THERMOFORMED FLEXIBLE STAND-UP DISPENSING PACKAGE WITH INTEGRAL POUR SPOUT

Abstract

A highly flexible thermoformed stand-up dispensing package for a flowable material that is produced from one or more highly flexible heat-sealable polymeric sheets is formed with a trapezoidal front wall and opposing back wall and is dimensional and configured so that the corner of the package formed by the intersection of the top and the projecting side wall, or walls, that extend at an obtuse angle from the base is removable along a weakened tear line that is positioned upon removal to provide an integral pour spout for the controlled dispensing of the flowable material; and the container portion of the package is dimensioned to (1) maintain the center of gravity of the flowable material in the package over the base wall when the base wall of the filled package is in contact with a horizontal surface, and (2) to maintain the level of flowable material in the opened package is below the opened integral pour spout.

Claims

1. A highly flexible thermoformed stand-up dispensing package for a flowable material, the package produced from one or more highly flexible heat-sealable polymeric sheets, the package comprising: a. a bottom sheet thermoformed into a container portion that includes a recessed chamber having a trapezoidal bottom wall and integrally formed opposing side walls, a top wall and a base wall parallel to the top wall, where at least one of the side walls forms an included obtuse angle with the base wall, the chamber being bounded by an outwardly extending peripheral area, the chamber being configured and dimensioned to receive the flowable material, and b. a top cover sheet superposed on, and heat-sealed to the periphery of the bottom sheet to form a trapezoidal front wall, wherein the opposing side walls are generally trapezoidal or triangular and the narrow end of the trapezoid or the apex of the triangle defines the top wall of the recessed chamber, and the opposite end of each of the side walls defines the base wall, the base wall being dimensioned to maintain the center of gravity of the flowable material in the package over the base wall due to the deformation of the highly flexible walls under the outward force of the flowable material when the base wall of the filled package is in contact with a horizontal surface, and where a predetermined portion of the corner of the package formed by the intersection of the top wall and the projecting side wall that extends at an obtuse angle from the base is removable to provide an opening to dispense the flowable material in the package.

2. The package of claim 1, where the side walls are triangular and the top wall is a line defined by the interior edge of the adjacent sealed peripheral area.

3. The package of claim 1 in which the side walls are parallel, and the bottom surface defines a parallelogram.

4. The package of claim 1 which includes a weakened tear line that extends at an acute angle between the top wall and the projecting side wall within the heat sealed periphery of the package.

5. The package of claim 1 in which the portion of the package that lies outside of the tear line firms part of the heat-sealed periphery of the package.

6. The package of claim 5 in which an imbedded dispensing spout extends in fluid communication with the container portion and through a portion of the heat-sealed periphery to terminate at a position exterior to the tear line.

7. The package of claim 1 in which the portion of the heat-sealed periphery adjacent either end of the tear line is notched to facilitate removal of the corner of the package along the tear line.

8. The package of claim 1 in which the side wall opposite the projecting side wall that extends at an obtuse angle from the base wall forms a right angle with the base wall.

9. The package of claim 1 in which the obtuse angle is in the range from 105 to 135, and preferably in the range of from 105 to 115.

10. The package of claim 1 which includes an interior wall that extends from the top wall parallel to the projecting side wall, the interior wall terminating at a position spaced apart a predetermined distance from the base wall and heat-sealed to the top cover sheet to form a dispensing channel of predetermined cross-section.

11. The package of claim 1 in which the projecting side wall terminates in a curvilinear portion adjacent the top wall.

12. The package of claim 1 in which both side walls form an included obtuse angle with the base wall.

13. The package of claim 12 which includes an interior wall that extends from the top wall to the base wall at a predetermined position intermediate the side walls, and heat-sealed to the top cover sheet to thereby divide the container portion into separate sealed compartments.

14. The package of claim 12 in which both corners of the projecting side walls are removable along tear lines to form separate pour sprouts.

15. The package of claim 12 in which the obtuse angles formed by the opposing side walls are the same.

16. The package of claim 14 in which the corners of the projecting side walls have an imbedded spout.

17. The package of claim 4 in which the weakened tear line is dimensioned and configured to provide an opening that will pass a drinking straw.

