DESC:FIELD OF THE INVENTION

The present invention relates generally to flexible containers for packaging a product. More particularly, the present invention relates to a flexible container having at least one shaped/profiled panel, and a method and an apparatus for manufacturing said flexible container.

BACKGROUND OF THE INVENTION

Various types of disposable, portable containers are known in the art for packaging of products including fluid such as liquids (e.g. beverages), solids (e.g. pieces, powdered or granular etc.) or semi-solids (e.g. pastes, creams or gels etc.) food or non-food products or the like. Rigid and Flexible containers for example plastic, paper/paperboards, glass containers and metal cans/containers have traditionally been used to package liquid and solid consumer products.

While most rigid containers are strong, they are, because of the amount of material used in their production more expensive than flexible containers. Further, the rigid containers take up more space due to inflexibility in the type of packaging.

In an effort to overcome the problems associated with these types of rigid packaging containers, flexible containers for example, flexible pouches are widely used for packaging a variety of consumer products.

Consumers prefer the convenience of flexible containers because the flexible packaging materials are less expensive, provide a lighter package and takes up less space when empty than metal, glass, rigid/semi-rigid plastic containers or rigid/semi-rigid paper/paperboard containers. Moreover, consumers prefer flexible containers due to their attractive shapes, size, easy handling(in terms of carrying from one place to another e.g. market to home), light weight, comparatively less consumption of raw materials (more environment friendly) and for the convenience features which can easily be induced for better product dispensing and consumption. As far as shelf life is concerned such flexible containers do not provide a similar shelf life as compared to rigid/semi-rigid metal, glass, paper and/or paperboard and plastic containers. However, flexible containers do provide enough shelf life to filled product till the time period it is bought and safely consumed by consumer.

Manufacturers recognize the packaging benefits of a flexible container, as said flexible container can be formed and filled on either the same or a little modified manufacturing and filling lines used for existing rigid/ semi-rigid metal, glass, paper and/or paper board and plastic containers with minimal increase in manufacturing cost and packaging costs.

The flexible container is made from a flexible material, preferably a laminate composed of sheets of plastic, paper or aluminum or the like. The flexible material, for example, may be in the form of a sheet or a roll. An outer layer of the flexible material may include preprinted information, such as a logo, or the like, to provide the consumer with information regarding the contents of the container.

The flexible container may be formed using conventionally known manufacturing techniques, such as a horizontal form-fill seal machine, a flatbed pre-made container machine, a vertical form-fill machine, or the like. The container is generally formed by folding sheets of material over each other to achieve a predetermined shape. Edges, such as a side edge, are joined together using a sealing technique such as bonding or welding.

Alternatively, the flexible container is formed by laying one layer of flexible material over a second layer of material and forming a gusset along two parallel edges to form a container capable of standing unsupported. An upper edge of the front panel and back panel is generally not sealed until after the flexible container is filled with the consumer product. The empty flexible container may be placed in a holder such as a cup or puck prior to the filling process. To fill the container, the upper edges of the pouch are spread apart. For example, a concentrated flow of gas is directed towards the upper edge of the pouch to separate the panels. Grippers may also be utilized at the same time to pull the panels apart. The flexible container is filled, sealed and finished.

However, the contemporary symmetrical, standard flexible containers are generally plane i.e. without having any shapes. As such, the contemporary flexible containers lack the ability to attract customers, promote sales, placement/launching of a product in market and to create awareness of the products among consumers.

Further, the contemporary symmetrical, standard flexible containers lack appeal to induce brand or product differentiation, brand or product identification, brand or product recognition and also limit the possibilities of enhancing brand value. Moreover, such containers usually cannot amuse consumers and cannot be utilized to replace rigid or semi-rigid three-dimensional packaging formats.

Furthermore, the contemporary symmetrical, standard flexible containers are often unstable when resting on a supporting surface. For example, when resting on a table the limited stability of these containers makes them highly prone to wobbling or toppling when subjected to even a minimal degree of external contact. This can be a significant problem when the packages fall from the shelves of retail outlets.

In the light of above, it is often desirable to get the attention of the consumer by providing a more aesthetically pleasing flexible container. In particular, it is desirable to produce flexible containers of alternative shapes that are still inexpensive to produce and that are capable of attracting the consumers and are also capable of standing upright on the retail store shelf.

To this end, it is desirable to have a flexible container which may have graphics or other indicia applied to the shaped or plane front panel, shaped or plane rear/back panel, side panels including both the sides, shaped/plane folded or plane bottom panel which may represent any shape or art. Such depictions would increase the potential attraction and amusement value of the flexible container among the consumers. Moreover, the packaging may be done in a way which gives a three dimensional effect to the flexible container thereby increasing the aesthetics of the flexible containers.

