Patent Application
20170121082
The present disclosure is directed to a stand-up container made from a flexible multilayer film.
A stand-up container is a container made from flexible polymeric film, the container having the ability to stand upright on a horizontal surface. Stand-up containers are also known as stand-up pouches or “SUPs.” In order to stand upright, the flexible polymeric film requires sufficient stiffness, so that when formed into the SUP, the SUP is capable of (i) standing upright without losing its shape, (ii) not distorting during content discharge, and (iii) not collapsing under its own weight. SUPs are used in a wide range of end-use applications and are common-place to today's consumers.
In addition to stiffness, SUP flexible polymeric film also requires mechanical properties, such as high drop impact strength, high tear strength, puncture resistance, sealability, and extrudability.
Current SUPs, suffer from high failure rates due to vibration during shipping and poor drop strength. Typical SUP film with a nylon layer(s) provides toughness and durability, yet can exhibit high vibration fail rates and high drop fail rates. Compounding these shortcomings, the art recognizes the need for all-polyethylene SUP film in order to advance sustainability and recyclability. Nylon-containing SUP film is difficult to recycle economically.
A need exists for flexible multilayer film for producing SUPs that improves vibration resistance and drop strength while not adversely affecting other film properties. A need further exists for an SUP multilayer film made from all-polyethylene with the foregoing improved properties.
The present disclosure provides a flexible container. In an embodiment, the flexible container includes
A. a front panel, a rear panel, a first gusseted side panel, and a second gusseted side panel, the gusseted side panels adjoining the front panel and the rear panel along peripheral seals to form a chamber, each panel is a multilayer film having at least three layers, each multilayer film comprising
B. each panel includes a bottom face comprising two opposing peripheral tapered seals, each peripheral tapered seal extending from a respective peripheral seal.
The present disclosure provides another container. In an embodiment, the flexible container includes:
A. a front panel, a rear panel, a first gusseted side panel, and a second gusseted side panel, the gusseted side panels adjoining the front panel and the rear panel along peripheral seals to form a chamber, each panel is a multilayer film having at least three layers, each multilayer film comprising
B. each panel includes a bottom face comprising two opposing peripheral tapered seals, each peripheral tapered seal extending from a respective peripheral seal, each peripheral tapered seal comprising an inner edge, the peripheral tapered seals converging at a bottom seal area;
C. the front panel bottom face comprises a first line defined by the inner edge of the first peripheral tapered seal and a second line defined by the inner edge of the second peripheral tapered seal inner edge, the first line intersecting the second line at an apex point in the bottom seal area;
D. the front panel bottom face has a bottom distalmost inner seal point on the inner edge; and
E. the apex point is separated from the bottom distalmost inner seal point by a distance from 0 mm to less than 8.0 mm.
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.
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.
An “ethylene-based polymer” is a polymer that contains greater than 50% by weight polymerized ethylene monomer (based on the total amount of polymerizable monomers) and, optionally, may contain at least one comonomer. Ethylene-based polymer includes ethylene homopolymer, and ethylene copolymer (meaning units derived from ethylene and one or more comonomers). The term “ethylene-based polymer” and “polyethylene” may be used interchangeably. Non-limiting examples of ethylene-based polymer (polyethylene) include low density polyethylene (LDPE) and linear polyethylene. Non-limiting examples of linear polyethylene include linear low density polyethylene (LLDPE), ultra low density polyethylene (ULDPE), very low density polyethylene (VLDPE), multi-component ethylene-based copolymer (EPE), ethylene/α-olefin multi-block copolymers (also known as olefin block copolymer (OBC)), single-site catalyzed linear low density polyethylene (m-LLDPE), substantially linear, or linear, plastomers/elastomers, and high density polyethylene (HDPE).
Generally, polyethylene, such as listed above, may be produced in gas-phase, fluidized bed reactors, liquid phase slurry process reactors, or liquid phase solution process reactors, using a heterogeneous catalyst system, such as Ziegler-Natta catalyst, a homogeneous catalyst system, comprising Group 4 transition metals and ligand structures such as metallocene, non-metallocene metal-centered, heteroaryl, heterovalent aryloxyether, phosphinimine, and others. Combinations of heterogeneous and/or homogeneous catalysts also may be used in either single reactor or dual reactor configurations.
