U.S. patent application number 11/551071 was filed with the patent office on 2007-05-17 for flexible pouch with ergonomic shape and method of forming.
This patent application is currently assigned to PPi Technologies, Inc.. Invention is credited to R. C. MURRAY.
Application Number | 20070110344 11/551071 |
Document ID | / |
Family ID | 36074081 |
Filed Date | 2007-05-17 |
United States Patent
Application |
20070110344 |
Kind Code |
A1 |
MURRAY; R. C. |
May 17, 2007 |
FLEXIBLE POUCH WITH ERGONOMIC SHAPE AND METHOD OF FORMING
Abstract
An ergonomically beneficial flexible pouch is provided. The
pouch includes a panel having an inner surface and an outer
surface, and an upper edge, an opposed lower edge and two side
edges extending therebetween. The flexible pouch may include a flat
seam that lies flat against the outer surface of the panel. An
upper edge of the pouch includes a first ultrasonic closing seal,
and a second seal is positioned above the first closing seal. The
pouch also includes opening means integral with the panel for
accessing a product contained within the pouch. For an ergonomic
flexible pouch containing a carbonated product, the pressure in the
pouch from the carbonated product ergonomically shapes the pouch,
such that the front wall and the back wall each have a
longitudinally oriented convex shape and the sealed side edge and
the smooth side edge each have a longitudinally oriented concave
shape.
Inventors: |
MURRAY; R. C.; (Lakewood,
FL) |
Correspondence
Address: |
GIFFORD, KRASS, SPRINKLE,ANDERSON & CITKOWSKI, P.C
PO BOX 7021
TROY
MI
48007-7021
US
|
Assignee: |
PPi Technologies, Inc.
Sarasota
FL
|
Family ID: |
36074081 |
Appl. No.: |
11/551071 |
Filed: |
October 19, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11195906 |
Aug 3, 2005 |
|
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11551071 |
Oct 19, 2006 |
|
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60598394 |
Aug 3, 2004 |
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Current U.S.
Class: |
383/107 ;
383/104; 383/120; 383/67; 383/80 |
Current CPC
Class: |
B31B 2155/00 20170801;
B65D 2575/583 20130101; B31B 2160/10 20170801; B31B 70/844
20170801; B65D 75/5883 20130101; B65D 33/2508 20130101; B31B 70/00
20170801 |
Class at
Publication: |
383/107 ;
383/120; 383/080; 383/067; 383/104 |
International
Class: |
B65D 30/00 20060101
B65D030/00; B65D 33/16 20060101 B65D033/16; B65D 30/16 20060101
B65D030/16; B65D 30/20 20060101 B65D030/20 |
Claims
1. A flexible pouch with a folded flat seam for containing a
product, said pouch comprising: a panel 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 folded portion in said second
side edge that is defined by a fold line extending transversely
along the second side edge and spaced a predetermined distance from
the outermost portion of said second side edge; a folded flat seam
joining said first side edge and said folded portion in said second
side edge to form a body of the pouch, wherein first side edge is
positioned over the folded portion in said second side edge, so
that an outermost portion of said the first side edge is aligned
with the outermost portion of said second side edge, and the folded
flat seam lies flat against the body of the pouch; and an opening
means integrally formed in said panel for accessing a product
contained within the pouch.
2. The pouch as set forth in claim 1 wherein said the outermost
portion of said second side edge is folded 180 degrees along said
fold line, so that the folded portion is adjacent the outer surface
of said panel.
3. The pouch as set forth in claim 1 wherein said pouch includes a
gusset.
4. The pouch as set forth in claim 1 wherein said pouch body
includes a front wall and a back wall and an insert positioned
between said front wall and said back wall.
5. The pouch as set forth in claim 1 further including a strip of
material sealed over said folded flat seam.
6. The pouch as set forth in claim 1 wherein said opening means
includes a fitment, and a cap removably attached to said
fitment.
7. The pouch as set forth in claim 1 further comprising a label
disposed over the outer surface of said panel.
8. An ergonomic flexible pouch for a carbonated product comprising:
a panel 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
side seal joining said first side edge of said panel to said second
side edge of said panel to form a body of the pouch having a front
wall and a back wall, and a smooth side edge and a sealed side
edge; a first closing seal sealing lower edges of said front wall
and said back wall together; a second closing seal sealing said
lower edges of said front wall and said back wall together, wherein
said second closing seal is spaced a predetermined distance
outboard of the first closing seal, and the carbonated product is
trapped between the first closing seal and the second closing seal;
and an opening means disposed between upper edges of said front
wall and said back wall, wherein a pressure in the pouch from the
carbonated product ergonomically shapes the pouch, such that said
front wall and said back wall each have a longitudinally oriented
convex shape and said sealed side edge and said smooth side edge
each have a longitudinally oriented concave shape.
9. The pouch as set forth in claim 8 wherein said side seal
includes an inner seal at a low temperature, and an outer seal at a
high temperature and spaced a predetermined distance outboard of
said inner low temperature seal.
10. The pouch as set forth in claim 9 wherein said first seal is a
tack seal that tacks the side edges together, and a gas in the
pouch is pushed out of the pouch through the side edges before the
second high temperature seal is applied.
11. The pouch as set forth in claim 9 wherein said side seal is
formed using a seal bar having a plasma coating.
12. The pouch as set forth in claim 9 wherein said opening means
includes a fitment, and a cap removably attached to said
fitment.
13. The pouch as set forth in claim 9 further comprising a label
disposed over said front wall and said back wall of said pouch.
14. A method of forming and filling an ergonomic flexible pouch
with a carbonated product, said method comprising the steps of:
forming a body of the pouch from a roll of laminate material,
wherein the body of the pouch includes a panel 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; aligning the first side edge with the second side
edge to form the front wall and back wall of the body of the pouch;
forming a side seal in the aligned first side edge and the second
side edge; sealing an opening means between the upper edges of the
front wall and back wall; opening the pouch; filling the pouch with
the carbonated product; sealing the lower edges of the front wall
and back wall using a first ultrasonic closing seal; applying a
second closing seal that is spaced a predetermined distance
outboard of said first ultrasonic closing seal, such that the
carbonated product is trapped in the space between said first
closing seal and said second closing seal, wherein the pressure in
the pouch due to the carbonated product ergonomically shapes the
pouch, such that the front wall and back wall each have a
longitudinally oriented convex shape and said sealed side edge and
said smooth side edge each have a longitudinally oriented concave
shape; and finishing the filled pouch.
15. The method as set forth in claim 14 wherein said step of
forming the side seal further includes the steps of: applying an
inner seal at a low temperature; and applying an outer seal at a
high temperature, wherein the outer seal is spaced apart from the
inner seal by a predetermined distance, so that there is an air gap
between the inner seal and the outer seal and a gas is pushed out
of the pouch through the open edges of the panels.
