Package and method and apparatus for forming a package

Abstract

A method of filling a package comprising a sealed body defining an interior volume, the body having first and second major surfaces and a gusset portion 140 therebetween at a first edge of the body, w

Description

The present invention relates to a package and to a method and apparatus for forming a package, and is concerned particularly, although not exclusively, with a package that can be filled in a sterile manner, and with a method and apparatus for forming such a package. Certain types of package are required to permit filling initially with a first material, which may comprise a liquid or a dry powder, for example, and then subsequently to have a second material injected therein using a filling nozzle or needle, which second material may comprise a liquid. A problem arises in that when the injector needle is withdrawn from the package, some of the first material may escape the aperture formed by the needle. Such packages are typically finally sealed by placing an adhesive sealing patch over the aperture. However, any escape of the contents, particularly the first material, has the potential to compromise the effectiveness of the adhesive patch, and thus the integrity of the seal. The steps of injecting the second material and subsequent application of the sealing patch are often undertaken manually, which is a slow, and therefore expensive, process and often produces an unreliable package. Where the contents of the package are sensitive to contamination, as is the case with a live culture of bacteria for example, the filling process must be performed aseptically. One prior approach to address this problem has been to attach to the package a filling gland, through which to introduce the filling nozzle. However, such glands are expensive and significantly add to the price of the package. There is a need for a low-cost, readily sterilisable package and an efficient method of introducing content into the package, and thereafter reliably sealing the package, across a range of commercial sectors, from the food industry to pharmaceuticals and agribusiness. Embodiments of the present invention aim to provide a package, and a method of introducing content to a package, in which at least some of the problems of the prior art are addressed. The present invention is defined in the attached independent claims, to which reference should now be made. Further, preferred features may be found in the sub-claims appended thereto . According to one aspect of the present invention, there is provided a method of filling a package, the package comprising a sealed body defining an interior volume, the body having first and second major surfaces and a gusset portion therebetween at a first edge of the body, wherein the method comprises a penetration step, in which the gusset is penetrated and a main content introduction step in which a main content material is introduced into the interior volume through the gusset. The method may include sterilising the gusset before and / or during and / or after introducing the main content material into the interior volume through the gusset. The method may include introducing the main content material into the interior volume through the gusset using an injector tool. In a preferred arrangement. the method includes sterilising the gusset and / or the injector tool before and / or during and / or after introducing the main content material. In a preferred arrangement, the method includes sterilising the gusset and / or injector tool before and / or during and / or after introducing the main content material by irradiation, more preferably by ultra-violet radiation, more preferably far-spectrum UV, or UVC, radiation. The method may include a preliminary introduction step, in which a preliminary content material is introduced into an interior of the package at an openable second edge thereof. The second edge may be substantially opposed to or adjacent the gusset. The method may include sealing the openable second edge before and / or after introducing the preliminary content into the package. The method may include sterilising the package and / or the preliminary content before the main content introduction step. In a preferred arrangement the method comprises sterilising the package and / or the preliminary content by irradiation, more preferably by gamma irradiation. The preliminary introduction step may take place prior to the main introduction step. The body is preferably formed by sheets of filmic material, more preferably of thermoplastics material, joined around the periphery of the body. The gusset is preferably formed between adjacent fins comprising portions of the filmic material sheets sealed to themselves. The method preferably comprises sealing together the fins after the main content introduction step. In a preferred arrangement, the method comprises sealing together the fins to form a pre-filling gusset seal substantially enclosing the gusset prior to the main content introduction step. Preferably the method comprises opening the pre-filling gusset seal prior to the main content introduction step. The method may include sealing together the fins to form a postfilling gusset seal after the main content introduction step. The package is preferably generally four-sided in plan. The package may comprise a flexible package, preferably of thermoplastics film such as, but not limited to polythene. Irradiation of the package and / or a filling nozzle may include irradiating with Ultra-Violet (UV) radiation, According to a second aspect, the present invention provides a sterile package comprising a sealed body of filmic material having an interior volume for receiving content, the body having first and second major surfaces and a sterile gusset therebetween at a first defined between a pair together to enclose the edge of the body, the gusset being of adjacent fins that are sealed sterile gusset. The invention may include any combination of the features or limitations referred to herein, except such a combination of features as