in
When the flexible container 10 is in the collapsed configuration, the flexible container is in a flattened state, or in an otherwise evacuated state. The gusset panels 18, 20 fold inwardly (dotted gusset fold lines 60, 62 of
The four panels 18, 20, 22 and 24 can each be composed of a separate web of film material. The composition and structure for each web of film material can be the same or different. Alternatively, one web of film material may also be used to make all four panels and the top and bottom segments. In a further embodiment, two or more webs can be used to make each panel.
In an embodiment, four webs of film material are provided, one web of film for each respective panel 18, 20, 22, and 24. The process includes sealing edges of each film to the adjacent web of film to form peripheral seals 41 and peripheral tapered seals 40a-40d (40) (
To form the top segment 28 and the bottom segment 26, the four webs of film converge together at the respective end and are sealed together. For instance, the top segment 28 can be defined by extensions of the panels sealed together at the tapered transition section III, and the neck section IV. The top end 44 includes four top panels 28a-28d (
The neck portion can be located at a corner of the body 47, or in one of the four panels. In an embodiment, the neck 30 is positioned at a midpoint of the top segment 28. The neck 30 may (or may not) be sized smaller than a width of the body section II, such that the neck 30 can have an area that is less than a total area of the top segment 28. The location of the neck 30 can be anywhere on the top segment 28 of the container 10.
In an embodiment, the neck 30 is formed from two or more panels. In a further embodiment, the neck 30 is formed from four panels.
In an embodiment, the neck 30 is sized to accommodate a wide-mouth fitment. A “wide-mouth fitment,” is a fitment 70 having a diameter greater than 50 mm.
Although
The four panels of film that form the flexible container 10 extend from the body section II (forming body 47), to the tapered transition section III (forming tapered transition portion 48), to form a neck 30 (in the neck section IV). The four panels of film also extend from the body section II to the bottom section I (forming bottom portion 49). When the flexible container 10 is in the collapsed configuration (
As shown in
Each panel includes a respective bottom face.
The front panel bottom face 26a includes a first line A defined by the inner edge 29a of the first peripheral tapered seal 40a and a second line B defined by the inner edge 29b of the second peripheral tapered seal 40b. The first line A intersects the second line B at an apex point 35a in the bottom seal area 33. The front panel bottom face 26a has a bottom distalmost inner seal point 37a (“BDISP 37a”). The BDISP 37a is located on the inner edge.
The apex point 35a is separated from the BDISP 37a by a distance S from 0 millimeter (mm) to less than 8.0 mm.
In an embodiment, the rear panel bottom face 26c includes an apex point 35c similar to the apex point 35c on the front panel bottom face 26a. The rear panel bottom face 26c includes a first line C defined by the inner edge of the 29c first peripheral tapered seal 40c and a second line D defined by the inner edge 29d of the second peripheral tapered seal 40d. The first line C intersects the second line D at an apex point 35c in the bottom seal area 33. The rear panel bottom face 26c has a bottom distalmost inner seal point 37c (“BDISP 37c”). The BDISP 37c is located on the inner edge. The apex point 35c is separated from the BDISP 37c by a distance T from 0 millimeter (mm) to less than 8.0 mm.
It is understood the following description to the front panel bottom face 26a applies equally to the rear panel bottom face 26c, with reference numerals to the rear panel bottom face 26c shown in adjacent closed parentheses.
In an embodiment, the BDISP 37a (37c) is located where the inner edges 29a (29c) and 29b (29d) intersect. The distance S (distance T) between the BDISP 37a (37c) and the apex point 35a (35c) is 0 mm.
In an embodiment, the inner seal edge diverges from the inner edges 29a, 29b (29c, 29d), to form an inner seal arc 39a (front panel) and inner seal arc 39c (rear panel) as shown in
In an embodiment, apex point 35a (35c) is separated from the BDISP 37a (37c) by the distance S (distance T), which is from greater than 0 mm to less than 6.0 mm.
In an embodiment, the distance S (distance T) from the apex point 35a (35c) to the BDISP 37a (37c) is from greater than 0 mm, or 0.5 mm or 1.0 mm, or 2.0 mm to 4.0 mm, or 5.0 mm, or less than 5.5 mm.
In an embodiment, apex point 35a (apex point 35c) is separated from the BDISP 37a (BDISP 37c) by the distance S (distance T), which is from 3.0 mm, or 3.5 mm, or 3.9 mm to 4.0 mm, or 4.5 mm, or 5.0 mm, or 5.2 mm, or 5.3 mm, or 5.5 mm.
In an embodiment, the distal inner seal arc 39a (39c) has a radius of curvature from 0 mm, or greater than 0 mm, or 1.0 mm to 19.0 mm, or 20.0 mm.
In an embodiment, each peripheral tapered seal 40a-40d (outside edge) and an extended line from respective peripheral seal 41 (outside edge) form an angle Z, as shown in
The bottom segment 26 includes a pair of gussets 54 and 56 formed there at, which are essentially extensions of the bottom faces 26a-26d. The gussets 54 and 56 can facilitate the ability of the flexible container 10 to stand upright. These gussets 54 and 56 are formed from excess material from each bottom face 26a-26d that are joined together to form the gussets 54 and 56. The triangular portions of the gussets 54 and 56 comprise two adjacent bottom segment panels sealed together and extending into its respective gusset. For example, adjacent bottom faces 26a and 26d extend beyond the plane of their bottom surface along an intersecting edge and are sealed together to form one side of a first gusset 54. Similarly, adjacent bottom faces 26c and 26d extend beyond the plane of their bottom surface along an intersecting edge and are sealed together to form the other side of the first gusset 54. Likewise, a second gusset 56 is similarly formed from adjacent bottom faces 26a-26b and 26b-26c. The gussets 54 and 56 can contact a portion of the bottom segment 26, where the gussets 54 and 56 can contact bottom faces 26b and 26d covering them, while bottom segment panels 26a and 26c remain exposed at the bottom end 46.
As shown in
The top handle 12 and the bottom handle 14 can comprise up to four plys of film sealed together for a four panel container 10. When more than four panels are used to make the container, the handles 12, 14 can include the same number of panels used to produce the container. Any portion of the handles 12, 14 where all four plys are not completely sealed together by the heat-sealing method, can be adhered together in any appropriate manner, such as by a tack seal to form a fully-sealed multilayer handle. Alternatively, the top handle 12 can be made from as few as a single ply of film from one panel only or can be made from only two plies of film from two panels. The handles 12, 14 can have any suitable shape and generally will take the shape of the film end. For example, typically the web of film has a rectangular shape when unwound, such that its ends have a straight edge. Therefore, the handles 12, 14 would also have a rectangular shape.
