Two-Part Spout Plug Insert for Inversion Leak Resistance
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Solution Overview
Problem
Existing aseptic pouch filling technologies face challenges in preventing leakage when the pouch is inverted, particularly when the cap and plug are removed, and incorporating flow inhibitors into the spout can complicate the filling process.
Innovation Solution
A two-part plug assembly with a flow inhibitor, comprising a plug and a plug insert, is used to seal the spout before filling, allowing removal and replacement in an aseptic environment, ensuring the plug insert remains fixedly engaged to prevent leakage during inversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flow inhibitor is incorporated into the spout to prevent leakage during inversion, then leakage prevention is improved, but the filling process becomes more complex due to the need to fill through the flow inhibitor
Solution Approach 1:
The plug assembly is divided into two separate parts: a plug and a plug insert. The plug insert containing the flow inhibitor remains fixedly engaged with the spout after filling, while the plug can be removed. This segmentation allows the flow inhibitor to stay in place for leakage prevention without complicating the filling process, as the filling tube can access the spout opening when the plug is removed.
Solution Approach 2:
The plug assembly is designed to be placed in a pre-filling position before the filling process, where it partially deprpresses along the spout to preclude access into the pouch. This preliminary positioning ensures the aseptic environment is maintained while allowing easy removal for filling, and subsequent fixed engagement for leakage prevention during storage and transport.
2Ease of operation
If the plug assembly is removed after filling to allow product dispensing, then dispensing functionality is improved, but leakage prevention is worsened when the pouch is inverted
Solution Approach 1:
By separating the plug into two parts where the plug insert remains fixedly engaged with the spout after the plug is removed, the flow inhibitor stays in position to prevent leakage during inversion. Meanwhile, the removed plug allows consumers to easily dispense product by squeezing the pouch, as the flow inhibitor only activates under inversion conditions.
Solution Approach 2:
The plug assembly transitions from a sealed state (plug engaged) to a dispensing state (plug removed, plug insert remains). This dynamic configuration allows the system to adapt between preventing leakage during storage/transport and enabling easy product dispensing during use, with the flow inhibitor providing passive leakage prevention when inverted.
3Reliability
If the plug assembly fixedly engages the spout at a location more proximal to the flexible container after filling, then sealing effectiveness is improved, but access for filling becomes more difficult
Solution Approach 1:
The plug assembly is designed with a pre-filling position where it partially depresses along the spout, maintaining a gap that allows filling tube access. After filling, the plug assembly is moved to a post-filling position where it fixedly engages the spout more proximal to the flexible container for enhanced sealing. This preliminary positioning strategy ensures both filling accessibility and subsequent sealing effectiveness.
Solution Approach 2:
The two-part plug assembly allows the plug insert to remain fixedly engaged for sealing while the plug can be removed for dispensing. This segmentation enables the sealing function to be maintained at the optimal location for leak prevention without permanently blocking the spout opening, as the removable plug component can be taken off after filling to restore access for product dispensing.
Data Source
AI summary
A two-part plug assembly is disclosed for a drip-proof spout on an aseptic flexible container for flowable materials. The two-part plug assembly may include a plug and a plug insert, wherein the plug insert may include a flow inhibitor such as a baffle or valve. In a first step, the plug assembly is removably placed in a first position on a spout prior to aseptic filling. During filling, the plug assembly is removed. After filling, the plug insert assembly is replaced in a second position further down the spout wherein the plug insert fixedly engages the spout. When fixedly engaged to the spout, the plug insert remains inside the spout when the plug is removed prior to a user dispensing the flowable material. The flow inhibitor in the plug insert provides protection from leaking when the flexible container is inverted or inadvertently squeezed.