U.S. patent application number 15/258638 was filed with the patent office on 2017-03-02 for water-soluble pouches.
The applicant listed for this patent is Rideau Machinery Inc.. Invention is credited to James Fowler, Boris Makutonin.
Application Number | 20170057716 15/258638 |
Document ID | / |
Family ID | 50680084 |
Filed Date | 2017-03-02 |
United States Patent
Application |
20170057716 |
Kind Code |
A1 |
Fowler; James ; et
al. |
March 2, 2017 |
WATER-SOLUBLE POUCHES
Abstract
A multi-compartment pouch is formed from two water soluble
substrates, wherein the pouch is substantially symmetrical about a
weld line between the two substrates.
Inventors: |
Fowler; James; (Aurora,
IL) ; Makutonin; Boris; (Cincinnati, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rideau Machinery Inc. |
Aurora |
IL |
US |
|
|
Family ID: |
50680084 |
Appl. No.: |
15/258638 |
Filed: |
September 7, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14785214 |
Oct 16, 2015 |
|
|
|
PCT/IB2014/060899 |
Apr 22, 2014 |
|
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15258638 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 65/46 20130101;
B65B 1/04 20130101; B65B 7/02 20130101; B65B 7/06 20130101; B65D
81/3261 20130101; B65B 9/042 20130101; B65B 47/02 20130101; C11D
17/045 20130101; B65B 1/02 20130101 |
International
Class: |
B65D 65/46 20060101
B65D065/46; B65B 1/02 20060101 B65B001/02; B65B 47/02 20060101
B65B047/02; B65B 9/04 20060101 B65B009/04; B65B 7/02 20060101
B65B007/02; B65D 81/32 20060101 B65D081/32; B65B 1/04 20060101
B65B001/04 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 19, 2013 |
GB |
1307160.0 |
Nov 15, 2013 |
GB |
1320204.9 |
Claims
1.-15. (canceled)
16. A multi-compartment pouch formed from two water soluble
substrates, wherein the pouch is substantially symmetrical about a
weld line between the two substrates.
17. The pouch of claim 16, wherein the pouch comprises at least two
compartments wherein each compartment is formed between the same
two substrates.
18. The pouch of claim 17, wherein the compartments contain
different products.
19. The pouch of claim 17, wherein the pouch comprises three or
more compartments.
20. The pouch of claim 17, wherein the compartments are disposed
within the pouch such that they provide at least one of resistance
to planar distortion or that any bending axis arbitrarily laid
across the pouch cuts through the body of at least one
compartment.
21. The pouch of claim 17, further comprising at least one of a
perimetric compartment or a divided perimetric compartment.
22. The pouch of claim 17, wherein at least one compartment is
filled with at least one of a flowable composition, a solid
composition, or more than one composition; and wherein the
compositions are mutually compatible and not antagonistic to each
other.
23. The pouch of claim 16, wherein one of the water soluble
substrates is a top lidding web and the other water soluble
substrate is a base web; and wherein the top lidding web is thinner
than the base web.
24. The pouch of claim 23, wherein the top lidding web has a
thickness of between 30% and 90% of that of the base web.
25. The pouch of claim 23, wherein the top lidding web has a
thickness of between 50% and 75% of that of the base web.
26. The pouch of claim 16, wherein each compartment is filled to at
least 80% of the available volume.
27. The pouch of claim 16, wherein each compartment is filled to at
least 90% of the available volume.
28. The pouch of claim 16, wherein the pouch is sealed to a second
closed multi-compartment pouch to form a combined pouch.
29. The pouch of claim 16, wherein the pouch is sealed to a second
open multi-compartment pouch to form a combined pouch.
30. A method of making a multi-compartment pouch from two water
soluble substrates including a base web and a top lidding web, the
method comprising: providing a former having a plurality of
multi-compartment pouch forming cavities in a peripheral surface of
the former; drawing the base web into the cavities to form a
plurality of pockets within each pouch; filling one or more pockets
with at least one product; closing the pockets in the base web with
the top lidding web to form a plurality of sealed multi-compartment
pouches; and separating the sealed multi-compartment pouches from
the combined base web and top lidding web; wherein the top lidding
web is thinner than the base web such that, as the base web
retracts or shrinks back after the pouch has left the former, the
pressure generated within the pouch causes the top lidding web to
distend to a greater extent than the contraction of the base web,
thereby increasing the internal volume of the pouch sufficiently to
form a multi-compartment pouch substantially symmetrical about the
weld line between the two substrates.
31. The method of claim 30, wherein the top lidding web has a
thickness of between 30% and 90% of that of the base web.
32. The method of claim 30, wherein the top lidding web has a
thickness of between 50% and 75% of that of the base web.
33. The method of claim 30, wherein each pocket of the
multi-compartment pouch is filled with at least one product.
34. The method of claim 30, wherein the former is configured such
that at least one open pocket of a pouch is formed and filled
before at least one other open pocket of the pouch is formed and
filled; and wherein the pouch closed by sealing with a lidding web
once all open pockets have been filled.
35. The method of claim 30, wherein a second pouch is affixed to
the multi-compartment water-soluble pouch to form a combined pouch.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] The present application is a Continuation of U.S. patent
application Ser. No. 14/785,214, filed Oct. 16, 2015, which is a
U.S. National Stage Application of International Application No.
PCT/IB2014/060899, filed Apr. 22, 2014, which claims priority to
and the benefit of GB Patent Application No. 1307160.0, filed Apr.
19, 2013, and GB Patent Application No. 1320204.9, filed Nov. 15,
2013. The entire disclosures of U.S. patent application Ser. No.
14/785,214, International Application No. PCT/IB2014/060899, GB
Patent Application No. 1307160.0, and GB Patent Application No.
1320204.9 are incorporated by reference herein.
BACKGROUND
[0002] This invention concerns improvements in or relating to
water-soluble pouches. More specifically, the invention concerns
apparatus and methods for producing multi-compartment water-soluble
pouches from two or more soluble substrates on continuous motion
rotatable forming machines. The invention also concerns
multi-compartment water-soluble pouches made from two or more
soluble substrates, and in particular, but not exclusively, pouches
made using the apparatus and methods of the present invention.
[0003] In our earlier applications WO2011/061628 and WO2013/190517,
continuous motion rotatable formers and pouches made thereon have
been described. In WO2011/061628, apparatus for making pouches from
two water-soluble substrates was described wherein a rotatable
former is provided with cavities into which a base web is formed to
create open pockets in the base web. Once formed, the base web is
tightly held by vacuum within the cavity throughout the process of
filling the pockets, sealing the pockets with a top or lidding web
to form pouches in the combined webs and separating the pouches
from the combined web by transverse and web direction knives. In
WO2013/190517, apparatus for making multi-compartment pouches from
four water-soluble substrates via two pouches was described wherein
each pouch was made from two water-soluble substrates on separate
rotatable formers similar to the process described in WO2011/061628
and the web of pouches on one former then joined to the web of
pouches on the other former produce combined pouches before
separating the combined pouches from the combined webs by
transverse and web direction knives.
[0004] As described in the above earlier applications, after
separating, many water-soluble substrates, especially those based
substantially upon polyvinyl alcohol, are subject to what is known
as shrink-back after forming but by holding the base web tightly
within the cavity throughout the filling, sealing and cutting
operations, shrink-back of the base web is prevented.
[0005] When the machines described in the above earlier
applications are used for making multi-compartment pouches from two
water-soluble substrates, a particular difficulty arises when the
number of compartments to be filled is greater than two due to the
lack of space across the web in which to fit the necessary number
of filling heads, and to the lack of time during which to complete
the filling operation if the machine is to operate at its optimal
manufacturing capacity. Lack of space across the web dictates the
use of point filling heads such as nozzle injectors for liquids and
gels, and augur fillers for powders and granules. However, even by
means of point filling heads, it can be difficult to accommodate
sufficient filling heads across the web, and particularly to fill
powders and granules quickly enough.