Additionally, the bottom handle 14 can contain a handle opening 16 or cutout section therein sized to fit a user's hand, as can be seen in
Furthermore, a portion of the bottom handle 14 attached to the bottom segment 26 can contain a dead machine fold 42 or a score line that provides for the bottom handle 14 to consistently fold in the same direction, as illustrated in
Additionally, as the flexible container 10 is evacuated and less product remains, the bottom handle 14 can continue to provide support to help the flexible container 10 to remain standing upright unsupported and without tipping over. Because the bottom handle 14 is sealed generally along its entire length extending between the pair of gusset panels 18 and 20, it can help to keep the gussets 54 and 56 (
As seen in
A portion of the top handle 12 can extend above the neck 30 and above the top segment 28 when the top handle 12 is extended in a position perpendicular to the top segment 28 and, in particular, the entire upper handle portion 12a can be above the neck wall 50 and the top segment 28. The two pairs of legs 13 and 15 along with the upper handle portion 12a together make up the top handle 12 surrounding a handle opening that allows a user to place their hand therethrough and grasp the upper handle portion 12a of the handle 12.
As with the bottom handle 14, the top handle 12 also can have a dead machine fold 34a, 34b that permits folding in a first direction toward the front side panel 22 and restricts folding in a second direction toward the rear side panel 24, as shown in
When the container 10 is in a rest position, such as when it is standing upright on its bottom segment 26, as shown in
The material of construction of the flexible container 10 can comprise food-grade plastic. For instance, nylon, polypropylene, polyethylene such as high density polyethylene (HDPE) and/or low density polyethylene (LDPE) may be used, as discussed later. The film of the plastic container 10 can have a thickness and barrier properties that are adequate to maintain product and package integrity during manufacturing, distribution, product shelf life and customer usage. In an embodiment, the flexible multilayer film has a thickness from 100 micrometers (μm), or 200 μm, or 250 μm to 300 μm, or 350 μm, or 400 μm. In an embodiment, the film material can also be such that it provides the appropriate atmosphere within the flexible container 10 to maintain the product shelf life of at least about 180 days. Such films can comprise an oxygen barrier film, such as a film having a low oxygen transmission rate (OTR) from greater than 0 to 0.4 cc/m2/atm/24 hrs at 23° C. and 80% relative humidity (RH). Additionally, the flexible multilayer film can also comprise a water vapor barrier film, such as a film having a low water vapor transmission rate (WVTR) from greater than 0 to 15 g/m2/24 hrs at 38° C. and 90% RH. Moreover, it may be desirable to use materials of construction having oil and/or chemical resistance particularly in the seal layer, but not limited to just the seal layer. The flexible multilayer film can be either printable or compatible to receive a pressure sensitive label or other type of label for displaying of indicia on the flexible container 10. In an embodiment, the film can also be made of non-food grade resins for producing containers for materials other than food.
In an embodiment, each panel is made from a flexible multilayer film having at least one, or at least two, or at least three layers. The flexible multilayer film is resilient, flexible, deformable, and pliable. The structure and composition of the flexible multilayer film for each panel 18, 20, 22, 24 may be the same or different. For example, each of the four panels 18, 20, 22, 24 can be made from a separate web, each web having a unique structure and/or unique composition, finish, or print. Alternatively, each of the four panels 18, 20, 22, 24 can be the same structure and the same composition.
In an embodiment, each panel 18, 20, 22, 24 is a flexible multilayer film having the same structure and the same composition.
The flexible multilayer film may be (i) a coextruded multilayer structure or (ii) a laminate, or (iii) a combination of (i) and (ii). In an embodiment, the flexible multilayer film has at least three layers: a seal layer, an outer layer, and a tie layer between. The tie layer adjoins the seal layer to the outer layer. The flexible multilayer film may include one or more optional inner layers disposed between the seal layer and the outer layer.
In an embodiment, the flexible multilayer film is a coextruded film having at least two, or three, or four, or five, or six, or seven to eight, or nine, or ten, or eleven, or more layers. Some methods, for example, used to construct films are by cast co-extrusion or blown co-extrusion methods, adhesive lamination, extrusion lamination, thermal lamination, and coatings such as vapor deposition. Combinations of these methods are also possible. Film layers can comprise, in addition to the polymeric materials, additives such as stabilizers, slip additives, antiblocking additives, process aids, clarifiers, nucleators, pigments or colorants, fillers and reinforcing agents, and the like as commonly used in the packaging industry. It is particularly useful to choose additives and polymeric materials that have suitable organoleptic and/or optical properties.
In another embodiment, the flexible multilayer film can comprise a bladder, wherein two or more films that are adhered in such a manner as to allow some delamination of one or more plies to occur during a significant impact such that the inside film maintains integrity and continues to hold contents of the container.
The flexible multilayer film is composed of a polymeric material. Nonlimiting examples of suitable polymeric materials for the seal layer include olefin-based polymer (including any ethylene/C3-C10 α-olefin copolymers linear or branched), propylene-based polymer (including plastomer and elastomer, random propylene copolymer, propylene homopolymer, and propylene impact copolymer), ethylene-based polymer (including plastomer and elastomer, high density polyethylene (“HDPE”), low density polyethylene (“LDPE”), linear low density polyethylene (“LLDPE”), medium density polyethylene (“MDPE”)), ethylene-acrylic acid or ethylene-methacrylic acid and their ionomers with zinc, sodium, lithium, potassium, magnesium salts, ethylene vinyl acetate copolymers, and blends thereof.
Nonlimiting examples of suitable polymeric material for the outer layer include those used to make biaxially or monoaxially oriented films for lamination as well as coextruded films. Some nonlimiting polymeric material examples are biaxially oriented polyethylene terephthalate (OPET), monoaxially oriented nylon (MON), biaxially oriented nylon (BON), and biaxially oriented polypropylene (BOPP). Other polymeric materials useful in constructing film layers for structural benefit are polypropylenes (such as propylene homopolymer, random propylene copolymer, propylene impact copolymer, thermoplastic polypropylene (TPO) and the like), propylene-based plastomers (e.g., VERSIFY™ or VISTAMAX™)), polyamides (such as Nylon 6; Nylon 6,6; Nylon 6,66; Nylon 6,12; Nylon 12; etc.), polyethylene norbornene, cyclic olefin copolymers, polyacrylonitrile, polyesters, copolyesters (such as polyethylene terephthlate glycol-modified (PETG)), cellulose esters, polyethylene and copolymers of ethylene (e.g., LLDPE based on ethylene octene copolymer such as DOWLEX™), blends thereof; and multilayer combinations thereof.
Nonlimiting examples of suitable polymeric materials for the tie layer include functionalized ethylene-based polymers such as ethylene-vinyl acetate (EVA) copolymer, polymers with maleic anhydride-grafted to polyolefins such as any polyethylene, ethylene-copolymers, or polypropylene, and ethylene acrylate copolymers such an ethylene methyl acrylate (EMA) copolymer, glycidyl containing ethylene copolymers, propylene and ethylene based olefin block copolymers (OBC) such as INTUNE™ (PP-OBC) and INFUSE™ (PE-OBC), both available from The Dow Chemical Company, and blends thereof.