18. The package of claim 12 in which the obtuse angles are different, and the projecting wall extending at the larger obtuse angle includes a weakened tear line.

19. The package of claim 4 in which at least one end of the weakened tear line terminates in a notch in the heat-sealed periphery.

20. A package in accordance with claim 1 that contains a volume of flowable material in which the surface of the flowable material is below the end of the corner of the projecting side wall when the package is placed on a horizontal surface.

21. A mold that is dimensioned and configured for integration and use in a molding machine for mass producing a highly flexible thermoformed dispensing package for a flowable material, the mold having a cavity defining a container portion, the opening of the cavity bounded by a planar peripheral margin extending horizontally a predetermined distance outwardly from the cavity opening, the peripheral margin being dimensioned to receive in heat-sealing relation a highly flexible thermoplastic top sheet sealed to a thermoformed highly flexible bottom sheet that lines the mold and overlies the peripheral margin of the mold during use to produce the thermoformed package, the container portion configured with: a trapezoidal bottom wall that is upwardly inclined from the horizontal from a bottom edge to a top edge, the top and bottom edges being parallel, a first side edge intersecting the bottom edge at an obtuse angle and an opposing second side edge extending between the top and bottom edges to define a straight line, a base wall extending vertically from the bottom edge of the bottom wall, opposing first and second side walls extending vertically from the respective first and second side edges of the trapezoidal bottom wall, and intersecting the base wall at an included acute angle, the side walls tapering from the base wall toward the inclined end of the trapezoidal bottom wall, a top wall extending between the tapered ends of the side walls and along the top edge of the inclined end of the trapezoidal bottom wall,

22. The mold of claim 21 in which the tapered side walls define a triangle, the apex of which triangle is positioned at the interior edge of the peripheral margin at the top edge of the bottom wall, wherein the top wall is defined by a line.

23. The mold of claim 21 in which the top edge of the bottom wall is coincident with the edge of the adjacent peripheral margin.

24. The mold of claim 21 in which the included angle defined by the intersection of first side wall and the base is in the range of from 100 to 135.

25. The mold of claim 24 in which the included angle is in the range of from 105 to 115.

26. The mold of claim 21 in which the opposing side walls are parallel and the bottom wall is a parallelogram.

27. The mold of claim 21 in which the second side edge of the trapezoidal bottom wall intersects the bottom edge to form a 90 angle.

28. The mold of claim 21 which is configured with one or more passages extending through the bottom wall, base wall and/or side walls that are configured to receive vacuum lines to provide a suction force inside of the mold cavity when a web or sheet of thermoformable flexible material is positioned over the cavity.

29. The mold of claim 21 in which the peripheral margins adjacent the intersection of the top wall and the first side wall include a channel extending outwardly from the cavity that is configured and dimensioned to form an imbedded spout in the bottom sheet of a package formed in the mold.

30. The mold of claim 21 in which the second side edge of the trapezoidal bottom wall intersects the bottom edge at an obtuse included angle.

31. The mold of claim 30 which includes a generally vertical interior wall that is integral with the bottom wall and extends between the base wall and the top wall to a height corresponding to the planar peripheral margin to divide the cavity into two compartments.

32. The mold of claim 30 in which the peripheral margins adjacent the intersection of the top wall and the first and second side walls each include a channel extending outwardly from the cavity through a portion of the peripheral margin, the channel being configured and dimensioned to form an imbedded dispensing spout in the bottom sheet of a package formed in the mold.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The various features and aspects of the present disclosure will be described in more detail below and with reference to the attached drawings in which like or similar elements are identified by the same reference numbers, and where:

[0045] FIG. 1 is illustrative of an HTFFS machine of the prior art with a single mold with a generally rectilinear cavity and a guillotine knife positioned at 90 to the longitudinal direction of travel to separate the filled and sealed packages;

[0046] FIG. 2 is an illustration of an HTFFS machine similar to that shown in FIG. 1 which is fitted with a single mold having a trapezoidal cavity in the form of a parallelogram in accordance with the present invention and a transverse guillotine blade mounted at an angle that is acute to the longitudinal axis of the bed which corresponds to the angle of the side walls to the base of the package;

