U.S. patent application number 12/511729 was filed with the patent office on 2011-02-03 for multi-layer product with sealing areas of varying temperature.
Invention is credited to Robert J. Mileti.
Application Number | 20110027507 12/511729 |
Document ID | / |
Family ID | 42813308 |
Filed Date | 2011-02-03 |
United States Patent
Application |
20110027507 |
Kind Code |
A1 |
Mileti; Robert J. |
February 3, 2011 |
Multi-Layer Product With Sealing Areas Of Varying Temperature
Abstract
An article of manufacture that has at least three layers of heat
sealable material. There is at least one first heat seal between at
least two of the layers in a first area effected at a first
temperature. There is also at least one second heat seal between at
least two more layers, where at least one of these two layers is
distinct from the at least two layers joined by the first heat
seal, in a second area effected at a second temperature, where the
second temperature is different than the first temperature, thereby
allowing for heat sealing of discrete areas of the article in
discrete steps.
Inventors: |
Mileti; Robert J.;
(Torrington, CT) |
Correspondence
Address: |
ST. ONGE STEWARD JOHNSTON & REENS, LLC
986 BEDFORD STREET
STAMFORD
CT
06905-5619
US
|
Family ID: |
42813308 |
Appl. No.: |
12/511729 |
Filed: |
July 29, 2009 |
Current U.S.
Class: |
428/35.2 ;
156/253; 156/290; 156/60; 428/174 |
Current CPC
Class: |
B29C 65/5057 20130101;
B29C 66/919 20130101; B31B 2155/00 20170801; B29C 66/723 20130101;
B29C 66/71 20130101; B29C 66/73116 20130101; B29C 66/3452 20130101;
B29C 66/71 20130101; B31B 70/00 20170801; B29C 66/43 20130101; B29C
2793/0045 20130101; B29C 66/1122 20130101; B29C 65/48 20130101;
B29C 66/004 20130101; B29C 66/71 20130101; Y10T 428/24628 20150115;
B29C 66/91413 20130101; Y10T 428/1334 20150115; B29K 2023/0633
20130101; B29C 65/74 20130101; B29C 65/5021 20130101; Y10T 156/10
20150115; B29C 66/3472 20130101; B29C 66/438 20130101; B31B 2160/10
20170801; B29C 65/4815 20130101; B29C 65/02 20130101; B29L
2031/7128 20130101; B29K 2023/065 20130101; Y10T 156/1057 20150115;
B29C 66/8511 20130101; B31B 70/64 20170801; B31B 2155/002
20170801 |
Class at
Publication: |
428/35.2 ;
428/174; 156/60; 156/290; 156/253 |
International
Class: |
B32B 1/00 20060101
B32B001/00; B32B 37/00 20060101 B32B037/00; B32B 37/30 20060101
B32B037/30; B32B 38/04 20060101 B32B038/04 |
Claims
1. An article of manufacture comprising: at least three layers of
heat sealable material; at least one first heat seal between at
least two of said at least three layers in a first area effected at
a first temperature; and at least one second heat seal between at
least two of said at least three layers, wherein at least one of
the at least two layers joined by said second heat seal is distinct
from the at least two said layers joined by said first heat seal,
in a second area effected at a second temperature, wherein the
second temperature is different than said first temperature,
thereby allowing for heat sealing of discrete areas of the article
in discrete steps.
2. The article of manufacture according to claim 1 wherein the at
least three layers of heat sealable material comprise at least one
laminate sheet, said sheet comprising a first face sealable at the
first temperature and a second face sealable at the second
temperature.
3. The article of manufacture according to claim 1 wherein said
article is a flexible ported pouch, and wherein said at least three
layers of heat sealable material comprise two pouch layers with
said first heat seal there between and two port layers with said
second heat seal there between.
4. The article of manufacture according to claim 1 wherein said
article is a dual layer baffle system, and wherein said at least
three layers of heat sealable material comprise two exterior layers
connected to a plurality of baffles by a plurality of said first
heat seals and a plurality of two baffle layers with said second
heat seal there between.
