Method and apparatus for filling pouches

Abstract

A method for filling a flat pouch is described, which includes the steps of: folding the lower part of the pouch relative to the upper part around a fold line; forming a shaped fold by lifting the central region of the folded lower part such that the distal regions of the lower part on both sides of the central region are inclined downward away from the central region, and the shaped fold is configured such that the first and second layers of the pouch are separated across the upper edge to form an opening to the cavity of the pouch; and filling the cavity of the pouch with the product through the opening. Related apparatus for carrying out this method is also described.

Description

Technical Field

[0001] The present invention relates to a method and an apparatus for filling a pouch.

Background Art

[0002] Flexible pouches are commonly used for packaging edible and non-edible items, especially for packaging pet food. In its simplest form, a flat pouch (i.e., a three-sided sealed pouch) is formed by two layers of packaging material sealed along three sides. This pouch can be filled from the fourth side, and then the fourth side is sealed to enclose the contents.

[0003] Such pouches are often formed from packaging materials having a laminated structure formed by multiple layers of different materials having desired properties. For example, the packaging material may include an outer layer of polyethylene terephthalate (PET) that is easy to print, a layer of aluminum foil (or metallized (e.g., MET-PET) film) that provides gas, odor, and water vapor barrier properties, and an inner layer of polyethylene (PE) that provides a reliable seal. Such packaging materials can maintain a shape that is convenient during filling.

[0004] Such packaging materials are generally difficult to recycle. Therefore, it is desirable to use mono-materials to improve sustainability. However, these materials have insufficient dead-fold properties that can make filling more problematic.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Therefore, it is desirable to provide a method and an apparatus for filling a flat pouch that addresses or alleviates these problems.

Means for Solving the Problems

[0006] According to one embodiment, a method for filling a flat pouch is provided, the method comprising: folding the lower part of the pouch relative to the upper part around a fold line; forming a shaped fold by lifting the central region of the folded lower part such that the distal regions of the lower part on both sides of the central region are inclined downward so as to be away from the central region, and the shaped fold is configured such that the first and second layers of the pouch are separated across the upper edge to form an opening to the cavity of the pouch; and filling the cavity of the pouch with a product through the opening.

[0007] This method may further include the step of forming a crease that forms a fold line between the lower and upper parts.

[0008] The lower part can be folded so that it extends perpendicularly to the upper part.

[0009] The central region can be lifted by a fold-shaping plate that rotates and / or translates between a first storage position and a second unfolded position.

[0010] The crease-shaping plate can also be folded at the bottom around the fold line.

[0011] The crease-shaping plate can rotate around its axis.

[0012] The axis can be positioned above the height of the fold line.

[0013] Before forming the shaped folds, the first and second layers of the pouch can be separated along the upper edge.

[0014] The first and second layers of the pouch can be separated by a pair of vacuum cups that engage with each other and separate from each other to open the pouch.

[0015] The method may further include inserting a guide into the cavity of the pouch to prevent the upper part from bending when the lower part is bent relative to the upper part before bending the lower part.

[0016] The guide can be configured to accommodate the creasing plate when in the second deployment position.

[0017] The guide can include a pair of fingers spaced laterally from each other so as to be able to accommodate the creasing plate therebetween.

[0018] The crease line can be adjacent to the bottom of the cavity.

[0019] Each of the first layer and the second layer can be formed from a single material.

[0020] According to one aspect, a pouch filling device configured to implement the above-described method is provided.

[0021] For a better understanding of the present invention and to more clearly show how the present invention can be implemented, reference is made hereinafter, by way of example, to the accompanying drawings.

Brief Description of the Drawings

[0022] [Figure 1] It is a perspective view of a packaging pouch. S [Figure 2] It is a side view of the pouch, showing the creasing assembly. [Figure 3] It is a perspective view of the pouch held by a pair of grippers. [Figure 4] It is a perspective view of the pouch and the opening device. [Figure 5] It is a perspective view of the pouch and the air nozzle. [Figure 6] It is a perspective view of the pouch, showing the guide before insertion into the pouch. [Figure 7]Perspective view of the pouch and the crease-shaped plate in the storage position. [Figure 8] Side view of the pouch and the crease-shaped plate in the storage position. [Figure 9] Perspective view of the pouch and the crease-shaped plate in the deployed position. [Figure 10] Side view of the pouch and the crease-shaped plate in the deployed position. [Figure 11] Perspective view of the pouch and the filling nozzle. [Figure 12] Front view of the pouch and the heat-sealing device. [Figure 13] Front view of the sealed pouch. [Figure 14] Flowchart of the method.

