User inflated breachable container and method

Description of equivalent WO 2007116054 A2

USER INFLATED BREACHABLE CONTAINER, AND METHOD

0002This application claims the benefit of provisional application Serial Number 60/790,863, filed April 11, 2007.

TECHNICAL FIELD

0004This invention relates to breachable product containers, and more particularly to such a container that is inflated by the user just prior to opening.

0005BACKGROUND US patent 6,726,364 issued on Apr 27, 2004 to the present inventor teaches a breaching bubble with opposed peel flaps along the breaching edge. The peel flaps are pulled back by the consumer to open a chamber and present a stored product. However, this earlier bubble is not inflated by the user. The subject matter of US patent 6,726,364 is hereby incorporated by reference in its entirety into this disclosure.

0006US 4,872,556 to Farmer teaches a container with two rupturing seals for controlling the discharge of a stored liquid or fluid commodity. The commodity is contained in a large storage chamber and dispensed through a smaller, adjacent discharge chamber. Pressure applied to the commodity in the storage chamber causes an inner storage seal between the two chambers to rupture, resulting in fluid flow from the storage chamber into the discharge chamber. Continued pressure on the storage chamber fluid causes an outer discharge seal to rupture permitting the fluid to discharge from the discharge chamber into the ambient. Major consumer pressure was required to rupture both the storage seal and the discharge seal. Farmer does not provide a passage through the storage seal from the storage chamber to the discharge chamber.

0007SUMMARY It is therefore an object of this invention to provide a breachable container which may be stored and shipped and handled partially or completed deflated. The containers with deflated product chambers and breaching bubbles requires minimal storage space and shipping volume, and undergoes minimal loss through accidental "poppage". Fully inflated containers may be subjected to the weight of other containers or to "rough" handling. Poppage, or breach during commerce exposes the product to the ambient .

0008It is another object of this invention to provide such a container in which a breaching bubble is inflated to breaching condition by the end-user just prior to opening. The user presses on the product chamber to transfer inflation fluid through a transfer passage into the breaching bubble. The breaching bubble inflates to breaching condition. The breaching bubble becomes sufficiently "plump" so as to be edge breached by sharply applied user pressure.

0009It is a further object of this invention to provide such a container in which the product chamber and the breaching bubble are in fluid equilibrium during storage and shipping. The inflation fluid may freely transfer forward into the breaching bubble and backward into the product chamber. It is a further object of this invention to provide such a container in which the flow of inflation fluid is controlled. A one-way valve in the transfer passage prevents backward flow. Only forward flow is permitted during storage and shipping.

0010Briefly, these and other objects of the present invention are accomplished by providing a first lamina and an opposed second lamina selectively pressed together. A perimeter seal around the container formed by the selective pressing. A product chamber and an inflatable breaching bubble between the selectively pressed opposed laminae, within the perimeter seal. An inner divider extends between the product chamber and the breaching bubble, and is formed by the selective pressing. A transfer passage through the inner divider permits inflation of the breaching bubble in response to moderate pressure applied to the product chamber during an extended inflation period. A breaching edge forms part of the perimeter seal around the breaching bubble. The breaching edge providing an edge breach by separating the opposed laminae along the breaching edge in response to substantial pressure applied to the breaching bubble during a brief breaching period.

BRIEF DESCRIPTION OF THE DRAWINGS

0012Further objects and advantages of the user inflated breaching bubble and the operation of the transfer passage will become apparent from the following detailed description and drawings (not drawn to scale) and flow chart in which:

0013FIG. IA is a plan view of breachable product container 10 showing product chamber 12P and breaching bubble 12 with transfer passage 14 therebetween; FIG. IB is a side view of container 10 of FIG. IA showing product chamber 12P and breaching bubble 12 before inflation (light lines) and during inflation (bold lines) ;

0014FIG. 1C is an end view in section of container 10 of FIG. 1 taken generally along reference line IC-IC thereof showing transfer passage 14;

0015FIG. ID is a graph depicting the pressure within breaching bubble 12 during Storage, Inflation, Breaching, and Access periods of the opening sequence;

0016FIG. IE is a side view of container 10 of FIG. IA during the breaching period;

0017FIG. IF is a side view of container 10 of FIG. IA during the access period showing opposed peel flaps 12C and 12B;

