Zipper Pouch Barrier With Local Quality Segmentation
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Solution Overview
Problem
The existing zippered pouches with spouts are prone to damage in the manufacturing process and rupture during retort sterilization, leading to potential leaks and compromised hygiene and quality control.
Innovation Solution
A zippered pouch design with a plastic zipper featuring a barrier portion protected by a tongue piece, which is reinforced to withstand manufacturing contact and heat sterilization, and has a rupture strength of 10 to 150 N/50 mm width to prevent contents from leaking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the barrier portion is made as a low-strength portion to allow easy opening, then ease of operation is improved, but reliability deteriorates due to damage during manufacturing and rupture during sterilization
Solution Approach 1:
The barrier portion is designed with non-uniform thickness to create different local properties: the thin section provides low strength for easy opening, while the thick section provides high strength for withstanding sterilization and manufacturing stresses. This local quality differentiation allows the same component to serve multiple functional requirements simultaneously.
Solution Approach 2:
The barrier portion is segmented into multiple regions with different thicknesses along its length. The thin-section region facilitates easy tearing and opening, while the thick-section region maintains structural integrity during manufacturing and sterilization. This segmentation allows each region to optimize for its specific function without compromising the other.
2Ease of operation
If the barrier portion is made thin for easy opening, then ease of operation is improved, but manufacturing precision deteriorates due to damage from guide rolls and pinholes
Solution Approach 1:
The barrier portion features local quality variations with different thicknesses at different locations. The thick-section regions protect the thin-section region from manufacturing damage, while still allowing the thin section to provide easy opening functionality. This prevents damage to the critical thin barrier areas during manufacturing.
Solution Approach 2:
The thick-section regions of the barrier portion serve as protective cushions before the thin-section barrier is exposed to manufacturing stresses. These thicker areas absorb and distribute the forces from guide rolls and other manufacturing equipment, preventing damage to the delicate thin barrier portions that will eventually be used for opening.
3Ease of operation
If the barrier portion is made as a low-strength portion, then ease of operation is improved, but loss of substance increases due to leakage during sterilization
Solution Approach 1:
The barrier portion is designed with local quality differences where thick-section regions prevent leakage during sterilization by providing structural integrity, while thin-section regions enable easy opening. This spatial differentiation of properties ensures that the barrier maintains its sealing function throughout sterilization while still allowing convenient opening when needed.
Solution Approach 2:
The barrier portion is segmented into thick and thin sections that perform different functions: the thick sections maintain fluid-tight integrity during sterilization and prevent contents leakage, while the thin sections facilitate easy opening. This segmentation allows the barrier to simultaneously prevent loss of substance and maintain ease of operation.
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 pouch maintains fluid-tight integrity during sterilization and use, reducing the risk of contents spilling and ensuring product stability and hygiene, allowing for easy manual opening and resealing.
Implementation Method 1
a tongue piece 24 covers an end surface of the folded portion (barrier portion) 23... to protect a fluid-tight barrier of the barrier portion
Implementation Method 2
a linear convexity 21b formed on one surface of a film base material 22; a concavity 21a into which the convexity 21b fits... the zipper 2 is configured to be opened and closed by the interlocking 21 of the convexity and the concavity
Implementation Method 3
the barrier portion 23 can be ruptured after the zipper portion has been unzipped... the rupture strength of the barrier portion is 10 to 150 N/50 mm width
Implementation Method 4
the pouch is heat-sterilized after being filled with contents and sealed... withstand manufacturing contact and heat sterilization
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
It is an object of the present invention to provide a pouch comprising a plurality of plastic sheets sealed on periphery, the pouch having a contents spout and a plastic zipper arranged in a fused state between the sheets whose outer periphery is sealed, and the pouch being heat-sterilized after being filled with contents. The aforedescribed aspect of the present invention is characterized in that a barrier portion is formed in a portion of the pouch interior set further toward the contents and away from the plastic zipper, the barrier portion formed in a state in which a film base material has been folded over. As a result, even if any damage is imparted during the step for manufacturing the plastic zipper or the step for mounting the zipper in the pouch, there will be no incidence of the contents leaking from the barrier portion and reaching the zipper portion due to heat and pressure encountered when retort sterilization, boiling, or another type of heat sterilization is performed after the pouch has been filled with foodstuffs or other material. The customer can thus be provided with a product that is stable in terms of hygiene and quality control.