U.S. patent application number 14/200124 was filed with the patent office on 2014-12-04 for packaging system and method.
The applicant listed for this patent is DUBBLE BUBBLE LIMITED. Invention is credited to Neville HOWES.
Application Number | 20140355909 14/200124 |
Document ID | / |
Family ID | 41572795 |
Filed Date | 2014-12-04 |
United States Patent
Application |
20140355909 |
Kind Code |
A1 |
HOWES; Neville |
December 4, 2014 |
Packaging System and Method
Abstract
A package for an article comprises a pressurised outer bag
having gas-tight seals at opposite ends, and an inner web for
supporting the article within the outer bag. The web extends along
the length of the outer bag and is secured to the outer bag only at
the gas-tight seals. The web is maintained under sufficient tension
by the pressure within the outer bag to suspend the article within
the bag and to maintain a space between the article and the outer
bag on all sides of the article.
Inventors: |
HOWES; Neville; (Suffolk,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DUBBLE BUBBLE LIMITED |
Suffolk |
|
GB |
|
|
Family ID: |
41572795 |
Appl. No.: |
14/200124 |
Filed: |
March 7, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13511444 |
May 23, 2012 |
8707660 |
|
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PCT/IB10/55183 |
Nov 16, 2010 |
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14200124 |
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Current U.S.
Class: |
383/38 ;
53/139.5 |
Current CPC
Class: |
B65D 81/2084 20130101;
B65D 77/04 20130101; B65D 81/07 20130101; B65D 81/075 20130101;
B65D 75/46 20130101; B65D 81/2023 20130101; B65B 2220/10 20130101;
B65D 81/2061 20130101; B65B 2220/20 20130101; B65B 31/04 20130101;
B65B 55/20 20130101; B65B 2220/12 20130101; B65B 9/04 20130101;
B65B 9/06 20130101; B65B 9/20 20130101; B65B 31/00 20130101; B65D
31/12 20130101 |
Class at
Publication: |
383/38 ;
53/139.5 |
International
Class: |
B65D 81/07 20060101
B65D081/07; B65D 30/22 20060101 B65D030/22; B65B 55/20 20060101
B65B055/20; B65B 31/00 20060101 B65B031/00; B65B 9/04 20060101
B65B009/04; B65B 9/20 20060101 B65B009/20 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 27, 2009 |
GB |
0920815.8 |
Claims
1. A package for an article comprising a pressurised outer bag
having gas-tight seals at opposite ends, and an inner pouch for
supporting the article within the outer bag, wherein (a) the pouch
extends along the length of the outer bag and is secured to the
outer bag only at the gas-tight seals; (b) the pouch is maintained
under sufficient tension by gas pressure within the outer bag to
suspend the article within the bag and to maintain a space between
the article and the outer bag on all sides of the article; and (c)
back seals closing the inner pouch and the outer bag respectively
are laterally offset from one another.
2. A package as claimed in claim 1, wherein the pouch is evacuated
or filled with an inert gas or gaseous mixture.
3. A package as claimed in claim 2, wherein the outer bag is
pressurised with an inert gas or gaseous mixture.
4. A package as claimed in claim 1, wherein the outer bag includes
longitudinally extending welded pinches to impart a cusped
cross-section to the outer bag.
5. An assembly comprising a plurality of packages as connected end
to end to one another, each package comprising a pressurised outer
bag having gas-tight seals at opposite ends, and an inner pouch for
supporting the article within the outer bag, wherein (a) the pouch
extends along the length of the outer bag and is secured to the
outer bag only at the gas-tight seals; (b) the pouch is maintained
under sufficient tension by gas pressure within the outer bag to
suspend the article within the bag and to maintain a space between
the article and the outer bag on all sides of the article; and (c)
back seals closing the inner pouch and the outer bag respectively
are laterally offset from one another.
6-9. (canceled)
10. A packaging machine for packaging a continuous stream of
articles, comprising: (i) a first forming and sealing station at
which the articles are supported within pouches formed at fixed
intervals in a longitudinally extending web; (ii) a second forming
and sealing station at which the web and the articles supported
thereby are enveloped in a tube; (iii) a source of pressurised gas
for inflating the tube, and (iv) a final sealing station at which
the inflated tube is sealed transversely to the length of the web
and the tube on opposing sides of each article, so as to form a
sealed outer bag within which an article is packaged; wherein (a)
the pressure within the tube serves to tension the web in order to
suspend the article within the outer bag and to maintain a space
between the article and the outer bag on all sides of the article;
and (b) back seals closing the inner web and the outer bag
respectively are laterally offset from one another.
