U.S. patent application number 14/293383 was filed with the patent office on 2014-12-04 for method and apparatus for forming a flexible pouch with fitment.
This patent application is currently assigned to Pouch Pac Innovations, LLC. The applicant listed for this patent is Pouch Pac Innovations, LLC. Invention is credited to R. Charles Murray.
Application Number | 20140352259 14/293383 |
Document ID | / |
Family ID | 51983560 |
Filed Date | 2014-12-04 |
United States Patent
Application |
20140352259 |
Kind Code |
A1 |
Murray; R. Charles |
December 4, 2014 |
METHOD AND APPARATUS FOR FORMING A FLEXIBLE POUCH WITH FITMENT
Abstract
A method for forming a flexible pouch having a fitment, the
method including the steps of sealing the bottom, top and one side
of a material to form a pouch. The pouch is formed around a forming
tube, leaving one side of the flexible pouch unsealed. A fitment is
installed on the flexible pouch, either on the corner (45 degree
angle) or on the top of the pouch. The product filled through the
unsealed side of the flexible pouch while continuously moving the
flexible pouch down the forming tube, the forming tube also
continuously supplying product to fill the flexible pouch and
sealing the unsealed side of the flexible pouch. An apparatus for
forming a flexible pouch is provided having a forming tube. The
forming tube is adapted to allow material to wrap around the
forming tube to form a flexible pouch, the forming tube also
operable to dispense product into the flexible pouch through an
exit of the forming tube. The apparatus further includes a first
sealer operable to seal a top portion of the flexible pouch while
the flexible pouch is wrapped around the forming tube. A fitment
installer is provided is provided to install a fitment into the
flexible pouch, the fitment installer positioned adjacent to and
down the line from the first sealer. A second sealer is operable to
seal the side portions of the flexible pouch after the product has
been filled into the flexible pouch through one of the side
portion.
Inventors: |
Murray; R. Charles;
(Sarasota, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Pouch Pac Innovations, LLC |
Sarasota |
FL |
US |
|
|
Assignee: |
Pouch Pac Innovations, LLC
Sarasota
FL
|
Family ID: |
51983560 |
Appl. No.: |
14/293383 |
Filed: |
June 2, 2014 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61829484 |
May 31, 2013 |
|
|
|
Current U.S.
Class: |
53/433 ; 53/450;
53/451; 53/576 |
Current CPC
Class: |
B65B 9/2056 20130101;
B65B 9/2042 20130101; B65B 31/045 20130101; B65B 9/213 20130101;
B65B 31/006 20130101; B65B 61/186 20130101; B65B 9/207
20130101 |
Class at
Publication: |
53/433 ; 53/450;
53/451; 53/576 |
International
Class: |
B65B 9/20 20060101
B65B009/20; B65B 7/14 20060101 B65B007/14; B65B 43/08 20060101
B65B043/08; B65B 9/207 20060101 B65B009/207; B65B 9/213 20060101
B65B009/213 |
Claims
1. A method of forming a flexible pouch with a fitment, the method
comprising the steps of: sealing the edges of a material to form a
pouch, leaving at least one side of the flexible pouch unsealed;
installing a fitment at the top of the flexible pouch, the fitment
sealed on the flexible pouch; filling the flexible pouch with
product, the product filled through the unsealed side of the
flexible pouch; and sealing the at least one unsealed side of the
flexible pouch.
2. The method of claim 1 further including the step of purging the
flexible pouch of oxygen before and/or after filling.
3. The method of claim 1 wherein the fitment is installed at a 45
degree angle.
4. The method of claim 1 wherein a gusset is installed into the
pouch.
5. The method of claim 1 wherein heat is used to seal the sides,
top and bottom of the flexible pouch.
6. The method of claim 1 wherein pressure is used to seal the
sides, top and bottom of the flexible pouch.
7. The method of claim 1 wherein ultrasonic means is used to seal
the sides, top and bottom of the flexible pouch.
8. The method of claim 1 wherein the fitment is installed at the
top corner of the pouch.
9. The method of claim 1 wherein a single sheet of material is used
to form the flexible pouch.
