U.S. patent application number 11/477996 was filed with the patent office on 2007-02-15 for dispensing pouch and a method of making the same.
Invention is credited to Michael K. Patrick.
Application Number | 20070034647 11/477996 |
Document ID | / |
Family ID | 37110282 |
Filed Date | 2007-02-15 |
United States Patent
Application |
20070034647 |
Kind Code |
A1 |
Patrick; Michael K. |
February 15, 2007 |
Dispensing pouch and a method of making the same
Abstract
A dispensing pouch and method for making the same are described.
One described dispensing pouch includes a flexible first sheet and
a flexible second sheet, each including at least one layer, and
where the flexible second sheet has substantially the same size and
shape as the flexible first sheet. The flexible second sheet is
joined to the flexible first sheet to define a compartment
configured to substantially contain a material. The flexible first
sheet and the flexible second sheet also define a channel
configured to allow dispensing of the material from the
compartment.
Inventors: |
Patrick; Michael K.;
(Greensboro, MD) |
Correspondence
Address: |
KILPATRICK STOCKTON LLP
1001 WEST FOURTH STREET
WINSTON-SALEM
NC
27101
US
|
Family ID: |
37110282 |
Appl. No.: |
11/477996 |
Filed: |
June 29, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60695144 |
Jun 29, 2005 |
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Current U.S.
Class: |
222/107 ;
222/541.6 |
Current CPC
Class: |
B65D 75/5811 20130101;
B65B 9/023 20130101 |
Class at
Publication: |
222/107 ;
222/541.6 |
International
Class: |
B65D 35/00 20060101
B65D035/00; B65D 47/10 20060101 B65D047/10 |
Claims
1. A dispensing pouch comprising: a flexible first sheet comprising
at least one layer; and a flexible second sheet comprising at least
one layer and having substantially the same size and shape as the
flexible first sheet, the flexible second sheet joined to the
flexible first sheet to define: (1) a compartment configured to
substantially contain a material, and (2) a channel configured to
allow dispensing of the material from the compartment.
2. The dispensing pouch of claim 1, further comprising at least one
notch formed on opposite sides of the dispensing pouch, the at
least one notch configured to allow a user to tear a portion of the
pouch to allow dispensing of material from the compartment through
the channel.
3. The dispensing pouch of claim 1, wherein the flexible first and
second sheets each comprises a three-layer of material.
4. The dispensing pouch of claim 3, wherein an outer layer of the
three-layer material comprises polyethelene terephthalate.
5. The dispensing pouch of claim 3, wherein a middle layer of the
three-layer material comprises foil.
6. The dispensing pouch of claim 3, wherein an inner layer of the
three-layer material has a melting point lower than the middle and
outer layers.
7. The dispensing pouch of claim 1, wherein the flexible first
sheet comprises an outer layer comprising paper.
8. The dispensing pouch of claim 1, wherein the flexible first
sheet and the flexible second sheet are part of a single flexible
sheet that has been folded to create the flexible first sheet and
the flexible second sheet.
9. The dispensing pouch of claim 1, wherein the flexible first
sheet and the flexible second sheet are joined by one or more
seals.
10. The dispensing pouch of claim 1, wherein the flexible first
sheet comprises a first side and a second side, which are
substantially parallel to each other, and a third and a fourth side
which are substantially parallel to each other, and substantially
perpendicular to the first side and the second side.
11. The dispensing pouch of claim 1, wherein the dispensing pouch
is configured to dispense a single drop of material.
12. The dispensing pouch claim 11 wherein the single drop of
material hangs on the end of the dispensing pouch.
13. The dispensing pouch of claim 1, wherein the dispensing pouch
is configured to dispense less than 1 ml of solution.
14. The dispensing pouch of claim 1, wherein the width of the
channel is approximately between 1/32 of an inch and 1/8 of an
inch.
