Flexible packaging and containers

Abstract

Flexible packaging and containers are provided. In one aspect, a flexible container is provided that comprises a single piece of flexible material as a primary or sole component of construction. In preferred aspects, the flexible container comprises at least six sides.

Description

348648.00700FLEXIBLE PACKAGING AND CONTAINERSThis application claims the benefit of U. S. provisional application no. 63 / 728,141 filed December 4, 2024, which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0001] The present disclosure relates to flexible packaging and containers, including child resistant flexible container.BACKGROUND

[0002] Certain flexible packaging materials and containers have been reported. For instance, flexible containers have been reported that consist of a pouch formed by two or more sealed sheets. The closed pouch is opened by tearing the pouch at one end such that each of the two or more joined sheets are tom.

[0003] It would be desirable to have new and improved packaging materials and containers.SUMMARY

[0004] We now provide new flexible packaging and containers. In one aspect, a flexible container is provided that comprises a single piece of flexible material as a primary or sole component of construction.

[0005] In preferred aspects, the flexible container comprises at least six sides. Each side may be substantially the same size, or the sides may differ in size. Preferably, the flexible container can securely rest on a surface on one or more of the sides or faces. Containers of a variety of overall configurations may be suitable, including substantially cubic, and a variety of cross-sectional shapes for example wedge shaped, rectangular and higher order configurations such as pentagonal, hexagonal and octagonal, or other crosse-sectional shapes that may not include sides (periphery) edges such as circular or oval (ellipsoidal) edges.

[0006] In certain preferred systems, a flexible container may comprise one or more gusset type sides. In certain aspects, a container bottom side has a gusset configuration. In certain aspects, a container bottom side and opposing top face both have a gusset configuration. As referred to herein a gusset includes an expandable panel on a portion of a container that can add dimension (e.g. depth) and volume to the container.179861977.1 1348648.00700

[0007] In certain preferred aspects, a flexible container will have a multiple use opening to add or remove materials to the container. That is, the opening can be opened and closed multiple times.

[0008] In certain aspects, the flexible container contains a child resistant opening. For example, in preferred systems, a flexible container comprises one or more child resistant zippers.

[0009] The present flexible containers may comprise other opening units including a cap that may include a lid portion. In aspects, the cap-lid component may be child resistant.

[0010] The flexible container may be formed from a variety of materials including a plastic, a polymer, one or more biodegradable materials or biocompostable materials, or a combination thereof. For example, the plastic is selected from the group consisting of polypropylene, polyethylene, polystyrene including high impact polystyrene (HIPS), polycarbonate, acrylic, polyethylene terephthalate (PET), polylactic acid (PLA - which can be biodegradable), or a combination thereof.

[0011] In a further system, a container unit is provided comprising a plurality of flexible containers as disclosed herein. The container unit may be a sleeve element, a box element, or a bag element. The flexible containers can be suitably arranged or nested in a packaging unit in a variety of configurations. In an aspect, the flexible containers are nested within the container unit in an abutting matter. In one aspect, a plurality of flexible containers are stored within the container unit in a stacked orientation, with each flexible container abutting the adjacent flexible container. In other aspects, such as where the container unit is a bag, the plurality of flexible containers may be loosely arranged. The container unit comprises for example at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32 or more flexible containers. In certain aspects, a container unit comprises less than 40, 35, 30, 25, 20.15 or 12 flexible containers.

[0012] In additional aspects, methods are provided for producing a flexible container as disclosed herein.

[0013] Other aspects are disclosed infra.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Features and advantages of the claimed subject matter will be apparent from the following description of embodiments consistent herewith, which the description should be considered in conjunction with the accompanying drawings.

[0015] FIG. 1 illustrates a top perspective view of an embodiment of a flexible container.179861977.1 2348648.00700

[0016] FIG. 2 illustrates a bottom view of the embodiment of a flexible container cap of FIG. 1.

[0017] FIG. 3 illustrates a top view of an embodiment of a flexible container.

[0018] FIG. 4 illustrates a stack of multiple flexible containers.

[0019] FIG. 5 illustrates a further stack of multiple flexible containers.

[0020] FIG. 6 illustrates a further stack of multiple flexible containers.

[0021] FIGS. 7, 8, 9 and 10 depict a preferred flexible container.DETAILED DESCRIPTION OF THE INVENTION

[0022] The present disclosure related to flexible containers. The disclosure also relates to child-resistant containers. The container can be understood more readily by reference to the following detailed description of the invention. It will be apparent to those skilled in the art that various modifications can be made without departing from the scope of the invention.

