Patent Application
20240109704
The present invention relates generally to a flexible pouch for packaging a product and, more specifically, to a flexible pouch for packaging a beverage containing alcohol.
Various types of disposable containers are known to those skilled in the art for storing fluid and/or dry products such as a liquid, granular material, powder, and the like. Examples of such containers include metal cans, plastic bottles, glass bottles, and flexible pouches. In some instances, consumers prefer the convenience of flexible pouches over other types of containers due to the shape, size, shelf life, and storage capability thereof. In addition, a flexible pouch can be formed and filled on a single manufacturing line and thereby reduce storage space, logistics related to the manufacture and shipping of filled flexible pouches, etc. As such, manufacturers have recognized the packaging benefits with respect to flexible pouches.
Although flexible pouches have been used for some time to package and distribute various products; however, previous pouches have not provided adequate protection for the product stored therein, specifically, alcoholic beverages. Previous flexible pouches resulted in inadequate levels of oxygen permeability and sensory qualities, such as taste, flavor, aroma, and color, due to the composition and structure of the flexible pouch. Specifically, the formulation of the pouch panel that forms the pouch and the seal that closes off the pouch after filling with product.
Accordingly, the present disclosure provides an improved flexible pouch for a liquid or beverage, e.g., having an alcoholic content. The flexible pouch includes a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and a first side edge and a second side edge extending therebetween the upper edge and the lower edge. The pouch also includes an opening structure or mechanism disposed in the panel for accessing the beverage having an alcoholic content contained within the pouch.
One advantage of the present invention is that a flexible pouch and method of making a flexible pouch is provided that utilizes a laminate material that is transparent or opaque. A further advantage of the present invention is that a flexible pouch and method of making a flexible pouch is provided that is cost effective to manufacture. Yet a further advantage of the present invention is that the flexible pouch retains its shape as the product is removed. Still yet a further advantage of the present invention is that a flexible pouch and method of making the flexible pouch is provided that retains its flavor, color, aroma, and taste over the shelf life of the product.
According to an aspect, a flexible pouch for alcoholic beverages is disclosed. The flexible pouch includes a front wall and a back wall defining a compartment. An opening structure is in fluid communication with the compartment. The front wall and/or the back wall is composed of a panel of film laminate. The film laminate includes an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE). The front wall and the back wall are joined together by a top seal.
Pursuant to an implementation, the top seal includes a double seal disposed along a top edge of the front wall and the back wall. The double seal may include at least one heat seal. For example, the double seal may include a first heat seal and a second heat seal. As another example, the double seal may include a first ultrasonic seal and a second heat seal. The provision of a double seal helps prevent leakage, for example by removing excess moisture during the filling process, and reduces oxygen permeability by providing a structurally sound top seal.
In an example, the middle barrier layer may comprise a titanium oxide film.
In another example, the middle barrier layer may comprise a silicon oxide film.
The laminate structure may include further interlayers. For example, a layer of ethylene vinyl alcohol (EVOH) may be provided between the outer layer and the inner layer. As another example, a layer of nylon may be provided between the outer layer and the inner layer.
The opening structure may include a tear notch disposed between the top seal and the compartment. Additionally, the opening structure may include a resealable zipper disposed between the tear notch and the compartment.
In another example, the opening structure may include a fitment with a spout extending through the top seal.
The flexible pouch may include a bottom gusset disposed at a bottom edge of the first wall and the second wall.
According to another aspect, a method of forming a flexible pouch for alcoholic beverages is disclosed. The method includes forming a pouch panel from a film laminate, the film laminate including an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE); forming a pouch body from the pouch panel, the pouch body including a first wall and a second wall defining a compartment with an open top; filling the compartment with a product; and sealing the open top with a top seal, the top seal joining the first wall and the second wall together.
Sealing the open top with the top seal may include forming a double seal along a top edge of the first wall and the second wall. The double seal may be formed by heat sealing a first seal along the top edge and then heat sealing a second seal in a region of the first seal. Alternatively, double seal may be formed by ultrasonic welding a first seal along the top edge and then heat sealing a second seal in a region of the first seal.
The middle barrier layer may comprise a titanium oxide film or a silicon oxide film.
