U.S. patent application number 11/367613 was filed with the patent office on 2006-09-07 for multi-compartment flexible pouch.
Invention is credited to R. Charles Murray.
Application Number | 20060196784 11/367613 |
Document ID | / |
Family ID | 36943096 |
Filed Date | 2006-09-07 |
United States Patent
Application |
20060196784 |
Kind Code |
A1 |
Murray; R. Charles |
September 7, 2006 |
Multi-compartment flexible pouch
Abstract
A flexible pouch with multiple compartments for packaging a
product includes a wall having an inner surface and an outer
surface, and an upper edge, an opposed lower edge and a side edge
extending therebetween the upper edge and the lower edge. A
mid-seam separates the wall into discrete compartments, and the
mid-seam is a frangible seal that remains intact when a pressure
within the pouch is below a predetermined bursting pressure, and
breaks when the pressure within the pouch is greater than the
predetermined bursting pressure. The pouch also includes an opening
means integrally formed in at least one compartment for accessing a
product contained within the pouch. A method of filling the
multi-compartment pouch with a product includes the steps of
simultaneously opening each compartment of the pouch using a pair
of opposed first grippers positioned on each side edge of the
pouch, a pair of opposed second grippers positioned on an upper
edge of the pouch, and a pair of opposed suction members positioned
on each compartment wall, and simultaneously pushing the first
grippers inwardly and second grippers and suction members
outwardly. The method further includes the steps of filling at
least one of the opened compartments with a product applying a
closing sealing to seal the filled compartments.
Inventors: |
Murray; R. Charles;
(Sarasota, FL) |
Correspondence
Address: |
GIFFORD, KRASS, GROH, SPRINKLE & CITKOWSKI, P.C
PO BOX 7021
TROY
MI
48007-7021
US
|
Family ID: |
36943096 |
Appl. No.: |
11/367613 |
Filed: |
March 3, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60658126 |
Mar 3, 2005 |
|
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|
Current U.S.
Class: |
206/219 |
Current CPC
Class: |
B65B 43/60 20130101;
B65D 75/5861 20130101; B65D 81/3266 20130101; B65D 77/225 20130101;
B65D 33/01 20130101; B65D 75/54 20130101; B65D 2205/00 20130101;
B65B 43/465 20130101; B65D 75/5816 20130101; B65D 75/48 20130101;
B65D 2231/02 20130101 |
Class at
Publication: |
206/219 |
International
Class: |
B65D 25/08 20060101
B65D025/08 |
Claims
1. A flexible pouch with multiple compartments for packaging a
product, said pouch comprising: a wall having an inner surface and
an outer surface, and an upper edge, an opposed lower edge and a
side edge extending therebetween said upper edge and said lower
edge; a mid-seam separating said wall into discrete compartments,
wherein said mid-seam is a frangible seal that remains intact when
a pressure within the pouch is below a predetermined bursting
pressure, and breaks when the pressure within the pouch is greater
than the predetermined bursting pressure; and an opening means
integrally formed in at least one compartment for accessing a
product contained within the pouch.
2. The pouch as set forth in claim 1 wherein said mid-seam extends
horizontally between a first side edge and a second side edge.
3. The pouch as set forth in claim 1 wherein said mid-seam extends
vertically between said upper edge and said lower edge.
4. The pouch as set forth in claim 1 further including another
mid-seam separating said wall into discrete compartments, wherein
said another mid-seam is a permanent seal that remains intact when
a pressure within the pouch is greater than the predetermined
bursting pressure.
5. The pouch as set forth in claim 1 further including an
insulating seal spaced a determined distance from either one of
said upper edge, lower edge or side edge, and said insulating seal
includes a first insulating seal spaced a predetermined distance
apart from a second insulating seal, and an insulating airspace
therebetween said first insulating seal and second insulating
seal.
6. The pouch as set forth in claim 1, wherein said opening means is
a fitment that includes a spout.
7. The pouch as set forth in claim 6 wherein said fitment includes
a cap removably attached to said spout.
8. The pouch as set forth in claim 1 further comprising a front
wall and a rear wall and an insert positioned between said front
wall and said rear wall.
9. The pouch as set forth in claim 1 further comprising an integral
vent means disposed in said wall, and said integral vent means is
enclosed by a frangible vent seal that remains intact when a
pressure within the pouch is below a predetermined vent seal
bursting pressure, and breaks when the pressure within the pouch is
greater than the predetermined vent seal bursting pressure.
10. The pouch as set forth in claim 9 wherein said vent means is a
one-way valve.
11. The pouch as set forth in claim 1 wherein said wall is formed
from a laminate of at least three layers, and one layer is selected
from a family of materials that includes cast polypropylene
(CPP).
12. The pouch as set forth in claim 1 further comprising a sleeve
bonded to the outer surface of said wall.
13. The pouch as set forth in claim 1 further comprising a securing
means for holding the compartments of the pouch together when the
pouch is folded along said mid-seal.
14. A flexible pouch with multiple compartments for packaging a
product, said pouch comprising: a front wall having an inner
surface and an outer surface, and an upper edge, an opposed lower
edge and a first side edge and a second side edge extending
therebetween said upper edge and said lower edge; a rear wall
having an inner surface and an outer surface, and an upper edge, an
opposed lower edge and a first side edge and a second side edge
extending therebetween said upper edge and said lower edge, wherein
said upper edge, opposed lower edge, first side edge and second
side edge of said front wall and said real wall are joined
together; a frangible mid-seal separating said joined front wall
and rear wall into discrete compartments, wherein said frangible
mid-seal remains intact when a pressure within the pouch is below a
predetermined bursting pressure, and breaks when the pressure
within the pouch is greater than the predetermined bursting
pressure; a permanent mid-seal further separating said joined front
wall and rear wall into discrete compartments, wherein said
permanent seal remains intact when a pressure within the pouch is
greater than the predetermined bursting pressure; and an opening
means integrally formed in at least one compartment for accessing a
product contained within the pouch.
15. The pouch as set forth in claim 14 wherein said frangible
mid-seal or said permanent mid-seal extends horizontally between
said first side edge and said second side edge.
16. The pouch as set forth in claim 14 wherein said frangible
mid-seal or said permanent mid-seal extends vertically between said
upper edge and said lower edge.
17. The pouch as set forth in claim 14 further including an
insulating seal spaced a determined distance from either one of
said upper edge, lower edge or first side edge or said second side
edge, and said insulating seal includes a first insulating seal
spaced a predetermined distance apart from a second insulating
seal, and an insulating airspace therebetween said first insulating
seal and second insulating seal.
18. The pouch as set forth in claim 14, wherein said opening means
is a fitment that includes a spout.
19. The pouch as set forth in claim 18 wherein said fitment
includes a cap removably attached to said spout.
20. The pouch as set forth in claim 14 further comprising an insert
positioned between said front wall and said back wall.
