U.S. patent application number 12/099825 was filed with the patent office on 2008-09-18 for flexible pouch with hanging aperture and method of forming.
This patent application is currently assigned to POUCH PAC INNOVATIONS, LLC. Invention is credited to R. C. Murray.
Application Number | 20080226200 12/099825 |
Document ID | / |
Family ID | 39762772 |
Filed Date | 2008-09-18 |
United States Patent
Application |
20080226200 |
Kind Code |
A1 |
Murray; R. C. |
September 18, 2008 |
FLEXIBLE POUCH WITH HANGING APERTURE AND METHOD OF FORMING
Abstract
A flexible pouch for packaging a product having a hanging
aperture for receiving a fastener and a method of forming is
provided. The flexible pouch includes a panel having an inner
surface and an outer surface, and an upper edge, an opposed lower
edge and a side edge. The edges are sealed, and a hanging aperture
for receiving a fastener is formed in the sealed edge. The pouch
also includes an opening means disposed in the panel for accessing
the product. The method includes the steps of forming a body of the
pouch from a roll of laminate material, and sealing the lower edge,
side edge, applying an opening means to the panel, closing the
pouch and forming the hanging aperture.
Inventors: |
Murray; R. C.; (Lakewood
Ranch, FL) |
Correspondence
Address: |
GIFFORD, KRASS, SPRINKLE,ANDERSON & CITKOWSKI, P.C
PO BOX 7021
TROY
MI
48007-7021
US
|
Assignee: |
POUCH PAC INNOVATIONS, LLC
Sarasota
FL
|
Family ID: |
39762772 |
Appl. No.: |
12/099825 |
Filed: |
April 9, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11683133 |
Mar 7, 2007 |
|
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12099825 |
|
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60779796 |
Mar 7, 2006 |
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Current U.S.
Class: |
383/7 ;
53/452 |
Current CPC
Class: |
B65B 3/045 20130101;
B65D 75/566 20130101; B65D 2203/00 20130101; B65D 75/5811 20130101;
B65D 75/545 20130101; B65D 2575/565 20130101; B65D 75/5883
20130101 |
Class at
Publication: |
383/7 ;
53/452 |
International
Class: |
B65D 33/08 20060101
B65D033/08; B65B 3/04 20060101 B65B003/04 |
Claims
1. A flexible pouch with a hanging aperture, for packaging 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
side edge extending therebetween the upper edge and the lower edge,
and the edges are sealed together to form a body of the pouch,
wherein the hanging aperture is formed in the sealed edge for
receiving a fastener; and an opening means disposed in said panel
for accessing the product contained within the pouch.
2. The pouch as set forth in claim 1 wherein two hanging apertures
for supporting the pouch are spaced a predetermined distance apart
in a sealed upper edge of the pouch.
3. The pouch as set forth in claim 2 wherein the opening means is
located between the two hanging apertures.
4. The pouch as set forth in claim 1 wherein the fastener is a
removable clip.
5. The pouch as set forth in claim 1 wherein the fastener is a
hook.
6. The pouch as set forth in claim 1 wherein the fastener is
connected to a cord.
7. A flexible pouch with a hanging aperture for packaging 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
side edge extending therebetween the upper edge and the lower edge,
and the edges are sealed together to form a body of the pouch,
wherein two hanging apertures are formed in the sealed edge; a
fastener disposed in each of the hanging apertures; a cord
interconnecting the fastener disposed in each of the hanging
apertures; and an opening means disposed in said panel for
accessing the product contained within the pouch.
8. The pouch as set forth in claim 7 further wherein the two
hanging apertures are spaced a predetermined distance apart in a
sealed upper edge of the pouch.
9. The pouch as set forth in claim 8 wherein the opening means is
located an equidistance between the two hanging apertures.
10. The pouch as set forth in claim 7 wherein the fastener is a
removable clip.
11. The pouch as set forth in claim 7 wherein the fastener is a
hook.
