U.S. patent application number 12/386996 was filed with the patent office on 2009-08-27 for flexible packaging.
Invention is credited to Michael T. Romanyszyn, Alfred A. Schroeder.
Application Number | 20090211204 12/386996 |
Document ID | / |
Family ID | 29215080 |
Filed Date | 2009-08-27 |
United States Patent
Application |
20090211204 |
Kind Code |
A1 |
Schroeder; Alfred A. ; et
al. |
August 27, 2009 |
Flexible packaging
Abstract
Methods and apparatus for forming and filling a flexible package
are provided in which an evacuation device (26) and a fitment (20)
are attached to a sheet of flexible material (16). The sheet of
flexible material (16) is formed into a package that is filled and
sealed.
Inventors: |
Schroeder; Alfred A.; (San
Antonio, TX) ; Romanyszyn; Michael T.; (San Antonio,
TX) |
Correspondence
Address: |
Dennis Braswell;Braswell & Associates, P.C.
105 Soost Court
Mobile
AL
36608
US
|
Family ID: |
29215080 |
Appl. No.: |
12/386996 |
Filed: |
April 27, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10842980 |
May 11, 2004 |
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12386996 |
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10126702 |
Apr 19, 2002 |
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10842980 |
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Current U.S.
Class: |
53/456 |
Current CPC
Class: |
B65B 61/186 20130101;
B65B 9/093 20130101 |
Class at
Publication: |
53/456 |
International
Class: |
B65B 43/08 20060101
B65B043/08 |
Claims
1. A method of forming and filling a flexible package, the package
to be filled with a liquid product, comprising: partially forming
the package from a sheet of flexible material; attaching an
evacuation device to the sheet of flexible material, the evacuation
device adapted to facilitate flow of at least some of the liquid
product by effectively preventing the sheet of flexible material
from closing off flow during evacuation of the package, the
evacuation device comprising a first evacuation device end and a
terminal end, with a length between the first evacuation device end
and the terminal end, wherein the evacuation device comprises a
channel directly open to the liquid product at intermediate
locations substantially the entire length between the first
evacuation device end and the terminal end, such that liquid
product may enter the channel at the intermediate locations;
filling the partially formed package with the liquid product after
attaching the evacuation device; and after filling, sealing the
package by making a top seal.
2. The method of claim 1, wherein the evacuation device is attached
before the package is partially formed.
3. The method of claim 1, wherein the evacuation device is attached
after the package is partially formed.
4. The method of claim 1, wherein the flexible package is formed
and filled on a horizontal form, fill, and seal machine.
5. The method of claim 1, wherein the flexible package is formed
and filled on a vertical form, fill, and seal machine.
6. The method of claim 1, and further comprising attaching a
fitment to the sheet of flexible material, the fitment comprising a
passageway through which a liquid product flows during evacuation
of the package, the fitment adapted to be coupled to a pump for
evacuation of the package, and wherein filling the partially formed
package comprises filling other than through the fitment.
7. The method of claim 6, and further comprising coupling the
evacuation device and the fitment before attaching the fitment to
the sheet of flexible material.
8. The method of claim 6, and further comprising attaching the
evacuation device to the fitment.
9. The method of claim 1, wherein the evacuation device is a dip
strip.
10. The method of claim 1, wherein the flexible package comprises
two sheets of flexible material, and the top seal is made by
sealing the two sheets together.
11. A method of forming and filling a flexible package, comprising:
attaching a fitment to a sheet of flexible material, the fitment
comprising a passageway through which a liquid product flows during
evacuation of the package, the fitment adapted to be coupled to a
pump for evacuation of the package; attaching an evacuation device
to the sheet of flexible material proximate the passageway, the
evacuation device adapted to facilitate flow of at least some of
the liquid product to the passageway by effectively preventing the
sheet of flexible material from closing off flow to the passageway
during evacuation of the package, the evacuation device comprising
a first evacuation device end and a terminal end, with a length
between the first evacuation device end and the terminal end,
wherein the evacuation device comprises a channel directly open to
the liquid product at intermediate locations substantially the
entire length between the first evacuation device end and the
terminal end, such that liquid product may enter the channel at the
intermediate locations; partially forming the package from the
sheet of flexible material; filling the partially formed package
with the liquid product after attaching the fitment; and after
filling and after attaching the evacuation device, sealing the
package by making a top seal.