21. The pouch as set forth in claim 14 further comprising an
integral vent means disposed in said front wall, and said integral
vent means is enclosed by a frangible vent seal that remains intact
when a pressure within the pouch is below a predetermined vent seal
bursting pressure, and breaks when the pressure within the pouch is
greater than the predetermined vent seal bursting pressure.
22. The pouch as set forth in claim 14 wherein said vent means is a
one-way valve.
23. The pouch as set forth in claim 14 wherein said panel is formed
from a laminate of at least three layers, and one layer is selected
from a family of materials that includes cast polypropylene
(CPP).
24. The pouch as set forth in claim 14 further comprising a sleeve
bonded to the outer surface of said front wall and said rear
wall.
25. The pouch as set forth in claim 14 further comprising a
securing means for holding the compartments of the pouch together
when the pouch is folded along both said frangible mid-seal and
said permanent mid-seal.
26. A method of filling a multi-compartment pouch with a product,
said method including the steps of: providing a pouch having a wall
with an upper edge, an opposed lower edge and a side edge extending
therebetween the upper edge and the lower edge, and a mid-seam
separating the pouch into discrete compartments and an opening
means integrally formed in at least one compartment for accessing a
product contained within the pouch; simultaneously opening each
compartment of the pouch using a pair of opposed first grippers
positioned on each side edge of the pouch, a pair of opposed second
grippers positioned on an upper edge of the pouch, and a pair of
opposed suction members positioned on each compartment wall, and
simultaneously pushing the first grippers inwardly and second
grippers and suction members outwardly; filling at least one of the
opened compartments with a product; and applying a closing sealing
to seal the filled compartment.
27. The method as set forth in claim 26 wherein said mid-seam is a
frangible seal that remains intact when a pressure within the pouch
is below a predetermined bursting pressure, and breaks when the
pressure within the pouch is greater than the predetermined
bursting pressure.
28. The method as set forth in claim 26 wherein said closing seal
further includes the step of applying an insulating seal spaced a
predetermined distance from the closing seal and an airspace is
formed between the closing seal and the insulating seal.
Description
RELATED APPLICATION
[0001] This application claims priority of U.S. Provisional Patent
Application Ser. No. 60/658,126 filed Mar. 3, 2005, which is
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a flexible pouch
for packaging products, and more particularly to a
multi-compartment pouch for packaging a product within a
compartment and a method of manufacturing the same.
[0004] 2. Description of the Related Art
[0005] Various types of disposable, portable containers are known
in the art for storing a fluid or dry product, such as a liquid,
granular material, powder or the like. An example of such a
container is a flexible pouch. Consumers prefer the convenience of
flexible pouches over other types of containers, due to their
shape, size, shelf life and storage adaptability. Manufactures
recognize the packaging benefits of a flexible pouch, since the
pouch can be formed and filled on the same manufacturing line. An
example of a method and apparatus for filling a flexible pouch with
a product is disclosed in commonly assigned U.S. Pat. No.
6,199,601, which is incorporated herein by reference.
[0006] The flexible pouch is preferably made from a flexible
material, such as an extrusion or laminate composed of sheets of
plastic or aluminum or the like. An outer layer of the material may
include preprinted information, such as a logo or the like, to
provide the consumer with information regarding the contents of the
pouch. The pouch may be formed using conventionally known
manufacturing techniques, such as a horizontal form-fill-seal
machine with single or multiple lanes, a flat bed pre-made pouch
machine, a vertical form-fill-seal machine, or the like. The pouch
is generally formed by folding sheets of material over each other
to achieve a predetermined shape. Edges, such as a side edge, may
be joined together using a sealing technique such as bonding or
welding. The pouch may also include a gusset inserted between two
parallel edges, to form a pouch capable of standing unsupported. An
upper or lower edge of the front panel and the back panel is
generally not sealed until after the pouch is filled. The empty
pouch may be placed in a gripper assembly or a holder such as a cup
or puck or combination of both prior to the filling process. To
fill the pouch, the upper edges of the pouch are first spread
apart. For example, grippers may be utilized to pull the panels
apart. In addition, a concentrated flow of gas may be directed
towards the upper edge of the pouch to separate the panels or a
suction cup or combinations of all of the above. The open pouch is
filled, sealed and finished as required.
[0007] Flexible pouches have been used for some time to store and
serve food products, such as fruit juice or cereal or the like. The
flexible pouch may also be used for both storing and cooking the
food product contained therein. A common feature of this type of
pouch is a venting means, which provides for the release of steam
or any other gas that may be generated within the package.
Advantageously, the flexible pouch may be used in cooking a frozen
food, or a food at room temperature. An example of a pouch with a
venting means is disclosed in commonly assigned U.S. patent
application Ser. No. 11/329,712 filed Jan. 11, 2006, which is
incorporated herein by reference.
[0008] Flexible pouches are also used to package non-carbonated
products, such as fruit juice and the like. However, their use with
carbonated products has been limited, due to the permeability of
presently available materials, thereby allowing loss of the
internal carbon dioxide gas from the pouch and its replacement with
oxygen. The presence of oxygen in the filled pouch increases the
chance of bacteria forming, or may affect the taste. An example of
a pouch for packaging a carbonated product is disclosed in commonly
assigned PCT Patent Application No. PCT/US03/034396, which is
incorporated herein by reference.
[0009] More recently, flexible pouches have been utilized to
package other types of products, such as lotions or personal care
items or the like. In addition, multi-compartment pouches have been
utilized to package a variety of products. While these flexible
pouches are useful, they are costly to produce and may not intermix
the products efficiently, or are prone to leakage between
compartments. Thus, there is a need in the art for a flexible pouch
with multiple compartments, and an improved method of making such a
flexible pouch, that can be used both to store various types of
products and also to intermix the products contained within the
compartments.
SUMMARY OF THE INVENTION
[0010] Accordingly, a flexible pouch for both storing and heating
or cooling a product contained therein, and a method of
manufacturing and filling such a flexible pouch is provided. A
flexible pouch with multiple compartments for packaging a product
includes a wall having an inner surface and an outer surface, and
an upper edge, an opposed lower edge and a side edge extending
therebetween the upper edge and the lower edge. A mid-seam
separates the wall into discrete compartments, and the mid-seam is
a frangible seal that remains intact when a pressure within the
pouch is below a predetermined bursting pressure, and breaks when
the pressure within the pouch is greater than the predetermined
bursting pressure. The pouch also includes an opening means
integrally formed in at least one compartment for accessing a
product contained within the pouch. A method of filling the
multi-compartment pouch with a product includes the steps of
simultaneously opening each compartment of the pouch using a pair
of opposed first grippers positioned on each side edge of the
pouch, a pair of opposed second grippers positioned on an upper
edge of the pouch, and a pair of opposed suction members positioned
on each compartment wall, and simultaneously pushing the first
grippers inwardly and pulling the second grippers and suction
members in an outwardly direction. The method further includes the
steps of filling at least one of the opened compartments with a
product, and applying a closing sealing to seal the filled
compartments.
