CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. App. No. 61/993,321 filed May 15, 2014 which is hereby incorporated by reference in its entirety.

FIELD

[0002] This application is directed to flexible film containers and processes of manufacturing that include using flexible films. More particularly, this application relates to flexible films and containers having support columns and processes for manufacturing such flexible films and containers.

BACKGROUND

[0003] Candy and other small or bite-size products like nuts, savory snacks, frozen heat-n-eat snacks, frozen heat-n-eat vegetables, ready-to-eat cereal, and mints are typically sold in multi- piece packages. In many cases, the package is designed for bulk sale of the product to the consumer rather than as a single serving size, although in some cases the individual product may still be separately wrapped prior to being placed in the package.

[0004] Historically, the packaging of multi-piece units, particularly for candy, was primarily accomplished through the use of paper bags or metal tins. More recently, plastic bags, and more particularly the plastic bag often referred to as a pillow pack or a lay-down bag has become the industry standard. While pillow packs are advantageous because they are relatively easy and inexpensive to manufacture, they have numerous drawbacks for both the retailer and the consumer.

[0005] Among the drawbacks faced by the retailer with pillow packs is that they are difficult to stack in a way that does not easily fall over in a retail setting where consumers are reaching in and out of shelves. Similar issues apply to gusseted bags and stand-up bags. As a result, it can be difficult for the retailer to present the product in a way that does not look disheveled and/or which does not require frequent attention by the retailer's staff. Furthermore, the portion most easily seen by the consumer can be narrow sides; the major surfaces of the package that provide the greatest area for graphics face toward the top of the shelf or being aligned to face away from a consumer. The reduced space for advertisements and branding can mean a lost opportunity to achieve a sale through brand recognition or a promotion advertised on the package. Likewise, the consumer must look more carefully to find his or her brand of choice on the store shelf, and may give up if the product cannot be found quickly.

[0006] Among drawbacks faced by consumers with current packs is that the consumer faces many of the same problems regarding stackability and storage of the product on the pantry shelf that the retailer encounters with the store shelf. Other disadvantages faced by the consumer with the packs currently used for packaging include difficulty in opening the package and additional storage problems after the package is opened.

[0007] A known process includes making containers that include pleats, which are folds in a film. Including pleats on the interior portions of a container with walls formed by a flexible film can increase strength and/or permit better display of packages than pillow packs. However, further improvements to strength and ability to display packages remain desirable, for example, to permit higher stacking of containers, to permit heavier contents to be placed in containers, and/or for larger walls capable of displaying more information.

[0008] Improvements in flexible films, containers formed from flexible films, and processes of manufacturing that include using flexible films, in comparison to the prior art would be desirable.

[0009] Other features and advantages of the present invention will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE INVENTION

[0010] According to an embodiment, a container comprises a container base and a flexible film attached to the container base forming a container wall and defining a packing region within the container. The container wall has at least one tubular support column integrally formed therein. [0011] According to another embodiment, a manufacturing process comprises providing a web of flexible film, forming tubular support columns in the web of flexible film and forming a container from the web of flexible film containing the support columns.

[0012] According to yet other embodiments, films, processes, and containers include that which is shown and described herein.

[0013] Advantages that may be achieved with exemplary embodiments include providing films and containers that contain additional strength and/or rigidity, permit lower cost production of containers, permit increased visibility of graphics or other identifiable information on packaging, permit easier and quicker restocking in retail settings, permit easier and less costly transportation, and provide other advantages that will be evident from the present disclosure, or a combination thereof. Other features and advantages of the present invention will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 shows a perspective view of an embodiment of a flexible film within a film sheet having support columns for extending throughout the film sheet, according to the disclosure.

[0015] FIG. 2 shows a perspective view of an embodiment of a flexible film having support columns, according to the disclosure.

[0016] FIG. 3 shows a schematic view of an embodiment of a flexible film having support columns, according to the disclosure.

[0017] FIG. 4 shows a perspective view of an embodiment of a container formed from a flexible film having support columns, according to the disclosure.

[0018] FIGS. 5-6 show perspective views of an embodiment of a container having a handle, according to the disclosure.

[0019] FIGS. 7-8 show perspective views of an embodiment of a container having pull-tabs, according to the disclosure.