12. The method of claim 11, wherein the evacuation device is
attached before the package is partially formed.
13. The method of claim 11, wherein the evacuation device is
attached after the package is partially formed.
14. The method of claim 11, wherein the flexible package is formed
and filled on a horizontal form, fill, and seal machine.
15. The method of claim 11, wherein the flexible package is formed
and filled on a vertical form, fill, and seal machine.
16. The method of claim 11, and further comprising coupling the
evacuation device and the fitment before attaching the fitment to
the flexible sheet of material.
17. The method of claim 11, wherein the fitment is attached to an
inside surface of the flexible package, and is located within the
flexible package.
18. The method of claim 11, wherein the fitment penetrates the
sheet of flexible material.
19. The method of claim 11, and further comprising attaching the
evacuation device to the fitment.
20. The method of claim 11, wherein the flexible package comprises
two sheets of flexible material, and the top seal is made by
sealing the two sheets together.
Description
[0001] This application is a continuation of co-pending U.S. patent
application Ser. No. 10/842,980, filed May 11, 2004, and entitled
Flexible Packaging, which in turn is a continuation of U.S. patent
application Ser. No. 10/126,702, filed Apr. 19, 2002, now
abandoned.
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates generally to packaging, and more
particularly to flexible packaging.
BACKGROUND OF THE INVENTION
[0003] The many advantages of flexible packaging have made it the
package of choice in many applications. Two prominent fields for
flexible packaging are the beverage industry, for example for wines
or for beverage syrups, and the pharmaceutical field. Of course,
many other applications exist as well.
[0004] In general, products are filled into flexible packages and
then distributed for use by customers for their particular
application. The products are either filled into pre-made bags
through fitments, or filled into bags as the bags are being made on
form, fill, and seal machines. Often the flexible packaging is
distributed in boxes, and such systems are commonly referred to as
bag-in-box ("BIB") systems. "Bag," as used in this disclosure, is
meant to include any flexible package, including, without
limitation, bags, pouches, and stand-up packages.
[0005] Significant efforts have been made at increasing the
efficiency of form, fill, and seal machines, and of operations that
make pre-made bags. Furthermore, there have been various
developments directed at improving the evacuation efficiency of
pre-made bags.
[0006] However, attempts at improving evacuation efficiency have
often reduced efficiencies during the bag filling operation. For
example, one approach for improving evacuation efficiency involves
the use of an evacuation device known as a dip strip, which
includes a base and raised ribs that create evacuation channels.
For this device to work well, it must be coupled closely to the
fitment through which product is evacuated from the bag. However,
on pre-made bags, the proximity of the evacuation device to the
fitment (which is also the filling spout) reduces the maximum flow
rate that can be used to fill the bag, thus slowing down the speed
of the filling operation. Also, form, fill, and seal systems have
not accommodated the manufacture of bags that include evacuation
devices to improve evacuation efficiencies. Therefore, a need has
arisen for a system that allows for the efficiencies that result
from form, fill, and seal machines, along with the evacuation
efficiencies that have been allowed with pre-made bag systems.
SUMMARY OF THE INVENTION
[0007] In accordance with the teachings of the present invention,
methods and apparatus for forming and filling flexible packages are
provided which substantially eliminate or reduce problems
associated with prior art systems.
[0008] In particular, a method of forming and filling a flexible
package is provided that includes partially forming the package,
attaching an evacuation device, filling the package, and sealing
the package. The evacuation device may be attached before the
package is partially formed or after it is partially formed. The
package may be sealed by making a top seal.
[0009] In other embodiments, the following are provided, alone or
together: partially forming the package by folding a sheet of
flexible material; partially forming the package by forming side
seals; and forming the side seals on a horizontal form, fill, and
seal machine.
[0010] In still other embodiments, the following are provided,
alone or together: partially forming the package by forming a tube
from a sheet of flexible material; partially forming the package by
forming a bottom seal; and forming the bottom seal on a vertical
form, fill, and seal machine.
[0011] In another embodiment, a fitment is attached to the flexible
package. One method of attaching the fitment includes coupling the
evacuation device and the fitment, and attaching the evacuation
device comprises attaching the coupled evacuation device and
fitment. In one embodiment, the fitment is attached to an inside
surface of the flexible package, and does not penetrate the
flexible package. In another, the fitment penetrates the flexible
package. In one method, a hole is formed for receiving the fitment.
