Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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MAKING WATER SOLUBLE POUCHES
This invention concerns improvements in or relating to water-soluble pouches.
More
specifically, the invention concerns apparatus and methods for producing multi-
compartment
water-soluble pouches from two or more soluble substrates on continuous motion
rotatable
forming machines. The invention also concerns multi-compartment water-soluble
pouches
made from two or more soluble substrates, and in particular, but not
exclusively, pouches made
using the apparatus and methods of the present invention.
In our earlier applications W02011/061628 and W02013/190517, continuous motion
rotatable
formers and pouches made thereon have been described. In W02011/061628,
apparatus for
making pouches from two water-soluble substrates was described wherein a
rotatable former is
provided with cavities into which a base web is formed to create open pockets
in the base web.
Once formed, the base web is tightly held by vacuum within the cavity
throughout the process
of filling the pockets, sealing the pockets with a top or lidding web to form
pouches in the
combined webs and separating the pouches from the combined web by transverse
and web
direction knives. In W02013/190517, apparatus for making multi-compartment
pouches from
four water-soluble substrates via two pouches was described wherein each pouch
was made
from two water-soluble substrates on separate rotatable formers similar to the
process described
in W02011/061628 and the web of pouches on one former then joined to the web
of pouches on
the other former produce combined pouches before separating the combined
pouches from the
combined webs by transverse and web direction knives.
As described in the above earlier applications, after separating, many water-
soluble substrates,
especially those based substantially upon polyvinyl alcohol, are subject to
what is known as
shrink-back after forming but by holding the base web tightly within the
cavity throughout the
filling, sealing and cutting operations, shrink-back of the base web is
prevented.
When the machines described in the above earlier applications are used for
making multi-
compartment pouches from two water-soluble substrates, a particular difficulty
arises when the
number of compartments to be filled is greater than two due to the lack of
space across the web
in which to fit the necessary number of filling heads, and to the lack of time
during which to
complete the filling operation if the machine is to operate at its optimal
manufacturing capacity.
Lack of space across the web dictates the use of point filling heads such as
nozzle injectors for
liquids and gels, and augur fillers for powders and granules. However, even by
means of point
filling heads, it can be difficult to accommodate sufficient filling heads
across the web, and
particularly to fill powders and granules quickly enough.
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It is an object of the present invention to provide apparatus and methods for
producing multi-
compartment water-soluble pouches from two or more soluble substrates on
continuous motion
rotatable forming machines that address one or more of the aforementioned
problems.
In one aspect, the present invention provides a multi-compartment pouch formed
from two
water soluble substrates wherein the pouch is substantially symmetrical about
a weld line
between the two substrates.
It may be that the pouch comprises at least two compartments and wherein each
compartment is
formed between the same two substrates. The compartments may contain different
products
selected for example from liquids, gels, powders and granules. At least one
compartment may
be empty, i.e.not filled.
It may be that the pouch comprises three or more compartments.
It may be that the compartments are disposed within the pouch such that they
provide resistance
to planar distortion.
It may be that the compartments are disposed within the pouch such that any
bending axis
arbitrarily laid across the pouch cuts through the body of at least one
compartment.
It may be that the pouch contains a perimetric compartment.
It may be that the pouch contains a divided perimetric compartment.
It may be that at least one compartment is filled with a flowable composition,
for example a
liquid or gel.
It may be that at least one compartment is filled with a solid composition,
for example a powder
or granules.
It may be that at least one compartment is filled with more than one
composition wherein the
compositions are mutually compatible and not antagonistic to each other.
It may be that one of the water soluble substrates is a top or lidding web and
the other water
soluble substrate is a base web. Multi-compartment pouches may be produced by
forming a
base web to create open pockets that are filled and then closed by a top or
lidding web. The
base web may be thermoformed.
It may be that the top or lidding web is thinner than the base web.
It may be that the top lidding web has a thickness of between 30% and 90%,
more preferably
between 50% and 75%, of that of the base web.