16. The method as set forth in claim 14 wherein said step of
forming the side seal includes the step of using a seal bar coated
with a plasma material.
17. The method as set forth in claim 14 further including the step
of applying a sleeve over the outer surface of the panel and
heat-shrinking sleeve to the outer surface of the panel.
18. An ergonomic flexible pouch for a carbonated product
comprising: a panel 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 side seal joining said first side edge of said panel
to said second side edge of said panel to form a body of the pouch
having a front wall and a back wall, and a smooth side edge and a
sealed side edge; a first closing seal sealing lower edges of said
front wall and said back wall together; a fitment ultrasonically
sealed between said upper edges of said front wall and said back
wall, wherein said fitment includes a base portion having a
vertically oriented wall, a pair of opposed fins extending
outwardly from an outer surface of said wall, a lip extending
outwardly from an upper edge of said wall, a spout projecting
upwardly from the upper edge said wall, and said spout includes a
thread encircling said spout with a plurality of vertically
oriented vents bisecting said thread; a replaceable cap secured to
said fitment, wherein said cap is a cylindrical member, having a
closed and an open end, and an inner surface of said cylindrical
member includes a thread with a plurality of vertically oriented
vents bisecting said thread, such that said cap vents are disposed
between said fitment vents when said cap is secured to said fitment
to control a release of pressure from the pouch due to the
carbonated product; and the pressure in the pouch from the
carbonated product ergonomically shapes the pouch, such that said
front wall and said back wall each have a longitudinally oriented
convex shape and said sealed side edge and said smooth side edge
each have a longitudinally oriented concave shape.
19. The ergonomic flexible pouch of claim 18 wherein said cap
includes a detachable collar that remains on the spout when said
cap is removed from said spout.
20. The ergonomic flexible pouch of claim 18 wherein said fitment
has an elongated oval shape.
21. The ergonomic flexible pouch of claim 18 wherein said fitment
is ultrasonically sealed by applying an ultrasonic seal to the
upper edges of said front wall and said back wall, applying a heat
seal, and applying a cool seal, so that there are no voids between
the fitment and upper edges of said front wall and said back
wall.
22. The pouch as set forth in claim 18 further comprising a label
disposed over the outer surface of said panel.
23. The pouch as set forth in claim 18 wherein said side seal
includes an inner seal at a low temperature, and an outer seal at a
high temperature and spaced a predetermined distance outboard of
said inner low temperature seal.
24. The pouch as set forth in claim 23 wherein said first seal is a
tack seat that tacks the side edges together, and a gas in the
pouch is pushed out of the pouch through the side edges before the
second high temperature seal is applied.
25. The pouch as set forth in claim 18 wherein said side seal is
formed using a seal bar having a plasma coating.
Description
RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 11/195,906 filed Aug. 3, 2005, which claims
priority of U.S. Provisional Patent Application Ser. No. 60/598,394
filed Aug. 3, 2004, 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 a product and, more specifically, to a flexible pouch
with an ergonomically beneficial shape for packaging a product 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. Examples of containers
include a cup, a metal can, a plastic bottle, a glass bottle or 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. Manufacturers 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] Flexible pouches have been used for some time to distribute
noncarbonated beverages, such as fruit juice and the like. However,
their use with other types of beverages, including carbonated
beverages, has been limited. With respect to carbonated beverages,
the presently available materials are somewhat permeable, 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 a carbonated beverage is disclosed
in commonly assigned PCT Patent Application No. PCT/US03/034396,
which is incorporated herein by reference.
[0007] The flexible pouch is made from a flexible material,
preferably a 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 and/or filled using conventionally known manufacturing
techniques, such as a horizontal form-fill-seal machine with a
single or multiple lanes, a flat bed pre-made pouch machine, a
vertical form-fill machine, or the like. The pouch includes a front
panel joined to a back panel. Edges of the panels, such as a side
edge, are joined together using a sealing technique such as bonding
or welding. The sealed edge resembles a fin.
[0008] While the above described pouch functions well, the exposed
"fin" edge may be sharp. Also, the potential shapes for the pouch
are limited using a "fin" edge. Thus, there is a need in the art
for a flexible pouch with an ergonomically beneficial shape, and an
improved method of making a flexible pouch, that can be used to
hold various types of prnducts.
SUMMARY OF THE INVENTION
[0009] Accordingly, the present invention is an improved flexible
pouch. A flexible pouch with a flat seam for a product and a method
for manufacturing the pouch is provided. The pouch includes a panel
having an inner surface and an outer surface, and an upper edge, an
opposed lower edge and two side edges extending therebetween. A
first side edge is positioned over the folded second side edge and
sealed to form a seam that lies flat against the outer surface of
the panel. An upper edge of the pouch includes a first ultrasonic
closing seal, and a second closing seal is positioned above the
first closing seal. The pouch also includes an opening means
integral with the panel for accessing a product contained within
the pouch.
[0010] The method includes the steps of forming a pouch by forming
a fold along each side edge of the panel and positioning the panel
so that the fold in each side edge is aligned and the first side
edge extends beyond the second side edge. The extending portion of
the first side edge is folded over the second edge to form a flap,
and is sealed. The lower edge of the pouch is sealed. The flap may
be tacked down to the lower edge and upper edge of the pouch during
the sealing step, so that the flap lies flat against the walls of
the pouch. The flap may also be sealed to the outer surface of the
pouch using a cover strip. The flap may also be folded into the
inside of the pouch or formed into a side gusset.
[0011] An ergonomic flexible pouch for a carbonated product
includes a panel 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 side seal joins the first side edge of the panel to
the second side edge of the panel to form a body of the pouch
having a front wall and a back wall, and a smooth side edge and a
sealed side edge. A first closing seal seals lower edges of the
front wall and the back wall together, and a second closing seal
seals the lower edges of the front wall and the back wall together.
The second closing seal is spaced a predetermined distance outboard
of the first closing seal, and the carbonated product is trapped
between the first closing seal and the second closing seal. An
opening means is disposed between upper edges of the front wall and
the back wall.
[0012] One example of an opening means is a fitment ultrasonically
sealed between the upper edges of the front wall and the back wall.
The fitment includes a base portion having a vertically oriented
wall, a pair of opposed fins extending outwardly from an outer
surface of the wall, and a lip extending outwardly from an upper
edge of the wall. A spout projects upwardly from the upper edge of
wall, and the spout includes a thread encircling the spout with a
plurality of vertically oriented vents bisecting the thread. A
replaceable cap is secured to the fitment. The cap is a cylindrical
member, having a closed and an open end. An inner surface of the
cylindrical member includes a thread with a plurality of vertically
oriented vents bisecting the thread, such that the cap vents are
disposed between the fitment vents when the cap is secured to the
fitment to control a release of pressure from the pouch due to the
carbonated product. The pressure in the pouch from the carbonated
product ergonomically shapes the pouch, such that the front wall
and the back wall each have a longitudinally oriented convex shape
and the sealed side edge and the smooth side edge each have a
longitudinally oriented concave shape.