[0011] One advantage of the present invention is that an improved
multi-compartment flexible pouch and an improved method of making
and filling a multi-compartment flexible pouch with a product is
provided, and the flexible pouch is suitable for storing and
processing of the product contained therein. Another advantage of
the present invention is that a flexible pouch and method of making
the same is provided that includes at least one mid-seam that is a
frangible seal separating the pouch into multiple compartments.
Still another advantage of the present invention is that a flexible
pouch and method of making the same is provided that includes a
frangible seal that prevents the leakage of product between
adjacent compartments. A further advantage of the present invention
is that a flexible pouch and a method of making the same are
provided that is cost effective to manufacture. Yet a further
advantage of the present invention is that the flexible pouch is
self-heating, in order to heat the contents of the pouch. Yet still
a further advantage of the present invention is that the flexible
pouch is self-cooling, in order to cool the contents of the
flexible pouch. Yet still a further advantage of the present
invention is that the flexible pouch includes a double top seal and
a double bottom seal, with an air pocket formed between the two
seals, that insulates the double seal so that the pouch can be
gripped by the ends when the contents of the compartments separated
by the frangible seal are mixed. Still yet a further advantage of
the present invention is that a method of filling the
multi-compartment pouch is provided that utilizes grippers to
simultaneously open each of the compartments for filling. Another
advantage of the present invention is that the flexible pouch
includes a venting means surrounded by a frangible seal. A further
advantage of the present invention is that the products contained
in each compartment are kept separate until mixed or combined for
use, to increase the shelf life of the combined product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a front view of a multi-compartment flexible
pouch, according to the present invention.
[0013] FIG. 2 is a front view of another example of a
multi-compartment flexible pouch, according to the present
invention.
[0014] FIG. 3 is a front view of yet another example of a
multi-compartment flexible pouch, according to the present
invention.
[0015] FIG. 4 is a front view of a further example of a
multi-compartment flexible pouch, according to the present
invention.
[0016] FIGS. 5a, 5b are front views of another example of a
multi-compartment flexible pouch with a venting means, according to
the present invention.
[0017] FIG. 6 is a front view of still another example of a
multi-compartment flexible pouch with a venting means, according to
the present invention.
[0018] FIG. 7 is a flowchart illustrating a method of manufacturing
and filling the flexible pouch of FIGS. 1-6, according to the
present invention.
[0019] FIG. 8 is an elevational view of a web of material,
according to the present invention.
[0020] FIGS. 9a-9c are elevational views of a method of
simultaneously opening each pouch compartment.
[0021] FIG. 10 is a block diagram of a form-fill-seal machine,
according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring to FIGS. 1-6, a sealed, multi-compartment flexible
pouch 10 is illustrated. Each compartment of the pouch 10 may be
filled with a product (not shown) and sealed, and each compartment
may contain a different product. The type of product packaged is
unlimited, as well as the form of the product, such as a solid,
liquid or gaseous form. In addition, it is contemplated that with
multiple products in one package, each product can assume a
different form, (i.e. one compartment holds a solid product and one
compartment holds a liquid product). For example, in a
two-compartment pouch, the product in each compartment may be a
food item that is stored separately and then mixed together for
serving. In another example of a two-compartment pouch, the product
in each compartment may be a chemical that is stored separately and
mixed together to provide a heat pack or cold pack. In a further
example of a three-compartment pouch, the product in one
compartment is a product to be heated, and the other two
compartments each contain a chemical that upon mixing undergoes an
exothermic reaction to produce heat. An example of a chemical is an
exothermic powder such as lime. Alternatively, the product is to be
cooled and the other compartments each contain a chemical substance
that upon mixing undergoes an endothermic reaction to produce
cooling. An example of a chemical is glycol. In the example of a
four-compartment pouch, it is contemplated that two of the
compartments may contain related products, and that the other two
compartments contain products that produce a thermal reaction upon
mixing. Advantageously, the number of compartments and type of
product contained within is determined by the specific use of the
package and product.
[0023] The flexible pouch may be formed on various types of
machines, such as a form machine, or a form-fill-seal machine. The
flexible pouch 10 is preferably formed from a roll of preprinted
material of or extruded laminate layers. The laminate or extruded
material is typically a three, or four, or five gauge material. The
outer layer is usually preprinted. Alternatively, at least a
portion of the material may be not printed, i.e. translucent, in
order to view the contents contained therein. The clear portion
could also be in a gusset or insert.
[0024] The choice of sheet layer material is non-limiting, and the
selection is influenced by factors such as the product contained in
the pouch, the shape of the pouch, or the anticipated use of the
pouch. One example of a laminate material structure includes at
least one layer of virgin polyethylene terphalate (PET), at least
one layer of aluminum foil and another layer such as EVOH, PET,
polyethylene or nylon or the like. Another type of laminate
material structure may also include a metalized foil paper layer
laminated to a cast polypropylene layer and another layer of PET,
polyethylene or EVOH. Similarly, the laminate structure may include
a cast polypropylene (CPP) layer, a polyethylene (PET) layer, a
foil (AL) layer, a nylon (ONO) layer and another CPP layer. Another
structure is the use of nylon, foil, nylon and cast polypropylene
(ONO/AL/ONO/CPP) or CPP/NY/AL/CPP or PET/AL/nylon/CPP. Material
structures that include CPP are well-suited for packaging a
beverage, such as beer, wine or other carbonated products, to add
strength to the walls of the pouch, preserve the carbonation, and
protect the AL layer from cracking. Carbonation is beneficial since
it acts as a microbiocide and preserves the flavor and aroma of
particular products. The use of cast polypropylene laminate
material also assists in retaining the filled shape of the
container, even as the product is removed from the pouch 10. This
is advantageous since it allows the pouch 10 to assume various
shapes such as cylindrical, although other shapes are contemplated.
A further example of a laminate material structure is
CPP/AL/ONO/PE. This structure works well when the product has a
short shelf life, and the nylon eliminates stretching or cracking
of the AL layer.
[0025] The pouch 10 includes a front wall 12 and a rear wall 14.
Each wall 12, 14 has an inner surface that is adjacent the product,
and an outer surface. Each wall 12, 14 is further defined by an
upper edge 16, an opposed lower edge 18, and a side edge 20
extending therebetween the upper and lower edges 16, 18. The side
edges 20 are joined by a side seal, as shown at 24.
[0026] The pouch may be formed from two facing sheets of material
that are joined together along corresponding side edges.