SUMMARY
[0006] It is an object of the present invention to provide
apparatus and methods for producing multi-compartment water-soluble
pouches from two or more soluble substrates on continuous motion
rotatable forming machines that address one or more of the
aforementioned problems.
[0007] In one aspect, the present invention provides a
multi-compartment pouch formed from two water soluble substrates
wherein the pouch is substantially symmetrical about a weld line
between the two substrates.
[0008] It may be that the pouch comprises at least two compartments
and wherein each compartment is formed between the same two
substrates. The compartments may contain different products
selected for example from liquids, gels, powders and granules. At
least one compartment may be empty, i.e. not filled.
[0009] It may be that the pouch comprises three or more
compartments.
[0010] It may be that the compartments are disposed within the
pouch such that they provide resistance to planar distortion.
[0011] It may be that the compartments are disposed within the
pouch such that any bending axis arbitrarily laid across the pouch
cuts through the body of at least one compartment.
[0012] It may be that the pouch contains a perimetric
compartment.
[0013] It may be that the pouch contains a divided perimetric
compartment.
[0014] It may be that at least one compartment is filled with a
flowable composition, for example a liquid or gel.
[0015] It may be that at least one compartment is filled with a
solid composition, for example a powder or granules.
[0016] It may be that at least one compartment is filled with more
than one composition wherein the compositions are mutually
compatible and not antagonistic to each other.
[0017] It may be that one of the water soluble substrates is a top
or lidding web and the other water soluble substrate is a base web.
Multi-compartment pouches may be produced by forming a base web to
create open pockets that are filled and then closed by a top or
lidding web. The base web may be thermoformed.
[0018] It may be that the top or lidding web is thinner than the
base web.
[0019] It may be that the top lidding web has a thickness of
between 30% and 90%, more preferably between 50% and 75%, of that
of the base web.
[0020] It may be that each compartment is filled to at least 80%,
more preferably at least 90%, of the available volume.
[0021] It may be that the compartments are formed sequentially in
the base web and each compartment is filled before a further
compartment is formed and filled until all compartments have been
filled whereupon the compartments are closed by sealing with a top
or lidding web.
[0022] It may be that the pouch is sealed to a second closed
multi-compartment pouch such that the combined pouch comprises four
water-soluble substrates.
[0023] It may be that the pouch is sealed to a second open
multi-compartment pouch such that the combined pouch comprises
three water-soluble substrates.
[0024] It may be that at least two compartments are filled with a
greater weight of a powder or granular composition than the weight
of any compartment filled with a liquid or gel.
[0025] In another aspect, the present invention provides a method
of making a multi-compartment pouch from two water soluble
substrates consisting of a base web and a top lidding web, the
method including providing a former having a plurality of
multi-compartment pouch forming cavities in a peripheral surface of
the former, drawing the base web into the cavities to form a
plurality of pockets within each pouch, filling one or more pockets
with at least one product, closing the pockets in the base web with
the top lidding web to form a plurality of sealed multi-compartment
pouches, and separating the sealed multi-compartment pouches from
the combined base web and top lidding web, wherein the top lidding
web is thinner than the base web so that, as the base web retracts
or shrinks back after the pouch has left the former, the pressure
so generated within the pouch causes the top lidding web to distend
to a greater extent than the contraction of the base web thereby
increasing the internal volume of the pouch sufficiently to form a
multi-compartment pouch substantially symmetrical about the weld
line between the two substrates.
[0026] It may be that each pocket of the multi-compartment pouch is
filled with at least one product.
[0027] It may be that the former is configured so that at least one
open pocket of a pouch is formed and filled before at least one
other open pocket of the pouch is formed and filled, and only once
all open pockets have been filled is the pouch closed by sealing
with a lidding web.
[0028] It may be that a second pouch is affixed to the
multi-compartment water-soluble pouch to form a combined pouch.
[0029] It may be that each pouch comprises two water soluble
substrates such that the combined pouch comprises four
water-soluble substrates. The second pouch may be a
multi-compartment pouch.
[0030] It may be that the top or lidding web of the
multi-compartment water-soluble pouch is provided by the second
pouch such that the combined pouches comprises three water-soluble
substrates. The second pouch may be a multi-compartment pouch.
[0031] In yet another aspect, the present invention provides
apparatus for producing multi-compartment water-soluble pouches,
the apparatus comprising a rotatable former having compartment
forming cavities into which a base web can be formed, wherein the
apparatus is configured so that at least one open compartment of a
pouch is formed and filled before at least one other open
compartment of the pouch is formed and filled, and only once all
open compartments have been filled is the pouch closed by sealing
with a lidding web.
[0032] It may be that the former is a horizontal former and the
multi-compartment pouch comprises two water soluble substrates.
[0033] It may be that the former is a horizontal former and the
apparatus includes a second former for producing water-soluble
pouches comprising one or more compartments, wherein the formers
are configured to affix a lidding web of a pouch on the horizontal
former to a lidding web of a pouch on the second former to form a
combined pouch comprising four water soluble substrates.
[0034] It may be that the former is a horizontal former and the
apparatus includes a second former for producing water-soluble
pouches comprising one or more compartments, wherein the formers
are configured to affix a lidding web of a pouch on the second
former to a base web of a pouch on the horizontal former to form a
combined pouch comprising three water soluble substrates.
[0035] In yet another aspect, the present invention provides a
multi-compartment water-soluble pouch comprising two water-soluble
substrates wherein at least two open compartments are formed and
filled in a base web and closed by sealing with a lidding web
wherein at least one open compartment is formed and filled before
another open compartment is formed and filled.
[0036] It may be that the pouch is substantially symmetrical about
a weld line between the two substrates.
[0037] It may be that each compartment is formed between the same
two substrates. The compartments may contain different products
selected for example from liquids, gels, powders and granules. At
least one compartment may be empty, i.e. not filled.
[0038] It may be that the pouch comprises three or more
compartments.
[0039] It may be that the compartments are disposed within the
pouch such that they provide resistance to planar distortion.
[0040] It may be that the compartments are disposed within the
pouch such that any bending axis arbitrarily laid across the pouch
cuts through the body of at least one compartment.
[0041] It may be that the pouch contains a perimetric
compartment.
[0042] It may be that the pouch contains a divided perimetric
compartment.
[0043] It may be that at least one compartment is filled with a
flowable composition, for example a liquid or gel.
[0044] It may be that at least one compartment is filled with a
solid composition, for example a powder or granules.
[0045] It may be that at least one compartment is filled with more
than one composition wherein the compositions are mutually
compatible and not antagonistic to each other.
[0046] It may be that the base web is thermoformed.
[0047] It may be that the top or lidding web is thinner than the
base web.
[0048] It may be that the top lidding web has a thickness of
between 30% and 90%, more preferably between 50% and 75%, of that
of the base web.
[0049] It may be that each compartment is filled to at least 80%,
more preferably at least 90%, of the available volume.
[0050] It may be that at least two compartments are formed
sequentially in the base web. All the compartments may be formed
sequentially.
[0051] It may be that the pouch is sealed to a second closed
multi-compartment pouch such that the combined pouch comprises four
water-soluble substrates.
[0052] It may be that the pouch is sealed to a second open
multi-compartment pouch such that the combined pouch comprises
three water-soluble substrates.
[0053] It may be that at least two compartments are filled with a
greater weight of a powder or granular composition than the weight
of any compartment filled with a liquid
[0054] It may be that the closed multi-compartment pouch is affixed
to a second, closed pouch such that the combined pouch comprises
four water-soluble substrates. The second pouch may be a
multi-compartment pouch.