12. A method of forming, filling and sealing a flexible pouch with
a product, said method comprising the steps of: forming a body of
the pouch from a panel of laminate material, wherein the body of
the pouch includes an upper edge, an opposed lower edge and a side
edge extending therebetween; sealing the lower edge and side edge;
applying an opening means to the panel; filling the pouch with the
product, wherein the product is beer or wine or a liquor; closing
the pouch; and forming a hanging aperture in a sealed edge for
receiving a fastener.
13. The method as set forth in claim 12 further including the step
of spacing two hanging apertures for supporting the pouch a
predetermined distance apart in a sealed upper edge of the
pouch.
14. The method as set forth in claim 13 further including the step
of locating the opening means between the two hanging
apertures.
15. The method as set forth in claim 12 wherein the fastener is a
removable clip.
16. The method as set forth in claim 12 wherein the fastener is a
hook.
17. The method as set forth in claim 13 wherein a cord
interconnects the fastener disposed in each of the hanging
apertures.
18. The method as set forth in claim 13, further including the
steps of: applying a first seal to seal the side edge, wherein the
first seal extends a predetermined amount into the upper edge; and
applying a second seal to seal the upper edge, wherein the second
seal overlaps the first seal a predetermined amount.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 11/683,133 filed Mar. 7, 2007, which claims
priority of U.S. Provisional Patent Application Ser. No. 60/779,796
filed Mar. 7, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a flexible pouch
for packaging a product and, more specifically, to a flexible pouch
for packaging a beverage having a hanging aperture for receiving a
fastener and a method of manufacturing the same.
DESCRIPTION OF THE RELATED ART
[0003] 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.
[0004] 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
includes a front and a back wall. Edges of the panel, such as a
side edge, upper edge or lower edge, are joined together using a
sealing technique such as bonding or welding. 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. 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.
[0005] While the above-described pouch functions well, it may be
desirable to enhance the portability of the pouch. Thus, there is a
need in the art for a flexible pouch having a hanging aperture to
secure the pouch to an object, and an improved method of making
such a flexible pouch.
SUMMARY OF THE INVENTION
[0006] Accordingly, the present invention is an improved flexible
pouch with a hanging aperture and a method for manufacturing the
pouch. The flexible pouch includes a panel having an inner surface
and an outer surface, and an upper edge, an opposed lower edge and
a side edge. The edges are sealed, and a hanging aperture for
receiving a fastener is formed in the sealed edge. The pouch also
includes an opening means disposed in the panel for accessing the
beverage. The method includes the steps of forming a body of the
pouch from a roll of laminate material, and sealing the lower edge
and side edge. The method further includes the steps of applying an
opening means to the panel, closing the pouch and forming the
hanging aperture for receiving a fastener in a sealed edge.
[0007] One advantage of the present invention is that a flexible
pouch with a hanging aperture for receiving a fastener 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 layers of 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 include two hanging apertures spaced an equidistance
apart for receiving a fastener. A further advantage of the present
invention is that the flexible pouch is more portable. Yet a
further advantage of the present invention is that the fastener and
flexible pouch can be attached to a cord and worn by a user. Still
another advantage is that the fastener is a clip. A further
advantage of the present invention is that a flexible pouch with a
hanging aperture and method of making a flexible pouch is provided
that is cost effective to manufacture.
[0008] 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
[0009] FIG. 1 is an elevational view of a flexible pouch for an
alcoholic beverage with an angled side edge and angled top seal and
a hanging aperture and fastener, according to the present
invention.
[0010] FIG. 2 is another elevational view of a flexible pouch for
an alcoholic beverage with an angled side edge and angled top seal,
according to the present invention.
[0011] FIG. 3 is still another elevational view of a flexible pouch
for an alcoholic beverage with an angled side edge and angled top
seal, according to the present invention.
[0012] FIG. 4 is an elevational view of a flexible pouch for an
alcoholic beverage with a centrally located fitment and an angled
top seal, according to the present invention.
[0013] FIG. 5 is another elevational view of a shaped flexible
pouch for an alcoholic beverage with a centrally located fitment,
according to the present invention.
[0014] FIG. 6 is another elevational view of a shaped flexible
pouch for an alcoholic beverage with an angled side edge and an
opposed angled top seal, according to the present invention.