11. A packaging machine as claimed in claim 10, wherein the web and
the tube are severed across the transverse seals to form discrete
packaged articles each suspended within a pressurised outer
bag.
12. A packaging machine as claimed in claim 10, wherein the first
station is operative to wrap the web around the articles to form
sealed inner pouches.
13. A packaging machine as claimed in claim 12, wherein within the
first station the inner pouches are evacuated or filled with an
inert gas.
14. A packaging machine as claimed in claim 10, wherein a station
forms longitudinally extending welded pinches in the outer bag to
impart a cusped cross-section to the outer bag.
15. (canceled)
Description
FIELD OF THE INVENTION
[0001] This invention concerns a flexible package that may be used
for packaging solid or liquid products and may be manufactured on
automated production machinery.
BACKGROUND OF THE INVENTION
[0002] Packaging of products serves several functions, including
protecting the contained item from contamination or deterioration,
and minimising mechanical damage during handling or transport.
[0003] Packaged items are often sealed within a pouch, for example
a vacuum pack or a blister pack. However, depending on the
packaging material, such sealed pouches may not provide sufficient
mechanical protection. Conventionally, this problem is addressed by
increasing the thickness or rigidity of the sealed pouch.
Additionally or alternatively, the sealed pouch may be cushioned by
surrounding material, such as bubble wrap, corrugated card or
expanded foam material, for example.
[0004] However, these and other methods of protection tend to
increase the bulk or weight of the package or a consignment of
packages, and thereby increase costs and waste along the supply
chain.
SUMMARY OF THE INVENTION
[0005] In accordance with a first aspect of the invention, there is
provided a package for an article comprising a pressurised outer
bag having gas-tight seals at opposite ends, and an inner web for
supporting the article within the outer bag, wherein the web
extends along the length of the outer bag and is secured to the
outer bag only at the gas-tight seals, and wherein the web is
maintained under sufficient tension by the pressure within the
outer bag to suspend the article within the bag and to maintain a
space between the article and the outer bag on all sides of the
article.
[0006] In the invention, the packaged articled is held in
suspension within a sealed inflated bag and is in this way
protected against mechanical impact.
[0007] In a preferred embodiment of the invention, the inner web is
wrapped around the article and sealed to form an inner pouch within
the outer bag. By providing an inner pouch within the outer
protective bag, this embodiment of the invention can be used to
package liquids as well as solid articles. A further advantage of
such an embodiment of the invention is that the pouch may be
evacuated or filled with an inert gas or gaseous mixture, as may be
desirable to prolong the shelf life of certain articles such as
foodstuffs.
[0008] The outer bag may itself be pressurised with an inert gas or
gaseous mixture.
[0009] An outer bag formed from a flat sheet that is drawn from a
reel and made into a tubular sleeve by means of a hermetic back
seal will be generally pillow shaped with a rounded cross section,
but to improve the stackability of packages and offer additional
protection, the outer bag may include longitudinally extending
welded pinches to impart a cusped cross section to the outer
bag.
[0010] Embodiments of the invention can thus be seen to provide an
integrated pack that protects and cushions a product, while
reducing extraneous packaging material. The pack can be produced on
a range of automatic packaging machinery or from pre-made
pouches.
[0011] According to two further aspects, the invention provides a
method as set forth in claim 6 of the appended claims and a
packaging machine as set forth in claim 12 of the appended
claims.
[0012] The term "pouch" as used herein is intended to include any
receptacle, cavity or wrapping surrounding and containing a liquid
or solid item.
[0013] Especially when a number of packages are produced on
automated or semi-automated machinery, those portions of the pouch
adhering to the outer bag are sealed thereto in substantially the
same manner as the pouch is sealed. Ideally, each sealed portion
comprises substantially the whole of the relevant edge of the inner
pouch. By "seal" is meant substantial integration of the material
or materials contacting each other. Depending on the package
requirements, all seals should be substantially hermetic, at least
for the expected lifetime of the package.
[0014] In accordance with known practice, the inner web may be a
pouch containing a vacuum. Depending on the degree of evacuation
required, this may be a hard or soft vacuum. Conveniently, the
pouch may be flushed with an inert gas or mixture of inert gases
before sealing to ensure that any residual gas within the inner
pouch is modified to be substantially unreactive in relation to the
contents of the inner pouch, at least for the expected lifetime of
the package. Preferably, the residual gas is substantially
oxygen-free.
[0015] The outer bag may be pressurised with air or any inert gas
or mixture of gases. Carbon dioxide and nitrogen are convenient and
readily available.
