Flexible sturdy base container and method for making the same

Abstract

Flexible sturdy base containers and methods for manufacturing the same are provided. The flexible sturdy base container includes a rigid base element formed of a relatively rigid material. The rigid base element includes a bottom and a perimeter wall having an outward facing surface. The container also includes a flexible wall element formed of a relatively flexible material. The flexible wall element is affixed to the outward facing surface of the perimeter wall of the rigid base element and extends in a direction away from the bottom of the rigid base element. The flexible wall element and the bottom of the rigid base element together form an exterior of the flexible sturdy base container.

1 . A flexible sturdy base container comprising:
 a rigid base element comprising a relatively rigid material, the rigid base element comprising a bottom and a perimeter wall having an outward facing surface; and   a flexible wall element comprising a relatively flexible material;   wherein the flexible wall element is affixed to the outward facing surface of the perimeter wall of the rigid base element and extends in a direction away from the bottom of the rigid base element; and   wherein the flexible wall element and the bottom of the rigid base element together form an exterior of the flexible sturdy base container.   
     
     
         2 . The flexible sturdy base container of  claim 1 , wherein the flexible wall element overlaps itself along a portion of the perimeter wall to form a lap seam. 
     
     
         3 . The flexible sturdy base container of  claim 2 , wherein an inward-facing surface of the flexible wall element is bonded to an outward-facing surface of the flexible wall element where the flexible wall element overlaps itself at the lap seam. 
     
     
         4 . The flexible sturdy base container of  claim 1 , the rigid base element further comprising a reclosable lid. 
     
     
         5 . The flexible sturdy base container of  claim 4 , further comprising a hinge connecting the reclosable lid to the rigid base element. 
     
     
         6 . The flexible sturdy base container of  claim 5 , wherein the hinge is a living hinge. 
     
     
         7 . The flexible sturdy base container of  claim 4 , the rigid base element further comprising a spout opening providing access to an interior of the container, the spout opening being selectively closable with the reclosable lid. 
     
     
         8 . The flexible sturdy base container of  claim 7 , the reclosable lid comprising an internal rib and the spout opening comprising an external rib, and wherein the internal rib engages the external rib when the reclosable lid is positioned in a closed position. 
     
     
         9 . The flexible sturdy base container of  claim 1 , wherein the flexible wall element covers only a first portion of the perimeter wall of the rigid base element thereby leaving a second portion of the perimeter wall exposed proximal the bottom of the rigid base element. 
     
     
         10 . The flexible sturdy base container of  claim 1 , wherein rigid base element comprises a molded or thermoformed article. 
     
     
         11 . The flexible sturdy base container of  claim 1 , wherein the relatively rigid material comprises a plastic material. 
     
     
         12 . The flexible sturdy base container of  claim 1 , wherein the rigid base element comprises a recessed panel and a standoff extending between the recessed panel and the bottom of the rigid base element. 
     
     
         13 . The flexible sturdy base container of  claim 12 , further comprising a reclosable lid attached to the recessed panel. 
     
     
         14 . The flexible sturdy base container of  claim 1 , wherein the perimeter wall has at least one flat, substantially planar portion. 
     
     
         15 . The flexible sturdy base container of  claim 4 , further comprising a locking tab for locking the reclosable lid in a closed position, the locking tab moveable between a unlocked position and a locked position. 
     
     
         16 . The flexible sturdy base container of  claim 1 , wherein the relatively flexible material comprises a polymeric material. 
     
     
         17 . The flexible sturdy base container of  claim 1 , wherein the relatively flexible material comprises a multilayer laminate structure. 
     
     
         18 . The flexible sturdy base container of  claim 17 , wherein the multilayer laminate structure comprises a heat-sealable inner layer comprising a heat sealable material. 
     
     
         19 . The flexible sturdy base container of  claim 17 , wherein the multilayer laminate structure comprises an oxygen and/or vapor barrier layer. 
     
     
         20 . The flexible sturdy base container of  claim 17 , wherein the multilayer laminate structure comprises a print layer. 
     
     
         21 . The flexible sturdy base container of  claim 1 , wherein the flexible wall element comprises a first end proximal to the bottom of the rigid base element and a second end distal to the bottom of the rigid base element, and wherein the second end of the flexible wall element comprises a heat seal region, the heat seal region hermetically sealing the container. 
     
     
         22 . The flexible sturdy base container of  claim 21 , wherein the flexible wall element further comprises a tear-away portion and a stress riser that facilitates the tearing away of the tear away portion. 
     
     
         23 . The flexible sturdy base container of  claim 1 , wherein the flexible wall element comprises a first end proximal to the bottom of the rigid base element and a second end distal to the bottom of the rigid base element, and wherein the second end of the flexible wall element comprises a reclosable element, the reclosable element allowing selective closure of the second end of the flexible wall element. 
     
     
         24 . The flexible sturdy base container of  claim 1 , wherein the container contains a bulk product.