Mode for Carrying Out the Invention

[0023] FIG. 1 shows a packaging pouch 2 that can be used in the method and apparatus of the present disclosure.

[0024] The pouch 2 is a flat pouch and includes a first layer 4 of a flexible packaging material and a second layer 6 of a flexible packaging material. The first layer 4 and the second layer 6 can be formed from the same material or from different materials. The first layer 4 and the second layer 6 can be formed from a laminated composite material or from a monolayer material.

[0025] The first layer 4 and the second layer 6 are sealed along the bottom edge 8 and along the opposing side edges 10a, 10b to form a cavity 12 that remains open along the upper edge 14 to allow filling. The cavity 12 has a width W1 measured between the opposing side edges 10a, 10b and a depth D1 measured from the upper edge 14 to the bottom edge 8.

[0026] As described below, the pouch 2 can be filled using the method and apparatus according to the present disclosure.

[0027] As shown in Figure 2, the apparatus comprises a creasing assembly. The creasing assembly comprises a female creasing platen 16 and a male creasing rule 20. The female creasing platen 16 has a groove 20 sized to receive a corresponding rib 19 provided in the male creasing rule 18. As shown in Figure 2, the pouch 2 is positioned between the female creasing platen 16 and the male creasing rule 18. The pouch 2 is positioned such that the groove 20 extends parallel to the bottom edge 8 and to or adjacent to the bottom of the cavity 12.

[0028] The male creasing rule 18 approaches the female creasing platen 16, and the rib 19 is received into the groove 20, thereby forming a crease 22 that extends across the pouch 2, as can be seen in Figure 3. The crease 22 forms a fold line, as will be further described below.

[0029] As shown in Figure 3, the device further comprises a pair of grippers 24a, 24b. Each of the grippers 24a, 24b is provided with a pair of gripping jaws that are operable to selectively grip the pouch 2 by contacting the first layer 4 and the second layer 6. As shown, the grippers 24a, 24b grip the pouch 2 along the side edges 10a, 10b and adjacent to the top edge 14.

[0030] As shown in Figure 4, the apparatus further comprises a pair of vacuum cups 26a, 26b mounted on arms 27a, 27b.

[0031] The vacuum cups 26a and 26b are adjacent to the upper edge 14 and contact the first layer 4 and the second layer 6, respectively. The vacuum cups 26a and 26b engage with the first layer 4 and the second layer 6 by suction and move away from each other to open the pouch 2 by separating the first layer 4 and the second layer 6 on the upper edge 14. Furthermore, in order to separate the first layer 4 and the second layer 6, the grippers 24a and 24b move toward each other as shown. The movement of the grippers 24a and 24b can be actively controlled (e.g., using appropriate actuators) or passively controlled in response to the separation of the first layer 4 and the second layer 6 creating a force that pulls the grippers 24a and 24b toward each other.

[0032] As shown in Figure 5, the apparatus may further include an air nozzle 28. The air nozzle 28 blows a jet of air into the cavity 12 to further separate the first layer 4 and the second layer 6 along the length of the cavity 12.

[0033] As shown in Figure 6, the apparatus further comprises a guide 30. The guide 30 comprises a pair of fingers 32a, 32b arranged laterally apart from each other. The fingers 32a, 32b define an inner width W2 between their opposing inward-facing faces and an outer width W3 between their respective outward-facing faces.

[0034] With pouch 2 open, guide 30 is inserted into cavity 12. The outer width W3 corresponds to the width W1 of cavity 12 (i.e., slightly smaller than the width W1 of cavity 12). Thus, fingers 32a, 32b are received within cavity 12 and extend parallel to the side edges 10a, 10b. Guide 30 is inserted so that fingers 32a, 32b extend into or toward the bottom corners of cavity 12 (which may be rounded in some examples). It should be noted that in other examples, fingers 32a, 32b can be formed separately rather than as part of a common guide 30.