[0055] It may be that the multi-compartment pouch is closed by
affixing a second closed pouch such that the combined pouch
comprises three water-soluble substrates. The second pouch may be a
multi-compartment pouch
[0056] In a further aspect, the present invention provides a
multi-compartment water-soluble pouch comprising two water-soluble
substrates wherein a plurality of compartments is formed
sequentially in a base web and each compartment is filled before a
further compartment is formed and filled until all compartments
have been filled whereupon the pouch is closed by sealing with a
lidding web.
[0057] It may be that the pouch is substantially symmetrical about
a weld line between the two substrates.
[0058] It may be that each compartment is formed between the same
two substrates. The compartments may contain different products
selected for example from liquids, gels, powders and granules. At
least one compartment may be empty, i.e. not filled.
[0059] It may be that the pouch comprises three or more
compartments.
[0060] It may be that the compartments are disposed within the
pouch such that they provide resistance to planar distortion.
[0061] It may be that the compartments are disposed within the
pouch such that any bending axis arbitrarily laid across the pouch
cuts through the body of at least one compartment.
[0062] It may be that the pouch contains a perimetric
compartment.
[0063] It may be that the pouch contains a divided perimetric
compartment.
[0064] It may be that at least one compartment is filled with a
flowable composition, for example a liquid or gel.
[0065] It may be that at least one compartment is filled with a
solid composition, for example a powder or granules.
[0066] It may be that at least one compartment is filled with more
than one composition wherein the compositions are mutually
compatible and not antagonistic to each other.
[0067] It may be that the base web is thermoformed.
[0068] It may be that the top or lidding web is thinner than the
base web.
[0069] It may be that the top lidding web has a thickness of
between 30% and 90%, more preferably between 50% and 75%, of that
of the base web.
[0070] It may be that each compartment is filled to at least 80%,
more preferably at least 90%, of the available volume.
[0071] It may be that the compartments are formed sequentially in
the base web and each compartment is filled before a further
compartment is formed and filled until all compartments have been
filled whereupon the compartments are closed by sealing with a top
or lidding web.
[0072] It may be that the pouch is sealed to a second closed
multi-compartment pouch such that the combined pouch comprises four
water-soluble substrates.
[0073] It may be that the pouch is sealed to a second open
multi-compartment pouch such that the combined pouch comprises
three water-soluble substrates.
[0074] It may be that at least two compartments are filled with a
greater weight of a powder or granular composition than the weight
of any compartment filled with a liquid.
[0075] It may be that the weight of a powder or granular
composition filled into one or more compartments of the pouch is
greater than the weight of a liquid or gel composition filled into
one more other compartments of the pouch.
[0076] It may be that the weight of a powder or granular
composition filled into at least two compartments of the pouch is
greater than the weight of a liquid or gel composition filled into
other compartments of the pouch.
[0077] In yet another aspect, the present invention provides a
method of making a water soluble multi-compartment pouch on a
continuous motion rotatable forming machine having compartment
forming cavities into which a base web can be formed, wherein the
forming machine is configured so that at least one open compartment
of a pouch is formed and filled before at least one other open
compartment of the pouch is formed and filled, and only once all
open compartments have been filled is the pouch closed by sealing
with a lidding web.
[0078] It may be that the closed multi-compartment water-soluble
pouch is affixed to a second closed pouch such that the combined
pouch comprises four water-soluble substrates. The second pouch may
be a multi-compartment pouch
[0079] It may be that the multi-compartment water-soluble pouch is
closed by affixing a second closed pouch such that the combined
pouch comprises three water-soluble substrates. The second pouch
may be a multi-compartment pouch
[0080] In a further aspect, the present invention provides a
multi-compartment water-soluble pouch comprising two water-soluble
substrates wherein a plurality of compartments is formed
sequentially in a base web wherein at least one compartment is
formed and filled before a further compartment is formed and filled
whereupon all compartments are closed by sealing with a lidding
web.
[0081] It may be that the pouch is substantially symmetrical about
a weld line between the two substrates.
[0082] It may be that each compartment is formed between the same
two substrates. The compartments may contain different products
selected for example from liquids, gels, powders and granules. At
least one compartment may be empty, i.e. not filled.
[0083] It may be that the pouch comprises three or more
compartments.
[0084] It may be that the compartments are disposed within the
pouch such that they provide resistance to planar distortion.
[0085] It may be that the compartments are disposed within the
pouch such that any bending axis arbitrarily laid across the pouch
cuts through the body of at least one compartment.
[0086] It may be that the pouch contains a perimetric
compartment.
[0087] It may be that the pouch contains a divided perimetric
compartment.
[0088] It may be that at least one compartment is filled with a
flowable composition, for example a liquid or gel.
[0089] It may be that at least one compartment is filled with a
solid composition, for example a powder or granules.
[0090] It may be that at least one compartment is filled with more
than one composition wherein the compositions are mutually
compatible and not antagonistic to each other.
[0091] It may be that the base web is thermoformed.
[0092] It may be that the top or lidding web is thinner than the
base web.
[0093] It may be that the top lidding web has a thickness of
between 30% and 90%, more preferably between 50% and 75%, of that
of the base web.
[0094] It may be that each compartment is filled to at least 80%,
more preferably at least 90%, of the available volume.
[0095] It may be that the compartments are formed sequentially in
the base web and each compartment is filled before a further
compartment is formed and filled until all compartments have been
filled whereupon the compartments are closed by sealing with a top
or lidding web.
[0096] It may be that the pouch is sealed to a second closed
multi-compartment pouch such that the combined pouch comprises four
water-soluble substrates.
[0097] It may be that the pouch is sealed to a second open
multi-compartment pouch such that the combined pouch comprises
three water-soluble substrates.
[0098] It may be that at least two compartments are filled with a
greater weight of a powder or granular composition than the weight
of any compartment filled with a liquid.
[0099] It may be that the weight of a powder or granular
composition filled into one or more compartments of the pouch is
greater than the weight of a liquid or gel composition filled into
one more other compartments of the pouch.
[0100] It may be that the weight of a powder or granular
composition filled into at least two compartments of the pouch is
greater than the weight of a liquid or gel composition filled into
other compartments of the pouch
[0101] In yet another aspect, the present invention provides a
method of making a water soluble multi-compartment pouch on a
continuous motion rotatable forming machine having compartment
forming cavities into which a base web can be formed, wherein the
forming machine is configured so that at least one open compartment
of a pouch is formed and filled before at least one other open
compartment of the pouch is formed and filled whereupon all
compartments are closed by sealing with a lidding web.
[0102] It may be that the closed multi-compartment water-soluble
pouch is affixed to a second closed pouch such that the combined
pouch comprises four water-soluble substrates. The second pouch may
be a multi-compartment pouch.
[0103] It may be that the multi-compartment water-soluble pouch is
closed by affixing a second closed pouch such that the combined
pouch comprises three water-soluble substrates. The second pouch
may be a multi-compartment pouch
[0104] In yet another aspect the present invention provides a
continuous motion rotatable forming machine for producing
multi-compartment water-soluble pouches, the machine comprising a
rotatable former having compartment forming cavities into which a
base web can be formed, wherein the forming machine is configured
so that at least one compartment of a pouch is formed and filled
before at least one other compartment of the pouch is formed and
filled, and only once all compartments have been formed is the
pouch closed and sealed by affixing a lidding web.
[0105] It may be that at least one compartment is empty, i.e. not
filled. It may be that at least two compartments are formed
simultaneously.