Alternatively, the pouch 10 may be formed from a sheet of material
that is folded so that the outer edges are joined together to form
one center seam. In an example of a pouch formed using a single
panel of material, the side edges 20 are joined along a center
seam. In an example of a pouch formed using two sheets of material,
the edges are joined along two side seams. The seam may be a flat
seam, as described in commonly assigned U.S. patent application
Ser. No. 11/195,906, or a "fin" type seam, or any other type of
seam. In this example, the pouch 10 has a generally rectangular
shape, although other shapes are contemplated. The choice of shape
for the pouch is influenced by the product contained within the
package and the use of the package. The pouch may be a stand-up
pouch.
[0027] The upper edges 16 of the pouch are joined by an upper seal
26. Similarly, the lower edges 18 of the pouch are joined by a
lower seal 28. The upper seal 26 or lower seal 28 may be a single
seal, or an insulating seal, as shown at 50. The insulting seal
includes two seals 50a, 50b separated by an airspace 50c. The
airspace 50c creates a pocket of air that serves as an insulator.
The insulated air pocket is advantageous, since the temperature
change of the pouch 10 after the frangible seal is broken and the
compartments undergo the thermal reaction, may make the pouch 10
uncomfortable to hold. The pouch 10 can be comfortably held by the
upper and lower edges 16, 18 due to the insulating ability of the
airspace 50c between the seal 50a, 50b. In this example, the
insulating seal has an overall width of at least 3/4'' wide.
[0028] The pouch 10 may include a shaping mean 30, such as an
insert 34, sidewall or gusset 32. The shaping means advantageously
directs the shape of the pouch 10. It may also have a functional
purpose, such as to allow the pouch stand upright, or provide a
base for an opening means. For example, a sidewall may be formed as
a gusset or pleat. The gusset 32 may be integrally formed in the
wall, or a separate piece of material. The gusset 32 may be
disposed between the side edges of the front and back walls 12, 14,
the lower edges, the upper edges, or any desired combination. It
should be appreciated that the shape of the gusset 32 is
nonlimiting. For example, the gusset 32 may be generally wider at
one end and taper upwardly towards the opposite end. The gusset 32
may also be of a uniform width. The use of the gusset 32 may be
functional, i.e. it may allow the pouch 10 to acquire another
shape, such as cylindrical, or to stand upright. The gusset 32 also
enhances the strength and rigidity of the pouch 10 during filling
and processing. A side gusset is advantageous since it allows the
walls of the pouch to expand as the internal pressure within the
pouch increases. A gusset 32 positioned between the lower edges of
the pouch 10 forms a base, which may enable the pouch 10 to stand
upright.
[0029] Similarly, the pouch may include an insert 34 as shown in
FIGS. 5a, 5b. The insert 34 is a generally planar member that is
inserted between the walls 12, 14 of the pouch 10. The shape of the
insert 34 is nonlimiting, and generally influences the shape of the
flexible pouch. The insert 34 may be positioned internally within
the pouch or externally. Various materials may be utilized for the
insert, such as foil, cardboard, plastic, nylon, laminate or the
like. Further, the insert 34 may be formed from a printed material,
or it may be clear. In one example, the insert 34 is inserted
between the lower edges of the panel and sealed to the walls of the
panel. The seal may be an ultrasonic seal or a heat weld or the
like. The insert 34 may provide a support for an opening means,
such as a fitment.
[0030] The pouch may contain two inserts, such as a first insert
positioned between the lower edges of the panel, and a second
insert positioned between the upper edges of the panel. The first
insert may include an integral opening means, such as a straw hole
for receiving a straw. The pouch of this example has a generally
square shape.
[0031] The pouch 10 is divided into multiple compartments 36 by at
least one mid-seal 22. It should be appreciated that the number of
compartments 36 is non-limiting. It should also be appreciated that
any arrangement of compartments 36 is contemplated. It should also
be appreciated that the compartments 36 may be of varying sizes.
Also, the compartments 36 can be arranged side-by-side horizontally
or vertically, or a combination of the two. Therefore, the mid-seal
22 can have a generally horizontal orientation, or a generally
vertical orientation. The mid-seal 22 advantageously isolates the
contents of one compartment 36 from the contents of an adjacent
compartment 36. Preferably, the mid-seal 22 is positioned so that
it does not interfere with filling of the pouch. The mid-seal 22
may include a score line 38 to facilitate folding over the
compartments of the pouch along the score line 38, if so desired.
The score line 38 does not affect the integrity of the
mid-seal.
[0032] At least one of the mid-seals 22 is a frangible seal 22a. In
the example illustrated in FIGS. 5a and 6, there is one vertically
oriented mid-seal 22 separating a first compartment 36a from a
second compartment 36b, and this mid-seal is a frangible seal
22a.
[0033] In another example illustrated in FIGS. 1-3, there are three
compartments 36 and two mid-seals 22. Also, in this example, the
first mid-seal 22a separating compartment 1 from compartment 2 is a
frangible seal. The second mid-seal 22b separating compartment 2
from compartment 3 is a permanent seal. Alternatively, the second
mid-seal could be a frangible seal if so desired. In still another
example shown in FIG. 4, the pouch 10 is a four-compartment pouch.
The first mid-seal separating the first and second compartments is
a frangible seal. The second mid-seal separating the second and
third compartments 36c is a permanent seal, and the third mid-seal
separating the third and fourth compartments is a frangible seal.
The frangible seal is a seal produced by reducing sealing
temperature to a lower setting, such as a reduction of about 60
degrees F. or a temperature just above the melting point of the
sealant layer. Another way is to reduce the pressure of the seal
bars to create a tack seal. A further method is to reduce both
pressure of the seal bars and the time of applying the seal
bars.
[0034] The frangible seal 22a is a seal with a predetermined burst
pressure that is less than the burst pressure of the other seals,
such as the side seal 24, upper seal 26 or lower seal 28. The
frangible seal is formed using a sealing technique that involves
the application of heat and pressure, such as a heat weld, or by an
ultrasonic seal. The frangible seal 22a is automatically broken
when the pressure within the compartment 36 exceeds a predetermined
burst pressure value, such as occurring when the pouch is folded
along the frangible mid-seal 22a.
[0035] For example, the first and second compartments 36a, 36b may
contain products to be mixed to undergo a thermal reaction, and the
third compartment 36c may contain a third product that benefits
from the thermal reaction. For example, the first and second
compartments 36a, 36b contain products that are mixed together when
the frangible seal 22a bursts to create a heat pack. The third
compartment 36c may be folded over the first and second
compartments 36a, 36b, or folded between the first and second
compartment 36a, 36b, in order to heat the third product. This
arrangement may also facilitate dispensing of the third product via
an opening means 40 located in the third compartment.
[0036] The pouch includes an opening means 40 for accessing the
contents or dispensing the contents from at least one compartment
36 of the pouch 10. Various types of opening means 40 are known in
the art for this purpose. It should be appreciated that the opening
means 40 may be incorporated into the pouch 10 prior to filling the
pouch 10.
