2. Description of Related Art Pouch Packaging Many snack foods, like chips, pretzels, etc. , are packaged in pouches formed of very thin packaging films. This method of packaging is best described in conjunction with a description of the vertical form, fill, and seal packaging machine that makes and fills the pouches, seen diagrammatically in Figure 1. Packaging film 110 is taken from a roll 112 of film and passed through tensioners 114 that keep it taut. The film then passes over a former 116, which directs the firm into a vertical tube around a product delivery cylinder 118. As the tube is pulled downward by drive belts 120, the vertical tube of film is sealed along its length by a vertical sealer 122, forming a back seal 124. The machine then applies a pair of heat-sealing jaws 126 against the tube to form a transverse seal 128. This transverse seal 128 acts as the top seal on the bag 130 below the sealing jaws 126 and the bottom seal on the bag 132 being filled and formed above the jaws 126. After the transverse seal 128 has been formed, a cut is made across the sealed area to separate the finished bag 130 below the seal

128 from the partially completed bag 132 above the seal. The film tube is then pushed downward to draw out another package length. Before the sealing jaws form each transverse seal, the product to be packaged is dropped through the product delivery cylinder 118 and is held within the tube above the transverse seal 128.

The material used in this type packaging is typically a packaging film, such as polypropylene, polyester, paper, polyolefin extrusions, adhesive laminates, and other such materials, or a layered combination of the above. For many food products, where flavor retention is important, a metalized layer will form the innermost layer.

One problem with this type of packaging is that the pouches will not stand up by themselves, but tend to fall over on their sides unless they are supported. This can create difficulties in storage, both for the seller and the consumer. Despite this drawback, this packaging method has remained popular, as it is a very cost effective means of packaging.

Paper Cups In a different area, paper cups and paper containers have been known for many years, although innovations to the process continue to the present. An overview of one method of forming a paper cup will now be discussed, but further details are available in many patents, such as U. S. Patents 4,452, 596 and 6,264, 100, which are both hereby incorporated by reference. Figure 2 shows a wall blank 210 and a circular base blank 212 that have been cut out of paperboard to use in forming a basic paper cup. Figure 3A shows a first step during manufacture, where the wall blank 210 is wound around a tapering mandrel 380, then the ends are secured with an adhesive to form the tapering tube 310 with seam 311. In a separate step, a piston forces the base blank 212 through an opening having a smaller diameter than the blank itself, forming a rim or short, cylindrical edge 314 that projects at a right angle to the circular base, as seen in Figure 3B. The formed base 312 is then inserted into the bottom of the now-sealed tube 310. As seen in Figure 3C, the rim of the base section 312 can be

positioned slightly above the lower edge 316 of the wall section 310. Finally, the lower edge 316 of the wall section 310 is crimped over the rim 314 of the base section 312 and sealed with an adhesive to form the reinforced rim 318, as seen in Figure 3D. Most cups will have the top edge 320 of the cup rolled in an early step to form a thicker lip for the cup, although that step is not shown here. This basic manufacturing process can be modified, of course, to provide additional improvements, such as a handle or a sealant/coating for the paperboard to prevent wetting of the cup by its contents, and a lid can be made separately if it is desired, such as when the cup will be used to transport hot soup or a similar liquid. These containers, unlike the pouch containers, have round bottoms, which give them a stable base on which they can sit. However, to ensure that the container will not collapse on itself and spill its contents, these containers are generally made of paperboard, and often they are treated with coatings or sealants to make them impervious to liquids. The result is a container that is heavier and more expensive than those used to package snack foods.

It would be desirable to find a method of packaging a product, such as a snack food, in an inexpensive container that would stand up and that could be formed out of less expensive, lightweight packaging materials.

SUMMARY OF THE INVENTION In the present invention, a package is formed having a rounded, recessed base, similar to the base on paper cups. The recessed base can be round or generally oval, while the sidewalls are preferably straight, rather than tapering, as do the sides of a paper cup. In the place of paperboard, thin packaging polymers are utilized, such as those packaging materials that are currently used in forming pouches for snack foods. The formed packages are filled with a product and opposite edges of the open walls are brought into close proximity for heat sealing.

A major advantage of the innovative package is that the round or oval base allows the package to be stored upright on a shelf without further support, maintaining its upright position even when filled with light-weight products. Unlike prior packages with rounded bases, it is not necessary to use a heavy paperboard to hold the shape, so the cost is reduced.

The materials for the package have been used for years, so they are well understood and well suited to food products. The size of the packages can be easily modified, so that, for example, a snack package can be sized to fit into the cup holders in an automobile. This pouch can be used for eating out of the container; for example, if used for packaged cereal, milk can be added directly to the pouch. Likewise, chips could be packaged in this pouch, with a cheese topping to be added before eating. Finally, this pouch has the potential for storing liquid products and can also be used in vending machines.