[0047] FIG. 3 is a top or plan view of a series of two (2) packages thermoformed by the mold prior to separation with the parallelogram cavity shown in FIG. 2;

[0048] FIG. 4 is a top or plan view of four (4) packages thermoformed in a mold having a pair of inverted mirror image trapezoidal cavities in which two of the walls are not parallel;

[0049] FIG. 5 is a perspective view of the container portion of a package thermoformed in one of the molds configured as illustrated in FIG. 4 following its removal from the mold cavity;

[0050] FIG. 6 is the container portion of FIG. 5 rotated to a vertical position with the projecting side wall and pour spout to the right;

[0051] FIG. 7 is a front elevation view of the completed sealed package filled with a liquid supported on a horizontal surface illustrating the deformation and expansion of the lower portion of the highly flexible package and showing the head space above the liquid fill line that is below the region in which the tear line is positioned:

[0052] FIG. 8 is a perspective view of the package of FIG. 7;

[0053] FIG. 9A is a simplified top plan view of a thermoformed package configured as a parallelogram in which an imbedded spout has been formed by a corresponding groove in the extended seal portion of the mold periphery providing a fluid communication channel to the interior of the container portion, and FIG. 9B is a package configures as is in FIG. 9A which includes an interior wall that forms a channel to control the flow to the imbedded spout;

[0054] FIG. 10 is a simplified schematic illustration of an HTFFS machine fitted with a trapezoidal mold for producing packages in a parallelogram configuration showing a single guillotine blade at an angle, e.g., of 65 to the longitudinal direction of travel and a pair of conventional rotary slitting blades for edge trimming the web to define the top and base peripheries of the finished package;

[0055] FIGS. 11A-11D are simplified schematic elevation illustrations of conventional transverse cutting knives of the prior art that are suitable for use in the practice of the invention: FIG. 11Astraight guillotine knife, FIG. 11Bserrated or serial guillotine knife, FIG. 11Cshuttle or flying rotary knife, and FIG. 11Dshuttle or flying straight blade knife;

[0056] FIG. 12 is a simplified comparative top plan view of a production line illustration of a second knife shown in phantom for producing a dispensing package of the prior art in which the side walls form a 90 angle with the base; and

[0057] FIG. 13 is a simplified top plan view of a thermoformed package configured as a parallelogram with a pair of opposing pour spouts defined by the top wall and the opposing side walls and an intermediate generally vertical interior wall extending between the top and base walls and from the bottom wall to the cover sheet to from two separate compartments.

DETAILED DESCRIPTION OF THE PRODUCTION METHOD AND APPARATUS

[0058] As noted above, the present disclosure provides an improved method for mass producing a flexible dispensing package having an integral highly functional pour spout for the controlled dispensing of liquids and other flowable materials without the need for die-cutting. Utilizing a plurality of molds, each having a cavity of novel trapezoidal configuration that can be arranged in an adjacent array on the bed of an HTFFS machine so that after forming of the container portion, the filled and sealed packages can be separated from the web by a single transverse guillotine cutting blade of novel configuration, and a plurality of longitudinal cutting wheels arranged conventionally to trim the outside edge margins of the webs and to separate a plurality of longitudinally extending packages.

[0059] Reference is made to FIG. 2 which schematically illustrates an apparatus (200) similar to that described in detail above with reference to FIG. 1 operating with a single vacuum mold (210). The transverse guillotine cutter (260) with blade (262) extends across the bed of the machine at an angle of 75. If multiple molds are employed, e.g., a 3-up production line, as described in more detail in conjunction with FIG. 10, the machine can alternatively be provided with a plurality of blades that corresponds to the number of longitudinal molds. As will be understood by one of ordinary skill in the art, each blade cuts through the periphery of the heat-sealed web that defines the marginal area between the filled and sealed longitudinally extending packages moving down the bed of the HTFFS machine following their forming and removal from the cavities of their respective molds. Because the opposite parallel side walls of the trapezoidal container portion are oriented with the longitudinal axis of the machine bed and the direction of travel of the web(s), the guillotine blade, or blades, must be oriented at the angle, or angles defined by the side walls of the trapezoidal package. Blades suitable for use in separating the filled and sealed packages are illustrated and described in detail below in the labeled simplified schematic representations of FIGS. 11A-11D.

