Note: Descriptions are shown in the official language in which they were submitted.
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MACHINE AND METHOD FOR MAKING A PLASTIC FILM
POUCH AND A7.'TACHING.A SPOUT THERETO
TECHNICAL FIELD ,
The present invention relates to a machine and a
method for the manufaci:ure of a plastic film pouch and
attaching a spout thereto and wherein the machine can also
fill the pouch with a content prior to the sealing and
discharge of the pouch from the machine.
BACKGROUND ART .
Pouches with dispensing spouts are usually utilized
for institutional use and wherein Large quantities of liquids,
such as milk, may be dispensed within a bag having a capacity
of retaining 5, 10 and even 20 liters of product therein.
Although the present machine was designed to form milk
pouched, it could be used to dispense materials other than
milk within these pouches and not necessarily liquid products.
Currently in:~titutional bag making consists
essentially of providing two rows of thin plastic film which
may be single or double ply, having a thickness of 2 mil per
ply to provide both top and bottom side walls of the bag.
Both rows of film are unwound simultaneously and are guided
towards a three sided sealing mechanism. Prior- to reaching
the sealer, a hole is punched out of one of the films in an
area where the bottom portion of the dispensing spout base
will be pushed up therethrough and a polyethylene film is heat
sealed-to the top of the cap flange. The two films then
continue into the three sided sealer. A horizontal sealer is
provided to seal the bag completely and separate it from the
next bag. A perforation is then made through the overlaid
plastic sheets whereby to connect the bags to one another.
The top of the cap is then placed automatically or manually
onto the dispensing spout.
In order to f3_11 the bags with a product, such as
liquid milk, an operator either fills individual bags through
the spout and then places a cap on the spout. If the bag is
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to be filled automatically, the caps are removed from the base
and the bag is filled. fhe bag then goes through a recapping
operation and the filled bag is then placed into a container.
If the bags are on rolls, the operator would start the process
by putting the first bag into a tracking area which would lead
the bag into a decapper, then through a filling station and
then through a recapper. The filled bag can then be dropped
automatically into a case or a transport - conveyor.
Accordingly, it can be seen that by forming these bags with
the prior art methods, it: is necessary to remove the cap from
the dispensing spout base to fill the bag and this can be done
automatically or semi-automatically but the cap has to then be
placed back onto the spout_ This is a slow process and
because the cap is removed and replaced onto the spout it may
not always provide a proper seal once a liquid mass is
provided in the bag as the bag becomes more difficult to
handle.
SUMMARY OF INVENTION
It is a feature of the present invention to provide
a machine for the automatic manufacturing a plastic film pouch
with a spout and a method of making same and which
substantially overcomes the above-mentioned disadvantages of
the prior art.
Another feature of the present invention is to
provide a machine and a method for fully automatically forming
a plastic film pouch from a folded film sheet and attaching a
spout thereto.
Another feature of the present invention is to
provide a machine and a method for automatically making the
plastic film pouch from a folded film sheet and attaching a
spout thereto without puncturing the film in the area of the
spout and wherein the formed bag is filled with a liquid and
completely sealed prior to being automatically conveyed to a
container.
According to the above features, from a broad
aspect, the present invention provides a machine for
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manufacturing a plastic film pouch with a dispensing spout
attached thereto. The spout has a dispensing orifice. The
machine comprises guide means for guiding two overlaid film
sheets through the machine to a positioner means to position a
dispensing spout adjacent one of the two overlaid film sheets
at a predetermined position with respect to a sealer device.
Means is provided to displace a portion of the other of the
sheets while the sheets are stationary to permit the sealer
device to seal the one of the sheets about the dispensing
orifice of the spout. Sealing means is provided to form seals
along at least some unconnected edges of the overlaid sheets
to form a pouch having the spout connected thereto.
The machine also has the capability of filling the
form pouch and sealing the entire pouch prior to automatically
discharging same from the machine. The machine also applies a
cap to the dispensing spout connected to one of the film
sheets.