“High density polyethylene” (or “HDPE”) is an ethylene homopolymer or an ethylene/α-olefin copolymer with at least one C4-C10 α-olefin comonomer, or C4 α-olefin comonomer and a density from greater than 0.94 g/cc, or 0.945 g/cc, or 0.95 g/cc, or 0.955 g/cc, to 0.96 g/cc to 0.97 g/cc, or 0.98 g/cc. The HDPE can be a monomodal copolymer or a multimodal copolymer. A “monomodal ethylene copolymer” is an ethylene/C4-C10 α-olefin copolymer that has one distinct peak in a gel permeation chromatography (GPC) showing the molecular weight distribution. A “multimodal ethylene copolymer” is an ethylene/C4-C10 α-olefin copolymer that has at least two distinct peaks in a GPC showing the molecular weight distribution. Multimodal includes copolymer having two peaks (bimodal) as well as copolymer having more than two peaks. Nonlimiting examples of HDPE are DOW™ High Density Polyethylene (HDPE) Resins (available from The Dow Chemical Company), ELITE™ Enhanced Polyethylene Resins (available from The Dow Chemical Company), CONTINUUM™ Bimodal Polyethylene Resins (available from The Dow Chemical Company), LUPOLEN™ (available from LyondellBasell) as well as HDPE products from Borealis, Ineos, and ExxonMobil.
“Linear low density polyethylene” (or “LLDPE”) is a linear ethylene-α-olefin copolymer containing heterogeneous short-chain branching distribution comprising units derived from ethylene and units derived from at least one C3-C10 α-olefin comonomer or at least one C4-C8 α-olefin comonomer, or at least one C6 -C8 α-olefin comonomer. LLDPE is characterized by little, if any, long chain branching, in contrast to conventional LDPE. LLDPE has a density from 0.910 g/cc, or 0.915 g/cc, or 0.920 g/cc, or 0.925 g/cc to 0.930 g/cc, or 0.935 g/cc, or 0.940 g/cc. Nonlimiting examples of LLDPE include TUFLIN™ linear low density polyethylene resins (available from The Dow Chemical Company), DOWLEX™ polyethylene resins (available from the Dow Chemical Company), and MARLEX™ polyethylene (available from Chevron Phillips).
ULDPE and VLDPE each is a linear ethylene-α-olefin copolymer containing heterogeneous short-chain branching distribution comprising units derived from ethylene and units derived from at least one C3-C10 α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6 -C8 α-olefin comonomer. ULDPE and VLDPE each have a density from 0.885 g/cc, or 0.90 g/cc to 0.915 g/cc. Nonlimiting examples of ULDPE and VLDPE include ATTANE™ ultra low density polyethylene resins (available form The Dow Chemical Company) and FLEXOMER™ very low density polyethylene resins (available from The Dow Chemical Company).
“Multi-component ethylene-based copolymer” (or “EPE”) comprises units derived from ethylene and units derived from at least one C3-C10 α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6 -C8 α-olefin comonomer, such as described in patent references U.S. Pat. No. 6,111,023, U.S. Pat. No. 5,677,383, and U.S. Pat. No. 6,984,695. EPE resins have a density from 0.905 g/cc, or 0.908 g/cc, or 0.912 g/cc, or 0.920 g/cc to 0.926 g/cc, or 0.929 g/cc, or 0.940 g/cc, or 0.962 g/cc. Nonlimiting examples of EPE resins include ELITE™ enhanced polyethylene (available from The Dow Chemical Company), ELITE AT™ advanced technology resins (available from The Dow Chemical Company), SURPASS™ Polyethylene (PE) Resins (available from Nova Chemicals), or SMART™ (available from SK Chemicals Co.).
