WO2004103797A2

WO2004103797A2 - Flexible containers

Info

Publication number: WO2004103797A2
Application number: PCT/EP2004/005419
Authority: WO
Inventors: Mathew Louis Steven Leigh; Daryl Louis Van Leigh
Original assignee: Phares Pharmaceutical Research N.V.
Priority date: 2003-05-20
Filing date: 2004-05-19
Publication date: 2004-12-02
Also published as: WO2004103797A3; EP1626911A2

Abstract

Primary and secondary containers for solid confectionery products are disclosed that may be used either together or separately. The primary container is a flexible container which is between 50mm to 100mm wide and 80mm to 95mm high and comprises a gusset pouch (10) made from laminates with dead fold characteristics that may be flared to provide a larger volume for filling and improved stability for upright display. The secondary container comprises a display outer (9) provided with a corrugated insert (1) for holding sachets and the like upright and optionally parasite clip arrangement (11) that is secured onto the back of the outer (9) to hang from the front and sides of shelves and stands including larger display units without taking up existing areas on top of counters or shelves.

Description

FLEXIBLE CONTAINERS

FIELD OF THE INVENTION

This invention relates generally to containers for confectionery products. More specifically it concerns flexible primary containers and secondary display outers.

BACKGROUND

Sachets and packets are flexible envelope-like containers with fixed volume for containment. Pouches are expandable /collapsible and more versatile than sachets for stand up display. They are sac-like primary containers with either parabolic or mitre seals at the bottom or they may be gusset-type bags and may be constructed from materials such as waxed paper, leather or thin plastic sheets and sealed along the folds at the bottom and crimped or sealed all around the base to add strength and provide a rigid and stable stand-up base. However it is difficult and expensive to form particularly small pouches that are less than about 75 to 100 mm wide that are heat sealed around the base and joined at the sides. Therefore pouches are usually employed only for large items and liquids.

Display outers are secondary containers for protection as well as merchandising. The boxes are usually made from rigid or semi rigid recycled paper or cardboard. Small primary containers such as sachets, pouches and packets for products as diverse as confectionery, cards, stickers, seeds, etc, are packed in display outers for point of sale display to encourage impulse buying. For this reason it is desirable that the outer should be as eye catching as possible, allow full visibility of the individual packs and further enable it to be sited anywhere.

Sachets and the like arranged upright in display outers will easily spill over unless adequate support is provided. The problem is greater in display outers where the sides and front are cut away and the sides slope down to a lowered front that does not provide adequate restraint. Furthermore, display outers require a flat or horizontal surface to sit on. For practical reasons inclined surfaces are not suitable because the individual sachets are not physically restrained and will topple over or fall off the shelves unless they are secured. Important factors which should also be considered are the limited counter and display areas available in retail outlets and fierce competition by manufacturers competing for premium display space. It is not unusual for display outers to have secondary 'piggy back' means so that they can be attached or hung from any surface. The attachment usually consists of hooks for hanging or pressure sensitive pads for adhesion on flat and clean surfaces. Neither method is satisfactory.

As used herein, the terms 'a', 'an' and 'any' are each intended to include both the singular and the plural forms.

SUMMARY OF THE INVENTION

The present invention is in the area of containers covering 'gusset pouches', 'display outer insert' and 'parasite arrangement for stand-up display of small packs preferably in an outer suspended from stands and the like without taking up existing counter top space.

Generally, the invention in one aspect deals with a handy flexible container comprising a sachet for pocket use and display containing small items such as sweets, compacts and solid unit dosage forms, with the functionality of a small expandable pouch having a fold inside the base which is neither crimped nor heat sealed, so that it may be flared to provide a larger volume for filling and improved stability for stand-up display. The gusset arrangement allows the pouches to be displayed separately standing up without using an outer for support, but preferably the pouches are packed in a secondary display outer. Furthermore, the light, deformable and compact size of the flexible container allow easy storage in the pocket or hand bag. In another aspect, the invention deals with a display outer comprising a novel and cost effective corrugated insert which provides all round support for containment and upright display of sachets and the like.