The flexible multilayer film may include additional layers which may contribute to the structural integrity or provide specific properties. The additional layers may be added by direct means or by using appropriate tie layers to the adjacent polymer layers. Polymers which may provide additional mechanical performance such as stiffness or opacity, as well polymers which may offer gas barrier properties or chemical resistance can be added to the structure.
Nonlimiting examples of suitable material for the optional barrier layer include copolymers of vinylidene chloride and methyl acrylate, methyl methacrylate or vinyl chloride (e.g., SARAN resins available from The Dow Chemical Company); vinylethylene vinyl alcohol (EVOH) copolymer; and metal foil (such as aluminum foil). Alternatively, modified polymeric films such as vapor deposited aluminum or silicon oxide on such films as BON, OPET, or oriented polypropylene (OPP), can be used to obtain barrier properties when used in laminate multilayer film.
In an embodiment, the flexible multilayer film includes a seal layer selected from LLDPE (sold under the trade name DOWLEX™ (The Dow Chemical Company)); single-site LLDPE; substantially linear, or linear ethylene alpha-olefin copolymers, including polymers sold under the trade name AFFINITY′″ or ELITE′″ (The Dow Chemical Company) for example; propylene-based plastomers or elastomers such as VERSIFY™ (The Dow Chemical Company); and blends thereof. An optional tie layer is selected from either ethylene-based olefin block copolymer PE-OBC (sold as INFUSE™) or propylene-based olefin block copolymer PP-OBC (sold as INTUNE™). The outer layer includes greater than 50 wt % of resin(s) having a melting point, Tm, that is from 25° C., to 30° C., or 40° C. higher than the melting point of the polymer in the seal layer, wherein the outer layer polymer is selected from resins such as VERSIFY™ or VISTAMAX™, ELITE™, HDPE or a propylene-based polymer such as propylene homopolymer, propylene impact copolymer or TPO.
In an embodiment, the flexible multilayer film is co-extruded.
In an embodiment, flexible multilayer film includes a seal layer selected from LLDPE (sold under the trade name DOWLEX™ (The Dow Chemical Company)); single-site LLDPE; substantially linear, or linear, olefin polymers, including polymers sold under the trade name AFFINITY™ or ELITE™ (The Dow Chemical Company) for example; propylene-based plastomers or elastomers such as VERSIFY™ (The Dow Chemical Company); and blends thereof. The flexible multilayer film also includes an outer layer that is a polyamide.
In an embodiment, the flexible multilayer film is a coextruded film and includes:
(i) a seal layer composed of an olefin-based polymer having a first melt temperature less than 105° C., (Tm1); and
(ii) an outer layer composed of a polymeric material having a second melt temperature, (Tm2),
wherein Tm2−Tm1>40° C.
The term “Tm2−Tm1” is the difference between the melt temperature of the polymer in the outer layer and the melt temperature of the polymer in the seal layer, and is also referred to as “ΔTm.” In an embodiment, the ΔTm is from 41° C., or 50° C., or 75° C., or 100° C. to 125° C., or 150° C., or 175° C., or 200° C.
In an embodiment, the flexible multilayer film is a coextruded film, the seal layer is composed of an ethylene-based polymer, such as a linear or a substantially linear polymer, or a single-site catalyzed linear or substantially linear polymer of ethylene and an alpha-olefin monomer such as 1-butene, 1-hexene or 1-octene, having a Tm from 55° C. to 115° C. and a density from 0.865 to 0.925 g/cm3, or from 0.875 to 0.910 g/cm3, or from 0.888 to 0.900 g/cm3 and the outer layer is composed of a polyamide having a Tm from 170° C. to 270° C.
In an embodiment, the flexible multilayer film is a coextruded and/or laminated film having at least five layers, the coextruded film having a seal layer composed of an ethylene-based polymer, such as a linear or substantially linear polymer, or a single-site catalyzed linear or substantially linear polymer of ethylene and an alpha-olefin comonomer such as 1-butene, 1-hexene or 1-octene, the ethylene-based polymer having a Tm from 55° C. to 115° C. and a density from 0.865 to 0.925 g/cm3, or from 0.875 to 0.910 g/cm3, or from 0.888 to 0.900 g/cm3 and an outermost layer composed of a material selected from LLDPE, OPET, OPP (oriented polypropylene), BOPP, polyamide, and combinations thereof.
In an embodiment, the flexible multilayer film is a coextruded and/or laminated film having at least seven layers. The seal layer is composed of an ethylene-based polymer, such as a linear or substantially linear polymer, or a single-site catalyzed linear or substantially linear polymer of ethylene and an alpha-olefin comonomer such as 1-butene, 1-hexene or 1-octene, the ethylene-based polymer having a Tm from 55° C. to 115° C. and density from 0.865 to 0.925 g/cm3, or from 0.875 to 0.910 g/cm3, or from 0.888 to 0.900 g/cm3. The outer layer is composed of a material selected from LLDPE, OPET, OPP (oriented polypropylene), BOPP, polyamide, and combinations thereof.
In an embodiment, the flexible multilayer film is a coextruded (or laminated) five layer film, or a coextruded (or laminated) seven layer film having at least two layers containing an ethylene-based polymer. The ethylene-based polymer may be the same or different in each layer.
In an embodiment, the flexible multilayer film includes a seal layer composed of an ethylene-based polymer, or a linear or substantially linear polymer, or a single-site catalyzed linear or substantially linear polymer of ethylene and an alpha-olefin monomer such as 1-butene, 1-hexene or 1-octene, having a heat seal initiation temperature (HSIT) from 65° C. to less than 125° C. Applicant discovered that the seal layer with an ethylene-based polymer with a HSIT from 65° C. to less than 125° C. advantageously enables the formation of secure seals and secure sealed edges around the complex perimeter of the flexible container. The ethylene-based polymer with HSIT from 65° C. to less than 125° C. is a robust sealant which also allows for better sealing to the rigid fitment which is prone to failure. The ethylene-based polymer with HSIT from 65° C. to 125° C. enables lower heat sealing pressure/temperature during container fabrication. Lower heat seal pressure/temperature results in lower stress at the fold points of the gusset, and lower stress at the union of the films in the top segment and in the bottom segment. This improves film integrity by reducing wrinkling during the container fabrication. Reducing stresses at the folds and seams improves the finished container mechanical performance. The low HSIT ethylene-based polymer seals at a temperature below what would cause the outer layer to be compromised.