[0013] One advantage of the present invention is that a flexible
pouch with an ergonomical shape and an improved method of making
the flexible pouch is provided. Another advantage of the present
invention is that a flexible pouch and method of making a flexible
pouch is provided that utilizes a laminate material that includes
PET, foil, nylon and cast polypropylene. Still another advantage of
the present invention is that a flexible pouch and the method of
making a flexible pouch is provided that includes a flat seam with
edges that overlap. A further advantage of the present invention is
that a flexible pouch and method of making a flexible pouch is
provided that includes a flat seam with edges that fold over to
form a flap, and the flap lies flat against the pouch with no sharp
edges. Still a further advantage of the present invention is a
flexible pouch and a method of making a flexible pouch filled with
a product is provided that is cost effective to manufacture. Yet a
further advantage of the present invention is that the flexible
pouch retains its shape as the product is removed. Still yet a
further advantage of the present invention is that the flexible
pouch includes an insert so that it can stand upright unsupported.
Another advantage of the present invention is that the pouch stands
up and is made of a laminate material with an opening means. Still
another advantage of the present invention is that the flexible
pouch is filled with a carbonated product, has an ergonomic shape
and is comfortable for a user to hold. A further advantage of the
present invention is that the flexible pouch is filled with a
carbonated product and has a spout fitment and cap.
[0014] Other features and advantages of the present invention will
be readily appreciated, as the same becomes better understood after
reading the subsequent description taken in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an elevational view of a flexible pouch with a
flat seam, according to the present inventions.
[0016] FIG. 2a is an elevational view of a flexible pouch with a
folded flat seam according to the present inventions.
[0017] FIG. 2b is a perspective side view illustrating a folded
flat seam for the pouch of FIG. 1, according to the present
inventions.
[0018] FIG. 2c is a partial elevational view of a flexible pouch
with a folded flat seam, according to the present inventions.
[0019] FIG. 3 is an elevational view of a panel with an integrally
formed gusset prior to sealing the side edges, according to the
present inventions.
[0020] FIG. 4a is an elevational view of a pouch having an
integrally formed gusset and an overlap flat seam, according to the
present inventions.
[0021] FIG. 4b is a detail view of the overlap flat seam, according
to the present inventions.
[0022] FIG. 5 is a side view of a flexible pouch with a seal strip
covering the flat seam, according to the present inventions.
[0023] FIG. 6a is an elevational view of a stand-up flexible pouch
with a flat seam, tear notch and insert, according to the present
inventions.
[0024] FIG. 6b is an end view of the pouch of FIG. 6a, according to
the present inventions.
[0025] FIG. 6c is a partial view of an insert for the pouch of FIG.
6a, according to the present inventions.
[0026] FIG. 7a is an elevational view of a stand-up flexible pouch
with a flat seam, straw hole, pull tab opening means and insert,
according to the present inventions.
[0027] FIG. 7b is a top view of an insert with a pull tab and straw
hole, according to the present inventions.
[0028] FIG. 7c is a cutaway view of an insert, according to the
present inventions.
[0029] FIGS. 8a and 8b are partial views of a stand-up flexible
pouch with a flat seam, fitment and side gussets, according to the
present inventions.
[0030] FIGS. 9a-9c are elevational views of a stand-up flexible
pouch with a flat seam, fitment and insert, according to the
present inventions.
[0031] FIG. 10 is another elevational view of a stand-up flexible
pouch with a flat seam and fitment, according to the present
inventions.
[0032] FIGS. 11a-11d are elevational views of stand-up caps for the
flexible pouch with fitment, according to the present
inventions.
[0033] FIG. 12 is a flowchart of a method of forming a flexible
pouch with a flat seam, according to the present inventions.
[0034] FIG. 13 is a schematic top view of a rotary fill machine
according to the present inventions.
[0035] FIGS. 14-16 are examples of fill machines according to the
present inventions.
[0036] FIG. 17 is an elevational view of a receptacle for
transporting the pouch, according to the present inventions.
[0037] FIG. 18a is an elevational view of a pouch with an overlap
flat seam in a side gusset, according to the present
inventions.
[0038] FIG. 18b is a detail view of the overlap flat seam in side
gusset, according to the present inventions.
[0039] FIG. 18c is another detail view of the overlap flat seam in
side gusset, according to the present inventions.
[0040] FIG. 19a is an elevational view of a panel for a pouch with
an overlap S-type flat seam, according to the present
inventions.
[0041] FIG. 19b is a sectional view of a pouch formed using the
panel of FIG. 19a, according to the present inventions.
[0042] FIG. 19c is a detail view of the S-type flat seam, according
to the present inventions.
[0043] FIG. 20 is an elevational view of an empty ergonomic pouch,
according to the present inventions.
[0044] FIG. 21 is an elevational view of the filled ergonomic pouch
of FIG. 20, according to the present inventions.
[0045] FIG. 22 is an elevational view of the filled ergonomic pouch
of FIG. 21 with a sleeve, according to the present inventions.
[0046] FIG. 23 is an elevational view of an unfilled ergonomic
pouch with a fitment for a carbonated product, according to the
present inventions.
[0047] FIG. 24a is a perspective view of the spout fitment for a
carbonated product for the pouch of FIG. 23, according to the
present inventions.
[0048] FIG. 24b is a perspective view of the cap for the spout
fitment of FIG. 24a, according to the present inventions.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0049] Referring to FIGS. 1-11 and 18a-23, a flexible pouch 10 is
illustrated. The pouch 10 may be filled with a product (not shown)
and sealed. Various types of products are contemplated, such as a
dry product or a fluid product. In addition, the product may be a
food item, or a non-food item. It is contemplated that the pouch
may contain a single portion or multiple portions of the product.
In this example, the product is a carbonated product.
[0050] The flexible pouch 10 is preferably formed from a roll of
preprinted material of laminate layers. The laminate material is
typically a three, or four, or five gauge material, and is
non-limiting. 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, as
shown in FIGS. 6a and 7 at 98 as a window. The clear portion could
be in a gusset or insert. An outer layer of material may include
preprinted information on this outer layer may be a sleeve, to be
described.
[0051] The choice of sheet layer material is non-limiting, and 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.
There may be a fourth layer of nylon. 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.
Another example of a material structure is ONO/AL/COEX-ONO-LDPE.
Material structures that include CPP are well suited for packaging
a beverage, such as beer, wine or other carbonated fluids, 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 the
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. The pouch 10 may have a
generally cylindrical shape, similar to a traditional metal can,
although other shapes are contemplated, as shown in FIGS. 5-10. 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.