In still another aspect, the invention deals with a display outer having a parasite clip arrangement that is secured onto the back of the outer, to hang from the front or sides of shelves or stands including larger display units, without taking up existing areas on counters or shelves.

More specifically, the invention deals with a handy flexible container comprising a gusset pouch for unit solid dosage forms measuring between 50 mm -100mm wide and between 60-150 mm high, in particular between 80 - 95 mm, made from flexible material comprising an inner fold in the base that is not rigid or stiffened and may be flared to expand the volume and facilitate filling and provide a stable base for stand up display. More specifically, the invention deals with a flexible container comprising a gusset pouch for unit solid dosage forms measuring between 50 mm - 100mm wide and 80 - 95 mm high, the pouch being made from flexible metal foils or laminates with dead fold characteristics comprising an inner fold in the base which is not heat sealed and joined at the corners and may be flared to expand the volume and facilitate filling and provide a stable base for stand up display.

In another aspect, more specifically the invention deals with a display outer with an insert fabricated from corrugated material provided with furrows and ridges or alternative retaining means which sits snugly on the floor of said display outer to enable stand up display of sachets and the like and to prevent the sachets from toppling over or spilling out when the display outer is tilted.

In still another aspect, more specifically the invention deals with a display outer comprising a parasite arrangement secured to the back wherein said parasite arrangement comprises a Spine clip that is between 1cm to 10cm long and 0.5cm to 3 cm wide and 0.2 cm to 1 cm in thickness. The invention will now be described by way of example with reference to the accompanying drawing in which:

Fig 1 shows a corrugated insert cut to shape and scored.

Fig 2 shows a corrugated insert folded along score lines to fit in a display outer with sloping sides.

Fig 3 shows a variant of the corrugated insert from Fig 2a with a tall centre partition.

Fig 4 shows a display outer without insert.

Fig 5 shows the outer and short insert in place.

Fig 6 shows the outer and tall insert in place.

Fig 7 shows an outer with tall insert holding the sachets upright on a tilted surface.

Fig 8 illlustrates a display outer with Spine clip arrangement for parasiting onto a stand or other suitable structure.

Fig 9 shows the base of a strip of laminated foil folded across the middle and folded back on both sides to form an inner fold.

Fig 10 shows an empty flexible container in profile partially flared and not joined at the four corners in the stand up position.

Fig 11 is a drawing of a filled flexible container in the stand up position resting on partially flared base. DETAILED DESCRIPTION OF THE INVENTION

'Parasite arrangement' is a device or clip arrangement which may be attached or secured by any suitable means to the back of a display outer for suspending from any support including display stands, shelves and other suitable rigid structures including larger display outers.

'Flexible container' is a type of flexible sachet or expandable pouch typically a small gusset pouch that is deformable and has at least one inner fold inside the base that may be flared or partially flared open to provide a larger volume for containment and a broad stand-up base with four corners for increased stability in the upright position.

'Pocket-use' includes storage in pockets and hand bags.

'Corrugated' is defined as an insert material made from layers of heavy paper the top layer of which is grooved and ridged. The definition also covers any rigid or semi rigid sheet material that has a corrugated surface or the like extending but not limited to slits, channels, furrows, and slots.

The flexible container

A handy flexible container for pocket use and/ or display comprising a small sachet with the functionality of a gusset pouch forms the first aspect of the invention. The container may be used on its own separate from the display outer as a primary container for small, compacted or moulded confectionery items such as sweets or the like. Preferably the sachet-like pouches are packed in the stand-up position in a secondary display outer provided with corrugated insert and preferably with Parasite clip. The weight of the empty flexible container is minimal, below 5 grams. The weight of a re-closable empty pouch with re-sealable zip closure, measuring about 60mm wide and 80 mm high with a 5 mm fold (gusset) giving a flared base of 10 mm (unfolded) is below 3 grams, preferably below 2 grams. By comparison a card-board container with a flip-top and similar nominal dimensions weighs over 5 grams whilst the equivalent in plastic weighs over 15 grams. The flexible container employs raw materials extremely cost efficiently. It reduces shipping costs and makes disposal or recycling easier because of the small amount of material used. Furthermore it facilitates storage due to the compact, handy size and combines the functionality of a pouch for carrying in pockets and personal hand bags compared to rigid containers.

