U.S. patent application number 15/994476 was filed with the patent office on 2018-12-06 for device, system, and method for providing modular vented opening package sealing.
This patent application is currently assigned to ALLEGIANCE CORPORATION. The applicant listed for this patent is ALLEGIANCE CORPORATION. Invention is credited to Nicholas Gus Fotis, Hean Huat Koed, Hooi Guan Kua, Danny W. Penny.
Application Number | 20180346171 15/994476 |
Document ID | / |
Family ID | 62705712 |
Filed Date | 2018-12-06 |
United States Patent
Application |
20180346171 |
Kind Code |
A1 |
Kua; Hooi Guan ; et
al. |
December 6, 2018 |
DEVICE, SYSTEM, AND METHOD FOR PROVIDING MODULAR VENTED OPENING
PACKAGE SEALING
Abstract
A modular attachment is provided to attach to a packaging
machine for forming a vent opening in a packaging film used for
packaging an item via a packaging machine, and attaching a
semipermeable or permeable vent covering material over the vent
opening. The vent opening with the attached vent covering material
may allow for sterilization of medical devices, medical equipment
or other medical supplies while packaged within the packaging film.
The modular attachment may include features for forming the vent
opening in the packaging film during delivery of the packaging film
for use in the packaging process, delivering the covering material
to the location of the vent opening, cutting the covering material
to size for covering the vent opening, and attaching the vent
covering material to the packaging film so as to cover the vent
opening.
Inventors: |
Kua; Hooi Guan; (Victoria,
AU) ; Koed; Hean Huat; (Penang, MY) ; Fotis;
Nicholas Gus; (McHenry, IL) ; Penny; Danny W.;
(Third Lake, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ALLEGIANCE CORPORATION |
Waukegan |
IL |
US |
|
|
Assignee: |
ALLEGIANCE CORPORATION
Waukegan
IL
|
Family ID: |
62705712 |
Appl. No.: |
15/994476 |
Filed: |
May 31, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62512788 |
May 31, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65B 55/10 20130101;
B65B 51/10 20130101; B65B 35/24 20130101; B65B 59/04 20130101; B65B
61/02 20130101; B65B 11/50 20130101; B65B 7/164 20130101; B65B
47/00 20130101; B65B 31/04 20130101; B65D 75/32 20130101; B65B
61/005 20130101; B65B 41/16 20130101; B65B 9/04 20130101; B65D
2205/025 20130101; B65B 55/103 20130101; B65B 61/06 20130101 |
International
Class: |
B65B 61/02 20060101
B65B061/02; B65B 41/16 20060101 B65B041/16; B65B 55/10 20060101
B65B055/10; B65B 11/50 20060101 B65B011/50; B65B 51/10 20060101
B65B051/10; B65B 35/24 20060101 B65B035/24 |
Claims
1. A machine for packaging an item, the machine comprising: a
conveyor for conveying the item; a packaging film for covering at
least a portion of the item; a packaging film roller assembly for
delivering the packaging film to the item; the machine further
comprising a convertible attachment, the attachment comprising: a
puncturing device for puncturing a vent opening in the packaging
film; a vent covering material for covering the vent opening; and a
vent covering material roller assembly for delivering the vent
covering material to the opening in the packaging film.
2. The machine of claim 1, wherein the packaging film is
non-permeable.
3. The machine of claim 1, wherein the packaging film is received
from a packaging film roll.
4. The machine of claim 1, wherein the vent covering material is
permeable.
5. The machine of claim 4, wherein the vent covering material is
permeable to a sterilization substance.
6. The machine of claim 5, wherein the sterilization substance is
ethylene oxide (ETO).
7. The machine of claim 1, wherein the vent covering material is
received from a vent covering material roll.
8. The machine of claim 1, further comprising: a second packaging
film for covering at least a second portion of the item.
9. The machine of claim 1, wherein the vent covering material
roller assembly is attachable to the packaging film roller
assembly.
10. The machine of claim 9, wherein the packaging film roller
assembly includes a frame, and wherein the vent covering material
roller assembly is attachable to the packaging film roller assembly
via the frame.
11. The machine of claim 1, wherein the puncturing device is
attachable to the packaging film roller assembly.
12. The machine of claim 11, wherein the packaging film roller
assembly includes a frame, and wherein the puncturing device is
attachable to the packaging film roller assembly via the frame.
13. The machine of claim 1, further comprising: an attaching
assembly for attaching the vent covering material to the packaging
film.
14. The machine of claim 13, wherein the attaching assembly
includes: a heat sealing device operable to heat sealably attach
the vent covering material to the packaging film.
15. The machine of claim 13, further comprising: a vent covering
material cutter for cutting the vent material.
16. The machine of claim 13, further comprising: a vent covering
material positioner for positioning the vent material.
17. A modular attachment for use with a packaging machine for
packaging an item, the packaging machine having a conveyor, a
packaging film roller assembly for delivering a packaging film for
packaging the item, the modular attachment comprising: a puncturing
device operable to puncture a vent opening in the packaging film; a
vent covering material for covering the vent opening; and a vent
covering material roller assembly for delivering the vent covering
material to the vent opening.
18. The modular attachment of claim 17, further comprising a vent
material cutter for cutting the vent covering material.
19. The modular attachment of claim 17, further comprising an
attachment assembly for attaching the vent covering material to the
packaging film.
20. The modular attachment of claim 17, further comprising a frame,
wherein the puncturing device and the vent covering material roller
assembly are attached to the frame.