[0052] It should be appreciated that if the filled carbonated pouch
is stored at ambient temperature, the laminate will start to creep
after a period of time, such as ten days. The laminate material may
include an extrusion layer to contain "creepage" or "stretch" of
the film after filling due to carbonation expansion, if the product
is carbonated. In addition, the selected material may be
organoleptic compliant in order to avoid the transfer of odor
contaminates to the product, or product contamination during the
shelf life period of the product.
[0053] The formed pouch includes a front wall 12 and a back wall
14. Each wall 12, 14 is further defined by an upper edge 16, an
opposed lower edge 18, and side edges 20 extending therebetween the
upper and lower edges 16, 18. The edges of the panel are joined
along a seam. The pouch may include two side seams, or one single
seam. In addition, the side edges 20 may be joined along a flat
seam 50, or a "fin" style seam. In an example of a pouch formed
using a single panel 48 of material, the side edges 20, or joined
along a flat center seam. In another example of a pouch formed from
a single panel, the side edges are formed along one side seam. In
an example of a pouch formed using two sheets of material, the
edges are joined along two flat side seams. The panel 48 has an
inner surface 24 that is adjacent the product, and an outer surface
22.
[0054] In an embodiment of a pouch 52 illustrated in FIGS. 2a-2c,
the flat seam 50 is a folded seam or reverse seal. A first and
second side edge includes a fold, as shown at 54 and 56. The first
fold 54 forms an obtuse angle along the first edge and the second
fold forms an acute angle 56 along a second edge 56. It should be
appreciated that only a minimal portion of the first side edge 54
extends beyond the second side edge 56. The first side edge 54 is
positioned over the second side edge 56, so that the folds are in
alignment and that a portion of the first side edge 54 extends
beyond the second side edge 56, as shown at 58. The first and
second edges 54, 56 are sealed together in a manner to be
described, and the extending edge 58 is folded over to form a flap
60 that can lie flat against the outer wall of the pouch 52.
Preferably, the flap 60 is secured to the outer wall of the pouch
52. For example, the flap 60 may be secured along an upper edge and
a lower edge to the walls of the pouch. Alternatively, the length
of the pouch may be secured to the walls of the pouch. The flap can
be secured using a sealing means, such as a tack seal, or an
adhesive or monolayer film or the like. In another alternative, the
flap may be sealed to the outer surface of the pouch using a second
strip 92 of material covering the seam, as shown in FIG. 5. The
seam cover 92 is secured using a sealing means, such as a weld or
an adhesive. The folded seal is advantageous, since it has a higher
seal bond strength than a typical layer on layer seal.
[0055] Another embodiment of a pouch 62 with an overlap flat seam
is illustrated in FIGS. 3-4. In this example, a first side edge 64
overlaps a second side edge 66 a predetermined amount.
Alternatively, each side edge 64, 66 may include a corresponding
fold, as shown at 64a and 66b in FIGS. 18a-18c. The first side edge
64 is positioned over the second side edge 64 so that the edges
overlap. Preferably, the amount of overlap is between 5-12 mm. The
first and second edges are sealed together using a technique to be
described. It should be appreciated that the inclusion of a CPP
layer of material on the inside of the pouch and on the outside
improves the seal strength of the overlap seal, since it has a
higher bond strength and prevents delamination.
[0056] Still another embodiment of a pouch 300 formed from one
panel of material 348 and having an overlap flat seam is
illustrated in FIGS. 19a-19c. In this example, a first side edge
302 overlaps a second side edge 304 a predetermined amount. The
second side edge includes a fold along a seal fold line, as shown
at 306. The first side edge does not include a fold. The second
side edge 304 is folded outwardly 180 degrees along the seal fold
line 306, and the first side edge 302 is positioned over the second
side edge 304 so that the first side edge 302 is adjacent the
folded second side edge 304. Preferably, an outer portion of the
first side edge and an outer portion of the second side edge are in
alignment with each other and shown at 308. Preferably, the amount
of overlap between the first side edge and second side edge is
about 5-12 mm. The first and second edges are sealed together using
a technique to be described. It should be appreciated that the
inclusion of a CPP layer of material on the inside of the pouch and
on the outside, improves the seal strength of the overlap seal,
since it has a higher bond strength and prevents delamination. As
previously described, a seam cover may be positioned over the seam
and sealed to the outer wall of the pouch.
[0057] Any of the pouches may include an insert, sidewall or gusset
70. The gusset 70 may be integrally formed in the panel 48, as
shown in FIGS. 3 and 4, or a separate piece of material. The gusset
may be disposed between the front and back walls, and positioned
between the side edges of the walls, the lower edges, the upper
edges, or any desired combination. It should be appreciated that
the shape of the gusset 70 is nonlimiting. For example, the gusset
70 may be generally wider at one end and taper upwardly towards the
opposite end. The gusset 70 may also be of a uniform width. The use
of the gusset 70 may be functional, i.e. it may allow the pouch 10
to acquire another shape, such as cylindrical, or to stand upright.
The gusset 70 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 70 positioned between
the lower edges of the pouch 10 forms a base, which may enable the
pouch 10 to stand upright.
[0058] Similarly, the pouch may include an insert, as shown in
FIGS. 6-9. The insert 72 is a generally planar member that is
inserted between the walls 12, 14 of the pouch 10. The shape of the
insert 72 is nonlimiting, and generally influences the shape of the
flexible pouch. The insert 72 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 72 may be formed from a printed material,
or it may be clear. In one example, the insert 72 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.
[0059] Referring to FIG. 7, a pouch with two inserts is
illustrated. In this example, there is a first insert 72a
positioned between the lower edges of the panel, and a second
insert 72b positioned between the upper edges of the panel. The
first insert 72a may include an integral fitment means, such as a
straw hole 80 for receiving a straw. The pouch of this example has
a generally square shape. As shown in FIGS. 6a-6c, the insert has a
round shape and the pouch has a tapered shape. Similarly, in FIGS.
9a-9c, the insert has a square shape and the finished pouch has a
tapered shape similar to a bottle.
[0060] The pouch 10 incorporates an opening means 74 for accessing
the contents of the pouch. Various types of opening means 74 are
known in the art for this purpose. It should be appreciated that
the opening means 74 may be incorporated into the pouch 10 prior to
filling the pouch 10. One example of an opening means is a tear-off
portion 76, as shown in FIG. 6. The tear-off portion 76 usually has
an integral tear notch 78. The tear notch 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 74 is a weakened, straw-pierceable portion 80 in the
pouch for receiving a straw. A further example of an opening means
74 is a pull tab 82 covering an opening in the pouch. Both are
illustrated in FIG. 7. Yet another example of an opening means is a
reseal able zipper, such as a hermetic seal.
[0061] Still a further example of an opening means 74 is a
removable and replaceable cap 84 secured to a fitment 86. The cap
and fitment may be positioned between the upper edges 16 or lower
edges 18 of the pouch. The cap 84 screws onto a spout end 88 of the
fitment 86. The cap 84 can be the traditional round shape.