The pouch is formed from a folded strip of flexible material with an inner fold tucked inside the blind end as in the letter ' W which may be flared or unfolded to provide a gusset for increased volume for contents and a broad base for better stability and stand up display. The versatility is particularly desirable because the gusset base may be folded or collapsed to resemble a small sachet and reduce the dead space inside the pouch for packing into display outers and storage. Because the base is not crimped or heat sealed all around for rigidity like other pouches particularly those with parabolic or mitre seals, it may be flared to stand the pouch upright e.g. when required for display without the outer.

The invention comprises deformable and expandable gusset pouches that are below 100mm wide x 150mm, within the range of 50mm -100mm width and 60mm-150mm height made from flexible aluminium, tin and laminated foils. Preferably the materials have dead fold characteristics to facilitate folding or creasing. More preferably it concerns small pouches between 50mm to 80mm wide and 60mm to 150mm in length. Most preferably it concerns small pouches between 50mm - 65mm wide by 60mm to 100mm in length made from said materials sandwiched between thermoplastic polymer layers of the desired thickness and hot melt properties. The pouches may be heat sealed or crimped along a width of about 5mm along the two edges (lateral) to provide more rigid side edging for locating between the grooves of the corrugations or similar arrangement. Unlike other pouches, the two folded panels at the base enclosing the inner fold (represented by the points in the letter 'W') are not heat sealed for rigidity. Therefore the two folds at the bottom on each side terminating at the four corners are not joined together and may be flared at the split to provide a flat base for standing up unsupported as illustrated in Figs 9 and 10 or 11, respectively.

The gusset pouch has a top opening optionally bonded with a re-closable or re- sealable closure to allow the pouch to be sealed again after use. Preferably the re- sealable pouches with closure are between 50mm - 80mm width by 60 mm to 100mm length. They may contain up to 50 grams of compressed or moulded sweets or other confectionery products, more preferably up to 25 grams, most preferably up to 20 grams gross weight.

Preferred examples of composite materials for making the pouches are laminates with dead fold characteristic and deformable. The laminate has an aluminium, foil sandwiched between a polymer like polyester (external printed surface), and a heat sensitive adhesive or thermoplastic polymer layers such as polyethylene (internal surface of the pouch). The heat sensitive side, e.g. polyethylene, is e.g. 25 to 100 micron layers, preferably about 50 to 75 micron of bonded on to 7 micron to 12 micron thickness aluminium foil. Other types of laminates with similar melting properties may be used.

These come in a roll with the desired nominal width corresponding to about twice the height of the pouch. Typically a roll of laminate 200mm wide is used for making flexible containers that are 85mm high with a 5mm inner fold that may be flared to give a 10mm base. The width of the pouch is 60mm with a 5mm wide heat seal along the 2 sides.

Fig 9 shows the base of the pouch. Typically in one embodiment the pouches are made by folding a strip of foil printed face down, along the middle. The folds are made using an upward 'kick' to the underside (print-side) along a horizontal strip of foil moving continuously forward in a form/ fill/ seal machine. The two side walls (panels) 16 are then folded in the opposite direction and brought together to form the front and the back panels 16 with an inner fold 12 between the two folds on each side forming the base (like the letter 'W'). The inner fold 12 may be up to 15 mm, preferably up to 10mm high. Using different dies and accessories depending on the type of machine, the inner fold may be formed between the folded base by means of an upward 'kick' after the two sides of the foil have been brought together. Yet again, all three folds may be formed simultaneously. This is not critical as long as the folds in the base are not made rigid, or otherwise stiffened, or strengthened by heat sealing, and they enclose an inner fold that may be flared. A re-sealable zip type closure 14 may be bonded inside the opening 15 at the top end of the two halves before the sides are sealed.