are mutually exclusive, or mutually inconsistent. A preferred embodiment of the present invention will now be described, by way of example only, with reference to the accompanying diagrammatic drawings, in which: Figure 1 shows, schematically, a conveyor carrying a film of packaging material; Figure 2 shows the film of packaging material folded to form a gusset; Figure 3 shows the film after a first sealing stage; Figure 3a shows an enlarged portion of the film of Figure 3 in a side view; Figure 4 shows a package formed from the web after a further sealing stage; Figure 5 shows the package in a first filling stage; Figure 6 shows the package after a further sealing stage; Figure 7 shows a portion of the package in an irradiation stage; Figure 8 shows the package in a second filling stage; and Figure 9 shows the package in a final sealing stage. In the following description, a series of stages in the production of a package will be described. The various stages include folding, sealing, and manipulating the packaging material. The folding, sealing, and manipulating tools are typically well represented in the prior art and have been omitted from the drawings in the interest of clarity and simplicity. Turning to Figure 1, this shows a conveyor 100 on which is located a continuous sheet 110 of filmic packaging material which is unwound from a roll (not shown) and which travels in the direction indicated by Arrows A. The film may be one of a number of materials, dependent upon the intended use for the final package, but in this example is of polythene. Referring to Figure 2, as the sheet 110 travels along the conveyor 100 the sheet becomes folded on itself, approximately in half, so that longitudinal edges 120 become substantially superposed. Additionally, a pleat 130 is made at the folded edge so that a gusset 140 is formed in the folded sheet, indicated by a broken line L in the drawing, between a pair of fins 150. In this example the gusset 140 extends approximately one fifth of the depth of the folded sheet 110. Figures 3a and 3b show the gusset in more detail. Figure 3b is a side view of the area enclosed by Circle C in Figure 3a. Each of the fins 150 is formed of two leaves of film that are sealed together. so that any content later introduced into the package cannot enter the fins 150 themselves . Figure 4 shows a next stage in the production of the package. The folded film is sealed along both transverse edges 160 to create a pouch with an open mouth formed by the two longitudinal edges 120 opposite the gusset 140. The pouch is then rotated Figure 5, and then a first, (not shown) is introduced through 90 degrees, as shown in or preliminary, content material into the pouch through the open mouth by a filler apparatus 170. At the next stage, shown in Figure 6, the longitudinal edges 120 are sealed together to create a sealed package P containing the first content material. The first content material is able to move around the whole of the enclosed volume inside the package P between the sealed longitudinal edges 120 and the edge of the gusset 140. At this stage, the package P essentially comprises a sealed bag formed between superposed portions of the sheet 110 that are sealed around both sets of transverse edges 160 and the sealed longitudinal edges 120. A sterilisation of the entire package, including the first-fill contents, can now be optionally performed. A preferred method of doing this is to expose the entire 5 package to Gamma radiation in an enclosed, shielded environment. Figure 7 shows a next stage, in which the gusset 140 is opened out and exposed to far-spectrum ultra-violet 10 radiation from a UV source 180. This permits an aseptic fill of a second, or main, content material, as will be described below. Figure 8 shows a next stage in which an injector apparatus 15 190 pierces the gusset and introduces a second content material (not shown) into the package. The injector apparatus 190 is also irradiated with UV prior to piercing the package. The gusset 140 and injector apparatus 190 may, as an 20 alternative, or in addition, be irradiated during the second filling operation. Figure 9 shows a final stage in the preparation of the package, in which the fins 150, between which the gusset 140 25 was formed, are pressed together and then sealed to each other at their outer edges, encapsulating and thus protecting the external surfaces of the gusset 140. As an option, where complete sterility is required, the 30 gusset 140 can also be irradiated and the fins 150 can be sealed together along the entire extent of their longitudinal edges to form a gusset seal at an earlier stage, such as before or after the first content is introduced. This sterilisation step may take place during manufacture of the 35 packages which may then be stored for a period of time before being used. The edge of the gusset can then be cut immediately prior to injecting the second content. There are numerous advantages of processes according to the present invention, and the packages thus formed. Firstly, there is no need to use a sterile filling gland, which saves cost. Secondly, the presence of the gusset reduces the likelihood of first-fill content being present in the region where the injector is introduced to the package for the second fill. Thirdly, as the process lends itself to sterilisation by UV radiation the package and method are suitable for sensitive contents, such as live bacteria, vaccines, foods and chemical reagents which may be compromised when using other sterilisation techniques, such as heat or barrier gas. Fourthly, the package can be made from relatively inexpensive filmic material, such as polythene film or composite barrier film, including breathable films which are essential when live bacterial cultures are to be packaged. Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance, it should be understood that the applicant claims protection in respect of any patentable feature or combination of features referred to herein, and / or shown in the drawings, whether or not particular emphasis has been placed thereon.