[0015] FIG. 7 is still another elevational view of a shaped
flexible pouch for an alcoholic beverage with an angled side edge
and an opposed angled top seal, according to the present
invention.
[0016] FIG. 8 is an elevational view of a flexible pouch for an
alcoholic beverage with a tear strip opening means and an angled
top seal, according to the present invention.
[0017] FIG. 9 is another elevational view of a shaped flexible
pouch for an alcoholic beverage with a tear strip opening means,
according to the present invention.
[0018] FIG. 10 is still another elevational view of a shaped
flexible pouch for an alcoholic beverage with a tear strip opening
means, according to the present invention.
[0019] FIG. 11a is an elevational view of a flexible pouch for an
alcoholic beverage with a fitment opening means and a gusseted side
seam, according to the present invention.
[0020] FIG. 11b is an enlarged view of the gusseted side seam for
the flexible pouch of FIG. 11a.
[0021] FIG. 12a is an elevational view of a flexible pouch for an
alcoholic beverage with a fitment opening means and a center seam,
according to the present invention.
[0022] FIG. 12b is an enlarged bottom view of the flexible pouch of
FIG. 12a, according to the present invention.
[0023] FIG. 13 is a flowchart of a method of forming a flexible
pouch for an alcoholic beverage, according to the present
invention.
[0024] FIG. 14 is a schematic view of a rotary fill machine for the
flexible pouch of FIGS. 1-12, according to the present
invention.
[0025] FIG. 15 is an elevational front view of a flexible pouch
with a hanging aperture in a side edge, according to the present
invention.
[0026] FIG. 16 is another elevational view of a flexible pouch with
a hanging aperture in a side edge, according to the present
invention.
[0027] FIG. 17 is an elevational side view of a flexible pouch with
a hanging aperture in a side edge, according to the present
invention.
[0028] FIG. 18 is a rear elevational rear view of a flexible pouch
with a hanging aperture in a side edge, according to the present
invention.
[0029] FIG. 19 is a plan bottom view of a flexible pouch with a
hanging aperture in a side edge, according to the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Referring to FIGS. 1-12 and 15-19 a flexible pouch 10 is
illustrated. The pouch 10 may be filled with a product 90 and
sealed. Various shapes are contemplated for the pouch. The pouch 10
may have a generally cylindrical shape, a box-like shape, an
hourglass shape, a barrel shape or another shape. It is
contemplated that the pouch may contain a single portion or
multiple portions of the product. In this example, the product is a
beverage having an alcohol content, such as wine, beer or liquor,
or a combination thereof or the like. The product may be
carbonated, such as a sparkling wine. 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.
[0031] The flexible pouch 10 is preferably formed from a roll of
preprinted material of extruded or laminate layers. The material is
typically a three, or four, or five or more gauge material, or two
laminations of material or the like. 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 product 90
contained therein, as shown in FIG. 1 at 40 as a window. The clear
portion could also be in a gusset or insert. The outer layer of
material may be a sleeve with preprinted information.
[0032] The choice of sheet layer material is nonlimiting, 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 terephthalate (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. Still another is PET/AL/NYLON/CPP. Material
structures that include CPP are well suited for packaging a
beverage having an alcoholic content, such as wine or beer or
another liquor, to add strength to the walls of the pouch, and to
preserve the product. CPP and nylon 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. 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.
[0033] For white wine, an example of a material structure is
PET/EVOH/PE or AL/PET/NY/PE. Similarly, a material structure for
red wine includes PET/EVOH/PE, or AL/NY/PET/PE. Still another
example of a material structure is a seven-layer structure that
includes a co-extruded laminate, such as PET/CO-PP/AL/NY/LLDPE, or
the like. It should be appreciated that the CO-PP layer can include
multiple layers, such as three in this example. Other film
structures may also be utilized that offer similar protection from
sunlight, as well as organoleptic protection from the development
of undesirable flavors.
[0034] It should be appreciated that if a pouch filled with a
carbonated product 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 of the carbonated product. 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.
[0035] The pouch 10 is formed from at least one panel of material.