The two side walls or panels 16 are heat sealed or crimped at the sides 17 to form a pouch with a top opening 15 and a hidden inward fold at the blind end which splits the base at the sides in two (Fig 9). Because the two folds at the base divided by the inner fold terminate at the four corner edges 13 are not heat sealed and joined together, this allows the split at the sides 17 corresponding to the height of the inner fold 12 to be flared to provide a pouch with a flat base for improved stand-up stability. As far as we are aware this feature is not shared by pouches with parabolic and mitre seals which provide a fixed permanent base. Gusset pouches that are heat sealed at the base do not have free or split ends that can be flared.

Fig 10 is the profile of a collapsed pouch that resembles a sachet, illustrating the front panel 16 of the flexible container heat sealed down the two sides at 17 with an opening 15 on top and a re-closable zip 14. The gusset is tucked inside the folded end which is shown partially unfolded to provide a base defined by the corners 13.

Fig 11 is an illustration of an expanded flexible container and contents in the upright position.

Any suitable method or machinery may be employed for fabricating the flexible container described in this invention as long as it is capable of forming, sealing and filling small gusset pouches with dimensions below 100 mm wide and 150 mm high comprising at least one inner fold in the base whereby the volume of the pouch may be enlarged for filling. The type of equipment that is most suitable for forming and filling said gusset pouch are horizontal form-fill-seal machines made by e.g. Bossard and Sig. The machine and method employed are not limiting factors for making said gusset pouch. The features described with the flexible container described in this invention are not seen in pouches which have parabolic or mitre seals and use foils without dead' fold characteristics wherein the base is crimped and sealed either all around or along the folds for rigidity in the stand up position. The present invention describes a small flexible container for use with confectionery products which has an inner fold inside the base wherein the two side walls are not joined at the corner edges thereby allowing the split fold at the base to be flared providing a wide or a flat base. Thus the invention describes small flexible containers and their use thereof as primary containers for pocket-use as well as for stand up display in confectionery. The gusset type sachets are characterised by compact size, deformability and an expandable base that is not heat sealed with split sides which may be flared.

Display outer

A display outer may be used for displaying the sachet, pouch or the like in the stand- up position. Preferably it is used for sachets and pouches that are below 200mm x 400mm made from laminated paper and/ or other laminated materials such as aluminium and plastic. Preferably the display outer may comprise a parasite arrangement.

There is no limit on the number of sachets, pouches or other types of containers that may be used with the invention. This is largely dictated by the pack size and other considerations. Normally between 10 and 20 individual packs are contained in a display outer with corrugated insert. However the total gross weight of each display outer should not exceed 500 grams, preferably below 300 grams. Referring to the drawings, Fig. 1 is a semi rigid sheet provided with corrugations 1, scored and cut to shape. In Fig 2 and Fig 3 the fabricated insert 1 has a short and tall partition 3 respectively in the middle which is formed by folding the insert back on itself to provide two compartments 4a and 4b with sides 2 turned at 90°. Fig 4 illustrates the floor 7 of a typical display outer 9 with sloping sides 5 and low retaining front 6 without insert. In Fig 5 and Fig 6 the short and tall insert respectively fit snugly and is held securely in place by the sloping sides 2 butting against the sides 5 of the outer 9. In Fig 7, gusset pouches 10 are held upright individually in the compartment separated by a tall partition 3. They sit within the grooves which continue up the sides of the corrugated insert preventing the sachets from toppling over when the outer is tilted.

Referring to the drawing in Fig 8, the back of the display outer 9 has a Spine clip 11 secured by means of a double sided adhesive tape 110.