[0060] Referring to the embodiment of FIG. 3, where the package (30) has the configuration of a parallelogram, the orientation of the leading and trailing edges of the packages (30A, 30B) are at the same angle, e.g., 75 as illustrated, and the remaining side walls (30C, 30D) are parallel to the longitudinal axis of the machine. In the embodiment illustrated in FIG. 4 in which the side wall (40B) opposite the projecting wall (40A) that defines the pour spout are at different angles, i.e. 75 and 90 as illustrated, the side walls are not parallel, and the alternating guillotine cuts must be at different angles. e.g., between adjacent side walls (40B and 42A). The cutting can be accomplished by two separate blades (not shown), each oriented at the desired angle. The apparatus supporting the blades can lower the blades sequentially as the web of sealed packages passes a cutting station on the bed of the machine in response to a programmed processor and controller. Alternatively, the blades can be mounted on the same supporting structure (not shown) and lowered simultaneously to separate the lead and trailing side walls of the passing package in a single movement.

[0061] In a further alternative, the apparatus supporting the guillotine blade assembly (260) includes, for example, an automated oscillating mechanism (not shown) that changes the angular orientation of a single pivotally-mounted blade to first cut the side wall that defines the pour spout and then moves to the angle of the opposing side wall as it passes below at the cutting station. Other mechanisms for moving the blade to predetermined positions will be apparent to those of ordinary skill in the art.

[0062] The package (50) illustrated in FIG. 5 corresponds generally to the configuration of the trapezoids shown in FIG. 4. The pour spout is formed in the upper corner (52) by the projecting wall (50A) and top wall (50C). As shown, the corner portion (52) is formed with an integral imbedded pour spout (56) that is in fluid communication with the interior (55) of the container portion of the package (50) and terminates within the heat-sealed periphery of the package. A weakened tear line (54), illustratively shown as perforations, extends across the pour spout (52) to facilitate manual removal of the exterior portion of corner (52) to permit the controlled dispensing of the flowable contents of the package.

[0063] FIG. 6 illustrates a package (60) having a configuration similar to that of FIG. 5 described above that has been moved to an upright or standing position. The projecting corner (62) is provided with an imbedded pour spout and weakened tear line as described in FIG. 5, but for convenience, are not shown. The package is also provided with a weakened tear line (66) in the opposite upper corner which extends over the container portion of the package (60) to facilitate the rapid dispensing of the contents of the package.

[0064] Illustrated in FIGS. 7 and 8, respectively, are a front perspective view and a front and left side perspective view of a trapezoidal package (70) with projecting wall (70A) and top wall (70C) in which the flowable contents (77) have caused the walls to expand and thereby lower the center of gravity when the base (70D) is placed on a horizontal surface. More specifically, FIG. 7 is illustrative of the filled package as it would appear supported by the mold in which the trapezoidal container portion was produced, while FIG. 8 is representative of the natural configuration that will be assumed by the highly flexible package and its contents under the influence of gravity when positioned for sale or during use.

[0065] FIGS. 9A and 9B are enlarged top plan views of two embodiments of a heat-sealed package (90) in which the projecting wall (90A) and top wall (90C) form a projecting corner (92) that has been provided with an imbedded pour spout (96) and a weakened tear line (94) as was described above in conjunction with FIG. 5.

[0066] In the alternative embodiment of FIG. 9B, the container portion of the package (90) also includes an interior wall (98) that extends from the top wall parallel to the projecting side wall (90A) and is heat-sealed to the cover or lidding of the package in accordance with methods known in the art. The interior wall (98) forms a channel (99) of predetermined cross-section which further controls the flow of, e.g., a liquid of low viscosity through the open imbedded pour spout (96) following removal of the exterior portion of the corner portion (92) along the tear line (94).