The panel has an inner surface that is adjacent the product, and an
outer surface. The pouch formed out of the panel has 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 first and second side
edges 20a, 20b extending therebetween the upper and lower edges 16,
18. The side edges 20a, 20b of the panel form a sealed seam. In
addition, the side edge, such as the second side edge, may include
an angled portion, as shown at 50. The pouch may include two side
seams if made from two panels or one single seam if made from one
panel. In an example of a pouch formed using a single panel of
material, the side edges 20a, 20b may be joined along a center
seam, as shown in FIG. 12a at 22. The seam may be a flat seam. In
an example of a pouch 10 formed using two panels of material, the
edges are joined along two side seams. Again, the side seam may be
a flat seam.
[0036] The pouch 10 may include an insert 24, sidewall or gusset
26. The gusset 26 may be integrally formed in the panel as shown in
FIG. 11b, or a separate piece of material. The gusset 26 may be
formed from the same material structure as the body of the pouch,
or a different structure. The gusset 26 may be disposed between the
front and back walls 12, 14, 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
26 is nonlimiting. For example, the gusset 26 may be generally
wider at one end and taper upwardly towards the opposite end. The
gusset 26 may also be of a uniform width. The use of the gusset 26
may be functional, i.e. it may allow the pouch 10 to acquire
another shape, such as cylindrical, or to stand upright. The gusset
26 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 26 positioned between the
lower edges 18 of the pouch 10 may form a base, enabling the pouch
10 to stand upright unsupported.
[0037] Similarly, the pouch may include an insert, as shown in FIG.
12b. The insert 24 is a generally planar member that is inserted
between the walls 12, 14 of the pouch 10. The shape of the insert
24 is nonlimiting, i.e. square, round or oval or rectangular, and
generally influences the shape of the flexible pouch. The insert 24
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 24 may be formed from a printed material, or it may be
clear. In one example, the insert 24 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 a combination of both
or the like.
[0038] The pouch may contain two inserts as shown in FIGS. 12a and
12b. In this example, there is a first insert positioned between
the lower edges 18 of the panel, and a second insert positioned
between the upper edges 16 of the panel. The first insert may
include an integral opening means, such as a fitment. The pouch of
this example has a generally cylindrical shape.
[0039] The pouch 10 incorporates an opening means 28 for accessing
the contents of the pouch. Various types of opening means 28 are
known in the art for this purpose, and is nonlimiting. The position
of the opening means is determinable by many factors, such as type
of opening means. The opening means may be positioned in an upper
edge, a lower edge or side edge, or front wall or back wall, or on
an insert or gusset. It should be appreciated that the opening
means 28 may be incorporated into the pouch 10 prior to filling the
pouch 10. One example of an opening means is a tear-off portion 30,
as shown in FIGS. 8-10. The tear-off portion 30 usually has an
integral tear notch 32. The tear notch 32 is typically formed near
an outermost edge of a seam, for initiating the removal of the
tear-off portion, such as a side edge. A further example of an
opening means 28 is a pull tab covering an opening in the pouch.
Yet another example of an opening means 28 is a resealable zipper,
such as a hermetic seal. Another example of an opening means 28 is
a weakened straw pierceable portion in the pouch for receiving a
straw.
[0040] Still a further example of an opening means 28 is a fitment
such as a removable and replaceable cap 34 secured to a spout 36,
or a tap, or the like. Various types of caps and spouts are
available. For example, the cap 34 can be the traditional round
shape, or have an elongated oval shape. An oval shape may support
the pouch is that it can stand up on its own. The cap 34 and spout
36 can be made from a variety of materials. For example, the cap 34
may be made from plastic, such as reground resins. The spout may be
made of polypropylene (PP), depending on the product. The spout 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
may include a removable seal 38 to prevent leakage of the product
or evidence of tampering.
[0041] The pouch 10 also includes an angled top seal 42 extending
between a first side edge 20a and a predetermined location on the
upper edge 16 of the pouch. The size, orientation or position of
the angled top seal 42 is dependent on factors such as the location
of the opening means, type of opening means or product or the like.
In one example, the angled top seal 42 extends a predetermined
length between a first edge 20a and the upper edge 16. A portion of
the pouch that is above the angled top seal 42 may be sealed, as
shown at 48. The corner seal 48 may be a cosmetic seal. The opening
means 28 is located to facilitate removal of the product. For
example, the opening means may be located in the upper edge.