One example is a flexible container with a front panel shaped like a teddy bear that can be pre-printed with the graphic and shape thereof. In the conventional method, there is no provision of giving shape to front panel, rear/back panel, side panels and folded/plane bottom panel. It is desirable to use the existing profile sealing and cutting tools in a new manner to give different shapes to front panel, rear/back panel, side panels and folded or plane bottom panel in various combinations to increase aesthetics of the flexible containers.

It is also desirable to be able to manufacture the flexible containers of the present invention using the same machinery and method with little to no modifications and the same or nearly the same amount of flexible material as that used to produce the symmetrical, standard containers, and to be able to fill these containers at the same rate as the symmetrical containers.

OBJECTS OF THE INVENTION

To address the aforesaid drawbacks, the present invention relates to a flexible container for packaging a product and a method and an apparatus for manufacturing the same.

A primary object and advantage of the present invention is to provide a flexible container comprising at least one of the shaped front panel, rear/back panel or side panel. The shaped panel has design such as any character or art, graphics or other indicia for example, design of a teddy bear, joker, dinosaur or the like, which makes the flexible container more attractive and aesthetically pleasing to the consumers.

Another object and advantage of the invention is to provide a flexible container with standup features capable of maintaining an upright position with minimum rocking, tilting or wobbling when filled and resting on a support.

Another object and advantage of the invention is to provide a flexible container wherein the shaped/profiled front or rear/back panel includes an internal volume which is capable to store/contain a portion of the product packaged in the container.

Another object and advantage of the invention is to provide a flexible container which may include various types of opening or dispensing features such as fitments, re-closable zipper/slider-type openings, spouts with caps, frangible seals straws, or the like etc.

Another object and advantage of the present invention is to provide a flexible container that can be used for holding or packaging products, such as liquids (e.g. beverages), solids (e.g. pieces, powdered or granular etc.) or semi-solids (e.g. pastes, creams or gels etc.) food or non-food products.

Another object and advantage of the present invention is to provide a flexible container capable of replacing different rigid or semi-rigid three-dimensional packaging containers.

Another object and advantage of the present invention is to provide a flexible container having an asymmetrical/symmetrical shape that can be filled with same amount of product at the same rate as conventional symmetrical, standard containers.

Another object and advantage of the present invention is to provide a flexible container which is capable of enhancing brand and packaged product recognition, identification, differentiation and values thereof.

Another object and advantage of the present invention is to provide a flexible container which has the potential to attract consumers, promote sales, placement/launching of a product in market and to create awareness of the products among consumers.
Another object and advantage of the present invention is to provide a flexible container which has design features capable of giving a three dimensional effect to the flexible container.

Another object and advantage of the present invention is to provide an inexpensive and improved method for manufacturing the flexible container with a transparent, non-transparent or a combination of both transparent and non-transparent flexible material, preferably a laminate composed of sheets of plastic, paper or aluminum or the like.

Another object and advantage of the present invention is to provide a method of manufacturing a flexible container having an asymmetrical/symmetrical shape that can be filled with product at the same rate and the same amount of product as conventional plane (without shape), standard containers.

Yet another object and advantage of the present invention is to provide an improved apparatus for manufacturing the flexible container with a transparent, non-transparent or a combination of both transparent and non-transparent flexible material, preferably a laminate composed of sheets of plastic, paper or aluminum or the like.

A further object and advantage of the present invention is to manufacture such flexible containers using the same machinery and method with little to no modifications being required and the same or nearly the same amount of flexible material as that used to produce the conventional plane, standard containers, and to be able to fill these containers at the same rate as the conventional plane or standard containers.

SUMMARY OF THE INVENTION

The present invention satisfies the objects described above by providing a flexible container for packaging a product comprising: a front panel; a rear/back panel; and a side panel joining the front panel and rear/back panel, wherein at least one of the panel is shaped. The shaped panel of the flexible container has a profile matching with a design such as any character or art like a teddy bear, joker, dinosaur or the like.

The front panel, rear/back panel and side panel may be collectively referred as “Panels”. Each front panel, rear/back panel and side panel has an inner surface, an outer surface, an upper edge, a lower edge opposite the upper edge and a side edge extending between the upper and lower edge. The inner surface of the front panel, rear/back panel and side panel include heat sealable area. The front panel, rear/back panel and side panel are sealed together along said upper, lower and side edges to contain the product.

The flexible container of the present invention may further comprise a top panel and a bottom panel with an outer surface, an inner surface and an outer edge. The inner surface of the outer edge of the top panel and the bottom panel may be sealed with the inner surface of the upper and lower edges of said front, back/rear and side panel.

In one embodiment of the present invention, the flexible container comprises a front panel, a rear/back panel and a side panel to join the front panel and rear/back panel, wherein at least one of the panel is shaped. The front panel, rear/back panel and side panel have substantially equal dimension. The front panel, rear/back panel and side panels are sealed together along upper, lower and side edges to contain the product. The front panel, rear/back panel and side panel after sealing converges or get folded at a point being substantially in the center of the flexible container, so as to form equidistant folds from the corners of the front panel, rear/back panel and side panel.