In an embodiment, the flexible multilayer film is a coextruded and/or laminated five layer, or a coextruded (or laminated) seven layer film having at least one layer containing a material selected from LLDPE, OPET, OPP (oriented polypropylene), BOPP, and polyamide.
In an embodiment, the flexible multilayer film is a coextruded and/or laminated five layer, or a coextruded (or laminated) seven layer film having at least one layer containing OPET or OPP.
In an embodiment, the flexible multilayer film is a coextruded (or laminated) five layer, or a coextruded (or laminated) seven layer film having at least one layer containing polyamide.
In an embodiment, the flexible multilayer film is a seven-layer coextruded (or laminated) film with a seal layer composed of an ethylene-based polymer, or a linear or substantially linear polymer, or a single-site catalyzed linear or substantially linear polymer of ethylene and an alpha-olefin monomer such as 1-butene, 1-hexene or 1-octene, having a Tm from 90° C. to 106° C. The outer layer is a polyamide having a Tm from 170° C. to 270° C. The film has a ΔTm from 40° C. to 200° C. The film has an inner layer (first inner layer) composed of a second ethylene-based polymer, different than the ethylene-based polymer in the seal layer. The film has an inner layer (second inner layer) composed of a polyamide the same or different to the polyamide in the outer layer. The seven layer film has a thickness from 100 micrometers to 250 micrometers.
In
In an embodiment, the apex point 35a is located above the overseal 64. The apex point 35a is separated from, and does not contact the overseal 64. The BDISP 37a is located above the overseal 64. The BDISP 37a is separated from and does not contact the overseal 64.
In an embodiment, the apex point 35a is located between the BDISP 37a and the overseal 64, wherein the overseal 64 does not contact the apex point 35a and the overseal 64 does not contact the BDISP 37a.
The distance between the apex point 35a to the top edge of the overseal 64 is defined as distance W, shown in
When more than four webs are used to produce the container, the portion 68 of the overseal 64 may be a 4-ply, or a 6-ply, or an 8-ply portion.
In an embodiment, the flexible container 10 has a vertical drop test pass rate from 90%, or 95% to 100%. The vertical drop test is conducted as follows. The container is filled with tap water to its nominal capacity, conditioned at 25° C. for at least 3 hours, held in upright position from its top handle 12 at 1.5 m height (from the base or side of the container to the ground), and released to a free fall drop onto a concrete slab floor. If any leak is detected immediately after the drop, the test is recorded as a failure. A minimum of twenty flexible containers are tested. A percentage for pass/fail containers is then calculated.
In an embodiment, the flexible container 10 has a side drop pass rate from 90%, or 95% to 100%. This side drop test is conducted as follows. The container is filled with tap water to its nominal capacity, conditioned at 25° C. for at least 3 hours, held in upright position from its top handle 12. The flexible container is released on its side from a 1.5 m height to a free fall drop onto a concrete slab floor. If any leak is detected immediately after the drop, the test is recorded as failure. A minimum of twenty flexible containers are tested. A percentage for pass/fail containers is then calculated.
In an embodiment, the flexible container 10 passes the stand-up test where the package is filled with water at ambient temperature and placed on a flat surface for seven days and it should remain in the same position, with unaltered shape or position.
In an embodiment, the flexible container 10 has a volume from 0.050 liters (L), or 0.1 L, or 0.15 L, or 0.2 L, or 0.25 L, or 0.5 L, or 0.75 L, or 1.0 L, or 1.5 L, or 2.5 L, or 3 L, or 3.5 L, or 4.0 L, or 4.5 L, or 5.0 L to 6.0 L, or 7.0 L, or 8.0 L, or 9.0 L, or 10.0 L, or 20 L, or 30 L.
The flexible container 10 can be used to store any number of flowable substances therein. In particular, a flowable food product can be stored within the flexible container 10. In one aspect, flowable food products such as salad dressings; sauces; dairy products; mayonnaise; mustard; ketchup; other condiments; syrup; beverages such as water, juice, milk, carbonated beverages, beer, or wine; animal feed; pet feed; and the like can be stored inside of the flexible container 10.
The flexible container 10 is suitable for storage of other flowable substances including, but not limited to, oil, paint, grease, chemicals, suspensions of solids in liquid, and solid particulate matter (powders, grains, granular solids).
The flexible container 10 is suitable for storage of flowable substances with higher viscosity and requiring application of a squeezing force to the container in order to discharge. Nonlimiting examples of such squeezable and flowable substances include grease, butter, margarine, soap, shampoo, animal feed, sauces, and baby food.
2. Fitment
The present flexible container includes a fitment 70 inserted into the neck 30 of the flexible container 10. The fitment 70 includes a base 72 and a top portion 74, as shown in
The top portion 74 may include threads 75 or other suitable structure for attachment to a closure. Nonlimiting examples of suitable fitments and closures, include, screw cap, flip-top cap, snap cap, liquid or beverage dispensing fitments (stop-cock or thumb plunger), Colder fitment connector, tamper evident pour spout, vertical twist cap, horizontal twist cap, aseptic cap, vitop press, press tap, push on tap, lever cap, conro fitment connector, and other types of removable (and optionally reclosable) closures. The closure and/or fitment 70 may or may not include a gasket. In an embodiment, the closure is watertight. In a further embodiment, the closure provides a hermetic seal to the container 10.
The base 72 has a cross sectional shape. The cross sectional shape of the base 72 is selected from ellipse, circle, and regular polygon.
In an embodiment, the cross-sectional shape of the base 72 is an ellipse. An “ellipse,” as used herein, is a plane curve such that the sums of the distances of each point in its periphery from two fixed points, the foci, are equal. The ellipse has a center which is the midpoint of the line segment linking the two foci. The ellipse has a major axis (the longest diameter through the center). The minor axis is the shortest line through the center. The ellipse center is the intersection of the major axis and the minor axis. As used herein, the diameter (d) for the ellipse is the major axis.
In an embodiment, the cross-sectional shape is slightly elliptical where the ratio of major axis to minor axis is between 1.01 to 1.25.
In an embodiment, the cross-sectional shape for the base 72 is a circle (or is substantially a circle). A “circle,” as used herein, is a closed plane curve consisting of all points at a given distance from a point within it called the center. The radius (r) for the circle is the distance from the center of the circle to any point on the circle. The diameter (d) for the circle is 2r.
In an embodiment, the cross sectional shape for the base is a regular polygon. A “polygon,” as used herein, is a closed plane figure, having three or more straight sides. The point where two sides meet is a “vertex.” A “regular polygon,” as used herein, is a polygon that is equiangular (all angles are equal in measure) and equilateral (all sides have the same length.
The radius (r) for a regular polygon is defined by Formula (1) below.