BRIEF DESCRIPTION OF THE DRAWINGS The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein: Figure 1 is a diagrammatic view of a form, fill, and seal machine, known in the prior art.

Figure 2 shows blanks for the sidewall and base of a paper cup.

Figure 3A shows the formed walls of a paper cup, while Figure 3B shows the formed base of the cup. Figure 3C shows the base and sides as they are first fitted together and Figure 3D shows the base of the container after the two pieces have been sealed together.

Figure 4A shows the blanks used to form an embodiment of the disclosed packaging, Figures 4B and 4C show the formed base and the formed sidewalls respectively of the package. Figures 4D and 4E show respectively the sidewalls and base of the package sealed together and the filled package after sealing.

Figures 5A-D show the disclosed package at various stages as it is being filled with product and sealed.

DETAILED DESCRIPTION The invention will now be described with reference to Figures 4-5, which depict an exemplary embodiment.

Figure 4A shows blanks 410,412 for an embodiment of the innovative package. The wall blank 410 is preferably rectangular in shape and has a length slightly greater than the desired finished height and a width appropriate to the base to which it will attach. The base blank 412 is round or generally oval in shape to accommodate the processing method and to form a stable base for the package. The packaging material from which the blanks are cut can be any of the popular packaging films now used in pouch manufacture. Examples are polypropylene, polyester, paper, polyolefin extrusions, adhesive laminates, and other such materials, or layered combinations of the above. Where flavor retention is important, a metalized layer will form the innermost layer. In the presently preferred embodiment, one of the following laminations is used: 1) a metallic oriented polypropylene layer on the inside having an exposed sealant layer that is heat activated, followed by a polyethylene layer, an ink layer, and an outer oriented polypropylene layer; 2) a metallic polyethylene terephthalate (PET) inner layer having an exposed sealant layer, followed by a polyethylene layer, an ink layer, and an oriented polypropylene layer on the outside; and 3) a metallic oriented polypropylene inner layer with an adhesive, followed by a polyethylene layer, a paper layer and ink.

The two blanks 410,412 are shaped in much the same manner as in paper cup manufacture. Figure 4B shows the base blank 412'after rim 414 has been formed on this piece. In this figure, the upper and outer surfaces of the base include a sealant layer. In Figure 4C, the sidewall blank 410'has been formed into a cylindrical shape and sealed at back seal 414. The back seal 414 can be formed as either an overlap seal or a fin seal and will be sealed by a pair of heat sealing jaws.

Figure 4D shows an embodiment of the disclosed package 400, after the sides and base have been joined. In this embodiment, the lower edge of rim 414 of base 412'has been positioned to coincide with the lower edge of sidewall 410', and the two pieces 410', 412' have been heat sealed to each other. In an alternate embodiment, rim 414 of base 412'is positioned slightly above the lower edge of sidewall 410', then the lower edge of sidewall 410'is folded over so that rim 414 is enclosed between two layers of sidewall 410'. This embodiment would give a somewhat sturdier rim to the base. In Figure 4E, the package 400' has been filled with a product and a top seal 420 formed using heat sealing by a pair of opposed jaws. Dwell times for the formation of the heat seals on the base of the package would generally be in the 0.5-1. 0 second range, while the back and top seals would typically have a dwell time of 0.1-0. 5 seconds.

Figures 5A-D show a diagram of one embodiment of the innovative packages being filled and sealed. In Figure 5A, empty package 500 has been formed and is ready to be filled. Since the package can maintain an upright position, no support is necessary as it is being filled and sealed. Figure 5B shows the package as it is being filled with a product, in this example, tortilla chips, one of the many products suitable for this type of packaging. In Figure 5C, the product is in the package 500, and sealing jaws 520 are preparing to bring the sides of the package 500 together so that they can be heat sealed. In this diagram, only the jaw facings themselves are shown, but one of ordinary skill in the art would recognize the machinery this represents. In Figure 5D, the final package 500'has top seal 510 and is ready for boxing and shipping to the retailer.

In the presently preferred embodiment, containers are made outside of the packaging plant and shipped, preferably in a nested formation, for filling and sealing in the plant.

Alternatively, the equipment to make the bags could replace an existing packaging machine,

so that the newly manufactured bags could immediately be filled with product and sealed.

The disclosed packaging is a novel combination of two technologies-the technology of making paperboard into a cup or container and the technology of packaging snack foods into thin-walled, inexpensive pouches. This novel package provides a simple, economical container that stands upright, yet is sturdy enough to use in storing many different lightweight products, including foods.

While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.