[0037] One example of an opening means is a tear-off portion, as
shown in FIG. 2 at 42. The tear-off portion 42 provides access to
at least one of the compartments 36. The tear-off portion 42
usually has an integral tear notch 44. The tear notch 44 is
typically formed near the upper edge, for accessing the product
contained therein although it could be located elsewhere. Another
example of an opening means 40 is a weakened, straw-pierceable
portion in the pouch for receiving a straw within at least one of
the compartments. A further example of an opening means 40 is a
pull tab covering an opening in the pouch. Again, the pull tab
provides for access to at least one of the compartments. Yet
another example of an opening means is a resealable zipper, such as
a hermetic seal, such as a zipper that is sold under the name
TopTite.TM. (not shown).
[0038] Still a further example of an opening means 40 is a fitment
46, such as a removable and replaceable cap 46a secured to a spout
46b. The fitment 46 may be mounted to the top portion or side
portion of the compartment 36 containing the product to be
dispensed. In FIG. 1, the fitment 46 is a screw-off cap 46a with a
pour spout 46b. FIG. 3 illustrates a flip-top cap secured to a pour
spout 46b. The cap 46a can be the traditional round shape.
Alternatively, the cap 46a can have an elongated oval shape so that
the pouch may stand up on its own. The cap 46a and spout 46b can be
made from a variety of materials. For example, the cap 46a may be
made from plastic, such as reground resins. The spout 46b may be
made of polypropylene (PP), depending on the product. The fitment
46 is sealed between the edges of the panel using a sealing means,
such as an ultrasonic seal or a heat weld, or the like. The spout
portion of the fitment 46 may include a removable seal (not shown)
to prevent leakage of the product or evidence of tampering.
[0039] One of the pouch compartments 36 may include an integral
vent means 60, as shown in FIGS. 5 and 6. The vent means, such as a
valve, is preferably positioned in an upper portion of one wall of
the compartment, such as the front wall 12 of this example. The
valve 60 is preferably welded in an aperture formed in the panel
during the flexible pouch forming process. The valve 60 functions
to exhaust gas, such as steam. The gas may be formed within the
package while heating the product contained within the compartment
36. The valve 60 may also be operable to respire gas formed in the
compartment 36 for other reasons, such as gas formed by decaying
food or during freezing or the like. The valve 60 remains tightly
closed, until pressure from the gas, such as steam, reaches a
predetermined pressure value. An example of a predetermined
pressure is approximately 3 mbar. The valve 60 opens and remains
open, to release the gas from the package in a controlled
manner.
[0040] Various types of valves 60 are contemplated. For example, a
tape may be used to cover a hole in the wall. Alternatively, a
pressure relief device, such as that manufactured by PPI
Technologies, Sarasota, Florida model number P00T, may be utilized.
Another example of a valve is disclosed in commonly assigned U.S.
patent application Ser. Nos. 10/228,430 and 10/967,547 and PCT
patent application Ser. No. PCT/US2004/34361.
[0041] The valve 60 is completely enclosed by a frangible valve
seal 62 formed in the walls of the pouch. The frangible valve seal
62 is designed to burst when subjected to a predetermined frangible
seal bursting pressure. The frangible valve seal 62 advantageously
isolates the valve 60 from the contents of the pouch. The valve 60
and frangible valve seal 62 are preferably positioned so as not to
interfere with filling or sealing of the pouch 10. The frangible
valve seal 62 is automatically broken when the pressure in the
pouch 10 exceeds a predetermined bursting value, such as occurring
when the pouch 10 is heated above a predetermined temperature. In
one example, the frangible valve seal 62 is broken due to the
pressure buildup of steam within the compartment 36, thus allowing
the steam to escape through the valve. In another example, the
pressure can be increased by manipulating the pouch 10 in order to
break the frangible valve seal 62.
[0042] In the example shown in FIGS. 5 and 6, the frangible valve
seal 62 has an "L" shape, although other shapes are contemplated.
The valve seal 62 of this example is preferably positioned so that
the side seal 24 serves to enclose the open end of the "L" shaped
valve seal 02. Other shapes for the frangible seal 62 are
contemplated, such as a "V-shape", or a circle, or a square, or the
like.
[0043] As shown in FIG. 5, the product is a food product such as
soup. One compartment of the pouch includes a vent means 60
surrounded by a frangible valve seal 62. This compartment may be
separated from other compartments by a mid-seal 22 that provides a
barrier, the other compartments may include a product that when
mixed produces heat to heat the soup. As shown in FIG. 6, a first
compartment 36a contains the vent means 60 and the vent means is
separated from a food product, such as a vegetable, by a frangible
seal 22a. The second compartment 36b contains a product such as
water, and the mid-seal is a frangible seal. In operation,
increasing the pressure in the pouch 10, such as by squeezing the
pouch, causes the mid-seal 22 to burst, so that the contents of the
first and second compartment are mixed together. The pouch may be
heated, such as using an external source, causing the frangible
valve seal 62 around the vent means 60 to burst, thus allowing the
escape of gas from the pouch 10.
[0044] It should be appreciated that the flexible pouch may
advantageously include other features that are known in the art.
One example of a feature is an integrally formed label 54 as shown
in FIG. 5. The label 54 may be formed from an outer layer of the
laminate material that includes preprinted information. The label
54 may also be a sleeve covering the outer surface of the pouch.
The sleeve may cover only a portion of the pouch outer surface.
Preferably, the sleeve is heat shrunk over the outer surface of the
pouch. This operation may occur either before or after filling of
the pouch with product. The sleeve is advantageous since it adds
one more layer of material to strengthen the pouch and improve its
durability. Various types of material may be utilized for the
sleeve, such as paper or a plastic, and the selection is
non-limiting.
[0045] Another example of a feature is an integrally formed
securing means 48, such as a tape, for securing the compartments 36
together. For example, two of the compartments may be sealed
together to create a heat pack or cold pack around the product
contained in another one of the compartments.
[0046] A further example of a pouch feature is a guide pocket 56
formed in a panel or wall of the pouch 10 prior to filling and
sealing, to facilitate the separation of the front and rear panels
prior to the filling of the pouch 10. Preferably, each compartment
36 would contain a guide pocket 56. An example of a pouch with a
guide pocket is disclosed in commonly assigned U.S. patent
application Ser. No. 10/310,221.
[0047] After the pouch 10 is formed, the pouch 10 is available for
filling, such as through an opening formed between open edges of
the panels, or through the fitment. After filling, the open edges
of the pouch are sealed using a conventional method, such as heat
sealing, or ultrasonic sealing or the like. The closing seal may be
a single seal, or a wide double seal, as previously described. The
sealed pouch is finished. For example, the pouch may be trimmed so
that the compartment containing the product is smaller than the
other compartments. This is advantageous when the compartment with
the product is positioned relative to the pouch containing the
thermal materials.