10. The method of claim 1 wherein multiple sheets of material are
used to form the flexible pouch.
11. A method of forming a flexible pouch with a fitment from a
single sheet of material, the method comprising the steps of:
wrapping the material around a forming tube, the tube being
directly connected to a hopper; pulling the material downward
around the forming tube; sealing a portion of the sides of the
material to form the sides a portion of the flexible pouch, leaving
one side unsealed; inserting and sealing a fitment in the flexible
pouch; and filling the flexible pouch through the unsealed side
with product and sealing the unsealed side.
12. An apparatus for forming a flexible pouch, the apparatus
comprising: a forming tube, the forming tube having a first end and
a second end, the first end connected to a first hopper operable to
hold product for filling the flexible pouch, the second end having
an exit, the forming tube adapted to allow material to wrap around
the forming tube to form a flexible pouch, the forming tube also
operable to dispense product into the flexible pouch through the
exit at the second end; a first sealer, the first sealer operable
to seal a top portion of the flexible pouch while the flexible
pouch is wrapped around the forming tube; a fitment installer, the
fitment installer in communication with a second hopper operable to
hold a plurality of fitments, the fitment installer operable to
install a fitment into the flexible pouch, the fitment installer
positioned adjacent to and down the line from the first sealer; and
a second sealer, the second sealer operable to seal the side
portions of the flexible pouch after the product has been filled
into the flexible pouch through one of the side portion.
13. The apparatus of claim 12 wherein a roller is provided adjacent
to the forming tube to supply material to form the flexible
pouch.
14. The apparatus of claim 12 wherein the flexible pouches are
filled continuously.
15. The apparatus of claim 12 wherein the flexible pouches are
filled intermittently.
16. The method of claim 12 wherein the fitment is installed at a 45
degree angle.
17. The method of claim 12 wherein a single sheet of material is
used to form the flexible pouch.
18. The method of claim 12 wherein multiple sheets of material are
used to form the flexible pouch.
19. The method of claim 18 wherein the fitment is installed at the
top of the pouch.
Description
[0001] This application claims priority of U.S. Patent Application
No. 61/829,484 filed May 31, 2013, the contents of which are
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method for forming and
filling a flexible pouch for packaging a product, the flexible
pouch having a fitment.
BACKGROUND OF THE INVENTION
[0003] Flexible pouches formed of a plastic, foil, or other laminar
material which are used to package a variety of products including
consumable liquids are generally known. These flexible pouches can
be formed from a single piece of laminar material, the laminar
material being folded or formed over itself. Once this flexible
pouch with a corner fitment is formed and sealed, it is common to
fill the pouch with product alongside the corner fitment in the top
of the pouch and through the fitment. Pouches are not filled
through the side of the pouch. For pouches that do not require a
StandUp feature (gusset in bottom of pouch) a vertical
form-fill-seal method can be used to make corner spout fitment
pouches.
[0004] As such, a method for forming a flexible pouch with a corner
fitment and filling the flexible pouch is desired wherein the
fitment, style, and shape can be changed independent of the pouch
filling, and the fitment can be installed in a closed
condition.
SUMMARY OF THE INVENTION
[0005] Provided is an improved method and apparatus for forming a
flexible pouch with a fitment. The method includes forming a
flexible pouch from a single sheet of extruded or laminate
material, sealing the pouch along the bottom edges of the folded
form, inserting a fitment in the top corner of the folded form,
sealing the fitment in the top corner of the folded form, filling
the pouch along a side edge, and finally sealing the side edge of
the folded form.
[0006] A method for forming a flexible pouch having a fitment, the
method including the steps of sealing the bottom, top and one side
of a material to form a pouch. The pouch is formed around a forming
tube, leaving one side of the flexible pouch unsealed. A fitment is
installed on the flexible pouch, either on the corner (45 degree
angle) or on the top of the pouch. The method further includes the
step of filling the flexible pouch with product. The product filled
through the unsealed side of the flexible pouch while continuously
moving the flexible pouch down the forming tube, the forming tube
also continuously supplying product to fill the flexible pouch and
sealing the unsealed side of the flexible pouch. The method may
further include the step of purging the flexible pouch of oxygen
before and/or after filling. The fitment may be installed at a 45
degree angle or at the top of the flexible pouch. Heat, pressure,
ultrasonic means or any combination thereof may be used to seal the
sides, top and bottom of the flexible pouch.