The diameter (d) for a regular polygon is 2(r) wherein the radius, r, for the regular polygon is determined by way of Formula (1). Nonlimiting examples of suitable regular polygon shapes for the cross-section of the base 72 include equilateral triangular, regular square, regular pentagon, regular hexagon, regular heptagon, regular octagon, regular nonagon, regular decagon, regular hendecagon, or regular dodecagon shape.
The cross-sectional shape of the top portion 74 may be the same or different than the cross-sectional shape of the base 72.
The cross-sectional shape of the base 72 may be circular, slightly elliptical, or regular polygonal. In an embodiment, the cross-sectional shape of the base 72 is circular, or substantially circular, as shown in
The base 72 with a circular or regular polygon cross-sectional shape is distinct from fitments with a canoe-shaped fitment base or fitments with a base having opposing radial fins. In an embodiment, the fitment 70 excludes fitments that include a canoe-shaped base, fitments with a base that has radial fins, fitments with a wing-shaped base, and fitments with an eye-shaped base.
The outer surface of the base 72 may or may not include surface texture. In an embodiment, the outer surface of the base 72 has surface texture. Nonlimiting examples of surface texture include embossment, and a plurality of radial ridges to promote sealing to the inner surface of the neck wall 50.
In an embodiment, the outer surface of base 72 is smooth and does not include surface texture, as shown in
In an embodiment, the diameter of the base 72 is greater than the diameter of the top portion 74.
The base 72 is welded, or is otherwise heat sealed to the multilayer film that forms the neck 30. In other words, the base 72 is welded to the neck 30. Heat sealing can be made by means of hot bar, impulse seal, ultrasonic or in some cases by high frequency (HF) sealing.
In an embodiment, the base 72 is welded to the neck 30 by way of a mandrel with an expandable collar as disclosed in co-pending case, U.S. Ser. No. 62/146,002, filed on 10 Apr. 2015, the entire content of which is incorporated by reference herein.
The fitment 70 is made from a polymeric material. Nonlimiting examples of suitable polymeric materials include propylene-based polymer, ethylene-based polymer, polyamides (such as Nylon 6; Nylon 6,6; Nylon 6,66; Nylon 6,12; Nylon 12; and the like), cyclic olefin copolymers (COC)(such as TOPAS™ or APEL™), polyesters (crystalline and amorphous), copolyester resin (such as PETG), cellulose esters (such as polylactic acid (PLA)), and combinations thereof.
In an embodiment, the fitment 70 is composed of, or is otherwise formed from, a propylene-based polymer. Nonlimiting examples of suitable propylene-based polymer include propylene homopolymer (hPP), impact copolymer polypropylene (ICP), random copolymer polypropylene (rPPO), propylene-based interpolymer both plastomers or elastomers such as VERSIFY™ (The Dow Chemical Company), syndiotactic polypropylene (sPP), metallocene polypropylene (mPP), thermoplastic polyolefin (TPO), and combinations thereof.
In an embodiment, the fitment 70 is composed of, or is otherwise formed from, a blend of one or more propylene-based polymers, and a modifier containing a block composite. A “block composite,” as used herein, is a block copolymer having from 70-99 wt % of ethylene/propylene (EP) soft blocks (with 65 wt % of ethylene, based on the total weight of the EP block) and from 30-1 wt % of isotactic polypropylene (iPP) hard blocks that is twin-screw compounded with the olefin modifier resin composition prior to blending with the propylene-based polymer. Suitable processes useful in producing the block composites may be found in, U.S. Pat. Nos. 8,053,529, 8,686,087, and 8,716,400. The blend can contain greater than 0 wt % to 40 wt % block composite. In a further embodiment, the blend includes 80 wt % of Pro-fax RP448S rPP (available from LyondellBasell) and 20 wt % of the modifier. The compounded modifier includes 30 wt % block composite (The Dow Chemical Company), 50 wt % AFFINITY™ GA 1950 (available from The Dow Chemical Company) and 20 wt % ENGAGE™ 8402 (available from The Dow Chemical Company). The blend has a transparency of 99%, a haze of 11% at (0.75 mm) and an Izod Impact Strength @−20° C. of 9 kJ/m2, measured according to ASTM D256 on 0.75 mm×76 mm×76 mm injection molded plaques.
In an embodiment, the fitment 70 is composed of, or is otherwise formed from, an ethylene-based polymer. Nonlimiting examples of suitable ethylene-based polymer include high density polyethylene (“HDPE”), medium density polyethylene (“MDPE”), low density polyethylene (“LDPE”), linear low density polyethylene (“LLDPE”), ultra low density polyethylene (“ULDPE”), very low density polyethylene (“VLDPE”), single-site LLDPE, substantially linear, or linear ethylene alpha-olefin copolymers, including polymers sold under the trade name ENGAGE™ elastomers, AFFINITY™ plastomers or ELITE′″ Enhanced Polyethylene resins (“EPE”) (all available from The Dow Chemical Company) for example, ethylene-alpha-olefin multi-block copolymer sold as INFUSE™ Olefin Block Copolymers (available from The Dow Chemical Company), copolymers of polyethylene such as ethylene-vinyl acetate (“EVA”) polymer, ethylene ethyl acrylate (“EEA”) polymer or ethylene methyl acrylate (“EMA”) polymer and combinations thereof.
In an embodiment, the fitment 70 is formed from an ethylene-based polymer having a 2% secant flexural modulus (ASTM D790) of less than 200 megapascal (MPa), or a 2% secant flexural modulus from 10 MPa, or 25 MPa, or 50 MPa, or 75 MPa, or 100 MPa to 125 MPa, or 150 MPa, or 175 MPa, or 200 MPa. A nonlimiting example of an ethylene-based polymer with a 2% secant flexural modulus from 10 MPa to 200 MPa is ethylene/alpha-olefin multi-block copolymer sold under the tradename INFUSE™ (available from the Dow Chemical Company) such as INFUSE™ 9817.
In an embodiment, the fitment 70 is composed of, or is otherwise formed from, a blend of one or more propylene-based polymers, alone, or in combination with one or more ethylene-based polymers. Nonlimiting examples of such blends include propylene-based polymer such as hPP or rPP or propylene based interpolymer (VERSIFY™) that is blended with from 5 wt % to 30 wt % of ethylene based plastomers or elastomers such as AFFINITY™ 1280, AFFINITY™ GA1950, ENGAGE™ 8100, ENGAGE™ 8200, ENGAGE™ 8401, ENGAGE™ 8402 ENGAGE™ 8411, ENGAGE™ XLT 8677, INFUSE™ 9817 olefin block copolymer resin, VERSIFY™ 2400, VERSIFY™ 3401 or VERSIFY™ 4301, and combinations thereof.