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It may be that each compartment is filled to at least 80%, more preferably at
least 90%, of the
available volume.
It may be that the compartments are formed sequentially in the base web and
each compartment
is filled before a further compartment is formed and filled until all
compartments have been
filled whereupon the compartments are closed by sealing with a top or lidding
web.
It may be that the pouch is sealed to a second closed multi-compartment pouch
such that the
combined pouch comprises four water-soluble substrates.
It may be that the pouch is sealed to a second open multi-compartment pouch
such that the
combined pouch comprises three water-soluble substrates.
It may be that at least two compartments are filled with a greater weight of a
powder or granular
composition than the weight of any compartment filled with a liquid or gel.
In another aspect, the present invention provides a method of making a multi-
compartment
pouch from two water soluble substrates consisting of a base web and a top
lidding web, the
method including providing a former having a plurality of multi-compartment
pouch forming
cavities in a peripheral surface of the former, drawing the base web into the
cavities to form a
plurality of pockets within each pouch, filling one or more pockets with at
least one product,
closing the pockets in the base web with the top lidding web to form a
plurality of sealed multi-
compartment pouches, and separating the sealed multi-compartment pouches from
the
combined base web and top lidding web, wherein the top lidding web is thinner
than the base
web so that, as the base web retracts or shrinks back after the pouch has left
the former, the
pressure so generated within the pouch causes the top lidding web to distend
to a greater extent
than the contraction of the base web thereby increasing the internal volume of
the pouch
sufficiently to form a multi-compartment pouch substantially symmetrical about
the weld line
between the two substrates.
It may be that each pocket of the multi-compartment pouch is filled with at
least one product.
It may be that the former is configured so that at least one open pocket of a
pouch is formed and
filled before at least one other open pocket of the pouch is formed and
filled, and only once all
open pockets have been filled is the pouch closed by sealing with a lidding
web.
It may be that a second pouch is affixed to the multi-compartment water-
soluble pouch to form
a combined pouch.
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It may be that each pouch comprises two water soluble substrates such that the
combined pouch
comprises four water-soluble substrates. The second pouch may be a multi-
compartment
pouch.
It may be that the top or lidding web of the multi-compartment water-soluble
pouch is provided
by the second pouch such that the combined pouches comprises three water-
soluble substrates.
The second pouch may be a multi-compartment pouch.
In yet another aspect, the present invention provides apparatus for producing
multi-
compartment water-soluble pouches, the apparatus comprising a rotatable former
having
compartment forming cavities into which a base web can be formed, wherein the
apparatus is
configured so that at least one open compartment of a pouch is formed and
filled before at least
one other open compartment of the pouch is formed and filled, and only once
all open
compartments have been filled is the pouch closed by sealing with a lidding
web.
It may be that the former is a horizontal former and the multi-compartment
pouch comprises
two water soluble substrates.
It may be that the former is a horizontal former and the apparatus includes a
second former for
producing water-soluble pouches comprising one or more compartments, wherein
the formers
are configured to affix a lidding web of a pouch on the horizontal former to a
lidding web of a
pouch on the second former to form a combined pouch comprising four water
soluble
substrates.
It may be that the former is a horizontal former and the apparatus includes a
second former for
producing water-soluble pouches comprising one or more compartments, wherein
the formers
are configured to affix a lidding web of a pouch on the second former to a
base web of a pouch
on the horizontal former to form a combined pouch comprising three water
soluble substrates.
In yet another aspect, the present invention provides a multi-compartment
water-soluble pouch
comprising two water-soluble substrates wherein at least two open compartments
are formed
and filled in a base web and closed by sealing with a lidding web wherein at
least one open
compartment is formed and filled before another open compartment is formed and
filled.
It may be that the pouch is substantially symmetrical about a weld line
between the two
substrates.
It may be that each compartment is formed between the same two substrates. The
compartments may contain different products selected for example from liquids,
gels, powders
and granules. At least one compartment may be empty, i.e.not filled.
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It may be that the pouch comprises three or more compartments.