[0007] In a more detailed embodiment, a method of forming a
flexible pouch with a fitment from a single sheet of material
includes the steps of wrapping the material around a forming tube,
the tube being directly connected to a hopper. Pulling the material
downward around the forming tube and sealing a portion of the sides
of the material to form the sides of the flexible pouch, leaving
one side unsealed. Inserting and sealing a fitment in the flexible
pouch filling the flexible pouch with product and sealing the
unsealed side.
[0008] An apparatus for forming a flexible pouch is provided having
a forming tube, the forming tube having a first end and a second
end, the first end connected to a first hopper operable to hold
product for filling the flexible pouch, the second end having an
exit. The forming tube is adapted to allow material to wrap around
the forming tube to form a flexible pouch, the forming tube also
operable to dispense product into the flexible pouch through the
exit at the second end. The apparatus further includes a first
sealer, the first sealer operable to seal a top portion of the
flexible pouch while the flexible pouch is wrapped around the
forming tube. A fitment installer, is provided and is in
communication with a second hopper operable to hold a plurality of
fitments, the fitment installer is operable to install a fitment
into the flexible pouch, the fitment installer positioned adjacent
to and down the line from the first sealer. The apparatus further
includes a second sealer. The second sealer is operable to seal the
side portions of the flexible pouch after the product has been
filled into the flexible pouch through one of the side portion.
[0009] A roller is provided adjacent to the forming tube to supply
material to form the flexible pouch. In one embodiment, the
flexible pouches are filled continuously. In another embodiment,
the pouches are filled intermittently. The fitment may be installed
at a 45 degree angle or at the top of the pouch. In one embodiment,
a single sheet of material is used to form the flexible pouch.
Multiple sheets of material may be used to form the flexible
pouch.
[0010] It is also appreciated that because the insertion of the
fitment into the top and sealing of the fitment into the top is
independent of the filling of the flexible pouch with product
through the side edge, that numerous designs of fitment may be used
without complicated filling station machine changes or redesigns.
The installed fitment can be provided in a closed form, for example
a fitment with an installed threaded cap may be used. Different
sealing "canoe shapes" may also be used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A better understanding of the present invention will be had
upon reference to the following detailed description when read in
conjunction with the accompanying drawings wherein like reference
characters refer to like parts throughout the several views in
which:
[0012] FIG. 1 illustrates a side view of the apparatus used in the
method of the present invention;
[0013] FIG. 2 illustrates an alternative side view of the apparatus
used in the method of the present invention;
[0014] FIG. 3 illustrates a pouch with a fin seal;
[0015] FIG. 4 illustrates a pouch with a fin seal and a 45.degree.
corner cut;
[0016] FIG. 5 illustrates a pouch with fin seal and fitment sealed
in place;
[0017] FIG. 6 illustrates the method of the present invention;
[0018] FIG. 7 illustrates the method in accordance with the present
invention; and
[0019] FIG. 8 illustrates the method in accordance with the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Provided is an improved method and apparatus for forming a
flexible pouch with a fitment. The method includes forming a
flexible pouch from a single sheet of extruded or laminate
material, sealing the pouch along the bottom edges of the folded
form, inserting a fitment in the top corner of the folded form,
sealing the fitment in the top corner of the folded form, filling
the pouch along a side edge, and finally sealing the side edge of
the folded form.
[0021] A method for forming a flexible pouch having a fitment, the
method including the steps of sealing the bottom, top and one side
of a material to form a pouch. The pouch is formed around a forming
tube, leaving one side of the flexible pouch unsealed. A fitment is
installed on the flexible pouch, either on the corner (45 degree
angle) or on the top of the pouch. The method further includes the
step of filling the flexible pouch with product. The product filled
through the unsealed side of the flexible pouch while continuously
moving the flexible pouch down the forming tube, the forming tube
also continuously supplying product to fill the flexible pouch and
sealing the unsealed side of the flexible pouch. The method may
further include the step of purging the flexible pouch of oxygen
before and/or after filling. The fitment may be installed at a 45
degree angle or at the top of the flexible pouch. Heat, pressure,
ultrasonic means or any combination thereof may be used to seal the
sides, top and bottom of the flexible pouch.