[0035] As shown in Figure 7, with the fingers 32a and 32b in their predetermined positions, the crease-shaping plate 34 is placed under the bottom edge 8 of the pouch 2. The crease-shaping plate 34 is mounted so as to be pivotable or pivot-rotatable around a shaft 36. The shaft 36 is positioned at or toward the edge of the crease-shaping plate 34 and is parallel to but offset from the plane of the pouch 2.

[0036] The crease-shaping plate 34 is rectangular and has a width W4 that is smaller than the inner width W2 between the fingers 32a and 32b.

[0037] As shown in Figures 7 and 8, the crease-shaping plate 34 has a first storage position in which it is angled downward. For example, in this first position, the crease-shaping plate 34 can be angled downward at 30 degrees from the horizontal (i.e., 120 degrees from the vertical; the 4 o'clock position in Figure 8). As shown in Figures 9 and 10, the crease-shaping plate 34 has a second unfolded position in which it is angled horizontally. In other examples, the crease-shaping plate 34 can be angled upward in the second position. For example, in the second position, the crease-shaping plate 34 can be angled upward at 30 degrees from the horizontal (i.e., 60 degrees from the vertical; the 2 o'clock position).

[0038] In the first position, the crease-shaping plate 34 is positioned at a distance from the bottom edge 8 of the pouch 2. The crease-shaping plate 34 is rotated around the axis 36 toward the second position by an appropriate actuator. During the transition from the first position to the second position, the crease-shaping plate 34 comes into contact with the bottom edge 8 of the pouch 2.

[0039] As can be seen in Figure 9, the continuous movement of the crease-shaping plate 34 to the second position causes the lower part 38 of the pouch 2 to fold horizontally around the crease 22. The fingers 32a and 32b support the pouch 2 and prevent the rest of the pouch 2 (i.e., the upper part) from bending or flexing due to the action of the crease-shaping plate 34, and as a result remain vertical. Thus, the lower part 38 extends perpendicular to the rest of the pouch 2.

[0040] The axis 36 of the crease-shaping plate 34 is positioned higher than the crease 22 formed across the pouch 2, as shown by line 37 in Figure 7. Therefore, as the crease-shaping plate 34 moves from the first position to the second position and folds the lower part 38 around the crease 22, the crease-shaping plate 34 also lifts the central region of the lower part 38 upward.

[0041] As described above, the width W4 of the crease-shaping plate 34 is smaller than the inner width W2 between the fingers 32a and 32b, so the crease-shaping plate 34 can be accommodated between the fingers 32a and 32b. Therefore, the crease-shaping plate 34 can be accommodated between the fingers 32a and 32b in order to lift the central area of ​​the lower part 38.

[0042] The distal regions of the lower 38 on both sides of the central region slope downward away from the central region. As a result of the shape of the lower 38, the lateral edges 10a, 10b of the pouch 2 are drawn to each other on the bottom of the pouch 2. To enable this, the fingers 32a, 32b can be made movable so as to move parallel to each other or rotatable so as to move their distal ends toward each other.

[0043] In other examples, the fingers 32a and 32b can be retracted (at least partially) as the crease-shaping plate 34 moves to a second position.

[0044] In another example, the crease-shaping plate 34 can first rotate around the axis 36 and then be translated upward to lift the central region of the lower part 38.

[0045] As shown in Figure 11, with a fold formed at the bottom of pouch 2, the guide 30 can be retracted to pull the fingers 32a and 32b out of the cavity 12 of pouch 2, and the fold-shaping plate 34 can be removed. The fold-shaping plate 34 can be retracted to the first storage position or completely removed from the vicinity of pouch 2.

[0046] The shape of the fold formed at the bottom of pouch 2 is effective in maintaining pouch 2 in an opening configuration in which the first layer 4 and the second layer 6 are separated on the upper edge 14 and along the length of the cavity 12. Thus, the vacuum cups 26a and 26b can be removed from the first layer 4 and the second layer 6 of pouch 2. In other examples, it should be understood that the vacuum cups 26a and 26b can be removed early in the process, for example, before or at the time the fingers 32a and 32b of guide 30 are inserted into the cavity 12. Furthermore, in other examples, the act of folding the bottom 38 can be effective in separating the first layer 4 and the second layer 6 so that it is not necessary to use the vacuum cups 26a and 26b, etc. to initially open pouch 2.