The fitment may comprise any suitable access device, and in a
particular embodiment, without limitation, is a port that includes
a valve.
[0012] In another embodiment, the fitment is attached before
attaching the evacuation device, and the evacuation device is
attached proximate the fitment. In a particular embodiment, the
evacuation device is attached to the fitment.
[0013] The evacuation device may be attached in many different ways
and places, and, for example, may be attached to an inside surface
of the flexible package, or seamed into a seal of the flexible
package. Without limitation, the evacuation device may be a dip
strip.
[0014] Another method of the present invention includes attaching a
fitment to a sheet of flexible material, attaching an evacuation
device proximate the fitment, partially forming the package from
the sheet of flexible material, filling the package, and sealing
the package. The fitment may be attached before the package is
partially formed, or after it is partially formed. Sealing the
package may comprise making a top seal.
[0015] In a particular embodiment of this method, partially forming
the package comprises folding the sheet of flexible material. Also,
partially forming the package may comprise forming side seals. The
side seals may be formed on a horizontal form, fill, and seal
machine.
[0016] In another embodiment of this method, partially forming the
package comprises forming a tube from the sheet of flexible
material. Also, partially forming the package may comprise forming
a bottom seal. The bottom seal may be formed on a vertical form,
fill, and seal machine.
[0017] In another embodiment, the evacuation device and the fitment
are coupled, and attaching the fitment and attaching the evacuation
device comprise attaching the coupled evacuation device and
fitment. In one embodiment, the fitment may be attached to an
inside surface of the flexible package, and does not penetrate the
flexible package. In another, the fitment penetrates the sheet of
flexible material. A hole may be made in the flexible material for
receiving the fitment. The fitment may comprise any suitable access
device, and in a particular embodiment, without limitation, is a
port that includes a valve.
[0018] In another embodiment, the fitment is attached before
attaching the evacuation device, and the evacuation device is
attached proximate the fitment. In a particular embodiment, the
evacuation device is attached to the fitment.
[0019] The evacuation device may be attached in many different ways
and places, and, for example, may be attached to an inside surface
of the flexible package, or seamed into a seal of the flexible
package. Without limitation, the evacuation device may be a dip
strip.
[0020] Also provided is apparatus for carrying out the methods
described herein.
[0021] An important technical advantage of the present invention is
that an evacuation device is included as part of a flexible package
on form, fill, and seal machines of any kind, including horizontal
and vertical machines. Another important technical advantage of the
present invention is that a fitment and an evacuation device may be
attached to a flexible package during a form, fill, and seal
operation, and may be attached as separate units or as a combined
or integrally formed unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Reference is made in description to the following briefly
described drawings, wherein like reference numerals refer to
corresponding elements:
[0023] FIG. 1 illustrates a particular embodiment of a horizontal
form, fill, and seal machine, and resulting bag, according to the
teachings of the present invention;
[0024] FIG. 2 illustrates a particular embodiment of a combined
evacuation device and internal fitment according to the teachings
of the present invention;
[0025] FIG. 3 illustrates another embodiment of a horizontal form,
fill, and seal machine, and resulting bag, according to the
teachings of the present invention;
[0026] FIG. 4 illustrates another embodiment of a horizontal form,
fill, and seal machine, and resulting bag, according to the
teachings of the present invention;
[0027] FIG. 5 illustrates a particular embodiment of a fitment
attaching station according to the teachings of the present
invention;
[0028] FIG. 6 illustrates a particular embodiment of an evacuation
device attaching station according to the teachings of the present
invention;
[0029] FIG. 7 illustrates a block diagram of a particular
embodiment of a method according to the teachings of the present
invention;
[0030] FIG. 8 illustrates a block diagram of another embodiment of
a method according to the teachings of the present invention;
[0031] FIG. 9 illustrates a block diagram of another embodiment of
a method according to the teachings of the present invention;
[0032] FIG. 10 illustrates a particular embodiment of a vertical
form, fill, and seal machine, and resulting bag, according to the
teachings of the present invention;
[0033] FIG. 11 illustrates a block diagram of a particular
embodiment of a method according to the teachings of the present
invention;
[0034] FIG. 12 illustrates a block diagram of another embodiment of
a method according to the teachings of the present invention;
[0035] FIG. 13 illustrates a block diagram of another embodiment of
a method according to the teachings of the present invention;
[0036] FIG. 14 illustrates a block diagram of another embodiment of
a method according to the teachings of the present invention;
and
[0037] FIG. 15 illustrates a block diagram of another embodiment of
a method according to the teachings of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] The horizontal form, fill, and seal machine 10 shown in FIG.