[0048] In operation, an example of a four-compartment pouch shown
in FIG. 4 contains a product in one pair of compartments that
undergoes a thermal reaction when mixed, and the other pair of
compartments each contains a product intended to be mixed. Each
pair of compartments may be separated by a permanent seal, so that
the products are kept separate. Within each pair of compartment, a
frangible seal separates each compartment, allowing contents of
within each pair of compartments to be mixed together. For example,
one pair of compartments may contain coffee grounds and the other
may contain water to make coffee when mixed together, and the other
pair of compartments may contain chemicals that produce heat when
mixed together. One compartment of each is folded along the
respective frangible mid-seal, in order to break the frangible
seal. The contents of the adjacent compartments are mixed together
after the seal separating them is broken. The compartments are
folded together in order form a compact package for drinking the
coffee.
[0049] Similarly, in an example of a three-compartment pouch with a
horizontal arrangement of compartments as shown in FIGS. 1-3, one
compartment may be folded in order to break a frangible mid-seal to
mix the contents of the two adjacent compartments. Another
compartment, separated from the other two by a solid mid-seam, may
be positioned between the first and second compartments, or
adjacent the second compartment. In this example, the mixed
contents undergo an exothermic reaction, creating heat, which may
be utilized to heat the contents of the third compartment. In
another example, the mixed contents may undergo an endothermic
reaction, which may be utilized to cool the contents of the third
compartment. In a further example of a two-compartment pouch with a
vertical arrangement of compartments as shown in FIGS. 5 and 6, a
lower compartment may contain water, a middle compartment contains
a powder, and an upper compartment contains a catalytic product. A
frangible seal separates each of the compartments. When the seals
are broken, the products are mixed, resulting in the production of
oxygen. It should be appreciated that the multi-compartment
flexible pouch may have many other uses and features other than
those described herein.
[0050] Referring to FIG. 7, a method for forming and filling the
multi-compartment flexible pouch 10, such as that described with
respect to FIGS. 1-6, using a high speed machine is illustrated.
The method begins in block 100 at a first station with the step of
forming the body of the pouch. Each pouch 10 has a predetermined
shape. For example, a roll of a preprinted laminate material as
previously described, is unrolled along a horizontally oriented
plane. In this example, the laminate material contains three layers
of material. The initial width of the roll of material is
determined by the desired finished size of the pouch and the number
of pouches to be obtained from the width. For example, three or
four or six pouches representing six to twelve wall panels can be
obtained from a width of the roll of material on a three-lane
machine or four-lane machine, respectively.
[0051] Each wall panel has an inner surface and an outer surface.
One layer of the material is preferably preprinted with information
or locating indicia (not shown), such as a registration mark. The
registration marks are located on the material to denote an edge of
a panel. The registration marks are read by an optical reading
device (not shown), such as a scanner, to index the material in a
predetermined position at the cutting station. The preprinted
information may include labeling information that describes the
product contained within the pouch, or instructions on how to use
the pouch. In this example, the layer of preprinted information is
located on an outer layer of the material.
[0052] Various techniques may be utilized to form the body portion
of the pouch, depending on the desired end shape of the pouch. The
pouch may be formed from one panel sheet of material or two panels,
as shown in FIG. 8 at 66. An example of a prefabricated pouch
forming machine is the Nishibe SMB500, SMB600 or SMB700. Another
example is the Laudenberg form-fill-seal machine, FBM 10, 54, 20,
22. Preferably, several pouches are formed from one width of
material. The material is removed from the roll, and may be cut
into sections that are positioned to form the front wall and rear
wall of the pouch. The methodology advances to block 105.
[0053] In block 105, a feature may be added to the pouch. For
example, shaping means 30 such as a gusset 32 or insert 34 may be
positioned between the aligned first and second unrolling sections
of material. Alternatively, the gusset or pleat is formed in the
panel using a folding operation. The insert 34 may be positioned at
any edge, such as a lower edge of the pouch or an upper edge. More
that one insert 34 may be utilized to achieve a desired shape.
[0054] In addition, an opening means 40 may be applied at this
time. For example, an opening means 40 such as a press-to-close
zipper may be positioned between the walls 12, 14. Another opening
means such as a straw hole, patch or tear notch 44 may be formed.
The methodology advances to block 110.
[0055] In block 110, the multiple compartments are formed in the
pouch and the edges are sealed in a sealing operation, as shown in
FIG. 8. For example, a mid-seal is applied to the pouch wall to
separate the pouch into a first and second compartment 36a, 36b.
The mid-seal 22 may be a frangible seal 22a as previously described
that prevents the product in one compartment from contaminating the
product in the adjacent compartment. The frangible mid-seal 22a
breaks open if subjected to a predetermined bursting pressure.
Another mid-seal 22 is a permanent seal 22b. This type of mid-seal
is desirable when the products within the compartments are to be
kept separate. In one example, the first mid-seal is a frangible
seal and the second seal is a permanent seal. The mid-seal 22 is
formed using a thermosealing process that includes in the
application of heat, or alternatively an ultrasonic sealing
process. Preferably, the frangible mid-seal 22a is formed at a low
temperature and pressure.
[0056] It is contemplated that the side edges may be sealed and a
lower edge may also be sealed at this time. The bottom seal may be
a single seal, or an insulating seal 50, as previously described.
The insulating seal 50 includes two seals 50a, 50b separated by an
airspace 50c. The airspace 50c creates a pocket of air that serves
as an insulator. Various sealing techniques are known in the art.
For example, an ultrasonic sealing process using vibrational energy
to seal, or a welded seal by applying heat and compression in a
two-step welding operation. One edge of the pouch may be left open,
designated as the upper edge 16 in this example, in order to fill
the pouch. Alternatively, the upper edge is sealed and the pouch is
filled through the fitment. The methodology advances to block
115.
[0057] In block 115, the individual pouches formed in the roll
width of material are separated from each other in a cutting
operation. For example, each section of material may be first
separated along its width, i.e. along the side seams of the
pouches, as shown in FIG. 8 at 68. The section is then is separated
into individual pouches along a cutting line, as shown at 69. In
this example, the width of unrolling material represents the side
edges. The material is cut into a pouch 10 using a known cutting
apparatus, such as a laser or punch or the like. The cutting
apparatus imparts a single cut in the material to separate the
pouches. The length of the pouch 10 is controlled by the distance
between the cuts. For example, a width of the web of material 66
may contain three multiple-compartment pouches. A single widthwise
and lengthwise cut separates the web into individual pouches.
[0058] Alternatively, two rows of pouches are cut out at one time
by adding a double cut between two lengthwise cuts, preferably in
the center. Advantageously, forming two pouches during the cutting
operation effectively doubles the assembly line speed.
[0059] It should be appreciated that the upper edge 16 or lower 18
edge may be further trimmed in a trimming operation. For example,
the end of the pouch may be trimmed to accommodate the fitment. In
another example, two legs are formed during the trimming operation
in order to recess the fitment, when the fitment is sealed to the
pouch. Further, the pouch may be trimmed to obtain a predetermined
final pouch shape.