Claims

1. A method of filling a package, the package comprising a sealed body defining an interior volume, the body having first and second major surfaces and a gusset portion therebetween at a first edge of the body, wherein the method comprises a penetration step, in which the gusset is penetrated and a main content introduction step in which a main content material is introduced into the interior volume through the gusset.

2. A method according to Claim 1, wherein the method includes sterilising the gusset before and / or during and / or after introducing the main content material into the interior volume through the gusset.

3. A method according to Clam 1 or 2, wherein the method includes introducing the main content material into the interior volume through the gusset using an injector tool.

4. A method according to any of the preceding claims, including sterilising the gusset before and / or during and / or after introducing the main content material.

5. A method according to Claim 3, including sterilising the injector tool before and / or during and / or after introducing the main content material.

6. A method according to Claim 4 or 5 wherein sterilising is by irradiation, more preferably by ultra-violetradiation, more preferably far-spectrum UV, or UVC, radiation.

7. A method according to any of the preceding claims, wherein the method includes a preliminary introduction step, in which a preliminary content material is introduced into an interior of the package at an openable second edge thereof.

8. A method according to Claim 7, wherein the second edge is substantially opposed to or adjacent the gusset.

9. A method according to Claim 7 or 8, wherein the method includes sealing the openable second edge before and / or after introducing the preliminary content into the package .

10. A method according to any of Claims 7-9, wherein the method includes sterilising the package and / or the preliminary content before the main content introduction step.

11. A method according to Claim 10, wherein the method comprises sterilising the package and / or the preliminary content by irradiation, more preferably by gamma irradiation.

12. A method according to any of Claims 7-11, wherein the preliminary introduction step takes place prior to the main introduction step.

13. A method according to any of the preceding claims, wherein the body is formed by sheets of filmic material, more preferably of thermoplastics material, joined around the periphery of the body.

14. A method according to Claim 13, wherein the gusset is formed between adjacent fins comprising portions of the filmic material sheets sealed to themselves.

15. A method according to Claim 14, wherein the method comprises sealing together the fins after the main content introduction step.

16. A method according to Claim 14 or 15, wherein the method comprises sealing together the fins to form a prefilling gusset seal substantially enclosing the gusset prior to the main content introduction step.

17. A method according to Claim 16, wherein the method comprises opening the pre-filling gusset seal prior to the main content introduction step.

18. A method according to any of Claims 14-17, wherein the method includes sealing together the fins to form a post-filling gusset seal after the main content introduction step.

19. A method according to any of the preceding Claims, wherein the package is generally four-sided in plan.

20. A method according to any of the preceding claims, wherein the package comprises a flexible package,preferably of thermoplastics film such as, but notlimited to polythene.

21. A sterile package comprising a sealed body of filmic material having an interior volume for receiving 10 content, the body having first and second major surfacesand a sterile gusset therebetween at a first edge of the body, the gusset being defined between a pair of adjacent fins that are sealed together to enclose the sterile gusset.15Application No: GB2018836.3Examiner: Joseph WebsterClaims searched: 1-20Date of search: 20 April 2021Patents Act 1977: Search Report under Section 17Documents considered to be relevant:Category Relevant to claims Identity of document and passage or figure of particular relevance X Y X: 1-6, 13-20Y: 7-12 IP 2008013235 A (DAINIPPON PRINTING CO) interior volume 1; first 6 and second 7 major surfaces; gusset portion 8. Paragraphs 64-69 describe a method of penetrating the gusset and filling. Paragraph 34 describes irradiation of the package. X,Y X: 1-6, 13-20 Y: 7-12 JP 2003118745 A (ASAHI KASEI PAX CORP) package 1 is filled through a gusset (paragraph 42) following penetration with an injection nozzle. See also paragraph 13 V V 1 X: 1-6, 13-20 Y: 7-12 JP 2017024727 A (HITACHI SHIPBUILDING) Filling nozzle 142 is inserted into gusset portion 50 to introduce content into sealed volume 20 (see paragraphs 19, 34-36) Y Y: 7-12 US 2014 / 215969 Al (MEDLINE) See especially figure 7, describing a preliminary content introduction step 704 prior to sealing 706, sterilising 708 and filling with main content 710Categories:X Document indicating lack of novelty or inventive step A Document indicating technological background and / or state of the art. Y Document indicating lack of inventive step if P Document published on or after the declared priority date but combined with one or more other documents of same category. before the filing date of this invention. & Member of the same patent family E Patent document published on or after, but with priority date earlier than, the filing date of this application.Field of Search:International Classification:Subclass Subgroup Valid From B65B 0055 / 08 01 / 01 / 2006 B65B 0001 / 04 01 / 01 / 2006 B65B 0003 / 04 01 / 01 / 2006

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