[0047] The shape of the fold formed at the bottom 38 of pouch 2 has been shown to provide a stable shape, ensuring that the fold is retained even after the fold-shaping plate 34 is removed. The fold is effectively retained even with sustainable monomaterials that generally have poor deadfold properties and are therefore prone to springing back to their original position.

[0048] As shown in Figure 11, the apparatus further comprises one or more filling nozzles 44. With the pouch 2 held in an open configuration by a fold formed at the bottom of the pouch 2, the pouch 2 can be filled with product using the above or each nozzle 44. For example, the pouch 2 can be used for packaging pet food, with the first filling nozzle 44 supplying liquid such as meat juice to the pouch 2, and the second filling nozzle 44 supplying solid such as meat to the pouch 2. In other examples, both liquid and solid can be supplied to the pouch 2 by using a single nozzle 44 and selectively connecting different supply lines / sources.

[0049] As shown in Figure 12, the apparatus further comprises a heat sealing device. The heat sealing device comprises a pair of jobbers 46 (only the front jobber 46 is visible in Figure 12). The pouch 2 is introduced between the jobbers 46, with the first layer 4 facing one jobber 46 and the second layer facing the other jobber 46. The jobbers extend across the width of the pouch 2. The pouch 2 is positioned so that the jobbers are adjacent to and parallel to the upper edge 14. The jobbers 46 are movable relative to each other so that they can contact the first layer 4 and the second layer 6 and thereby push the first layer 4 and the second layer 6 toward each other to close the pouch 2. One or both of the jobbers 46 are heated so that the first layer 4 and the second layer 6 are welded together along a seal line 48 adjacent to the upper edge 14 (see Figure 13) to seal the pouch 2. The Jawbar 46 can be heated continuously, or intermittently only when the Jawbar 46 is used together.

[0050] As described above, the shape of the fold formed at the bottom of pouch 2 is known to provide a stable shape that retains the fold and does not easily spring back to its original position. An unstable fold that is prone to springing back can cause the contents of pouch 2 to spurt upward into the area where the seal line 48 is formed. This can cause problems related to the integrity of the seal, as the presence of contaminants along the seal line 48 can make it difficult for the heat sealing device to properly weld the first layer 4 and the second layer 6 together. This, in turn, can lead to leakage of the product from the pouch. To reduce the risk of contaminants being present along the seal line, the pouch can be filled less, but this increases the amount of material used. The stable geometric shape provided by the fold disclosed herein allows pouch 2 to be filled to its maximum level while ensuring the integrity of the seal, which minimizes the amount of material used.

[0051] As shown in Figure 13, with pouch 2 fully sealed, the fold formed at the bottom of pouch 2 can be removed. This ensures that multiple pouches 2 can be packaged together for efficient transport and display.

[0052] Figure 14 shows a flowchart illustrating an exemplary method for filling a flat pouch according to the present disclosure.

[0053] In the first step S2, the bottom of the pouch is folded relative to the top around a fold line. A crease may be pre-formed between the bottom and top, which forms the fold line. The bottom can be folded so as to extend perpendicular to the top. As described above, a guide can be inserted into the cavity of the pouch to prevent the top from bending or flexing when the bottom is folded relative to the top.

[0054] In the second step S4, the lower central region is lifted, forming a shaped fold in which the lower distal regions on both sides of the central region are tilted downward away from the central region. The shaped fold is configured to maintain the pouch in an open configuration, in which the first and second layers of the pouch are separated along the upper edge to form an opening to the cavity of the pouch.

[0055] As described above, the central region can be lifted by a crease-shaping plate that rotates and / or translates between a first storage position and a second unfolded position. The crease-shaping plate can also fold the lower part around the fold line. For example, the crease-forming plate can fold and shape the lower part in a single motion, or it can perform a first motion of folding the lower part and a second motion of shaping the crease.

[0056] In the third step S6, the product can then be filled into the pouch through the opening.

[0057] Please understand that this method can be carried out using the apparatus described above.

[0058] Please understand that this method and apparatus may be modified from those described above.