[0020] FIG. 9 shows a perspective view of a container cover having a bendable joint for an embodiment of a container, according to the disclosure.

[0021] FIG. 10 shows a perspective view of a container cover having externally- protruding pull tabs for an embodiment of a container, according to the disclosure.

[0022] FIG. 1 1 shows a perspective view of a container cover having a two-piece arrangement of a lower rectangular recessed portion and an upper substantially planar rectangular portion for an embodiment of a container, according to the disclosure.

[0023] FIG. 12 shows a perspective view of a container cover having a two-piece arrangement of a lower rectangular open portion and an upper rectangular substantially planar portion for an embodiment of a container, according to the disclosure.

[0024] FIG. 13 shows a perspective view of a container cover having a two-piece arrangement of a lower circular open portion and an upper circular substantially planar portion for an embodiment of a container, according to the disclosure.

[0025] FIG. 14 shows a container cover having a flap for an embodiment of a container, according to the disclosure.

[0026] FIG. 15 shows an embodiment of a container with a container base and container cover positioned horizontally relative to a flexible film, according to the disclosure.

[0027] FIGS. 16-19 show perspective views of stacked containers, according to an embodiment of the disclosure.

[0028] FIG. 20 pictorially depicts an embodiment of a manufacturing process, according to the disclosure.

[0029] FIG. 21 shows a perspective view of a roll connected to a web-tensioning mechanism that leads to a web steering system for use in an embodiment of a manufacturing process, according to the disclosure. [0030] FIG. 22 shows a perspective view of a first web guide, a column forming mechanism, and a second web guide for use in an embodiment of a manufacturing process, according to the disclosure.

[0031] FIG. 23 shows a perspective view of a column forming mechanism for use in an embodiment of a manufacturing process, according to the disclosure.

[0032] FIG. 24 shows a perspective view of a web spreading mechanism for use in an embodiment of a manufacturing process, according to the disclosure.

[0033] FIG. 25 shows a section of a flexible film sheet having a support column with a second portion and a first portion on opposite sides of a centerline through the flexible film, according to an embodiment of the disclosure.

[0034] FIG. 26 shows a perspective view of a column flattening mechanism for use in an embodiment of a manufacturing process, according to the disclosure.

[0035] FIG. 27 shows a perspective view of a tension maintaining device for use in an embodiment of a manufacturing process, according to the disclosure.

[0036] FIG. 28 shows a perspective view of a device that includes a first transformation mechanism, a tube welder, a second transformation mechanism, and a cutting mechanism for use in an embodiment of a manufacturing process, according to the disclosure.

[0037] FIG. 29 shows a perspective view of a welding system for use in an embodiment of a manufacturing process, according to the disclosure.

[0038] FIG. 30 shows a perspective view of a rotating weld head for use in an embodiment of a manufacturing process, according to the disclosure.

[0039] FIG. 31 shows a perspective view of an expanding corner anvil head for use in an embodiment of a manufacturing process, according to the disclosure.

[0040] FIG. 32 shows a perspective view of a nesting system for use in an embodiment of a manufacturing process, according to the disclosure. [0041] FIG. 33 shows a diagrammatic view of loading of an embodiment of a container, according to the disclosure.

[0042] FIG. 34 illustrates a partial cross-sectional view of the column forming mechanism of FIG. 23.

[0043] FIG. 35 illustrates a support column in accordance with another exemplary embodiment of the disclosure.

[0044] Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.

DETAILED DESCRIPTION OF THE INVENTION

[0045] Provided are a flexible film, a container, and a manufacturing process. Embodiments of the present disclosure, for example, in comparison to similar concepts failing to include one or more of the features disclosed herein, provide additional strength and/or rigidity, permit lower cost production of containers, permit increased visibility of graphics or other identifiable information on packaging, permit easier and quicker restocking in retail settings, permit easier and less costly transportation, provide other advantages that will be evident from the present disclosure, or a combination thereof.