Description
TECHNICAL FIELD
[0001] Aspects of the disclosure relate generally to the field of
packaging and sterilization, and in particular to devices, systems,
and methods for providing one or more vented openings in a
non-permeable packaging material and attaching a permeable or
semi-permeable cover to the packaging material utilizing a
convertible or modular attachment to a machine, so as to enable
sterilization of the contents of the packaging therethrough.
BACKGROUND
[0002] It is known to provide package sealing using a
form-fill-seal machine or the like (also interchangeably referred
to herein as "thermoform fill and seal" or "TFFS" machines), such
as the Multivac R535 Thermoforming Packaging Machine, made by
Multivac, Inc., of Kansas City, Mo. Such machines may include
various features, for example, as shown and described in U.S. Pat.
No. 5,105,603 ("the '603 patent"). The assembly machine 1 of
the'603 patent, as shown in FIG. 1 reproduced herein, may include a
roller based mechanism for moving items to be sealed along a top
side of an assembly machine 1. As shown in the '603 patent, items
to be sealed may include, for example, packages placed in
trough-shaped containers 6. The trough-shaped containers 6 are
moved along the assembly machine 1 to a location where a cover film
11 is fed from a roll to cover the containers 6. The fed film 11
may seal the items, such as by use of heat, and the film may be cut
after sealing, such that an encapsulated, sealed item is produced
thereby. Such film may be used, for example, to seal the top of a
container holding the item, or for sealing the upper half of an
item that is also being sealed from beneath by another film
feed.
[0003] Where packages are to be sterilized, it was known in the art
to provide a package having an entire top film or entire packaging
material overall that was composed entirely of a material that
allows ETO, steam, or other gas passage therethrough. Drawbacks of
these materials include high costs for the large top permeable or
semi-permeable material quantities to provide for either an entire
package made from permeable or semi-permeable material or a
pre-made top film portion comprising this permeable or
semi-permeable material, as well as other difficulties or
complexities with manufacture.
[0004] There are some machine makers that may provide an option to
make a package having this permeable or semi-permeable material in
a portion of the package rather than in an entire top portion of
the film. However, these machines are not convertible back to a
standard TFFS machine without having this feature; thus, once the
machine is made to provide this hybrid package it cannot later be
used to make a non-hybrid package. Moreover, such machines can only
be made to prepare one size of packaging; thus, the machine is
pre-ordered and made to accommodate that one size of packaging
without it being possible to later change those sizes. Finally, the
machines on the market can only make at most two packages per
machine index or cycle.
[0005] There is a need, however, for devices, systems, and methods
for providing one or more openings, such as vent openings, in such
films, along with the addition of a covering feature for such vents
that allows vent communication with the contents of such packages,
such as for use in sterilization, without requiring such large
amounts of film to encapsulate the packaged product, while allowing
for interchangeability of the machine to provide packages with such
vent openings (also known as hybrid packages) or to provide
packages without vent openings (also known as non-hybrid
packages).
SUMMARY
[0006] A device, system, and method for packaging that includes
providing a modular attachment to standard TFFS machines to make a
vent opening and a vent covering in a sealing or other packaging
film (e.g., a polymer film) is disclosed herein. Such packaging may
encapsulate an item by using a packaging machine, such as a TFFS
machine, to seal the item in a package, and may further include
attaching a semipermeable or permeable vent covering material to
the packaging film via a convertible or modular attachment system
that provides a vent passageway. For example, the packaging film
may be used to sealably protect an item that may be sterilized,
such as a medical or surgical instrument, device or product,
including but not limited to, a surgical drape, surgical gown,
medical suction tubing, medical suction handle, laryngeal mask
airway (LMA), catheter, syringe, gloves, wound care dressing
products, and/or other medical related clothing, equipment, and
medical instruments, including instruments contained in a
container, such as may comprise or be used in a medical kit, and
the like. The semipermeable or permeable vent covering material may
be used to allow sterilization of the item contained within the
packaging film by allowing sterilization gases to pass
therethrough. Such sterilization gases may include use of ethylene
oxide (ETO), for example, or steam sterilization. The device,
method, and system may include a modular attachment having features
for forming a vent opening in the packaging film during delivery of
the packaging film for use in the packaging process, delivering the
vent covering material to the location of the vent opening, cutting
the vent covering material to size for adequately covering the vent
opening, and attaching the vent covering material to the packaging
film so as to cover the vent opening. The joining of the vent
covering material to the packaging film may include a heat sealing
process or other conventional technique used in the art. This is
advantageous because the entire film of the outer package does not
need to be made from a semipermeable or permeable film, thus saving
on cost and production complexities with using such film, and
instead the final package can comprise at least one such vent
opening sealed with a semipermeable or permeable vent covering
material. This saves on the cost of film as well as allowing for
ease of manufacture by attaching a modular attachment to the
desired machines.
[0007] Aspects of the present disclosure further relate to a
modular attachment to a machine for automated packaging of an item,
such as a medical instrument, device, or product that may need to
be sterilized, the attachment may include features for providing an
opening in the packaging and a vent covering material for covering
the opening in the packaging. The machine may include a conveyor
for conveying the item in an assembly line fashion, such as to a
location where a packaging material may cover at least a portion of
the item. The packaging material may be delivered via a roller
assembly and/or other features that deliver the film to the
location where the item is covered. Any method commonly used in the
art for delivering of packaging material may also be used.