1 illustrates a particular embodiment of the present invention,
wherein an internal fitment is provided against which an external
fitment can be pressed, for mating with the internal fitment and
piercing the bag for evacuation of the product. Other embodiments
that do not require such fitments, but which are made with fitments
that provide a passageway through the bag wall, will be discussed
in connection with other FIGUREs.
[0039] The form, fill, and seal machine 10 of FIG. 1 is a
horizontal type machine, and creates filled bags 12. A roll 14
provides a supply of bag material 16 that is used to form the bags
of the present invention. The bag material 16 may comprise any
material suitable for flexible packaging, such as, without
limitation, single or multi-layer plastics, and other materials,
such as foils. The bag material 16 is often called a sheet or web
of material.
[0040] The plastic material 16 is rolled across a roller 18 and
then folded (for example with a collar) to prepare for seaming and
filling. Before roller 18, however, a supply of fitments 20 are
advanced along a guide 22. Also, a roll 24 of evacuation devices 26
is provided for supplying an evacuation device for each bag.
Preferably the roll 24 of evacuation devices 26 is a continuous
roll, thus allowing the evacuation devices 26 to be efficiently
manufactured as one extrusion (and cut into individual devices for
each bag). However, no such roll is needed, and other approaches
may be used, such as, without limitation, supplying separated
evacuation devices, or using rolls of evacuation devices that
include periodic features (such as thin areas for facilitating
seaming in to seams).
[0041] In the particular embodiment shown in FIG. 1, internal
fitments 20 and evacuation devices 26 are combined for being
attached to the bag material 16. In particular, a positioning pin
28 moves horizontally within guide rail and press 30 to position
each fitment 20. The evacuation devices 26 are fed into the guide
22 and heat-sealed to fitments 20 with heat sealer (weldhead) 32
pressing against the guide rail and press 30. Although heat sealing
is preferable, other ways of attaching the evacuation devices 26 to
the internal fitments 20 may be used without departing from the
intended scope of the present invention. Furthermore, they may also
be combined in a process separate from the machine, and indeed may
be formed integrally during their manufacturing.
[0042] A combined evacuation device 26 and fitment 20 are advanced
to the next station where they are attached to the bag material 16.
This station includes heat sealer 34 and press 36. The bag material
16 and a combined internal fitment 20 and evacuation device 26 are
passed between the heat sealer 34 and the press 36, and the heat
sealer 34 presses the bag material 16 and fitment 20 together
against press 36 and heat seals them together. A cutter 38 is
provided for cutting the evacuation device 26 so as to separate the
appropriate length for each bag. The cutter 38 cuts the material
against a stop, which may be part of the guide 22, or any other
suitable stop.
[0043] As can be seen in FIG. 1, the bag material 16 with attached
fitment 20 and evacuation device 26 is folded after roller 18 to
prepare for filling. The first side seal for each bag is made with
sealer 40, by pressing the two folds (bag walls) of the bag
material 16 against each other and heat-sealing them. The bag
material 16 is then advanced the length of one bag, and sealing
station 40 seals the second side seal (which is on the opposite
side from the first seal) to form a bag that is folded on the
bottom, seamed on each side, and still open at the top. At this
point, the first side seal, which had been made on sealer 40, has
been advanced to the general position 42 shown in FIG. 1.
[0044] The bag is filled through filler 46 (which may move up and
down as each bag is advanced) with the appropriate product. The bag
may be widened, to facilitate filling, with vacuum separators 47.
After filling, the bag material 16 is advanced to the next station
where top sealer 48 seals the top seam, such as with a heat-sealing
press, to complete formation of the bag. The bag is then cut at
support and cut station 44 and then handled for commercial
distribution. For example, without limitation, a conveyer may be
positioned to take the bag, after it is cut, to a station for
inserting bags into boxes, for BIB-type systems.
[0045] FIG. 2 illustrates a particular embodiment of an evacuation
device 26 combined with an internal fitment 20. In the particular
embodiment shown, the fitment 20 is welded to the evacuation device
26 at tabs 51 of the fitment 20. The particular embodiment
discussed in connection with FIG. 1 uses an internal fitment 20,
which, in the illustrated embodiment, has a section 49 across which
the bag material 16 passes and onto which the bag material 16 is
sealed. In use, a user attaches an external fitment that couples to
the internal fitment 20 through the bag material 16 and pierces the
bag material 16 to allow access to the product within the bag 12.
