Flexible Fitment Sealing Using Multi-Block Copolymer Base

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Solution Overview

Problem

Conventional pour-pouch production is inefficient due to the need for specialized heat seal equipment, precise alignment requirements, high failure rates from misalignment, and increased quality control steps, particularly with winglet-based spouts.

Innovation Solution

A process using a fitment base made from ethylene/α-olefin multi-block copolymer, positioned between multilayer films and heated seal bars with curved surfaces, allowing for heat sealing without precise alignment, resulting in a flexible and resilient seal that reduces material usage and production time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If winglet-based spouts are used to increase adhesion surface area, then adhesion between spout and flexible packaging film is improved, but specialized heat seal equipment and precise alignment are required

Engineering Contradiction:

ImproveadhesionVSAvoidheat seal equipment

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention extracts the problematic winglet structure from the spout base, replacing it with a simplified annular base that achieves adhesion through material compatibility and heat seal geometry rather than increased surface area. This eliminates the need for specialized seal bars while maintaining sealing effectiveness.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of adding winglets to increase adhesion surface area, the invention inverts the approach by using a smooth annular base that relies on the heat seal bar geometry and material properties to achieve secure adhesion. The problem is solved by doing the opposite of the conventional approach.

Inventive Principle:

Principle #13The other way round (Inversion)

2Strength

If winglet-based spouts are used, then adhesion surface area is increased, but production time increases due to alignment requirements

Engineering Contradiction:

ImproveadhesionVSAvoidproduction time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The winglet structure is extracted from the design, eliminating the time-consuming alignment steps required for winglet-based sealing. The simplified annular base allows for faster, less precise positioning while maintaining adhesion strength through material compatibility.

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If winglet-based spouts are used, then adhesion is improved, but failure rate increases due to misalignment

Engineering Contradiction:

ImproveadhesionVSAvoidfailure rate

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention inverts the conventional approach by eliminating winglets and using a smooth annular base. This paradoxically improves reliability by removing the alignment-critical features that cause misalignment failures, while maintaining adhesion through material compatibility and heat seal geometry.

Inventive Principle:

Principle #13The other way round (Inversion)

4Ease of manufacture

If conventional spouts without winglets are used, then production process is simplified, but adhesion between spout and flexible packaging film is reduced

Engineering Contradiction:

Improveproduction processVSAvoidadhesion

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention changes the material parameters of the spout base, using ethylene/α-olefin multi-block copolymer with specific properties that enable strong adhesion to polyolefin seal layers. This material parameter change allows simplified geometry to achieve the same adhesion strength as complex winglet structures.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The process simplifies pour-pouch production, reduces material usage, and decreases failure rates by enabling a flexible fitment that springs back to an open position, improving productivity and efficiency.

Implementation Method 1

the base with sufficient integrity to survive compression during heat seal and the sufficient resiliency to spring back to an open position post-heat seal

Methodology Applied

Scientific EffectElastic recovery: Elastic Recovery

Implementation Method 2

positioning the base and opposing multilayer films between opposing seal bars... heat sealing the base to each multilayer film

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS10668670B2Process for sealing flexible fitment to flexible film

Publication Date: 2020.06.02 DOW GLOBAL TECHNOLOGIES LLC

AI summary

The present disclosure provides a process. In an embodiment, the process includes (A) providing a fitment with a base having a wall thickness (Tw). The base comprises an ethylene/a olefin multi-block copolymer. The process includes (B) placing the base between two opposing multilayer films. Each multilayer film has a respective seal layer comprising an olefin-based polymer. The process includes (C) positioning the base and opposing multilayer films between opposing seal bars. Each seal bar comprises (i) a front surface, (ii) a recessed surface a distance (x) behind the front surface, the recessed surface having a first end and an opposing second end. Each seal bar comprises (iii) a curved surface at each opposing end. The curved surface extends between the front surface and the recessed surface. Each curved surface has a radius of curvature (Rc) greater than or equal to distance (x). The process includes (D) heat sealing the base to each multilayer film.