In another embodiment of the present invention, the flexible container comprises a front panel, a rear/back panel, a side panel to join the front panel and rear/back panel, wherein at least one of the panel is shaped. In this embodiment, the dimension of the front panel, rear/back panel is not equal to the dimension of the side panel. The front panel, rear/back panel and side panels are sealed together along upper, lower and side edges to contain the product.

In another embodiment of the present invention, the flexible container is made of a single sheet folded into a front panel and a rear/back panel, wherein at least one of the panel is shaped. The said single sheet is folded and sealed at the side edges so as to form a front panel and a rear/back panel opposing each other such that the inner surfaces of said sheet face each other. When the dimension of the front panel and rear/back panel is substantially equal, the front panel and rear/back panel after sealing converge or get folded at a point being substantially in the center of the flexible container forming equidistant folds from the corners of the front panel and rear/back panel.

In another embodiment of the present invention, the flexible container may further comprise a bottom panel to enhance the standup feature of the flexible container. In the alternative, the flexible container may also be folded at the bottom to improve the standup feature of the flexible container. The bottom panel may be plane and die-cut in desired shape without having any fold.

In one embodiment of the present invention, the front panel of the flexible container may be cut into a shape/profile matching with any design for example any character or art as desired. Graphics or other indicia may be applied to such shaped/profiled front panel of the flexible container. As such, the shaped/profiled front panel is capable of including an internal volume for containing a portion of the product being packaged in the flexible container.

In another embodiment of the present invention, both the front panel and rear/back panel of the flexible container may be cut into a shape/profile matching with any design for example any character or art as desired. Graphics or other indicia may be applied to such shaped/profiled front panel and rear/back panel of the flexible container. As such, both the shaped/profiled front panel and rear/back panel are capable of including an internal volume for containing a portion of the product being packaged in the flexible container.
In another embodiment of the present invention, the front panel, rear/back panel and side panel of the flexible container may be cut into a shape/profile matching with any design for example any character or art as desired. Graphics or other indicia may be applied to such shaped/profiled front panel, rear/back panel and side panels of the flexible container. As such, all the shaped/profiled front panel, rear/back panel and side panel are capable of including an internal volume for containing a portion of the product being packaged in the flexible container.

In another embodiment of the present invention, the front panel, rear/back panel and side panel may be cut into a similar shape matching with any design. In the alternative, shapes of different designs may be used for the front panel, rear/back panel and side panels.

In one embodiment of the present invention, the flexible container may also be provided with an opening and closing means comprising a pourer body associated with an opening and closing cap having a base in communication with the interior of the flexible container and provided with a through channel.

In one embodiment of the present invention, the flexible container is formed from one or more sheets of flexible packaging material, preferably a laminate material composed of layer of polymeric substances, which includes metal/non metal foil, paper, nylon, polyester or the combination thereof. The sheets may generally have, not being limited to, rectangular shape. The sheets may also be shaped into other geometrical shapes, for example square, rectangles.

According to another aspect of the present invention, an apparatus for forming a flexible container for packaging the product is provided, the apparatus comprising: one or more supply means for feeding a supply of one or more flexible packaging materials for front panel, rear/back panel and side panel; one or more sensing means for maintaining a pre-determined length of said flexible materials and for ensuring accuracy of sealings; one or more controlling means for maintaining a pre-determined tension in the feeding line of said flexible materials; one or more folding means for folding and positioning the side panel between the front panel and rear/back panel; one or more sealing means for sealing said panels, one or more cooling means for immediate cooling of said sealings; one or more cutting means for cutting said flexible container to pre-determined profile; one or more filling means for filling a product in said flexible container.

The apparatus may further comprise optional means for punching outer surfaces of the side panels to reveal inner surface which may be sealed together to provide additional strength to the flexible container. The apparatus may also comprise additional sealing means such as K sealing means to further seal the bottom part of the flexible container. Various means used in the apparatus of the present invention may be added or removed to suit the needs and requirements of the flexible container being manufactured.

According to another aspect of the present invention, a method for forming a flexible container for packaging a product is provided, the method comprising the steps of: feeding a supply of one or more flexible packaging materials for a front panel, a rear/back panel and a side panel from one or more supply means, positioning and folding the side panel between the front panel and rear/back panel by one or more folding means; sealing the front panel/ rear/back panel and side panel by one or more sealing means; cutting said sealed/finished flexible container in required shape by one or more cutting means; filling the product in said flexible container by one or more filling means.