Olefin block copolymers (OBC) are ethylene-α-olefin multi-block copolymers comprising units derived from ethylene and units derived from at least one C3-C10 α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6 -C8 α-olefin comonomer, such as INFUSE™ (available from The Dow Chemical Company) as described in U.S. Pat. No. 7,608,668. OBC resins have a density from 0.866 g/cc, or 0.870 g/cc, or 0.875 g/cc, or 0.877 g/cc to 0.880 g/cc, or 0.885, or 0.890 g/cc.
Single-site catalyzed linear low density polyethylenes (m-LLDPE) are linear ethylene-α-olefin copolymers containing homogeneous short-chain branching distribution comprising units derived from ethylene and units derived from at least one C3-C10 α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer. m-LLDPE has density from 0.913 g/cc, or 0.918 g/cc, or 0.920 g/cc, to 0.925 g/cc, or 0.940 g/cc. Nonlimiting examples of m-LLDPE include EXCEED metallocene PE (available from ExxonMobil Chemical), LUFLEXEN™ m-LLDPE (available from LyondellBasell), and ELTEX™ PF m-LLDPE (available from Ineos Olefins & Polymers).
Ethylene plastomers/elastomers are substantially linear, or linear, ethylene-α-olefin copolymers containing homogeneous short-chain branching distribution comprising units derived from ethylene and units derived from from at least one C3-C10 α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer. Ethylene plastomers/elastomers have a density from 0.870 g/cc, or 0.880 g/cc, of 0.890 g/cc to 0.900 g/cc, or 0.902 g/cc, or 0.904 g/cc, or 0.909 g/cc, or 0.910 g/cc, or 0.917 g/cc. Nonlimiting examples of ethylene plastomers/elastomers include AFFINITY™ plastomers and elastomers (available from The Dow Chemical Company), EXACT™ Plastomers (available from ExxonMobil Chemical), Tafmer (available from Mitsui). Nexlene (available from SK Chemicals Co.), and Lucene (available LG Chem Ltd.).
The term “low density polyethylene,” or “LDPE,” consists of ethylene homopolymer, or ethylene-α-olefin copolymer comprising at least one C3-C10 α-olefin, preferably C3-C4 that has a density from 0.915 g/cc to 0.940 g/cc, contains long chain branching with broad MWD. LDPE is typically produced by way of high pressure free radical polymerization (tubular reactor or autoclave with free radical initiator). LDPE examples include MarFlex (Chevron Phillips), LUPOLEN™ (LyondellBasell), as well as LDPE products from Borealis, Ineos, ExxonMobil, and others.
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. Non-limiting 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 weight percent polymerized propylene monomer (based on the total amount of polymerizable monomers) and, optionally, may contain at least one comonomer.
2% Secant Modulus (machine direction, MD and cross direction CD) is measured according to ASTM D882-10 (average of five film samples in each direction; each sample “1 in×6 in” or 25 mm×150 mm).
Density is determined in accordance with ASTM D792.
Elmendorf Tear Strength (MD and CD) is measured according to ASTM D 1922-09 (average of 15 film samples in each direction; each sample “3 in×2.5 in” half moon shape).
Melt Flow Rate or “MFR” is determined according to ASTM D1238 (230° C., 2.16 kg).
Melt index (or “MI”) is determined according to ASTM D1238 (190° C., 2.16 kg).
The term “molecular weight distribution” or “MWD” is the ratio of weight average molecular weight to number average molecular weight (Mw/Mn). Mw and Mn are determined according to conventional gel permeation chromatography (GPC).
Tm or “melting point” or “Tm,” 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.
Tensile Strength and Tensile Energy to Break (MD and CD) are measured in accordance with ASTM D882-10 (average of five film samples in each direction; each sample “1 in×6 in” or 25 mm×150 mm).
The present disclosure provides a multilayer film. In an embodiment, a multilayer film is provided and includes at least three layers—(i) an outermost layer, (ii) one or more core layers, and (iii) an innermost seal layer. The multilayer film is flexible, resilient, deformable, and pliable. The outermost layer (i) and the innermost seal layer (iii) are surface layers with the one or more core layers (ii) sandwiched between the surface layers. The outermost layer may include a (a-i) a HDPE, (b-ii) a propylene-based polymer or combinations of (a-i) and (b-ii), alone, or with other olefin-based polymers such as LDPE. Suitable propylene-based polymers include propylene homopolymer, random propylene/α-olefin copolymer (majority amount propylene with less than 10 wt % ethylene comonomer), and propylene impact copolymer (heterophasic propylene/ethylene copolymer rubber phase dispersed in a matrix phase).