[0008] The modular attachment may further include an automated
puncturing device and/or other features for puncturing or otherwise
creating or forming a vent opening in the packaging material as
part of the assembly process. The features for puncturing or
otherwise creating such opening may be located so as to integrate
in an automated fashion with the automated packaging of the item,
such as by integrating a convertible or modular attachment to a
TFFS machine that can provide such puncturing feature. The vent
opening may be circularly or ovally shaped, or may have a
rectangular or square shape, for example, or any other shape that
is appropriate for providing a vent.
[0009] Aspects further include automated delivery, cutting to size,
and emplacement of a vent covering material for covering the vent
opening. Delivery of the vent covering material may include, for
example, use of a vent material roller assembly for delivering the
vent covering material to the vent opening in the packaging
material. Such roller assembly may be located so as to integrate in
an automated fashion with the automated packaging of the item, such
as by integrating a convertible or modular attachment to a TFFS
machine that can provide a roller assembly.
[0010] Cutting to size of the vent material may include, for
example, use of a cutting device for cutting the vent covering
material prior to delivery for covering the opening in the
packaging material. Such cutting device may be located so as to
integrate in an automated fashion with the automated packaging of
the item, such as by integrating a convertible or modular
attachment to a TFFS machine that can provide a cutting device.
[0011] Emplacement of the vent material may include, for example,
devices and/or mechanisms for positioning and holding the vent
covering material at the vent opening location, and heating and/or
use of an adhesive, and/or other features for attaching the vent
covering material to the packaging film. Such emplacement
mechanisms may be located so as to integrate in an automated
fashion with the automated packaging of the item, such as by
integrating a convertible or modular attachment to a TFFS machine
that can provide an emplacement mechanism.
[0012] Another advantage of the modular attachment added to a
machine as disclosed herein is the convenience of being able to
switch back and forth between a machine that makes standard
packages, e.g., packages without the vented opening and cover and
without the modular attachment (e.g., non-hybrid packages), and a
machine that contains the modular attachment and can make vented
packages (e.g., hybrid packages). The modular or convertible
attachment can be easily added to or removed from a standard
packaging machine depending on the type of packages that are
desired. For example, where a vented package is desired, the
modular attachment can be connected to the packaging machine being
used to make the standard packages. Once the vented packages are
completed and it is desired to convert back to the standard
packages, the modular attachment can be easily removed, or
alternatively bypassed, to allow for continued operation of the
packaging machine to form the standard packages. Adding the modular
attachment to an existing packaging machine allows for a low cost
option to modify the existing equipment and machine to allow for a
modification to the type of packages that are produced without
permanently changing the packaging machine.
[0013] Yet another advantage of the modular attachment is that any
number of vent openings and covers can be placed on multiple
packages. For example, one or more packages or at least the top
film of one or more packages can be fed through the attachment to
create a vent opening and to seal it with the vent covering
material. In yet another embodiment, a single package can be made
with one or more vent openings in the package, depending on how
many entry points are desired to the interior of the package for
the sterilization gases. Moreover, the modular attachment can be
used on any size packaging, such that different size packages can
be made on the same machine and do not require use of a different
modular attachment but merely an adjustment of the components on
the existing modular attachment.
[0014] Additional advantages and novel features of these aspects
will be set forth in part in the description that follows, and in
part will become more apparent to those skilled in the art upon
examination of the following or upon learning by practice of the
disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are incorporated into and
constitute a part of this specification, illustrate one or more
example aspects of the present disclosure and, together with the
detailed description, serve to explain their principles and
implementations.
[0016] FIG. 1 shows a packaging machine of the prior art.
[0017] FIG. 2 shows an example packaging machine with a modular
attachment for providing an opening and a vent, in accordance with
aspects of the present disclosure.
[0018] FIG. 3 shows a perspective view of an example convertible or
modular machine attachment comprising a vent opening and covering
station, in accordance with aspects of the present disclosure.
[0019] FIG. 3A shows a cross-sectional view of the example vent
opening and covering station 250a of FIG. 3, including details of
various additional features in accordance with aspects of the
present disclosure.
[0020] FIG. 4 shows an example modular vent opening and covering
station from a perspective view on one side of a packaging film
being drawn therethrough, in accordance with aspects of the present
disclosure.
[0021] FIG. 5 shows a side view of a portion of the modular vent
opening and covering station of FIG. 4.
[0022] FIG. 6 shows a perspective view of the modular vent opening
and covering station of FIG. 4 from the reverse side angle from the
view shown in FIG. 4.
[0023] FIG. 7 shows a close up view of the packaging film for the
modular vent opening and covering station of FIG. 4 moving past an
element of an example puncturing device for forming vent openings,
just after a vent opening has been formed in the packaging
film.
[0024] FIG. 8 shows a close up view of the device for attaching a
vent covering material to a packaging film using the modular vent
opening and covering station of FIG. 4.
[0025] FIG. 9 shows a perspective view of the modular vent opening
and covering station of FIG. 4 from the same side of the packaging
film as shown in FIG. 4.
[0026] FIGS. 10 and 11 show partially disassembled views of
elements of an example cutter, as well as other components, in
accordance with aspects of the present disclosure.
[0027] FIG. 12 shows a partially disassembled view showing the roll
for the packaging material and an element of the cutter, as well as
other components, in accordance with aspects of the present
disclosure.
[0028] FIG. 13 shows a partially disassembled side view showing
various portions of the feeder, the packaging material, and other
components, in accordance with aspects of the present
disclosure.
[0029] FIG. 14 shows a perspective view of another example modular
vent opening and covering station, in accordance with aspects of
the present disclosure.
[0030] FIG. 15 shows a side view of an example packaging machine
having a modular vent opening and covering station, along with a
schematic indication of the sequence of various functions for vent
opening and covering related operation, in accordance with aspects
of the present disclosure.