The Insert

Any semi rigid sheet material which is ridged or grooved may be used as insert material provided that it can be cut or moulded to shape, foldable and is cheap. In one embodiment, the insert is fabricated to cover only the floor of the display box. In preferred embodiments, the insert is provided with sides which may continue up the sides of the display thereby providing more corrugations for support. Preferably, the insert is folded back on itself across the corrugations at least once to provide two or more compartments with grooves running across it. The partition/ s may be higher

/taller or lower/ shorter than the height of the sachets and provide good lateral support. Thus each sachet will be held upright and constrained at the base and preferably on both sides. It may also be possible to use a thermoplastic material in place of paper laminate or cardboard within the scope of the invention provided that it is corrugated or has alternative retaining features for locating the crimped ends of the sachets or the like. The grooves or similar locating means may have straight or inclined sides which are at least 1mm deep and from 1 mm to 10mm, preferably from 2 mm to 5mm wide. If the insert is fabricated from substantially rigid material lighter board may be used for the display outer because the insert adds to the rigidity. Very little extra work is required to fabricate and assemble the inserts for use in display outers. Furthermore the corrugations or channels allow the sachets to settle into position effortlessly.

The Parasite arrangement

The parasite arrangement comprises a Spine clip, preferably fabricated from a thermoplastic material. The clip has a flat and a slightly convex side forming a rounded spine meeting in a closed lip in front that can be readily prised open for inserting over any suitable support such as display stands (wire), cabinets, shelves and the like. Indeed the support or structure that the invention may parasite onto is not a limiting factor and may even be a larger display outer.

A preferred embodiment of the Parasite arrangement comprises a plastic Spine clip sirnilar in principle to the plastic Spines used for binding sheets of loose paper into folders. A double sided adhesive tape such as 3 M pressure sensitive tape is used for securing the flat surface of the Spine clip to the back of the display outer as shown in Fig 8. The clip may be used to parasite the display outer and contents by hanging or suspending from display stands, shelves and other support means by simply inserting the clip over the host without using hooks or adhesive pads.

The dimensions and size of the Parasite arrangement depend on the size and weight of the display outer. Typically, each individual Spine clip may be between 1cm and 10 cm long and 0.5 cm to 3 cm wide and 0.2 cm to 1 cm in thickness. Preferably for a display outer measuring approximately 12 cm wide x 10 cm deep and 9.5 cm high with a gross weight about 250 gm, the clip measures about 4 cm in length, 1.3 cm wide and 0.6 mm thick. The material used may be e.g. PVC or other rigid but deformable plastic material. A suitable and cost effective method of fabricating the clips may be from A4 Spine bars supplied by Hunke & Jochheim GmbH and Co. D- 58634 Iserlohn under the trade name Durable. Seven 4 cm Spine clips may be cut from a length of A4 Spine bar measuring 30 cm long x 1.3cm wide and 0.6cm thickness. A pressure sensitive double sided tape from 3M is used to secure each cut- length to the back of a display outer. The tape may be applied to the Spine bars either before or after cutting to size. The Parasite arrangement or Spine clips may also be fabricated by injection moulding to specification. In this case the specially formed Spine clips may be provided with rounded ends on the convex side to guide it over a support. The Parasite arrangement which forms another aspect of this invention is used with a stand up display outer and insert containing multiple packs, preferably small gusset pouches and sachets with a total gross weight of up to about 500 gm, preferably about 400 grams, most preferably below 300 grams. However it should be clearly understood that the Spine clip may be fixed to any secondary display outer with insert for any type of primary pack including rigid box-like containers. The main object is to utilise/create new display space for the display outer by parasiting onto supporting structures including but not limited to wire framed display stands, cabinets, shelves and other display outers or appliances without using hooks and self adhesive pads.

Given the advantages in having some means which allow small pouches and the like to be attractively displayed anywhere including flat surfaces without toppling and spilling over in the display box, the extra cost of material involved should also be affordable. Thus for any improvement to be adopted, the invention must have marginal impact on the costs of assembly and packaging. Taking these into account, the invention has high industrial applicability because the extra costs for parasiting and creating additional display space do not involve anything more than allowing for an extra piece of economical and readily available Spine bar cut to size and secured onto the back of the display outers. Furthermore for inserts, any semi rigid sheet material which is ridged or grooved may be used as alternative insert material provided that it can be cut or moulded to shape, foldable and is cheap.