The method of the present invention may further comprise the optional steps of, not being limited to, punching of the outer surface of the side panel, K sealing the bottom part of the flexible container, folding of the panels in the required shape for either one or all of the panels. Various steps in the method of the present invention may be added or removed to suit the needs and requirements of the flexible container being manufactured.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS:

The foregoing and other objects, features, and advantages of the invention will be apparent from the following detailed description taken in conjunction with the accompanying drawing, wherein:

Fig. 1 is a perspective view of the flexible container according to the present invention;
Fig. 2 is an another perspective view of the flexible container according to the present invention;
Fig. 3 is a front view of the flexible container according to the present invention;
Fig. 4 is a top view of the flexible container according to the present invention;
Fig. 5 is a side view of the flexible container according to the present invention;
Fig. 6 is a flow chart illustrating a method for manufacturing the flexible container according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As summarized above, the present invention encompasses a flexible container for packaging a product and a method and an apparatus for manufacturing the same. While this invention is susceptible of embodiments in many different forms, there will be described specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments detailed herein. The structure of a flexible container made according to an embodiment of the present invention is described below, followed by a description of an apparatus and a method for making the flexible container.

As used herein, the “front panel”, “rear/back panel” and “side panel” may be collectively referred as “Panels”.
Referring to Fig. 1 and Fig. 2, a perspective view of a flexible container (10) according to the present invention is illustrated. The flexible container comprises a front panel (12), a rear/back panel (14) and a side panel (16, 18), wherein at least one of the panels is shaped, and wherein the front panel (12), rear/back panel (14) and side panel (16, 18) have substantially equal dimension. The shaped panel of the flexible container (10) has a profile matching with a design such as any character or art for example design of a teddy bear, joker, dinosaur or the like. Each of the front panel (12), rear/back panel (14) and the side panel (16, 18) have an outer surface (26), an inner surface (28), an upper edge (20), an opposed lower edge (22) and a side edge (24) extending between said upper edge (20) and the lower edge (22).

The inner surface (28) of the front panel (12), rear/back panel (14) and side panel (16, 18) include heat sealable area. The inner surface (28) of the front panel (12), rear/back panel (14) and side panel (16, 18) are joined and sealed together along upper (20), lower (22) and side edges (24) to provide a flexible container (10) of the present invention. The front panel (12), rear/back panel (14) and side panel (16, 18) after sealing converges or get folded at a point (34) being substantially in the center of the flexible container (10), so as to form equidistant folds from the corners of the front panel (12), rear/back panel (14) and side panel (16, 18).

The flexible container (10) of the present invention may be optionally provided with a bottom panel (30) (not shown) to improve its standup feature without any support. The said flexible container (10) may also be folded at the bottom to improve its standup feature without any support.

Fig. 3 illustrates a front view of the flexible container (10) according to the present invention, wherein the front panel (12) is shaped/profiled matching with a design of a teddy bear.

Reference is now made to Figs. 4 and 5 illustrating a top view and side view of the of the flexible container (10) according to the present invention, wherein the front panel (12), rear/back panel (14) and side panel (16, 18) after sealing converge or get folded at a point (34) being substantially in the center of the flexible container (10), so as to form equidistant folds from the corners of the front panel (12), rear/back panel (14) and side panel (16, 18).

Each of the front panel (12), rear/back panel (14) and the side panel (16, 18) have an outer surface (26), an inner surface (28), an upper edge (20), a lower edge (22) and a side edge (24) extending between said upper edge (20) and said lower edge (22).

The inner surface (28) of the front panel (12), rear/back panel (14) and side panel (16, 18) include heat sealable area. The inner surface (28) of the front panel (12), rear/back panel (14) and side panel (16, 18) are joined along upper (20), lower (22) and side edges (24) and are sealed together to form a flexible container (10).

To illustrate another embodiment the flexible container (10) of the present invention comprises a front panel (12), a rear/back panel (14), and a side panel (16, 18), wherein at least one of the panels is shaped and wherein the dimension of the side panel (16, 18) is not equal to the dimension of the front panel (12) and the rear/back panel (14).

The flexible container (10) may optionally be provided with a bottom panel (30). The bottom panel (30) has an outer surface (26) and an inner surface (28) having an outer edge (32). The inner surface (28) of the front panel (12), rear/back panel (14) and side panel (16, 18) are joined along upper (20), lower (22) and side edge (24) and are sealed followed by the sealing of the outer edge (32) of the inner surface (28) of the bottom panel (30) with the inner surface (28) of the lower edge (22) of the front panel (12), rear/back panel (14) and the side panel (16, 18) to form a flexible container (10). The bottom panel (30) may be folded to enhance the standup feature of the flexible container (10). In the alternative, the bottom panel may be plane or die cut in desired shape without any fold. A top panel (36) may also be provided, in addition to the bottom panel (30) to provide a covering means for the flexible container (10).