It may be that the compartments are disposed within the pouch such that they
provide resistance
to planar distortion.
It may be that the compartments are disposed within the pouch such that any
bending axis
5 arbitrarily laid across the pouch cuts through the body of at least one
compartment.
It may be that the pouch contains a perimetric compartment.
It may be that the pouch contains a divided perimetric compartment.
It may be that at least one compartment is filled with a flowable composition,
for example a
liquid or gel.
It may be that at least one compartment is filled with a solid composition,
for example a powder
or granules.
It may be that at least one compartment is filled with more than one
composition wherein the
compositions are mutually compatible and not antagonistic to each other.
It may be that the base web is thermoformed.
It may be that the top or lidding web is thinner than the base web.
It may be that the top lidding web has a thickness of between 30% and 90%,
more preferably
between 50% and 75%, of that of the base web.
It may be that each compartment is filled to at least 80%, more preferably at
least 90%, of the
available volume.
It may be that at least two compartments are formed sequentially in the base
web. All the
compartments may be formed sequentially.
It may be that the pouch is sealed to a second closed multi-compartment pouch
such that the
combined pouch comprises four water-soluble substrates.
It may be that the pouch is sealed to a second open multi-compartment pouch
such that the
combined pouch comprises three water-soluble substrates.
It may be that at least two compartments are filled with a greater weight of a
powder or granular
composition than the weight of any compartment filled with a liquid
It may be that the closed multi-compartment pouch is affixed to a second,
closed pouch such
that the combined pouch comprises four water-soluble substrates. The second
pouch may be a
multi-compartment pouch.
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It may be that the multi-compartment pouch is closed by affixing a second
closed pouch such
that the combined pouch comprises three water-soluble substrates. The second
pouch may be a
multi-compartment pouch
In a further aspect, the present invention provides a multi-compartment water-
soluble pouch
comprising two water-soluble substrates wherein a plurality of compartments is
formed
sequentially in a base web and each compartment is filled before a further
compartment is
formed and filled until all compartments have been filled whereupon the pouch
is closed by
sealing with a lidding web.
It may be that the pouch is substantially symmetrical about a weld line
between the two
substrates.
It may be that each compartment is formed between the same two substrates. The
compartments may contain different products selected for example from liquids,
gels, powders
and granules. At least one compartment may be empty, i.e.not filled.
It may be that the pouch comprises three or more compartments.
It may be that the compartments are disposed within the pouch such that they
provide resistance
to planar distortion.
It may be that the compartments are disposed within the pouch such that any
bending axis
arbitrarily laid across the pouch cuts through the body of at least one
compartment.
It may be that the pouch contains a perimetric compartment.
It may be that the pouch contains a divided perimetric compartment.
It may be that at least one compartment is filled with a flowable composition,
for example a
liquid or gel.
It may be that at least one compartment is filled with a solid composition,
for example a powder
or granules.
It may be that at least one compartment is filled with more than one
composition wherein the
compositions are mutually compatible and not antagonistic to each other.
It may be that the base web is thermoformed.
It may be that the top or lidding web is thinner than the base web.
It may be that the top lidding web has a thickness of between 30% and 90%,
more preferably
between 50% and 75%, of that of the base web.
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It may be that each compartment is filled to at least 80%, more preferably at
least 90%, of the
available volume.
It may be that the compartments are formed sequentially in the base web and
each compartment
is filled before a further compartment is formed and filled until all
compartments have been
filled whereupon the compartments are closed by sealing with a top or lidding
web.
It may be that the pouch is sealed to a second closed multi-compartment pouch
such that the
combined pouch comprises four water-soluble substrates.
It may be that the pouch is sealed to a second open multi-compartment pouch
such that the
combined pouch comprises three water-soluble substrates.
It may be that at least two compartments are filled with a greater weight of a
powder or granular
composition than the weight of any compartment filled with a liquid.
It may be that the weight of a powder or granular composition filled into one
or more
compartments of the pouch is greater than the weight of a liquid or gel
composition filled into
one more other compartments of the pouch.