With the one or more core layers (ii), the number of total layers in the present multilayer film can be from three layers (one core layer), or four layers (two core layers), or five layers (three core layers, or six layers (four core layers), or seven layers (five core layers) to eight layers (six core layers), or nine layers (seven core layers), or 10 layers (eight core layers), or 11 layers (nine core layers), or more.
The multilayer film has a thickness from 75 microns, or 100 microns, or 125 microns, or 150 microns to 200 microns, or 250 microns or 300 microns or 350 microns.
The multilayer can be (i) coextruded, (ii) laminated, or (iii) a combination of (i) and (ii). In an embodiment, the multilayer film is a coextruded multilayer film.
In an embodiment, the multilayer film has
In an embodiment, the outermost layer includes a HDPE. In a further embodiment, the HDPE is an EPE.
In an embodiment, the outermost layer includes a blend of HDPE and a LDPE.
The present multilayer film includes one or more core layers. Each core layer includes one or more linear or substantially linear ethylene-based polymers or block copolymers having a density from 0.908 g/cc, or 0.912 g/cc, or 0.92 g/cc, or 0.921 g/cc, to 0.925 g/cc, or less than 0.93 g/cc.
In an embodiment, each of the one or more core layers includes one or more ethylene/C3-C8 α-olefin copolymers selected from:
The present multilayer film includes an innermost seal layer (or seal layer). The seal layer includes one or more seal ethylene-based polymer having a density from 0.86 g/cc, or 0.87 g/cc, or 0.875 g/cc, or 0.88 g/cc, or 0.89 g/cc, to 0.90 g/cc, or 0.902 g/cc, or 0.91 g/cc, or 0.92 g/cc.
In an embodiment, the seal layer includes one or more ethylene/C3-C8 α-olefin copolymer selected from:
Each layer in the multilayer film may include one or more optional additives. Non-limiting examples of suitable additives include stabilizers, slip additives, antiblocking additives, process aids, clarifiers, nucleators, pigments or colorants, fillers and reinforcing agents. It is particularly useful to choose additives and polymeric materials that have suitable organoleptic and or optical properties.
In an embodiment, the seal ethylene-based polymer has a first melt temperature, Tm1, less than 105° C. The HDPE in the outermost layer has a second melt temperature, Tm2, and Tm2-Tm1 is from 20° C., or 25° C., or 30° C. to 35° C., or 40° C., or 45° C., or 50° C.
In an embodiment, the multilayer film contains from 5 vol %, or 10 vol %, or 15 vol %, or 20 vol %, to 25 vol %, to 30 vol %, or 35 vol %, or 40 vol %, or 45% HDPE. In a further embodiment, the multilayer film contains from 10 vol %, or 15 vol %, to 20 vol %, or 25 vol %, or 30% vol % HDPE.
In an embodiment, the multilayer film includes
In an embodiment, Film 1 has a thickness from 100 microns and 250 microns and Film 1 has one, some, or all of the following properties:
In an embodiment, the multilayer film is a coextruded three layer film (single core layer).
In an embodiment, the multilayer film is a coextruded five layer film, with three core layers. The core layers may be the same or different.
In an embodiment, the multilayer film is a coextruded seven layer film, with five core layers. The core layers may be the same or different.
The present disclosure provides a flexible container. In an embodiment, the flexible container includes
A. a front panel, a rear panel, a first gusseted side panel, and a second gusseted side panel, the gusseted side panels adjoining the front panel and the rear panel along peripheral seals to form a chamber, each panel is a multilayer film having at least three layers, each multilayer film comprising
B. each panel includes a bottom face comprising two opposing peripheral tapered seals, each peripheral tapered seal extending from a respective peripheral seal.