[0022] The method for forming a flexible pouch of the preferred
embodiment with a fitment of the present invention begins with
obtaining 200 a roll of extruded or laminate material or film 100.
This material can be plastic 202, foil 204, or any other material
206 known to those skilled in the art which is capable of being
formed into a pouch and sealed and is safe for packaging food
product.
[0023] The typical machine is loaded with a continuous flat roll
of, which has had and artwork applied to the exterior or interior
of the film. Note that while is the most commonly used packaging
material in the, the technology can also be used to form continuous
paper and fabric product containers by changing the edge
sealing/seaming methods. For some products the film may first be
fed through a chemical bath and dryer prior to use in the packaging
system.
[0024] The film 100 approaches the back of a long hollow conical
tube 102, which is called the forming tube. When the center of the
film is near the tube 102, the outer edges of the film form flaps
that wrap 208 around the conical forming tube. The film 100 is
pulled downward 210 around the outside of the tube and a vertical
heat-sealing bar clamps (first sealer) 104 onto the edges 106 of
the film 100, bonding the film by melting the seam edges
together.
[0025] The film 100 is unrolled and run over the tube 102 (or
forming plow), the tube 102 the film 100 to fold over itself
thereby creating a pouch-like form 212 having a front panel 108 and
a back panel 110. The folded form is secured with one or more
grippers 112 to move and manipulate the pouch. It is appreciated
that the plow or tube may include a gusset forming portion.
[0026] One example of a laminate material structure include as
least one layer of virgin polyethylene terphalate (PET), at least
one layer of aluminum foil and another layer such as EVOH, PET,
polyethylene or nylon or the like. Another type of laminate
material structure may also include a metalized foil paper layer
laminated to a cast polypropylene layer and another layer of PET,
polyethylene or EVOH. There may be a fourth layer of nylon.
Similarly, the laminate material structure may include a cast
polypropylene (CCP) layer, a polyethylene (PET) layer, a foil (AL)
layer, a nylon (ONO) layer and another CPP layer. Another structure
includes the use of nylon, foil, nylon, and cast polypropylene
(ONO/AL/ONO/CPP) or CPP/NY/AL/CPP. Further examples include
ONO/AL/COEX-ONO-LDPE or PET/AL/NYLON/CPP or CPP/AL/ONO/PE. These
examples and the choice of material is non-limiting, and is
influenced by factors such as the product contained in the pouch,
the shape of the pouch, or the anticipated use of the pouch.
[0027] The folded form is then cut by a corner fitment cutter 116
(45.degree.) (see also reference numeral 214) creating a folded
form having a folded edge which will be a first side edge or the
final flexible pouch 114, and a plurality of unsealed edges which
will create a bottom edge, a top edge, and a second side edge of
the flexible pouch. The top edge and bottom edge being adjacent to
the folded edge. The grippers 112 used to secure the folded form
are used to transport the cut folded form to a sealing station.
Alternative to the grippers 112, other mechanisms may be used to
secure and/or transport the folded form and resulting flexible
pouch including, but not limited to, suction or vacuum cups,
conveyor belts, gravity slides, rotating tables, etc.
[0028] At a sealing station (second sealer) 118, the bottom edge of
the flexible pouch is sealed. The sealing can be done using heat,
pressure, ultrasonic, a combination there of, or any other method
known to those skilled in the art. It is appreciated that before
the bottom edge is sealed, a gusset may be inserted which provides
a shape to the flexible pouch allowing it to stand freely on its
base in its finished form. The gusset is secured using sealing
techniques described above.
