GB2356854A

GB2356854A - Dual chamber flexible container

Info

Publication number: GB2356854A
Application number: GB0026049A
Authority: GB
Inventors: James E Rozmarek
Original assignee: Scholle Custom Packaging Inc
Current assignee: Scholle Custom Packaging Inc
Priority date: 1999-10-27
Filing date: 2000-10-25
Publication date: 2001-06-06
Also published as: AU6806900A; GB0026049D0

Abstract

A container which may be located in a rigid outer box has two separate chambers defined by a first liner 402 and a second liner 408 located within the first liner 402, with the second liner 408 being movable relative to the first liner 402 to vary the volumes of both chambers. The two chambers are preferably separate from one another with a seal therebetween to isolate the contents of one chamber from the other chamber. Desirably, a first chamber may be constructed to carry the contents of the container and a second chamber may be constructed to receive a pressurized fluid, such as compressed air, which provides a force acting on the contents of the first chamber through the second liner to facilitate completely emptying the first chamber. The pressurized fluid in the second chamber can be used to discharge the contents of the first chamber under at least some pressure which is in addition to or even against the force of gravity on the contents of the first chamber. Preferably, both the first and second liners 402, 408 are formed of a thin, flexible plastic film or sheet material such as polyethylene and polypropylene plastic films. Respective openings 424, 426 with spouts 425, 427 are provided for the chambers. The container is preferably formed by connecting blanks of flexible material.

Description

2356854 DUAL CHAMBER FLEXIBLE CONTAINER

Field of the Invention

This invention relates generally to shipping and storage containers and more particularly to such a container formed of a flexible material.

Backaround of the Invention

Containers of all shapes and sizes and constructed of a wide range of materials have been used to transport and store flowable granular and liquid products.

Some of these containers have been made from flexible materials, such as plastic films and woven plastic materials, which may be folded generally flat when empty. Some of these flexible containers may be used to transport bulk materials weighing a ton a more, and others may be used on a smaller scale in place of, for example, five- gallon buckets or other rigid containers. Further, these containers may be used as liners within an outer container. Often, a spout is provided within the flexible container or liner to facilitate filling and emptying the contents of the container. To limit waste, it is desirable to completely empty the container and even with the force of gravity, some of the contents of past containers may not be discharged because of the configuration of the containers, the location of their spouts or for other reasons. Additionally, in some applications it may be desirable or necessary to discharge the contents of a container under some pressure particularly with viscous flowable products.

According to the invention, there is provided a container comprising:

a first liner having a first portion and a second portion; a second liner received within the first liner and having at least a portion movable from a first position where it is adjacent to the first portion of the first liner to a second position where it is adjacent to and generally conforms to the shape of the second portion of the first liner a first chamber defined by at least one of the first and second liners; a second chamber separated from the first chamber and defined by at least one of the first and second liners; a first opening communicating the first chamber with the exterior of the container; and a second opening communicating the second chamber with the exterior of the container whereby, the first chamber is constructed to receive the contents of the container through the first opening and when the first chamber is filled, the second liner is in its first position, and the second chamber is constructed to receive a fluid through the second opening to move the second liner from its first position to its second position.

Further provided in accordance with the invention is a method of making a container, comprising the steps of.

a) providing a first blank of flexible material; b) providing a second blank of flexible material; c) connecting together the first blank and the second blank along at least one line to define first and second liners of the container with the first liner having first and second portions, the second liner received vAthin the first liner and having at least a portion movable relative to the first liner from a first position adjacent to the first portion and a second position adjacent to and generally conforming to the shape of the second portion of the first liner, connecting together the first blank and second blank also provides a first chamber defined by at least one of the first and second liners and a second chamber separate from the first chamber and defined by at least one of the first and second liners; and d) providing a first opening communicating the first chamber with the exterior of the container and a second opening communicating the second chamber with the exterior of the container.

Accordingly, there is provided in accordance with the invention a container having two separate chambers defined by a first liner and a second liner received within the first liner, with the second liner being movable relative to the first liner to vary the volumes of both chambers. The two chambers are preferably separate from one another with a seal therebetween to isolate the contents of each chamber from the other chamber. Desirably, a first chamber may be constructed to carry the contents of the container and a second chamber may be constracted to receive a pressurized fluid, such as compressed air, which provides a force acting on the contents of the first chamber through the second liner to facilitate completely emptying the first chamber. The pressurized fluid in the second chamber can be used to discharge the contents of the first chamber under at least some pressure which is in addition to or even against the force of gravity acting on the contents of the first chamber. Preferably, both the first and second liners are formed of a thin, flexible plastic film or sheet material such as polyethylene and polypropylene plastic films.

In one form, the first liner is a hexahedron, and is preferably generally cubical to be received in a complementary shaped container or box, if needed for support.

The second liner is constructed to conform to the interior of approximately one half of the first liner and is connected or sealed to the first liner such that the second liner is movable from a first position received against and conforming to the interior of a first half of the first liner and a second position received against and conforming to a second half of the first liner. The first chamber and second chamber are both defined between the first liner and second liner with the first chamber on one side of the second liner and the second chamber on the other side of the second liner.

Desirably, when the second liner is in its first position, the first chamber has its maximum volume so that the container may be substantially completely filled with the desired product and when the second liner is in its second position, the first chamber has its minimum volume to facilitate completely discharging the contents of the first chamber.

The second liner may also be used in an intermediate position between the first and second positions when the first chamber is not completely filled. In such circumstances, it may be desirable to maintain a pressurized fluid in the second chamber which acts on the contents of the first chamber through the second liner to maintain the contents of the first chamber under at least some pressure, and to inflate or completely fill the volume of the container to prevent the flexible container from sagging or becoming "bunched up" within the outer container in which it may be received. Also, it may be desirable to ship two different materials or products with one product received in the first chamber and a separate product received within the second chamber. Or, the container may be used two times, first with the product in the first chamber, and second with the product in the second chamber, without contamination of either shipment of the product.