Similarly, an upper portion of the second side edge may be angled
as shown at 50. The shape and position of the angled top seal 42
facilitates the removal of product from the pouch 10 by directing
the flow of the product towards the opening means. The angled top
seal 42 may have a radius to keep the interior of the pouch rounded
as shown at 52. The angled top seal 42 preferably reduces the
headspace in the pouch. This is advantageous because it assists in
pouring the product, reduces headspace (and oxygen), and influences
the shape of the pouch.
[0042] The pouch 10 further includes a hanging aperture 44 located
within a portion of the pouch, such as an upper edge or side edge.
It may be located in the corner seal 48 portion of the pouch. The
hanging aperture may be positioned between the angled top seal and
the outermost edge. The aperture 44 may have various shapes, such
as round or curved. As shown in FIGS. 10 and 15-19, the pouch
includes two hanging apertures 44 spaced a predetermined distance
apart along the upper edge. The positioning of the hanging aperture
is selectively determined. For example, the intended use of the
pouch may determine the location and number of hanging apertures.
In addition, a particular feature of the pouch, such as the type of
opening means, may influence the location and number of apertures.
For example, the hanging aperture may be positioned above the angle
top seal 42, or within the corner seal 48 or within a sealed side
edge 20a, 20b or the like. The position of the hanging aperture may
be selectively determined so that the pouch is balanced when
attached to another object, i.e. to avoid any leakage of the
contents of the pouch 10.
[0043] The pouch 10 may be supported by a support means 60
extending through the hanging aperture 44 for supporting the pouch
10. It is contemplated that one or more pouches may be supported by
a support means. For example, the support means 60 may be a hook,
such as for displaying the pouch. The support means may be a
fastener 62, whereby the fastener 62 is removably connected to
pouch 10 through the hanging aperture 44. The fastener 62 may also
be directly or indirectly connected to another object 64. An
example of a fastener 62 is a clip or a hook or a clasp or the
like. A multitude of styles of fasteners and uses therefore are
contemplated for a pouch 10 and hanging aperture. By way of
example, the object 64 may be a cord or necklace or the like
secured a fastener 62 such as a clip, enabling a user to wear the
pouch, such as around their neck or their wrist. In another example
of a fastener such as a clip 62, the pouch 10 could be removably
secured to another object, such as a belt loop, by way of example.
The fastener 62 may also be used to removably attach the pouch 10
to a loop disposed on a carrier, such as a handbag, totebag,
backpack, briefcase, suitcase or the like. Still another example of
a fastener 64 is a button and the button is disposed within the
hanging aperture 44.
[0044] It should be appreciated that the flexible pouch 10 may
advantageously include other features that are known in the art.
For example, the flexible pouch 10 may include a guide pocket
formed in a wall 14, 16 of the pouch 10 prior to filling and
sealing, to facilitate the separation of the front and back walls
14, 16 prior to the filling of the pouch 10. An example of such a
pouch is disclosed in commonly assigned U.S. patent application
Ser. No. 10/310,221. The pouch may include an integrally formed rib
46 that adds rigidity to the pouch.
[0045] The pouch may include a feature such as an ergonomic shape,
as shown in FIG. 5 or 11a. An example of an ergonomically shaped
pouch for a carbonated beverage is disclosed in commonly assigned
U.S. patent application Ser. No. 11/454,241 which is incorporated
by reference. The ergonomic shape may be achieved through
carbonation since as the pouch 10 is filled with a carbonated
product, the carbonation causes the pressure within the pouch to
increase. The increased pressure causes the front wall 12 and back
wall 14 to assume a longitudinally oriented convex shape, and each
side edge 20a, 20b assumes a longitudinally oriented concave shape.
Thus, the width across the pouch is less in the middle, than at the
upper edge or lower edge. The overall hourglass shape assumed by
the pouch 10 due to the internal pressure within the pouch
facilitates holding of the pouch in the hand of a user.