[0016] The inner web or pouch and the outer bag may be made of the
same or different materials, provided that they can be sealed or
otherwise adhere to each other. The inner pouch and the outer bag
may be substantially gas tight, taking account of the applicable
pressure differentials.
[0017] Materials to produce both the inner web/pouch and outer bag
can each be tailored to the varied requirements of the products
contained. To this, a wide range of flexible packaging materials
may be utilised. Examples of suitable materials are:
[0018] 1. Recyclable materials such as Mono or co-extruded
Polyethylene- and Mono Polypropylene-based flexible materials.
[0019] 2. Co-extrusions of (for
example)Polyethylene/Nylon/Polyethylene, where oxygen barriers may
be incorporated in the co-extrusion.
[0020] 3. Two layer laminates of Oriented Polypropylene/modified
Polyethylene (sealing compatible to the OPP).
[0021] 4. Three or more layer laminates of (for example)
Polyethylene/ Polyester/Polyethylene.
[0022] Embodiments of the invention may allow the potential
replacement of several current packaging systems offering product
protection methods that are more energy hungry in their
construction and manufacture. The package uses air or an inert gas
as the protective medium rather than rigid or semi-rigid
constructions such as: blister pack materials (amorphous
polyethylene terephthalate, polyvinyl chloride etc); polystyrene;
carton and corrugated board; or cellulose acetate propionate food
packs ((amorphous) polyethylene terephthalate /polyethylene). The
invention may thus be environmentally friendly.
[0023] The invention allows lower weight flexible packaging
materials to be tailored to the exact oxygen and barrier
requirements of the product. It may be possible to enable
significant reductions in the total weight of packaging material
required and in the carbon footprint resource.
[0024] The invention also offers the potential to use recycled
materials in its construction and to use recyclable materials to
pack many non-oxygen sensitive products.
[0025] Some embodiments of the invention may enable continuous
assembly of packages by modifying existing machines.
[0026] The description below relates to a preferred embodiment in
which the inner web is formed as a sealed inner pouch.
[0027] When produced in Horizontal Form Fill & Seal form, the
package is produced by folding a flexible material around a product
horizontally and sealing together the two edges of the folded
material by means of a back seal, before pulling a soft vacuum
around the product if required. The product is then enclosed within
the flexible material and end seals applied to seal substantially
across the axis of the back seal, so that the product is gently
restrained inside the pouch.
[0028] At this point the flexible material is not cut, and the
material now encasing the product continues to a second stage on
the machine, where a wider material is formed around the inner
pouch. A back seal is made to the outer material before an
overpressure of either air or mixed gases is blown into the package
to inflate the outer bag, before end seals are applied. Only at
this stage is the outer bag sealed to the inner pouch and only
through the end seals of the outer bag. The inner pouch is
therefore held in suspension within the outer bag, protecting it
within a cushion of air or mixed gases. The pressure within the
outer bag serves to tension the inner pouch suspending the inner
pouch clear of the walls of the outer bag. The inner pouch may be
gas flushed before sealing, and a mixture of gases may be used to
inflate the outer bag when a controlled atmosphere is
desirable.
[0029] When produced in Vertical Form Fill & Seal form, the
package is produced by forming a flexible material around a product
vertically and sealing a back seal to the material, before pulling
a soft or hard vacuum around the product if required. The product
is then enclosed within the flexible material and end seals applied
so that the product is held within an inner pouch, which may
contain a vacuum. At this stage the pouch remains uncut, and the
material now encasing the product continues to the second stage of
the machine, where a wider material is formed around the inner
pouch. A back seal is applied to the outer material before an
overpressure of either air or mixed gases is blown into the pack to
inflate the outer bag before an end seal is applied. The inner
pouch is therefore held in suspension within the outer bag, the two
packs being sealed together through the end seals only and with the
outer bag protecting the inner pouch within a cushion of air or
mixed gases. The inner pack may be gas flushed before sealing, and
a mixture of gases may be used to inflate the outer bag when a
controlled atmosphere is desirable
[0030] When producing the package in-line from Vacuum Forming
machinery, the inner pouch is produced by thermoforming a bottom
layer of material in a conventional way, with the product then
being inserted into the formed cavity, before a top web of material
is sealed to the base web. If required, a hard or soft vacuum may
be pulled around the product in the conventional manner of vacuum