[0106] It may be that the lidding web comprises a web of formed
filled and sealed pouches. It may be that the machine comprises two
formers of which at least one is a horizontal former wherein each
former is able to produce water-soluble pouches comprising one or
more compartments, the lidding films of which are then sealed or
bonded together to form a combined pouch. It may be that the
machine comprises two formers of which at least one is a horizontal
former wherein each former is able to produce water-soluble pouches
comprising one or more compartments, the lidding film of pouches on
one former closing pouches on the other former to form a combined
pouch.
[0107] In yet another aspect the present invention provides a
multi-compartment water-soluble pouch comprising two water-soluble
substrates wherein a plurality of compartments is formed
sequentially in a base web and each sequentially formed compartment
is filled before a further compartment is formed until all
compartments have been formed whereupon the pouch is closed and
sealed by affixing a lidding web.
[0108] It may be that at least one compartment is empty, i.e. not
filled. It may be that at least two compartments are formed
simultaneously.
[0109] It may be that the pouch is affixed to a second closed pouch
such that the combined pouch comprises four water-soluble
substrates. It may that the pouch is affixed to a second open pouch
such that the combined pouch comprises three water-soluble
substrates. It may be that the second pouch comprises one or more
compartments.
[0110] It may be that at least two compartments are filled with a
greater weight of a powder or granular composition than the weight
of liquid or gel filled into any other compartment.
[0111] It may be that each compartment is formed by and between the
base web and lidding web.
[0112] It may be that the pouch is symmetrical about a weld line
between the base web and the lidding web.
[0113] In yet another aspect the present invention provides a
method of making a water soluble multi-compartment pouch on a
continuous motion rotatable forming machine having compartment
forming cavities into which a base web can be formed, wherein the
forming machine is configured so that at least one compartment of a
pouch is formed and filled before at least one other compartment of
the pouch is formed and filled, and only once all compartments have
been formed is the pouch closed by sealing with a lidding web.
[0114] It may be that at least one compartment is empty, i.e. not
filled. It may be that at least two compartments are formed
simultaneously.
[0115] It may be that the multi-compartment water-soluble pouch is
affixed to a second closed pouch such that the combined pouch
comprises four water-soluble substrates. It may be that the lidding
web of the multi-compartment water-soluble pouch comprises a
lidding web comprising a second closed pouch such that the combined
pouch comprises three water-soluble substrates. It may be that the
second closed pouch comprises one or more compartments.
[0116] Aspects of the invention described herein may overcome the
difficulties in the prior art described above of filling pouches
comprising two substrates and containing multiple compartments, by
forming and filling containers in the base web at separate stations
along the web. These aspects are described herein as sequential
forming and filling. The term container describes an open pocket
created within the base web as a result of the forming process.
[0117] In contrast, our earlier aforementioned applications
describe forming containers in the base web contemporaneously (at
the same moment) and subsequently filling the containers
contemporaneously (at the same moment). Sequential forming and
filling may be of particular use for powder or granule filling
without the use of point filling heads, allowing greater
flexibility of filling and resulting in multi-compartment pouches
which have hitherto not been possible to produce.
[0118] Powders or granules are often filled by spreading the powder
or granules upon the surface of an already formed base web and then
removing the excess by means of a scraper or doctor blade, leaving
the powder or granules filling the formed container or a plurality
of formed containers wherein there is substantially no powder or
granules left upon the unformed portions of the base web.
[0119] The base web may be formed into cavities within the former
by different means known to those skilled in the art, including
therefore vacuum forming, if necessary assisted by pre-treating the
base web by spraying it with or passing it through a water mist,
and/or by pre-heating the base web (thermoforming).
[0120] Once formed, the base web may be held by vacuum within the
cavity throughout the process of filling, sealing and separating
the pouches by transverse and web direction knives from a combined
base web and top or lidding web. Many water-soluble substrates,
especially those based substantially upon poly-vinyl alcohol, are
subject to what is known as shrink-back after forming but by
holding the base web tightly within the cavity throughout the
filling, sealing and cutting operations, shrink-back of the base
web may be prevented.
[0121] The foregoing is a summary and thus, by necessity, contains
simplifications, generalizations, and omissions of detail. Any or
all of the features, limitations, configurations, components,
subcomponents, systems, and/or subsystems described above may be
used in combination. Consequently, those skilled in the art will
appreciate that the summary is illustrative only and is not
intended to be in any way limiting. Other aspects, inventive
features, and advantages of the devices and/or processes described
herein, as defined by the claims, will become apparent in the
detailed description set forth herein and taken in conjunction with
the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
[0122] FIG. 1 shows plan and sectional views of a multi-compartment
pouch made from two substrates according to the present
invention;
[0123] FIG. 2 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0124] FIG. 3 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0125] FIG. 4 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0126] FIG. 5 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0127] FIG. 6 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0128] FIG. 7 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0129] FIG. 8 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0130] FIG. 9 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0131] FIG. 10 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0132] FIG. 11 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0133] FIG. 12 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0134] FIG. 13 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0135] FIG. 14 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0136] FIG. 15 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0137] FIG. 16 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0138] FIG. 17 shows plan, sectional and perspective views of a
multi-compartment pouch made from two substrates according to the
present invention;
[0139] FIG. 18 shows reconfiguration of a formed pouch to a
symmetrical configuration;
[0140] FIG. 19 shows arrangements for filling a multi-compartment
pouch comprising two compartments;
[0141] FIG. 20 shows an arrangement for filling a multi-compartment
pouch comprising three compartments;
[0142] FIG. 21 shows arrangements of the filling heads for filling
multi-compartment pouches;
[0143] FIG. 22 shows an embodiment of a horizontal rotatable
forming machine for producing pouches from two substrates;
[0144] FIG. 23 shows an embodiment of a horizontal rotatable former
machine and a cylindrical rotatable forming machine for producing
pouches from four substrates;
[0145] FIG. 24 shows an embodiment of a horizontal rotatable former
machine and a cylindrical rotatable forming machine for producing
pouches from three substrates;
[0146] FIG. 25 shows an embodiment of two horizontal rotatable
forming machines for producing pouches from four substrates;
[0147] FIG. 26 shows an embodiment of two horizontal rotatable
forming machines for producing pouches from three substrates;
[0148] FIG. 27 shows a pouch with three compartments;
[0149] FIGS. 28 and 29 show a method sequentially forming and
filling the pouch of FIG. 27
[0150] FIG. 30 shows apparatus for forming sequentially forming the
compartments of the pouch shown in FIG. 27;
[0151] FIG. 31 shows another apparatus for forming sequentially
forming the compartments of the pouch shown in FIG. 27;
[0152] FIG. 32 shows a method of sequentially forming and filling a
pouch with two compartments;
[0153] FIG. 33 shows a method of sequentially forming and filling a
pouch with three compartments;
[0154] FIG. 34 shows a method of sequentially forming and filling a
pouch with four compartments;
[0155] FIG. 35 illustrates examples of pouch designs which may be
produced by means of the present invention.
[0156] Various multi-compartment pouches 1 are shown in FIGS. 1 to
17 and summarised in the following Table:
TABLE-US-00001 Number of FIG. Number Configuration in Plan View
Compartments 1 Circular or Elliptical with a complete 2 perimetric
compartment 2 Circular or Elliptical with a divided 3 perimetric
compartment 3 Triangular with rounded corners and a 2 complete
perimetric compartment 4 Triangular with rounded corners and a 3
divided perimetric compartment 5 Square or Rectangular with a
complete 2 perimetric compartment 6 Square or Rectangular with a
divided 4 perimetric compartment and a divided central compartment
7 Horseshoe 2 8 Horseshoe with a divided external 3 compartment 9
Central Tee compartment 3 10 Central H compartment 3 11 Rectangular
with a divided perimetric 3 compartment 12 Rectangular with a
divided perimetric 3 compartment 13 L-shaped external compartment 2
14 Wedge compartments 2 15 Wedge compartments with a central 3
compartment 16 Shamrock compartments 4 17 Clover Leaf compartments
3
DETAILED DESCRIPTION
[0157] Each pouch 1 is formed from two water soluble substrates 2,
3 which may be referred to as a base web 2 and a top or lidding web
3. Any suitable water soluble substrates may be employed. Pouches 1
having two compartments 1a, 1b are shown in FIGS. 1,3,5,7,13,14.
