System and method for forming a sealed air bubble for packaging.

Abstract

A fluid bubble valve device or element, method, system, and apparatus may comprise multiple films or webs aligned on top of each other. For example, two separate material webs or film layers may be formed from two or more different film layers combined to provide various necessary advantages in the manufacture or formation of the valve and sealing it to a pouch or package later. Two individual forming webs or film layers are fed together into a machine to form a channel seal and bubble pocket, creating a path for controlling the direction in which the fluid product flows later when the finished pouch or package is used by the consumer. The pocket is formed simultaneously in both of the two individual forming webs or film layers. A separate lid material web or layer is introduced and sealed beneath the bubble pocket to trap air or gas between the lid layer and the individual forming webs or film layers combined.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the priority and benefit of U.S. Provisional Patent Application No. 63 / 454,016, filed on March 22, 2023, which is hereby incorporated by reference in its entirety herein.

[0002] (Technical Field) The present invention generally relates to packaging, and more specifically, to manufacturing bubble or valve structures sealed to a package to control the dispensing of fluids from a package such as a flexible package using a formable film or film layer.

Background Art

[0003] (Background) Typically, when formable flexible packaging materials are formed, these materials are formed, for example, by thermoforming to create pockets for holding products. After the formed pockets are filled with products, typically, another material called a lid material is used to seal the pocket areas.

[0004] In addition, certain processes can make it difficult to align multiple pockets to form a valve.

[0005] Therefore, there is a need for systems and methods to improve upon the prior art and solve various problems associated with existing valve forming methods, such as cost, efficiency, and alignment issues.

Summary of the Invention

Means for Solving the Problems

[0006] (Summary) The present invention may include embodiments comprising two or more formed films or webs, one aligned on top of the other. These are separate material webs or portions that can be formed of two or more different film layers, providing various necessary advantages in the manufacture of valves and sealing to subsequent packaging. Two individual formed webs, or a single web that has been elongated and positioned or folded on top of itself to form two webs, are fed together into a machine, a channel seal is formed, and they are joined and sealed in a selected area. Pockets are then formed in both webs simultaneously. In various embodiments, a portion of the film is formed as a bubble pocket formed by a rotating machine or other known process. Once pockets are formed in each of the two films / webs, the two films / webs proceed to another section of the machine, into which a “lid” web is introduced and sealed on the underside of the pocket area, trapping air or gas between the lid layer and the core layer of the film to form a bubble valve device or element.

[0007] The above summary is not intended to describe each exemplary embodiment, the claimed embodiment, or the implementation of the invention. Detailed technical and preferred embodiments implemented for the subject invention are described in the following paragraphs with reference to the accompanying drawings, so that the features of the claimed invention may be readily understood by those skilled in the art. It should be understood that the features described above and those described below may be used individually, in any combination, or in any other combination, without departing from the scope of the invention.

[0008] (Brief explanation of the drawing) The present invention can be more fully understood by considering the following detailed description of various embodiments of the invention related to the accompanying drawings. [Brief explanation of the drawing]

