Two-Part Spout Plug Assembly for Inverted Pouch Leak Prevention
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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 is used, where the plug is removable in an aseptic zone before filling, and after filling, it is fixedly engaged with the spout to prevent leakage by retaining the plug insert and flow inhibitor in the spout, allowing dispensing only when the pouch is squeezed with sufficient force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flow inhibitor is incorporated into the spout to prevent leakage when inverted, 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 in the spout after the plug is removed, allowing filling to proceed without obstruction while maintaining leakage prevention capability.
Solution Approach 2:
The flow inhibitor is extracted from the plug assembly and placed in a separate plug insert that remains in the spout. This allows the main plug to be removed for filling while the flow inhibitor stays behind to prevent leakage during storage and transport.
2Reliability
If the plug assembly is fixedly engaged with the spout to prevent leakage, then sealing reliability is improved, but the ease of removal for filling deteriorates
Solution Approach 1:
The plug assembly is segmented into a removable plug and a fixed plug insert. The plug can be easily removed for filling while the plug insert remains fixedly engaged with the spout to maintain sealing reliability.
Solution Approach 2:
The sealing function is extracted from the removable plug and placed in the fixed plug insert that remains in the spout. This allows the plug to be easily removed while the sealing function is maintained by the remaining insert.
3Reliability
If the plug insert with flow inhibitor remains in the spout after plug removal, then leakage prevention is improved, but the device complexity increases
Solution Approach 1:
The plug insert serves multiple functions: it provides structural support within the spout, maintains the sealing interface, and houses the flow inhibitor mechanism. This multi-functionality justifies the additional component while achieving reliable leakage prevention.
Solution Approach 2:
The flow inhibitor is nested within the plug insert, which itself is nested within the spout. This compact nested arrangement minimizes the overall device complexity while maintaining the leakage prevention function.
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 solution effectively prevents leakage from inverted pouches by maintaining the flow inhibitor in the spout, ensuring aseptic conditions and enabling controlled dispensing of contents.
Implementation Method 1
The flow inhibitor may be designed to prevent leakage of a liquid or semi-liquid product contained in the flexible container prior to consumer use
Implementation Method 2
Retention of the plug insert and associated flow inhibitor in the spout may prevent flowable material in the pouch from leaking out of the spout when the container is inverted
Implementation Method 3
a two-part plug assembly may be sealingly engaged to the spout. Prior to filling the pouch, the plug assembly may be placed in a pre-filling position, partially depressed along the spout, thereby precluding access into the pouch
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.