The multilayer film can be a multilayer film as previously disclosed herein. In an embodiment, the bottom faces form a base segment, and the base segment supports the flexible container in a free-standing upright position on a flat surface bottom faces form a base segment. The base segment supports the flexible container in a free-standing upright position on a flat surface.
In an embodiment, the flexible container has a volume from 1 liter to 20 liters and the flexible container passes the vertical drop test. In a further embodiment, the flexible container also passes the side drop test.
In an embodiment, the flexible container includes components (A)-(E) described below.
A. A front panel, a rear panel, a first gusseted side panel, and a second gusseted side panel, the gusseted side panels adjoining the front panel and the rear panel along peripheral seals to form a chamber. Each panel is a multilayer film having at least three layers, each multilayer film comprising
B. Each panel includes a bottom segment comprising two opposing peripheral tapered seals, each peripheral tapered seal extending from a respective peripheral seal, each peripheral tapered seal comprising an inner edge, the peripheral tapered seals converging at a bottom seal area.
C. The front panel bottom segment includes a first line defined by the inner edge of the first peripheral tapered seal and a second line defined by the inner edge of the second peripheral tapered seal, the first line intersecting the second line at an apex point in the bottom seal area.
D. The front panel bottom segment has a bottom distalmost inner seal point on the inner edge.
E. The apex point is separated from the bottom distalmost inner seal point by a distance from 0 mm to less than 8.0 mm.
The four panels 18, 20, 22 and 24 each can be composed of a separate web of film. The composition and structure for each web is the present multilayer film having at least three layers as previously disclosed herein. Alternatively, one web of film may also be used to make all four panels and the top and bottom segments. In a further embodiment, two or more webs can be used to make each panel.
In an embodiment, four webs of film are provided, one web of film for each respective panel 18, 20, 22, and 24. The film is any of the present multilayer films having at least three layers as previously disclosed herein. The edges of each film are sealed to the adjacent web of film to form peripheral seals 41 (
To form the top segment 28 and the bottom segment 26, the four webs of the present multilayer film converge together at the respective end and are sealed together. For instance, the top segment 28 can be defined by extensions of the panels sealed together at the top end 44 and when the container 10 is in a rest position it can have four top panels 28a-28d (
In an embodiment, a portion of the four webs of the multilayer film 28 that make up the top segment 28 form a neck. The neck can be sealed. The neck seal can be a tear seal. Alternatively, the neck seal can be a re-sealable seal. Nonlimiting examples of suitable re-sealable seals include peelable seal, a flap seal, an adhesive seal, and a zipper seal.
In an embodiment, a portion of the four webs of the multilayer film that make up the top segment 28 terminate at a spout 30. A portion of a top end section of each of the four webs of film is sealed, or otherwise welded, to an outer, lower rim 52 of the spout 30 to form a tight seal. The spout is sealed to the flexible container by way of compression heat seal, ultrasonic seal, and combinations thereof. Although the base of spout 30 has a circular cross-sectional shape, it is understood that the base of spout 30 can have other cross-sectional shapes such as a polygonal cross-sectional shape, for example. The base with circular cross-sectional shape is distinct from fitments with canoe-shaped bases used for conventional two-panel flexible pouches.
In an embodiment, the outer surface of the base of spout 30 has surface texture. The surface texture can include embossment and a plurality of radial ridges to promote sealing to the inner surface of the top segment 28.
In an embodiment, the spout 30 excludes fitments with oval, wing-shaped, eye-shaped, or canoe-shaped bases.
Furthermore, the spout 30 can contain a removable closure 32. The spout 30 has an access opening 50 through the top segment 28 to the interior as shown in
The spout 30 can be made of a rigid construction and can be formed of any appropriate plastic, such as high density polyethylene (HDPE), olefin block copolymer (OBC) or low density polyethylene (LDPE), and combinations thereof. The location of the spout 30 can be anywhere on the top segment 28 of the container 10. In an embodiment the spout 30 is located at the center or midpoint of the top segment 28. The closure 32 covers the access opening 50 and prevents the product from spilling out of the container 10. The cap 32 may be a screw-on cap, a flip-top cap or other types of removable (and optionally reclosable) closures. In an embodiment, the spout can be a flange style fitment installed in a hole of any one panel.