5. A method for forming an article of manufacture, the method
comprising the steps of: providing at least three layers of heat
sealable material; heating at least one of said at least three
layers and at least one opposing layer of said at least three
layers to a first temperature in a first area to effect at least
one first heat seal; and heating at least one of said at least
three layers and at least one opposing layer of said at least three
layers to a second temperature, wherein the second temperature is
different from said first temperature, in a second area to effect
at least one second heat seal, thereby allowing for heat sealing of
discrete areas of the article in discrete steps.
6. The method for forming an article of manufacture according to
claim 5 wherein the at least three layers of heat sealable material
comprise at least one laminate sheet, said sheet comprising a first
face sealable at the first temperature and a second face sealable
at the second temperature.
7. A flexible ported pouch having an interior, said pouch
comprising: a first pouch sheet and a second pouch sheet formed by
a first heat seal at a first temperature around a periphery of said
first and second pouch sheets, said first heat seal having at least
one gap having an opening spaced from said first heat seal for
providing a channel between said first pouch sheet and said second
pouch sheet; and a port interposed between said first pouch sheet
and said second pouch sheet, and in communication with said
interior of said pouch, said port comprising a first port sheet and
a second port sheet, and formed by a second and third heat seal
along longitudinal edges of said first and second port sheets, at a
second temperature, wherein the second temperature is higher than
said first temperature, and wherein said first and second port
sheets are further heat sealed to said pouch where said first and
second port sheets intersect with said periphery of said first and
second pouch sheets at said first temperature.
8. The flexible ported pouch according to claim 7 wherein at least
one of the first and second port sheets is a laminate comprising a
first face sealable at the first temperature and a second face
sealable at the second temperature wherein said first face forms an
exterior face of said port.
9. The flexible ported pouch according to claim 7 wherein the first
and second pouch sheets comprise a single pouch sheet folded about
an axis to create a folded pouch edge, and at least two open pouch
edges.
10. The flexible ported pouch according to claim 9 wherein the
first heat seal around said periphery comprises a first heat seal
along said at least two open pouch edges.
11. The flexible ported pouch according to claim 7 wherein the
first and second port sheets comprise a single port sheet folded
about an axis to create a folded longitudinal port edge and an open
longitudinal port edge.
12. The flexible ported pouch according to claim 11 wherein the
second and third heat seals comprise a single heat seal along said
open longitudinal port edge.
13. The flexible ported pouch according to claim 11 wherein the
single port sheet comprises a laminate comprising a first face
sealable at the first temperature and a second face sealable at the
second temperature wherein said first face forms an exterior face
of said port.
14. A method of manufacturing a flexible ported pouch comprising
the steps of: providing a first and second port sheet of heat
sealable material in parallel; heating said first port sheet and
said second port sheet along the longitudinal edges of said first
and second port sheets to a first temperature to effect a first and
second heat seal forming a port with an exterior and an interior;
providing a first and second pouch sheet of heat sealable material
in parallel; introducing said port by interposition between said
first and second pouch sheets; and heating a periphery of said
first pouch sheet, said second pouch sheet and said exterior of
said port where said exterior of said port intersects with said
periphery of said first and second pouch sheets to a second
temperature, wherein said second temperature is lower than said
first temperature, to effect a third heat seal.
15. The method of manufacturing a flexible ported pouch according
to claim 14 wherein the first and second port sheets comprise a
single port sheet of heat sealable material folded about an axis to
create a folded longitudinal port edge and an open longitudinal
port edge.
16. The method of manufacturing a flexible ported pouch according
to claim 14 wherein the first and second pouch sheets comprise a
single pouch sheet of heat sealable material folded about an axis
to create a folded pouch edge, and at least two open pouch
edges.
17. A dual layer film baffle system comprising: a first and second
sheet of heat sealable material; and a plurality of baffle elements
interposed between said first and second sheets, said baffle
elements comprising a third sheet of heat sealable material heat
sealed at said first temperature along one edge of said third sheet
and latitudinally across said first sheet and a fourth sheet of
heat sealable material heat sealed at said first temperature along
one edge of said fourth sheet and latitudinally across said second
sheet and further heat sealed to said third sheet at a second
temperature wherein said second temperature is higher than said
first temperature, along a common edge of said third sheet and said
fourth sheet.