To illustrate yet another embodiment the flexible container (10) of the present invention comprises a single sheet with an outer surface (26) and an inner surface (28). The sheet further comprises an upper edge (20), a lower edge (22) and a side edge (24) extending between said upper edge (20) and the lower edge (22). The said single sheet is folded and sealed at the side edge (24) so as to form a front panel (12) and a rear/back panel (14), wherein at least one of the front panel (12) and a rear/back panel (14) is shaped. The front panel (12) and the rear/back panel (14) oppose each other in such a way that the inner surface (28) of said sheet faces each other. When the dimension of the front panel (12) and rear/back panel (14) is substantially equal, the front panel (12) and rear/back panel (14) after sealing converge or get folded at a point (34) being substantially in the center of the flexible container (10) forming equidistant folds from the corners of the front panel (12) and rear/back panel (14).

The flexible container (10) may optionally be provided with a bottom panel (30). The bottom panel (30) has an outer surface (26) and an inner surface (28) having an outer edge (32). The flexible container (10) is formed by sealing the outer edge (32) of the bottom panel (30) with the lower edge (22) of said sheet.

The flexible container (10) of the present invention is preferably formed from a roll of preprinted material of extruded or laminate layers. The flexible packaging material typically comprising three, or four, or five or more layers of different polymeric/non-polymeric material or multiple laminations of material or the like. The thickness of different layers may vary as per requirement. The outer layer is usually preprinted. Alternatively, at least a portion of the flexible material may/may not be printed, i.e. translucent/transparent, in order to view the contents contained therein as a window. The flexible container (10) may include more than one type of material.

The flexible container (10) of the present invention may be made of a flexible packaging material preferably a laminate material composed of layer of polymeric substances. The suitable flexible packaging materials include metal/non-metal foil, paper, nylon, vinyl, polyester, polypropylene, polyethylene or the like as well as combinations thereof. The choice of flexible packaging material is non-limiting, and is influenced by factors such as the product contained in the pouch, the shape of the pouch, or the anticipated use of the pouch.

The flexible container (10) of the present invention may also be provided with an opening and closing means comprising a pourer body associated with an opening and closing cap having a base associated with the flexible container (10) and provided with a through channel. Thus, the flexible container (10) may include various types of opening and closing means such as fitments, re-closable zipper/slider-type openings, frangible seals straws, spouts with cap, any combination thereof or the like etc.

Yet another aspect of the invention relates to an apparatus for forming a flexible container (10) for packaging a product. The said apparatus comprising: one or more supply means for feeding a supply of one or more flexible packaging material for a front panel (12), a rear/back panel (14) and a side panel (16, 18); one or more sensing means for maintaining a pre-determined length of said flexible packaging material and for ensuring accuracy of sealing; one or more controlling means for maintaining a pre-determined tension in the feeding line of said flexible packaging material; one or more folding means for folding and positioning the side panel (16, 18) between the front panel (12) and rear/back panel (14); one or more sealing means for sealing said front (12), rear/back (14) and side panel (16, 18); one or more cooling means for immediate cooling of said sealing; one or more cutting means for cutting said flexible container (10) to pre-determined profile; and one or more filing means for filing a product in said flexible container (10).

The supply means include roll un-winding stations for feeding a web of flexible packaging material for front panel (12), rear/back panel (14) and side panel (16, 18).

The sensing means are employed to sense the repeat lengths, tension elements, cutting positions and the likes may be provided at regular intervals to maintain the precision and accuracy of the flexible container (10). The sensing means such as, being not limited to, optical (e.g. photo electric sensors, color sensors), electrical (e.g. electromagnetic sensors), and mechanical (e.g. time temperature sensors) and a combination thereof (e.g. photo-electronic load sensors) used in the methods are commonly known to the skilled person in the art.

The controlling means include electronic servo drive for controlling/maintaining a pre-determined tension in the feeding line of said flexible packaging material.

The folding means include a folder plate fitted on the apparatus for folding or positioning said side panel (16, 18) between said front panel (12) and rear/back panel (14).

The sealing means include sealers fitted with heaters such as, not being limited to, vertical heat sealer, profile sealing tool bearing the required shape. The sealing means further comprising: first sealing means for sealing the side edges (24) of said front panel (12) and rear/back panel (14) with the side edges (24) of said side panel (16, 18); second sealing means for profile sealing of side edges (24) of another side of said front panel (12), rear/back panel (14) and side panel (16, 18) with a pre-determined shape; third sealing means for sealing the lower edges (22) of the front panel (12) and rear/back panel (14) with the lower edges (22) of the side panel (16, 18); and fourth sealing means for sealing the upper edges (20) of said front panel (12) and said rear/back panel (14) with the upper edges (20) of side panel (16, 18). The sealing means my optionally be provide with a fifth sealing means for sealing and folding bottom portion of the flexible container (10).

The cooling means include cooling stations with hollow tubes to pass the chilled water for immediate cooling of the sealed flexible container (10).