15. The dispensing pouch of claim 1, wherein the material comprises
a liquid configured to mimic blood.
16. A method of manufacture of a dispensing pouch comprising the
steps of: joining a flexible first sheet to a flexible second sheet
along a first side, a second side, and a third side of the flexible
first sheet and the flexible second sheet to define a compartment;
forming a channel extending from a fourth side of the flexible
first sheet and a fourth side of the flexible second sheet to the
compartment; inserting a material into the compartment; and sealing
the channel along the fourth side of the flexible first sheet and
the fourth side of the flexible second sheet.
17. The method of claim 16, further comprising folding a single
flexible sheet to form the flexible first sheet and the flexible
second sheet.
18. The method of claim 16, wherein joining the flexible first and
second sheets comprises sealing the corresponding first, second,
and third sides of the flexible first sheet and the flexible second
sheet.
19. The method of claim 18, wherein sealing the dispensing pouch
comprises applying heating bars to the pouch.
20. The method of claim 16, wherein forming the channel comprises
placing a heat-sinking material between the flexible first sheet
and the flexible second sheet and applying heat.
21. The method of claim 16, further comprising forming a first
notch on one side of the joined sheets adjacent to the fourth side
of the joined sheets.
22. The method of claim 21 further comprising forming a second
notch on the other side of the joined sheets adjacent to the fourth
side of the joined sheets.
23. The method of claim 16, further comprising creating a plurality
of dispensing pouches from two large sheets, and perforating the
large sheets between each of the plurality of dispensing
pouches.
24. The method of claim 16, further comprising cutting a hang hole
into the dispensing pouch.
25. The method of claim 16, further comprising one of stamping,
debossing, or printing a code on the dispensing pouch.
26. The method of claim 16, further comprising sterilizing the
dispensing pouch.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 60/695,144, filed Jun. 29, 2005, entitled
"Dispensing Pouch," the entirety of which is herein incorporated by
reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to product
packaging. The present invention relates more particularly to a
dispensing pouch.
BACKGROUND
[0003] A variety of pouches have been created to dispense liquids.
Such pouches are used in retail and industrial applications,
including for condiments, lotions, and diagnostic applications.
Some of these pouches include a pre-formed spout or narrowing at
the top so that the liquid can be directed. For instance, some
conventional pouches for dispensing hand lotion include a spout so
that the lotion can be directed to a specific portion of the hand.
The portion of the hand at which the lotion is directed is
relatively large. Additionally, some packaging for cold sore
medications has a `V`-shaped, tapered opening to allow more
controlled dispensing of the product.
[0004] Some pouches are designed to hold or to dispense a single
dose of a liquid. For example, in some medical and laboratory
applications, a single dose of a liquid agent is used for
calibrating certain meters, such as a glucose meter. The meter
includes on-board diagnostics, which can use a control solution to
automatically calibrate the meter. These liquid agents have
typically been stored in bottles or vials. However, some pouches
have been designed for such applications.
[0005] Some pouches have been described for dispensing a liquid
agent that is designed to mimic blood so that the liquid is
dispensed in a manner that mimics a drop of blood occurring when a
patient pricks her finger. U.S. Pat. No. 6,887,709, the entirety of
which is incorporated herein by reference, describes one such
application in which a micro needle is inserted into a pouch to
withdraw a sample of a liquid agent. The '709 patent describes such
pouches for use in diagnostic applications. The pouch described in
the '709 patent mimics the skin of a patient when pierced by the
micro needle.
SUMMARY
[0006] One embodiment of the present invention provides a
dispensing pouch. In one embodiment, a dispensing pouch comprises a
flexible first sheet and a flexible second sheet, each comprising
at least one layer and where the flexible second sheet has
substantially the same size and shape as the flexible first sheet.
The flexible second sheet is joined to the flexible first sheet to
define a compartment configured to substantially contain a
material. The flexible first sheet and the flexible second sheet
also define a channel configured to allow dispensing of the
material from the compartment.