18. The dual layer film baffle system according to claim 17 wherein
the first and second sheets of heat sealable material are low
temperature heat sealing material and the third and fourth sheets
of heat sealable material are laminates comprising a first face of
high temperature sealing material and a second face of low
temperature sealing material.
19. The method of manufacturing a dual layer baffle system
comprising the steps of: providing a first and second sheet of heat
sealable material in parallel; heating said first sheet and said
second sheet at a first temperature latitudinally across said first
and second sheets at a longitudinal interval to effect a plurality
of first heat seals; perforating said first sheet and said second
sheet latitudinally across said first and second sheets at said
longitudinal interval effecting a plurality of perforated lines;
introducing a third sheet of heat sealable material to the exterior
of said first sheet; introducing a fourth sheet of heat sealable
material to the exterior of said second sheet; heating said third
sheet, said first sheet, said fourth sheet and said second sheet to
a second temperature, wherein said second temperature is lower than
said first temperature, latitudinally across said first, second,
third and fourth sheets at said longitudinal interval, effecting a
plurality of second heat seals between said fourth sheet and said
first sheet and a plurality of third heat seals between said third
sheet and said second sheet; and spreading said fourth sheet away
from said third sheet thereby separating said first and second
sheet along said perforated lines to effect baffles between said
fourth sheet and said third sheet.
Description
FIELD OF THE INVENTION
[0001] The subject invention relates to products formed of multiple
layers of heat sealable materials. More particularly, the subject
invention relates to products formed of multiple layers of heat
sealable materials that are sealable at different temperatures in
discrete areas of the product.
BACKGROUND OF THE INVENTION
[0002] There are numerous products formed using heat sealable
materials, including pouches and other containers. They are
manufactured by heat sealing together different layers of the
materials in multiple locations to achieve the various sizes and
shapes desired. U.S. Pat. Nos. 5,536,542 and 5,484,375 generally
disclose articles created by heat sealing polymeric layers
together.
[0003] It is often desirable to heat seal a multi-layer product in
an area at a given temperature while not affecting one or more of
the layers for design or functional reasons. Currently, this is
achieved by introducing barrier layers such as paper, treating the
layer that is to be protected with a lubricant or paint, or using a
mechanical process to prevent a heat seal from occurring between
certain layers in that area. This inevitably leads to additional
multi-step processes which add time and cost to the manufacturing
process. It would be advantageous to effect heat seals between
layers in some areas at one temperature and in other areas at a
different temperature without the need for additional intermediary
steps.
[0004] U.S. Pat. No. 6,996,951 discloses a flexible
multi-compartment container with peelable seals and a method for
making such a container. In one specific embodiment, the container
includes multiple layers, with an outer layer having a higher
melting temperature than an inner seal layer. U.S. Pat. No.
4,147,827 discloses a method for the production of heat sealable
co-extruded films having a high melting point core layer coated on
at least one side with a lower melting point skin layer.
[0005] Thus, while the above references describe articles created
by sealing together multiple layers of material, some of which may
have different melting temperatures, none of them discloses,
teaches or suggests a product formed of multiple layers that are
heat sealed together wherein, in some areas, the materials forming
the product are heat sealable at a lower temperature, and in other
areas, the materials forming the product are heat sealable at a
higher temperature, thereby allowing for heat sealing of discrete
areas of the product in discrete steps.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention to
provide an improved process for producing articles formed of
multiple layers of heat sealable material, which accommodates the
heat sealing of discrete areas of the product in discrete
steps.
[0007] It is a further object of the present invention to provide
such an improved process which eliminates the need for intermediary
steps within the process to impede heat sealing between layers in
certain areas, where heat seals are not desired, to make the
process more efficient and cost effective.
[0008] The subject invention results from the realization, in part,
that a more time and cost effective process for producing articles
formed of multiple layers of heat sealable material can be achieved
by providing a process wherein certain layers of the product are
heat sealable at a lower temperature, and in other areas, certain
layers of the product are heat sealable at a higher
temperature.