In another form, the first chamber is defined completely within a second liner received within a first liner and the second chamber is defined between at least a portion of the first and second liners. In this embodiment, the second liner is preferably connected to the first liner along a line or plane generally bisecting the first liner to maintain a desired orientation of the second liner within the first liner and to permit a controlled movement of the second liner relative to the first liner. When the first chamber is filled, the second liner preferably substantially completely fills the first liner. When it is desired to empty the contents of the first chamber, a pressurized fluid may be introduced into the second chamber to act on the contents of the first chamber through the second liner. The second liner has a first position defirting a maximum volume of the first chamber and a second position defining a minimum volume of the first chamber. The pressurized fluid introduced into the second chamber causes the second liner to collapse or fold into itself about the points or lines of connection between the first and second liners as the first chamber is being emptied to facilitate discharging the contents of the first chamber. Preferably, the points or lines of connection between the first and second liners are such that when the second liner is folded into itself to its second position, a first portion of the second liner is received within and substantially conforms to a second portion of the second liner defined on the opposite side of the lines of connection from the first portion.

Objects, features and advantages of this invention include providing a container with at least two separate chambers which may be form fitted to be received within an outer container, is formed of a flexible material, facilitates emptying the container, reduces waste, can be used to discharge the contents of the container under pressure, can be used to carry two separate products, provides two chambers of infinitely variable volume, reduces the time to empty the container, permits the container to be used twice without contamination of the product either time, provides a double- walled container to resist rapture of the container, may be formed from various materials, is of relatively simple design and economical manufacture and assembly, is rugged, durable and has a long and useful in service life.

Brief Description of the Drawings

These and other objects, features and advantages of this invention will be apparent from the following detailed description of the preferred embodiments and best mode, appended claims and accompanying drawings in which:

FIG. I is perspective view of a flexible container according to the present invention received within an outer rigid container or box; FIG. 2 is a perspective view of the flexible container of FIG. 1 with parts broken. away; FIG. 3 is a cross sectional view taken along line 3 - 3 of FIG. 2; FIG. 4 is a cross sectional view taken along line 4 - 4 of FIG. 2; FIG. 5 is a sectional view as in FIG. 4 illustrating a second liner of the container in an intermediate position; FIG. 6 is a cross sectional view taken along line 6 - 6 of FIG. 5; FIG. 7 is a plan view of a blank of flexible material used to form a liner of the container; FIG. 8 is a cross-sectional view of the blank of material taken along line 8 - 8 of FIG. 7; FIG. 9 is a plan view of the blank of material after heat sealing; FIG. 10 is a cross-sectional view of the blank taken along line 10 - 10 of FIG. 9; FIG. 11 is a cross-sectional view of the blank illustrating a re-folding step to properly orient the blank for use in the container; FIG. 12 is a plan view of the blank after it has been folded as in FIG. 11; -B- FIG. 13 is a cross-sectional view of the blank taken along line 13 - 13 of FIG. 12; FIG. 14 is an exploded/assembly view illustrating the first and second blanks which form the container of FIG. 1; FIG. 15 is a plan view of the blanks of FIG. 14 assembled together and folded flat; FIG. 16 is a cross sectional view taken generally along line 16 - 16 of FIG.

15; FIG. 17 is a cross sectional view taken generally along line 17 - 17 of FIG.

15; FIG. 18 is a sectional view taken generally along line 18 - 18 of FIG. 15; FIG. 19 is a simplified cross sectional view as in FIG. 17; FIG. 20 is a cross sectional view of the first and second blanks being unfolded to form first and second liners of the container; FIG. 21 is a cross sectional view of the first of second blanks unfolded to form the first and second liners of the container; FIG. 22 is a plan view of a modified container according to a second embodiment of the invention folded flat; FIG. 23 is a fragmentary cross sectional view taken along line 23 - 23 of FIG. 22; FIG. 24 is a cross sectional view taken along line 24 - 24 of FIG. 22; FIG. 25 is a perspective view of the container of FIG. 22 when expanded; FIG. 26 is a plan view of a third embodiment container according to the present invention; FIG. 27 is a cross sectional view taken along line 27 - 27 of FIG. 26; FIG. 28 is a cross sectional view taken along line 28 - 28 of FIG. 26; FIG. 29 is a plan exploded/assembly view illustrating the arrangement of the first and second liners of the container of FIG. 26; FIG. 30 is a perspective view of the liner of FIG. 26 when expanded; FIG. 31 is a side view of the container of FIG. 30; FIG. 32 is a plan view of a fourth embodiment of a container of this invention; FIG. 33 is a cross sectional view taken generally along line 33 - 33 of FIG.

32; FIG. 34 is a perspective view of the container of FIG. 32 when expanded; FIG. 35 is a fragmentary sectional view of the container of FIG. 32 illustrating the second liner in its second position; and FIG. 36 is a plan view of a fifth embodiment of a container of this invention; FIG. 37 is a cross sectional view taken generally along line 37 - 37 of FIG.

36; and FIG. 38 is a plan view of a sixth embodiment of a container of this invention; FIG. 39 is a perspective assembly view of panels or blanks of material used to form a seventh embodiment of a container; FIG. 40 is a plan view of the seventh embodiment of a container folded flat; FIG. 41 is a cross sectional view taken generally along line 41-41 of FIG.

40; FIG. 42 is a perspective view of the seventh embodiment of a container; and FIG. 43 is a perspective view of an eighth embodiment of a container and having a generally cylindrical shape.