In an embodiment, the fitment 70 is formed from a compounded blend containing 80 wt % of R751-12N rPP (available from Braskem) and 20 wt % ENGAGE™ 8411 (available from The Dow Chemical Company) with a transparency of 99.2+/−0.2%, a haze of 6.9+/−0.4% at 0.5 mm and a Gardner Impact @−29° C. of 3.0+/−0.7 J, measured in accordance with ASTM D5420GC at −29° C. using standard ring in method with a 1.8 kg hammer on plaques with the following dimensions: 0.5 mm×60 mm×60 mm.
In an embodiment, the fitment 70 is composed of, or is otherwise formed from, a polyamide. Nonlimiting examples of suitable polyamide include Nylon 6; Nylon 6,6; Nylon 6,66; Nylon 6,12; Nylon 12 and the like.
In an embodiment, the fitment 70 is composed of, or is otherwise formed from, a copolyester. As used herein, the term “copolyester” is a polymer that contains repeating units of two or more different polyester monomers. Nonlimiting examples of suitable copolyesters include copolyesters formed from aromatic dicarboxylic acids, esters of dicarboxylic acids, anhydrides of dicarboxylic esters, glycols, and mixtures thereof. Suitable partially aromatic copolyesters are formed from repeat units comprising terephthalic acid, dimethyl terephthalate, isophthalic acid, dimethyl isophthalate, dimethyl-2,6 naphthalenedicarboxylate, 2,6-naphthalenedicarboxylic acid, 1,2-, 1,3- and 1,4 phenylene dioxydoacetic acid, ethylene glycol, diethylene glycol, 1,4-cyclohexane-dimethanol, 1,4-butanediol, and neopentyl glycol mixtures thereof.
In an embodiment, the fitment 70 is composed of, or is otherwise formed from, a cycle olefin copolymer. Nonlimiting examples of suitable COC's include “COC”, such as TOPAS™ or APEL™
In an embodiment, the copolyester includes polymerization units derived from terephthalic acid (TPA) and, optionally polymerization units derived from cyclohexanedimethanol (CHDM), and ethylene glycol (EG), and the copolyester includes greater than 50 mol % glycol polymerization units (such as PETG) or wherein the copolymer includes greater than 50 percent by mole of CHDM, such as glycol-modified polycyclohexylenemethylene terephthalate, PCTG.
In an embodiment, the copolyester includes terephthalic acid, Spiro glycol, and ethylene glycol known as SPG-PET available from Mitsubishi. Alternatively, copolyesters can include polymerization units derived from terephthalic acid, cyclohexanedimethanol (CHDM) and isophthalic acid (IPA) such as used to produce PCTA resins.
In an embodiment, the copolyester is polyethylene terephthlate glycol-modified (PETG) such as Eastman's Eastar™ copolyester 6763 with a haze of 0.8% or a branched PETG such as Provista™ copolymer MP002 with 1.3% haze and notched izod at −40° C. of 0.63 J/cm, as determined by ASTM D256.
In an embodiment, the copolyester is a PCTG such as Eastman's Eastar™ copolyester DN010, with 1.4% haze and notched izod at −40° C. of 0.77 J/cm, as determined by ASTM D4812
In an embodiment, the copolyester is a PCTA including DuraStar™ polymer DS2010 (available from Eastman) having haze of 0.3% and notched izod at −40° C. of 0.6 J/cm, as determined by ASTM D256.
In an embodiment, the copolyester is impact modified with from 5 wt % to 30 wt % of one or more of the following nonlimiting modifiers: styrene-ethylene/butylene-styrene block copolymers (SEBS) which have been functionalized with maleic anhydride (such as KRATON® FG 1901X supplied by the Shell Chemical Co.), ethylene methacrylic acid copolymers (such as SURLYN® ionomer resins supplied by DuPont Polymer Products like SURLYN® 1601-2 ionomer resin), and butadiene/acrylic monomer shell core polymers (such as Paraloid® compositions based on butyl acrylate or methyl acrylate supplied by The Dow Chemical Company like Paraloid® EXL-3361).
In an embodiment, copolyester has an intrinsic viscosity (IV) from 0.5 deca-liters per gram (dl/g), or 0.6 dl/g, or 0.7 dl/g to 0.80 dl/g, or 0.85 dl/g, or 0.90 dl/g, or 1.1 dl/g. The copolyester IV is determined on a 0.5 gram sample in 100 ml of a by weight solution of 60/40 phenol/tetrachloroethane at 25° C., as taught in U.S. Patent Publication 2003/0141625.
The polymeric material used to make the fitment 70 can include additives such as stabilizers (such as hindered phenol or phosphites or blends therein), slip additives (such as erucamide or polymethyl siloxane), antiblocking additives (such as synthetic silica), process aids, clarifiers, nucleators, crack stopping agents, pigments or colorants, fillers and reinforcing agents, and the like as commonly used in the packaging industry. It is particularly useful to choose additives and polymeric materials that have suitable organoleptic properties and can impart benefit optical properties to the fitment.
In an embodiment, the fitment 70 is formed from any of the foregoing polymeric materials, the polymeric material having one, some, or all of the following properties:
a 2% secant flexural modulus (ASTM D790) from 10 MPa, or 25 MPa, or 50 MPa, or 75 MPa, or 100 MPa to 125 MPa, or 150 MPa, or 175 MPa, or 200 MPa;
a clarity from 80%, or 83%, or 85%, or 87%, or 89% to 90%, or 92%, or 94%, or 96%, or 98%, or 99%, or 99.5%; and
a haze from 0.3%, or 0.5%, or 1.0%, or 3.0%, or 5.0%, or 7.0%, or 9.0%, or 10%, or 11% to 13%, or 15%, or 17%, or 19%, or 20%.
In an embodiment, the fitment 70 is composed of a resin sold under the tradename ELITE™ Enhanced Polyethylene resin, such as ELITE™ 5230G (available from The Dow Chemical Company).
In an embodiment, the fitment 70 includes a polymeric composition having an Izod impact resistance from greater than 50 Joules (J)/meter (m), or 100 J/m, or 150 J/m, or 200 J/m, or 250 J/m to 300 J/m, or 350 J/m, or 400 J/m, or 450 J/m, or 500 J/m. Izod impact resistance is measured in accordance with ASTM D 256. In a further embodiment, the fitment includes a polyolefin having an Izod impact resistance from greater than 50 J/m, or 100 J/m, or 150 J/m, or 200 J/m, or 250 J/m to 300 J/m, or 350 J/m, or 400 J/m, or 450 J/m, or 500 J/m.
In an embodiment, the fitment 70 includes a polymeric composition containing a polyolefin with a melt temperature (Tm) greater than or equal to the melt temperature of the polyolefin present in the seal layer of the multilayer film used to make the panels 18, 20, 22, 24. When clamp heat sealing is utilized to form the seal between the base 72 and the neck 30, a nonlimiting example includes a fitment 70 composed of a HDPE having a Tm of 125° C. and the seal layer for the container 10 contains an LDPE with a Tm of 105° C. Another nonlimiting example is a fitment 70 composed of LLDPE with Tm of 120° C., and the container 10 has a seal layer containing an ethylene/α-olefin copolymer (AFFINITY™ PL 1140G) with a Tm 96° C.