[0031] FIG. 16 shows the schematic portion of FIG. 15, including
details on the sequence of various vent opening and covering
related operations thereof.
[0032] FIGS. 17 and 18 show additional representative schematic
views of operation in accordance with example implementations of a
packaging machine having a modular vent opening and covering
station in accordance with aspects of the present disclosure.
[0033] FIG. 19 shows additional representative views of various
features in accordance with a packaging machine having a modular
vent opening and covering station in accordance with aspects of the
present disclosure.
[0034] FIG. 20 shows an example packaged product produced using a
modular packaging attachment in accordance with aspects of the
present disclosure, the package is shown with the top film being
opened.
DETAILED DESCRIPTION
[0035] The detailed description set forth below in connection with
the appended drawings is intended as a description of various
configurations and is not intended to represent the only
configurations in which the concepts described herein may be
practiced. The detailed description includes specific details for
the purpose of providing a thorough understanding of various
concepts. However, it will be apparent to those skilled in the art
that these concepts may be practiced without these specific
details. In some instances, well known structures and components
are shown in block diagram form in order to avoid obscuring such
concepts.
[0036] Aspects of the present disclosure relate to devices,
systems, and methods for providing a vent opening and a
semipermeable or permeable vent covering material in a sealing or
other packaging film (e.g., a polymer film) for packaging at least
a portion of an item, such as by using a packaging machine, such as
a thermoform fill and seal (TFFS) machine, in combination with a
convertible or modular attachment comprising a vent opening and
vent covering material station, or alternatively, having the vent
opening/covering station built into the machine. For example, the
packaging film may be used to sealably protect an item that may be
sterilized, such as a drape, gloves, gown, or other medical related
clothing or equipment, or a medical instrument, which may be
contained in a container, film package, or such as may comprise or
be used in a medical kit. A semipermeable or permeable vent
covering material can be placed on a top film layer or cover having
an opening or puncture, to enclose the container, package or kit
that may be used to allow sterilization of the item contained
within the packaging film by allowing sterilization gases to pass
therethrough while preventing other gases or contaminants from
entering the package through the vent covering, maintaining the
interior of the package in a sterilized and relatively contaminant
free state. Such sterilization gases may include use of ethylene
oxide gases (ETO), for example. In one embodiment, a modular
attachment can be placed on or attached to a packaging machine and
may include features for forming the vent opening in the packaging
film during delivery of the packaging film for use in the packaging
process, delivering the vent covering material to the location of
the vent opening, cutting the vent covering material to size for
covering the vent opening, and attaching the vent covering material
to the packaging film so as to cover the vent opening. These steps
may be performed on a standard TFFS machine, for example, via
coupling of the convertible or modular attachment to the standard
TFFS machine, or alternatively, via the integration of the vent
opening/covering station into the TFFS machine such that it is not
modular.
[0037] FIG. 2 shows an exemplary embodiment of a packaging machine
including a modular attachment for providing an opening and a vent,
in accordance with aspects of the present disclosure. The packaging
machine 200 of FIG. 2 can include a machine frame 202 and supply
roll 203 for supplying a bottom film for covering a lower portion
of a product with film. The machine 200 can include a product
delivery belt and/or other transport features 210 for moving
products to be packaged, for example in a machine direction from
the first end 202a of the frame 202 toward the second end 202b. A
top film may be supplied from a supply roll 220 to cover an upper
portion of the product with film and/or to seal the product within
a package. Sealing of the film about the product can be done by
conventional techniques known as part of the standard TFFS machine
features. For example, in one standard embodiment a top web of film
and a formed bottom web of film can be drawn together to a seal
station where heat sealing can be performed. The machine 200 can
further include a vent opening and covering station 250, which is
part of a convertible or modular attachment for coupling to the
machine 200, that may include various features for punching or
cutting a vent opening in the film delivered from the top film
supply roll 220, delivering vent covering material, cutting the
vent covering material to an appropriate size to cover the vent
opening, and attaching the vent covering material to the top film
so as to cover the vent opening. In one aspect, a vent covering
material can be provided from a material consisting of Tyvek.RTM.
at different grammage, such as 1073, 1059, 2FS, a paper material,
either re-inforced or not re-inforced, and the like. In another
aspect, a vent covering material can be provided from a material
such as Tyvek.RTM. made by DuPont.RTM. of Wilmington, Del.
[0038] FIG. 3 shows a perspective view of an example convertible or
modular attachment comprising a vent opening and covering station
250a. As shown in FIG. 3, the vent opening and covering station
250a may include a single covering roll 300, which may be used to
supply a vent covering material for covering a vent opening in a
top film (e.g., top film from supply roll 220 of FIG. 2). The
station 250a may further include a puncturing device 310, such as a
punch or cutter, to create the vent opening in the top film. The
top film (e.g., from supply roll 220 of FIG. 2) may be fed into the
station 250a at or near location F1 and past location F2. A vent
opening may be formed, for example, in the top film during the feed
of the top film past the puncturing device 310. Vent openings may
be punched at intervals in the film feed, such that the vent
opening can then be located above a top surface of items being
sequentially covered by the top film, for example, as the top film
is emplaced on the item being covered as it passes along the
product delivery belt and/or other transport features (see belt
and/or other transport features 210 of FIG. 2).