0018FIG. 2 is a plan view of breachable product container 20 showing product chamber 22P and breaching bubble 22 with transfer passage 24 therebetween;

0019FIG. 3A is a plan view of breachable product container 30 showing tortuous transfer passage 34;

0020FIG. 3B is a side view of container 30 of FIG. 3A showing the container in a deflated condition;

0021FIG. 4A is a plan view of breachable product container 40 showing closed flapper valve 44V preventing backward flow through transfer passage 44;

0022FIG. 4B is a side view of container 40 of FIG. 4A showing open flapper valve 44V permitting forward flow through transfer passage 44;

0023PIG. 5A is a plan view of breachable product container 50 showing closed resilient valve 54V preventing backward flow through transfer passage 54;

0024FIG. 5B is a side view of container 50 of FIG. 5A showing open resilient valve 54V permitting forward flow through transfer passage 54; and

0025FIG. 6 is a flow chart showing the basic steps of the general method of gaining access to a product in a the container.

0026The first digit of each reference numeral in the above figures indicates the figure in which, an element or feature is most prominently shown. The second digit indicates related elements or features, and a final letter (when used) indicates a sub-portion of an element or feature.

0027REFERENCE NUMERALS IN DRAWINGS The table below lists the reference numerals employed in the figures, and identifies the element designated by each numeral.

0028Breachable Product Container 10

0029First Lamina 1OB

0030Second Lamina 1OC Perimeter Seal 1OS

0031Breaching Bubble 12

0032Corner Apex 12A

0033Opposed Peel Flap 12B

0034Opposed Peel Flap 12C Breaching Edge 12E

0035Product Chamber 12P

0036Corner Sides 12S

0037Transfer Passage 14

0038Divider 14D Product 16

0039Inflation Fluid 18 Breachable Product Container 20

0040Breaching Bubble 22

0041Header Space 22H

0042Product Chamber 22P Transfer Passage 24

0043Particle Product 26

0044Inflation Fluid 28

0045Header Portion 28H

0046Interstitial Portion 281

0047Breachable Product Container 30

0048Receiving Portal 3OP

0049Perimeter Seal 3OS

0050Product Chamber 32P Transfer Passage 34

0051Product 36

0052Inflation Fluid 38

0053Breachable Product Container 40 Breaching Bubble 42

0054Product Chamber 42P

0055Transfer Passage 44

0056Relief Course 44R

0057Flapper Valve 44V

0058Breachable Product Container 50

0059Breaching Bubble 52

0060Product Chamber 52P

0061Transfer Passage 54 Inner Divider 54D

0062Relief Course 54R

0063Resilient Valve 54V

0064GENERAL EMBODIMENT - (FIG.S 1 ABCDEF) Breachable product container 10 is formed by first lamina 1OB and opposed second lamina 1OC selectively- pressed together (see FIG. IB) . Perimeter seal 1OS (indicated by a solid bold line in FIG. IA) extends around the perimeter of the container, and is formed by the selective pressing. Product chamber 12P and inflatable breaching bubble 12 are between the selectively pressed opposed laminae, within the perimeter seal. Product 16 is contained within the product chamber. Inner divider 14D (indicated by single hatched lines) , extends between the product chamber and the breaching bubble, and is formed by the selective pressing. Transfer passage 14 (indicated by a wide bold line) , through the inner divider permits inflation of the breaching bubble in response to moderate pressure applied to the product chamber during an extended inflation period. Breaching edge 12E (indicated by double hatched lines) forms part of the perimeter seal around the breaching bubble . The breaching edge provides an edge breach by separating the opposed laminae along the breaching edge in response to substantial pressure applied to the breaching bubble during a brief breaching period.

0065Opposed peel flaps 12C and 12B (see FIG. IF) are formed along the edge breach by the separated opposed laminae. The end-user pulls the peel flaps apart causing detachment of the inner divider for permitting access to the product chamber. Breaching bubble 12 has a corner with corner apex 12A and two adjacent corner sides 12S (see FIG. IA) . Breaching edge 12E starts at the apex, which is the focus of the separation, and extends along both adjacent sides. The opposed peel flaps are formed by the opposed laminae at the corner and are generally triangular in shape for easy gripping by the end-user. Inflation fluid 18 within the product chamber is transferred through the transfer passage to inflate the breaching bubble during the extended inflation period. The inflation fluid may be ordinary ambient air, or a suitable special purpose fluid such as dry air, or an inert gas such as nitrogen.