[0007] Another embodiment comprises a method of manufacture of a
dispensing pouch. The method comprises the steps of joining a
flexible first sheet to a flexible second sheet along a first side,
a second side, and a third side of the flexible first sheet and the
flexible second sheet to define a compartment. The method also
includes forming a channel extending from a fourth side of the
flexible first sheet and a fourth side of the flexible second sheet
to the compartment. Material is inserted into the compartment, and
the channel is sealed along the fourth side of the flexible first
sheet and the fourth side of the flexible second sheet.
[0008] These embodiments are mentioned not to limit or define the
invention, but to provide examples of embodiments of the invention
to aid understanding thereof. Embodiments are discussed in the
Detailed Description, and further description of the invention is
provided there. Advantages offered by the various embodiments of
the present invention may be further understood by examining this
specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other features, aspects, and advantages of the
present invention are better understood when the following Detailed
Description is read with reference to the accompanying drawings,
wherein:
[0010] FIG. 1 is a perspective view of a dispensing pouch according
to one embodiment of the present invention;
[0011] FIG. 2 is a cut-away view of a dispensing pouch similar to
the one shown in FIG. 1 in one embodiment of the present
invention;
[0012] FIG. 3 is a flow chart illustrating one method for
manufacturing a dispensing pouch according to one embodiment of the
present invention; and
[0013] FIG. 4 shows an illustrative example of a dispensing pouch
according to one embodiment of the present invention.
DETAILED DESCRIPTION
[0014] Embodiments of the present invention provide a dispensing
pouch. Illustrative embodiments are described below.
Dispensing Pouch
[0015] In one illustrative embodiment, a dispensing pouch is
configured to contain a liquid agent designed to mimic blood for
calibrating a glucose meter. FIG. 1 is a perspective view of a
dispensing pouch in one embodiment of the present invention. The
terms pouch and packet may be used interchangeably herein.
[0016] The pouch 100 shown comprises two sheets of multilayer
material, a first flexible sheet 102 and a second flexible sheet
104. The material shown in FIG. 1 is a multi-layer, heat sealable
film. Various suitable films may be used in different embodiments
of the present invention.
[0017] The two sheets 102, 104 are formed into a pouch and are
sealed at a first side 111, a second side 107, and a third side 108
by a form, fill, and seal machine to create a first seal 114.
[0018] During the initial sealing step, the two sheets 102, 104 are
also sealed at a second seal 113 and a third seal 109. Seal 113
extends from side 107 towards the center of the sheets 102, 104 and
from side 108 towards the center of the sheets 102, 104. Seal 113
does not completely seal the compartment 110, which is configured
to substantially contain the material, but, rather, forms a channel
112 extending from the compartment 110 towards side 111. The
channel 112 opens into the compartment so that a liquid agent can
flow from the compartment 110 through the channel 112. A heat sink
may be placed between the sheets 102, 104 where the channel 112 is
to be formed to prevent the inner materials from sealing the
channel. The third seal 109 extends to a point 122 approximately
one-half the length of the dispensing pouch 100. In another
embodiment, the seals could be located in a different position or
elsewhere on the packet to define the compartment and the
channel.
[0019] The channel 112 approximates a tube. However, since the film
shown in FIG. 1 is flexible, it may not be a cylindrical tube. The
width or diameter of the channel 112 shown in FIG. 1 is
approximately 1/32'' to 1/8''. In other embodiments, the channel
112 may have a larger or smaller diameter. The viscosity of the
material and the desired dispensing type can affect the channel
width. For instance, certain materials may require channels wider
than 1/8''. The dispensing pouch shown in FIG. 1 may be referred to
as a micro-mini dispensing pouch and the channel 112 as a micro
channel.