[0023] As used in the specification and the appended claims, the singular forms “a,” “an” and ‘“the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “an element” includes two or more elements.

[0024] Ranges can be expressed herein as from one particular value, and / or to another particular value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent ‘about,’ it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0025] As used herein, the terms “about” and “at or about” mean that the amount or value in question can be the value designated some other value approximately or about the same. It is generally understood, as used herein, that it is the nominal value indicated ±10% variation unless otherwise indicated or inferred. The term is intended to convey that similar values promote equivalent results or effects recited in the claims. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and / or larger or smaller, as desired, reflecting 179861977.1 3348648.00700tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is “about’’ or “approximate” whether or not expressly stated to be such. It is understood that where “about” is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless specifically stated otherwise.

[0026] The terms “first,” “second,” “first part.” “second part,” and the like, where used herein, do not denote any order, quantity, or importance, and are used to distinguish one element from another, unless specifically stated otherwise.

[0027] As used herein, the terms “optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. For example, the phrase “optionally affixed to the surface” means that it can or cannot be fixed to a surface.

[0028] As used herein, a “flexible container” of a “flexible material” includes a thin, readily deformable material, for example having a flexibility factor of 1,000-2,500,000 N / m. A flexible container and flexible material of a container preferred can be folded or flattened and then expanded to provide interior space of the container when in use. Exemplary materials of construction of a flexible container include e.g. films (such as plastic films), elastomers, foils, fabrics (including wovens and nonwovens), biosourced materials, and papers. In particular aspects, flexible materials such as films and nonwovens can be provided thermoplastic polymers, e.g. polyolefins such as polyethylene and / or copolymers thereof, including low density, high density, linear low density, or ultra low density polyethylenes. Nylons and other materials including fabrics can be utilized. Biodegradable materials can be preferred.

[0029] Other suitable polymers include polyamides or copolymers thereof, such as Nylon 6, Nylon 11, Nylon 12, Nylon 46, Nylon 66; polyesters and / or copolymers thereof, such as maleic anhydride polypropylene copolymer, polyethylene terephthalate; olefin carboxylic acid copolymers such as ethylene / acrylic acid copolymer, ethylene / maleic acid copolymer, ethylene / methacrylic acid copolymer, ethylene / vinyl acetate copolymers or combinations thereof; polyacrylates, polymethacrylates, and / or their copolymers.

[0030] It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that 179861977.1 4348648.00700the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification.

[0031] It is understood that the containers, materials and devices disclosed herein have certain functions. Disclosed herein are certain structural requirements for performing the disclosed functions, and it is understood that there are a variety of structures that can perform the same function that are related to the disclosed structures, and that these structures will typically achieve the same result.

[0032] One aspect of the present disclosure is a child-resistant container. The childresistant containers are configured to store, hold and / or preserve a substance or a material as well as providing a mechanism for child-resistance.

[0033] Generally, the child-resistant containers described herein comprise a flexible container base together with an ingress (opening) to the container that can be secured to be child resistant. When the flexible container is in a closed configuration, the child resistant closing unit (e.g. zipper, cap) is engaged or in a closed or sealing position, or otherwise inhibiting or preventing entry to the interior of the flexible container. In this aspect, in a closed configuration, the container is substantially child-resistant, that is, a child would have a difficult time accessing the interior of the flexible container.

[0034] The flexible container suitably may have a closed bottom end, an open or openable top end and an outer or side surfaces.

[0035] The flexible container suitably may have topography and / or markings on one or more sides of the container. The visual markings and / or topography (e.g. ridges or indentations) can be used for gripping the flexible container and / or distinguish one side of the container from another side or to identify the container and source. In one aspect, the markings can be, for example, slightly raised from the outer surface of the container base.

[0036] As discussed above, in certain aspects, the flexible containers may be stackable or otherwise nestable with each other. In certain preferred aspects, the flexible containers are child resistant.

[0037] FIG. 1 depicts an exemplary preferred flexible container 10 that includes top portion 12, sides 18 and 20and bottom portion 22. Container 10 includes a releasable closing unit 14 such as a client resistant zipper of the drawings. Dimensions of the container can suitably vary widely. For example, container width (shown by "x” in FIG. 1) may be e.g. up 179861977.1 5348648.00700to or at least 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.4, 1.6, 1., 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 15, 18, or 24 inches, and container height (shown byin FIG. 1) may be e.g. up to or at least 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.4, 1.6, 1., 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 15, 18, or 24 inches. In certain preferred embodiment, container width (“x” in FIG. 1) and container height ("y" in Fig. 1) are substantially the same and differ by no more than 2, 5, 10, 20 or 30 percent.