[0059] The various features of the apparatus described above can be implemented in separate modules or integrated into a single filling and sealing machine. In other examples, the apparatus can be an integrated forming-filling-sealing machine that also manufactures the pouches themselves, rather than being provided with pre-formed pouches for filling and sealing.

[0060] It should be understood that the crease 22 can be formed when the pouch 2 is lying horizontally oriented on the female crease-forming platen 16. Alternatively, if the crease 22 is formed, the pouch 2 can be held vertically oriented by the grippers 24a, 24b. In another example, the crease-shaping plate 34 can reliably form a crease at the bottom of the pouch 2 without requiring a pre-formed crease 22.

[0061] The arrangement of the guide 30 may differ from that shown in the illustration. For example, the branching sections of fingers 32a and 32b can spread out by a distance sufficient to accommodate the crease-shaping plate 34 between them as the crease-shaping plate 34 moves to the second unfolded position. Thus, the guide 30 may have a body portion that extends further into the pouch 2 than shown. For example, the body portion may extend to the level of the crease 22, or, if a pre-formed crease is not required, to the position where the lower part 38 is folded. Thus, the body portion can assist in folding the lower part 38.

[0062] In other examples, the top of pouch 2 can be held in some other way. For example, an external gripper can be used to hold pouch 2 above the crease 22 and maintain the top in a vertical orientation. Such an external gripper can be used in addition to or instead of the guide 30.

[0063] In another example, a pair of external grippers can grasp the distal region of the lower 38 and bend it downward away from the central region. These external grippers can also lift the central region in the same motion and thus provide an alternative (or additional) means for the crease-shaping plate 34.

[0064] As used herein, the relative terms “upper” and “lower” are defined with respect to the opening of the pouch where filling takes place and do not necessarily reflect how the pouch is oriented for subsequent display and / or use (e.g., when opened). [Explanation of Symbols]

[0065] 2 pouches 4. The first layer 6. The second layer 8 Bottom edge 10a side edge 10b Side edge 12 Cavity 14 Upper edge

Claims

1. A method for filling flat pouches, The lower part of the aforementioned pouch is folded relative to the upper part around the fold line, Forming a shaped fold by lifting the folded lower central region such that the distal regions of the lower region on both sides of the central region are inclined downward so as to be separated from the central region, and the shaped fold is configured to maintain the pouch in an opening configuration in which the first and second layers of the pouch are separated across the upper edge to form an opening to the cavity of the pouch, Filling the cavity of the pouch with the product through the opening, A method that includes this.

2. The method according to claim 1, further comprising forming a crease between the lower part and the upper part that forms the fold line.

3. The method according to claim 1 or 2, wherein the lower part is bent so as to extend perpendicularly to the upper part.

4. The method according to any one of claims 1 to 3, wherein the central region is lifted by a crease-shaping plate that rotates and / or moves parallel to each other between a first storage position and a second unfolded position.

5. The method according to claim 4, wherein the crease-shaping plate also folds the lower part around the fold line.

6. The method according to claim 4 or 5, wherein the crease-shaping plate rotates around an axis.

7. The method according to claim 6, wherein the axis is located above the height of the fold line.

8. The method according to any one of claims 1 to 7, wherein the first and second layers of the pouch are separated along the upper edge before the shaped fold is formed.

9. The method according to claim 8, wherein the first and second layers of the pouch are separated by a pair of vacuum cups that engage with the first and second layers, respectively, and separate from each other to open the pouch.

10. The method according to any one of claims 1 to 9, further comprising inserting a guide into the cavity of the pouch before the lower part is folded relative to the upper part, in order to prevent the upper part from bending when the lower part is folded relative to the upper part.

11. The method according to claim 10, as dependent on claim 4, wherein the guide is configured to accommodate the crease-shaping plate when it is in the second unfolded position.

12. The method according to claim 11, wherein the guide comprises a pair of fingers spaced laterally apart from each other so that the crease-shaping plate can be accommodated between the pair of fingers.

13. The method according to any one of claims 1 to 12, wherein the fold line is adjacent to the bottom of the cavity.

14. The method according to any one of claims 1 to 13, wherein each of the first layer and the second layer is formed from a monomaterial.

15. A pouch filling apparatus configured to carry out the method according to any one of claims 1 to 14.

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