[0009] (Brief explanation of the drawing) [Figure 1A-1B]Figures 1A and 1B show side views of the steps for joining multiple films and layers, forming a bubble valve device from the multiple films and layers, and molding the bubble valve device, according to an embodiment of the present invention. [Figure 2] Figure 2 shows an exploded side view of the material configuration of multiple films and layers in a bubble valve device according to an embodiment of the present invention. [Figure 3A] Figure 3A shows a side view of the process of joining two film layers according to an embodiment of the present invention. [Figure 3B] Figure 3B shows an embodiment of the present invention in which the two film layers in Figure 3A are sealed to form a channel seal and a fluid channel. [Figure 3C] Figure 3C shows a side view of the sealed film layer of Figure 3B according to an embodiment of the present invention. [Figure 3D] Figure 3D shows an expanded and enlarged view of the film layer and channel seal in Figure 3C according to an embodiment of the present invention. [Figure 3E] Figure 3E shows an expanded and enlarged side view of the flattened channel seal of Figure 3D according to an embodiment of the present invention. [Figure 4] Figure 4 shows a diagram of the combined film layer and the formed bubble pockets before attaching the lid film or layer, according to an embodiment of the present invention. [Figure 5] Figure 5 shows a side view of the bonding of the lid layer to the combined film layer according to an embodiment of the present invention. [Figure 6] Figure 6 shows a side view of the formation of a seal and bubble seal on the combined film layer of the lid layer according to an embodiment of the present invention. [Figure 7] Figure 7 shows a top view of a bubble seal and a channel seal defining a fluid channel according to an embodiment of the present invention. [Figure 8] Figure 8 shows a side view of a bubble valve device according to an embodiment of the present invention, which has a V-shaped end for facilitating attachment of a pouch or package to a panel. [Figure 9]FIG. 9 shows a view including an enlarged and expanded side view of a layer of a bubble valve device including a channel seal region, according to an embodiment of the present invention. [Figure 10] FIG. 10 shows an enlarged and expanded side view of the channel seal region of FIG. 9 that is flattened or tapered, according to an embodiment of the present invention. [Figure 11] FIG. 11 shows a top view of two layers of a bubble valve device with formed bubble pockets that are sealed together to form a combined film layer, according to an embodiment of the present invention. [Figure 12] FIG. 12 is a side cross-sectional view showing cross-section 12-12 of FIG. 11, according to an embodiment of the present invention. [Figure 13] FIG. 13 shows a top view of a completed bubble valve device, according to an embodiment of the present invention. [Figure 14] FIG. 14 shows an enlarged and expanded side view of the completed bubble valve device of FIG. 13, according to an embodiment of the present invention. [Figure 15] FIG. 15 shows a top view of a completed bubble valve device showing channel seals and bubble seals, according to an embodiment of the present invention. [Figure 16] FIG. 16 shows a top view of a completed bubble valve device including one or more alignment punches, according to an embodiment of the present invention. [Figure 17] FIG. 17 shows a manufacturing and forming system for a bubble valve device, according to an embodiment of the present invention. [Figure 18] FIG. 18 shows a plurality of formed bubble valve devices continuously connected along a portion of a chain removed from the manufacturing and forming system of FIG. 17, according to an embodiment of the present invention. [Figure 19] FIG. 19 shows a chain of continuously connected bubble valve devices wound around a spool, according to an embodiment of the present invention. [Figure 20-25] FIGS. 20-25 show exemplary pouches or packages including a bubble valve device incorporated to control dispensing of fluid from the pouch or package, according to an embodiment of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The present invention is capable of accommodating various changes and alternative forms, and its details are shown in the drawings by way of example and will be described in detail. However, it should be understood that the present invention is not intended to be limited to the specific embodiments described. On the contrary, the present invention includes all changes, equivalents, and alternative means that fall within the spirit and scope of the present invention as defined by the appended claims. Further, the various figures in the exemplary drawings are enlarged or expanded views, exaggerating or expanding the size of the structure to clarify and better represent the structure of the present invention.

[0011] (Detailed Description of the Invention) Embodiments of the present invention may include two formed films or webs aligned one on top of the other. These two separate material webs or portions can be formed of two or more different film layers that provide various necessary advantages in the manufacture of the valve and subsequent sealing to the package. The two individual formed webs are fed together into a machine, and a channel seal is formed to create a path for controlling the direction in which the product will later flow when the completed package is used by the consumer.

[0012] Furthermore, when the films are joined and sealed, the edges of the seal may form undesirable bulges and / or fluid channels, which can be flattened or tapered in part, along the length, end, or edge, for example, to facilitate proper valve function, primarily in thin liquids. Flattening or tapering in part, along the length, end, or edge of the channel seal reduces or minimizes the bulges or small channels formed by the seal forming process that forms the channel seal. Pockets are then formed simultaneously in both webs at approximate locations along the channel seal. In various embodiments, a portion of the film is formed as a bubble pocket by a rotating machine or similar process. Once pockets are formed in each of the two films / webs, the two films / webs proceed to another machine section or process, where a third “lid” web is introduced and sealed beneath the pocket area, trapping air or gas between the lid layer and the central layer of the film to form a bubble valve device. Bubble seals are typically formed outside the channel seal area to ensure that the air within the bubble makes full contact across the desired portion of the channel area. The configuration of the bubble valve, e.g., dimensions, ratios, shape, and size, can vary depending on the various specifications and applications, such as dispensing liquids of varying viscosities. When the fluid is a thick, viscous liquid, a lower or flatter (e.g., lower apex) bubble valve can be used to control the flow of the fluid product within the package. Bubble valves formed higher or deeper (e.g., higher apex) can be used for thinner liquids with lower viscosity (e.g., water, alcohol, etc.), and a bubble valve with greater resistance to the fluid and fluid flow is desirable. Furthermore, the size and shape of the bubble valve can be configured such that the user needs to apply some compressive pressure to the package in order to discharge or dispense the liquid through the bubble valve from the package. For example, if it is desirable to facilitate the user's compression of a viscous fluid product through the bubble valve, the bubble valve can be configured to be lower in height (e.g., lower apex).