The evacuation device 26, in a particular embodiment, is a strip of
material referred to as a dip strip, which includes a base 50 and a
plurality of ribs 52. The ribs 52 are relatively rigid, and provide
evacuation channels 54 between them, which allow product to flow to
the fitment 20 and out of the bag 12. Without the evacuation device
26, the bag material 16 has a tendency to seal against the fitment
20 during evacuation, thus blocking evacuation of the bag 12.
[0046] Although the particular evacuation device 26 shown in FIG. 2
is a dip strip-type evacuation device, any other evacuation device
may be used (with any embodiment or FIGURE described herein)
without departing from the intended scope of the present invention.
Evacuation devices include any device intended to improve
evacuation efficiencies. For example, without limitation, devices
such as meshes, pillowed plastics, and other devices may be used as
well. Also, the evacuation device may be an integral part of a
fitment (such as without limitation, raised ribs on the base of the
fitment). Thus, attaching evacuation devices includes, without
limitation, attaching fitments that have features for improving
evacuation efficiencies (even where no separate evacuation device
is used) or attaching evacuation devices that may be joined to,
combined with, or separate from fitments
[0047] FIG. 3 illustrates another embodiment of a horizontal form,
fill, and seal machine according to the teachings of the present
invention. Form, fill, and seal machine 60 is similar to that of
FIG. 1, in that internal fitments 20 and evacuation devices 26 are
combined before being attached to the bag wall material 16.
However, in the embodiment shown in FIG. 3, the internal fitments
20 and evacuation devices 26 are attached to the bag wall 16 after
it has been folded after roll 18. As shown, the fitments 20 and
evacuation devices 26 are combined in a guide 22 with heat sealer
32 sealing them together against guide rail and press 30, as
discussed above in connection with FIG. 1. However, in the
embodiment of FIG. 3, the heat sealing to the bag wall 16 occurs
with heat sealer 62 sealing the bag wall 16 to the internal fitment
20 against press 63. A blade 66 cuts the evacuation devices 26
against the guide 22 or other stop.
[0048] Heat seal station 68 operates to form the side seals of the
bag formed with the embodiment shown in FIG. 3. After the first
side seal of a bag is formed at heat seal station 68, the bag
material 16 is advanced so that heat sealing station 68 then forms
the second side seal, creating a bag that is formed except that it
has an open top. Then, product is filled into the bag through
filler 70, as discussed above in connection with FIG. 1. The open
top of the bag material may be widened for filling with vacuum
separators 71. The filled bag is then advanced for top sealing,
cutting, and handling as discussed above in the connection with
FIG. 1.
[0049] FIG. 4 illustrates another embodiment of the present
invention in which a horizontal form, fill, and seal machine 80 is
used to make and fill bags that include fitments that pass through
the bag wall so as to eliminate the need for any piercing or other
coupling to an internal fitment at the time of use. In particular,
holes for the fitments are made in the bag wall by a hole punch
station 82. An exemplary hole 83 is shown. Preferably a system is
used that collects the plugs that are made when the hole is
punched, so as to keep the plugs out of the bags. In particular, a
vacuum system or other suitable system may be used for this
purpose. The bag material 16 is folded after roller 18 and advanced
to a fitment attachment station 84. Hole punch station 82 may be
positioned before or after the bag folding. A particular embodiment
of fitment attachment station 84 is shown more particularly in FIG.
5. As shown in FIG. 5, a fitment 86 (fitments 86 are supplied by a
guide 87) is inserted through the bag hole formed at hole punch
station 82. The fitment 86 includes a flange 88 (or any other
suitable part) that extends outward from the base of the fitment.
The flange 88 is heat sealed to the bag material 16 by heat sealer
90 pressing against stop 92.
[0050] Next, the web of bag material 16 is advanced to evacuation
device attachment station 100. Here, the evacuation devices 26 are
advanced along guide 112 between the folds of bag material 16 and
heat-sealed in place. In a particular embodiment, each evacuation
device 26 is heat sealed to a fitment 86, as is shown in FIG. 6.