Detailed Description of the Preferred Embodiments

Referring in more detail to the drawings, FIGS. I - 21 illustrate a flexible container 10 according to the present invention and having a first liner 12 and a second liner 14 received within the first liner 12 to define a pair of separate chambers 16, 18 of the container 10 with at I east a portion of the second liner 14 movable relative to the first liner 12 to vary the volumes of both chambers 16, 18. Each chamber 16, 18 is communicated with the exterior of the container through at least one opening 20, 22, respectively with each opening 20, 22 preferably communicating with a spout 24, 26 closeable by a cap 28, 30 or valve. The first chamber 16 of the container 10 is constructed to receive and retain a viscous or flowable material such as a liquid, gas or granular material for storage or transportation of the material. The second chamber 18 is preferably constructed to receive a pressurized fluid, such as water or compressed air, to provide a force through the second liner 14 acting on the contents of the first chamber 16 to facilitate emptying the first chamber 16. The fluid may be heated to facilitate discharge of the contents of the first chamber if desired. Desirably, the second liner 14 is fixed to the first liner 12 such that it is movable from a first position defining a maximum volume of the first chamber 16 to a second position defining a minimum volume of the first chamber 16. Desirably, the container 10 may be received within an outer supporting rigid container or box 32 (FIG. 1) to facilitate handling and stacking of the filled containers 10. In any event, it has been found that for containers 10 constructed to contain more than one cubic foot of material an outer rigid container 32 is desirable to support the container 10 and facilitate its handling.

As best shown in FIGS. 2- 6, the first liner 12 comprises a single ply or layer of flexible plastic material or film defining the exterior of the container 10 which is desirably a hexahedron, and preferably generally cubical in shape when filled or expanded. The first liner 12 has four interconnected sidewalls 34, 35, 36, 37 that are preferably integral and circurnferentially continuous and a pair of end walls 3 8, 3 9 formed by connecting together adjacent side edges of adjacent triangular portions 40 of material with one triangular portion 40 extending from each of a pair of opposed edges 42, 43 of each side wall 34, 35, 36, 37. Preferably, the side edges of each triangular portion 40 are heat sealed together to provide a fluid-fight container 10. Representative materials for the first liner are polypropylene or polyethylene plastic films between 4 and 10 mils thick although any other suitable flexible material may be used.

The second liner 14 is received within the first liner 12 and is attached thereto along a plane which generally bisects the first liner 12. When in its first position, the second liner 14 is constructed to conform to the interior shape of one half of the first liner 12. The second liner 14 has a pair of sidewalls 44, 46 complementary to two sidewalls 34, 37 of the first liner 12 and a pair of end walls 48, 50 complementary shaped to one half of each end wall 38, 39 of the first liner 12. Preferably, the second liner 14 is heat sealed to the first liner 12 along a first pair of heat seal lines 52, 54 each generally diagonally spanning a separate end wall 3 8, 3 9 of the first liner 12 and extending from a first comer 56, 57 to a diagonally opposed corner 58, 59 of the end walls 38, 39, respectively. The second liner 14 is also attached to the first liner 12 along a second pair of heat seal lines 60, 62 with each extending along and generally coincident with a separate one of a pair of diagonally opposed seams 64, 66 between adjacent sidewalls 34, and 36, 37 of the container 10. Desirably, to completely separate the first and second chambers 16, 18, all of the heat seal lines 52, 54, 60 62 are connected together to form a continuous seal between the first and second liners 12, 14. Thus, the first chamber 16 is defined between the first and second liners 12, 14 on one side of the second liner 14 and the second chamber 18 is defined between the first and second liners 12, 14 on the other side of the second liner 14.

As best shown in FIGS. 7 - 2 1, to form such a container 10 having a first liner 12 and a second liner 14 received within the first liner 12, two blanks of material 70, 72 are joined together and manipulated as described below. Before the blanks 70, 72 are joined together, each blank 70, 72 is prepared as shown in FIGS. 7 - 13. To start, as shown in FIGS. 7 and 8 a generally tubular blank 70' of a suitable flexible material is folded flat to provide a pair of gusseted panels 74, 76 folded inwardly and received between a pair of overlying flat panels 78, 80. Next, as shown in FIGS. 9 and 10, a plurality of heat seals 82 are provided along canted lines to interconnect the overlying flat panels 74, 76 with their adjacent gusseted panels 74, 76. As shown in FIG. 8, to prevent the adjacent overlapping halves of each gusseted panel 74, 76 from being heat sealed ( ' a7m) together, a layer of material 84 of low thermal conductivity, such as Teflo is inserted between the gusseted panels 74, 76 before the heat seal operation. Generally triangular waste portions 85 may be removed from the blank 70'by severing the blank outboard of each heat seal 82.

Next, as shown in FIG. 11, the gusseted panel 76 on one side of the blank 70'is folded outwardly of the overlying flat panels 78, 80 and the blank 70 is configured as shown in FIGS. 12 and 13 with gusseted panel 76 unfolded and on top, and panels 78 and 74 received between panel 76 and panel 80. As best shown in figure 14, panels 76 and 80 are connected together along three edges 90, 91, 92. The inner panels 74, 78 are likewise connected along three complementary edges. The outer panels 76, 80 are connected to the inner panels 74, 78 along six edges 93, 94, 95, 96, 97, 98. The opening 20 and spout 24 are located and provided on the blank 70. The second blank 72' is formed in the same manner prior to connecting together both blanks 70, 72. The opening 22 and spout 26 are positioned in a different location on the blank 72 compared to the opening 20 and spout 24 of blank 70 to properly orient them on the container 10 when it is filled or expanded. Preferably, the second blank 72 is slightly larger than the first blank 70 to facilitate receiving the first blank 70 in the second blank 72. The configuration of figures 12 and 13 can optionally be obtained by sealing together two flat sheets of material folded into a "C-shape" for the first blank and two "C-shape" layers of material for the second blank.

With both the first and second blanks 70, 72 folded and heat sealed in the above manner, as shown in FIG. 14, the assembly of the container 10 begins by inserting the first blank 70 into the second blank 72 so that the first blank 70 is aligned with the second blank 72 and received between its inner flat panels 86,87 with the connected edges 90, 91) 92 of each blank 70, 72 adjacent to each other. After inserting the first blank 70 into the second blank 72 to provide the configuration shown in FIGS. 15, 16 and 18, the first and second blanks 70, 72 are heat scaled together along heat seal lines 60, 66, 99, 101, 102, 104 interconnecting adjacent side edges 93 - 98 of the blanks 70, 72. As best shown in FIGS. 15 and 17, the heat seal lines 99, 101, 102,104 extend from the point or apex 105 at each end of the blanks 70, 72 to the open side 107 of the blanks. More specifically, the edges 93 of both blanks 70, 72 are heat sealed together along line 99, edges 95 along line 101, edges 96 along line 102, and edges 98 along line 104. Heat seal lines 99 and 10 1 are joined by heat seal line 60 connecting edges 94 of each blank and lines 102 and 104 are joined by line 66 which connects together the edges 97 of each blank 70, 72. To prevent the adjacent inner panels 86, 87 of the first blank 70 from being heat scaled to each other, a layer of a thermally non-conductive material is disposed between them during the heat scaling operation. Notably, when the container 10 is expanded, as shown in FIG. 2, heat seal lines 99 and 102 are aligned to define elongate heat seal line 52, and similarly, heat seal lines 10 1 and 104 define heat seal line 54. With the exception of these heat seal lines 60, 66, 99, 101, 102, 104 the first and second blanks remain separate from each other.