[0013] The present invention solves the problem of precise registration of the second forming pocket onto the first forming pocket when forming a bubble valve device, ensuring a consistently precise and accurate match. The forming process can be achieved by thermoforming, a mechanical forming method using an anvil and die, or a combination of both.

[0014] Referring to Figures 1A to 25 in general, the present invention prevents, obstructs, or controls the passage of a liquid through a bubble seal valve device or element until the user / consumer compresses the package or pouch to push the liquid out of the pouch or package through the valve's channel area. This is achieved by controlling the tightness relationship between two formed pockets so that the two formed pockets can be precisely and accurately aligned and nested together. This is more important the thinner the liquid (e.g., the lower the viscosity). In addition, the precise configuration of the bubble seal valve device or element of the present invention also ensures that the liquid product (even if it is a thin liquid with low viscosity) does not leak through the bubble seal valve device or element even if the accompanying pouch or package is turned upside down, tilted, or inverted (e.g., upside down).

[0015] Referring to Figures 1A and 1B, embodiments of the present invention include a plurality of films or webs, e.g., at least a third valve film layer 110 and a second central film layer 112, arranged or combined together, for example, with or without seals, to form a new combined film material or layer 114. A convex bubble or valve pocket 116 is formed in part of the film material 114 (e.g., layers 110 and 112 simultaneously). A first lid film layer 122 is provided, as shown in Figure 1B, below, across, or around the bubble pocket 116 in the film material 114, sealed or otherwise (e.g., sealed to the film layer 112), to form a completed bubble valve device or element 130. The lid layer 122 may also be sealed along or at the edges of the film material (e.g., film layer 112). These seals are provided to ensure fluid flow between film layer 110 and film layer 112 and to prevent fluid flow between film layer 112 and film layer 122. In certain embodiments, one or more unsealed, generally one or more V-shaped ends 126 are defined to allow free layer separation between the ends of the film layers 110, 112 and the end of the lid layer 122. The end V-shaped ends 126 have free ends 126a, 126b for sealing to a pouch or package.

[0016] Figure 2 shows illustrative but not limited material configurations of various layers 110, 112, and 122. For example, in certain embodiments, film layer 110 may comprise a sealant top or layer 110a made of polyethylene (PE) and a bottom or layer 110b made of cast polypropylene (CPP). Film layer 112 may comprise a top or layer 112a made of CPP and a sealant bottom or layer 112b made of PE. As will be further detailed below, the fluid valve channel is defined between the CPP bottom / layer 110b of film layer 110 and the CPP top / layer 112a of film layer 112. Cover layer 122 may comprise a top or layer 122a and a bottom or layer 122b, both made of sealant PE. In various embodiments, cover layer 122 may be a single-material PE layer. Other materials and combinations of materials can also be employed to achieve the desirable and / or required manufacturing, forming, and sealing advantages of the present invention.

[0017] Figures 3A to 16 illustrate the bubble valve element 130 of the present invention and exemplary manufacturing or forming processes for forming the bubble valve element 130. To solve the registration problem in valve formation, the forming films or webs 110, 112 are aligned one on top of the other. These are typically separate material webs or portions formed of two or more different film layers themselves (e.g., each layer may comprise multiple layers of co-extruded or laminated material) that provide various necessary advantages in the manufacturing, formation, and / or sealing of the valves 116, 130 and when sealing the complete bubble valve element 130 to the package afterward. The individual layers typically consist of PP, PE, nylon, polyester, and other similar film types or combinations of films that are co-extruded or laminated simultaneously to provide the necessary advantages.

[0018] Figures 3A to 4 show first and second film layers 110, 112 joined to form a combined film layer 114 and a fluid valve channel 124, the fluid valve channel 124 being defined by one or more channel seals 120. Such a configuration and method of forming the channel seals 120 before forming the bubble pocket 116 is beneficial in avoiding rupture or damage to the film of the bubble pocket 116. This allows the channel seals 120 to align more closely with the top or apex of the bubble pocket 116, resulting in a better functional bubble seal where the two layers 110, 112 are precisely aligned and coincide before air or gas is trapped inside the bubble pocket 116 by the seal of the lid layer 122. As detailed herein, when films are joined and sealed, the edges of the seal may form undesirable bulges and / or fluid channels, which may be flattened or tapered in part along their length, ends, or edges, for example, to facilitate proper functioning of the valve, primarily in thin fluids.