According to a further broad aspect of the present
invention there is provided a method of forming a plastic film
pouch and automatically securing a dispensing spout thereto.
The spout has a dispensing orifice. The method comprises
guiding- two overlaid film sheets along a predetermined path.
A dispensing spout is positioned adjacent one of the two
overlaid film sheets at a predetermined position with respect
to a sealer device with the spout oriented in a specific
manner. A portion of the other of the sheets is retracted
while -the sheets are stationary to permit the sealer device to
seal the one of the sheets about the dispensing orifice of the
spout. The said overlaid film sheets are sealed together
along at least some unconnected edges to form a pouch having
the spout connected thereto.
The method also comprises the step of securing a
closing cap in sealing engagement with an outer end of the
spout, filling the bag vuith a liquid content and completely
sealing same.
The method a7.so further -provides the step of
puncturing a hole in the one film sheet to which the spout
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base is secured to in the area of the dispensing orifice of
the spout.
BRIEF DESCRIPTION OF DRAWINGS
A preferred embodiment of the invention will now be
described with reference to the accompanying drawings in
which:
FIG. 1 is a simplified side -view showing the
construction of the pouch manufacturing machine of the present
invention;
FIG. 2 is an opposed side view of the machine
illustrating other features thereof;
FIG. 3 is an end view of the machine showing the
filling station and the control panel;
FIG. 4 is a side view of a spout base being guided
to a base picker;
FIG. 5 is a simplified schematic view showing a
folded film sheet with one of the sheets being withdrawn for
welding the spout base to one of the film sheets;
FIG. 6 is a simplified side view showing the
ultrasonic welder for fu:>ing the plastic film sheet to a base
flange of the spout base;
FIG. 7 is a fragmented section view showing a cap
being positioned onto the spout base by a cylinder head with
the spout base resting against a back plate;
FIG. 8 is a simplified fragmented view illustrating
the bag forming and filling station of the machine; and
FIG. 9 is a perspective view of a plastic film pouch
having a capped spout secured thereto and filled with a
product, all of which is fabricated in accordance with the
present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now 1.o the drawings and more particularly
to Fig. 1, there is shoHm generally at 10 the machine of the
present invention for manufacturing the plastic film pouch 11
as illustrated in Fig. 9 and having a dispensing spout 12
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secured to a side wall 13. of the pouch. The dispensing spout
12 has a cap 14 secured thereto.
The machine 10 is provided with a dispensing spout
base vibratable dispensing container 18 in which is fed a
plurality of spout bases 16 as illustrated in Fig. 4. A
plurality of spout caps 17, as illustrated in Fig. 7, are also
contained within a cap container 15. The spout bases 16 are
discharged from the container 18 in a predetermined oriented
manner along guide rails 19 to a base picker device 20. The
caps 17 in the container 15 are likewise guided by guide rails
18' to a cylinder head 21 to apply the cap onto the spout base
16, as will be described later.
As hereinshown a supply roll 22 of a folded plastic
film sheet 23 is retained at a lower end of the machine 10 on
a support frame 24 and the sheet is guided through a plurality
of dancer rolls and guide rolls 25 to maintain a predetermined
tension in the folded sheet and to guide same on a vertical
travel path 26 in the machine.
with further reference to Figs. 4 to 7 there will be
described the manner in which the spout base 16 is secured to
one of the overlaid film sheets 23' and 23" of the folded film
sheet 23. As the folded film sheet 23-travels through the
vertical travel path 26, which is equipped with a guide plate
27 provided with a longii;udinal slot 28 therein. The slot has
an enlarged bottom end 29 which is aligned with an ultrasonic
ring-shaped welding head 30. In opposed axial alignment with
the welding head 30 is the base picker 20 having a suppport
end cavity (not shown) and in which one of the spout bases 16
is retained. A transfer cartridge 20' transfers the spout
bases from the rails to the picker 20. During the ultrasonic
welding cycle of the machine the travelling folded sheet 23 is
stopped at a predetermined location and a retracting mechanism
31 having a cylinder operated retracting plate 32 with a U-
shaped slot through which an outer free edge 33 of the plastic
film sheet 23' extends whereby to, withdraw the sheet to move
it away from the enlarged bottom end 29 in the guide plate 27.