[0009] The subject invention, however, in other embodiments, need
not achieve all these objectives and the claims hereof should not
be limited to structures or methods capable of achieving these
objectives.
[0010] The subject invention features an article of manufacture
comprising at least three layers of heat sealable material. There
is at least one first heat seal between at least two of the layers
in a first area and effected at a first temperature. Also, there is
least one second heat seal between at least two of the layers,
wherein at least one these two layers is distinct from the two
layers joined by the first heat seal. This second heat seal is in a
second area and is effected at a second temperature that is
different than the first temperature, thereby allowing for heat
sealing of discrete areas of the article in discrete steps.
[0011] In one example, the at least three layers of heat sealable
material comprise at least one laminate sheet. This sheet comprises
a first face of material which is sealable at the first temperature
and a second face of material that is sealable at the second
temperature.
[0012] In another example, the article of manufacture is a flexible
ported pouch. Here, the least three layers of heat sealable
material comprise two pouch layers with the first heat seal
therebetween and two port layers with the second heat seal
therebetween.
[0013] In still another example, the article of manufacture is a
dual layer baffle system. In this embodiment, the at least three
layers of heat sealable material comprise two exterior layers
connected to a plurality of baffles by a plurality of first heat
seals, and a plurality of two baffle layers with the second heat
seal there between.
[0014] The subject invention also features a method for forming an
article of manufacture. The method comprises the steps of providing
at least three layers of heat sealable material. At least one layer
of the at least three layers and at least one opposing layer of the
at least three layers are heated to a first temperature in a first
area to effect at least one first heat seal. Then, at least one
layer of the at least three layers and at least one opposing layer
of the at least three layers are heated to a second temperature,
wherein the second temperature is different from the first
temperature. This forms at least one second heat seal in a second
area, thereby allowing for heat sealing of discrete areas of the
article in discrete steps.
[0015] In one example of this process, the at least three layers of
heat sealable material comprise at least one laminate sheet. This
sheet comprises a first face of material sealable at the first
temperature and a second face of material sealable at the second
temperature.
[0016] The subject invention also features a flexible ported pouch
with an interior. In an exemplary embodiment, the pouch comprises a
first pouch sheet and a second pouch sheet and is formed by a first
heat seal at a first temperature around a periphery of the first
and second pouch sheets. This first heat seal has at least one gap
having an opening spaced from the first heat seal to provide a
channel between the first pouch sheet and the second pouch sheet.
There is a port that is interposed between the first pouch sheet
and the second pouch sheet, and is in communication with the
interior of the pouch. This port comprises a first port sheet and a
second port sheet, and is formed by a second and third heat seal
along the longitudinal edges of the first and second port sheets at
a second temperature wherein the second temperature is higher than
the first temperature. The first and second port sheets are further
heat sealed to the pouch where the first and second port sheets
intersect with the periphery of the first and second pouch sheets
at the first temperature. The difference in sealing temperatures
allows the port to be sealed to the pouch without the interior of
port also being sealed.
[0017] Also, in the exemplary embodiment of the flexible ported
pouch, the first and second port sheets are laminates comprising a
first face sealable at the first temperature and a second face
sealable at the second temperature. The first face forms the
exterior of the port. The first face is sealable at a lower
temperature so this allows the port to be sealed to the pouch at
the point of intersection at the low temperature while leaving the
interior of the port unsealed at this intersection.
[0018] In other aspects of the present invention, the flexible
pouch configuration can also be achieved by substituting the first
and second pouch sheets with a single pouch sheet, folding it over
on an axis, and effecting the first heat seal at the first
temperature around the open pouch edges that are formed. Similarly,
the flexible port configuration can be achieved by substituting the
first and second port sheets with a single port sheet folded about
an axis and replacing the second and third heat seals with a single
heat seal at the second temperature along the open longitudinal
edge. The single sheet port configuration can also feature a single
port sheet comprising a laminate. This laminate comprises a first
face sealable at the first temperature and a second face sealable
at the second temperature with the first face forming the exterior
of the port.