Alternatively, the cap 84 can have an elongated oval shape so that
the pouch may stand up on its own, as shown in FIGS. 11a-11d and
21-22. The cap 84 and fitment 86 can be made from a variety of
materials. For example, the cap 84 may be made from plastic, such
as reground resins. The fitment 86 may be made of polypropylene
(PP), depending on the product. The fitment 86 is sealed into the
upper 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 86 may include a removable seal 90 to prevent leakage
of the product or evidence of tampering.
[0062] Referring to FIGS. 20-22, examples of an ergonomic pouch 400
are illustrated. The ergonomic pouch has similar features as the
previously described pouches. In this example, the pouch is formed
from a single panel of material 402, and the side edges are joined
along one side seam 404. The one side seam may be a "fin" style
seam, or a flat seam formed as previously described. In this
example, a "fin" style side seam is shown. If the pouch 400 is
filled with a carbonated product, the carbonation causes the
pressure within the pouch to increase. As a result of this
increased pressure, the front wall 406 and back wall 408 each
assume a longitudinally oriented convex shape, and each side edge
410 assumes a longitudinally oriented concave shape. Thus, the
width across the pouch is less in the middle as shown at 412, than
at the upper edge 414 or lower edge 416. The overall hourglass
shape assumed by the pouch 400 due to the internal pressure within
the pouch is ergonomically advantageous.
[0063] Referring to FIG. 22, the flexible pouch may include an
outer layer or sleeve 420 covering the outer surface of the pouch.
The sleeve may be a label containing information about the product,
such as a barcode or the like. The sleeve 420 may cover only a
portion of the pouch outer surface. Preferably, the sleeve 420 is
shrunk over the outer surface of the pouch after the pouch is
formed and filled with the product. The sleeve is advantageous
because it covers the side seam. It also adds one or 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 plastic including PET or PVC and the choice is
non-limiting.
[0064] Referring to FIGS. 23-24b, still another example of a
flexible pouch with a fitment for preserving carbonation of a
carbonated product is illustrated. In this example, an unfilled
ergonomic pouch 400 is illustrated by way of example; however,
other types of flexible pouches are contemplated. Further, the
pouch may assume the hourglass shape previously described, when
filled. The fitment 472 includes a canoe-shaped base 487 that is
heat sealed between the edges of the pouch, and an upwardly
projecting spout 486. A removable and replaceable cap 484 is
secured to the spout 486.
[0065] The cap 484 and spout 486 can be made from a variety of
materials. For example, the cap 484 may be made from plastic, such
as reground resins. The spout 486 may be made of PE or
polypropylene (PP), depending on the product.
[0066] The base 487 or canoe portion of the fitment includes a
vertically extending wall 488a. In this example, the base portion
has an elongated oval shape. The base 487 also includes a pair of
sealing ribs 488b protruding outwardly from the wall 488a.
Preferably, one rib 488b is positioned on each outermost edge of
the base 487. An upper edge of the wall 488a includes an integrally
formed lip 489 that extends outwardly a predetermined distance. The
base 487 is fixedly retained within the flexible pouch when the
walls of the pouch are sealed around the base portion using a
sealing means, such as an ultrasonic seal. Alternatively, a heat
weld, or the like could be utilized to seal the fitment into the
pouch. Advantageously, the symmetrical shape of the base portion
and protruding lip allows for enhanced precision in positioning the
spout between the walls of the pouch during the pouch forming
process. During sealing, material flows around the sealing rib 488b
and fills in any void between the panel wall and the fitment, to
increase the retention of the fitment 472 within the panel
walls.
[0067] The spout 486 also includes at least one outwardly extending
flange or collar 490a. The flange 490a is spaced a predetermined
distance above the lip 489, and the space in between provides a
tool support surface for a holding means during the manufacturing
operation, as shown at 495. For example, the tool support surface
491 is used to support; the pouch 400 during manufacturing
operations, such as filling, sealing or the like. The spout 486
includes a second flange 490b parallel to, and spaced a
predetermined distance above the first flange 490a. In this
example, the first flange extends out farther than the second
flange. As such, the first flange 490a also serves as a lower
"stop" for the cap 484, while the second flange 490b serves as an
upper "stop" for the tamperproof feature of this cap, in a manner
to be described.
[0068] The spout 486 includes an elongated thread 491 encircling
the outer surface of the tube, just above the second flange. In
this example, the thread 491 has a spiral shape. The thread 491
assists in retaining the cap on the spout. The spout includes a
plurality of vertically oriented vent channels or grooves 492 that
bisect the thread. The grooves 492 are spaced a predetermined
distance apart, around the outer surface of the spout. The grooves
492 provide for the controlled release of pressure from within the
pouch due to the carbonated product, when the cap 484 is secured to
the spout 486. Another feature of the spout is a removable seal
(not shown) located on the upper, open end of the spout, to prevent
leakage of the product or provide evidence of tampering.
[0069] The cap 484 includes a cylindrical member 484a having an
open end 484b for receiving the spout, and a closed end 484c. The
cap may include a tamperproof feature, which in this example is a
detachable collar 493 connected to the cylindrical member 484a by a
plurality of connecting walls 494. The connecting walls 494 are
thin wall sections that break away from the cylindrical member 484a
upon the application of a force, so that the cap 484 can be removed
from the spout 486. The detachable collar 493 is retained on the
spout and is held in place between the first and second flanges.
The outer surface of the cylindrical member may include a plurality
of vertically oriented gripping ribs 484d that assist a user in
removing or replacing the cap on the spout.
[0070] An inner surface of the cylindrical member 484a also
includes an outwardly projecting thread 484e. The thread 484e has a
spiral shape. The inner surface of the cylindrical member also
includes a plurality of vertically oriented vent channels grooves
484f that bisect the thread 484e. It should be appreciated that the
vent grooves 484f in the cap 484 are located between the vent
grooves 492 in the spout 486, when the cap is screwed onto the
spout.
[0071] In operation, the cap 484 is initially pushed on the spout
486 and retained by the engagement of the detachable collar between
the spout second flange and first flange. To remove the cap, the
user grips the cap by the outer surface of the cylindrical member,
and twists the cap until the thin wall sections between the
cylindrical member and detachable collar are severed. The cap can
then be twisted off from the spout. The detachable collar may be
retained on the spout, and only the cylindrical member is
removable. The cap can be replaced on the spout to reseal the
spout. Alternatively, the collar may have a tab that is pulled to
sever the connecting walls 70 to remove the cap from the spout.