[0019] Figures 5 to 8 show film layers 110, 112 (114), and 122 joined and sealed at sealing portions 128. In this way, one or more sealing portions 128 seal the central film layer 112 to the lid film layer 122, and one or more sealing portions 129 are provided around the bubble pocket 116 to trap air between the central film layer 122 and the lid film layer 122 in the bubble pocket 116. Trapping air or gas in the pocket 116 formed by sealing the lid film layer 122 only on the underside of the three-layer central film layer 112 is beneficial because it eliminates the need to form a functional seal between two previously formed webs or layers 110, 112 (e.g., constituting a combined film material or layer 114).

[0020] Figure 8 shows a completed valve device or element 130 with a defined fluid valve channel 124, a channel seal 120, and one or more sealing portions 129 around the bubble pocket 116. Furthermore, ends 126 for sealing to a corresponding package or pouch panel or for other mounting purposes are shown.

[0021] In various embodiments, as described above, two individual forming films / webs 110, 112 are formed with one side made of CPP and the other side made of PE to form a new film material 114. These films / webs 110, 112 are positioned so that their CPP sides face each other. The films / webs 110, 112 are then fed into a machine to form a channel seal, which in certain embodiments is flattened for a selective path for the contents of the pouch or package to pass through at the stage when the consumer uses the finished package. The films / webs 110, 112 are then fed together into a molding machine so that a pocket 116 is formed in both webs simultaneously.

[0022] Figures 9 to 16 show various diagrams, including the bubble valve formation process and exploded views of the final bubble valve element 130.

[0023] As shown in Figures 9 to 14 (and Figures 3A to 3E), the film layers 110 and 112 are joined to define the fluid valve channel 124 (Figure 9), and the channel seal 120 can be flattened or molded 120f (Figure 10). In certain embodiments, the channel seal 120 can be flattened (120f) during the forming process to better control the fluid flow through the bubble valve element 130. Similarly, when the films are joined and sealed, the edges of the seal may form undesirable bulges and / or fluid channels, which can be flattened or tapered in part, along length, at the ends, or along the edges 120f, for example, to facilitate proper function and precise operation of the valve, mainly with thin, low-viscosity liquids. Flattening or tapering of the channel seal 120 reduces or minimizes any bulges or small channels formed by the seal forming process that forms the channel seal 120. The degree or level of flattening may vary depending on the specific configuration required for the fluid flowing through the fluid valve channel 124. For example, the lower the viscosity of the fluid, the more the channel seal needs to be flattened to ensure proper fluid flow without leakage or unwanted discharge. Packages designed for dispensing thicker, more viscous fluids may require no flattening of the channel seal 120 at all, or only minimal flattening. In various embodiments, the flattened seal 120f can be formed using a molding rod, roller, or other known techniques and mechanisms. The molding rod may be a "cooled" rod that can be applied to the channel seal 120 immediately after its formation. This ensures that the film material remains flexible and malleable, thus facilitating the flattening process.

[0024] The bubble pocket 116 is formed by film layers 110 and 112, and one or more sealing portions 129 are provided around the bubble pocket 116 (Figures 13-14). The bottom cover layer 122 is then sealed or attached to the bottom surface of the central film layer 112 with one or more seals 123 (Figure 14) to form the completed bubble valve element 130 (Figure 15). A registration notch or punch 131 may be provided on part of the bubble valve element 130 (Figure 16).

[0025] As shown in Figures 17 to 19, one or more embodiments of the present invention may employ a manufacturing and forming system. The forming machine 113 (e.g., rotary in the exemplary embodiment) has a plurality of pockets or cavities 115 defined around or along the circumference of the forming machine 113, which receives or draws in a portion of film material 114 (e.g., a joint of film layers 110, 112) by one or more molds 118 or similar devices and techniques. Thus, a portion of the film 114 is formed, for example, by the mold 118, as a bubble pocket 116 formed in the cavity 115 of the forming machine 113. Other non-rotating devices and techniques may also be employed for forming or creating the bubble pockets. The bubble pockets 116 can be formed in various sizes, shapes, and configurations to suit the viscosity of the liquid designed to be retained during use. As described in detail above, if the fluid is a thick liquid with high viscosity, a lower or flatter (e.g., lower apex) bubble valve may be used to control the flow of the fluid product in the package. For low-viscosity, thin liquids (e.g., water, alcohol, etc.), bubble valves formed higher or deeper (e.g., with higher apex) can be used, and bubble valves with greater resistance to the fluid and fluid flow are desirable. Thus, the cavity and / or mold can be formed in countless sizes, shapes, and orientations to provide the desired structure and configuration of the bubble pockets 116. The channel seal 120 can be formed on these web or film layers before or after the pockets 116 are formed.