[0046] The flexible pouch 10 may include a feature such as an outer
layer or sleeve 54 covering the outer surface of the pouch. The
sleeve 54 may be a label containing information about the product,
such as a barcode or the like. The sleeve 54 may cover only a
portion of the pouch outer surface. Preferably, the sleeve 54 is
shrunk over the outer surface of the pouch 10 after the pouch 10 is
formed and filled with the product. The sleeve 54 is advantageous
because it covers the side seam. It also adds one or more layers 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
nonlimiting.
[0047] The pouch 10 may include a feature as a result of a
secondary process after it is filled with the product. For example,
the filled pouch 10 may be frozen. Alternatively, the filled pouch
10 may be pasteurized in order to have an extending shelf stable
life under ambient temperature.
[0048] It is contemplated that the flexible pouch 10 may
incorporate any of the above-described features in any combination.
For example, the pouch 10 may include an insert 24 in the bottom
portion of the pouch and a tapered top portion, or an insert 24 in
the bottom portion of the pouch and a spout 36 and cap 34 in the
top portion of the pouch. In addition, the finished pouch may
assume various shapes, such as cylindrical, cubical, and conical,
hourglass or barrel shaped or the like, as influenced by the type
of product and intended usage of the pouch.
[0049] Referring to FIG. 13, a method for forming and filling the
flexible pouch 10 using a high-speed machine 80, such as that
described with respect to FIG. 14 is illustrated. The method begins
in block 100 at a first station with the step of forming the body
of the pouch 10. 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 has an inner surface and an outer
surface. One layer of the material is preferably preprinted with
information or locating indicia (not shown), such as a registration
mark. The registration marks are located on the material to denote
an edge of the panel. The registration marks are read by an optical
reading device (not shown), such as a scanner or registration eye,
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. An example of a high speed,
multiple lane machine for forming a pouch is described in commonly
assigned U.S. patent application Ser. No. 11/674,923, which is
incorporated herein by reference.
[0050] The methodology advances to block 105 and a feature, such as
a gusset 26 or insert 24, 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, 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 or fitment may be applied.
[0051] The methodology advances to block 110 and the edges of the
walls are sealed together, such as the side edges 20a, 20b, or the
upper edge 16, or the lower edge 18. One edge may be left open for
filling purposes. In this example, the open edge is designated the
upper edge, as a reference. Alternatively, all of the edges are
sealed and the pouch is filled through a fitment. The angled top
seal may also be applied at this time. Various sealing techniques
are contemplated. For example, an ultrasonic sealing process may be
used. Another technique is a heat weld that includes the
application of heat and compression. Advantageously, the seal may
be shaped so as to avoid sharp radiuses at the interior corners of
the pouch, as shown at 52. A rounded interior shape facilitates
removal of the product. In an example, the hanging aperture is
formed in a sealed edge. It should be appreciated that a side edge
seal may extend a predetermined distance into an upper edge, as
shown in FIG. 10 (45a). A closing seal is applied to close the
pouch, and a portion of the closing seal overlaps the side seal 109
a predetermined amount as shown at 45b. The hanging aperature 44
may be formed in the overlap seal portion 45b.
[0052] 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.
[0053] In still another example of a sealing technique, the side
seal is a two-step seal. An example of a two-step seal is disclosed
in commonly assigned U.S. patent application Ser. No. 11/551,071.
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.
[0054] The methodology advances to block 115, and a 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, or the side seam
of the pouches. The section is then separated into individual
pouches. In this example, the width of unrolling material
represents the side seams. 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 size of the pouch 10 is controlled by the
distance between the cuts.
[0055] Alternatively, two consecutive pouches 10 separated using a
double cutting process, whereby two cuts are made at the same time
to separate the upper and lower edges of adjacent pouches at the
same time from the sheet of material. Advantageously, forming
multiple pouches during the cutting operation effectively doubles
the assembly line speed.
[0056] 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. In another example, two legs are
formed during the trimming operation, in order to recess the
fitment.
[0057] The methodology advances to block 120 and a feature, such as
an opening means 28 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. An
example of an ultrasonic seal for a fitment is disclosed in
commonly assigned U.S. patent application Ser. No. 11/195,906,
which is incorporated herein by reference. Accordingly, the base
portion of the fitment 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 on the base portion, and fills in any
void between the base portion 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.