[0072] The flexible pouch may incorporate any of the
above-described features in any combination. For example, any of
the pouches may include an insert 72 in the bottom portion of the
pouch and a tapered top portion, or an insert 72 in the bottom
portion of the pouch and a fitment and cap in the top portion of
the pouch, or an insert 72 in the bottom portion and the top
portion of the pouch. The flexible pouch may include any one of the
described opening means. In addition, the finished pouch may assume
various shapes, such as cylindrical, cubical, and conical,
hourglass or the like, as influenced by the type of product and
intended usage of the pouch.
[0073] It should be appreciated that any of the above-described
flexible pouches may advantageously include other features that are
known in the art. For example, the flexible pouch may include a
guide pocket formed in a wall of the pouch prior to filling and
sealing, to facilitate the separation of the front and back walls
prior to the filling of the pouch. An example of such a pouch is
disclosed in commonly assigned U.S. patent application Ser. No.
10/310,221.
[0074] It is also contemplated that any of the described pouches
may undergo a secondary process after it is filled with the
product. For example, the filled pouch may be frozen.
Alternatively, the filled pouch may be pasteurized in order to have
an extended shelf stable life under ambient temperature. Examples
of pasteurized food products include dairy products such as milk,
or meat products such as chicken or the like.
[0075] Referring to FIG. 12, a method for forming and filling any
of the previously described flexible pouches using a high-speed
machine, such as that described with respect to FIGS. 13-16, is
illustrated. The flexible pouch 10 described above is referenced by
way of example. The method begins in block 100 at a first station
with the step of forming the body of the pouch. For example, a roll
of laminate material, as previously described, is unrolled along a
horizontally oriented plane. The initial width of the roll of
material is determined by the desired finished size of the pouch 10
and the number of pouches to be obtained from the width. For
example, three or four or six pouches, representing six to twelve
panels, can be obtained from a width of the roll of material on a
three-lane machine or four-lane machine, respectively. Each panel
48 has an inner surface 24 and an outer surface 22. 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 wall 12,
14. 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. in this example, the layer of
preprinted information is located on an outer layer of the
material.
[0076] The methodology advances to block 105 and a feature, such as
a gusset 70 or insert 72, is optionally positioned between the
aligned first and second unrolling sections of material. In
addition, an opening means may be applied at this time. For
example, an opening means 74, such as a press-to-close zipper, may
be positioned between the panels. Another opening means such as a
straw hole, patch or tear notch may be applied.
[0077] The methodology advances to block 110 and the edges of the
walls are sealed together to form a flat seam 50. For example, to
form a folded flat seam 52, a fold is formed along an edge of the
sheet of material. The angle of the fold is determined, according
to the width of seam desired, as previously described. The fold in
the first edge 54 is aligned with the fold in the second side edge
56 and the edges are sealed together, in a manner to be described.
The extending edge 58 is folded over to form the flap and sealed.
At least a portion of the flap may be secured to the outer portion
of the material.
[0078] To form an overlap flat seam 68, the edges of the sheet of
material are positioned together, such that a first edge 64
overlaps a second edge 68 a predetermined amount, and the edges are
sealed together. To form an overlap flat seam as shown in FIGS. 19a
and 19b, the second edge is folded outwardly along a seam line. The
first edge is positioned over the second edge a predetermined
overlap amount. The outer portion of the first edge and the outer
portion of the second edge are in alignment. The edges are sealed
together as previously described. With either of these types of
flat searns, a second strip of material 92 may be positioned over
the seam and sealed onto the wall or the pouch.
[0079] Various techniques are contemplated for sealing the edges
together. For example, an adhesive may be used to seal the first
and second edge of the flat seam together. Alternatively, the edges
may be sealed using an ultrasonic sealing process. Another
technique is a heat weld that includes the application of heat and
compression.
[0080] In still another example, the edges are sealed using a seal
bar or forming plate having a plasma coating. One advantage of the
plasma coating is that the line speed may increase. Another
advantage is that the coating makes the surface of the seal bar or
forming plate more resilient. When the seal bar is heated, the
coating expands due to this resiliency. The shear stress on the
inner edge of the seal is reduced; resulting in reduced creepage of
the material and greater durability of the seal. The plasma coating
reduces the opportunity for potential damage to the material during
the sealing step. In this example, the plasma coating is a smooth,
hard plastic that mimics glass. Since the outer layer of material
is not weakened, there is no creepage of the outer layer.
[0081] In still another example of a sealing technique, the side
seal is a two-step seal, as shown in FIG. 20. The two-step seal
advantageously avoids the generation of ketones due to application
of heat to the material. The first or inner seal is a low
temperature seal. The second or outer seal is a high temperature
seal. The second seal is spaced apart from the first seal by a
predetermined distance, to create an air gap. The first seal is a
tack seal, such as 6 mm wide, and is of a sufficient temperature so
as to melt the layers of material and tack the edges together. The
predetermined distance between the first and second seal is 1/2-1
mm. The second seal is applied at a higher temperature and pressure
than the first seal. As a result, any gas, such as steam, ketones,
aromatics or the like are pushed in an outwardly direction, out
through the open edges of the panels, and not into the pouch. Thus,
the first seal prevents entry of contaminates into the pouch to
avoid organoleptic contamination.
[0082] The methodology advances to block 115, and the section of
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 seam of the pouches. The section is then separated into
individual pouches. In this example, the width of unrolling
represents the side edges. The material is cut using a known
cutting apparatus, such as a laser or punch or the like. 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 forms a
single cut in the material to separate the pouches. The length of
the pouch 10 is controlled by the distance between the cuts.
[0083] Alternatively. two pouches 10 are cut out at one time by
adding a double cut between two cuts, preferably in the center.
Advantageously, forming two pouches during the cutting operation
effectively doubles the assembly line speed.
[0084] It should be appreciated that the upper edge or lower edge
may be further trimmed. For example, the end of the pouch may be
trimmed to accommodate a fitment 86. In another example, two legs
are formed during the trimming operation, in order to recess the
fitment. The fitment may be ultrasonically sealed to the pouch.
[0085] The methodology advances to 120, and an edge is sealed, such
as the lower edge 18. The lower edge 18 may be sealed using a known
sealing process, such as an ultrasonic sealing process. Another
sealing technique is a heat weld that involves the application of
heat and compression. As previously described, the seal bar may
have a plasma coating. In addition, the flap 60 for a folded flat
seam 62 may be tacked down to the outer wall of the pouch, such as
at an upper or lower end of the center seam. The flap is held in
place such as by using an adhesive, or sealed while applying the
heat weld or ultrasonic seal. It should be appreciated that the
outermost layer of the pouch material may be coated with a heat
sealable material to assist in securing the flap to the outer wall
of the pouch 10.
[0086] The methodology advances to block 125 and an opening means
74 may also be applied to the pouch 10 at this time. For example, a
fitment, as previously described, may be sealed within the walls of
the pouch 10, such as between the upper edges 16. The fitment may
be sealed using an ultrasonic seal, or a heat weld, or by a
combination of ultrasonic seal and heat weld. For example, the base
portion 487 of the fitment 472 is sealed between the walls of the
pouch using an ultrasonic seal, a heat seal, and then a cool seal.