0066The opposed laminae may have multiple layers to provide properties such as waterproofing, UV protection, increased bulk, and strength. The opposed laminae may be any suitable enclosing material such as plastic, paper fabric, cellophane, or bio-degradable matter. Thin mylar plastic is a flexible film with hermetic properties, and may be employed as a container material . The perimeter of the container has a breaching seal along the breaching edge for product access, and a non-breaching seal along the remaining perimeter. The breaching seal may be a frangible laminae union and the non-breaching seal may be a destructive laminae union. The frangible breaching seal is formed at a lower lamina-to-lamina pressure and a lower temperature for a shorter time than the destructive non-breaching seal. The frangible seal is weaker than the destructive seal, and breaches at a lower separation force and requires less compressive pressure applied by the end-user during the breaching period.

GENERAL OPENING SEQUENCE - (PIG. ID)

0068The pressure within the breaching bubble during each period of the opening sequence is graphically depicted in FIG. ID. During an indefinite storage period (warehousing, shipping, and shelf display) , the breaching bubble typically experiences little or no pressure. During storage, the product chamber and the breaching bubble may be partially inflated and flaccid (see FIG. IB light lines) or completely deflated and pressed flat (see FIG. 3B) . During an extended inflation period, the end- user applies moderate pressure to the product chamber (indicated by opposed arrows labeled Ip in FIG. IB) . The pressure restricts the envelope of the product chamber, causing the product chamber to "plump-up" and become firm (see FIG. IB, bold lines) . Inflation fluid is forced from the taut product chamber, through the transfer passage, into the breaching bubble. The pressure within the breaching bubble "ramps-up" during the inflation period, causing the reaching bubble to also "plump-up".

0069During a brief breaching period, the end-user applies substantial pressure sharply to the breaching bubble (indicated by opposed arrows Bp in FIG. IE) . The pressure in the breaching bubble rises to the breaching level, separating the opposed laminae along the breaching edge. The expanding bubble breaches into the ambient forming an edge breach. During an access period, the breached bubble is exposed to the ambient, at neutral pressure. The inflation fluid is lost and the container becomes flaccid. The inflation period should last only a moment or so, and the brief breaching period is shorter, perhaps less then a second. The method steps for the opening the product container are described in connection with PIG. 6.

0070EQUILIBRIUM EMBODIMENTS - (FIG. S 2 3AB) The transfer passage in the equilibrium embodiments, is an open channel with free flowing inflation fluid. The product chamber and breaching bubble are in fluid communication through the transfer passage during the indefinite storage period and the extended inflation period and the brief breaching period. The inflation fluid in the product chamber and the breaching bubble is in a state of fluid equilibrium maintained by migration of inflation fluid forward and backward through the unobstructed transfer passage. In the equilibrium embodiment of FIG. 2, open channel transfer passage 24 is sufficiently narrow to restrain backward flow of inflation fluid 28 from of breaching bubble 22 into product chamber 22P under the substantial pressure applied during the brief breaching period.

0071During the extended inflation period, the moderate user pressure produces a slow forward inflation transfer.

0072During the brief breaching period, the substantial user pressure produces a higher backward leakage transfer. The backward transfer flow rate (indicated by arrow Fb in FIG. IE) may be higher than the forward transfer flow rate (indicated by arrow Ff in FIG. IB) because the substantial breaching pressure is higher than the moderate inflation pressure. However, the total volume of the backward flow (Volume B = Fb x brief time) is far less than the volume of the forward flow (Volume F = Ff x extended time) , because the brief breaching period is much shorter than the extended inflation period.

0073The product chamber has a header space adjacent to the inner divider, which holds the inflation fluid prior to transfer through the transfer passage into the breaching bubble. Preferably, the header space holds enough inflation fluid to plump the breaching bubble during the extended inflation period. The product may be in particle form with inflation fluid filling the space between the product particles. As the particles gravity settle into a more compact format through shipping and handling, the header space enlarges. In the embodiment of FIG. 2, inflation fluid 28 has an active header portion 28H in header space 22H for transfer into the breaching bubble. The inflation fluid also has a passive interstitial portion 281 distributed among product particles 26.