The evacuation device 26 is advanced between heat sealer 102 and
stop 104. Stop 104 is shaped so as to surround the exterior portion
of fitment 86. Also shown in FIG. 6 is cutter 106. Cutter 106 is
used to cut the evacuation device material 26 for each bag (and may
cut from the front or the back side). The blade 108 of cutter 106
cuts against guide mechanism 112 or other stop. Vacuum separators,
such as those discussed above, or guides may be used to widen the
space between the bag material folds to facilitate the various
stations, such as stations 84 and 100.
[0051] It should be understood that attaching the evacuation device
26 to the fitment 86 is exemplary only, and the evacuation device
26 may also be attached, without limitation, to the bag material 16
itself, in one or more places, such as by tacking with heat
sealing, and may be attached to the bag wall 16 alone or in
combination with attaching it to the fitment 86, or may be seamed
into the top seam (with or without other attachments). Furthermore,
the cutting mechanism shown in FIG. 6 is exemplary only, and any
cutting mechanism (or pre-made individual evacuation devices for
each bag) may be used without departing from the intended scope of
the present invention. After the fitment 86 and evacuation device
26 are attached, the bag is advanced to sealing station 68 and then
further filled, cut, and handled as discussed above in connection
with FIG. 3 and the other descriptions.
[0052] It should also be understood that the particular approach
shown for attaching the fitment 86 is exemplary only, and other
approaches may be used without departing from the intended scope of
the present invention. In particular, the following US patents
provide examples of particular ways of attaching a fitment to a web
of film (although other approaches may also be used), and are
herein incorporated by reference in their entirety; U.S. Pat. No.
5,203,819 entitled Apparatus For Attaching A Fitment To A Web of
Film; U.S. Pat. No. 4,779,397, entitled Apparatus and Method for
Attaching A Fitment to a Web of Film; U.S. Pat. No. 4,512,136,
entitled Fitment Attachment Methods in Horizontal Form/Fill/Seal
Machines; U.S. Pat. No. 4,718,215, entitled Apparatus and Method
for Attaching Fitments to Flexible Containers; U.S. Pat. No.
4,246,062, entitled Apparatus for Attaching a Fitment to a Pouch;
and U.S. Pat. No. 4,695,337, entitled Apparatus and Method for
Attaching a Fitment to a Web of Film. These examples apply both to
the horizontal form, fill, and seal apparatus discussed herein, and
to the vertical form, fill, and seal apparatus to be discussed
below.
[0053] Furthermore, the particular fitment 86 shown in FIG. 3 is
exemplary only, and other fitments may be included as well. Indeed,
throughout this description, the term fitment is used to describe
any device that allows or facilitates the transfer of product from
inside a flexible bag to the outside of the flexible bag. For
example, fitments include spouts, valves, ports, bases such as that
described in connection with FIG. 1 that allow an external piercing
mechanisms to couple to them to allow access, and single or
multiple-piece parts, among others. A particular example of a
fitment that includes a valve, and which is suitable for use in the
beverage syrup industry, is described in U.S. Pat. No. 5,477,883,
entitled Self-Sealing Bag Valve, which is herein incorporated by
reference in its entirety. However, with the present invention,
such a fitment and valve may be made (although need not be) without
the need for the valve to be removable (which is required where the
a bag is filled through the fitment), because the bag is not filled
through the fitment in the present invention. In the context of the
present invention, if a fitment is used that includes a removable
valve or other removable part (such as, without limitation, a cap),
the removable part may be in place when the fitment is attached to
the bag, or another step may be added to couple the removable part
to the attached fitment.
[0054] Also, with the horizontal apparatus discussed above, it is
preferred that the bag walls be formed by folding one sheet of bag
material. However, two sheets may be brought together and sealed
without departing from the intended scope of the present
invention.
[0055] As discussed above in connection with fitment 20, the
evacuation device 26 significantly increases evacuation efficiency
with fitment 86 (or any fitment) by providing evacuation channels
for the product to flow through, and preventing the bag walls from
closing flow through the fitment during evacuation.
[0056] It should also be understood that pass-through fitments,
such as though discussed in connection with FIG. 4, may be combined
with evacuation devices before being attached to the bag material
(for example, without limitation, similar to the approach shown in
FIG. 3). In such case, a station such as station 100 need not be
used. Also, internal fitments, such as fitments 20 discussed above,
may be attached separately from the evacuation devices.