forming machinery. The side trims are then removed but the end
seals are however not cut at this stage. The material encasing the
product continues to a second stage on the machine or a second
filling machine, where it enters a horizontal form fill and seal
section forming a larger outer bag around the inner vacuum-formed
pack. A wider material encases this inner pouch and a back seal is
made to the outer material before an overpressure of either air or
mixed gases is blown into the pack to inflate the outer bag before
the end seals are applied. A mixture of gases may be applied when a
controlled atmosphere is desirable. As previously, the inner pouch
is held in suspension within the outer bag, the two packs being
sealed together through the end seals only and with the outer bag
protecting the inner pouch within a cushion of air or mixed
gases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The invention will now be described further, by way of
example, with reference to the accompanying drawings, in which:
[0032] FIG. 1 is a drawing of the finished package profile for both
horizontal and vertical production methods,
[0033] FIG. 2 shows the finished package where the inner pouch is
produced from a vacuum forming machine adapted to run in-line
through a horizontal form fill and seal machine (see FIG. 7),
[0034] FIG. 3 is a drawing of uncut but sealed and vacuumed pouches
after the first stage of production in both the horizontal form
fill and seal version (see FIG. 5) and the vertical form fill and
seal version (see FIG. 6),
[0035] FIG. 4 is a drawing of uncut but sealed and vacuumed pouches
after the first stage of production in the vacuum
forming/Horizontal form fill and seal version (see FIG. 7),
[0036] FIG. 5 shows the principle of production using horizontal
form fill and seal machinery,
[0037] FIG. 6 shows the principle of production using vertical form
fill and seal machinery,
[0038] FIG. 7 shows as a schematic a machine adaptation wherein a
conventional vacuum forming machine operates in tandem with a
horizontal form fill and seal machine to produce the package shown
in FIG. 2,
[0039] FIG. 8 is a transverse section through an alternative
packaging embodying the invention,
[0040] FIG. 9 shows the packaging of FIG. 8 as viewed from the
side, and
[0041] FIG. 10 shows a perspective view of the packaging of FIGS. 8
and 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0042] In FIG. 1, the product to be packaged is designated 1. An
inner pouch 2 is formed by wrapping an inner web around the product
1, and creating a back seal 3 and inner end seals 4 allowing the
product to be gently restrained within the inner pouch and held in
a vacuum if required. An outer material 5 is wrapped around the
inner pouch 2 with an over pressure being trapped inside the pack
by virtue of a back seal 6 and end seals 7, hermetically sealing
the material together. The final pack end seal 7 seals the material
of the inner pouch 2 to the outer material 5, thus allowing the
product 1 to be held in suspension within a cushion of air or mixed
gases. The region of the end seal 7 designated 8 shows that the
back seals 3 and 6 of the inner pouch 2 and the outer bag 5, are
laterally offset from one another to reduce the potential of over
pressure loss through pinholing or piping.
[0043] In FIG. 2, the product is again designated 1. 21 indicates
the inner vacuum-formed pack produced from a conventional top and
base web with side seals 22 and the end seals 23 applied to the
inner pouch 21 to include a vacuum, if required, around the product
1 before the sealing is applied. The outer bag inflated with air or
a mixture of gases is shown at 5, with the outer horizontal form
fill and seal pack being sealed along a back seal at 6 and the end
seals 7 being applied to seal the outer material. The final pack
end seals 7 seal the inner material 21 to the outer material 5,
thus allowing the product 1 to be held in suspension within a
cushion of air or mixed gases.
[0044] In FIG. 3, 1 is the product and 2 shows the inner web sealed
around the product by means of a back seal 3 and end seals 4. The
drawing shows the completed but uncut inner pack before entering
the second stage where the outer bag is applied, inflated and
sealed.
[0045] In FIG. 4, 1 is the product held in a soft or hard vacuum,
if required, and sealed within a formed cavity after leaving the
vacuum forming stage of providing the first (inner) pouch 21. 41
shows the knives that remove the reel edge trim 42 from both sides
of the material. Side seals 22 have been made in the machine
direction to seal the top web to the bottom web and cross seals 23
have been made to encapsulate the product after it may have been
gas flushed and held in a soft or hard vacuum. 43 shows the formed
base web cavity around the product, which may have been gas flushed
with a mixture of gases if required before vacuuming and sealing
the inner pouch 21.
[0046] In FIG. 5, 1 is the product on a supporting conveyor (not
shown) entering the machine and 2A is the reel of material to form
the inner pouch 2. The material is wrapped around the product in
the forming box 51 and a fin or lap back seal applied by either
heated rollers or heated pads 52 to produce a back seal (see FIG.