Pouches 1 having three compartments 1a,1b,1c are shown in FIGS.
2,4,8,9,10,11,12,15,17. Pouches having four compartments 1,1b,1c,1d
are shown in FIGS. 6,16. Each pouch 1 is symmetrical about a weld
line 4 between the base web 2 and top lidding web 3. Each
compartment 1a,1b,1c,1d is formed between the base web 2 and the
top or lidding web 3. The footprint 5 of the pouches 1 and the
number, shape and arrangement of the compartments 1a,1b,1c,1d is
exemplary only and other configurations that may be employed will
be apparent to those skilled in the art. The term "footprint" is
defined as the plan view of the pouch 1 as seen from above the top
or lidding web 3 of the pouch 1.
[0158] Water-soluble substrates are often by the very nature of the
materials, lacking in rigidity. As a result, when forming a water
soluble pouch from two water soluble substrates, the resulting
pouch will itself have a tendency to lack rigidity or planar
strength which will give an unattractive floppy aspect to the pouch
when handled by the consumer. Such a lack of rigidity or planar
strength is referred to herein as planar distortion. Whilst the
majority of water-soluble substrates capable of being formed, for
example thermoformed or vacuum formed, are at the present time,
made substantially from polyvinyl alcohol resins, other
water-soluble substrates capable of being formed may be used to
practise the present invention.
[0159] Planar distortion of multi-compartment pouches may be
overcome or significantly reduced in this invention by one or more
of the following factors: [0160] i) relative position and/or shape
of the compartments 1a,1b,1c,1d within the footprint 5. [0161] ii)
filling each compartment 1a,1b,1c,1d to a level of at least 80%,
preferably at least 90%, of the available volume, [0162] iii)
selecting the relative thicknesses of the top lidding web 3 and the
base web 2 in order to utilise the retraction or shrinkback of the
base web 2 after the webs have been sealed together and the pouch
ejected from the forming machine or apparatus,
[0163] These factors and their impact on planar distortion of the
resulting pouch 1 are now discussed. It may be that these factors
can be employed separately, or in combination of any two, or
preferably in a combination of all three. The invention extends to
and includes pouches 1 so formed. Aspects of the invention referred
to herein may include any of these factors and we do not intend the
invention to be limited to those aspects specifically
mentioned.
[0164] Position and/or Shape of Compartments
[0165] Planar distortion may be reduced by employing a perimetric
compartment as one of the compartments. The term "perimetric" in
this context describes a compartment which is situated around the
perimeter of the pouch. In its simplest form, the perimetric
compartment may be square or rectangular with rounded corners,
allowing maximum use of the area of the footprint, and hence
providing maximum possible compartment fill volumes. When viewed
from above the top lidding web, such a square or rectangular
perimetric compartment may follow the cut edges of the pouch with
its outer limit set back from the cut edges of the pouch, for
example at least 1.5 mm from the cut edges of the pouch. A square
or rectangular perimetric compartment may be rejected for marketing
or other reasons in favour of other shapes, such as triangular with
rounded corners, or pentagonal with rounded corners, or circular or
elliptical although these shapes are by no means limiting. It will
be apparent that departing from a square or rectangular perimetric
compartment can reduce the combined fill volume of the compartments
within the pouch and leave a larger flange around the perimetric or
semi-perimetric compartment.
[0166] The perimetric compartment may be divided into two or more
separate compartments in order to increase the number of
compartments within a pouch of a given footprint. However, by
sub-dividing the perimetric compartment, there may be a loss of
planar stability. The invention overcomes this loss of planar
stability by compartmental design. As an example, if the perimetric
compartment is divided into two semi-perimetric compartments, the
pouch may, unless corrective design features are introduced to
prevent it, flex about a line joining the seal areas between the
semi-perimetric compartments. A multi-compartment pouch which is
able to flex will be less appealing to the consumer than one which
has planar stability.
[0167] One or more of the compartments within the multi-compartment
pouch may be left unfilled in order to provide additional
resistance to planar distortion of the pouch.
[0168] Compartment Fill Levels
[0169] Planar distortion may be reduced by filling each compartment
of the pouch to at least 80%, preferably at least 90%, of its
available volume. Such a percentage fill of the available volume of
each compartment has been found to contribute to planar stability
of the pouch.
[0170] Web Thicknesses
[0171] The thickness of the top lidding web 3 may be selected to be
between 30% and 90%, preferably between 50% and 75%, of that of the
base web 2. By this means, when, after the pouches 1 have been
sealed and ejected from the machine, the base web 2 retracts or
shrinks back to reduce the internal volume of each compartment. The
pressure so generated within each compartment of the pouch 1 causes
the thinner top lidding web 3 to distend, typically to a greater
degree than the shrinkage of the base web 2, thereby increasing the
internal volume of each compartment of the pouch 1. This can result
in the formation of a substantially symmetrical pouch 1 about the
weld line 5. This reconfiguration of pouches 1 ejected from
cavities 6 of a rotatable former 7 configured with a cylindrical
surface is shown in FIG. 18. The former may 7 may be circular as
shown in FIG. 18 although this is not essential and other
configurations of former may be employed, for example a rotatable
former configured with a flat horizontal surface. Examples of
cylindrical and horizontal formers that may be employed are shown
and described in WO2011/061628 to which the reader is directed for
further details.
[0172] Whilst the reduction in planar distortion provided by any
single factor may not be sufficient to assure planar rigidity of
the pouch, when all three factors are combined, there is an
unexpected increase in planar rigidity which in turn provides a
marketing advantage to the multi-compartment pouch of the present
invention.
[0173] Referring now to FIGS. 19 and 20, examples of filling
multi-compartment pouches 1 according to the present invention are
illustrated although these examples are by no means limiting. The
number of pouches 1 formed, filled and sealed across the web of a
machine is known as the number of tracks or lanes.
[0174] In FIG. 19, filling of pouches 1 with two compartments 1a,1b
similar to the pouch shown in FIG. 14 is illustrated. The rotatable
former 7 of the pouch making machine may be configured as shown and
described in WO2011/061628 with a cylindrical surface 7a or
alternatively with a flat horizontal surface. The compartments
1a,1b may be filled by heads 8a,8b. The heads 8a,8b may be point
fillers. The heads 8a,8b may be configured to add a liquid, gel,
powder or granules, for example nozzle injectors for liquids or
gels or augur fillers for powders or granules. Heads 8a,8b may be
connected to a feed for the same or different materials. The heads
8a, 8b may be arranged with a space offset in the direction of
movement of the surface 7a and fire simultaneously (option A) or
with no space offset and fire at slightly different set points
(option B). A similar arrangement may be provided for each track or
lane across the web of the machine. Heads in different tracks or
lanes may be connected to the same or different supplies of
material. This method is equally applicable where the
multi-compartment pouch comprises more than two compartments.
Generally, a filling head is provided for each compartment.