[0019] The subject invention further features a method of
manufacturing a flexible ported pouch. The method comprises the
steps of providing a first and second port sheet of heat sealable
material in parallel. The first and second port sheets are then
heated along their longitudinal edges to a first temperature to
effect a first and second heat seal to form a port with an exterior
and an interior. First and second pouch sheets of heat sealable
material are then provided in parallel. The port is introduced by
interposition between the first and second pouch sheets. Finally, a
periphery of the first pouch sheet, the second pouch sheet and the
exterior of the port, where the exterior of the port intersects
with the periphery of the first and second pouch sheets, is heated
to a second temperature. The second temperature is lower than the
first temperature and effects a third heat seal without sealing the
interior of the port at the intersection of the periphery of the
pouch.
[0020] The subject method can also be executed by substituting the
first and second port sheets with a single port sheet and folding
it upon an axis. The open longitudinal edge can then be heated to
the first temperature to effect a first heat seal to replace the
first and second heat seals of the exemplary method. Similarly, the
first and second pouch sheets can be replaced by a single pouch
sheet folded upon an axis and sealed along the open edges at the
second temperature.
[0021] The subject invention also includes a dual layer film baffle
system. The exemplary embodiment of the baffle system comprises a
first and second sheet of heat sealable material. There is then a
plurality of baffle elements interposed between the first and
second sheets. These baffle elements comprise a third sheet of heat
sealable material heat sealed at a first temperature along one edge
of the third sheet and latitudinally across the first sheet. A
fourth sheet of heat sealable material is heat sealed at the first
temperature along one edge of the fourth sheet and latitudinally
across the second sheet. The third and fourth sheets are further
heat sealed together along their common edge at a second
temperature wherein the second temperature is higher than the first
temperature.
[0022] In the exemplary embodiment of the baffle system, the first
and second sheets of heat sealable material are low temperature
heat sealing material and the third and fourth sheets of heat
sealable material are laminates comprising a first face of high
temperature sealing material and a second face of low temperature
sealing material.
[0023] The subject invention also features a method of
manufacturing a dual layer baffle system. The method comprises the
steps of providing a first and second sheet of heat sealable
material in parallel. The sheets are then heated to a first
temperature latitudinally across the first and second sheets at a
longitudinal interval to effect a plurality of first heat seals.
The first and second sheets are then perforated latitudinally
across the sheets at the longitudinal interval effecting a
plurality of perforated lines. A third sheet of heat sealable
material is then introduced to the exterior of the first sheet. A
fourth sheet of heat sealable material is then introduced to the
exterior of the second sheet. Then, the third sheet, the first
sheet, the fourth sheet and the second sheet are heated to a second
temperature, wherein the second temperature is lower than the first
temperature, latitudinally across the sheets at the longitudinal
interval, effecting a plurality of second heat seals between the
fourth sheet and the first sheet and a plurality of third heat
seals between the third sheet and the second sheet. Finally, the
fourth sheet and third sheet are spread apart, thereby separating
the first and second sheet along the perforated lines to effect
baffles between the fourth sheet and the third sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Other objects, features and advantages will occur to those
skilled in the art from the following description of an exemplary
embodiment and the accompanying drawings, in which:
[0025] FIG. 1 shows a schematic cross sectional view of an article
of manufacture consisting of multiple layers of heat sealable
material and multiple heat seals;
[0026] FIG. 2 shows a perspective view of a portion of an assembled
flexible ported pouch employing the multiple layers and multiple
heat seals shown in FIG. 1;
[0027] FIG. 3 shows a greatly enlarged schematic cross sectional
view of the port opening of an assembled flexible ported pouch of
FIG. 2;
[0028] FIG. 4 shows a greatly enlarged schematic cross sectional
view of the port opening of the exemplary embodiment of an
assembled flexible ported pouch of FIG. 2 wherein the port sheets
are laminates;
[0029] FIG. 5 shows a two dimensional side view of a dual layer
film baffle system manufacturing process schematic featuring the
multiple layers of heat sealable material and multiple heat seals
shown in FIG. 1;
[0030] FIG. 6 shows a greatly enlarged schematic two dimensional
view of the baffle sheets from the dual layer film baffle system
schematic of FIG. 5 as laminates;
[0031] FIG. 7 shows a two dimensional overhead view of the dual
layer film baffle system manufacturing process schematic of FIG.