[0057] FIG. 7 illustrates a block diagram of a particular
embodiment of a method according to the teachings of the present
invention. As shown in FIG. 7, at block 120 an evacuation device is
attached to bag material, directly or indirectly (for example,
without limitation, to a fitment, to the bag, seamed into side or
top seams, or any combination thereof). It may be attached before
or after the bag material is folded or a bag is otherwise partially
formed. At block 122, side seals are formed. At block 124, product
is filled through the open top of the partially formed bag. Then,
at block 126, the top of the bag is sealed, thereby completing the
filling portion of the bag. The bag is then ready to be cut loose
handled for distribution. In most cases, a fitment will also be
used as part of the present invention; but, without limitation, one
broad sense of the present invention includes merely attaching an
evacuation device in connection with forming and filling a flexible
package, whether or not a fitment is also used.
[0058] FIG. 8 illustrates another embodiment of the present
invention, in which a fitment is attached to a web of bag material
at block 130. At block 132, an evacuation device is attached. The
attachment can occur, without limitation, to the bag material
itself, to the fitment, to both, into seams, or any combination of
these. At block 134, side seals are formed. Then, at block 136,
product is filled into the partially formed bag. At block 138, the
top of the bag is sealed, and the bag is then ready to be cut and
handled for distribution.
[0059] Although the present invention encompasses attaching the
evacuation device anywhere within the bag, it is preferred that the
evacuation device be positioned in such a way that it is in
relatively close proximity to the fitment through which product
will be accessed. This close proximity helps insure that the web of
bag material will not seal off the fitment through which product is
accessed during evacuation of the bag.
[0060] FIG. 9 illustrates another embodiment of a method according
to the teachings of the present invention. As shown in FIG. 9, a
fitment and evacuation device are combined at block 140. At block
142, the combined fitment and evacuation device are attached to a
web of bag material. The attachment may occur either before or
after the bag material is folded or the bag is otherwise partially
formed. At step 144, side seals are formed, and at block 146
product is filled in to the open top of the partially formed bag.
At step 148, the open top is sealed. The bag is then ready for
cutting loose and distribution.
[0061] FIG. 10 illustrates another embodiment of the present
invention in which fitments and evacuation devices are attached to
a bag on a vertical form, fill, and seal machine. As shown in FIG.
10, a roll 200 of bag material 202 is provided to supply a vertical
form, fill, and seal machine. The bag material 202 is formed (for
example with a collar and guide) into a generally tubular shape
(tubular is meant to indicate a shape is formed that has an open
top and open bottom, and need not have a round or oval
cross-sectional shape). Indeed, any cross-sectional shape may be
used. To seal the tubular shape, heat sealer 204 is used to seal
the bag material 202 near or at its ends 206 and 208 after they are
overlapped, thus creating a partially formed bag that is open at
the top and the bottom. A filler 210 is used to fill product into
the bags. The product is filled through filler 210 after a bottom
seal of a bag is formed by heat sealer 212. Heat sealer 212 also
serves to create a top seal of an already filled bag. Roller guides
213 support and shape the bags during filling and top sealing, and
allow most air to be expelled from the bag before sealing. (Guides
such as these may also be used on the horizontal embodiments in
connection with top sealing.) The bags are cut free for further
distribution by a cutter 215. A supply of fitments 214 is provided
on guide 216 into the tubular structure, and evacuation devices 220
are supplied from a roll 218.
[0062] As discussed above in connection with the horizontal form,
fill, and seal machines, the fitments 214 and evacuation devices
220 may be combined and attached to the bag material 202, or
separately attached, and may be attached before or after the bag
material is formed into a "tube" and before or after any seals are
made. Also, any kind of fitment may be used, including, without
limitation, internal fitments such as fitments 20, or pass-through
fitments such as fitments 86 discussed above. The particular
devices for accomplishing this attachment are similar to those
discussed above in connection with the other embodiments (such as
the devices discussed above in connection with FIGS. 1-6), and thus
may be used with the vertical machine embodiment. Without
limitation, the particular example shown in FIG. 10 shows the
pre-combining approach such as that discussed in FIG. 1, with heat
sealer 32 combining the evacuation devices 220 with fitments 214.
Cutter 38 cuts the evacuation device, and heat sealer 34 attaches
the combination to the bag material 206 against a stop. Completed
bags 224 are shown in FIG. 10.