[0039] The top film with the vent opening may pass location F2
after puncturing by puncturing device 310. As the vent opening
passes location F2, a portion of the vent covering material 301 fed
from roll 300 may align with the vent opening. A cutter may cut the
vent covering material 301 to size so as to cover the vent opening,
and the cut portion of the vent covering material 301 may be
emplaced and attached to the top film so as to cover the vent
opening. The covering material 301 may be attached to the top film,
for example, via various attachment features as known in the art,
which may include, for example, use of a heated press 320, with or
without use of an adhesive, or other appropriate features and/or
procedures to ensure the covering material 301 is sealably attached
to the top film about the vent opening.
[0040] FIG. 3A shows a cross-sectional view of the modular vent
opening and covering station or attachment 250a of FIG. 3. In
addition to the features shown in FIG. 3, FIG. 3A further shows an
additional portion of the puncturing device 315, elements of a
feeder 350, a cutter 360, and various features 380 for electrical
or other operational control of the heated press, the feeder, and
the cutter. For example, such features 380 may include one or more
solenoids, electric motors, and electronic or other automated or
other control features to control such operations.
[0041] FIGS. 4-13 contain pictures of various views of other
exemplary embodiments of a modular vent opening and covering
station or attachment 250b and portions thereof, as well as
portions of an overall packaging device in which the vent opening
and covering station 250b operates, in accordance with aspects of
the present disclosure. The vent opening and covering station 250b
of FIGS. 4-13 may be, or may be similar to, the vent opening and
covering station 250 shown in FIG. 2 or the station 250a shown in
FIG. 3, for example. As shown in FIGS. 4-13, operations of the vent
opening and covering station or attachment 250b may include
receiving a top film 221 (e.g., received from a top film roll, such
as or similar to the roll 220 of FIG. 2), which passes locations
F1' and F2'; the top film 221 may thereby be engaged with a
puncturing device 310', 315' and various features for cutting,
positioning, and attachment of the covering material to the top
film 221.
[0042] FIG. 4 shows the vent opening and covering station 250b from
a perspective view where one side of a film 221 can be drawn
therethrough. In operation for creating a vent opening in the top
film 211, for example, the top film 221 may be drawn past the
element of the puncturing device 310' to the point shown in FIG. 4,
and movement of the top film 221 may then be momentarily stopped.
The puncturing element 310' may then operate a punch feature so as
to cause an outer shaped punch to be expelled from the puncturing
element 310' so as to cut a vent opening, for example, in
conjunction with cooperative operation of a second element 315'
(FIGS. 6 and 10-12), which may include, for example, a punch
receiving opening and a source of suction, thereby enabling a clean
cut of the vent opening in the top film 221 and can draw the cut
portion away by suction therefrom. FIG. 5 shows a side view of a
portion of the vent opening and covering station 250b. FIG. 6 shows
a perspective view from the reverse side of the film 221 from the
view shown in FIG. 4.
[0043] FIG. 7 shows a close up view of the film 221 moving past an
element 310' of a puncturing device for forming vent openings, just
after a vent opening 601 has been formed. FIG. 7 is from a
perspective view from the reverse side of the film 221 from the
view shown in FIG. 4. The image of FIG. 7 shows a close up view of
the film 221 moving past an element of the puncturing device 310'
for forming vent openings, just after a vent opening 601 has been
formed in the top film 221.
[0044] FIG. 8 shows a close up view of a portion 320 of the device
for attaching the vent covering material to the top film 221. After
the vent opening has been formed in the top film 221, the portion
of the top film 221 having the vent opening therein may be moved to
a position adjacent or near the device 320 for attaching the vent
covering material to the top film 221. The top film 221 may be
stopped, such that the vent opening remains adjacent to or near the
device 320. A portion of the vent covering material may also be
drawn from the vent covering material roll 300' (FIGS. 5 and 6) so
as to be adjacent to the vent opening in the top film 221 and
adjacent or near the device 320 when the film 221 is at the stopped
point. A properly sized portion of the vent covering material from
roll 300' may then be cut to a size so as to cover the vent opening
and held in place thereby (e.g., by pressure between a portion of
the device 320 and the film 221). The device 320 may then be used
to attach the cut cover portion to the top film 221 portion about
the vent opening. For example, the cut cover film portion 221 may
be sandwichably compressed to the top film 221 between two portions
of the device 320, and the device 320 may then heatably seal the
cover film portion to the top film 221, where device 320 can be a
support plate that allows heat sealing to take place, as shown in
FIG. 3A. For the vent covering material, it typically can be cut to
a size that is just larger than the vent opening. For example, in
one aspect, a seal width of about 6 mm can be assumed such that at
least an additional 6 mm is allowed for sealing width and at least
an additional 2 mm can be added for all edges. For example, where
the vent opening is 30 mm.times.40 mm, the vent covering material
can be cut to at least 46 mm.times.56 mm, however, any dimensions
are possible. Any dimension vent opening can be used as well as any
size vent covering material that adequately covers and seals the
vent opening.
[0045] FIG. 9 shows a perspective view of the vent opening and
covering station 250b from the same side of the film 221 as shown
in FIG. 4, and also shows the film 221 being drawn along the
product delivery belt and/or other transport features of the
packaging machine. The view of FIG. 9 shows a vent opening covered
by a cover film portion 901 that is sealably attached to the film
221.
[0046] FIGS. 10 and 11 present partially disassembled views of
elements of the cutter 310', and the suction chute 315', as well as
other components, in accordance with aspects of the present
disclosure. The vent dimension can be changed, in one embodiment,
by changing the cutter tooling. The suction chute 315' can be used
to vacuum and direct and/or remove the cut pieces from the punch
holes section to a waste collector or a trash bin.
