Flexible Pouch Microcapillary Spray Dispensing System
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Solution Overview
Problem
Flexible pouches lack flow control capabilities, requiring rigid components for spray applications, which are heavy, expensive, and not recyclable, limiting their use in spray segments.
Innovation Solution
A process involving a microcapillary strip is integrated between two flexible films, sealed at specific conditions to create a flexible pouch capable of delivering a controlled spray without rigid components, utilizing heat sealing techniques to form a hermetic seal and collapse channels for dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid spray components are used in flexible pouches, then spray flow control is achieved, but weight increases and recyclability is compromised
Solution Approach 1:
The invention extracts the spray flow control function from rigid components and transfers it to the flexible pouch structure itself through heat-sealed channels and cavities formed directly in the pouch walls, eliminating the need for separate rigid spray nozzles or fitments
Solution Approach 2:
The patent uses the flexible pouch films themselves to create flow control channels and spray cavities through heat sealing, replacing traditional rigid spray components with flexible film-based structures that provide equivalent flow control functionality
2Reliability
If rigid spray components are used in flexible pouches, then spray flow control is achieved, but manufacturing cost increases
Solution Approach 1:
The invention merges the spray flow control function with the pouch structure by integrating heat-sealed channels and spray cavities directly into the pouch walls during the pouch manufacturing process, eliminating the need for separate rigid spray components and their associated assembly steps
Solution Approach 2:
The flexible pouch films serve multiple functions: containment of liquid, structural integrity, and flow control through heat-sealed channels, replacing the need for specialized rigid spray components that would add complexity and cost
3Reliability
If heat sealing process is used for rigid fitments, then assembly is achieved, but production efficiency decreases due to slow speed and high failure rate
Solution Approach 1:
The heat sealing channels and spray cavities are formed into the pouch structure during the pouch manufacturing process itself, before the pouch is filled with liquid, eliminating the need for subsequent assembly operations and improving production efficiency
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 flexible pouch achieves controlled spray dispensing without rigid components, offering lightweight, recyclable, and cost-effective packaging solutions for liquid products.
Implementation Method 1
first sealing, at a first seal condition, the microcapillary strip between the two flexible films
Implementation Method 2
second sealing, at a second seal condition, a peripheral seal along at least a portion of the common peripheral edge
Implementation Method 3
The peripheral seal includes a sealed microcapillary segment
Data Source
Figure 1~3
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Figure 7~8
AI summary
The present disclosure provides a process. In an embodiment, a process for producing a flexible pouch is provided and includes placing a microcapillary strip between two opposing flexible films. The opposing flexible films define a common peripheral edge. The process includes positioning a first side of the microcapillary strip at a first side of the common peripheral edge and positioning a second side of the microcapillary strip at a second side of the common peripheral edge. The process includes first sealing, at a first seal condition, the microcapillary strip between the two flexible films; and second sealing, at a second seal condition, a peripheral seal along at least a portion of the common peripheral edge. The peripheral seal includes a sealed microcapillary segment.