[0020] The channel 112 may be of varying length. For example, the
length of the channel 112 may be optimized for ergonomics,
providing a sufficient area for a consumer to grip the pouch and
tear across the channel 112 at tear notches 118, 120. The length of
the channel 112 may also be optimized for aesthetics, e.g., to
allow sufficient space for artwork on the outside of the pouch.
[0021] The design of the channel 112, including the length and
width (diameter), may also depend on the properties of the liquid
to be dispensed, such as the viscosity, surface tension, or other
relevant properties. The design of the channel 112 may also depend
on the desired effect when the liquid is dispensed. For instance,
the channel 112 may be designed to produce a hanging drop, small
drip, stream, or other effect. The outer layer of the pouch may be
selected based on the effect as well. For instance, an outer paper
layer may absorb some of the liquid. In one embodiment for
calibrating a meter, this absorption may serve to provide a better
sample for the calibration of the meter.
[0022] In an embodiment of the present invention, the channel may
extend away form the compartment at an angle and may be directed
towards a corner of the pouch. In another embodiment, the channel
may extend away from the compartment towards an edge of the pouch.
In such an embodiment, the channel may extend towards an area
substantially in the middle of one side of the pouch. In another
such embodiment, the channel may extend towards a portion of an
edge near the comer of the pouch.
[0023] FIG. 4 shows a dispensing pouch 400 according to one
embodiment of the present invention comprising a compartment 402
and channel 404 formed between two sheets of multi-layer material.
The channel 404 is angled towards a comer of the pouch 400. Two
sides 406, 408 adjacent to the corner have notches 410, 412 such
that the notches may be used to tear away the corner and expose the
channel to allow dispensing of material within the compartment.
Such an embodiment may provide a more suitable exit location for
particular products. For instance, for some products, such an
embodiment may limit any interference in the dispensing process
caused by the packet itself.
[0024] In the embodiment shown in FIG. 1, the compartment 110 is
configured to contain a liquid, such as one designed to mimic
blood. Other types of material, including, for example, other
diagnostic solutions, liquid bandages, adhesives, liquids with high
staining properties, perfume, or any material desired in a small
volume delivery mechanism may also be contained in the compartment
110.
[0025] The sheets 102, 104 are also sealed at a fourth seal 124,
which extends along side 106 between sides 107 and 108. The fourth
seal 124 seals the liquid in the compartment 110 and channel
112.
[0026] The sheets 102, 104 are also cut at two points along sides
107 and 108 to form tear notches 118, 120. When the pouch is torn
from 118 to 120, the channel is exposed, and the liquid can be
dispensed. While the embodiment shown has two notches, 118, 120,
other embodiments may have no notches, or one or more notches.
Further, while the embodiment in FIG. 1 shows notches that are made
perpendicular to edges of the pouch, in other embodiments, the
notches may be cut at other angles relative to an edge of the
pouch.
[0027] The sheets 102, 104 shown in FIG. 1 are multi-layer
structures. The outer layer, which may also be referred to as the
structural layer, may be a paper layer or may be a varnish or
finish layer or other suitable material. In one embodiment, the
outer layer is made from PET (polyethelene terephthalate), the
middle layer is a foil, and the inner layer is the sealing layer.
In such an embodiment, one or more adhesives bond the three layers
of the film to the adjacent layer or layers. In other embodiments,
other types of structures may be used.
[0028] In one embodiment, the inner layer has the lowest melting
point of the three layers. Thus, when the multilayer film is
heated, the inner layer melts and forms a seal without destroying
the integrity of the rest of the film. The inner layer also
prevents chemicals in the pouch from corroding the foil. The foil
provides a light, moisture, and vapor barrier. Other types of film
may be used, depending on, for example, the type of material to be
contained in the pouch. For instance, particular types of inner
layers may be used to effectively contain the material placed in
the compartment 110.
[0029] FIG. 2 is a cut-away view of a dispensing pouch similar to
the one shown in FIG. 1 in one embodiment of the present invention.