The cutting means to cut the panels in the desired shape along the sealed edges may be, not being limited to, cutting die tools having required shape such as any graphics or art.

The filling means include an apparatus to pick and fill the contents in the flexible container (10).

The apparatus may further comprise punching means for punching outer surfaces of the side panels to reveal inner surface which may be sealed together to provide additional strength to the flexible container (10). The punching means include designed die to cut the punch hole. The apparatus may also comprise additional sealing means such as K sealing means to further seal the bottom part of the flexible container (10).

Referring now to Fig. 6 a flow chart of a method for forming said flexible container (10) for packaging a product is shown according to the present invention. To begin with a supply of flexible packaging materials for front panel (12) and rear/back panel (14) is provided by a laminate roll main body (110). The web coming out of the laminate roll main body (110) passes through a slitter (140) to form two identical webs i.e. front web (160a) and rear/back web (160b) of equal dimension. The front web (160a) and rear/back web (160b) act as a front panel (12) and a rear/back panel (14) of the flexible container (10) respectively. Side webs (150a, 150b) are supplied from a left gusset roll (120) and a right gusset roll (130), wherein said side webs (150a, 150b) placed at either side of the front web (160a) and back web (160b). The side webs (150a, 150b) act as side panel (16, 18) of the flexible container (10) of the present invention.

The flexible packaging material has an outer surface (26), inner surface (28), an upper edge (20), a lower edge (22) opposite the upper edge (20) and a side edge (24) extending between said upper edge (20) and lower edge (22). A pre-determined length & width of said flexible material is maintained by one or more sensing means and pre-determined tension is maintained by one or more tension controlling means. Thereafter, the side panels (16, 18) are folded and positioned between said front panel (12) and rear/back panel (14) by one or more folding means.

The next step involves vertical sealing (170a) of the properly aligned front panel (12), rear/back panel (14) and side panels (16, 18). The properly aligned front panel (12), rear/back panel (14) and side panels (16, 18) are passed though first sealing means such as vertical heat sealer for vertical sealing (170a) the side edges (24) of said front panel (12) and rear/back panel (14) with the side edges (24) of said side panel (16, 18). The vertical sealing (170a) of the side edges (24) by the first sealing means is followed by immediate cooling by cooling means. Thereafter, the accuracy of the said sealing is checked by one or more sensing means.

The next step involves profile sealing (170b) of another side edge (24) of the front panel, (12) rear/back panel (14) and side panel. One of the pre-decided side edge (24) of the flexible container (10) is sealed by second sealing means such as profile sealing tool bearing the predetermined shape; followed by immediate cooling by cooling means. Once again the accuracy of the said sealing is checked by one or more sensing means. One or more Panels of the flexible container (10) may be given a predetermined shape by sealing means bearing a predetermined shape.

Once the accuracy of said sealing is checked, the next step involves cutting (180) the flexible container (10) to its pre-determined dimension by one or more cutting means. The cutting position along the length of said flexible container (10) is checked by one or more sensing means.

The next step involves sealing lower edges (190) of the flexible container (10).The lower edges (22) of the front panel (12) and rear/back panel (14) are sealed with the lower edges (22) of the side panels (16, 18) by third sealing means followed by immediate cooling by cooling means and checking the accuracy of said sealing by one or more sensing means.

Now, the flexible container (10) is ready for filling (200) the product by one or more filling means. Once; the product is filled, the next step is sealing upper edges (210) of the flexible container (10). The upper edges (20) of said front panel (12) and rear/back panel (14) are sealed with the upper edges (20) of side panels (16, 18) by fourth sealing means forming a shaped flexible container (10). The sealed and filled flexible container (10) comprise a front panel (12), a rear/back panel (14) and side panel (16, 18), wherein at least one of the panel is shaped, matching with any character or art or the like, wherein the sealed flexible container (10) comprise equidistant folds converging at a point (34) being substantially in the center of the corners of the front panel (12), rear/back panel (14) and side panel (16, 18).

In another embodiment of the present invention, the method disclosed above can be adopted to form said flexible container (10) for packaging a product with a front panel (12), rear/back panel (14) and side panel (16, 18) having unequal dimension.

In another embodiment of the present invention, the method disclosed above can be adopted to form said flexible container (10) for packaging a product with a front panel (12) and rear/back panel (14) formed from a single sheet.

In another embodiment, the method for forming said flexible container (10) for packaging a product is provided according to the present invention, wherein the flexible container (10) may further comprise a bottom panel (30) to enhance the standup feature of the flexible container (10). In the alternative, the flexible container (10) may also be folded at the bottom so as to improve the stand-up feature of the flexible container (10).