[0067] In the embodiment of FIG. 10, a production run of packages (1020) configured as parallelograms in a three-up array is shown after filling, with the lidding (1050) being positioned by guide roller (1056) and sealed to the container portion at the heat-sealing station (1054) in conjunction with pressure applied to the periphery of the upper surface by heated platens schematically represented by arrows 1055. Slitting wheels (1070) separate the container from the web longitudinally, and transverse cutting bar (1060) raises and lowers the guillotine (1062) that is angularly aligned with the side walls to separate the parallelogram packages (1080).

[0068] Referring now to the series of FIGS. 11A-11D, there are shown highly simplified illustrations of four types of cutting devices known in the art that are suitable for use in the practice of the invention. FIG. 11A is a single guillotine blade (1110) that is tapered along the cutting edge (1112) to facilitate penetration at one side of the edge of the heat-sealed polymer webs used to form the container portion and cover or lidding.

[0069] In an alternative configuration schematically illustrated in FIG. 11B, the cutting edge (1122) of blade (1120) has four serrations that are configured to facilitate penetrating the web simultaneously at four locations, thereby reducing the vertical displacement of blade (1120) to completely sever the adjacent packages.

[0070] Referring now to FIG. 11C, there is illustrated a transverse supporting bar (1130) that is configured to carry a shuttle or flying cutting wheel (1132) that is mounted on an axis (1134) for rotation while oscillating across the bed of the machine generally transverse to the direction of movement of the sealed packages.

[0071] A shuttle or flying straight cutting knife is shown in FIG. 11D with a supporting bar (1140) that carries double-edged knife (1142) that can cut in both directions as the knife oscillates across the web of completed packages.

[0072] In preferred embodiments, the cutting edges of each of the devices is periodically or continuously sharpened by automated means in order to assure that the packages are cleanly severed from the adjacent packages, and along the marginal edges of completed packages before leaving the production machine.

[0073] Referring now to FIG. 12, a simplified comparative schematic illustration is provided of a transverse cutting bar (1270) nominally positioned at an angle of 75 to separate filled and sealed containers (1260) shown in shading to provide separated packages (1262). Also shown for comparative purposes only, and to distinguish the method from the prior art, rectilinear containers (1280) are shown in broken lines on the web following heat-sealing to be severed by transverse cutting bar (1270B), also shown in broken lines, to produce the rectilinear separated package (1282) at the end of the production line.

[0074] It will also be understood that the cutting station will have blades positioned above the bed of the machine that are dimensioned and configured to correspond to the size and layout of molds at the vacuum forming station.

[0075] Referring now to the simplified plan view of the embodiment of FIG. 13, the thermoformed dispensing package is configured with opposing projecting side walls (1390A, 1390B) each of which form an obtuse included angle (, .sup.1) with the base wall (1390D) so that opposing projecting top corners are formed. The angles formed with the base can be the same or different. In the embodiment shown, the top corners are configured with optional imbedded dispensing spouts (1396) and weakened tear lines (1394). With the removal of one of the corners (1392) to provide an opening to the interior of the chamber or container portion, the opposite projecting top corner can be manually gripped. e.g., between the thumb and forefinger of the user to further facilitate control during dispensing.

[0076] In an alternative configuration also illustrated in FIG. 13, an interior partition wall (1398) that extends between the base wall (1390D) and top wall (1390C) and from the bottom wall to a heat-sealed contact with the top cover sheet defines two separate compartments (1380, 1382). In this embodiment, each of the projecting corners (1392) can be removed, e.g., as along the optional weakened tear lines (1392), to provide an opening to the compartments (1380, 1382) for dispensing of the flowable contents of the package. As in previously described embodiments, one or both of the projecting top corners can be provided with an embedded dispensing spout (1396) to permit precise and controlled dispensing of the contents from each of the compartments. This configuration has particular utility where a product, such as an epoxy resin or a medication must be compounded from two components that must be maintained separately until the time of use when they are mixed.

[0077] Other aspects and features of the flexible dispensing package of the disclosure as described in conjunction with the above embodiments can be incorporated in the embodiment illustratively depicted in FIG. 13.

[0078] The present invention has been described in detail above and in the attached drawings and additional modifications and embodiments will be apparent to those of ordinary skill in the art from this disclosure, and the scope of protection for the invention is to be determined by the claims that follows.