[0175] In FIG. 20, filling of pouches 1 with three compartments
1a,1b,1c similar to the pouch shown in FIG. 15 is illustrated. The
rotatable former 7 of the pouch making machine may be configured as
shown and described in WO2011/061628 with a cylindrical surface 7a
or alternatively with a flat horizontal surface. The compartments
1a,1b,1c may be filled by heads 8a,8b,8c. The heads 8a,8b,8c may be
point fillers. The heads 8a,8b,8c may be configured to add a liquid
or gel or a powder or granules, for example nozzle injectors for
liquids and gels or augur fillers for powders and granules. In this
embodiment, the heads 8a,8b are configured to add a liquid or gel
and head 8c is configured to add a powder or granules. Heads 8a,8b
may be connected to a feed for the same or different liquids or
gels. A similar arrangement may be provided for each track or lane
across the web of the machine. Heads in different tracks or lanes
may be connected to the same or different supplies of material.
Other arrangements of heads 8a,8b,8c for delivering any combination
of liquids, gels, powders and granules are envisaged. This method
is equally applicable where the multi-compartment pouch comprises
two or more compartments. Generally a filling head is provided for
each compartment.
[0176] Referring now to FIG. 21, methods of arranging the heads are
illustrated. The heads may be arranged to create space for a
plurality of heads within the confined space available. In one
arrangement, the heads may be inclined to each other. For example,
a head 8a for a liquid or gel and a head 8b for a powder or
granules may be inclined to each other. In another arrangement, a
head 8b for a powder or granules may be provided with a chute 9.
The liquid or gel filling head 8a and chute 9 may be inclined to
each other. The heads 8a, 8b may be arranged to follow the cavity 6
of the former 7 as it advances so that the time available for
completion of the filling operation is thereby increased and the
product being filled is spread more evenly along the compartment in
the base web.
[0177] By use of the above filling arrangements and/or by the
programming of the software integrating the filling operation with
the running speed of the machine, it may be possible to fill the
compartments of a multi-compartment pouch 1 during a time interval
of up to one second. In this way, the machine may be capable of
providing an output of approximately 60 pouches per minute for each
track or lane of the machine. In the case of granular or powder
solid products, the filling equipment is typically a multi-head
auger filler and in the case of liquid products, the filling
equipment is typically cylinder operated nozzle injectors with a
cut off such that no drips arrive on the base web surrounding the
cavities. Such contamination of the base web can subsequently
inhibit good sealing of the base web with the top or lidding web.
Hitherto, the filling operation has not allowed such filling speeds
across so many tracks, preventing the compartments of a
multi-compartment pouch from being filled within such a short time
interval.
[0178] Embodiments of pouch forming machines are shown in FIGS. 22
to 26 wherein like reference numerals are used to indicate the same
or similar parts such that the operation of the same or similar
parts will be understood from a description of any embodiment
without being repeated for other embodiments.
[0179] An embodiment of a pouch forming machine 20 is shown in FIG.
22 comprising a horizontal rotatable former 21. The term horizontal
rotatable former describes a machine wherein part of the former 21
comprises a horizontal surface or section 21a. The former 21 may
comprise an endless belt (only part of the former is shown in FIG.
22). The machine is configured to form multi-compartment pouches
from two water soluble substrates by sequential forming and filling
each compartment of the pouch. In this embodiment, the former is
provided with pouch forming cavities 23 configured to form pouches
with three compartments but it will be understood this is not
limiting and the cavities 23 can be configured to form pouches
having two or more compartments.
[0180] A base web 24 is unwound from an unwinding station 25 and a
first open pocket or container 26 is formed in the base web at 27
and filled at 28. A second open pocket or container 29 is formed in
the base web at 30 and filled at 31. A third open pocket or
container 32 is formed in the base web at 33 and filled at 34. A
lidding web 35 is unwound from an unwinding station 36 and affixed
to the base web at 37 thereby sealing and closing all the open
pockets or containers 26, 29, 32 in the base web to form
multi-compartment pouches 38 within the cavities 23. The combined
base web and lidding web is then moved to a cutting station 39
where the pouches 38 are separated from the combined web. In this
embodiment, the top or lidding web 35 is affixed to the base web 24
by solvent welding by wetting the lidding web 35 at 40. Other
methods of affixing the top or lidding web may be employed such as
heat sealing.
[0181] It is important to note that many possible designs of
multi-compartment pouches having at least two compartments may be
produced employing the machine 20 by appropriate design of the
pouch forming cavities. For example, the machine 20 may produce any
of the pouches shown in FIGS. 1 to 17 although this is not limiting
on the scope of the invention. Each compartment may be sequentially
formed and filled with different compositions. Alternatively, where
more than one compartment contains the same composition, these
compartment may be formed and filled simultaneously with at least
one other compartment being formed and filled sequentially.
[0182] Further embodiments of a pouch forming machine 20' are shown
in FIGS. 23 and 24 comprising a combination of two rotatable
formers wherein one rotatable former is a horizontal rotatable
former 21 similar to FIG. 22 and the other rotatable former is a
cylindrical rotatable former 41. The term cylindrical rotatable
former describes a machine where the former 41 comprises a circular
surface or section 41a. The cylindrical former 41 is positioned
above the horizontal section 21a of the horizontal former 21. The
former 41 is provided with pouch forming cavities 42 and may
comprise a drum.
[0183] In FIG. 23, multi-compartment water pouches 38 comprising a
water-soluble base web 24 and a water-soluble top or lidding web 35
are formed on the horizontal rotatable former 21 as described
previously and water-soluble pouches 38' comprising a water soluble
base web 24' and a water soluble top or lidding web 35' are formed
on the cylindrical former 41. The pouches 38,38' are brought
together in register and combined by joining the top or lidding
webs 35,35' to each other at 44. The resulting combined pouch is
formed from four water soluble webs or substrates. In this
embodiment, the pouch 38' comprises a single compartment filled at
43. In other embodiments, the pouch 38' may comprise more than one
compartment. The pouches 38,38' may comprise any of the pouches
shown in FIGS. 1 to 17 although this is not limiting on the scope
of the invention. In other embodiments, the pouch 38 may be a
single compartment and the pouch 38' may be multi-compartment.
[0184] In FIG. 24, the top or lidding web 35 is omitted and the
open pouches or containers formed by the base web 24 on the former
21 are closed by the top or lidding web 35' of the pouches 38' on
the former 41. The resulting pouch is formed from three water
soluble webs or substrates
[0185] Further embodiments of a pouch forming machine 20'' are
shown in FIGS. 25 and 26 comprising a combination of two rotatable
formers wherein both rotatable formers are horizontal rotatable
formers 21,21'' similar to FIG. 22 with a horizontal lower section
21b'' of the former 21'' positioned above the horizontal upper
section 21a of the former 21.
[0186] In FIG. 25, multi-compartment pouches 38 comprising a
water-soluble base web 24 and a water-soluble top or lidding web 35
are formed on the horizontal rotatable former 21 as described
previously and water-soluble pouches 38'' comprising a water
soluble base web 24'' and a water soluble top or lidding web 35''
are formed on the horizontal former 21''. The pouches 38,38'' are
brought together in register and combined by joining the top or
lidding webs 35,35'' to each other at 44. The resulting combined
pouch is formed from four water soluble webs or substrates. An
additional cutting station 39'' may be provided in at least the
transverse direction so that the closed pouches 38'' produced on
the upper horizontal former 21'', despite the vacuum holding them
within the cavities 23'' of the former 21'', are not dislodged as
the former 21'' passes over the roller at 45.
[0187] In this embodiment, the pouch 38'' is a multi-compartment
pouch formed in similar manner to the pouch 38. In other
embodiments, the pouch 38'' may comprise a single compartment or
any other design with two or more compartments. The pouches 38,38''
may comprise any of the pouches shown in FIGS. 1 to 17 although
this is not limiting on the scope of the invention.