Forming the pouch body may include providing an opening structure in the pouch panel, the opening structure in fluid communication with the compartment. The opening structure may include at least one of a tear notch, a resealable zipper, and a weakened straw pierceable portion. Pursuant to another example, the opening structure includes a fitment (e.g., a spout).
Other features and advantages of the present invention will be readily appreciated, as the same becomes better understood after reading the subsequent description taken in conjunction with the accompanying drawings.
It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein and together with the description serve to explain the principles and operations of the claimed subject matter.
Referring to
In one aspect, the pouch may be transparent. Various laminate structures may be utilized for the transparent pouch.
One example of a transparent laminate, as shown in
Another example of a transparent laminate, as shown in
Another example of a transparent laminate, as shown in
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In one aspect, the pouch may be opaque. Various laminate structures may be utilized for the opaque pouch.
One example, as shown in
Another example, as shown in
In the above examples, the outer layer of PET may have a thickness ranging from 10-20 microns (μm). Additionally or alternatively, the layer of SiOx and/or the layer of TiOx may respectively have a thickness of 5-15 μm. Additionally or alternatively, the layer of nylon may have a thickness of 10-20 μm. Additionally or alternatively, the layer of EVOH may have a thickness of 5-25 μm. Additionally or alternatively, the layer of PE may have a thickness of 50-200 μm.
The above-described laminate material structures are well suited for packaging a beverage having an alcoholic content, such as wine or beer or another liquor, to add strength to the walls of the pouch, and to preserve the product. The pouch may be transparent, allowing the contents of the pouch to be viewed. The pouch may also be opaque when desired. The outer PET layer may be printed with any desired indicia. The AlOx, SiOx, and TiOx materials provide a transparent barrier layer that also ads strength. The Al and EVOH layers provide a vapor barrier preventing introduction of air and oxygen. Nylon protects the Al, SiOx, TiOx, or EVOH layer from cracking in a lager pouch application. The PE layer acts as a barrier between the middle barrier layer and the compartment, and provides organoleptic protection from the development of undesirable flavors.
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In one aspect, the pouch 10 incorporates an opening structure 28 for accessing the contents of the pouch. Various types of opening structures 28 are known in the art for this purpose, and is non-limiting. The position of the opening structure is determinable by many factors, such as type of opening mechanism. The opening structure 28 may be positioned in an upper edge, a lower edge or side edge, or front wall or back wall, or on an insert or gusset. It should be appreciated that the opening structure 28 may be incorporated into the pouch 10 prior to filling the pouch 10. One example of an opening structure is a tear-off portion 30. The tear-off portion 30 usually has an integral tear notch 32. The tear notch 32 is typically formed near an outermost edge of a seam, for initiating the removal of the tear-off portion, such as a side edge 20. Another example of an opening structure 28 is a resealable zipper 34. Another example of an opening structure 28 is a weakened straw pierceable portion 36 in the pouch 10 for receiving a straw.
Still a further example of an opening structure 28 is a fitment such as a removable and replaceable cap 38 secured to a spout 40, or a tap, or the like. Various types of caps and spouts may be utilized. The spout is sealed into the upper edges of the panel using a sealing structure, such as an ultrasonic seal or a heat weld, or the like, as described below. The spout 40 may include a removable seal to prevent leakage of the product or evidence of tampering.
Pursuant to an implementation, the flexible pouch 10 includes a top seal 22 joining the front wall 12 and the back wall 14 together. The top seal 22 may comprise a double seal 24A, 24B to help prevent leakage of contents and oxygen or air from entering into the compartment containing the product. The double seal 24A, 24B may be provided along the top of the pouch 10 (e.g., along the top edge 16), above the opening mechanism 28 (e.g., above the tear line, zipper, etc.), to seal the front and back walls 12, 14 together after filling the pouch with the liquid product. The double seal 24A, 24B may extend continuously from first edge seam 20 to second side edge seam 20, and seals the first and second walls 12, 14 together. The double seal 24A, 24B may include a first seal 24A at the top edge 16, and a second seal 24B in a region of the first seal 24A (e.g., the second seal 24B is adjacent to the first seal 24A). The first seal 24A and the second seal 24B may extend generally parallel to one another. Additionally or alternatively, the first seal 24A and the second seal 24B are arranged adjacent to one another. Additionally or alternatively, the first seal 24A and the second seal 24B at least partially overlap (e.g., overlap in at least one region) and/or abut one another. Alternatively, the first seal 23A and the second seal 24B are arranged separate from one another (e.g., a gap is present (interposed) between the first seal 24A and the second seal 24B). The double seal structure along the top edge helps prevent the ingress of oxygen/air during the filling process to maintain a structurally sound, air-tight seal for extended shelf-life, as discussed below.