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 an inner seal edge defined by inner edge 29a and inner edge 29b.
The apex point 35a is separated from the BDISP 37a by a distance S from 0 millimeter (mm), or greater than 0 mm to less than 8.0 mm.
In an embodiment, the rear panel bottom face 26c includes an apex point similar to the apex point on the front panel bottom face. The rear panel bottom face 26c includes a first line C defined by the inner edge of the 29c first peripheral tapered seal 40c and a second line D defined by the inner edge 29d of the second peripheral tapered seal 40d. The first line C intersects the second line D at an apex point 35c in the bottom seal area 33. The rear panel bottom face 26c has a bottom distalmost inner seal point 37c (“BDISP 37c”). The BDISP 37c is located on an inner seal edge defined by inner edge 29c and inner edge 29d. The apex point 35c is separated from the BDISP 37c by a distance T from 0 millimeter (mm), or greater than 0 mm to less than 8.0 mm.
It is understood the following description to the front panel bottom face applies equally to the rear panel bottom face, with reference numerals to the rear panel bottom face shown in adjacent closed parentheses.
In an embodiment, the BDISP 37a (37c) is located where the inner edges 29a (29c) and 29b (29d) intersect. The distance between the BDISP 37a (37c) and the apex point 35a (35c) is 0 mm.
In an embodiment, the inner seal edge diverges from the inner edges 29a, 29b (29c, 29d), to form a distal inner seal arc 39a (front panel) a distal inner seal arc 39c (rear panel) as shown in
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 from S (distance T) from the apex point 35a (35c) to the BDISP 37a (37c) is from greater than 0 mm, or 0.5 mm or 1.0 mm, or 2.0 mm to 4.0 mm or 5.0 mm or less than 5.5 mm.
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 G as shown in
The bottom segment 26 includes a pair of gussets 54 and 56 formed thereat, which are essentially extensions of the bottom faces 26a-26d. The gussets 54 and 56 can facilitate the ability of the flexible container 10 to stand upright. These gussets 54 and 56 are formed from excess material from each bottom face 26a-26d that are joined together to form the gussets 54 and 56. The triangular portions of the gussets 54 and 56 comprise two adjacent bottom segment panels sealed together and extending into its respective gusset. For example, adjacent bottom faces 26a and 26d extend beyond the plane of their bottom surface along an intersecting edge and are sealed together to form one side of a first gusset 54. Similarly, adjacent bottom faces 26c and 26d extend beyond the plane of their bottom surface along an intersecting edge and are sealed together to form the other side of the first gusset 54. Likewise, a second gusset 56 is similarly formed from adjacent bottom faces 26a-26b and 26b-26c. The gussets 54 and 56 can contact a portion of the bottom segment 26, where the gussets 54 and 56 can contact bottom faces 26b and 26d covering them, while bottom segment panels 26a and 26c remain exposed at the bottom end 46.
As shown in
The bottom handle 14 can comprise up to four layers of film sealed together when four webs of film are used to make the container 10. When more than four webs are used to make the container, the handle will include the same number of webs used to produce the container. Any portion of the bottom handle 14 where all four layers are not completely sealed together by the heat-sealing method, can be adhered together in any appropriate manner, such as by a tack seal to form a fully-sealed multi-layer bottom handle 14. The bottom handle 14 can have any suitable shape and generally will take the shape of the film end. For example, typically the web of film has a rectangular shape when unwound, such that its ends have a straight edge. Therefore, the bottom handle 14 would also have a rectangular shape.
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 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 side panels 18 and 20, it can help to keep the gussets 54 and 56 (
As seen in
The bottommost edge of the upper handle portion 12a when extended in a position above the spout 30, can be just tall enough to clear the uppermost edge of the spout 30. A portion of the top handle 12 can extend above the spout 30 and above the top segment 28 when the handle 12 is extended in a position perpendicular to the top segment 28 and, in particular, the entire upper handle portion 12a can be above the spout 30 and the top segment 28. The two pairs of legs 13 and 15 along with the upper handle portion 12a together make up the handle 12 surrounding a handle opening that allows a user to place her hand therethrough and grasp the upper handle portion 12a of the handle 12.