[0188] In FIG. 26, the top or lidding web 35 is omitted and the
open pouches or containers formed by the base web 24 on the former
21 are closed by the top or lidding web 35'' of the pouches 38'' on
the former 21''. The resulting pouch is formed from three water
soluble webs or substrates
[0189] By way of non-limiting example, a multi-compartment water
soluble pouch 60 with three compartments 60a,60b,60c is shown in
FIG. 27. The method of sequentially forming and filling the pouch
60 is illustrated in FIGS. 28 and 29.
[0190] Referring to FIGS. 28 and 29, a former 61 has a cavity 62
with three recessed areas 62a,62b,62c corresponding to the
compartments 60a.60b,60c of the pouch 60. A base web 63 is formed
into area 62a to form an open pocket or container for compartment
60a. Compartment 60a is then filled for example with a powder or
granules by a belt feeder 64. The feeder 64 may have a scraper
blade 66 to prevent overfilling of the compartment 60a. Next, the
base web 63 is formed into area 62b to form an open pocket or
container for compartment 60b. Compartment 60b is then filled for
example with a powder or granules by a belt feeder 64. Finally the
base web 63 is formed into area 62c to form an open pocket or
container for compartment 60c. Compartment 60c is then filled for
example with a liquid or gel by a nozzle feeder 65. The
sequentially formed and filled compartments 60a,60b,60c can then be
closed and sealed by a top or lidding web (not shown) by any of the
methods and machines described previously.
[0191] By means of sequential forming and filling, it may be
possible to form and fill open pockets or containers in a base web
to form compartments which, in plan view, "overlap" each other in
the direction of travel of the web. In this way, multi-compartment
pouches containing overlapping compartments can be made employing
the sequential forming and filling method described herein which
could not be made by conventional methods employing contemporaneous
forming of the compartments followed by filling due to filling
constraints. The above method may be employed for any design of
multi-compartment pouch.
[0192] Sequential forming of the base web 63 may be effected by
different methods. One method involves applying a vacuum to each
recessed area 62a,62b,62c of the cavity 62 in turn. Preferably the
vacuum is maintained in each area in which the base web 63 is
formed and filled until the pouch 60 is ejected from the former 61.
Sequential forming and filling offers the advantage of greater
space, longer filling times and therefore ease of filling for
powders or granules which do not flow freely from the filling
heads.
[0193] The sequential vacuum supply to the cavities 62 may be
provided in various ways. Generally mechanical methods of vacuum
control are preferred as being potentially more reliable than, for
example, an electrical method that would require spinning
electrical connections. Two methods of arranging the vacuum supply
for sequential forming the base web 63 to form open pockets or
containers corresponding to compartments 60a,60b,60c of the pouch
60 are described below with reference to FIGS. 30 and 31, although
other methods will be envisaged by those skilled in the art.
[0194] In FIG. 30, a vacuum shoe arrangement for sequential forming
of base web 63 is employed comprising three vacuum slots
66a,66b,66c wherein each slot 66a,66b,66c controls the vacuum start
and stop to each of the three recessed areas 62a,62b,62c
respectively. The slots 66a,66b,66c are of different lengths and
are configured so that stop point is the same for all recessed
areas 62a,62b,62c in order to release the pouch from the cavity 62.
The first slot 66a has the earliest start point, then the second
slot 66b and lastly the third slot 66c. In this way the vacuum is
applied first to the area 62a through vacuum slot 66a so that the
base web 63 can be drawn into the area 62a only to form an open
pocket or container corresponding to compartment 60a which can then
be filled. Whilst the vacuum to the area 62a is maintained, the
vacuum is next applied to the area 62b through vacuum slot 66b so
that the base web 63 can be drawn into the second area 62b to form
an open pocket or container corresponding to compartment 60b which
can then be filled. Whilst the vacuum to the areas 62a,62b is
maintained, the vacuum is applied to the area 62c through slot 66c
so that the base web 63 can be drawn into the area 62c to form an
open pocket or container corresponding to compartment 60c which can
then be filled . . . . When all the pockets or containers have been
formed and filled, a lidding web (not shown) can be affixed to the
base web 63 around the open pockets or containers to close and seal
the compartments to form the multi-compartment pouch 60. The pouch
60 can then be separated from the combined web, the vacuum supply
to all three recessed areas released and the pouch ejected from the
cavity 62 in the rotatable former either by falling under gravity
or by ejection with compressed air or a combination of both on to a
suitable conveyor system.
[0195] In FIG. 31, a vacuum valve arrangement for sequential
forming of base web 63 is employed comprising three vacuum valves
67a, 67b, 67c wherein each valve 67a,67b,67c controls the vacuum
start and stop to each of the three recessed areas 62a,62b,62c
respectively. Each valve 67a, 67b, 67c is mechanically controlled
by an actuator 68a,68b,69c co-operable with a straight cam 69a,
69b, 69c arranged underneath the valve. The cams 69a,69b,69c are of
different lengths and are configured so that the stop point is the
same for all recessed areas 62a,62b,62c in order to release the
pouch from the cavity 62. The first cam 69a is the longest, then
the second cam 69b and the third cam 69c is the shortest. In this
way vacuum valve 67a is actuated first to apply vacuum to the area
62a so that the base web 63 can be drawn into the area 62a only to
form an open pocket or container corresponding to compartment 60a
which can then be filled. Whilst the vacuum to the area 62a is
maintained, the vacuum valve 67b is next actuated to apply vacuum
to the area 62b so that the base web 63 can be drawn into the
second area 62b to form an open pocket or container corresponding
to compartment 60b which can then be filled. Whilst the vacuum to
the areas 62a, 62b is maintained, the vacuum valve 67c is actuated
to apply vacuum to the area 62c so that the base web 63 can be
drawn into the area 62c to form an open pocket or container
corresponding to compartment 60c which can then be filled . . . .
When all the pockets or containers have been formed and filled, a
lidding web (not shown) can be affixed to the base web 63 around
the open pockets or containers to close and seal the compartments
to form the multi-compartment pouch 60. The pouch 60 can then be
separated from the combined web, the vacuum supply to all three
recessed areas released and the pouch ejected from the cavity 62 in
the rotatable former either by falling under gravity or by ejection
with compressed air or a combination of both on to a suitable
conveyor system.
[0196] In arrangement of FIG. 31, a simple vacuum shoe or some kind
of a vacuum manifold for the initial vacuum connection to the valve
block 70 is required. However, the cams 69a,69b,69c can be
configured to be adjustable to alter the vacuum start and/or stop
points to change the valve timing. For example the cams 69a,69b,69c
may be made of two pieces (dove tailed, for example) which allows
for length adjustment. Such adjustment may be effected remotely.
This may allow easier adjustment of the valve timing compared to
the arrangement of FIG. 30 where the vacuum shoe has to be removed
and either replaced by a vacuum shoe with different length slots or
the slots cut to change the length and the shoe refitted.
[0197] A further advantage of the arrangement of FIG. 31 is that
there is only one vacuum line going to the valve block for the
valves 67a,67b,67c for each of the recessed areas 62a,62b,62c. In
the arrangement of FIG. 30, individual lines from the vacuum shoe
to each recessed area 62a,62b,62c are required.
[0198] In some embodiments the cavities 62 in the former may be
heated by internal and/or external heaters to assist forming the
base web 63 into the cavities. In some embodiments the base web 63
may pass over a heated roller prior to being drawn into the first
recessed area 62a. In some embodiments, the base web 63 may be
heated prior to be drawn into the second and/or third recessed
areas to maintain flexibility of the web and assist forming into
the recessed areas. Such heating may be effected from above for
example by means of externally mounted hot air jets or externally
mounted infra-red heaters.