After connecting the first and second blanks 70, 72 together as described above, an innermost layer 108 of the first blank 70 is pulled outwardly as shown in FIGS.

19 and 20 until it forms a generally rectilinear configuration, as shown in FIG. 21, to provide a generally cubical container when filled or expanded. FIGS. 19 - 21 diagrammatically illustrate the blanks 70, 72 as a single layer or ply of material to facilitate the description and understanding of the unfolding of the joined blanks 70, 72 to form the liners 12, 14 of the container 10. When heat sealed and manipulated into this configuration, the first blank 70 defines one-half of the first liner 12 of the container 10 and one-half of the second liner 14. Likewise, the second blank 72 defines one-half of the first liner 12 and one-half of the second liner 14. The second liner 14 is formed from two, overlapping layers of material which in use, remain close together and function generally as a single layer or unit.

Operation of the First Embodiment As best shown in FIG. 3, to receive a product within the container 10 the spout 24 or opening 20 into the first chamber 16 is opened and the product is introduced into the first chamber 16 through the spout 24. When the first chamber 16 is completely filled, the second liner 14 is in its first position defining a minimum volume of the second chamber 18 and a maximum volume of the first chamber 16. As shown in FIG. 4, when it is desired to discharge the product from the container 10 the spout 24 is again opened to permit the product to be discharged from the container 10 therethrough and the other spout 26 is opened to permit a pressurized fluid, such as water or compressed air, to be admitted into the second chamber 18.

The pressurized fluid in the second chamber 18 acts on the product within the first chamber 16 through the second liner 14 to facilitate discharging the product from the first chamber 16. As shown in FIGS. 5 and 6, as the product is being emptied, the second liner 14 will collapse or be forced towards its second position thereby increasing the volume of the second chamber 18 and decreasing the volume of the first chamber 16.

To ensure that the product is completely emptied from the first chamber 16, the second liner 14 is moved to its second position, as shown in phantom in FIGS. 4 - 6, defining a maximum volume of the second chamber 18 and a minimum volume of the first chamber 16.

Preferably, the second liner 14 is sized so that it conforms to the shape of and is closely received with one half of the first liner 12 in its first position and relative to the other half of the first liner 12 when in its second position. Desirably, the second liner 14 is large enough to engage and conform to the shape of the interior of the first liner 12 without being oversized to prevent it from bunching up and thereby reducing the effective volume of the container 10. Advantageously, the diagonal heat seal lines 52, 54 of connection between the first and second liners 12, 14 facilitate the movement of the second liner 14 between its first and second positions by reducing the likelihood of the second liner 14 binding or sticking in the comers of the first liner 12. Further, the spout 24 is preferably positioned in the sidewall generally opposite the second liner when in its first position such that the movement of the second liner 14 from its first position to its second position is generally in the direction of the spout 24 to facilitate completely emptying the first chamber 16.

Thus, with the force of the pressurized fluid in the second chamber 18, the contents of the container 10 may be discharged under pressure to ensure that the contents are completely discharged from the container 10. Further, the fluid provided to facilitate discharge of the product from the container 10 is maintained completely separate from the product to avoid contamination of the product. The pressurized discharge could also facilitate emptying the container 10 against the force or pressure of, for instance, the pressure or head of fluid in another container or the force of gravity. Still further, the container 10 can be reversed after use with the product being added to the second chamber 18 and a pressurized fluid to facilitate discharge subsequently applied to the first chamber 16. In this way, the container 10 may be used twice without contaminating the product for either use.

Second Embodiment FIGS. 22 - 25 illustrate a modified container 200 according to a second embodiment of the invention with a first liner 204 and a modified second liner 202 received within the first liner 204 to define first and second chambers 206, 208 of the container each communicating with a separate opening 210, 212 and preferably, separate spouts 214, 216. The first liner 204 is formed from a first blank of material and the second liner 202 is formed from a second blank of material manipulated in the same general manner as the first blank and having approximately one-half the length of the first blank. A first blank may be cut in half to provide two-second blanks or second liners 202. One end of the first liner 204 is not initially heat sealed and is left open to permit the second liner 202 to be slidably inserted into the open end of the first liner 204.

The first and second liners 204, 202 are preferably formed from tubular blanks of material. As best shown in FIG. 24, both the first liner 204 and second liner 202 have a pair of gusset panels 222, 224 and 226, 228 respectively received within overlying flat panels 230, 232 and 234, 236, respectively. Adjacent panels of thefirst liner 204 are heat sealed together along lines 218, 219 and 220 to close one end of the first liner 204. The adjacent panels of the second liner 202 are similarly heat sealed along lines 250, 252, 254 to close one of its ends.

More specifically, the flat panels 230, 232 and 234, 236 are heat sealed only to their in-unediately adjacent portion of a gusset panel 222, 224, 226, 228 of their respective liners 202, 204.