[0047] FIG. 12 is a partially disassembled view showing the roll
300' for the covering material 301' and the elements of the cutter
301' and suction chute 315', and the corresponding heat sealer
assembly 316' for the covering material, as well as other
components.
[0048] FIG. 13 is another partially disassembled side view showing
various portions of the feeder 350', the covering material 301',
the heated press 320' and other components, in accordance with
aspects of the present disclosure.
[0049] FIG. 14 shows a perspective view of another embodiment of a
modular and moveable attachment comprising a vent opening and
covering station 1250, in accordance with aspects of the present
disclosure. The station 1250 of FIG. 14 is similar to that shown in
FIG. 3, but includes three sets of vent opening and covering
components, along with three corresponding covering rolls 1300,
which may be used to supply covering material for covering three
vent openings in a top film (e.g., top film from supply roll 220 of
FIG. 2); more or less covering rolls can be used. The station 1250
may include three puncturing devices 1310 to create three vent
openings in the top film; again more or less puncturing devices and
covering rolls may be used, however, it is preferred that the same
number of covering rolls as puncturing devices or puncturing
mechanisms be used. In accordance with aspects of the present
disclosure, the top film (e.g., from supply roll 220 of FIG. 2) may
be fed into the station 1250 through location F5 and past location
F6. The vent openings may be formed, for example, in the top film
during the feed of the top film past the puncturing devices 1310.
The vent openings may be punched at intervals such that the vent
openings will then be located above the top surfaces of items being
covered by the top film. For example, the top film with three vent
openings may be cut into multiple film strips, which may then each
be emplaced on items being covered as these items pass along a
product delivery belt and/or other transport features for a
packaging machine (see belt and/or other transport features 210 of
FIG. 2, which may include, for example, three spaced rows of
devices).
[0050] The top film with the vent openings may pass location F6
after being punctured by puncturing devices 1310, as shown in FIG.
14. As the vent openings pass near location F6, a portion of the
covering material 1301 fed from each of rolls 1300 may align with
corresponding vent openings in the film. A cutter may cut
corresponding portions of covering material 1301 to size such that
it may cover the corresponding vent openings in the top film, and
the cut portions of the covering material 1301 may be attached to
the top film so as to cover each vent opening. The vent covering
may be sized similarly to the vent opening or it may be larger than
the vent opening; however, the vent covering is at least large
enough to cover the vent opening. Each portion of the covering
material 1301 may be attached to the top film, for example, via
various attachment features (also interchangeably referred to
herein as an "attachment assembly"), which may include, for
example, use of a heated press 1320 and/or positioning and/or other
mechanisms; the attachment process may also or alternatively
include use of an adhesive, or other appropriate features and/or
procedures to ensure the covering material 1301 is sealably
attached to the top film.
[0051] FIG. 15 shows a side view of yet another embodiment of a
packaging machine 2200 having a modular vent opening and covering
station or attachment 2250, along with a schematic indication of
the sequence of various functions for vent opening and covering
related operation, in accordance with aspects of the present
disclosure. The packaging machine 2200 of FIG. 15 may be similar to
the machine 200 of FIG. 2, including having a machine frame 2202
and supply roll 2203 for supplying a bottom film for covering with
film a lower portion of a product to be packaged. The machine 2200
may include a product delivery belt and/or other transport features
2210 for moving products to be packaged, for example in a direction
from a first end 2202a of the frame 2202 toward a second end 2202b.
A top film may be supplied from a supply roll to cover with film an
upper portion of the product to be packaged. The machine 2200 may
further include a modular and moveable attachment comprising a vent
opening and covering station 2250 that may include various features
for punching or cutting a vent opening in film delivered from the
top film supply roll, delivering, cutting, and positioning a vent
covering material, and attaching the cut and positioned vent
covering material to the top film to cover the vent opening.
[0052] The schematic portion of FIG. 15, appearing at the lower
portion of the figure as shown, indicates the sequence of various
vent opening and covering related operations, which are further
shown and detailed in FIG. 16. As shown in the representative
schematic of FIG. 16, in a first sequence for operating the machine
(e.g., packaging machine 2200 of FIG. 15), the bottom film, the top
film, and the vent covering material may all be loaded to the
packaging machine. The top film may be fed through the modular vent
opening and covering station (e.g. station 2250 of FIG. 15), and
the covering material may also be fed within the modular vent
opening and covering station. The top film may pass through the
features for vent formation, such as through a punching device, for
example. These operations may occur via any known method in the
art, such as, for example, via servo driven feed and cutting.
[0053] Next, as further shown in FIG. 16, the vent covering
material may be fed, positioned, cut, and then attached to the top
film, such as by heat sealing (e.g., at a heat sealing station).
The top film with the attached vent covering material may then be
delivered for further operations of the packaging machine, along
the lines as normally provided by a packaging machine in the
absence of the vent opening and covering related operation. These
further packaging related features may include, for example,
sealing the packages with the contained item, providing ink jet or
other printing on the packaging, and cutting and/or slitting the
cover film for the packages to provide separated, individually
covered and sealed packages, with various features as needed for
use thereof. In the embodiment shown in FIGS. 15 and 16, Step 1
shows an un-winder for loading the top and bottom forming web
(e.g., roll of forming film). The top web roll can be loaded and
threaded through the modular attachment. The bottom web roll can be
loaded using a normal loading process that is typically used for
TFFS machines; it is not required to thread the bottom film through
the attachment. Next, the packages can be formed and preheated at
Step 2. At this step, the top web passes through the attachment for
hole punching the vent holes and is then followed by a heat-sealing
step to attach the vent material. In the embodiment shown, the
holes that are punched are in a series of 4 punches, but any size
and number can be used that fits the width of the packaging
machine. At Step 8, the roll of vent material can be loaded and
threaded through the attachment; the vent material in this
embodiment can be a Tyvek or paper material.