The heat seal melts a layer of the pouch material, and the material
flows around the sealing ribs 488 on the base portion 487, and
fills in any void between the base portion 487 and the wall of the
pouch. The cool seal sets the seal and provides an attractive
finish to the overall seal. Advantageously, fewer stations are
required to seal the fitment between the walls of the pouch, since
a tack seal is eliminated.
[0087] In addition, an insert 72 may be likewise applied to the
pouch 10 at this time. The insert 72 may be positioned at a lower
edge of the pouch, an upper edge, or both an upper and lower edge.
The methodology advances to block 130.
[0088] In block 130, the individual pouches are finished. For
example, a lower edge of the pouch 10 may be trimmed to shape, i.e.
the corners may be angled. This operation may be performed using a
cutter or a die cut or the like.
[0089] In another example of a finishing operation, a crease or
guide pocket may be formed in a top portion of each wall 12, 14 in
a creasing operation, in order to facilitate opening and filling of
the pouch. An example of a method of forming a crease in a wall to
facilitate opening the pouch is disclosed in commonly assigned U.S.
patent application Ser. No. 10/310,221, which is incorporated
herein by reference. It should be appreciated that the shape of the
finished pouch is non-limiting, and may be round, square, oval,
triangular or the like. In still another example of a finishing
operation, the sleeve is applied over the individual pouch and
shrunk to fit using an application of heat to the pouch.
[0090] The methodology advances to block 135 and the pre-made pouch
10 is then transported to the filling machine. The completed pouch
may include any combination of the previously described features.
Further, the completed pouch may be filled through an open edge,
i.e. upper or lower, or through the fitment. The pouches may be
loaded into a carrier and transferred to a filling machine. It
should be appreciated that the filling machine may be integral with
the pouch forming machine, or a separate machine. This portability
increases the flexibility of the pouch and may result in a
manufacturing cost savings.
[0091] The methodology advances to block 140, and the pouch is
unloaded from the carrier and placed in a holder for moving the
pouch between stations. 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 using grippers (not shown)
as is known in the art. The methodology advances to block 145.
[0092] In block 145, the pouch 10 is opened in an opening
operation. Various techniques are conventionally known in the art
for opening the pouch 10, and may depend on whether the pouch is
filled through the fitment or the open edges of the pouch. For
example, the guide pocket formed by the crease in the front wall 12
and back wall 14 facilitates opening of the pouch. A nozzle (not
shown) may be mechanically lowered into the guide pocket to direct
a stream of compressed gas into the guide pocket, to force the
walls of the pouch 10 away from each other. An example of a gas is
carbon dioxide or nitrogen, or the like. The blowing station may
include a manifold, with a hood extending over the top of the edges
of the pouch as known in the art. The manifold has rows of
apertures (not shown) formed above the upper edges 16 of the pouch
10. 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 16 to assist in
overcoming the surface tension of the pouch and assist in
separation of the walls 12, 14. A diving rod (not shown) may then
be used to make sure the pouch 10 is fully opened. If the pouch has
a fitment, the gas is injected through the spout fitment. After the
pouch is opened, it may be injected with super-saturated steam to
eliminate any pathogens or the like. The methodology advances to
block 150.
[0093] In block 150, the pouch 10 is filled with the product in a
filling operation. For example, a fill tube (not shown) is lowered
into the opened pouch 10 and the product is dispensed into the open
pouch 10.
[0094] 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 desirable, 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 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 155.
[0095] In block 155, the filled pouch is sealed. For example, if
the pouch is filled through open edges, the open edge of the pouch
10 is closed by applying a closing seal The closing seal may be an
ultrasonic seal, or an ultra pulse seal, or a heat weld or the
like. If the pouch holds a carbonated beverage, the pouch may be
sealed as described in commonly owned PCT Patent Application No.
PCT/US03/034396 which is incorporated herein by reference. In the
example of a carbonated beverage, the first seal 94 is an
ultrasonic seal or an ultra pulse seal. If desired, an end of the
flap flat seam may be tacked down in this operation, or sealed with
the cover strip 92.
[0096] In block 160, a second cosmetic seal 96 is applied above the
first seal 94 for a carbonated product. The second seal may be a
heat weld. Some of the product may be trapped between the first and
second seals 94, 96. 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. As previously described,
the closing seal may include a first closing seal. A cosmetic seal
is applied above the first and second closing seals. The first
closing seal is a tack seal, and the second closing seal is a high
pressure, high temperature seal.
[0097] Alternatively, the pouch is filled through the spout fitment
and the cap is applied to close the pouch. The cap may be a
tamper-evident cap for a carbonated product, as previously
described. The cap contains the product in the filled pouch, to
prevent leakage of the product from the pouch. The complementary
arrangement of threads and grooves in the cap and spout provides
for the controlled release of pressure from the pouch.
[0098] The methodology advances to block 165 and the pouch 10 is
finished in a finishing operation. For example, the edges 16, 18,
20 of the pouch 10 are trimmed to achieve a predetermined shape, In
addition, the pouch 10 may be cooled at a cooling station, where
the pouch 10 is cooled using a conventionally known cooling
technique. Optionally, the sleeve may be placed over the filled
pouch and shrunk to fit over the pouch by applying heat. The sleeve
layer forms an outer layer of the pouch. The methodology advances
to block 170.
[0099] In block 170 the filled pouch 10 is discharged from the
machine. A plurality of pouches may be placed in a package for
sales or shipping purposes.
[0100] It should be appreciated that the pouch may undergo other
processing steps, such as such as an upstream oxygen purging
station, downstream oxygen purging station, pasteurization or the
like. For example, the filled pouch 10 may be pasteurized in
integral retort chamber (not shown) that heats and then cools the
pouch 10. The pouch 10 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.
[0101] It should be appreciated that the order of steps may vary
depending on the pouch and its features. Also, a particular
manufacturing station may perform one or a plurality of operations,
to enhance the efficiency of the methodology and apparatus.
[0102] Referring to FIGS. 13-16, an example of a fill-seal machine
30 for carrying out the method described with respect to FIG. 12 is
illustrated. The fill machines illustrated are 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 30 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.
[0103] In operation, the carrier with the pouch is loaded onto the
machine 30 as shown at "1". The pouches 10 are removed from the
receptacle and placed in a holder as shown at "2", such as by using
a gripper.
[0104] The pouch 10 is transported along the conveyor belt to
operation "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 guide pocket formed by the crease in the
front panel and back panel facilitates opening the upper edges of
the pouch. For example, a nozzle may be mechanically lowered into
the pouch to direct a stream of compressed gas downwardly into the
pouch to force the walls of the pouch away from each other to
further open an upper edge of the pouch. An example of a gas is
carbon dioxide or nitrogen. The lever arms assist in maintaining
the pouch in an open position.