Thereafter, the second liner 202 is inserted into the first liner 204 such that its gusset panels 226, 228 and flat panels 234, 236 are aligned and interposed with the gusset panels 222, 224 and flat panels 230, 232 of the first liner so that in use the second liner 202 conforms to and isreceived closely adjacent to the corresponding one-half portion of the interior of the first liner 204. In this embodiment, the second liner 202 is formed from a single layer of material. To connect the first and second liners 204, 202 together and provide a seal between the first and second chambers 206, 208, the second liner 202 is heat scaled to the first liner 204 along a circumferentially continuous heat seal line 238 which generally bisects four side walls of the first liner 204. As shown in FIG. 23, to enable the container 200 to be expanded into a generally cubical configuration, the second liner 202 is sealed only to the adjacent corresponding panels of the first liner 204 without heat sealing any of the panels 226, 228, 234, 23 6 of the second liner 202 to another panel of the second liner. To accomplish this, a material of low thermal conductivity, such as Teflo is disposed between adjacent layers or panels of the second liner 202 before heat sealing. After providing the heat seal line 238 and removing the material of low thermal conductivity, the open end of the first liner 204 is closed by heat sealing along its canted or inclined edges 240, 242 and interconnecting edge 243 to enclose the second liner 202.

The second liner 202 has roughly one half the surface area of the first liner 204 and as shown in Fig. 25 is movable from a first position received within and closely adjacent to a first half 244 of the first liner 204 and a second position as shown in phantom lines in FIG. 25, received within and closely adjacent to a second half 246 of the first liner 204. Both the first and second chambers 206, 208 are defined between the first and second liners 204, 202 with the first chamber 206 on one side of the second liner 202 and the second chamber 208 on the other side of the second liner 202. The first and second chambers 206, 208 have substantially the same minimum and maximum volumes as defined by the second liner 202 when it is in its first and second positions.

When expanded, the first liner 204 has a generally cubical configuration and the second liner 202 is constructed to define half a cube and to conform to and underlie one half 244 of the first liner 204. When the first chamber 206 is filled with a product, the second liner 202 in its first position defining a maximum volume of the first chamber 206 and a minimum volume of the second chamber 208. To discharge the product from the first chamber 206, a pressurized fluid may be introduced into the second chamber 208 to displace the second liner 202 toward its second position wherein it conforms to and is received closely adjacent to the other half 246 of the first liner 204. The second liner 202 hinges or moves about the seal line 238 between it and the first liner 204 which, as best shown in FIG. 25, defines a plane generally parallel to a pair of end or top and bottom walls 248 of the first liner 204. This second embodiment container 200 thus functions in substantially the same manner as the first embodiment container 10 with the difference being in the construction of the second liner 202 and its interconnection with the first liner 204.

Third Embodiment FIGS. 26 - 31 illustrate a third embodiment of a container 300 having a first liner 302 which is generally cubical when expanded and a second liner 304 received and heat sealed within the first liner 302 which conforms to and is received closely within approximately one half of the first liner 302 and is movable between first and second positions, as in the previous embodiments. The first liner 302 is constructed in substantially the same manner as the first liner 204 of the second container 200 with gusset panels 306, 308 (shown by their fold lines in FIG.

26) received within overlying flat panels 310, 312 and with heat seals 314, 315, 316, 317 connecting adjacent panels together at one end 318 of the first liner 302 with the other end 320 of the first liner 302 temporarily left open to pem-iit insertion of the second liner 304 into thefirst liner 302. A first spout 321 and second spout 323 open into first and second chambers 350, 352, respectively, similar to the previous embodiments.

As best shown in FIGS. 26, 27 and 29, the second liner 304 has a relatively intricate shape and construction with a flat bottom panel 322 having a generally rectilinear lower portion 324 and generally triangular upper portion 326 and being overlied by a pair of inwardly extending gusset panels 328, 329. The gusset panels 328, 329 each have a first portion 330, 331 of a single layer of material shaped generally like a parallelogram extending from a lower edge 332 of the bottom panel 322 to the upper triangular portion 326 of the bottom panel 322 and having a common side edge 334, 335 with the upper triangular portion 326. The gusset panels 328, 329 also have a second portion 336, 337 folded back over a section of the first portion 330 and being formed of a single layer of material of generally triangular shape having edges 341, 343 overlying the common edges 334, 335 of the first portion 330, 331 of its gusset panel 328, 329 and the upper triangular portion 326 of the bottom panel 322. The folding of the second portion 336, 337 of each gusset panel 328, 329 over its corresponding first portion 330, 331 defines fold lines 338, 339 extending from the initial point of overlap between the first and second portions to an apex 340 of the triangular portion 326. An upper triangular flap 342 overlies a portion of each of the second portions 336, 337 of the gusset panels 328, 329 and has a lower edge or base 344 generally parallel to the lower edge 332 of the bottom panel 322 and a pair of side edges which are aligned with and common to the side edges 341, 343 of the second portions 336, 337 of the gusset panels 328, 329. Desirably, the second liner 304 is formed from a single sheet of flexible material such that all of its panels 322, 328, 329, 342 are integral with each other. As shown in FIG. 27, heat-seals 345 and 346 are provided in the second liner 304 along edges 334 and 335 between flap 342 and second gusset portions 336 and 337, respectively.

Similarly, heat seals 347, 348 are provided along edges 341 and 343 between triangular portion 326 of bottom panel 322 and first gusset portions 330, 33 1, respectively.

The second liner 304 is slidably received within the first liner 302 until the upper triangular portion 326, and flap 342 are received within the corresponding and complementary shaped closed end 318 of the first liner 302. The second liner 304 is received within the first liner 302 such that the triangular flap 342 and the second portions 336, 337 of each gusset panel 328, 329 are received between the upper flat panel 3 10 and the adjacent portion of the gusset panels 306, 308 of the first liner 302. The first portion 330, 331 of each gusset panel 328, 329 and the entire bottom panel 322 of the second liner 304 are received between the lower flat panel 312 and the adjacent portion of the gusset panels 306, 308 of the first liner 302. Thesecondliner 304 is inserted and positioned within the first liner 302 in this manner to align the gusset panels 306, 308 and 328, 329 of the first and second liners 302, 304, respectively, with each other to facilitate connecting the second liner 304 to the first liner 302 and the expansion of the liners into the configuration of the container 300 shown in FIG. 30.