[0046] FIG. 1 shows an embodiment of a flexible film 101. The flexible film 101 is shown within a film sheet 100 having a plurality of the flexible films 101 adjacently arranged for the manufacturing process, prior to cutting the plurality of the flexible films 101 to produce discrete arrangements of the flexible films 101. The flexible film 101 permits increased strength, increased stackability, and easier display on a container 401 (see FIG. 4) including the flexible film 101. As shown in FIGS. 1-4, the flexible film 101 includes wall portions 103 in a flexible film material 105 that are separated by support columns 107 in the flexible film material 105, the support columns being formed from the same web of flexible film as the container wall and thus being formed integral therewith. While primarily shown and described with respect to tubular support columns 107, it will be appreciated that the invention is not so limited and that the support columns 107 may be formed in any suitable manner, including, for example, one or more z-folds as illustrated in FIG. 35 and discussed subsequently herein. [0047] The flexible film material 105 is any material that is generally capable of being used for packaging, with a general preference for two side sealable films. The container 401, the flexible film 101, and/or the film sheet 100 include materials that are microwaveable or are not suitable for microwaving and that contain vents for the release of pressure or do not contain vents for the release of pressure. Suitable materials include, but are not limited to, a single or multiple layer film, composite, or laminate, for example, including ethylene vinyl alcohol copolymer, polyamide, polyacrylonitrile, polyethylene terephthalate (PET), polyalkene (polyolefin), polyethylene, polypropylene, polylactic acid (PLA), cellophane, bioplastic-based film, any suitable polymer, or a combination thereof as well as metalized film, paper, or any other materials or laminates employing such materials. In one embodiment, the film comprises an oriented and/or cast polypropylene (OPP and CPP, respectively).

[0048] Among the factors in film selection for a particular embodiment, aside from properties for containing a particular type of food, are those that impact the manufacture of the packaging, such as film stiffness. Films that are too stiff can result in large tension variations across a web of film during manufacture, as well as result in friction that can result in delamination or breakage. The flexible films 101 typically used in exemplary embodiments have a Gurley stiffness in the range of 80 to 140 mg (as measured using a standard Gurley-type stiffness tester). Film thickness to achieve the desired stiffness may vary depending upon the particular composition(s) of the flexible film material, but can range, by way of example, up to about 100 microns or greater.

[0049] Any suitable number of the support columns 107 providing desired strength is capable of being used. For example, in various embodiments of the flexible film 101 , three, four, five, or six of the support columns 107 are included in the flexible film 101. In one embodiment, the support columns 107 are ultrasonic ally welded into form during the production of the film sheet 100, for example, providing the increased strength for the container 401, permitting the flexible film 101 to be self-supported, with or without rigid supports being positioned in the container 401 and/or the flexible film 101. While one of the advantages of exemplary embodiments is the ability to provide a self-supported container without the use of rigid supports, they are not necessarily excluded and may be used in combination with the support columns 107. Exemplary embodiments achieve a force load measurement - without relying on container contents and/or rigid supports - that is two to eight times stronger than conventional flexible packages.

[0050] Additionally or alternatively, the support columns 107 are formed during the production of the film sheet 100 by adhesive, mechanical techniques, ultrasonic welding, cold seal, hot seal, or any other suitable technique of welding two or more surfaces to another. Additionally or alternatively, in one embodiment, the support columns 107 enclose a gas (such as, air or an inert gas), for example, providing the increased strength for the container 401 , permitting the flexible film 101 to be self-supported, with or without rigid supports being positioned in the container 401 and/or the flexible film 101.

[0051] While primarily discussed herein as containing a gas, it will be appreciated that the invention is not so limited and that any fluid material (i.e., any flowable matter) may be contained within the support columns 107, including a liquid, fine powder, etc. In some embodiments, for example, it may be desirable to fill one or more of the support columns 107 itself with a food item such that the support column acts as a package within a package to separate contents within the container 401, such as nuts and candy or chips and dip, for example. As a result, exemplary embodiments permit a single web of flexible film to be used in making a multi-compartment container.

[0052] To maintain tension, reduce friction, and result in a gradual narrowing of the film sheet 100, in one embodiment, the support columns 107 are produced in a staggered, sequential, or periodic manner. For example, in an embodiment, with four of the support columns 107, one or two of the support columns 107 are formed at a time. The support columns 107 are formed while the film sheet 100 is static or as it moves.