According to the present invention there is provided primary and secondary containers for solid confectionery products that may be used either together or separately. The primary container comprises a flexible container between 50mm to 100mm wide and 80mm to 95mm high and comprises a folded gusset at the base made from laminates with dead fold characteristics that may be flared to provide a larger volume for filling and improved stability for upright display. The secondary container comprises a display outer provided with a corrugated insert for holding sachets and the like upright and optionally parasite clip arrangement that is secured onto the back of the outer to hang from the front and sides of shelves and stands including larger display units without taking up existing areas on top of counters or shelves.

Claims

1. A flexible container comprising a gusset pouch (10) for unit solid dosage forms measuring between 50 mm -100mm wide and 60mm -150mm high made from flexible material comprising an inner fold (12) in the base that may be flared to expand the volume and facilitate filling and provide a stable base for stand up display.

2. A flexible container according to claim 1, wherein the gusset pouch is made from flexible metal foils or laminates with dead fold characteristics wherein the inner fold in the base is not heat sealed and joined at the corners

3. A flexible container according to claim 1 or claim 2, weighing less than 3 grams when empty.

4. A flexible container according to any one of the preceding claims for use as a primary container, further containing unit solid dosage forms such as sweets or confectionery and having a gross weight below 20 grams.

5. A flexible container according to any one of claims 2 to 5, wherein the laminate comprises an aluminium foil sandwiched between a polymer like polyester, and a heat sensitive adhesive or thermoplastic polymer layers such as polyethylene, wherein the heat sensitive adhesive or thermoplastic polymer layers is between 25 to 100 micron, preferably between about 50 to

75 micron, bonded on to 7 micron to 12 micron thickness aluminium foil.

6. A display outer (9) comprising a parasite arrangement secured to the back wherein said parasite arrangement comprises a Spine clip (11) that is between 1cm to 10cm long and 0.5cm to 3 cm wide and 0.2 cm to 1 cm in thickness.

7. A display outer according to claim 6, wherein the Spine clip (11) is fabricated from PVC or a thermoplastic material and is secured to the back of a display outer by means of pressure sensitive tape (110).

8. A display outer according to claim 6 or claim 7, further comprising a corrugated insert (1) provided with furrows and ridges or alternative retaining means, the insert (1) sitting snugly on the floor (7) of said display outer (9) to enable stand up display of flexible containers, sachets and rigid primary containers to prevent them from toppling over or spilling out when the display outer (9) is tilted.

9. A display outer according to claim 8, wherein the insert (1) further comprises corrugated sides (2) which are arranged to continue up the sides (5) of the outer (9).

10. A display outer according to claim 9, wherein the insert (1) further comprises a partition (3) to form two compartments with the sides (5) of the insert (1).

11. A display outer (9) comprising a corrugated insert (1) provided with furrows and ridges or alternative retaining means, the insert (1) sitting snugly on the floor (7) of said display outer (9) to enable stand up display of flexible containers, sachets and rigid primary containers to prevent them from toppling over or spilling out when the display outer (9) is tilted.

12. A display outer (9) according to claim 11, wherein the insert (1) further comprises corrugated sides (2) which are arranged to continue up the sides (5) of the outer (9).

13. A display outer (9) according to claim 12, wherein the insert further comprises a partition (3) to form two compartments with the sides (5) of the insert (1).

14. A display outer according to any one of claims 11 to 13, further comprising a parasite arrangement secured to the back wherein said parasite arrangement comprises a Spine clip (11) that is between 1cm to 10cm long and 0.5cm to 3 cm wide and 0.2 cm to 1 cm in thickness.

15. A display outer according to claim 14, wherein the Spine clip (11) is fabricated from PVC or a thermoplastic material and is secured to the back of a display outer by means of pressure sensitive tape (110).

16. A display outer according to any one of claims 6 to 15, further comprising a plurality of flexible containers according to any one of claims 1 to 4, wherein the flexible containers are arranged to stand in an upright position within the display outer.