[0029] Before the top edge is sealed in the sealing station 118, a
fitment 120 is inserted into the top edge 122 (at the 45.degree.
cut or the top portion) (see also reference numeral 216), the
fitment 120 being of a material and design known to those skilled
in the art. The fitment 120 of the preferred embodiment includes a
threaded opening which is closed by a threaded cap 124. It is
appreciated however that the fitment 120 can be of any design known
to those skilled in the art, such as a hinged snap on top style
fitment, a pull to open and push to close style fitment, etc. The
fitment 120 and cap 124 can are provided and installed as a single
assembly. The fitment 120 inserted into the top edge can then be
sealed to the fitment using methods discussed above. The fitment is
installed and sealed by means of the fitment sealer 126. The
fitment sealer 126 may use similar sealing methods as described
above in the sealer bar 118. The fitments 120 are delivered to the
fitment sealer 126 by means of the cap and fitment vibratory bowl
feeder 132 and the cap and fitment track 134.
[0030] The apparatus may include a first vertical (also known in
the art as a fin seal) sealer 104 and a second sealer 118. The
first sealer 104 seals the top portion 134 of the pouch. The second
sealer 118 seals the side portions 130, 132 of the pouch. The side
portion 132 is sealed first (as shown in FIG. 1). Product is then
filled into the flexible pouch. The second unsealed side 130 is
then sealed to finish production of the pouch. The pouch then falls
onto a conveyor belt and is moved away from the manufacturing area
or for packaging and shipping.
[0031] After the flexible pouch has been formed, the fitment 120
installed and sealed (see also reference numeral 218) and top edge
134 sealed, the gusset installed and bottom edge sealed, then the
pouch is filled with product 128 (see also reference numeral 220)
by means of the product hopper 136 along the second side edge 130
of the flexible pouch 114. The forming tube 102 includes a first
end and a second end. The first end having a hopper 136 and the
send end having an exit allowing the product to enter the flexible
pouch through the side edge. Filling can include multiple steps and
be in the presence of inert gases as is known to those skilled in
the art. Filling methods depend on the type of product used. For
example, in the preferred embodiment the flexible pouch is first
sent to a purging station which purges the flexible pouch of oxygen
through the use of purging gas such as carbon dioxide or nitrogen
directed into the pouch at high pressure through the unsealed
second side edge. Once purged, the flexible pouch is sent to a
filling station that fills the flexible pouch with the desired
product through the unsealed second side edge 130. After filling
the flexible pouch is sent to a post-filling purge station that
purges the flexible pouch of oxygen as discussed above. To
facilitate purging and filling the flexible pouch, a gas knife is
used to open the second side edge of the flexible pouch. As an
alternative to a gas knife, grippers, suction cups or and or method
know to those skilled in the art may be used.
[0032] To start the bagging process, a horizontal sealing bar
clamps across the bottom edge of the tube, bonding the film
together, and cutting off any film below. This sealing bar can be
on a fixed height, which is called an intermittent sealing process.
Faster systems include a sealing bar that moves down with the bag
while sealing. This is called a continuous process. The sealed tube
end is then lowered onto a precision weighing table and the product
to be bagged is dispensed through the long conical tube in the
center of the bag. When the of the product filled bag is reached,
filling stops, and the horizontal sealing bar seals the top of the
bag, simultaneously forming the bottom of the next bag above. This
bag is then cut off from the tube and is now a sealed package,
ready to advance onward into the product boxing and shipping
processes. After the flexible pouch has been filled the flexible
pouch can be sent to a sealing station where the second side edge
along which the flexible pouch was filled is sealed using methods
discussed above, this final sealing creating a closed flexible
pouch with a fitment of the present invention.
[0033] During the final sealing process (at the seal bar 118), the
bag may be filled with air from a blower or from air supply.
Inflating the bag helps reduce the crushing of fragile products
such as, while inflating with inert gas 318 helps drive out oxygen
and retards the growth of that would spoil the product.
[0034] Filling the flexible pouch through the second side edge
allows uniform purging and filling stations to be used regardless
of the type of fitment installed in the flexible pouch.
Additionally, because the fitment is installed as a single closed
assembly, an additional step of closing the fitment after the pouch
has been filled is not required.