The pouch shown in FIG. 2 is approximately 1.375 inches wide and
1.75 inches long. The pouch comprises a compartment 202 and a
channel 204. The pouch also comprises a tear notch 206 for tearing
the film so that the liquid in the compartment 202 can be dispensed
through the channel 304.
Application of a Dispensing Pouch
[0030] Embodiments of the present invention may provide significant
improvements in the controlled dispensation of material from within
the pouch. Embodiments of the present invention may also allow a
person to dispense a controlled quantity of material to a specific
location with a highly customizable delivery method. For example,
one embodiment of the present invention may allow a user to suspend
a controlled amount of liquid as a drop from the channel of the
pouch, allowing the user to accurately control the quantity of
liquid delivered and to accurately deliver the drop to desired
location at the appropriate time. Such control over the delivery of
material from the pouch may provide significant advantages to users
of the pouch in a variety of settings.
[0031] For instance, one embodiment of the present invention
provides a channel 112 that allows a small droplet to hang on the
end of the pouch 100. This may simulate when a patient pricks a
finger and squeezes out a droplet of blood, which is then touched
to a test strip. The test strip uses capillary action to draw in
the liquid to a test meter for calibration purposes.
[0032] Another embodiment provides a mechanism for sampling liquid
products at low cost. With such a pouch, applicators, such as swabs
or towels, are unnecessary. For example, a customer wishing to
sample a perfume simply tears the pouch perpendicular to the
channel 112 and applies the perfume.
[0033] Yet another embodiment of the present invention provides a
means for delivering a liquid that has high staining properties. A
consumer of such a liquid would want to avoid touching the liquid.
It would also be advantageous to limit the flow of the liquid.
Examples of such a liquid include iodine solution, tooth whitening
solution, and dyes.
[0034] Embodiments of the present invention may also be used for
transdermal medications or single-use liquid bandages. Embodiments
of the present invention may also be used advantageously for
applications in which less than 1 ml of solution is needed, e.g.,
<0.3 ml. In addition, embodiments of the present invention may
be used advantageously for applications in which 1 ml or more of
solution is needed.
[0035] One embodiment of the present invention provides an
application mechanism for liquids that react with or degrade once
in contact with air. For instance, one such pouch is used to
dispense fast acting glue, which begins to set as soon as exposed
to air.
[0036] Embodiments of the present invention may provide numerous
advantages over conventional pouches and delivery methods. For
instance, one embodiment of the present invention may reduce the
risk of exposure of the liquid agent to contamination versus
conventional delivery mechanisms, such as a bottle containing
multiple applications. Also, the dispensing pouch may be small
enough to be carried on the person of the consumer. In addition, if
the dispensing pouch is formed on a sheet with multiple other
dispensing pouches, the consumer can cut or tear off only the
number of dispensing pouches she anticipates using over a given
time period. For example, in one embodiment of the present
invention, a plurality of pouches may be formed on a single sheet,
where the sheet is perforated to allow the one or more pouches to
be more easily detached.
[0037] One embodiment of the present invention may be easier to use
than conventional pouches that require the consumer to use a
towlette or that require the consumer to attempt to meter the
output of the liquid through a spout or opening in the top of a
bottle. One embodiment of the present invention also may allow a
manufacturer to print an expiration date directly on the pouch so
that the consumer can easily determine what the expiration date is.
Determining the expiration date for material in conventional
delivery mechanisms may be more difficult. Other information may be
printed on the pouch. A coding, such as the date, may alternatively
be debossed or stamped on the pouch.
[0038] Embodiments of the present invention may also be produced
and sold at a reduced cost compared to conventional dispenser
products, such as those that include pre-saturated swabs and
towelettes for sampling, and when compared to conventional sellable
products that require small doses. Embodiments of the present
invention also provide a user with the ability to predict where the
liquid will come out of the pouch, thereby allowing a consumer to
direct it to the exact spot it needs to go (e.g., to the test strip
for a glucose measurement device, to the area of bruised or cracked
skin, or to the spot that needs glue).