0074In the embodiment of FIG. 3A, open channel transfer passage 34 is sufficiently tortuous with turns and curves to restrain backward flow of inflation fluid 38 during the brief breaching period. Receiving portal 3OP through perimeter seal 3OS around product chamber 32P receives inflation fluid 38 and product 36 into the product chamber. Prior to receiving, the empty deflated proto- containers may be easily shipped and handled. A perimeter seal may be pressed across the receiving portal, after receiving the inflation fluid into the product chamber and the breaching bubble, and the product into the product chamber. CONTROLLED FLOW EMBODIMENTS - (FIG. S 4AB 5AB) The transfer passage in the controlled flow embodiments has a one-way valve for controlling the inflation fluid flow. The product chamber and breaching bubble are in fluid communication through the transfer passage during the extended inflation period when the one-way valve is open. The fluid communication is blocked during the brief breaching period when the valve is closed. In the embodiment of PIG. 4, transfer valve 44V is a flapper valve positioned on the breaching bubble side of transfer passage 44. The flapper valve is open (see FIG. 4B) when the pressure in product chamber 42P is greater than the pressure in breaching bubble 42. The flapper valve is closed (see FIG. 4A) when the pressure in the product chamber is less than the pressure in the breaching bubble. The closed valve reduces leakage backward flow during the breaching period. Therefore the transfer passage may be wider without undue loss of breaching pressure during the breaching period.

0075In the embodiment of FIG. 5A and FIG. 5B, transfer valve 54V is a resilient valve having an internal resilience urging the resilient valve toward closed. The resilient valve is open (see FIG. 5B) when the pressure in product chamber 52P is sufficient to overcome the pressure in breaching bubble 52 plus the internal resilience. The resilient valve is closed (see FIG. 5A) when the pressure in the product chamber is insufficient to overcome the pressure in the breaching bubble plus the internal resilience. The resilient is self-closing at the end of the inflation period.

0076The one-way valves may completely prevent backward flow and the release of pressure from the breaching bubble. As a consequence, the pressure in the breaching bubble may build-up monotonically. Pressure bleed-off or relief course 44R (see FIG. 4A) and 54R (see FIG. 5A) may- extend between the breaching bubble and the product chamber. Relief course 44R extends through the flapper valve, and relief course 54R extends through inner divider 54D. These fine relief courses permit a minor bleed-off flow of inflation fluid to trickle from the breaching bubble back to the product chamber.

0077METHOD - (FIG. 6) The steps of the general method of gaining access to a product in a container are shown in the flow chart of FIG. 6, and described below. The apparatus required for carrying out the above method of operation are disclosed in FIG. s 1-5 and in the related detailed descriptions. The container has a product chamber and a breaching bubble with an inner divider therebetween, formed by opposed laminae .

0078Applying moderate external pressure to the product chamber during an extended inflation period (see Fig. IB) .

0079Inflating the breaching bubble by transferring inflation fluid from the product chamber into the breaching bubble through a transfer passage in the inner divider (see FIG. IB) .

0080Applying substantial pressure to the breaching bubble during a brief breaching period (see FIG. IE) .

0081Breaching the breaching bubble by separating the opposed lamina forming the breaching bubble (see FIG. IF) .

0082Forming peel flaps during the breaching step. Pulling peel flaps apart to detach an inner divider between the product chamber and the breaching bubble .

0083INDUSTRIAL APPLICABILITY It will be apparent to those skilled in the art that the objects of this invention have been achieved as described hereinbefore by providing a container which may be partially or completed deflated. Delated containers require have less volume, and less accidental "poppage". The deflated breaching bubble is inflated to breaching condition by the end-user by pressing on the product chamber. The product chamber and the breaching bubble may be in fluid equilibrium through a transfer passage. Alternatively, the flow of inflation fluid may be controlled by a one-way valve in the transfer passage.

0084Various changes may be made in the structure and embodiments shown herein without departing from the concept of the invention. Further, features of embodiments shown in various figures may be employed in combination with embodiments shown in other figures. Therefore, the scope of the invention is to be determined by the terminology of the following claims and the legal equivalents thereof.