[0026] Before entering or being supplied to the molding machine 113, the individual webs or layers 110, 112 can be passed through the channel sealing station 111 to define the channel seal 120, and the webs or layers 110, 112 can be sealed together to form a combined web or film layer 114. The channel seal 120 can then be flattened or tapered in the flattening station 111a.

[0027] Once the bubble pocket 116 is formed, the web or layers 110, 112 are fed into another section 117 of the molding machine, and a third lid web or film layer 122 is introduced and sealed to the underside of the pocket 116, trapping the air or gas between the lid film layer 122 and the core film layer 112 within the bubble pocket 116. In this example, the lid film layer 122 is formed of PE on both sides, or has a nylon or “reinforcement” film layer sandwiched between them. The layers of lid material can be joined together by lamination, co-extrusion, or a similar process.

[0028] Next, if the channel seal 120 was not formed before the forming step, the channel seal 120 is formed or defined between the two forming film layers 110, 112 (e.g., Figure 9). These channel seals 120 guide the liquid from inside the pouch or package through the channel 124 to the formed bubble valve element 130. The bubble valve element 130 prevents the liquid from passing through the bubble valve element 130 and being discharged from the pouch until sufficient pressure is applied to the pouch to force the trapped air inside the bubble valve element 130 through the valve channel 124 formed between the two forming web layers (e.g., layers 110, 112).

[0029] Other seals (e.g., seals added along the sides or longitudinal edges to reinforce the valve and help prevent twisting) may be formed on or inside the bubble valve element 130 to seal different layers of film (e.g., three or more film layers) to themselves at different positions, in order to assist the function of the bubble valve element 130, the molding of the bubble valve element 130, and the sealing of the bubble valve element 130 to the pouch or package. The valve may be placed inside a ready-made pouch or package that will be filled and sealed at a later date, or it may be attached to the package during the molding, filling, and sealing stages of manufacturing the pouch or package.

[0030] A registration notch or punch 131 may be provided on a portion of the bubble valve element 130 located in the punch station 133. The registration notch or punch 131 is provided to align the bubble valve element 130 when it is cut or otherwise removed from the continuous chain 134 of the bubble valve element 130.

[0031] In various embodiments, both the forming and sealing processes can be carried out using rotary or continuous motion processes / mechanisms. However, other manufacturing systems, technologies, and processes can also be employed for forming and sealing processes and stages without departing from the scope of the present invention. For example, in various embodiments, various parts of a bubble valve element are formed and sealed using a linear intermittent motion machine that uses heat sealing. Various seals can be formed using ultrasonic sealing or other known seal forming processes and technologies.

[0032] As shown in Figures 18-19, the reel of bubble valve elements 130 in the continuous chain 134 can be wound helically onto the spool 132, so that individual bubble valve elements 130 can be cut or otherwise removed from the spool and placed in the desired pouch or package for sealing.

[0033] Figures 20–25 show an exemplary pouch or package 140 in which a bubble valve element / device 130 is attached to, sealed, or otherwise incorporated into a portion of the pouch or package 140. The bubble valve element 130 is configured to prevent the liquid (low or high viscosity) from passing through the bubble valve element 130 and being discharged from the pouch until sufficient pressure is applied to the pouch, thereby forcing the pressurized and trapped air within the bubble valve element 130 to pass through a valve channel formed between two forming web layers 110, 112. In addition, the precision structure of the bubble valve element 130 of the present invention also ensures that the liquid product (even a low-viscosity, thin liquid) does not leak through the bubble valve element 130 when the pouch or package 140 is inverted or upside down (e.g., upside down). Various embodiments may include one or more removable pouch / film portions 142 that include peel-off areas 144 defined by laser scores, perforations, and fragile areas, in order to facilitate peeling or removal of the portion 142 by the consumer or user and to allow access to and use of the bubble valve element 130.

[0034] With respect to packages equipped with the bubble valve element 130, side, front, back, and bottom panel portions with or without gussets may also be provided. These panel portions are often referred to as webs, films, or layers. References to “top,” “bottom,” “front,” “side,” and “back” are for illustrative purposes only and are not intended to limit the scope of the disclosed invention.