Methods of Manufacturing an Illustrative Pouch
[0039] Various methods may be used to manufacture a dispensing
pouch according to embodiments of the present invention. FIG. 3 is
a flow chart illustrating one method for manufacturing a dispensing
pouch according to one embodiment of the present invention. The
process 300 shown begins when a section of multilayered film is
folded 302. The film may be, for example, a portion of a roll of
film. The film is folded so that one piece of film becomes two
sheets as shown in FIG. 1. In some embodiments, individual sheets
are oriented face-to-face and cut to size. In the embodiment shown
in FIG. 3, the two sheets are approximately rectangular in shape
after folding.
[0040] The sheets are next sealed at one end 304. For example, in
one embodiment, heating bars are applied to a first end of the
sheets to melt the inner layer of the multilayered film to create
the seal. The sheets are also sealed at two edges to create a
compartment 306 and a channel 308. The edges are substantially
parallel to one another and substantially perpendicular to the end
sealed in step 302. The seal may extend along approximately the
entire length of the edges. A channel may be created be inserting a
heat-sinking material between the two sheets to prevent the first
and second sheets from joining in the locality of the heat sink. In
another embodiment, a tool design is utilized that allows the
channel to remain cooler than the rest of the tool, eliminating the
need for a heat sink between the sheets.
[0041] Creating the end seal, the compartment, and the channel may
occur as a single step in one embodiment of the present
invention.
[0042] The sheets are oriented so that the end seal and channel are
at the bottom. An injector is then used to inject a measured amount
of liquid into the compartment 310.
[0043] Once the compartment and channel have been created, and the
material injected, a final seal is created, sealing the second end
of the film 312. The final seal seals the compartment at an end
opposite the channel. The final seal prevents any material inserted
in the compartment from escaping.
[0044] In the embodiment shown in FIG. 3, the pouch is then cut at
two points on opposite edges, creating tear notches. In other
embodiments, no such tear notches are created, or one or more
notches are created. The sealed film is then cut, forming the
individual pouch. In one embodiment, the steps described above may
be performed in a different sequence. For example, in one
embodiment, the material may be injected into the compartment
before the channel is formed.
[0045] Additional steps may be performed on the pouch. In one
embodiment, the pouch is die cut into a desired shape (e.g., create
oversized outer seals and the cut through them). For instance, in
one embodiment, the pouch is cut in a shape resembling a
needle.
[0046] In another embodiment, a set of pouches is perforated rather
than cut. For example, it may be advantageous to create a plurality
of pouches according to the present invention with two large
flexible sheets of material. The joined sheets may then be
perforated to allow one or more pouches to be easily detached. In
another embodiment, a hang-hole is punched in the pouch. In yet
another embodiment, a date is stamped on the package. In one
embodiment, the pouch is sterilized using a radiation or other
sterilization processes after the packaging process in a separate
operation.
[0047] In one method for manufacturing a dispensing pouch, a metal
tool is used to affect the seals. The metal tool is set to a
temperature of approximately 240 degrees Fahrenheit. The dwell is
set to approximately 1.5 seconds. The pressure is set at
approximately 6-8 psi on a 4'' air cylinder with a spring return
function. The net pressure on the film is equal to the cylinder
pressure less the force of the return spring. In one method
according to the present invention, a heat-sinking material is
placed between the film sheets where the channel is formed. The
heat-sinking material helps to keep the channel from becoming
sealed or narrowing to a point of ineffectiveness.
General
[0048] The foregoing description of the embodiments of the
invention has been presented only for the purpose of illustration
and description and is not intended to be exhaustive or to limit
the invention to the precise forms disclosed. Numerous
modifications and adaptations thereof will be apparent to those
skilled in the art without departing from the spirit and scope of
the present invention.
* * * * *