The base picker then moves the spout base 16 with its outer
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circumferential flange 34 positioned against the other plastic
film sheet 23". The ultrasonic welding head 30 then moves in
the direction of the enlarged opening 29 and welds the film
sheet 23" about the outer circumferential flange 34 of the
spout base. Both the base picker and the ultrasonic welding
head then retract and the spout base 16 is now connected to
the film sheet 23". The retracting mechanism 31 also moves to
its initial position in alignment with the straight edge 33 of
the film sheet 23' and the sheet i.s then advanced a
predetermined length to the next cycle.
As shown in Fig. 1, the machine may also be provided
with a puncture cylinder 35 having a puncture rod 36 at the
end thereof displaceable from a retracted position to a
working position to puncture the plastic sheet 23' inside the
nozzle orifice 41 at another location where the plastic film
sheet 23' is not in obstruction with the film sheet 23"
whereby to form a hole to provide access to the inside of the
pouch to be formed. It is pointed out that the puncture
cylinder 35 could also be located at the same station as the
ultrasonic welder and move in and out of position in that
area.
At the same time as the ultrasonic welding head is
applied to the film sheet:, the cap 17 may also be connected to
another spout base 16 already attached to the film sheet and
this is done at the cap application station 37. As shown in
Fig. 7 at that station the film sheets are both positioned in
front of a backing plate 38 and a cylinder head 39 picks up
one of the caps 17 from the guide rails 18' at a loading
station and transfers it in engagement about the outer end
portion 40 of the spout base 16 for sealing engagement
therewith. It is pointed out that it is not essential to
puncture the film sheet 23" in the area of the orifice 41 of
the spout base as a bag could be formed as a sealed bag and
the film sheet 23" may be punctured by the end user by
inserting a puncturing element through the spout orifice 41.
It is also conceivable that these bags may be thus formed
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without a cap positioned over the spout depending on the
intended use of the bag.
With the spout now attached to one of the film
sheets of the folded plastic film sheet 23 they now travel
onto a pouch forming and filling station where a pouch is
formed. a product, such as liquid milk is dispensed therein,
the pouch is completely sealed and discharged onto a discharge
conveyor 43. The pouches 11 are then discharged into handling
containers (not shown) which are also transferred on a
conveyor.
The pouch forming and filling station operates in
the following manner. AS can be seen dispensing means in the
form of two conduits 43 and 44 are positioned side-by-side and
extend axially between the overlaid film sheets 23' and 23".
These conduits have a right angle joint 43' and 44' over which
the unconnected edges 33 of the film sheet extend. The free
ends of the conduits 43 and 44 have a dispensing nozzle 43"
and 44", respectively. Metering devices 45 are associated
with each of the pipes 43 and 44 to dispense predetermined
quantities of liquid, herein milk, through the nozzles. The
nozzle 43" is utilized to dispense a fixed quantity of liquid
while the nozzle 44" regulates the exact amount of milk
dispensed within the pouch. However, before dispensing the
liquid the pouch has to be formed.
The pouch is formed by a horizontal sealing device
46 and a vertical sealing device 47. The horizontal sealing
device is an impulse device equipped with two hot sealing
strips 48 and 49 with sealing strip 48 sealing the bottom of
the top pouch 11' being formed and sealing strip 49 sealing
the top of the filled pouch 11". Intermediate the sealing
strips 48 and 49, there is provided a straight electrically
conductive cutting wire 50 to which is fed electrical
impulses. The sealing pressure is generated by compressed air
cylinder 51, as shown in Fig. 1. The sealing and cutting of
the pouches as well as the sealing time can be adjusted
separately. Both sealing devices 46 and 47 are cooled with
water, the flow of which. is adjusted with a valve (not shown)
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situated on the rear part of the machine where the control
panel 52 is located.