[0035] The feeding of material and cutting of the pouch can be
determined either by pouch length, or by indexing to an eyespot,
which is detected by a visual sensor. While single web systems are
popular for food applications, the dual web four side seal system
is often popular for IVD and Medical device products. Closely
related is the horizontal form-fill-seal machine, which generally
uses more floor space than a vertical system. Modern advancements
in pouch forming technology have allowed for smaller and smaller
vertical pouch forming systems.
[0036] Many food filled packages are filled with nitrogen to extend
shelf life. Food manufacturers are often looking for ways to
improve their geographical reach or otherwise extending the shelf
life of their product without the use of chemicals. Nitrogen
filling is a natural means of extending shelf life. More and more
manufacturers are choosing to create and control their own nitrogen
supply by using an on demand.
[0037] Dual web systems are also available for four side sealed
pouches, as well as pouches requiring different materials for each
side. Dual web systems use two rolls of material instead of one,
which are fed in from opposite sides of the machine. The bottom and
sides are heated sealed together to form the pouch, and the product
is loaded from the top. The pouch with the loaded product then
advances downwards; the top is sealed and the pouch is cut off. The
sealing of the top of the pouch forms the bottom of the next pouch.
During this process a tear notch may be added.
[0038] The invention is not restricted to the illustrative examples
and embodiments described above. The embodiments are not intended
as limitations on the scope of the invention. Methods, apparatus,
compositions, and the like described herein are exemplary and not
intended as limitations on the scope of the invention. Changes
therein and other uses will occur to those skilled in the art.
[0039] A method for forming a flexible pouch having a fitment, the
method including the steps of sealing the bottom, top and one side
of a material to form a pouch. The pouch is formed around a forming
tube, leaving one side of the flexible pouch unsealed 302. A
fitment is installed on the flexible pouch 304, either on the
corner (45 degree angle) or on the top of the pouch. The method
further includes the step of filling the flexible pouch with
product 306. The product filled through the unsealed side of the
flexible pouch while continuously moving 308 the flexible pouch
down the forming tube, the forming tube also continuously supplying
product to fill the flexible pouch and sealing the unsealed side of
the flexible pouch. The method may further include the step of
purging the flexible pouch of oxygen before and/or after filling
310. The fitment may be installed at a 45 degree angle or at the
top of the flexible pouch 312, 314. Heat, pressure, ultrasonic
means or any combination thereof may be used to seal the sides, top
and bottom of the flexible pouch 202, 204, 206.
[0040] In a more detailed embodiment, a method of forming a
flexible pouch with a fitment from a single sheet of material
includes the steps of wrapping the material around a forming tube
208, the tube being directly connected to a hopper. Pulling the
material downward 210 around the forming tube and sealing a portion
of the sides of the material to form the sides of the flexible
pouch, leaving one side unsealed. Inserting and sealing a fitment
in the flexible pouch filling the flexible pouch with product and
sealing the unsealed side 212.
[0041] An apparatus for forming a flexible pouch is provided having
a forming tube, the forming tube having a first end and a second
end, the first end connected to a first hopper operable to hold
product for filling the flexible pouch, the second end having an
exit. The forming tube is adapted to allow material to wrap around
the forming tube to form a flexible pouch, the forming tube also
operable to dispense product into the flexible pouch through the
exit at the second end. The apparatus further includes a first
sealer, the first sealer operable to seal a top portion of the
flexible pouch while the flexible pouch is wrapped around the
forming tube. A fitment installer, is provided and is in
communication with a second hopper operable to hold a plurality of
fitments, the fitment installer is operable to install a fitment
into the flexible pouch, the fitment installer positioned adjacent
to and down the line from the first sealer. The apparatus further
includes a second sealer. The second sealer is operable to seal the
side portions of the flexible pouch after the product has been
filled into the flexible pouch through one of the side portion.
[0042] A roller is provided adjacent to the forming tube to supply
material to form the flexible pouch. In one embodiment, the
flexible pouches are filled continuously. In another embodiment,
the pouches are filled intermittently. The fitment may be installed
at a 45 degree angle or at the top of the pouch. In one embodiment,
a single sheet of material is used to form the flexible pouch.
Multiple sheets of material may be used to form the flexible
pouch.
* * * * *