[0058] In addition, an insert 24 may be likewise applied to the
pouch 10 at this time. The insert 24 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 125.
[0059] In block 125, the individual pouches are finished. For
example, an edge of the pouch 10 may be trimmed to shape, i.e. the
comers may be angled or edges trimmed fitment. It is sometimes
advantageous for the pouch corners to have a radius, to eliminate
right angles at the corners. The hanging aperture 44 may be formed
at this time. This operation may be performed using a cutter or a
die cut or the like. In addition, a tear notch may be cut out of an
edge of the pouch to facilitate opening of the pouch.
[0060] 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 nonlimiting, and may be round, square, oval,
triangular or the like. In still another example of a finishing
operation, the sleeve 54 is applied over the individual pouch and
shrunk to fit using an application of heat to the pouch. A further
example of a finishing operation is the formation of a rib 46, such
as a thermoformed rib, to add rigidity to the pouch.
[0061] The methodology advances to block 130 and the pre-made pouch
10 is discharged from the form machine. 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.
[0062] The methodology advances to block 135, and the pouch is then
transported to the filling machine, 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 140.
[0063] In block 140, the pouch 10 is opened in an opening
operation. Various techniques are conventionally known in the art
for opening the pouch 10. For example, 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. 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 145.
[0064] In block 145, 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. The pouch may be filled through an open edge, or through
the fitment, as previously described. If the pouch is large, the
pouch may be filled at more than one station.
[0065] If the product is naturally carbonated, such as a sparkling
wine or the like, the pouch is preferably filled while immersed in
a nitrogen or carbon dioxide 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.
[0066] The filled pouch may have the oxygen removed from the pouch.
For example, the pouch may be flushed with carbon dioxide. The
methodology advances to block 150.
[0067] In block 150, the pouch is sealed. For example, if the pouch
is filled through the open edges with a product, the open edges of
the pouch are closed by applying a first closing seal 56. The type
of seal varies according to the product and the closing means. In
an example of a noncarbonated or nonalcoholic product, the first
closing seal may be an ultrasonic seal, or an ultra pulse seal or a
heat weld. The first closing seal 56 may be an ultrasonic seal, or
an ultra pulse seal for a product having an alcohol content or a
carbonated liquid or the like. An example of a closing seal for a
pouch containing a carbonated liquid, is described in commonly
owned PCT Patent Application No. PCT/US03/034396 which is
incorporated herein by reference.
[0068] In block 160, a second seal 58 if utilized may be is applied
a predetermined distance apart from the first seal 56. The second
seal 58 may be a heat weld or a cosmetic seal or an ultrasonic seal
or the like. For a carbonated product or product having an alcohol
content, the location of the second seal 58 is selected so that
some of the product is trapped between the first and second seals
56, 58. This is advantageous since eliminates the potential for gas
in the head space, i.e. the region between the product and the heat
seal. In this example the second seal is spaced outboard of the
first seal. Another advantage of the location of the second seal 58
is that the overall length of the pouch may be reduced, resulting
in less pouch material. In still another example, the first closing
seal 56 is a tack seal, and the second closing seal 58 is a high
pressure, high temperature seal. A cosmetic seal may be applied
with respect to the first and second closing seals, or the second
seal 58 may be a cosmetic seal. In a further example, if the side
edge seal 45a extends into the upper edge of the pouch, the first
closing seal 56 or second closing seal may overlap the side edge
seal 45a by a predetermined amount, as shown at 45b.
[0069] Alternatively, the pouch is filled through the spout fitment
and the cap is applied to close the pouch. The cap contains the
product in the filled pouch, to prevent leakage of the product from
the pouch. The cap may be a tamper-evident cap for a carbonated
product. For a carbonated product or other product under pressure,
the complementary arrangement of threads and grooves in the cap and
spout provides for the controlled release of pressure from the
pouch, as disclosed in commonly assigned U.S. patent application
Ser. No. 11/195,906, which is incorporated herein by reference.