[0053] In the embodiment shown in FIG. 1, the flexible film 101 includes the support columns 107 enclosing the gas. The support columns 107 enclose the gas between flattened regions 109, for example, positioned along a direction 1 11 for cutting the film sheet 100 to discrete arrangements of the flexible film 101, which are capable of being used to produce the container 401. FIGS. 2 and 3 show embodiments of the flexible film 101 as such discrete arrangements capable of being used to produce the container 401. It will be appreciated that for embodiments which use one or more support columns 107 to also used as a storage area to contain a food or other item, that the support column to be filled is typically not permanently flattened during processing and at least one end is left unsealed to allow later filling. It will further be appreciated that the size of a column that is to subsequently be filled with a product to be consumed may be different (typically larger) than those used primarily to impart strength to the container 401.

[0054] As shown in FIG. 2, in one embodiment, the support columns 107 are arranged within the flexible film 101 , and the wall portions 103 abut each side of the support columns 107. In this embodiment, two of the wall portions 103 are capable of overlapping and/or being fused together to wrap the flexible film 101 in a continuous manner as is shown in FIG. 4 to form the sidewall of the container 401. Among the advantages of exemplary embodiments is that the support columns 107, formed integral from the same web of film 101 used to form the container wall portions 103, can each be formed on the same side of the web. Thus, when wrapped and sealed to form the continuous container wall, the support columns 107, and any associated seams and/or welds from their formation, are hidden from view within the interior of the container 401. As a result, an essentially continuous printable surface is provided on the exterior of the container 401 for presenting graphics or other text or branding without multiple visible seals or seams that could otherwise interrupt and/or make printing graphics (or aligning pre-printed graphics) more difficult, with only the single seam joining the two ends of the film visible on the exterior of the container 401.

[0055] As shown in FIG. 3, the support columns 107 have a support column width 301 that is smaller than a wall portion width 303 for the wall portions 103 and a film length 305 for the flexible film 101. Suitable values for the support column width 301 include, but are not limited to, being less than 50 millimeters, being less than 40 millimeters, being less than 30 millimeters, being between 20 and 30 millimeters, or any suitable combination, sub-combination, range, or sub-range therein. Suitable values for the film length 305 range include, but are not limited to being greater than 100 mm, being less than 1000 mm, being between 100 and 1000 mm, such as 200, 300, 400, 500, 600, 700, 800, or 900 mm or any suitable combination, sub-combination, range, or sub-range therein.

[0056] Suitable values for the wall portion width 303 include, but are not limited to, being greater than 50 millimeters, being less than 200 millimeters, being between 50 and 200 millimeters, such as 60, 70, 80, 90, 100, 1 10, 120, 130, 140, 150, 160, 170, 180, or 190 mm or any suitable combination, sub-combination, range, or sub-range therein. In one embodiment, the relative value of the wall portion width 303 in comparison to the support column width 301 is at a ratio, for example, of 10 to 1 , 9 to 1 , 8 to 1 , 7 to 1 , 6 to 1 , 5 to 1 , 4 to 1, 3 to 1 , 2 to 1 , 1 to 1 , or any suitable combination, sub-combination, range, or sub-range therein.

[0057] Suitable values for the column length 307 (also generally corresponding to container height) include, but are not limited to, being greater than 50 millimeters, being less than 200 millimeters, being between 50 and 200 millimeters, such as 60, 70, 80, 90, 100, 1 10, 120, 130, 140, 150, 160, 170, 180, or 190 mm, or any suitable combination, sub-combination, range, or sub-range therein. In one embodiment, the relative value of the film length 305 in comparison to the support column width 301 is at a ratio, for example, of 10 to 1, 9 to 1 , 8 to 1, 7 to 1, 6 to 1, 5 to 1, 4 to 1, 3 to 1 , 2 to 1, 1 to 1 , or any suitable combination, sub-combination, range, or subrange therein.