[0105] The pouch 10 is then fully opened. For example, a blowing
station may include a manifold, with a hood extending over the top
of the edges of the pouch. The manifold has rows of apertures (not
shown) formed above the upper edges of the walls of the pouch. The
hood is placed over the pouch to assist in maintaining the air
pressure in the pouch. 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 walls and assist in separation of the walls.
A diving rod may then be used to make sure the pouch is fully
opened.
[0106] The opened pouch is transferred to a filling station as
indicated at operation "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 size of
the pouch, there may be two fill stations.
[0107] If the product is naturally carbonated, such as beer or soda
or the like, the pouch is preferably filled while immersed in a
nitrogen or carbon dioxide atmosphere. The pouch may be flushed
with nitrogen or carbon dioxide or a mixture of both. If the
product is not naturally carbonated, it is immersed in a carbon
dioxide process 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 six 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.
[0108] The pouch 10 is transferred to a station "5" for removing
any oxygen from the pouch. The headspace of the pouch may be
flushed with a gas. The pouch is then transferred to a sealing
station and the open edges of the pouch are first sealed, as
indicated at operation "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 seal 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. As previously described the heat sealing member may
have a plasma coating.
[0109] 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 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.
[0110] If the pouch is filled through the fitment, the pouch is
closed by securing a cap to the fitment. The cap may have a
temper-evident feature. The cap and fitment preferably have
leak-proof features as previously described for a carbonated
product.
[0111] The pouch is transferred to a finishing station as shown at
"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, grippers may be utilized to place the pouch in a box for
shipment.
[0112] 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 Lhen 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.
[0113] Referring to FIGS. 14-16, another example of a machine for
carrying out the above-described method is illustrated. As shown in
FIG. 16-17, the machine 160 is of a turret-type having radially
extending arms 162. Each arm 162 carries a predetermined number of
cuplike receptacles 164. As shown in FIG. 17, the receptacles 164
have a cylindrical wall extending upwardly from a bottom, as
disclosed in co-pending Patent Application No. 60/345,230. There
may be up to ten receptacles 164 on each arm 162. 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.
[0114] The cups are delivered to a loading station by conveyor
where empty pouches are loaded into the receptacles from magazines
166 onto a rotary turret 163. The pouches 10 are fully formed but
the upper edges 16 of the walls 12, 14 are unsealed. Each magazine
166 or turret segment holds a supply of empty flat pouches 10. The
same number of magazines or segments are needed as the number of
receptacles 164, which will be loaded onto the arm 162 of the
turret. The magazines are positioned side by side with the
receptacles 164 below. A linear cam servo feed-in device 168 moves
to push an empty pouch 10 from the magazine 166 into a receptacle
162 positioned beneath the magazine 166. The cam 170 engages the
top pouch. The magazines are angled so that gravity pulls the
pouches 10 downwardly to the cam 170 which pushes against the
bottom pouch in the magazine and is rotated to slide the pouch from
the magazine downwardly into the corresponding awaiting receptacle
164. The cams 170 are mounted to a single rod 172 which is rotated
to move the cams in unison. The rotary turret picks a pouch 10
horizontally from the magazine 166 and loads onto a segment which
transfers the empty pouch into the receptacle 164.
[0115] The group of receptacles 164 is then fed by the conveyor 174
sideways onto a radial arm 162 of the turret 163. The arms 162 are
sequentially indexed through a number of stations. The turret 163
is rotated to move the receptacles 164 containing the pouches 10 to
an opening station 176 where the flat pouches 10 are opened by a
group of nozzles positioned above the pouches 10. The pouches 10
then are moved to a checking station where photocells or pressure
is used to make sure the pouches have been opened, 178. The pouches
10 then move to a first filling station 180 where pouches could be
evacuated and diving nozzles are lowered into the pouch 10 to fill
the pouch 10 with the product. In the case of larger pouches, it
may be necessary to move the pouches to a second fill station 182
to complete the filling of the pouch. The pouches 10 then are moved
to a station 184 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.
[0116] The pouches 10 are then moved to a pouch closing station 186
to entirely seal the pouch. For example, an ultrasonic sealing
apparatus pushes the upper edges 16 of the walls 12, 14 together
over the product and seals the walls 12, 14 together. As previously
described, the heat sealing means may have a plasma coating. For a
carbonated product, a first seal may be an ultrasonic seal and a
second seal is applied above the first seal. The second seal is a
heat weld, and some of the product may be trapped between the first
seal and the second seal. For a noncarbonated product, the seal may
be a heat weld, ultrasonic seal or the like. The pouches are then
moved to a finishing station 188. The pouches 10 may be cooled. The
pouches may undergo a secondary operation, such as pasteurization
at a pasteurization station 190.
[0117] The pouches are moved to a discharge station 192 where the
receptacles 164 are moved from the arm 162 of the turret 163
outwardly onto the conveyor 174. The receptacles 164 are then moved
by the conveyor 174 under robotic arms 194 having grippers which
are then lowered to grab the pouch 10 and lift the pouch 10 from
the receptacles 164. The receptacles 164 are then moved by the
conveyor 174 through a rinsing station 196 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. Alternatively, the filled pouch 10 may be placed
onto another conveyor belt for additional processing, such as
tunnel pasteurization for shelf stabilization. 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.
[0118] As shown in FIGS. 14-15, the pouches 10 may be filled using
an example of a continuous motion machine 210. The continuous
motion machine has rows 212 of receptacles 164 mounted to a
conveyor which are moved in an elliptical path past the same
stations as set forth for the rotary machine above. Up to ten
receptacles may extend across a row. Preformed pouches are fed from
magazines located above the receptacles.
[0119] The various operations such as opening, checking, filling
and sealing are performed by apparatus which moves over the
receptacles at the same speed as the receptacles. Two sets of
identical equipment such as opening equipment are utilized. The
first set travels with the belt performing the operation while a
second set is lifted upwardly by a chain along a frame and then
moved rearwardly and down to the start position where it meets the
next row of receptacles. The pouches are loaded into the
receptacles and then moved to the start of the opening station 214
where blowers are moved down and travel with the pouches while the
alternate set of blowers are moved upwardly and rearwardly. At the
end of the travel through the opening station, the pouches are
fully opened by diving wands 216. The pouches are then turned
180.degree. to travel back down through the apparatus where they
are moved sequentially through an evacuation station 218, fill
station 220, closing station 222 and top seal station 226. At the
opposite end of the machine, the robotic arms 228 move downwardly,
grab the pouches and move them to a conveyor for loading into
packaging. The pouches then are rotated 180.degree. to the start
position and the receptacles may be washed as they move around to
the start position.
[0120] 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.
[0121] 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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