To illustrate the method, in another embodiment, the method for forming a flexible container (10) for packaging a product is provided comprising the following steps:
a supply of flexible packaging materials for front panel (12), rear/back panel (14), and side panel (16, 18) and bottom panel (30) is provided/fed from one or more supply means, wherein said front panel (12) and rear/back panel (14) are of equal dimension. A pre-determined length & width of said flexible material (10) is maintained by one or more sensing means and maintaining a pre-determined tension by one or more tension controlling means. Thereafter, side panels (16, 18) is folded and positioned between said front panel (12) and rear/back panel (14) by one or more folding means. The next step involves vertical sealing of the side edges (24) of said front panel (12) and rear/back panel (14) and side panel (16, 18). The side edges (24) of said front panel (12) and rear/back panel (14) are sealed with the side edges (24) of said side panels (16, 18) by first sealing means followed by immediate cooling by cooling means. Thereafter, the accuracy of the said sealing is checked by one or more sensing means.

The next step involves profile sealing of side edges of another side of the front panel (12), rear/back panel (14) and side panel (16, 18). One of the pre-decided side edge (24) of flexible container (10) sealed by second sealing means such as profile sealing tool bearing the predetermined shape; followed by immediate cooling by cooling means. Once again the accuracy of said sealing is checked by one or more sensing means. One or more panels of the flexible container (10) may be given a predetermined shape by sealing means bearing a predetermined shape.

Once the accuracy of said sealing is checked, the flexible container (10) is cut to its pre-determined dimension by such as to its desired length by one or more cutting means. The cutting position along the length of said flexible container (10) is checked by one or more sensing means.

Thereafter, the inner surface (28) of lower edges (22) of said front panel (12), rear/back panel (14) and the side panels (16, 18) are sealed with the inner surface (28) of the outer edge (32) of said bottom panel (30) followed by immediate cooling by cooling means. Once again the accuracy of said sealing is checked by one or more sensing means.

Now, the flexible container (10) is ready for filling the product by one or more filling means. Once the product is filled into the flexible container (10) the upper edges (20) of said front panel (12) and rear/back panel (14) are sealed with the upper edges (20) of side panels (16, 18).

In another embodiment of the present invention, the method disclosed above can be adopted to form said flexible container (10) for packaging a product with a front panel (12), rear/back panel (14), side panel (16, 18) and a bottom panel (30), wherein said front panel (12), rear/back panel (14) and side panel (16, 18) having unequal dimension.

In yet another embodiment, the method disclosed above can be adopted to form said flexible container (10) for packaging a product with a front panel (12), rear/back panel (14) and bottom panel (30), wherein said front panel (12) and rear/back panel (14) formed from a single sheet.

The inner surface (28) of the flexible packaging material is heat sealable whereas the outer surface (26) of the flexible packaging material is made of a non-heat sealable material. As a result, when the sealing means are applied to the outer surface (26) of side edges (24) of the front panel (12) and the rear/back panel (14), the sealing of the inner surface (28) of the side edge (24) of the side panel (16, 18) with the inner surface (28) of the side edge (24) of the rear/back panel (16, 18) and the sealing of the inner surface (28) of the opposite side edge (24) of the side panel (16, 18) with the inner surface (28) of the side edge (24) of the front panel (12) is achieved in a single step.

Likewise, sealing by the third sealing means is a one step process wherein sealing of the lower edges (22) of said front panel (12) and rear/back panel (14) with the lower edges (22) of side panels (16, 18) is achieved in a single step. The sealing machines normally used works on the principle of heat and pressure applied together commonly known to the skilled person in the art but may also work on other methods of sealing commonly known to the skilled person in the art.

Various means to provide additional strength to the flexible container such as K sealing and punching already known to skilled person in the art may be optionally provided to the flexible containers. K sealing takes the stress off the seals on either side of the package, and allows for additional volume. Punching allows the outer surfaces of the side panels to be sealed together to provide additional strength to the flexible container. Both K sealing and punching can be done by using method and tools commonly known to the skilled person in the art.

Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. Thus, from the foregoing description, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention as set forth herein.

Accordingly, it is not intended that the scope of the foregoing description be limited to the exact description set forth above, but rather that such description be construed as encompassing all of the features that reside in the present invention, including all the features and embodiments that would be treated as equivalents thereof by those skilled in the relevant art and should be determined only by a fair reading of the appended claims.

List of reference numerals

10 Flexible Container
12 Front Panel
14 Rear/Back Panel
16 Side Panel
18 Side Panel
20 Upper edge
22 Lower edge
24 Side edge
26 Outer surface
28 Inner surface
30 Bottom Panel
32 Outer edge
34 Point
36 Top Panel
110 Laminate roll main body
120 Left Gusset roll
130 Right Gusset roll
140 Slitter
150a Side web
150b Side web
160a Front web
160b Back web
170a Vertical sealing
170b Profile sealing
180 Cutting
190 Lower edge sealing
200 Filling
210 Upper edge sealing
220 Shaped flexible container
,CLAIMS:WE CLAIM:

1. A flexible container (10) for packaging a product, comprising:
a front panel (12);
a rear/back panel (14); and
a side panel (16, 18) joining said front panel (12) and said rear/back panel (14),
wherein each said panel having an inner surface (28), an outer surface (26), an upper edge (20), an opposed lower edge (22) and a side edge (24) extending between said upper edge (20) and lower edge (22) , wherein said front panel (12), rear/back panel (14) and side panel (16, 18) are sealed together along said upper (20), lower (22) and side edge (24) to contain the product, wherein at least one of the panel is shaped.