In an embodiment, the flexible container 10 includes a hermetic seal between the neck 30 and the base 72.
In an embodiment, the polymeric material for the fitment 70 has a haze as determined by ASTM D1003 (method B) at 0.5 mm thickness from 0.3%, or 0.5%, or 1.0%, or 3.0%, or 5.0%, or 7.0%, or 9.0%, or 10%, or 11% to 13%, or 15%, or 17%, or 19%, or 20% and also has high clarity where the clarity is determined by ASTM D1746 and clarity is from 80%, or 83%, or 85%, or 87%, or 89% to 90%, or 92%, or 94%, or 96%, or 98%, or 99%, or 99.5%.
In a further embodiment, the fitment 70 is made from a copolyester resin having a haze from 0.3% to 4% and a clarity from 80% to 90%.
In an embodiment, the base 72 has a diameter (d) and a wall thickness (WT) as shown in
In an embodiment, the diameter of the base 72 is uniform along the base length and the wall thickness (WT) is uniform along the base length.
In an embodiment, the base 72 has a diameter (d) from 5 mm, or 10 mm or 20 mm, or 25 mm, or 30 mm, or 35 mm, or 38 mm, or 40 mm, or 45 mm, or 47 mm, or 50 mm, or 60 mm, or 70 mm, or 80 mm, or 90 mm to 100 mm, or 110 mm, or 125 mm, or 150 mm, or 175 mm, or 200 mm.
In an embodiment, the base 72 has a wall thickness (WT) from 0.15 mm, or 0.2 mm, or 0.3 mm, or 0.4 mm, or 0.5 mm, or 0.6 mm, or 0.7 mm, or 0.75 mm, or 0.8 mm, or 0.9 mm, or 1.0 mm to 1.3 mm, or 1.5 mm, or 1.7 mm, or 1.9 mm, or 2.0 mm.
In an embodiment, the base 72 has a wall thickness (WT) from 0.15 mm, or 0.2 mm, or 0.3 mm, or 0.4 mm to 0.5 mm, or 0.6 mm, or 0.7 mm, or 0.75 mm. As used herein, a base wall thickness (WT) with the foregoing wall thickness from 0.15 mm to 0.75 mm is a “thin-wall.”
The base 72 has a diameter to wall thickness ratio. The “diameter to wall thickness ratio” (denoted as “d/WT”) is the diameter (d) of the base 72 (in millimeters, mm) divided by the wall thickness (WT), in mm, of the base 72. In an embodiment, the base 72 has a d/WT from 5, or 8, or 10, or 20, or 30, or 40, or 50, or 60, or 70, or 80, or 90, or 100, or 125, or 150, or 175, or 200 to 500, or 525, or 550, or 575, or 600, or 625, or 650, or 675, or 700, or 725, or 750, or 775, or 800, or 825, or 850, or 875, or 900, or 925, or 950, or 975, or 1000, or 1100, or 1200, or 1300, or 1400, or 1500, or 1600, or 1700, or 1800, or 1900, or 2000.
In an embodiment, the base 72 has a d/WT from 35, or 40, or 50, or 60, or 70, or 80, or 90, or 100, or 125, or 150, or 175 to 200, or 225, or 250, or 275, or 300, or 325, or 350, or 375, or 400, or 425, or 450, or 475, or 500, or 525, or 550 or 600, or 650, or 700, or 750, or 800.
In an embodiment, the base 72 has a d/WT ratio from 35 to 800, the diameter (d) is from 10 mm, or 20 mm, or 30 mm, or 35 mm, or 38 mm, or 40 mm, or 45 mm, or 47 mm, or 50 mm to 60 mm, or 70 mm, or 80 mm, or 90 mm, or 100 mm, or 110 mm, or 120 mm; and the wall thickness (WT) is from 0.15 mm, or 0.2 mm, or 0.3 mm, or 0.4 mm to 0.5 mm, or 0.6 mm, or 0.7 mm, or 0.75 mm. Thus, the base 72 has a thin-wall structure.
In an embodiment, the base 72 has a d/WT ratio from 35 to 800 as disclosed above. The diameter (d) for the base 72 is from 47 mm to 120 mm. The wall thickness (WT) for the base 72 is from 0.15 mm to 0.75 mm. Thus, the base 72 has a thin-wall structure.
In an embodiment, the base 72 has a d/WT ratio from 50 to 550 as disclosed above. The diameter (d) for the base 72 is from 10 mm to 110 mm. The wall thickness (WT) for the base 72 is from 0.2 mm to 0.5 mm. Thus, the base 72 has a thin-wall structure.
The fitment with a d/WT from 35 to 800 can include a base with a thin-wall structure. Thin-wall fitments advantageously reduce production costs, reduce material cost, and reduce the weight of the final flexible container 10.
The present flexible container may comprise two or more embodiments disclosed herein.
The numerical ranges disclosed herein include all values from, and including, the lower value and the upper value. For ranges containing explicit values (e.g., 1, or 2, or 3 to 5, or 6, or 7) any subrange between any two explicit values is included (e.g., 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.).
Unless stated to the contrary, implicit from the context, or customary in the art, all parts and percents are based on weight, and all test methods are current as of the filing date of this disclosure.
Clarity is measured in accordance with ASTM-D1746.
The term “composition,” as used herein, refers to a mixture of materials which comprise the composition, as well as reaction products and decomposition products formed from the materials of the composition.
The terms “comprising,” “including,” “having,” and their derivatives, are not intended to exclude the presence of any additional component, step or procedure, whether or not the same is specifically disclosed. In order to avoid any doubt, all compositions claimed through use of the term “comprising” may include any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless stated to the contrary. In contrast, the term, “consisting essentially of” excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability. The term “consisting of” excludes any component, step or procedure not specifically delineated or listed.
Density is measured in accordance with ASTM D 792.
An “ethylene-based polymer,” as used herein is a polymer that contains more than 50 mole percent polymerized ethylene monomer (based on the total amount of polymerizable monomers) and, optionally, may contain at least one comonomer.
Haze is measured in accordance with ASTM D1003 (method B) and noting the thickness of the part.
The term “heat seal initiation temperature,” is minimum sealing temperature required to form a seal of significant strength, in this case, 2 lb/in (8.8N/25.4 mm). The seal is performed in a Topwave HT tester with 0.5 seconds dwell time at 2.7 bar (40 psi) seal bar pressure. The sealed specimen is tested in an Instron Tensiomer at 10 in/min (4.2 mm/sec or 250 mm/min).
Melt flow rate (MFR) is measured I accordance with ASTM D 1238, Condition 280° C./2.16 kg (g/10 minutes).