3, seal 3). Within this stage the product may be gas flushed if
required before a vacuum, if required, is applied around the
product by means of a conventional vacuum lance (not shown) and the
end seals 4 formed at a heated station 53. The uncut vacuum packs
indicated at 54 then move along a supporting conveyor (not shown)
to the secondary forming box 55 where an outer reel of material 5A
is formed around the inner pack 2. A fin or lap back seal is then
applied by either heated rollers or heated pads 56 to produce a
back seal 6 in any suitable position which seals the outer material
5A only to itself. The outer material is not attached to the inner
pack. 2B shows the inner pouch still held in suspension within the
outer wrap and 5B the outer bag inflated with either air or a
mixture of gases, such as carbon dioxide or nitrogen. The outer bag
is then sealed as shown at 57, with the inner and outer bags also
being sealed together at 57 before being cut into individual
packages. 58 indicates the finished individual packages leaving the
production machine (see also FIG. 1).
[0047] In FIG. 6, 1 is the product being dropped vertically. 2A
shows a reel of material to form the inner pouch being formed
around a forming collar at 61. The material is then pulled or
driven by conventional methods, such as a moving belt or
reciprocating jaws 59, with a fin or lap back seal being applied at
52. The inner pouch may at this stage be gas flushed with a mixture
of gases before a vacuum is applied around the product, if
required, and the pouch is end-sealed at 53. 54 indicates the uncut
inner pouches continuing vertically into the second forming collar
and tube at 62, where material from reel 5A is formed around the
collar 62 and pulled or driven down the outer tube, for example by
means of a moving belt or reciprocating jaws 63, with a fin or lap
back seal being applied at 56 in any suitable position. The back
seal is applied only to the outer material, with the inner pouch
being in free suspension at this stage. The outer bag is then
inflated with an overpressure of either air or a combination of
gases, such as carbon dioxide or nitrogen, before the end seals are
applied at 57. This sealing station also seals the inner pouch to
the outer bag before being cut at 57 and dropping onto a supporting
conveyor (not shown), with the finished packages being indicated at
58 (see also FIG. 1).
[0048] In FIG. 7, 1 indicates the product gently restrained or held
in a soft or hard vacuum after the sealing station on a
conventional vacuum forming machine 71 where a base web has been
formed to accommodate the product and then a top web is sealed to
the base web around the product. At vacuum forming machine 71, a
top and base web has been used in conventional manner to encase the
product with side and end seals sealing the top to the base web
around the pouch, that may have been gas flushed with a mixture of
gases before sealing. 72 indicates the uncut inner sealed packs
continuing on a supporting conveyor 73 before entering a horizontal
form fill and seal machine, with an outer material 5A being formed
around the inner pack at forming station 55. A fin or lap back seal
6 is then applied by either heated rollers or heated pads (not
shown) to produce a back seal which seals the outer material 5A
only to itself. The back seal 6 is not attached to the inner pouch.
2B shows the inner pouch still held in suspension within the outer
wrap and 5B the outer bag inflated with either air or a mixture of
gases, such as carbon dioxide or nitrogen. The outer bag is then
sealed as shown at 57, with the inner and outer bags also being
sealed together at 57 before being cut into individual packs. 58
indicates the finished individual packs leaving the production
machine (see also FIG. 2).
[0049] An alternative embodiment of the invention is shown in FIGS.
8 and 9, which differs from that shown in FIG. 1 only in that that
material of the outer bag 5 is pinched at four locations and welded
to form four reinforced lines extending along the length of the
outer bag. Because of these welded reinforcements, when the bag is
inflated, the cross section shown in FIG. 8 has four cusps so that
the shape of the outer bag is not a smooth ellipse but approximates
more to a rectangle. This improves the stackability of the
packages.
[0050] In FIG. 8, the product 1 is shown in end profile held within
the inner pouch 2 which is sealed by a lap or find seam 3. 5 The
outer wrap bag 5 in this embodiment has four welded pinches which
define four corner cusps 80. The outer bag is shown with a back
seal 6 of the same construction as described in the previous
embodiments but in this case it is alternatively possible for the
seal to acts as, or to be incorporated into, one of the cusps as
shown at 6' in the FIG. 8.
[0051] FIG. 9 shows another profile of the same packaging
demonstrating the manner in which the product 1 is restrained from
moving in the inner pouch 2 by means of the seals 4. FIG. 9 also
shows the outer bag 5 with the pinched longitudinal cusps 80. The
outer pack end seals 7 seal the material of the outer bag 5 to that
of the inner pouch 2 to suspend the article 1 in the bag.
[0052] FIG. 10 indicates how the inclusion of the cusps 80
approximates the outer pack into more of a rectangular shape.
[0053] While the description and drawings relate to the formation
of an inner pouch, it should not be considered an essential part of
the invention. The essential feature is that the inner web
supporting the article or product is trapped within the end seals
of the outer bag, and maintained in tension. The tension serves to
suspend the inner web (or pouch) relative to the inflated outer
bag.
* * * * *