5;
[0032] FIG. 8 shows a greatly enlarged schematic two dimensional
view of the dual layer film baffle system schematic of FIG. 5 as
the exterior sheets are being spread apart; and
[0033] FIG. 9 shows an enlarged perspective view of a finished dual
layer film baffle system produced by the manufacturing process of
FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Aside from the exemplary embodiments disclosed below, this
invention is capable of other embodiments and of being practiced or
being carried out in various ways. Thus, it is to be understood
that the invention is not limited in its application to the details
of construction and the arrangements of components set forth in the
following description or illustrated in the drawings. Moreover, the
claims hereof are not to be read restrictively unless there is
clear and convincing evidence manifesting a certain exclusion,
restriction, or disclaimer.
[0035] In general, the subject invention is heat sealing multiple
layers of material at different temperatures at various locations.
A sheet of material may be a laminate and have one face of
material, or layer, with a heat sealing temperature that is higher
than the heat sealing temperature of the opposite face of material,
or layer.
[0036] One embodiment of the subject invention is article of
manufacture 2, FIG. 1. Sheet 5 is laminate where layer 6 and layer
7 are heat sealable at different temperatures. Heat seal 8 is
formed by heating layer 3 and sheet 5 to a first temperature at
which a seal between layer 3 and layer 6 is effected. Heat seal 9
is formed by heating layer 4 and sheet 5 to a second temperature,
which is different than the first temperature, and at which a seal
between layer 4 and layer 7 is effected.
[0037] In one particular embodiment, flexible ported pouch 10, FIG.
2, has a top pouch sheet 20 and a bottom pouch sheet 22 each made
of heat sealable material. In one exemplary embodiment, the
material is Low Density Polyethylene (LDPE) and is heat sealable
between 225-275 degrees F., but other heat sealing sheets or heat
sealing laminates can be used. In some other embodiments, pouch
sheets 20 and 22 may be a single heat sealable sheet or heat
sealable laminate folded about an axis to create top sheet 20 and
bottom pouch sheets 22.
[0038] Port 26, also FIG. 2, has a top port sheet 30 and bottom
port sheet 28 each made of heat sealable material. In the exemplary
embodiment in FIG. 4, top port sheet 30 is a laminate having one
layer 42 with a low sealing temperature and the opposite layer 44
having a high sealing temperature. Likewise, bottom port sheet 28
is a laminate having one layer 38 with a low sealing temperature
and the opposite layer 40 having a high sealing temperature. In
this exemplary embodiment, layers 38 and 42 which form the exterior
face of port 26 are made of LDPE and are heat sealable between
225-275 degrees F. while layers 40 and 44 which form the interior
of port 26 are made of High Density Polyethylene (HDPE) and are
heat sealable between 325-375 degrees F. Other heat sealable sheets
or heat sealable laminates may be used for port sheet 28 and port
sheet 30 as long as the interior of port 26 is heat sealable at a
temperature that is higher than the heat sealing temperature of
pouch sheets 20 and 22. This prevents the sealing of the interior
of port 26 where it intersects with pouch 10 at gap 12. Port sheet
28 and port sheet 30 may, in other embodiments, be a single heat
sealable sheet or heat sealable laminate folded about an axis to
create top port sheet 30 and bottom port sheet 28.
[0039] In FIG. 2, port 26 is interposed between top pouch sheet 20
and bottom pouch sheet 22 at gap 12. FIG. 3 shows port edge heat
seal 32 and port edge heat seal 34 between top port sheet 30 and
bottom port sheet 28. In the exemplary embodiment in FIG. 4, layer
44 of top port sheet 30 and layer 40 of bottom port sheet 28 are
heat sealed at port edge heat seals 32 and 34. Preferably, these
heat seals are effected between a temperature of 325-375 degrees F.
In other embodiments, if port 26 is formed using a single sheet or
laminate folded about an axis, only one heat seal would need to be
effected along the open edge of the folded sheet.