[0058] Referring to FIG. 4, the container 401 formed from the flexible film 101 includes the flexible film 101 affixed to a container base 403, for example, by heat welding and/or ultrasonic welding, to define a packing region 405 within the container 401. The packing region 405 is any suitable geometry capable of being formed with the flexible film 101 having the support columns 107 (for example, in corners 407 of the container 401) and the wall portions 103. Suitable geometries, include, but are not limited to, generally having a sectional profile of a triangle, a square, a rectangle, a pentagon, a hexagon, or any other polygon, although it will be appreciated that exemplary embodiments also include geometries with rounded sides, such as cylindrical (both round and ovular, for example). Although the container 401 shown in FIG. 4 includes the section profile being the square, the size of the wall portions 103 and/or the support columns 107 are capable of being varied to produce a complex-shaped embodiment of the container 401. The packing region 405 is capable of being used for storing any collection of small articles such as food (for example, candy, nuts, mints, and/or pasta), spices, seeds/bulbs, or fasteners, all by way of example.

[0059] The container base 403 corresponds to the desired geometry for the container 401. FIG. 4 shows the container base 403 corresponding to embodiments of the container 401 generally having the sectional profile of the square. The container base 403 shown is a strengthened base having a strength-enhancing design, for example, a rigid thermoplastic having a pre-determined defined shape such as those produced during cold-forming, thermoforming, or a combination thereof. In other embodiments, the container base 403 is a flexible film that is formed to a pre-determined defined shape, such as just mentioned with respect to rigid thermoplastics and/or which is formed into its shape as part of container manufacturing operations. The container base 403 may be configured either in advance or during container manufacturing such that a surface portion of the container base 403 is in a parallel plane with a portion of the container wall portions 103 to create a sealable edge (as shown, for example, in FIG. 33).

[0060] In one embodiment, the strength-enhancing design and/or the container base 403 in general decrease(s) the amount of deformation within the wall portions 103 during stacking of the containers 401. Other suitable features capable of being included in the container base 403 to provide strength include, but are not limited to, raised edges 41 1 or chamfers for nesting and/or stacking containers 401 on top of one other. In embodiments in which the container base 403 is itself formed of a flexible film material, that material may be of the same or a different material from that used to form the side walls of the container 401.

[0061] In addition to the container base 403 being affixed to the flexible film 101, in one embodiment, a container cover 409 is affixed to the flexible film 101 to form the container 401. The container cover 409 is affixed to the flexible film 101 by ultrasonic welding, adhesive, mechanical techniques, cold seal, hot seal, or any other suitable technique.

[0062] The container cover 409 is any suitable design meeting the desired end use, such as, but not limited to, being microwavable, having instructions for use, being sealed, being re- sealable, allowing hot gases to vent, allowing pouring, and/or having heating/cooling packs and/or insulation. For example, in one embodiment, as shown in FIG. 4, the container cover 409 is substantially planar and rigid. In one embodiment, as shown in FIGS. 5-6, the container cover 409 includes a handle 501 and vent holes 601 exposed by repositioning the handle 501 in a direction 603 from the orientation in FIG. 5 to the orientation in FIG. 6. In some embodiments, the vent holes 601 (see FIG. 6) may instead be formed as a plurality of small holes or other punctures in the cover 409 that may be sized to allow some pressurization when the container's contents are heated (for example during micro waving of a container 401 containing a food product), which in some embodiments is accomplished by the vent holes 601 being configured to achieve a vent pressure of 0.5 psig or less.

[0063] In another embodiment, as shown in FIGS. 7-8, the container cover 409 includes pull- tabs 701 capable of opening and/or tearing a portion 801 of the container cover 409 when pulled in a direction 703 from the position in FIG. 7 to the position in FIG. 8. Other embodiments include, but are not limited to, the container cover 409 having a bendable joint 901 positioned substantially in the center of the container cover 409 (see FIG. 9), having externally-protruding pull tabs 1001 that extend beyond the profile of the container cover 409 upon being adjusted (see FIG. 10), having a two-piece arrangement of a lower rectangular recessed portion 1 101 and an upper substantially planar rectangular portion 1103 configured to be secured within the lower rectangular recessed portion 1 101 (see FIG. 1 1), having a two-piece arrangement of a lower rectangular open portion 1201 and an upper rectangular substantially planar portion 1203 configured to cover an open rectangular portion 1205 of the lower rectangular open portion 1201 upon being secured to the lower rectangular open portion 1201 (see FIG. 12), having a two-piece arrangement of a lower open portion 1301 and an upper circular substantially planar portion 1303 configured to cover an open circular portion 1305 of the lower open portion 1301 upon being secured to the lower open portion 1301 (see FIG. 13), the container cover 409 having a flap 1401 or pealable portion capable of being opened upon bending at edge 1403 or otherwise ripping/tearing of the container cover 409 (see FIG. 14), a feature within the container cover 409 being arranged as or in conjunction with a vent, or a combination thereof.