[0035] The packages used in the present invention may include packages composed of, in whole or in part, flexible, rigid, semi-rigid, or semi-flexible materials or panels. Briefly, the panel portions of the package generally consist of flexible sheet materials such as PE, polyester, nylon, metal foil, PP, or PP laminated or otherwise bonded with other materials such as PE or nylon, polyester, and similar films. To enhance barrier properties, embodiments may use composite or laminated layers of the aforementioned materials and similar materials. Generally, in such composite or laminated embodiments, a material having preferred sealing properties can be bonded, bonded, or laminated with a material having different preferred properties (e.g., beneficial oxygen barrier properties). In any case, single sheets, composites / laminates, and countless other materials and techniques known to those skilled in the art can be implemented on a case-by-case basis based on specific applications and manufacturing needs without departing from the spirit and scope of the present invention.

[0036] In various embodiments, the panel portion is formed from a single continuous web material. In other embodiments, at least one of the panel portions may be a separate web material bonded or sealed to each of the other panel portions to form the pouch or package of the present invention.

[0037] Since the present invention can be carried out in other specific forms without departing from its spirit or essential attributes, these embodiments should be considered illustrative in all respects and not restrictive. Similarly, the above methods and techniques for forming the present invention are exemplary processes and are not intended to limit the methods of manufacturing / forming the present invention to those specifically defined herein. Numerous other unexpressed steps and procedures can also be carried out to manufacture or form the packages of the present invention. Furthermore, features and aspects of the various embodiments described herein can be combined to form additional embodiments within the scope of the invention, even if not specifically described herein.

[0038] References to the front, back, and side panels of applicable packages as described herein are made to facilitate understanding of orientation and direction and are not intended to limit it. For example, sealing devices, access devices, filling devices, seals, and other structures or parts of the package may be provided on or along any part of the package, regardless of the references to the front, back, side, and bottom panels herein.

Claims

1. A method for forming a bubble valve device: A step of supplying a first film layer web and a second film layer web to a channel sealing station to form one or more channel seals defining one or more fluid channels between the first film layer web and the second film layer web, and sealing the first film layer web and the second film layer web together to define a combined film layer web; A step of supplying the combined film layer web to a forming station to simultaneously form a plurality of bubble pockets in both the first film layer web and the second film layer web, wherein the forming station comprises a plurality of cavities that receive the combined film layer web and form the plurality of bubble pockets; and The method comprising the steps of supplying the combined film layer web, which includes the plurality of formed bubble pockets, to a lid station to manufacture a bubble valve device web having a plurality of formed bubble valve devices, wherein the lid film layer web is sealed beneath the plurality of bubble pockets formed in the combined film layer web to confine the gas between the lid film layer web and the combined film layer web within the plurality of bubble pockets.

2. The method according to claim 1, further comprising the step of receiving the bubble valve device web at a registration punch station and punching out a portion of the bubble valve device web for each of the plurality of formed bubble valve devices.

3. The method according to claim 1, further comprising the steps of receiving the bubble valve device web at a winding station and winding up the bubble valve device web having the plurality of formed bubble valve devices.

4. The method according to claim 1, wherein at least a portion of the one or more channel seals is flattened or tapered to control the flow of fluid through the one or more fluid channels defined by the one or more channel seals.

5. The method according to claim 4, wherein the fluid is a liquid with low viscosity.

6. The method according to claim 1, wherein the first film layer web comprises at least a first layer and a second layer.

7. The method according to claim 6, wherein the first layer of the first film layer web is made of polyethylene (PE) material.

8. The method according to claim 6, wherein the second layer of the first film layer web is made of polypropylene (PP) material.

9. The method according to claim 1, wherein the second film layer web comprises at least a first layer and a second layer.

10. The method according to claim 9, wherein the first layer of the second film layer web is made of PP material.

11. The method according to claim 9, wherein the second layer of the second film layer web is made of PE material.

12. The method according to claim 1, wherein the lid film layer web comprises at least a first layer and a second layer.

13. The method according to claim 12, wherein the first and second layers of the lid film layer web are made of PE material.

14. The method according to claim 1, wherein multiple bubble seals are attached around the multiple bubble pockets that have been formed.

15. The method according to claim 14, wherein the plurality of bubble seals extend within the one or more fluid channels and intersect the one or more channel seals.

16. The method according to claim 1, wherein the forming station comprises a rotational molding machine or a linear intermittent motion machine.

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