2. The flexible container (10) for packaging a product according to claim 1, wherein said front panel (12), rear/back panel (14) and side panel (16, 18) when sealed comprise equidistant folds from the corner of the front panel (12), rear/back panel (14) and side panel (16, 18), wherein said equidistant folds converges at a point (34) being substantially in center of the flexible container (10).

3. The flexible container (10) for packaging a product according to claim 1, wherein the shaped panel has a profile matching with a design such as any character or art.

4. The flexible container (10) for packaging a product according to claim 1, wherein said front panel (12), rear/back panel (14) and side panel (16, 18) has equal dimension.

5. The flexible container (10) for packaging a product according to claim 1, wherein said front panel (12), rear/back panel (14) and side panel (16, 18) has unequal dimension.

6. The flexible container (10) for packaging a product according to claim 1 further comprising: a top panel (36) and a bottom panel (30); wherein each said top (36) and bottom panel (30) have an inner surface (28), an outer surface (26) and an outer edge (32).

7. The flexible container (10) for packaging a product according to claim 1 and 6, wherein the inner surface (28) of the outer edge (32) of the top panel (36) and the bottom panel (30) is sealed with the inner surface (28) of the upper (20) and lower edges (22) of said front (12), rear/back (14) and side panel (16, 18).

8. The flexible container (10) for packaging a product according to claim 6, wherein said bottom panel (30) is folded.

9. A flexible container (10) for packaging a product according to claim 1 and 5, wherein the panel of said flexible container (10) is formed from one or more sheets of flexible packaging material.

10. A flexible container (10) for packaging a product according to claim 9, wherein said flexible packaging material includes a laminate material composed of layer of polymeric substances.

11. A flexible container (10) for packaging a product according to claim 9 and 10, wherein the flexible packaging material includes metal/non metal foil, paper, nylon, vinyl, polyester, polypropylene, polyethylene or the combinations thereof.

12. A flexible container (10) for packaging a product according to any one of the preceding claims, wherein said flexible container (10) is provided with a means for closing and opening the flexible container.

13. A flexible container (10) for packaging a product according to claim 12, wherein said opening and closing means comprises re-closable zipper/slider-type openings, frangible seals straws, spouts, fitments, any combination thereof or the like.

14. An apparatus for forming a flexible container for packaging a product, said apparatus comprising:
one or more supply means for feeding a supply of one or more flexible packaging material for a front panel, back panel and side panel;
one or more sensing means for maintaining a pre-determined length of said flexible packaging material and for ensuring accuracy of sealing;
one or more controlling means for maintaining a pre-determined tension in the feeding line of said flexible packaging material;
one or more sealing means for sealing said front, rear/back and side panel;
one or more cooling means for immediate cooling of said sealing;
one or more cutting means for cutting said flexible container to pre-determined profile; and
one or more filing means for filing the product in said flexible container.

15. An apparatus for forming a flexible container for packaging a product according to claim 14, further comprising:
one or more punching means for punching the outer surface of said panel to reveal inner surface; and
one or more K- sealing means for sealing a top and/or bottom part of the flexible container.

16. An apparatus for forming a flexible container for packaging a product according to claim 14, wherein one or more sealing means further comprising:
first sealing means for vertical sealing the side edges of said front panel and rear/back panel with the side edges of said side panel;
second sealing means for profile sealing of side edges of another side of said front panel, rear/back panel and side panel;
third sealing means for sealing the lower edges of the front panel and rear/back panel with the lower edges of the side panels; and
fourth sealing means for sealing the upper edges of said front panel and said rear/back panel with the upper edges of side panel.

17. A method for forming a flexible container for packaging a product, said method comprising the steps of:
feeding a supply of one or more flexible packaging materials for a front panel, a rear/back panel and side panel from supply means;
folding said side panel between said front and back panel by folding means;
sealing side edges of said front panel, rear/back panel and side panel by first sealing means;
sealing side edges of another side of said front panel, rear/back panel and side panel with a predetermined shape by second sealing means;
cutting said sealed flexible container in required shape by cutting means;
sealing lower edges of said front panel, rear/back panel and side panel by third sealing means;
filling the product in said flexible container by filling means; and
sealing upper edges of said front panel and back panel with the upper edges of side panels by the fourth sealing means.

Dated this 15th day of May, 2014.