[0070] The methodology advances to block 155 and the pouch 10 is
finished in a finishing operation. For example, the edges of the
pouch 10 are trimmed to achieve a predetermined shape. In another
example, the hanging aperture 44 is formed in the pouch. The
hanging aperature 44 may be formed in the overlap seal portion 45b
of the upper edge. 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 160.
[0071] In block 160 the filled pouch 10 is discharged from the
machine. A plurality of pouches may be placed in a package for
sales or shipping purposes.
[0072] 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.
[0073] 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.
[0074] Referring to FIG. 14, an example of a fill-seal machine 80
for carrying out the method described with respect to FIG. 23 is
illustrated. The fill machine illustrated is by way of example, and
other configurations may be utilized. It should be appreciated that
a particular manufacturing station may perform one or more
operations. It should also be appreciated that the order of
operations may vary. The fill-seal machine 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.
[0075] In operation, the carrier with the pouch is loaded onto the
machine 80 as shown at "1". The pouches 10 are removed from the
receptacle and placed in a transport means as shown at "2". The
transport means may be a carrier or a gripper or a combination of
the two.
[0076] 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.
[0077] 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.
[0078] 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.
[0079] If the product is naturally carbonated, such as with a
sparkling wine or the like, the pouch is preferably filled while
immersed in a nitrogen atmosphere 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 may be
immersed in a carbonator to introduce carbon dioxide into the
product. For example, carbon dioxide is introduced into cold water
or juice to provide a carbonated beverage. The product may contain
a mixture of up to four volumes of carbon dioxide. It should be
appreciated that the carbon dioxide masks any undesirable taste
from ketones and other solvents released during the sealing
process. The carbon dioxide also increases the pressure within the
product so that the walls of the pouch 10 are rigid after the top
is sealed. The product is preferably filled at a temperature
ranging from 29.degree. F. to ambient temperature. The carbonation
is advantageous as a microbiocide which can enhance the flavor or
prevent mold or contamination.
[0080] 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.
[0081] The pouch is then transferred to a sealing station and if
filled through the open edges of the pouch, 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. In
an example, the first seal may be a thermal seal. In this example,
a heat-sealing member extends through the slots in the sides of the
cup to seal the upper edge of the pouch. As previously described,
the heat sealing member may have a plasma coating. For example, a
heat-sealing member extends therethrough the slots in the sides of
the cup, to seal the edge of the pouch. 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.
[0082] Another example of a first seal 56 for a 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 58 may be
applied using a heat seal means to form a second heat seal spaced
apart a predetermined distance from the first seal 56. It should be
appreciated that the second seal 58 may be spaced slightly outboard
of the first seal 56, in order to trap some of the product between
the two seals. The second heat-sealing station is conventional and
utilizes heat or a combination of heat and pressure to form the
seal. The second seal 58 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 or
product having an alcohol content as disclosed in commonly assigned
PCT Patent Application No. PCT/US03/34396, which is incorporated
herein by reference.
[0083] If the pouch is filled through the fitment, the pouch is
closed by securing a cap to the fitment. The cap may have a
tamper-evident feature. The cap and fitment preferably have
leak-proof features as previously described for a carbonated
product.
[0084] 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 hanging aperture
44 may be formed at this time. Similarly, 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 container. For
example, grippers may be utilized to place the pouch in a box for
shipment.
[0085] If desired, the pouch may be transferred to a pasteurization
station. Pasteurization enhances the shelf life of the product. The
pouch is inserted into an enclosed retort chamber. Air is extracted
from the chamber, such as using a vacuum source. The product inside
the pouch is pasteurized. For example, a combination of steam and
water is used to heat the pouch to a predetermined temperature for
a predetermined period of time to pasteurize the product contained
within the pouch. The package is then cooled. In this example,
recirculated water surrounds the pouch to cool the pouch. In
certain instances, it may be desirable to apply steam to sterilize
the pouch 10 and to wet the inner surface of the walls to
facilitate handling.
[0086] The present invention has been described in an illustrative
manner. It is to be understood that the terminology which has been
used is intended to be in the nature of words of description rather
than of limitation.
[0087] Many modifications and variations of the present invention
are possible in light of the above teachings. Therefore, the
present invention may be practiced other than as specifically
described.
* * * * *