Pursuant to an implementation, the double seal 24A, 24B may comprise two heat seals. Pursuant to another implementation, the double seal 24A, 24B may comprise an ultrasonic seal and a heat seal. In this case, the ultrasonic seal may form the first seal 24B and the heat seal may form the second seal 24A. It should be appreciated that ultrasonic welding as the inner seal 24B is preferred to heat sealing, as ultrasonic welding is more effective through liquids.
It should be appreciated that the flexible pouch 10 may advantageously include other features that are known in the art.
The pouch 10 may include a feature such as an ergonomic shape. Thus, the width across the pouch is less in the middle, than at the upper edge or lower edge. That is, one or both of the side edges 20 may form an arc or curve, which facilitates controlling the volume of the compartment. The overall hourglass shape assumed by the pouch 10 due to the internal pressure within the pouch 10 facilitates holding of the pouch in the hand of a user.
It is contemplated that the flexible pouch 10 may incorporate any of the above-described features in any combination. In addition, the finished pouch may assume various shapes as influenced by the type of product and intended usage of the pouch.
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At step 205, the method 200 may include laminating a plurality of layers together including an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE) to form a pouch panel. The middle barrier layer may be chosen from SiOx, TiOx, and AlOx. The middle barrier layer is configured to prevent permeability of oxygen and air into the sealed compartment. Further layers, such as nylon and ethylene vinyl alcohol (EVOH), may also be provided. The pouch panel may be transparent or opaque. Further, the step 205 may be repeated if a second pouch panel is to be used to form the flexible pouch 10.
At step 210, a pouch body is formed from the pouch panel (or two pouch panels) wherein the pouch panel(s) is sealed together to form the pouch body including front and back walls defining a compartment and having a pair of opposite side seal/seam edges 20 and a bottom (e.g., including bottom gusset 26) with an open top. An opening structure 28 (e.g., resealable zipper 34, piercable straw hole 36, tear strip 32, fitment/spout 40) may be incorporated at or near the open top.
At step 215, the compartment of the pouch body is filled with product (e.g., an alcoholic beverage). This may be performed in an inert atmosphere and/or with gas purge.
At step 220, the filled pouch body is sealed along the top edge 16 to form a top seal 22 closing the open top. As described above, the top seal 22 may comprise a double seal 24A, 24B to help prevent leakage and ingress of oxygen. The double seal 24A, 24B is provided along the top of the pouch 10, above the opening mechanism 28 (e.g., above the tear line, zipper, etc.), to seal the front and back walls 12, 14 together.
The double seal may include heat sealing the open top at a first seal station (forming a first heat seal), and then forming a second heat seal in a region of or adjacent to the first heat seal. The second heat seal may be formed at a second seal station that repeats the heat sealing in a region of the first seal. The double seal ensures no leaking should some product have contaminated the inside of the seal area during the first heat sealing, which contamination may cause a weak seal that can leak in the area of the moisture. The second hot seal helps ensures the area is well and tightly sealed, thereby enhancing the structural integrity of the top seal.
Pursuant to another example, the double seal may include a first ultrasonic seal followed by a hot seal. More specifically, a first seal is formed along the open top using ultrasonic welding techniques to form the first seal. The ultrasonic first seal utilizes the principles of ultrasonic acoustic vibrations to generate heat at a molecular level inside the films themselves and this energy joins the two materials together. Ultrasonic weld tools (e.g., anvil or sonotrodes) focus the energy on the point at which the welding should take place and friction is generated in milliseconds and the process removes the moisture and makes a dry seal. Then, a second seal in the form of a hot seal is heat sealed along the top of the pouch. The hot/heat seal may be formed outside the first ultrasonic seal (e.g., so that the ultrasonic seal is disposed between the hot/heat seal and the contents). The second heat seal ensures that any remaining moisture is removed and helps prevent leakage.