Melt index (MI) is measured in accordance with ASTM D 1238, Condition 190° C./2.16 kg (g/10 minutes).
Tm or “melting point” as used herein (also referred to as a melting peak in reference to the shape of the plotted DSC curve) is typically measured by the DSC (Differential Scanning calorimetry) technique for measuring the melting points or peaks of polyolefins as described in U.S. Pat. No. 5,783,638. It should be noted that many blends comprising two or more polyolefins will have more than one melting point or peak, many individual polyolefins will comprise only one melting point or peak.
An “olefin-based polymer,” as used herein is a polymer that contains more than 50 mole percent polymerized olefin monomer (based on total amount of polymerizable monomers), and optionally, may contain at least one comonomer. Nonlimiting examples of olefin-based polymer include ethylene-based polymer and propylene-based polymer.
A “polymer” is a compound prepared by polymerizing monomers, whether of the same or a different type, that in polymerized form provide the multiple and/or repeating “units” or “mer units” that make up a polymer. The generic term polymer thus embraces the term homopolymer, usually employed to refer to polymers prepared from only one type of monomer, and the term copolymer, usually employed to refer to polymers prepared from at least two types of monomers. It also embraces all forms of copolymer, e.g., random, block, etc. The terms “ethylene/α-olefin polymer” and “propylene/α-olefin polymer” are indicative of copolymer as described above prepared from polymerizing ethylene or propylene respectively and one or more additional, polymerizable α-olefin monomer. It is noted that although a polymer is often referred to as being “made of” one or more specified monomers, “based on” a specified monomer or monomer type, “containing” a specified monomer content, or the like, in this context the term “monomer” is understood to be referring to the polymerized remnant of the specified monomer and not to the unpolymerized species. In general, polymers herein are referred to has being based on “units” that are the polymerized form of a corresponding monomer.
A “propylene-based polymer” is a polymer that contains more than 50 mole percent polymerized propylene monomer (based on the total amount of polymerizable monomers) and, optionally, may contain at least one comonomer.
Some embodiments of the present disclosure will now be described in detail in the following Examples.
1. Production of Flexible Container (No Fitment)
Four panel flexible containers having a neck and a body as shown in
Four panels made from the flexible multilayer film in Table 1 are heat sealed together under the heat seal conditions provided in Table 2 (below) to produce flexible containers. The flexible containers are fabricated by KRW Machinery Inc (Weaverville, N.C.). All heat seals in the flexible containers are made with one strike.
2. Fitment Sealed to Neck Using Expandable Mandrel
Fitments with different base diameters and different base wall thicknesses are inserted into the neck for respective flexible containers. The fitments are made from the same high density polyethylene (HDPE). The dimensions and surface texture of the base for each fitment are provided in Table 3 below.
The fitments are washed thoroughly in denatured alcohol and allowed to dry to prepare surfaces prior to heat sealing to the neck of the flexible container.
Two mandrels are used to heat seal fitments to the flexible containers. A 38 mm diameter mandrel is used for the 3.875 L flexible containers. A 110 mm diameter mandrel is used for the 20 L flexible containers. Each mandrel includes an expandable collar. Each expandable collar is made of Shore A 30+/−5 durometer FDA approved silicone rubber. Applicant discovered that silicone rubber is advantageous because of its heat stability, softness and durability.
Properties for the expandable collars are provided in Table 4 below.
For the 3.875 L flexible containers, opposing seal bars each with a length of 41 mm are used. The seal width for each opposing seal bar is 10.2 mm. The seal bar area for each 41 mm seal bar is 0.0004907 m2.
For the 20 L flexible containers, opposing seals bars each with a length of 110 mm are used. The seal width for each opposing seal bar is 15.2 mm. The seal bar area for each of the 110 mm seal bars is 0.00179 m2.
The base of the fitment is heat sealed to the neck of the flexible container using a mandrel with an expandable collar as set forth in copending case, U.S. Ser. No. 62/146,002, filed on 10 Apr. 2015, the entire contents of which are incorporated by reference herein. The heat seal conditions for the fitment seal are provided in Table 5 below. Table 5 also provides fitment seal integrity data—(i) burst test data and (ii) hang test data for the fitment seal. In Table 5, “E” denotes inventive example, “CE” denotes comparative sample, and “NS” denotes not sampled.
3. Tests
Burst Test Procedure
Process:
Gravity Hang Test Procedure
Process:
Applicant discovered that utilization of the mandrel with expandable collar during the fitment heat seal procedure advantageously enables the use of fitment base having thin-wall structure. Thin-wall or thin-walling is the reduction of the wall thickness for the fitment base. Examples E2, E4, E5, E6, and E7, show that fitments with d/WT ratio from 35, or 54.7 (thin-wall), or 86.7 to 220 (thin-wall), or 550 (thin-wall) (i) can be successfully heat sealed to the neck of the flexible container, (ii) avoid deformation, (iii) pass the burst test, (iv) pass the hang test, and (v) simultaneously fulfill each of (i) through (iv).
Utilization of the mandrel with expandable collar during the fitment heat seal procedure also enables the use of polymeric materials not previously suitable for fitment applications. The mandrel with expandable collar supports the fitment during the sealing, and prevents deformation. Thus, the mandrel with expandable collar enables polymeric materials previously either too soft or too rigid (cracking) to now be used as fitments alone or thin-walled. Example E8 (with expandable collar) shows that INFUSE 9817, an elastomer, can be used as a suitable fitment material. Whereas comparative sample CE7 (INFUSE 9817) sealed without the expandable collar fails the burst test. Example E8 (i) is successfully heat sealed to the neck of the flexible container, (ii) avoids deformation, (iii) passes the burst test, (iv) pass the hang test, and (v) simultaneously fulfill each of (i) through (iv).
Utilization of the mandrel with expandable collar during the fitment heat seal procedure also enables shorter seal times without degrading seal strength. Example E3 (with expandable collar) yields an acceptable fitment seal (passing burst test and hang test) with 7 seconds seal time while comparative sample CE3 (no expandable collar) requires 20 seconds to produce an acceptable fitment seal.
The mandrel with expandable collar enables greater seal pressure to be applied to the fitment. Example E2 (with expandable collar) yields an acceptable fitment seal (passing burst test and hang test) at 4.9 seal bar pressure, whereas comparative sample CE2 at 4.9 seal bar pressure is permanently deformed.
Applicant unexpectedly found that the mandrel with expandable collar enables the production of a four-panel flexible container with a hermetically sealed fitment wherein the base wall thickness is from 0.2 mm, or 0.5 mm to 0.75 mm (thin-wall base).
It is specifically intended that the present disclosure not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come with the scope of the following claims.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2016/026113 | 4/6/2016 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62146021 | Apr 2015 | US |