As with the bottom handle 14, the top handle 12 also can have a dead machine fold 34a-34b that permits folding in a first direction toward the front side panel 22 and restricts folding in a second direction toward the rear side panel 24. The machine fold 34a-34b can be located in each leg 13, 15 at a location where the seal begins. The handle 12 can be adhered together, such as with a tack adhesive, beginning from the machine folded portion 34a-34b up to and including the horizontal upper handle portion 12a of the handle 12. The positioning of the machine fold 34a-34b can be in the same latitude plane as the spout 30 and, in particular, as the bottommost portion of the spout 30. The two machine folds 34a-34b in the handle 12 can allow for the handle 12 to be inclined to fold or bend consistently in the same first direction X as the bottom handle 14, rather than in the second direction Y. As shown in
When the container 10 is in a rest position, such as when it is standing upright on its bottom segment 26, as shown in
Alternatively, in another aspect the flexible container can contain a fitment or pour spout positioned on a sidewall, where the top handle is essentially formed in and from the top portion or segment. The top handle can be formed from the four webs of film, each extending from its respective sidewall, extending into a sidewall or flap positioned at the top end of the container, such that the top segment of the container converges into the handle and they are one and the same, with the spout to the side of the extended handles, rather than underneath.
The material of construction of the flexible container 10 can comprise a food-grade plastic. For instance, nylon, polypropylene, polyethylene such as high density polyethylene (HDPE) and/or low density polyethylene (LDPE) may be used as discussed later. The film of the flexible container 10 can have a thickness that is adequate to maintain product and package integrity during manufacturing, distribution, product shelf life and customer usage. In an embodiment, the flexible multilayer film has a thickness from 100 micrometers, or 200 micrometers, or 250 micrometers to 300 micrometers, or 350 micrometers, or 400 micrometers. The film material can also be such that it provides the appropriate atmosphere within the flexible container 10 to maintain the product shelf life of at least about 180 days. Such films can comprise an oxygen barrier film, such as a film having a low oxygen transmission rate (OTR) from 0, or greater than 0 to 0.4, or 1.0 cc/m2/24 hrs/atm) 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 0, or greater than 0, or 0.2, or 1.0 to 5.0, or 10.0, or 15.0 g/m2/24 hrs at 38° C. and 90% RH. OTR and WVTR are measured in accordance with ASTM E 96/E 96 M-05. 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.
Flexible container 10 has an expanded configuration (shown in
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, placed on a platform at 1.5 m height (from the base or side of the container to the ground), and released to a free fall drop onto a concrete slab floor. If any leak is detected immediately after the drop, the test is recorded as a failure. If no leak is detected immediately after the drop, the test is recorded as a success or “pass.” A minimum of twenty flexible containers are tested. A percentage for pass/fail containers is then calculated.
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, and placed on a platform with a drop mechanism. The flexible container is released on its side from a 1.5 m height to a free fall drop onto a concrete slab floor. If any leak is detected immediately after the drop, the test is recorded as failure. If no leak is detected immediately after the drop, the test is recorded as a success or “pass.” A minimum of twenty flexible containers are tested. A percentage for pass/fail containers is then calculated.
In an embodiment, the flexible container 10 passes the stand-up test where the package is filled with water at ambient temperature and placed on a flat surface for seven days. The flexible container remains in the same position, with unaltered shape or position for the seven days.
In an embodiment, the flexible container 10 has a volume from 0.25 liters (L), or 0.5 L, or 0.75 L, or 1.0 L, or 1.5 L, or 2.5 L, or 3 L, or 3.5 L, or 3.78 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.
In an embodiment, the flexible container 10 having a volume from 1 liter (L), or 1.5 L, or 2.5 L, or 3 L, or 3.5 L or 3.78 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, 15 L, or 20 L, has a vertical drop test pass rate from 90%, or 95% to 100%.