[0054] Then the desired items to be packaged can be loaded into the
formed packages, whether manually or automatically, depending on
the machine capabilities, as shown at Step 3. At Step 4, a sealing
step is shown where the vented web is advanced in the machine
direction D to the heat sealing station at Step 4, where sealing
can occur as in a conventional TFFS machine. Step 5 illustrates ink
jet printing, which is a conventional process, and at Step 6, a
cross-cutting of the packages occurs to separate the connecting
rows of packages into separated strips, which is also
conventionally known. Finally, at Step 7, the slitting step occurs
to separate or singulate the strips of packages into individual
packages.
[0055] It is not necessary to follow the numeric order of these
steps in practice; for example, step 8 would not occur as the last
step in the process but would rather occur early on in the process
so that the vent material is pre-loaded and ready for use when the
packages are being made. In one instance, the length of the machine
can be designated as L, which can vary depending upon the machine
steps present in the TFFS machine. In another instance, the machine
length L can be tailored to product requirements, and for example
can be a length greater than 8000 mm. FIG. 15 demonstrates one
embodiment of a finished, packaged product 2260 where four packages
per machine cycle were made within a mold area of approximately 500
mm.times.500 mm.
[0056] FIGS. 17 and 18 show additional representative schematic
views of operation in accordance with example implementations of a
packaging machine having a modular vent opening and covering
station, in accordance with aspects of the present disclosure. In
the example implementation as shown in FIGS. 17 and 18, one or more
diverters 3306 can be provided to direct the web/film to the
desired path and a dancer 3300, which can function as a web/film
accumulator, may be used to facilitate operation. A servo-feed 3301
can also be provided, to provide unwinding of the web/film, which
can be motorized. In addition, a paper de-winder 3305 may be
included, and in the embodiment shown in FIGS. 17 and 18, since it
is a 2.times. line, there can be two de-winders. A paper cutting
station 3303 can be situated adjacent the paper de-winder 3305. A
sealing station 3304 is provided. After the web/film passes the
cutting station 3303, the punched holes 3307 in the film are shown.
FIGS. 17 and 18 further describes the detailed area shown in FIG.
16.
[0057] FIG. 19 shows additional representative views of various
features in accordance with a packaging machine having a modular
vent opening and covering station in accordance with aspects of the
present disclosure. As shown in FIG. 19, in representative diagram
portion 1500a, the attachment process for attaching the vent cover
film to the top film may include, for example, air pressure based
use of one or more press components 1510, such as air pressure
driven pistons in cylinders, to compress the vent covering material
1515 and top film 1520 between a cold mold or molds 1525 and a hot
seal mold or molds 1530, as shown at Step 4, in accordance with
aspects of the present disclosure. The top press and the bottom
press can both be compressed using air pressure. The top film 1520
can comprise an HDPE film, for example. In addition, the top film
1520 can comprise an HDPE material, for example, with holes. The
top cold mold, for example, can be transferred by an X-Y-Z arm
(i.e., 3 servo-axis). The cold mold 1525 may, for example, be water
cooled. In certain aspects, the seal can be a circular seal or a
square seal, and in another aspect, the seal can have a width of
about 6 mm.
[0058] Representative diagram portion 1500b of FIG. 19 shows a
representative top view of the cold mold portions 1525 having
features for holding and positioning of the vent cover material, in
accordance with aspects of the present disclosure. These holding
and positioning features may be suction based, for example, and may
include one or more vacuum operated suction/silicon pads to pick
and transfer the paper or Tyvek to the sealing station. The top
mold can be operated by, for example at Step 3, a 3-axis arm and
vacuum.
[0059] Representative diagram portion 1500c of FIG. 19 shows a
representative top view of an example insertion portion 1535 and
receiving portion 1540 for a cutting device used to form vent
openings in a top film, such as by a punch operation of the
insertion portion 1535 into the receiving portion 1540, in
accordance with aspects of the present disclosure. For example, at
Step 2 of 1500c cutting into 4 pieces is illustrated and then
applying auto-pitch (i.e., y-axis pitching).
[0060] Representative diagram portion 1500d of FIG. 19 shows a
representative top view of the example insertion portion 1535 and
auto-pitch portion 1540 of diagram portion 1500c in an engaged
position for cutting, such as via servo operation. In the example
shown, there can be vacuum blocks along the bottom and x-pitching
to mechanically adjust. The vacuum blocks can operate to hold the
Tyvek in position before cutting. In the embodiment shown at Step
1, the servo-feed can have a 2.times. length of the vent
material.
[0061] Representative diagram portion 1500e of FIG. 19 shows a
representative cross-sectional view of another aspect of a cutting
feature and cover feed for a two vent opening and cover device, in
accordance with aspects of the present disclosure. Illustrated at
1500e are two servo-feed nip rollers 1708 that can be driven by,
for example, a servo-motor, and can feed or pull the vent material
1700, for example Tyvek or paper or the like, toward the cutters
1702, 1704, where the servo-feed nip rollers. Two vent coverings
can be stamped out of the vent material using two cutters, 1702 and
1704, such as shear cutters, for example. Each cutter can have a
top vertical bar and a bottom vertical bar that comes together
toward the film to cut a vent covering out of the vent material.
The cutters 1702 and 1704 can be slightly off-set from one another,
this off-set feature aids in providing the desired cutting action.