[0038] FIG. 2 depicts flexible container 10 with folded portions 30. 32. 34 and 36 that form a side of container 10. FIG. 3 shows container 10 that depicts the top face with extended width (e.g. a width of at least 5, 10, 15, 20, 30, 40 or 50 percent of the container length) distinct from a package that does not have a top face, such as where material of construction is folded or sealed together without an extended side face. In FIG. 3, container 10 top face includes portions 51 and 54. Container 10 suitably may have a one-time or re-sealable (multi-use) opening 52.

[0039] FIGS. 4, 5 and 6 show containers 10 in stacked arrangement. In FIGS. 4, 5 and 6, stack of containers 10 include mating portions 60. 62 to form container face. As shown in FIGS. 5 and 6, preferred container 10 at the top of the stack includes a re-sealable opening 51 which may include e.g. a zipper or press-fit engagement and may be a child resistant opening. As ca be seen in FIGS. 5 and 6, opening portion 51 in preferred aspects extends upward from the planer surface of container top face. For example, the length of upward extending portion 51 may be up to or at least 0.1. 0.2, 0.3, 0.4. 0.5, 0.6, 0.7, 0.8. 09.9, 1. 1.4, 1.6, 1.8, 2, 3 or 4 inches or more.

[0040] In certain aspects, the opening portion (51 in FIGS 4-6), may have a greater width (e.g. 1, 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 30, or 40 percent or more greater width) than the container width that the opening portion adjoins or mates with.

[0041] In certain aspects, the opening portion (51 in FIGS 4-6), may extend outward from the container at varying configurations, e.g. substantially perpendicular from adjoining container planar surface, or other angle either greater than or less than 90 degrees, including about 30-80 degrees such as about 40-60 or about 45 degree.

[0042] As discussed, the present flexible containers can be formed from any suitable material. For example, a flexible container may comprise as a material of construction a plastic, a polymer, paper-based material, recycled material, or a combination thereof. For example, the plastic is selected from the group consisting of polypropylene, polypropylene copolymer, ultra-clarified polypropylene, colored polypropylene, polyethylene, polystyrene,179861977.1 6348648.00700polycarbonate, acry lic, polyvinyl chloride, PET, acrylic, or a combination thereof. Suitable materials of construction may be commercially available.

[0043] To form a flexible container, a single sheet or piece of a material of construction (e.g. flexible polymer web) can be folded over with spaced provided for bottom and top sides, e.g. through use of a forming collar, that can provide folds or spaced and thereby form gussets on the container side. As desired, an opening unit can be included in the container, e.g. zipper component that may be child resistant. The edges of folded material of construction suitably can be sealed, e g. heat sealed optionally with use of an adhesive.

[0044] In one preferred construction process, the following steps may be employed: 1. Material (e g. polymer sheet) is printed; 2. The printed material is laminated; 3. The material is laser scored across the web, preferably with multiple such as 2 laser scores per pouch; 4. material is taken to the pouch machine for converting.

[0045] Thereafter, after those steps 1-4, the following steps 1-6 may be employed to fold the material (web) processed above and form a flexible container: 1. Web is folded e.g. in half; 2. e side gusset is plowed in on one side; 3. an opening unit such as a zipper (may be a child resistant zipper, including a commercially available child resistant zipper) is inserted; 4. side seal and second gusset is plowed into the other side; 5. In a preferred aspect, seal bars seal the sides; and 6. in preferred aspects, diecut cuts the material in the seal area.

[0046] The material being packaged can be e.g. a material sensitive to one or more environmental factors. Sensitivities include, but it not limited to, air, water, oxygen, light, UV, temperature, bacteria, or combinations thereof. For example, the material is a consumer product, pharmaceutical, nutraceutical, herbal material, botanical material, food product, animal-based product, plant-based product, or the like. In certain aspects, preferred flexible containers can create a substantially air-tight seal, liquid-tight seal or both.