[0060] An opening means 40 may be added at this time. For example,
a fitment 46, as previously described, may be sealed within the
walls of the pouch. The fitment 40 may be located on the pouch 10
in a variety of locations, such as mounted on a bottom, or a top,
or a side portion of the pouch. Various types of fitments or
opening means are contemplated, as previously described
[0061] Using the example of a fitment located in a corner of the
pouch as shown in FIGS. 1 and 4, the corner of the pouch is cut to
receive the fitment. The pouch may be transferred to another
machine for the insertion of the fitment, such as a HAMA-type
machine. The fitment is inserted through the opening in the pouch,
and attached to the pouch by heat sealing.
[0062] The methodology advances to block 120, and the pouch is then
cooled and/or otherwise finished. For example, a crease or guide
pocket 56 may be formed in a top portion of each compartment 36 in
a creasing operation in order to facilitate opening and filling the
pouch. A forming technique, such as stamping, may be utilized.
Another example of a forming technique is the use of heated tubes
that thermoform a crease in each panel. An example of a method of
forming a crease in the compartments to facilitate opening the
pouch is disclosed in commonly assigned patent application Ser. No.
10/310,221, which is incorporated herein by reference.
[0063] The methodology advances to block 125, and the pouches 10
are removed from the machine. For example, the pouches 10 are
loaded into a magazine that aligns the pouches in a predetermined
position, such as an upright position. The pouches 10 may all be
aligned in the same direction, or depending on the type of fitment,
alternating. Preferably, the magazine is a boxlike structure. The
width of the magazine corresponds to the width of the pouch 10. The
magazine may include a mechanism that exerts a preload force on the
pouches 10, so that the pouches 10 remain adjacent each other. The
methodology advances to block 130.
[0064] In block 130, the pouches are loaded onto a fill-seal
machine. Advantageously, the fill-seal machine can be integral with
the pouch forming machine, or a separate fill-seal machine. It is
contemplated that the pouches 10 may be temporarily stored in a
magazine between the forming and filling operations. This increases
the flexibility of the pouch and may result in a manufacturing cost
savings. The fill-seal machine can have stations arranged in a
linear manner, or rotary configuration, as shown in FIG. 10.
[0065] In block 135, the pre-made pouch 10 is then unloaded from
the magazine and loaded into a carrier or holder. It should be
appreciated that the pouches are unloaded and uniformly aligned. An
example of a holder is a cup-shaped member, as disclosed in
commonly assigned U.S. patent application Ser. No. 10/336,601,
which is incorporated herein by reference. Alternatively, the pouch
10 may be held with grippers. The methodology advances to block
140.
[0066] In block 140, the pouch 10 is opened in an opening
operation. Various techniques are conventionally known in the art
for opening the pouch 10. For example, as shown in FIGS. 9a-9c, for
a three-compartment pouch, each compartment of the pouch is opened
simultaneously using grippers arranged in a predetermined manner. A
first pair of grippers 70 is positioned along each side edge of the
pouch. A second pair of grippers 72 is positioned near the upper
edge of the front panel and rear panel for the middle compartment.
In addition, a third pair of grippers 74 is positioned near the
upper edge of the front panel and rear panel for each compartment.
The third pair of grippers 74 is of the suction vacuum type. To
open the pouch, the side grippers 70 move inwardly towards each
other while the grippers 72, 74 adjacent each panel move in an
outwardly direction, as shown in FIGS. 9b and 9c. In this manner,
each compartment of the pouch is simultaneously opened.
[0067] In addition, a nozzle (not shown) may be mechanically
lowered into each guide pocket 56 to direct a stream of compressed
gas into the guide pocket 56, to force the walls of the pouch 10
away from each other. An example of a gas is carbon dioxide or
nitrogen. The blowing station may include a manifold, with a hood
extending over the top of (not shown) the upper edges of the pouch
10, as is known in the art. The manifold has rows of apertures (not
shown) formed above the upper edges of the pouch. The hood is
placed over the pouch 10 to assist in maintaining the air pressure
in the pouch 10. The supply of pressurized gas is directed through
the aperture to form a plurality of jets of pressurized gas or air.
The jets are directed downwardly at the diamond-shaped openings
formed at the upper edges to assist in overcoming the surface
tension of the pouch and assist in separation of the walls of each
compartment. A diving rod (not shown) may then be used to make sure
the pouch 10 is fully opened. It should be appreciated that for a
multi-compartment pouch, each compartment may be opened
simultaneously using a plurality of gas streams and diving rods.
The methodology advances to block 145.
[0068] In block 145, at least one compartment of the pouch 10 is
filled with the product in a filling operation. For example, a fill
tube is lowered into the compartment and the product is dispensed
into the open compartment. The fill tube may be lowered into the
opened compartment, or through the opening means, such as the
spout. The product is preferably dispensed at a predetermined
temperature, depending on the type of product. In the case of
distinct products, it may be necessary to move the pouches to
another fill station to complete the filling of the other
compartments. For example, the first and second compartments are
filled at a first station with the first two products, and the
third compartment containing the third product is filled at another
filling station.
[0069] The pouches 10 may be moved to a station where any oxygen in
the pouch residing above the product is removed, if necessary. This
can be done by providing a hood or diving nozzle where oxygen is
either evacuated or replaced with carbon dioxide or nitrogen into
the pouch to displace the oxygen. A diving nozzle is used to inject
the gas.
[0070] For example, if the product is naturally carbonated, such as
beer or soda or the like, the pouch is preferably filled while
immersed in a nitrogen atmosphere. If the product is not naturally
carbonated and carbonation is desirably, it may be immersed in a
carbonator to introduce carbon dioxide into the product. For
example, carbon dioxide is introduced into water or juice to
provide a carbonated beverage. The product may contain a mixture of
up to four volumes of carbon dioxide. It should be appreciated that
the carbon dioxide masks any undesirable taste from the ketones
released during the sealing process. The carbon dioxide also
increases the pressure within the product so that the walls of the
pouch are rigid after the top is sealed. The product is preferably
filled at a temperature ranging from 29.degree. F. to ambient
temperature. The methodology advances to block 150.
[0071] In block 150, the open upper edge of the pouch is closed by
applying a closing seal. In this example, the pouch is closed by
sealing the upper edges 16 together using a closing sealing process
as previously described. The closing seal may be an ultrasonic seal
or an ultra pulse seal or a heat weld or the like. Preferably, the
upper seal is a wide, insulating seal 50 with each seal 50a, 50b
separated by an air pocket 50c. It should be appreciated that the
steps of filling and sealing may be repeated for each compartment,
if necessary. That is, one compartment is filled and sealed, and
then the adjacent compartment is filled and sealed.