[0199] FIG. 32 illustrates an example, which is by no means
limiting, of a two compartment pouch 70 that can be produced on a
machine similar to FIG. 22 wherein a first open pocket or container
71 is formed in a base web and in this example filled using a belt
feeder 72 or similar type area filler and only once the first
container 71 has been filled, is a second open pocket or container
73 sequentially formed in the base web and in this example, filled
using a point feeder 74. The feeders 72,74 may be replaced by any
other feeders to suit the product added to the containers
71,73.
[0200] FIG. 33 illustrates an example, which is by no means
limiting, of a three compartment pouch 80 that can be produced on a
machine similar to FIG. 22 wherein a first open pocket or container
81 is formed in a base web and in this example filled using a belt
feeder 82 or similar type area filler and only once the first
container 81 has been filled is a second open pocket or container
83 sequentially formed in the base web and in this example filled
using a belt feeder 84 or similar type area filler and only once
the second container 83 has been filled, is a third container 85
sequentially formed in the base web and in this example filled
using a point feeder 86. The feeders 82,84,86 may be replaced by
any other feeders to suit the product added to the containers
81,83,85. In a modification, containers 81 and 83 may be formed and
filled simultaneously and container 85 formed and filled
sequentially.
[0201] FIG. 34 illustrates an example, which is by no means
limiting, of a four compartment pouch 90 that can be produced on a
machine similar to FIG. 22 wherein a first container 91 is formed
in a base web and in this example filled using a belt feeder 92 or
similar type area filler and only once the first container 91 has
been filled, is a second container 93 sequentially formed in the
base web and in this example filled using a belt feeder 94 or
similar type area filler and only once the second container 93 has
been filled are a third container 95 and a fourth container 96
formed simultaneously in the base web and in this example, filled
simultaneously using point feeders 97 and 98 respectively. The
feeders 92,94,97,98 may be replaced by any other feeders to suit
the product added to the containers 91,93,95,96. In other
arrangements, containers 91, 93, 95 and 96 may each be formed and
filled sequentially. In other arrangements, containers 91 and 93
may be formed and filled simultaneously and containers 95 and 96
may be formed and filled sequentially. Other combinations of
simultaneous and sequential forming and filling of the containers
will be apparent to those skilled in the art.
[0202] FIG. 35 illustrates examples, which are by no means
limiting, of pouch designs which may be produced by means of the
present invention.
[0203] FIG. 35(i) illustrates a two compartment pouch 100 where
typically, although the nature of each composition as described
hereafter is by no means limiting, open pocket or container 101 is
formed first in a base web and filled with a powder or granular
composition by means of a belt feeder or similar type area feeder,
and container 102 is formed second and filled with a liquid or gel
composition filled by means of a point feeder. The pouch 100 is
then closed by means of a lidding web.
[0204] FIGS. 35(ii), 35(v), and 35(ix) illustrate different three
compartment pouches 110 where typically, although the nature of
each composition as described hereafter is by no means limiting, an
open pocket or container 111 is formed first in a base web and
filled with a powder or granular composition by means of a belt
feeder or similar type area feeder, open pocket or container 112 is
formed second and filled with a powder or granular composition by
means of a belt feeder or similar type area feeder, and container
113 is formed third and filled with a liquid or gel composition
filled by means of a point feeder. The pouch 110 is then closed by
means of a lidding web.
[0205] FIGS. 35(iii), 35(iv), 36(vi) and 35(vii) illustrate
different four compartment pouches 120 where typically, although
the nature of each composition as hereafter described is by no
means limiting, an open pocket or container 121 is formed first in
a base web and filled with a powder or granular composition by
means of a belt feeder or similar type area feeder, container 122
is formed second and filled with a powder or granular composition
by means of a belt feeder or similar type area feeder, containers
123 and 124 are formed and filled either sequentially or
contemporaneously with the same or different liquid or gel
composition(s) filled by means of point feeders. The pouch 120 is
then closed by means of a lidding web.
[0206] FIG. 35(viii) illustrates a six compartment pouch 130 where
typically, although the nature of each composition as hereafter
described is by no means limiting, container 131 is formed first in
a base web and filled with a powder or granular composition by
means of a belt feeder or similar type area feeder, container 132
is formed second and filled with a powder or granular composition
by means of a belt feeder or similar type area feeder, and
containers 133, 134, 135, and 136 are formed and filled either
sequentially or contemporaneously and filled with the same or
different liquid or gel composition(s) by means of point feeders.
The pouch is then closed by means of a lidding web.
[0207] For the two compartment pouch illustrated in FIG. 35(i), the
method of fill may be as follows: [0208] 1. Vacuum is applied to
form container 101 in the base web [0209] 2. Container 101 is
filled by a belt feeder or similar type area filler [0210] 5.
Whilst maintaining the vacuum to form container 101, vacuum is
applied to form container 102 [0211] 6. Container 102 is filled
with a point type filler, i.e auger or liquid nozzle.
[0212] For the remaining pouches illustrated in FIG. 35 the method
of fill may be the same wherein: [0213] 1. Vacuum is applied to
form container 111,121,131 only in the base web [0214] 2. Container
111,121,131 is filled by a belt feeder or similar type area filler
[0215] 3. Whilst maintaining the vacuum to form container
111,121,131, vacuum is applied to form container 112,122,132 in the
base web [0216] 4. Container 112,122,132 is filled by similar means
as container 111,121,131 [0217] 5. Whilst maintaining the vacuum to
form containers 111,112,121,122,131,12, vacuum is applied to form
containers 113,123,133 and above (134, 135, 136) in the base web
[0218] 6. Containers 113,123,133 and above (134,135,136) are filled
with a point type filler, i.e auger, or liquid nozzle.
[0219] The construction and arrangement of the elements as shown in
the exemplary embodiments are illustrative only. Although only a
few embodiments of the present disclosure have been described in
detail, those skilled in the art who review this disclosure will
readily appreciate that many modifications are possible (e.g.,
variations in sizes, dimensions, structures, shapes and proportions
of the various elements, values of parameters, mounting
arrangements, use of materials, colors, orientations, etc.) without
materially departing from the novel teachings and advantages of the
subject matter recited. The elements and assemblies may be
constructed from any of a wide variety of materials that provide
sufficient strength or durability, in any of a wide variety of
colors, textures, and combinations. Additionally, in the subject
description, the word "exemplary" is used to mean serving as an
example, instance, or illustration. Any embodiment or design
described herein as "exemplary" is not necessarily to be construed
as preferred or advantageous over other embodiments or designs.
Rather, use of the word "exemplary" is intended to present concepts
in a concrete manner. Accordingly, all such modifications are
intended to be included within the scope of the present disclosure.
Other substitutions, modifications, changes, and omissions may be
made in the design, operating conditions, and arrangement of the
preferred and other exemplary embodiments without departing from
the scope of the appended claims.
[0220] For purposes of this disclosure, references to the
orientation of the elements in this description are merely used to
identify the various elements as they are oriented in the FIGURES.
These terms are not meant to limit the element which they describe,
as the various elements may be oriented differently in various
applications. Further, the order or sequence of any process or
method steps may be varied or re-sequenced according to alternative
embodiments. Any means-plus-function clause is intended to cover
the structures described herein as performing the recited function
and not only structural equivalents but also equivalent structures.
Other substitutions, modifications, changes and omissions may be
made in the design, operating configuration, and arrangement of the
preferred and other exemplary embodiments without departing from
the scope of the appended claims. For example, the methods and
apparatus described herein may be adapted to produce
multi-compartment pouches wherein all compartments of the pouch are
filled with a composition or wherein at least one compartment is
filled and at least one compartment is empty (i.e. not filled). All
combinations of filled and empty compartments may be produced by
the method and apparatus described herein. Multi-compartment
pouches may have the compartments formed simultaneously or
sequentially or a combination of simultaneous and sequentially
formed compartments may be produced by the method and apparatus
described herein.
* * * * *