[0064] As will be appreciated, the container base 403 and/or the container cover 409 are capable of being arranged in any orientation with respect to the flexible film 101. For example, as shown in FIG. 15, in one embodiment, the container base 403 and the container cover 409 are positioned horizontally relative to the flexible film 101, with the term horizontal representing a direction perpendicular or substantially perpendicular to the direction of gravity. In a further embodiment, the container cover 409 includes a seal portion 1501 and a cover portion 1503 for covering the seal portion 1501, the cover portion 1503 having a removable region 1505 or spout, allowing access to the seal portion 1501, which is capable of being punctured to allow fluid contents to exit the container 401.

[0065] Referring to FIG. 16, the containers 401 are capable of being stacked with or without other structures, such as trays or cartons, with the containers 401 in some embodiments being stacked in a nestable fashion, with the base 403 of one container 401 being nested by the cover 409 of a second container on which it is stacked. In the illustrated embodiment, one or more stacks 1601 of the containers 401 is/are positioned within a tray 1603, such as a corrugated and/or die cut material. In a further embodiment, the stacks 1601 are positioned adjacent and within recesses 1605 having a die cut 1609 and geometry corresponding with the container base 403 for each of the containers 401 positioned on the bottom of the stacks 1601. The stacks 1601 are capable of including any suitable number of the containers 401, for example, two of the containers 401, three of the containers 401, four of the containers 401, or more of the containers 401, so long as the containers 401 positioned on the bottom of the stacks 1601 are not crushed or damaged by the containers positioned above them. In one embodiment, a covering 1607, such as a card hood, is capable of being positioned on the stacks 1601, thereby enclosing them in conjunction with the tray 1603, providing protection (for example, from debris, damage, early- display, or a combination thereof), providing a display arrangement that decreases the duration of time for replenishment, providing simpler transportation and/or storage, providing increased freshness of contents, or a combination thereof.

[0066] Referring to FIGS. 17 through 19, in one embodiment, the stacks 1601 are wrapped with a collation wrap 1701 to provide structural support within the stacks 1601 and/or to prevent damage to the containers 401. The collation wrap 1701 reduces or eliminates movement and/or damage of the containers 401 by securing them together. The collation wrap 1701 is capable of extending around one of the stacks 1601 or a plurality of the stacks 1601 and/or is capable of being wrapped with a film wrap 1703. In one embodiment, as shown in FIGS. 18 and 19, the film wrap 1703 includes a lip 1801 for retaining the stacks 1601 within the collation wrap 1701 inside of the film wrap 1703. As shown in FIG. 19, in one embodiment, the lip 1801 is capable of being folded to open or close an access region 1901 for accessing the stacks 1601 and/or the containers 401. [0067] FIG. 20 shows an embodiment of a manufacturing process 2000 for producing the flexible film 101 and/or the container 401. The flexible film 101 is formed by forming the support columns 107 (step 2002) and forming the wall portions 103 (step 2004). The container 401 is formed by attaching the container base 403 (step 2006) and, in a further embodiment, attaching the container cover 409 (step 2008).

[0068] Referring to FIG. 21 , in one embodiment, the forming of the support columns 107 (step 2002) includes unwinding a roll 2102 connected to a web-tensioning mechanism 2103 that leads to a web steering system 2105 to produce the film sheet 100. In a further embodiment, the unwinding further includes splicing of the film sheet, for example, with an automatic splicing system. In some embodiments, a turner bar may be employed to flip the film sheet, isolating a bow wave formed in the web by column forming from the steering system. This can help overcome misalignments between unwinding of the film and the column formation, as well as helping to overcome tracking effects of column formation.