When a fitment in the form of a spout 40 is used, the spout seal may be heated as the spout is positioned in the open top between the front and back walls 12, 14, and then a heated seal bar is provided to heat seal the spout fitment to the front and back walls to form a first heat seal 24A. A second heat seal 24B may then be formed in a region of the first heat seal to ensure that the area is well and tightly sealed. Under certain circumstances, the spout 40 may be incorporated into the pouch 10 in step 210 (e.g., prior to filling with product). Alternatively, the spout 40 may be incorporated into the pouch 10 after the filling step 215 (e.g., in step 220).
It will be appreciated that the seals used herein (e.g., top seal 22 including double seals 24A, 24B, side seals along side edges 20) are peripheral seals that form a permanent bond between layers of the pouch that is not intended to rupture. A peripheral seal is a fixed barrier and has a peel strength significantly greater than that of the frangible seal. As such the bond of the peripheral seal is solid between the different layers to form a barrier, or permanent seal between the layers. That is, the peel strength of the peripheral seal is limited only by the burst properties of the materials used to form the peripheral seal. In some embodiments described herein, the peel strength of the peripheral seal is in a range between 9.18 and 11.22 pounds per square inch of force to rupture the peripheral seal.
The provision of one or more pouch panels formed from a laminate material (e.g., film laminate) together with the double seal structure provides a flexible pouch 10 that retains its flavor, color, aroma, and taste over the shelf life of the product.
It will be appreciated that the double seal may include two seals adjacent to one another, optionally running in parallel. The two seals may at least partially overlap and/or abut.
Pursuant to an implementation, the first and second seals 24A, 24B may overlap and/or abut along an entire extend of the top seal 22 (e.g., from one side edge to the other side edge). Pursuant to another implementation, the two seals may be separate from one another (e.g., a gap may be present between the first and second seals), at least in one region or optionally along an entire extent of the top seal 22. Moreover, it will be appreciated that more than top seal may comprise more than two seals (e.g., formed from heat and/or ultrasonic welding) without departing from the scope of the disclosure.
As can be seen from the above descriptions, the pouch may have various shapes and sizes and include various opening structures. Any of the embodiments described above may include different opening structures or laminate materials other than a specifically described.
Although not shown, the pouch may include one or more frangible seals. For example, a frangible seal may be formed (e.g., ultrasonically welded) in the compartment.
It will be appreciated that although the flexible pouch is described with reference to an alcoholic beverage, it will be appreciated that other liquid beverages are contemplated herein.
It will further be appreciated that the top seal 22 may instead correspond to a bottom seal where the top is sealed by a peripheral seal and the bottom is open for filing, without departing from the scope of the disclosure.
The present invention has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, the present invention may be practiced other than as specifically described.
It should be understood that references to a single element are not necessarily so limited and may include one or more of such element. Further, all numbers expressing dimensions, ratios and the like, used in the specification and claims, are to be understood to encompass tolerances and other deviations as represented by the term “about” or “approximately.”
The use of “e.g.” in the specification is to be construed broadly and is used to provide non-limiting examples of embodiments of the disclosure, and the disclosure is not limited to such examples. Uses of “and” and “or” are to be construed broadly (e.g., to be treated as “and/or”). For example and without limitation, uses of “and” do not necessarily require all elements or features listed, and uses of “or” are inclusive unless such a construction would be illogical.
All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those knowledgeable in the technologies described herein unless an explicit indication to the contrary in made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary. Further, the use of “at least one of” is intended to be inclusive, analogous to the term and/or. As an example, the phrase “at least one of A, B and C” includes A only, B only, C only, or any combination thereof (e.g. AB, AC, BC or ABC). Additionally, use of adjectives such as first, second, etc. should be read to be interchangeable unless a claim recites an explicit limitation to the contrary.
This application claims priority to U.S. Prov. App. No. 63/412,722 filed on Oct. 3, 2022, the contents of which are hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63412722 | Oct 2022 | US |