[0072] If the compartment holds a carbonated beverage, the pouch
may be sealed as described in commonly owned PCT Patent Application
No. PCT/JUS03/034396, which is incorporated herein by reference. A
second cosmetic seal may be applied over the first seal for a
carbonated product, as shown at 78. The second seal may be a heat
weld. Some of the product may be trapped between the first and
second seals. This is advantageous since there is no gas in the
head space, i.e. the region between the product and the heat seal,
and less pouch material is required.
[0073] In block 155, the filled pouch 10 is finished in a finishing
operation. For example, the edges of the pouch may be trimmed to
achieve a predetermined pouch shape. In addition, the filled pouch
may be cooled at a cooling station using a conventionally known
cooling technique. The methodology advances to block 160.
[0074] In block 160, the filled pouch 10 is discharged from the
machine. For example, the pouches are moved to a discharge station
where the receptacles are moved from the arm of the turret
outwardly onto a conveyor. The receptacles are then moved by the
conveyor under robotic arms having grippers, which are then lowered
to grab the pouch 10 and lift the pouch 10 from the receptacles.
The receptacles are then moved by the conveyor through a rinsing
station and returned to the other side of the turret for use. The
pouches 10 are placed by the grippers into cartons. At this point,
the filled pouch is available for distribution.
[0075] It should be appreciated that the methodology may include
other steps, such as an upstream oxygen purging station, a
downstream oxygen purging station, or pasteurization or the like.
For example, the filled pouch may be pasteurized in an integral
retort chamber (not shown) that heats and then cools the pouch. The
pouch may be tested, such as burst testing or the like prior to
packaging for shipping. These additional processing steps may take
place at a station on the form/fill/seal apparatus, or on another
apparatus.
[0076] It is also contemplated that the order of implementing the
steps may vary to facilitate the manufacturing process. In
addition, a manufacturing station may perform one or a plurality of
operations, to enhance the efficiency of the methodology and
apparatus.
[0077] Referring to FIG. 10, an example of a fill-seal machine 80
for carrying out the method described with respect to FIG. 7 is
illustrated. The fill machine illustrated is by way of example, and
other configurations may be utilized. It should be appreciated that
a particular manufacturing station may perform one or more
operations. It should also be appreciated that the order of
operations may vary. The fill-seal machine 80 may be configured as
a flat bed, a conveyor, a rotary turret or the like. An example of
a flat bed form machine is manufactured by Nishibe, such as the
model number SBM500, SMB600 or SMB700. It should be appreciated
that the fill-seal machine may be integral with the form machine,
or a separate machine.
[0078] In operation, the carrier with the pouch 10 is loaded onto
the machine 80 as shown at station 1. The pouches 10 are removed
from the receptacle and placed in a holder as shown at station 2,
such as by using a gripper.
[0079] The pouch 10 is transported along the conveyor belt to
operation station 3, and the pouch 10 is opened in an opening
operation. Various techniques are conventionally known in the art
for further opening the pouch 10. The pouch compartments may be
opened using the opening grippers as previously described. The
guide pocket formed by the crease in the front panel and back panel
facilitates opening the upper edges of the pouch, as previously
described. The lever arms assist in maintaining the pouch in an
open position.
[0080] The fully opened pouch 10 is transferred to a filling
station as indicated at station 4, and the pouch is filled with the
product. For example, a nozzle dispenses a predetermined amount of
product into the opened pouch. The product may be dispensed into
the opened edges of the pouch or through a fitment. In this
example, the fill nozzle is lowered into the opened pouch, and the
product is dispensed into the open pouch. Depending on the number
of compartments and type of products, there may be more than one
filling station.
[0081] If the product is naturally carbonated, such as beer or soda
or the like, the pouch is preferably filled while immersed in a
nitrogen atmosphere. If the product is not naturally carbonated, it
is immersed in a carbonator to introduce carbon dioxide into the
product. For example, carbon dioxide is introduced into cold water
or juice to provide a carbonated beverage. The product may contain
a mixture of up to four volumes of carbon dioxide. It should be
appreciated that the carbon dioxide masks any undesirable taste
from ketones and other solvents released during the sealing
process. The carbon dioxide also increases the pressure within the
product so that the walls of the pouch 10 are rigid after the top
is sealed. The product is preferably filled at a temperature
ranging from 29.degree. F. to ambient temperature. The carbonation
is advantageous as a microbiocide which can enhance the flavor or
prevent mold or contamination.
[0082] The pouch 10 is transferred to station 5 for removing any
oxygen from the pouch. The pouch is then transferred to a sealing
station and the open edges of the pouch are first sealed, as
indicated at station 6. For example, at the sealing station 6, the
lifting surface ends, causing the lever arms to return to their
original position, and the pouch to close. It should be noted that
the filled pouch might return to a partially closed position due to
the product contained therein. The first may be a thermal seal. For
example, a heat-sealing member extends therethrough the slots in
the sides of the cup, to seal the upper edge of pouch.
[0083] Another example of a first seal for a carbonated product
utilizes an ultrasonic sealing process. Preferably the ultrasonic
seal includes sound waves and is formed using a horn and anvil. A
second seal is applied at a second sealing station 7. The second
seal may be applied using a heat seal means to form a second heat
seal over the first seal. It should be appreciated that the second
seal may be spaced slightly above the first seal. The second
heat-sealing station 7 is conventional and utilizes heat or a
combination of heat and pressure to form the seal. The second seal
may also be a cosmetic seal or another type of seal, such as
ultrasonic, ultra pulse or the like. The first and second seals are
applied for a carbonated product as disclosed in commonly assigned
Patent Application No. PCT/US03/34396, which is incorporated herein
by reference.
[0084] The pouch is transferred to a finishing station 8 for
finishing and removal from the filling machine. For example, the
pasteurized pouch 10 may be cooled. A tear notch may be formed in
the pocket portion of the pouch to facilitate opening the pouch to
access the product in the pouch. In another finishing operation,
the edges of the pouch are trimmed to achieve a desired shape. The
finished pouches may be discharged into a package. For example,
transfer grippers may be utilized to place the pouch in a box for
shipment.
[0085] If desired, the pouch may be transferred to a pasteurization
station. Pasteurization enhances the shelf life of the product. The
pouch is inserted into an enclosed retort chamber. Air is extracted
from the chamber, such as using a vacuum source. The product inside
the pouch is pasteurized. For example, a combination of steam and
water is used to heat the pouch to a predetermined temperature for
a predetermined period of time to pasteurize the product contained
within the pouch. The package is then cooled. In this example,
recirculated water surrounds the pouch to cool the pouch. In
certain instances, it may be desirable to apply steam to sterilize
the pouch 10 and to wet the inner surface of the walls to
facilitate handling.
[0086] The present invention has been described in an illustrative
manner. It is to be understood that the terminology which has been
used is intended to be in the nature of words of description rather
than of limitation.
[0087] Many modifications and variations of the present invention
are possible in light of the above teachings. Therefore, the
present invention may be practiced other than as specifically
described.
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