Liquid product is supplied through the conduits 43
and 44 and their metering device that portions out a certain
preprogrammed amount of the product to - be dispensed into the
pouch. As the horizontal sealing device 46 forms the seal of
the bottom seal of the top pouch 11' and the top seal of the
fill pouch 11" and the bottom pouch is cut off,
simultaneously, the vertical sealing device 47 effectuates the
vertical seam also by means of a sealing strip 53. The top
pouch 11' thus being formed, the metering device starts
portioning liquid into the pouch. After a preprogrammed time
the horizontal and vertical sealers are opened and while the
pouch starts to go down by product weight, a film traction
motor unwinds the film :from the film supply roll 22 for a
preprogrammed time. A lever mechanism 54 opens the sealing
jaws 57 and 56 of the horizontal sealing device 46 for the
passage of the filled pouch. When the filled pouch 11" is
released it falls onto a. discharge conveyor 43, as shown in
Fig. 2.
As shown in Fig. 3, the control panel 52 is provided
with a metering device 58 which is a magnetic-inductive flow
meter to select the amount of product, herein milk, to be
dispensed. The selection is programmed through a thumb wheel
59. In order to improve the metering accuracy and capacity,
the pressure in the di;;pensing conduits is as constant as
possible and varies no more than 5 percent. It is also
important not to have any air in the conduits.
The control panel 52 also has an operating panel 60
through which various settings of the machine can be
controlled. A pouch counter 61 automatically counts the
number-of pouches being formed and filled by the machine_ The
program selector switch 62 selects the program suited for
different products as wel_1 as selecting a wash program wherein
the pipes are flushed with water. A plurality of switches 63
are also provided to control the voltage, the temperatures,
and the start and stop of the machine. Signal lamps 64 also
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provide a visual indication of various machine functions such
as end of film, emergency stopping, etc. The machine
incorporates numerous other features not described herewith
and such as the feed slide 64 in order to feed spouts having
discharge hoses and end caps (not shown) connected thereto
into the machine for securement to the film sheets and guide
rolls to assure that the film sheets are retained in proper
alignment and under proper tension. The machine is also
equipped with housing panels 65 and various doors 66 -to
provide for a clean environment within the machine and further
to provide access for maintenance and repair and permits ease
of repositioning the film sheets. Pressurized air can also be
injected within the machine housing to maintain a clean
environment.
Summarizing the method of automatically forming a
plastic film pouch with a dispensing spout thereon there is
provided a supply roll 22 of folded film sheet and wherein
both sheets are guided through the machine along a
predetermined path with the two film sheets 23' and 23"
overlaid. A dispensing spout base 16 is positioned adjacent
one of the two overlaid sheets at a predetermined position
with respect to a sealer device, herein the ultrasonic sealer
30, to seal one of the film sheets against a contour flange of
the spout base. A portion of the other film sheet is
retracted to permit the sealing operation. A cap may then be
applied to the orifice end or outer end portion 40 of the
spout, and the film sheet to which the spout base is secured
may be punctured whereby liquid can be later dispensed
therethrough.
The overlaid film sheets are sealed together along
some of their connected edges with a product dispensing
conduit means disposed between the film sheets whereby to form
a pouch. A metered amount of product is dispensed within the
bag which is then advanced and sealed and released on a
discharge conveyor. This operation is done quickly and
automatically and there is no need to fill the pouch through
the dispensing orifice of the spout which includes the removal -
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of a spout cap as well as the replacement thereof. The
machine is entirely automatic and all that is necessary is for
an operator to set the various controls and switches on the
control panel and to monitor the panel from time to time.
It is within the ambit of the present invention to
cover any obvious modifications of the preferred embodiment
described herein, provided such modifications fall within the
scope of the appended claims.