[0040] Top pouch sheet 20, FIG. 2, is heat sealed to bottom pouch
sheet 22 along periphery heat seal 24 at a temperature which is
lower than that of the temperature used to seal port 26 at port
edge heat seals 32 and 34. In FIG. 3, where periphery heat seal 24
intersects with port 26 at gap 12, heat seal 36 is formed between
top pouch sheet 20 and top port sheet 30 and heat seal 37 is formed
between bottom pouch sheet 22 and bottom port sheet 28. In the
exemplary embodiment in FIG. 4, where periphery heat seal 24
intersects with port 26 at gap 12, heat seal 36 is formed between
top pouch sheet 20 and layer 42 of top port sheet 30 and heat seal
37 is formed between bottom pouch sheet 22 and layer 38 of bottom
port sheet 28. It is preferable that heat seals 24, 36 and 37 are
effected at a temperature between 225-275 degrees F. This seals the
exterior of port 26 to pouch 10 at gap 12 without sealing the
interior of port 26 along gap 12.
[0041] The exemplary embodiment of a dual layer film baffle system
manufacturing process 60 is shown in FIG. 5. Roll 70 dispenses heat
sealable sheet 72 in parallel with heat sealable sheet 74 which is
dispensed by roll 71. In the exemplary embodiment, heat sealable
sheet 72 and heat sealable sheet 74, FIG. 6, are laminates. Layers
73 and 76 are made of a low temperature heat sealable material,
LDPE, and are sealable between a temperature of 225-275 degrees F.
Layers 77 and 75 are made of a high temperature sealable material,
HDPE, and are sealable between a temperature of 325-375 degrees
F.
[0042] Sheet 72 and sheet 74, FIG. 5, are brought together at high
temperature and perforation station 78. At this point, sheet 72 and
sheet 74 are heated to create heat seal 79, FIG. 7, latitudinally
across the sheets at some interval 81 dependent upon the desired
length of baffles 90 and 91, FIG. 8. Interval 81 may, for example,
be one inch. Also at station 78, FIG. 5, the now sealed sheets are
perforated at interval 81 and immediately preceding heat seal 79 to
create perforated line 80 across the sheets.
[0043] Roll 82, FIG. 5, dispenses low temperature sheet 84 onto
sheet 72 while roll 83 dispenses low temperature sheet 85 onto
sheet 74. Sheets 84 and 85 may be made of LDPE and are heat
sealable at a temperature of 225-275 degrees F. The sheets are
brought together at low temperature sealing station 88 where low
temperature seal 86 is effected between sheet 84 and 72 and low
temperature seal 87 is effected between sheets 85 and 74. These low
temperature seals also cross the sheets latitudinally and are
spaced at interval 81.
[0044] Sheets 84 and 85, FIG. 9, are then spread apart. This causes
baffle 90, FIG. 8, to separate from baffle 91 at perforated line
80. The end result is a plurality of two piece baffles between
sheets 84 and 85. The two pieces of the baffle are joined to each
other at high temperature seal 79 and joined to sheet 84 and 85 at
low temperature seals 86 and 87.
[0045] Although specific features of the invention are shown in
some drawings and not in others, this is for convenience only as
each feature may be combined with any or all of the other features
in accordance with the invention. The words "including",
"comprising", "having", and "with" as used herein are to be
interpreted broadly and comprehensively and are not limited to any
physical interconnection. Moreover, any embodiments disclosed in
the subject application are not to be taken as the only possible
embodiments.
[0046] In addition, any amendment presented during the prosecution
of the patent application for this patent is not a disclaimer of
any claim element presented in the application as filed: those
skilled in the art cannot reasonably be expected to draft a claim
that would literally encompass all possible equivalents, many
equivalents will be unforeseeable at the time of the amendment and
are beyond a fair interpretation of what is to be surrendered (if
anything), the rationale underlying the amendment may bear no more
than a tangential relation to many equivalents, and/or there are
many other reasons the applicant can not be expected to describe
certain insubstantial substitutes for any claim element
amended.
[0047] Other embodiments will occur to those skilled in the art and
are within the following claims.
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