To connect the second liner 304 to the first liner 302 and to define between the first and second liners a first chamber 350 on one side of the second liner 304 and a second chamber 352 on the other side of the second liner 304, the second liner is connected to the first liner 302 along a plurality of heat seal lines. More specifically, the second liner 304 is heat sealed to the first liner 302 along a heat seal line 354 at the lower edge 332 of the bottom panel 322 of the second liner 304 sealing the bottom panel 322 to the lower flat panel 312 of the first liner 302. A second heat seal line 356 extends from a lower comer 358 of the bottom panel 322 of the second liner 304 along an edge 359 of the first portion 330 of the gusset panel 328 of the second liner 304 to the fold line 338 to connect this portion of the gusset panel 328 to the overlying gusset panel 306 of the first liner 302. The same heat seal line 356 continues along an edge 360 of the second portion 336 of the gusset panel 328 and tenninates at a side edge 362 (FIG. 26) of the first and second liners to attach the gusset panel 328 of the second liner 304 to the gusset panel 306 of the first liner 302. A corresponding heat seal line 364 connects the other gusset panel 329 of the second liner 304 along its edge in the same manner to the other gusset panel 308 of first liner 302. To facilitate forming the heat seals 356, 364 the position of the gusset panels 306, 308 and the flat panels 310, 312 may be reversed so that the gusset panels 306, 308 overlie the flat panels 310, 312, and then, the heat seal lines 356, 364 extend along generally straight lines. Finally, the base of the generally triangular flap 342 of the second liner 304 is heat sealed to the overlying upper flat panel 3 10 of the first liner 302 along a line 3 66 generally transverse to the fold lines 338 of the gusset panels 328, 329.

When sealed to the first liner 3 02 in this mariner, the heat seal lines 3 54, 3 5 6, 3 64 and 366 define a plane when the container 300 is expanded which generally diagonally bisects the first liner 302 in a similar manner as the second liner 14 of the first embodiment container 10, The second liner 304 completely underlies one end wall 370 and one side wall 372 and covers slightly more than half of a pair of opposed side walls 374, 376 along generally diagonal heat seal lines as in the first embodiment container 10. Thus, as best shown in FIG. 30, the second liner 304 conforms to and is received closely within slightly more than one half of the first liner 302 when in its first position to ensure that when the second liner 304 is moved to its second position to discharge the contents of the first chamber 350, the second liner 304 can move fully within the other somewhat smaller, remaining portion of the first liner 302 to ensure that the contents of the first chamber 350 can be completely discharged from the container 300. The function and operation of the container 300 of the third embodiment is substantially the same as that of the first and second embodiments of containers 10, 200 and hence will not be described further.

Fourth Embodiment FIGS. 32 - 35 illustrate a fourth embodiment container 400 having a first liner 402 with a pair of flat and generally rectilinear panels 404, 406 disposed one on top of the other and connected together about their peripheries to define an enclosure in which a second liner 408 is received. The second liner 408 is similarly formed of a pair of flat and generally rectilinear panels 410, 412 of material disposed one on top of the other and connected to each other about their peripheries to define a first chamber 414 within the second liner 408. Preferably, the panels 404, 406 and 410, 412 for each liner are defined by a separate tubular blank of material for each liner, folded flat and scaled at their ends. More specifically, the first liner 402 is initially heat sealed along line 413 to close one end of the first liner 402. The other end is left open to permit the second liner 408 to be inserted into and heat-scaled to the first liner 402. The second liner 408 is also closed at its corresponding end by heat seal 415. Alternatively, the first and second liners may each be formed by flat sheets of material disposed one on top of the other and sealed about the periphery of each edge, such as by heat sealing.

The second liner 408 is connected to the first liner 402 by heat sealing along a circumferentially continuous middle heat seal line 416 which generally bisects the first and second liners 402, 408. Desirably, as shown in FIG. 21, the middle heat seal line 416 connects the adjacent panels 404 to 410 and 406 to 412 of the first and second liners 402, 408 without sealing together the panels 410, 412 of the second liner 408. This may be accomplished by ( P'.T M) inserting a material of low thermal conductivity such as Teflonithin the second liner 408 in the area in which the heat seal is formed. So connected, a second chamber 422 is defined between the first liner 402, the exterior of the second liner 408 and one side of the middle heat seal 416.

Additionally, to provide a desired orientation of the second liner 408 within the first liner 402, the second liner 408 and first liner 402 are joined along another heat seal line 418 extending along a common edge 420 at one end of the liners 402, 408 and generally parallel to the middle heat seal line 416.

A pair of openings 424,426 and associated spouts 425, 427 are provided into the container 400 with a first opening 424 on one side of the middle heat seal line 416 opening into the first chamber 414 defined within the second liner 408. The second opening 426 is on the other side of the middle heat seal line 416 and opens into the second chamber 422 defined between the first liner 402 and the second liner 408 as best shown in FIG. 33. Preferably the spout 427 is heat scaled to the first liner 402 before the second liner 408 is inserted therein and the spout 425 is scaled to both liners before the heat seal 418 is joined along the edge 420 to close off the liner 402.

The second liner 408 has a lower portion 430 and an upper portion 432 defined on opposed sides of the middle heat seal line 416. The upper portion 432 is movable relative to the first liner 402 and the lower portion 430 of the second liner 408 from a first position defining a maximum volume of the first chamber 414 to a second position defining a minimum volume of the first chamber414. As shown in FIG. 35, to move to its second position, the upper portion 432 hinges or folds about the middle heat-seal 416 to be received within the lower portion 430 when in its second position to facilitate emptying the first chamber 414.

In use, to fill the container 400 of the fourth embodiment, the product is supplied into the first chamber 414 through the first opening 424 and thus fills and expands the second liner 408 into its first position. When filled, the container 400 is generally "pillow" shaped, as shown in FIG. 34, with the second liner 408 expanding into and causing the first liner 402 to likewise expand outward as the container 400 is filled. The second liner 408 is preferably the same shape and substantially the same size as the first liner 402 such that when filled, the second liner 408 substantially completely fills the first liner 402. Desirably, this provides a double walled container to reduce leakage of the container 400.