[0063] FIGS. 11-13 illustrate particular embodiments of methods
according to the teaching of the present invention that are most
suited for use with vertical form, fill, and seal processes. As
shown in FIG. 11 a "tube" of bag material is formed at block 230.
At block 232, an evacuation device is attached (directly or
indirectly) to the bag material. At block 234, a bottom seal is
created, thus forming a bag with a bottom seal, a tube-like
structure, and an open top. At block 236, product is filled to this
partially formed bag, and at block 238, the top of the bag is
sealed. In a particular embodiment, the top sealing occurs after
advancing the partially filled bag so that the top seal of the
filled bag is formed at the same time and by the same mechanism as
the bottom seal of the next-to-be filled bag. Also, step 238, the
bag is cut free for distribution. In most cases, a fitment will
also be used as part of the present invention; but, without
limitation, one broad sense of the present invention includes
merely attaching an evacuation device in connection with forming
and filling a flexible package, whether or not a fitment is also
used.
[0064] FIG. 12 illustrates another embodiment in which a "tube"
structure is formed from bag material to make a partially formed
bag at block 240. At block 242, a fitment is attached to the bag
material. At block 244, an evacuation device is attached to the bag
material (directly or indirectly), for example by attaching it to
the fitment, or to the bag material, or to both. At block 246, a
bottom seal is made to create a partially formed bag ready for
filling. At block 248, product is filled into the partially formed
bag, which is then advanced for top sealing at block 250. As
discussed above, the top-sealing station may be the same as the
bottom-sealing station used at block 246, although this is not
necessary. After sealing the top, the bag is then separated for
distribution.
[0065] FIG. 13 illustrates another embodiment of the present
invention in which a tube of bag material is formed at block 260.
At block 262, a combined fitment and evacuation device is attached
to the bag material. The fitment and evacuation device have been
previously combined (by the same machine or a different one than is
used for forming and filling bags) in this embodiment. At block
264, a bottom seal is made to create a partially formed bag ready
for filling, which filling occurs at block 266. After filling at
block 266, a top seal is created at block 268 and the bag is then
cut and is ready for distribution.
[0066] FIG. 14 illustrates another embodiment of the present
invention in which an evacuation device is seamed into the bottom
seam at block 270. Then, at block 272 the partially formed bag is
filled and then advanced so that the top seam can be made at block
274. Also at block 274, the evacuation device is seamed into the
top seam and cut. Thus, in this particular embodiment, no separate
mechanism is needed for sealing the evacuation device to the
fitment or to the bag material, although such sealing may be done
in combination with this method, if desired. Furthermore, as
discussed above, it is preferable that the evacuation device be in
close proximity to the fitment to provide higher evacuation
efficiencies. Also, it should be recognized that, as discussed
above, the top and bottom seaming may be accomplished on the same
station with the same physical devices, and thus the bottom sealing
of one bag is performed with the top sealing of another bag, and
the cutting of the evacuation device. However, in all embodiments,
these tasks may be performed separately or together. Also, the
method of FIG. 14 may be used on a horizontal system, wherein the
evacuation device is seamed into one or both side seals, or into
the top seal.
[0067] FIG. 15 illustrates another method according to the
teachings of the present invention in which an evacuation device is
inserted into a partially formed bag at block 280. At block 282,
the evacuation device is attached in some way, directly or
indirectly, to the partially formed bag. At block 284, the
partially formed bag is filled with product and then sealed at
block 286. The sealed bag is ready to be cut loose for
distribution.
[0068] Throughout the description of the methods of the present
invention, it should be understood that, where appropriate, the
order of the process may be changed without departing form the
intended scope of the present invention. For example, in the
vertical embodiments, the fitments and evacuation devices may be
attached to the bag material before or after the "tube" structure
is formed, and before or after any seals (such as bottom seals) are
made. Similarly, for the horizontal embodiments, such attaching may
occur before or after folding (or the like), and before or after
any seals (such as side seals) are made. Also, it should be
understood that any fitment type can be used with each embodiment,
including, without limitation, internal type fitments or
pass-through type fitments.
[0069] The particular descriptions provided are illustrative
examples, and features and advantages of each example may be
interchanged with, or added to the features and advantages in the
other embodiments and examples herein. And, in general, although
the present invention has been described in detail, it should be
understood that various changes, alterations, substitutions,
additions and modifications can be made without departing from the
intended scope of the invention, as defined in the following
claims.
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