In an embodiment, In an embodiment, the flexible container 10 having a volume from 1 liter (L), or 1.5 L, or 2.5 L, or 3 L, or 3.5 L, or 3.78 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, 15 L, or 20 L, has a side drop test pass rate from 90%, or 95% to 100%.
In an embodiment, the flexible container 10 having a volume from 1 liter (L), or 1.5 L, or 2.5 L, or 3 L, or 3.5 L, or 3.78 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, 15 L, or 20 L, has a vertical drop test pass rate from 90%, or 95% to 100% and has a side drop test pass rate from 90%, or 95% to 100%.
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, beverages such as water, juice, milk, or syrup, carbonated beverages, beer, wine, animal feed, pet feed, and the like can be stored inside of the flexible container 10.
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.
Many conventional SUPs are constructed using greater than 50 vol % of HDPE to provide adequate stiffness to the SUP geometry. The HDPE is primarily used in the inner layers and is frequently blended with other polyethylenes such as LLDPE or mLLDPE to some extent into the external layer to improve gloss.
Conventional SUPS typically place HDPE in a non-surface layer, such as the core layer.
Applicant discovered that (i) moving the HDPE to the outermost layer and (ii) reducing the amount of HDPE to less than 30 vol % surprising yields a film with sufficient stiffness for SUP production. Moving the HDPE to the outer layer also permits tougher resins to be placed in the core layers(s). Placing the HDPE in the outermost layer also enables a greater temperature differential between the innermost seal layer and outermost layer of the film, facilitating manufacture of the flexible container without outer surface sticking to tool or other outer film layer. In addition, placing the HDPE in the outermost layer reduces film damage during sealing process and widens seal windows for fitments. This provides improved seal with reduced leakage and prevents thinned film areas in the SUPs thereby improving vibration and drop resistance. The present multilayer film allows a greater portion of the film to be constructed with greater amount of more durable polymers such as ELITE™ enhanced polyethylene resins or DOWLEX™ LLDPE resins. This also helps to improve the overall durability. A surprising feature of the present flexible container, particularly at sizes between 1 liter and 20 liters, is that the flexible container has sufficient standup capability while using a film having low modulus but at same thickness (lower stiffness). Furthermore, four panel stand-up flexible containers made with the present multilayer film in volumes from 1 liter to 20 liters surprisingly pass the vertical drop test.
Some embodiments of the present disclosure will now be described in detail in the following Examples.
Polymeric compositions for the production of multilayer films are provided in Table 1 below.
Co-extruded blown multilayer films are produced as follows. The multilayer films are made on a Hosokawa/Alpine 7 layer blown film line equipped with seven 50 mm, grooved-feed extruders with 30:1 L/D ratio. The line is equipped with a 250 mm Alpine X die with a 2 mm die gap. The line uses Alpines Resin Miser control system and is capable of running as fast as 3.57 Kg/cm of die circumference. Table 2 shows the run conditions and parameters for the production of Example 1, Example 2, and Comparative Sample 1 (CS1).
The structure, composition and the properties of the multilayer films Example 1, Example 2, and Comparative Sample 1 (CS1) are provided in Table 3 below.
The properties of the multilayer films Example 1, Example 2, and Comparative Sample 1 (CS1) are provided in Table 4 below.
Flexible containers (SUPS) are produced with design and geometry as shown in
Flexible containers are drop tested after filling with 3.78 liters of water and tightening the screw cap closure. A drop tower is used to drop from various heights up to 1.68 meters and using ASTM D2463 standard test method for drop impact resistance. Failure is defined as any rupture visible to an observer or any evidence of container contents outside of the container. The drop time is the time after the fall is initiated and video trigger is activated until the largest force of the container hits the bottom plate. The force is the actual load recorded when the container hits the plate. If the container hits on one edge first and not flat the drop time will change. When bottles bounce, multiple readings occur with the first hit usually having the biggest load. Pass-Fail is used to signify performance at a given height as shown in Tables 4A-4C.
Tables 4A-4C. Drop test results for 3.78 liters flexible container filled with water
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.
| Number | Date | Country | |
|---|---|---|---|
| 62248552 | Oct 2015 | US |