[0069] Referring to FIG. 22, in one embodiment, the forming of the support columns 107 (step 2002) includes the film sheet 100 entering a first web guide 2201, prior to the film sheet 100 travelling to a column forming mechanism 2203 that produces the support columns 107 in the film sheet 100 after exiting a second web guide 2201. In a further embodiment, the film sheet 100 then travels through a web spreading mechanism 2205 and a column flattening mechanism 2207, where the support columns 107 are flattened. In one embodiment, the forming of the support columns 107 (step 2002) is adjustably controlled by a hitch fixed clamp 2209, a hitch index 221 1, and a hitch moving clamp 2213.

[0070] As shown in FIG. 23, in one embodiment, the column forming mechanism 2203 ploughs/forms and seams/welds the flexible film material 105 in the film sheet 100 to produce the tubular support columns 107 integral with the web, thereby laterally defining the wall portions 103. The forming includes guiding the film sheet 100 through the column forming mechanism 2203, integration and seaming by the column forming mechanism 2203, inflation of the support column 107 (for example, with compressed air, ambient/entrained air, or another suitable inert gas to increase the structural integrity of the support column 107) by the column forming mechanism 2203, or a combination thereof. FIG. 34 illustrates a partial cross-sectional view of the column forming mechanism 2203 including a ploughing tool 3401, plough mandrel 3407 and weld tool 3403. As shown, the plough mandrel has an interior chamber that provides a gas inflation channel 3405 for embodiments in which air or another gas is optionally introduced into the column 107 during formation.

[0071] The column forming mechanism 2203 moves relative to the web of flexible film material 105 which may be accomplished either by continuous flow of the web through the mechanism or, more typically, incremental movement of the web, followed by movement of the column forming mechanism 2203 relative to the web while the web remains temporarily stationary.

[0072] As shown in FIG. 24, in one embodiment, the web spreading mechanism 2205 spreads the film sheet 100 after the column forming mechanism ploughs/forms and seams/welds the flexible film material 105 in the film sheet 100 to produce the support columns 107. The web spreading mechanism 2205 spreads the film sheet 100 to align the support columns 107 for flattening. For example, referring to FIG. 25, in one embodiment, a first portion 2501 of the support column 107 and a second portion 2503 of the support column 107 are aligned such that each of the first portion 2501 and the second portion 2503 are on opposite sides of a centerline 2505 that is perpendicular, or substantially perpendicular, to the film sheet 100. In a further embodiment, the first portion 2501 has a first volume that is within a selected relative range of a second volume of the second portion 2503, for example, the first volume being within 20% of the second volume, the first volume being within 10% of the second volume, the first volume being within 8% of the second volume, within 5% of the second volume, the first volume being within 3% of the second volume, being within 1% of the second volume, or any suitable combination, sub-combination, range, or sub-range therein. That is, the support column 107 is preferably flattened evenly so that there is an equal or approximately equal amount of the material forming the support column 107 on both sides of the centerline 2505.

[0073] As shown in FIG. 26, in one embodiment, the column flattening mechanism 2207 applies pressure to one or more of the support columns 107 in the film sheet 100, for example, on both the first portion 2501 and the second portion 2503 of the support columns 107. The pressure adjusts the geometry of at least a portion of the support columns 107, for example, from having a circular profile to a rectangular profile. Flattening in conjunction with a lower volume variation of the first volume and the second volume provides additional strength in comparison to flattening with a higher volume variation. In one embodiment, ends of the support columns 107 are sealed by the flattening, thereby defining a region where the support columns 107 are capable of being cut without allowing the gas to escape from within the support columns 107. In another embodiment, the entire support column 107 is flattened, either partially or entirely, with entrained air able to escape by sealing one end of the support column 107 followed by sealing the opposite end after flattening.

[0074] In still another embodiment of the invention, illustrated in FIG. 35, the support column 107 is formed as a series of overlapping folds 3503, such as one or more z-folds. In this embodiment, rather than forming a tube, the plowing and forming step includes one or more additional folds in the web to form the support column 107. Depending on the number of folds and/or the order and direction of sealing operations, gas may or may not still be trapped within the support column 107. In some embodiments in which the support column 107 is a folded column, the support column 107 is entirely flattened and then welded over its full width and/or length.