When it is desired to empty the contents from the container 400, the first and second openings 424, 426 are opened and a pressurized fluid, such as compressed air, is discharged through the second opening 426 into the second chamber 422 to provide a force acting inwardly on the second liner 408 tending to force the contents of the second liner 408 out of the first opening 424. As the second liner 408 is being emptied, the pressurized air will continue to act on the second liner 408 causing it to collapse within the first liner 402 and to fold about the middle heat seal 416 until the upper portion 432 of the second liner 408 reaches its second position received within and conforming to the lower portion 430 of the second liner 408 when the first chamber 414 is completely emptied. Thus, similar to the first, second and third embodiments of containers 10, 200, 300, the movement of at least a portion of the second liner 408 relative to the first liner 402 decreases the volume of the first chamber 414 in which the contents of the container 400 are received to facilitate discharging the contents of the container 400 and to ensure that the contents are completely discharged to reduce waste. However, in the fourth embodiment of container 400, this is achieved in a slightly different manner in that the first chamber 414, in which the contents of the container 400 are received, is defined completely within the second liner 408 and only a portion of the second liner 408 moves relative to the first liner 402. Nevertheless, despite these differences in construction, the operation of the fourth embodiment container 400 is very similar to the operation of the first, second, and third embodiment containers 10, 200, 300 and the fourth embodiment container 400 has similar uses and significant practical advantages.

Fifth Embodiment FIGS. 36 and 37 illustrate a fifth container 500 embodying the present invention.

The fifth container 500 is constructed substantially the same as the fourth 'container 400 and thus, to the extent the fifth container 500 is the same as the fourth container 400 it will not be described further herein. To further facilitate the description of the fifth container 500, elements which are the same as the fourth embodiment will be given the same reference number.

The fifth embodiment of container 500 has a first liner 502 and a second liner 504 received within the first liner 502. As in the fourth embodiment, a first chamber 506 is defined completely within the second liner 504 and a second chamber 508 is defined between a middle heat seat 5 10, an upper portion 5 12 of the second liner 5 04 and a corresponding upper portion of the first liner 502. The upper portion 512 of the second liner 504 has a gusseted portion 516 received between a pair of outer flat panels 518, 520 defting the second liner 504. The gusseted portion 516 is formed by folding inwardly an upper edge 522 of the second liner 504 to provide clearance or a gap 526 between the uppennost section of the second liner 504, which is preferably tapered along inclined edges 524, 525, and the adjacent portion of the first liner 502.

This gap 526 facilitates expansion of the second liner 504 within the first liner 502 as the first chamber 506 is filled and also facilitates discharge of the contents of the first chamber 506 by permitting the upper portion 512 of the second liner 504 to more easily fold onto or into itself during discharge of the contents and to prevent the second liner 504 from binding in the upper comers of the first liner 502. Further, the folded, gussetted portion of the second liner 504 also facilitates installation of the container 500 into an external contaim- nent vessel which may be needed to support the container 500 or to facilitate handling or storage of several containers 500.

In all other respects, the fifth container 500 is constructed and functions in the same manner as the fourth container 400.

Sixth Embodiment FIG. 38 illustrates a sixth embodiment of container 600 according to the present invention which is constructed in substantially the same manner as the fourth embodiment container 400 with the exception that the middle heat seal 602 extends between opposed side edges 604, 606 of both the first and second liners 608, 610 and is inclined relative to each edge 604, 606 of the liners 608, 610. Preferably, the middle heat seal line 602 extends generally diagonally across the liners 608, 610 and joins the adjacent panels of the first and second liners 608, 610 together withoutjoining the layers or walls of the second liner 610 to themselves in the same manner as the fourth container 400. Preferably, the middle heat seal line 602 intersects the side edges 604, 606 of the first and second liners 608, 610 at a location spaced from a pair of 7 - diagonally opposed comers 612, 614 such that it is not a true diagonal across the liners 608, 610.

This construction and arrangement facilitates the folding or hinging of the second liner 610 about the middle heat seal line 602 as the second liner 610 is driven from its first position to its second position to empty the contents of a first chamber 616 defined within the second liner 6 10.

In any event, the middle heat seal 602 preferably generally bisects the first and second liners 608, 610 to provide a generally equal volume and surface area of the liners 608, 610 on either side of the middle heat seal line 602. The remainder of the sixth container 600 has substantially the same construction as the fourth container 400 and its operation is the same as that of the fourth container 400 and thus, the sixth container 600 will not be described further.

Seventh Embodiment FIGS. 39 - 42 illustrate a seventh embodiment of a container 700 according to the invention. As shown in FIGS. 39 - 41 three generally C-shaped blanks 702, 704, 706 each having a pair of overlapping flat panels connected along edges 707, 708, 709, to define a closed side 710 are inserted one into the next as shown in FIG. 39, and are thereafter heat sealed together along common edges 711, 712 and 713 (FIG. 40) to close their open sides 715. Spouts 717, 719 are provided as in the other containers 10, 200, 300, 400, 500, 600, to communicate separately with first and second chambers of the container 700. Upon expanding the container 700, as shown in FIG. 42, a first liner 714 and a second liner 716 are provided with the second liner 7 16 received within the first liner 714 and having about one-half the surface area of the first liner 714. The first liner 714 is defined by blanks 702 and 706 and the second liner 716 is defined by blank 704. The second liner 716 is shaped and connected to the first liner 714 in substantially the same manner as the second liner 14 of the first container 10 except that the second liner 716 is formed of a single panel or layer of material and not two layers of material like second liner 14 of the first container 10. Otherwise, the container 700 is constructed and functions in substantially the same manner as the first container 10 with the second liner 716 movable between two positions to vary the volume of first and second chambers of the container 700 which are defined on opposite sides of the second liner 716.

EiRhth Embodiment An eighth embodiment of a container 800 is shown in FIG. 43 and has a generally cylindrical shape with a generally cylindrical first finer 802 having top and bottom walls 803, 805 and a second liner 804 received within the first liner 802 and having roughly one-half of the surface area of the first liner 802 and the shape of one-half of a cylinder. The second liner 804 is connected to the first liner along circumferentially continuous heat seal line 806 and is movable between first and second positions about the heat seal line 806 in the same general manner as the second liners of the containers 10, 200, 300, 700 to vary the volumes of first and second chambers of the container 800. Spouts 808 and 810 are also provided each communicating with one of the first and second chambers in the same manner as the previous embodiments. Thus, with the exception of its shape, the container 800 is constructed and functions in substantially the same manner as the other containers disclosed above.