The cutters 1702 and 1704 can be activated by cylinder or by
servomotor. After the vent material 1700 is fed through the
machine, the cutters 1702 and 1704 can be activated. The cutting
action can result in two pieces of vent material covering (not
shown) of approximately equal length. In this embodiment, a square
or rectangular vent covering can be provided. If a more circular
vent covering cutout is desired a different cutter mechanism can be
provided, such as a punch cutter. In addition, two vacuum blocks
1706 can be provided to hold or retain the cutout vent covering for
the next process step, which is the heat sealing step. In referring
to the previous figures in FIG. 19, at 1535, for example, the first
two vents can be stationary where the next two vents are moveable
by Y-pitching.
[0062] FIG. 20 show an example packaged product produced using a
packaging device in accordance with aspects of the present
disclosure. As shown in FIG. 20, the packaged product 1600 may
include a film 1610 for containing the product 1615 and a
semipermeable or permeable vent cover portion 1620 attached to the
top film 1610 to cover the vent opening. The film 1610 may
comprise, for example, a polymer film, such as high density
polyethylene (HDPE) with a peelable layer, PolyEthylene
Terephthalate (PET) laminate with a peelable layer, linear tear
opening film for non-peelable pouches, and the like. The
semipermeable or permeable vent cover portion 1620 may comprise a
film that will allow ETO or steam sterilization, such as, for
example, Tyvek.RTM. or paper material. Any size packages can be
provided with the vent feature as described herein. The sample
package shown in FIG. 20 is in the process of being opened where
the top lid including vent covering is in the process of being
peeled off of the package.
[0063] In addition, there is no limit to the number of packages
across that can be made, with the exception of being limited by the
width of the machine. Moreover, the vent location, i.e., where in
the package it is placed, and the dimension can be changed and
modified as the user wishes by simply making changes to the modular
unit settings. For example, packages of different dimensions can be
made using the modular attachment by moving the punch and seal
mechanism up and down accordingly. In FIG. 3A, an embodiment is
shown where the distance between the punch and the seal station is
exactly the length of a package. In order to accommodate packages
of different lengths, in one aspect, one can move just the
punch/seal station up or down accordingly to the desired size. In
another example, the dimensions of packages can be adjusted by
moving the entire attachment, which can be on a rail, and can be
moved back and forth accordingly. In an example shown in FIG. 2A,
the attachment distance to the TFFS seal station is a round
multiple number length of the package length, thus, this can be
adjusted accordingly in conjunction to the adjustment made to the
punch/seal station. In contrast, where the station is not a round
multiple number of length of packages, then the hole design may be
in a location that is in the middle of the pouch, thus, the
location of the hole with respect to the pouch may be shifted or
uncontrollable in position.
[0064] A regular package without the vent described herein can
easily be made from a TFFS machine having the modular attachment in
place by either removing the attachment fully or, alternatively,
one can by-pass the attachment and use the remaining stations of
the machine to produce packages without the vented feature
described herein. This easy conversion to/from hybrid packages
saves on time and cost when different types of packages are
required or even different sizes, as sizes can also easily be
interchanged as discussed above.
[0065] While the aspects described herein have been described in
conjunction with the example aspects outlined above, various
alternatives, modifications, variations, improvements, and/or
substantial equivalents, whether known or that are or may be
presently unforeseen, may become apparent to those having at least
ordinary skill in the art. Accordingly, the example aspects, as set
forth above, are intended to be illustrative, not limiting. Various
changes may be made without departing from the spirit and scope of
the disclosure. Therefore, the disclosure is intended to embrace
all known or later-developed alternatives, modifications,
variations, improvements, and/or substantial equivalents.
[0066] Thus, the claims are not intended to be limited to the
aspects shown herein, but are to be accorded the full scope
consistent with the language of the claims, wherein reference to an
element in the singular is not intended to mean "one and only one"
unless specifically so stated, but rather "one or more." All
structural and functional equivalents to the elements of the
various aspects described throughout this disclosure that are known
or later come to be known to those of ordinary skill in the art are
expressly incorporated herein by reference and are intended to be
encompassed by the claims. Moreover, nothing disclosed herein is
intended to be dedicated to the public regardless of whether such
disclosure is explicitly recited in the claims. No claim element is
to be construed as a means plus function unless the element is
expressly recited using the phrase "means for."
[0067] It is understood that the specific order or hierarchy of the
processes/flowcharts disclosed is an illustration of example
approaches. Based upon design preferences, it is understood that
the specific order or hierarchy in the processes/flowcharts may be
rearranged. Further, some features/steps may be combined or
omitted. The accompanying method claims present elements of the
various features/steps in a sample order, and are not meant to be
limited to the specific order or hierarchy presented.
[0068] Further, the word "example" is used herein to mean "serving
as an example, instance, or illustration." Any aspect described
herein as "example" is not necessarily to be construed as preferred
or advantageous over other aspects. Unless specifically stated
otherwise, the term "some" refers to one or more. Combinations such
as "at least one of A, B, or C," "at least one of A, B, and C," and
"A, B, C, or any combination thereof" include any combination of A,
B, and/or C, and may include multiples of A, multiples of B, or
multiples of C. Specifically, combinations such as "at least one of
A, B, or C," "at least one of A, B, and C," and "A, B, C, or any
combination thereof" may be A only, B only, C only, A and B, A and
C, B and C, or A and B and C, where any such combinations may
contain one or more member or members of A, B, or C. Nothing
disclosed herein is intended to be dedicated to the public
regardless of whether such disclosure is explicitly recited in the
claims.
* * * * *