[0075] As shown in FIG. 27, in one embodiment, the forming of the wall portions 103 (step 2004) includes use of a tension maintaining device 2701. In one embodiment, the tension maintaining device has a receiving roller 2703 for receiving the film sheet 100, a dancing arm 2705 positioned to receive the film sheet 100 from the receiving roller 2703 and to maintain tension of the film sheet 100 despite adjustments in the rate of movement after the tension maintaining device 2701 , and a roller 2707 positioned proximal to a guide roller 2709, where the film sheet exits the tension maintaining device 2701. The rollers are any suitable geometry capable of supporting the film sheet 100. The rollers are triangular, square, pentagonal, hexagonal, or any other suitable geometry. In one embodiment, the rollers have planar portions 271 1 of equal or slightly smaller size than the wall portions 103 and corner portions 2713 separating the planar portions 271 1. In one embodiment, the rollers are designed to accommodate a change in direction of the film sheet 100, for example, while prohibiting bending within the support columns 107. [0076] As shown in FIG. 28, in one embodiment, the forming of the wall portions 103 (step 2004) is achieved by a device 2800 that includes a first transformation mechanism 2801 (for example, to transform the film sheet 100 from planar to round), a tube welder 2803 (for example, to weld the film sheet 100 from the round geometry into a tube), a second transformation mechanism 2805 (for example, to transform the film sheet 100 from being round to being square or another suitable geometry for the flexible film 101), and a cutting mechanism 2807 used for cutting the film sheet 100 into discrete units of the flexible film 101 capable of being used to form the container 401, for example, in a circular fashion around the perimeter of the flexible film 101. Cutting of the polygonal perimeter in a circular or arc like fashion results in the cutting occurring with a slicing action in contrast to stabbing or square pecking found in conventional cutting operations. In a further embodiment, the movement of the film sheet 100 through the device 2800 is performed by an urging force applied by a tube drive 2809, for example, positioned between the second transformation mechanism 2805 and the cutting mechanism 2807. In one embodiment, one or more of the components of the device 2800 are held under vacuum to provide additional stability for the film sheet 100 during the transformation, welding, and/or cutting.

[0077] Forming of the container 401 from the flexible film 101 begins with the attaching of the container base 403 (step 2006) or the attaching of the container cover 409 (step 2008) to one or more of the wall portions 103 of the flexible film 101, for example, using a welding system 2901 as is shown in FIG. 29. An embodiment of the welding system 2901 includes a nesting system 2903 (see FIG. 32) for receiving the wall portion(s) 103 and an insertion head 2905 for receiving the container base 403 and/or the container cover 409. The nesting system 2903 is a precision- machined part providing location accuracy, having a vacuum plenum 3201 capable of temporarily holding the wall portion(s) 103 (for example, during re-referencing), and having interchangeable geometry-defining elements 3203, permitting use with different sized-parts.

[0078] The container base 403 and/or the container cover 409 are welded to the wall portion(s) 103 by any suitable technique. Suitable techniques include, but are not limited to, being ultrasonically welded and/or being heat- welded. In one embodiment, the welding begins with a tack weld to hold the container base 403 or the container cover 409 in position and is followed by a finish weld for complete attachment to be achieved. The welding is achieved by using any suitable devices, such as, rotating weld heads 2907 (see FIG. 30), an expanding corner anvil head 2909 (see FIG. 31), and/or an energy chain tray 291 1. The rotating weld heads 2907 have a tool geometry configured to the desired end-product, such as the container 401. The expanding corner anvil head 2909 is an expanding mechanism configured to stretch out the flexible film 101 during the welding, for example, by being pre-heated to reduce welding times.

[0079] Referring to FIG. 33, in one embodiment, after the positioning of the wall portions 103 and the attaching of the container base 403 within the nesting system 2903, the packing region 405 is loaded with a product 3301 prior to the attaching of the container cover 409 and the completion of the container 401. In this embodiment, the container base 403 is shown as a sheet of flexible film that is pushed through what will become the top of the container and then sealed at its edges, the sheet used for the container base being wider than the space defined by the wall portions 103, leaving selvedge that folds against the inner wall that forms an overlapping surface for sealing. Alternatively, the container cover 409 is attached prior to the loading of the product 3301 and the container base 403 is attached afterward. In either case, in some embodiments in may be desirable to introduce air or another gas (such as nitrogen in the case of most food products) to fill head space over the container contents and optionally to pressurize the container 401.

[0080] While the invention has been described with reference to one or more embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.