-29

Claims

1. A container, comprising:

2. A container according to claim 1 wherein the first chamber is defined between the second liner and a portion of the first liner.

3. A container according to claim 1 or claim 2 wherein the second chamber is defined between the second liner and a portion of the first liner.

4. A container according to claim 1 wherein the first chamber is defined within the second liner.

5. A container according to any one of claims 1 to 4 wherein the maximum volume of the first chamber is substantially equal to the total volume of the first liner.

6. A container according to any one of claims 1 to 5 wherein the second liner is sealed to the first liner to prevent communication of the first chamber with the second chamber.

7. A container according to any one of claims 1 to 6 wherein the second liner has approximately one-half the surface area of the first liner and is attached to the first liner along a plane which generally bisects the first liner.

8. A container according to claim 7 wherein the plane along which the second liner is attached to the first liner extends generally diagonally through the first liner.

9. A container according to any one of claims 1 to 8 wherein the first liner has a hexahedron shape when expanded.

10. A container according to any one of claims 1 to 9 wherein the second liner is attached to the first liner along a plane which generally bisects the first liner and when the second liner is in its first position, the second liner is received adjacent to a first portion of the first liner and when the second liner is in its second position, the second liner is received adjacent to the remaining portion of the first liner not included in the first portion of the first liner.

11. A container according to any one of claims 1 to 10 wherein the second liner is attached to the first liner along a pair of diagonally opposed side edges of the first liner, each side edge being defined at the juncture of adjacent sidewalls, and along generally diagonal lines across each end wall connecting the opposing comers on each end wall which are aligned with said pair of diagonally opposed side edges such that when the second liner is in its first position, the second liner is received adjacent to two sidewalls and one half of each end wall and when the second liner is in its second position, the second liner is received adjacent to the other two sidewalls and the other half of each end wall.

12. A container according to any one of claims I to I I wherein the second liner is attached to the first liner along a plane generally parallel to the end walls and generally bisecting each sidewall and when the second liner is in its first position, the second liner is received adjacent to one end wall and one-half of each sidewall and when the second liner is in its second position, the second liner is received adjacent to the other end wall and the other half of each sidewall.

13. A container according to any one of claims I to 12 wherein the second liner has substantially the same surface area as the first liner and is closed about its periphery to define the first chamber therein.

14. A container according to any one of claims 1 to 13 wherein the second liner is attached to the first liner along a seal line generally bisecting the first liner to define the second chamber between the first liner, the second liner and the seal line.

15. A container according to any one of claims I to 14 wherein at one end the second liner is gusseted to provide clearance gaps between the second liner and the first liner at said one end.

16. A container according to any one of claims 1 to 15 wherein both the first and second liners are defined at least in part by a pair of blanks of material connected to each other.

17. A container according to claim 16 wherein the first and second blanks are each formed by at least one generally C-shaped panel of material.

18. A container according to any one of claims 1 to 17 wherein the first liner is formed from two blanks of material and the second liner is formed from one blank of material.

19. A container according to any one of claims 1 to 18 wherein the first liner is generally cylindrical in shape.

20. A container according to any one of claims 1 to 19 wherein the second liner is formed from two layers of material.

2 1. A container according to any one of claims 1 to 20 wherein the second liner has approximately one-half the surface area of the first liner.

22. A container constructed and arranged substantially as described herein and with reference to the drawings.

23. A method of making a container, comprising the steps of.

a) providing a first blank of flexible material; b) providing a second blank of flexible material; c) connecting together the first blank and the second blank along at least one line to define first and second liners of the container with the first liner having first and second portions, the second liner received within the first liner and having at least a portion movable relative to the first liner from a first position adjacent to the first portion and a second position adjacent to and generally conforming to the shape of the second portion of the first liner, connecting together the first blank and second blank also provides a first chamber defined by at least one of the first and second liners and a second chamber separate from the first chamber and defined by at least one of the first and second liners; and d) providing a first opening communicating the first chamber with the exterior of the container and a second opening communicating the second chamber with the exterior of the container.

24. A method according to claim 23 wherein each blank has a pair of flat panels disposed one on top of the other and being connected to each other along at least one edge and the blanks are connected together along heat seal lines such that both the first and second liners are formed by a portion of each of the first and second blanks.

25. A method according to claim 23 or claim 24 wherein each blank is initially generally "C-shaped" in cross section, and initially has an open side opposite to a closed side connecting together overlying flat panels of the blank, with a first blank inserted between the flat panels of a second blank and attached thereto along lines joining adjacent flat panels of each blank at their free sides without joining one flat panel of either blank directly to its other flat panel.

26. A method according to any one of claims 23 to 25 wherein the blanks are heat-sealed together along lines on a plane generally bisecting the container.

27. A method according to claim 26 wherein said plane extends generally diagonally through the container.

28. A method according to claim 26 wherein said plane is generally parallel to a pair of opposed walls of the container when the container is expanded.

29. A method according to any one of claims 23 to 28 wherein the first blank defines the first liner and the second blank defines the second liner and the second liner is connected to the first liner along at least one line permitting movement of the second liner relative to the first liner between first and second positions.

30. A method according to any one of claims 23 to 29 wherein the first blank and second blank are generally rectangular when empty and laid flat and are each formed by sealing a pair of superimposed flat panels about their perimeters to define an enclosure therein, with the second blank received within the enclosure of the first blank and heat sealed to the first blank.

3 1. A method according to any one of claims 23 to 30 which also comprises the step of providing a gusset within the second blank at one end thereof.

32. A method according to any one of claims 23 to 31 wherein the first blank is formed from two panels generally C-shaped in cross-section and the second blank is formed from a single panel generally C-shaped in cross-section and disposed between the panels of the first blank in assembly.