[0047] FIGS. 7, 8, 9 and 10 depict a preferred flexible container. Referring to FIG. 7, in one aspect, container 100 is shown in substantially folded configuration, wherein top portion 102 is depicted folded together. In an aspect, top portion 102 a top end 104 that may include notch 106 that can facilitate opening of the container 100 and top portion 102 and separation of two sheets of top portion 102 to provide ingress of selected materials to the flexible container 100. Bottom container portion 110 suitable includes a plurality of distinct or separate portions such as such as 2, 3, 4 or more of distinct or separate portions 112, 114 and 116 as shown exemplified in FIG. 7. In FIG. 7, those portions 110 114 and 116 can be folded over each other so the entire container 100 can be stored (typically substantially empty of contained materials) substantially flat. The dimensions of each bottom portion 112, 114 179861977.1 7348648.00700and 116 can vary. Each of the portions can be substantially the same (e.g. 15, 10, 5, 4, 3, 2 or 1 percent of the same length and width) or more differing dimensions. For instance, the dimensions x and y of portion 116 as shown in FIG. 7 may be about the same or different (e.g. differ up to or at least 3, 5, 8, 10, 12, 15 or 20 percent) and in aspects suitably each independently may be in 0.2. 0.4, 0.6, 0.8, 1, 1.2, 1.4, 1.6, 1.8, 2.0, 2.2, 2.4, 2.6, 2.8, 3.0, 3.2, 3.4, 3.6, 3.8, 4, 4.2, 4.4, 4.6, 4.8 or 5, 6, 7, 8, 9 or 10 inches. Also, the dimensions x’ and y’ of portion 114 as shown in FIG. 7 may be about the same or different (e.g. differ up to or at least 3, 5, 8, 10, 12, 15 or 20 percent) and in aspects suitably each independently may be in 0.2. 0.4, 0.6, 0.8, 1, 1.2, 1.4, 1.6, 1.8, 2.0, 2.2, 2.4, 2.6, 2.8, 3.0, 3.3, 3.4, 3.6, 3.8, 4, 4.2, 4.4, 4.6, 4.8 or 5, 6, 7, 8, 9 or 10 inches.

[0048] FIG. 8 shows flexible container 100 with bottom portions including 112 and 116 is expanded or more open configurations as may be suitable to receive or contain materials. Top portion 102 is also depicted in a opened arrangement in FIG. 8.

[0049] FIG. 9 shows a bottom view with flexible container 100 having bottom portions 114 and 116 in an open and expanded arrangement and configured to receive materials.

[0050] FIG. 10 shows a side view of flexible container 100 with the bottom portion 110 (including 112, 114 and 116) in a more fully expanded arrangement, for example to either receive or contain added materials.

[0051] The present disclosure relates, in various aspects, to containers for storing substances of restricted use. The Consumer Product Safety Commission (CSPC, www.cspc.gov) provides guidance for packaging drugs and other controlled substances for special child-resistant and senior friendly packaging (CRP). The CSPC also administers the Poison Prevention Packaging Act of 1970 (PPP A), 15 U. S C. § 1471-1476 Substances for restricted use as intended in this application include but are not limited to tobacco, medicines, federally controlled substances, nutraceuticals and / or vitamins. The substance may be sensitive to environmental exposure and is liable to decay, decomposition, loss of desirable property upon exposure, for example, pharmaceutical medications, herbal products, botanical products. A substance for storage in a container of the invention may include but is not limited to one or more of the components or drugs classified under Schedules I, II, III, or Schedule IV in the Controlled Substance Act (CSA) by the Drug Enforcement Authority of the United States of America (https: / / www.dea.gov / druginfo / ds.shtml): combination products with less than 15 milligrams of hydrocodone per dosage unit (Vicodin), cocaine, methamphetamine, methadone, hydromorphone (Dilaudid). meperidine (Demerol). oxycodone (OxyContm), fentanyl Dexedrine, Adderall, and Ritalin; products containing less 179861977.1 8348648.00700than 90 milligrams of codeine per dosage unit (Tylenol with codeine), ketamine, anabolic steroids, testosterone; or products including Xanax, Soma, Darvon, Darvocet, Valium, Ativan. Talwin, Arnbien, Tramadol.

[0052] The present disclosure relates, in various aspects, to containers and devices for storing other substances including food products (both liquids and solids).

[0053] The present disclosure relates, in various aspects, to containers for storing noningested materials such as cosmetics, personal items such as jewelry, watches. The present container also may be used to store and dispense topical applied products as creams (including hydrating creams) and sun-screen products, cleaning products including soaps and shampoos.

[0054] The flexible container can be comprised of one or more of the same, similar or distinct materials including one or more plastics, plastic composite, reinforced plastic, a copolymer polypropylene, ultra-clarified polypropylene, colored PP, PET, PETE, PS, PC, a combination thereof and other materials as discussed above. The container could be prepared, for example, from a combination of any of the materials listed below: polypropylene, high density polyethylene, polystyrene, polytetrafluoroethylene, polyvinylchloride (PVC), polychlorotrifluoroethylene, phenol-formaldehyde resin, para-aramid, polyethylene terephthalate, polychloroprene, polyamide, polyacrylonitrile, copolyimide, aromatic polyester, or other resin or plastic,

[0055] The disclosure provides a method of storing a material in a child resi stant container.

[0056] In aspects, the present containers may be disposable for example, the container which, after dispensing a product to an end user, is not configured to be refilled with an additional amount of the product, but is configured to be disposed of (i.e. as waste, compost, and / or recyclable material). In other aspects, a container may be re-usable, i.e. for example, the container which, after dispensing a product to an end user, is configured to be refilled with an additional amount of the product.

[0057] The present container also may include either visual or tactile indicators which may be color, textual, or shape-coded. Other types of detectable labels may also be used. These labels or indicators provide a notification of the content or content category of materials contained in the container.

[0058] For example, a container may including printed labelling directly printed on a container. The container also may comprise tactile or other indicators such as contacts / dots, a QR code, or an RFID chip enabling e.g. identifying materials contained within the container.179861977.1 9348648.00700The QR code or other label (e.g., lot code, bar code, consumer readable information such as product name, expiration date, or the like) may be applied e.g. to a side, top or bottom of a container

[0059] In aspects, a container may be suitably formed to contain up to or at least about 1 to 30, 150, 80, 100, 200, 300, 400 or 500 grams or more materials including ingestible materials. In aspects, the contained materials (including ingestible materials) may be of solid form and / or liquid form.

[0060] In aspects, the longest dimension of a container may suitably be at least about or up to about 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 18, 24 or 36 inches, and more typically may be at least about or up to about 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 15 or 18 inches.

[0061] While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.179861977.1 10

Claims

348648.00700CLAIMSWhat is claimed is:

1. A flexible container comprising:a single piece of flexible material; andat least six sides.

2. The flexible container of claim 1 wherein the container further comprises a child resistant opening.

3. The flexible container of claim 1 or 2 wherein the container comprises one or more gusset sides.

4. The flexible container of any one of claims 1 to 3 wherein the container comprises a bottom face gusset.

5. The flexible container of any one of claims 1 to 3 wherein the container comprises a bottom face gusset and a top face gusset.

6. The flexible container of any one of claims 1 to 5 wherein the container width is at least or up to 0.5 inches.

7. The flexible container of any one of claims 1 to 5 wherein the container width is at least or up to 1, 2, 3, 4, 5 or 6 inches.

8. The flexible container of any one of claims 1 to 7 wherein the container height is at least or up to 1. 2, 3, 4. 5 or 6 inches.

9. The flexible container of any one of claims 1 to 8 wherein the container comprises a polymer material of construction.

10. The flexible container of any one of claims 1 to 8 wherein the container comprises a paper material of construction.179861977.1 11348648.0070011. The flexible container of any one of claims 1 to 10 wherein the container comprises a biodegradable material of construction.

12. The flexible container of any one of claims 1 to 11 wherein the container comprises a polymer material of construction.

13. The flexible container of any one of claims 1 to 12 wherein the container comprises a transparent or translucent material of construction.

14. The flexible container of any one of claims 1 to 13 wherein the container comprises an opening portion.

15. The flexible container of claim 14 wherein the opening portion is sealable.

16. The flexible container of claim 14 wherein the opening portion comprises a zipper.

17. The flexible container of claim 14 wherein the opening portion comprises a cap unit.

18. The flexible container of any one of claims 14 to 17 wherein the opening portion is child resistant.

19. The flexible container of any one of claims 1 to 18 wherein the container comprises an outwardly extending flange portion.

20. The flexible container of any one of claims 1 to 19 wherein the container top face comprises an outwardly extending flange portion.

21. The flexible container of any one of claims 19 or 20 wherein the flange portion comprises an opening portion.

22. The flexible container of any one of claims 1 to 21 wherein the container is substantially cube shaped.

23. The flexible container of any one of claims 1 through 22 wherein the container crosssection shape is substantially square, rectangular, wedge-shaped, pentagonal, hexagonal, octagonal, circular or elliptical.179861977.1 12348648.0070024. The flexible container of any one of claims 1 through 22 wherein the container crosssection shape is substantially square or rectangular.

25. The flexible container of any one of claims 1 to 24 wherein the container is at least partially filled with a consumable material.

26. A method for producing a flexible container of any one of claims 1 to 24 as described herein.

27. A method of claim 26 wherein a single unitary material of construction is utilized to form the flexible container.

28. A container unit comprising one or more flexible containers of any one of claims 1 to 25.179861977.1 13

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