It may be that the weight of a powder or granular composition filled into at
least two
compartments of the pouch is greater than the weight of a liquid or gel
composition filled into
other compartments of the pouch.
In yet another aspect, the present invention provides a method of making a
water soluble multi-
compartment pouch on a continuous motion rotatable forming machine having
compartment
forming cavities into which a base web can be formed, wherein the forming
machine is
configured so that at least one open compartment of a pouch is formed and
filled before at least
one other open compartment of the pouch is formed and filled, and only once
all open
compartments have been filled is the pouch closed by sealing with a lidding
web.
It may be that the closed multi-compartment water-soluble pouch is affixed to
a second closed
pouch such that the combined pouch comprises four water-soluble substrates.
The second
pouch may be a multi-compartment pouch
It may be that the multi-compartment water-soluble pouch is closed by affixing
a second closed
pouch such that the combined pouch comprises three water-soluble substrates.
The second
pouch may be a multi-compartment pouch
In a further aspect, the present invention provides a multi-compartment water-
soluble pouch
comprising two water-soluble substrates wherein a plurality of compartments is
formed
sequentially in a base web wherein at least one compartment is formed and
filled before a
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further compartment is formed and filled whereupon all compartments are closed
by sealing
with a lidding web.
It may be that the pouch is substantially symmetrical about a weld line
between the two
substrates.
It may be that each compartment is formed between the same two substrates. The
compartments may contain different products selected for example from liquids,
gels, powders
and granules. At least one compartment may be empty, i.e.not filled.
It may be that the pouch comprises three or more compartments.
It may be that the compartments are disposed within the pouch such that they
provide resistance
to planar distortion.
It may be that the compartments are disposed within the pouch such that any
bending axis
arbitrarily laid across the pouch cuts through the body of at least one
compartment.
It may be that the pouch contains a perimetric compartment.
It may be that the pouch contains a divided perimetric compartment.
It may be that at least one compartment is filled with a flowable composition,
for example a
liquid or gel.
It may be that at least one compartment is filled with a solid composition,
for example a powder
or granules.
It may be that at least one compartment is filled with more than one
composition wherein the
compositions are mutually compatible and not antagonistic to each other.
It may be that the base web is thermoformed.
It may be that the top or lidding web is thinner than the base web.
It may be that the top lidding web has a thickness of between 30% and 90%,
more preferably
between 50% and 75%, of that of the base web.
It may be that each compartment is filled to at least 80%, more preferably at
least 90%, of the
available volume.
It may be that the compartments are formed sequentially in the base web and
each compartment
is filled before a further compartment is formed and filled until all
compartments have been
filled whereupon the compartments are closed by sealing with a top or lidding
web.
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It may be that the pouch is sealed to a second closed multi-compartment pouch
such that the
combined pouch comprises four water-soluble substrates.
It may be that the pouch is sealed to a second open multi-compartment pouch
such that the
combined pouch comprises three water-soluble substrates.
It may be that at least two compartments are filled with a greater weight of a
powder or granular
composition than the weight of any compartment filled with a liquid.
It may be that the weight of a powder or granular composition filled into one
or more
compartments of the pouch is greater than the weight of a liquid or gel
composition filled into
one more other compartments of the pouch.
It may be that the weight of a powder or granular composition filled into at
least two
compartments of the pouch is greater than the weight of a liquid or gel
composition filled into
other compartments of the pouch
In yet another aspect, the present invention provides a method of making a
water soluble multi-
compartment pouch on a continuous motion rotatable forming machine having
compartment
forming cavities into which a base web can be formed, wherein the forming
machine is
configured so that at least one open compartment of a pouch is formed and
filled before at least
one other open compartment of the pouch is formed and filled whereupon all
compartments are
closed by sealing with a lidding web.
It may be that the closed multi-compartment water-soluble pouch is affixed to
a second closed
pouch such that the combined pouch comprises four water-soluble substrates.
The second
pouch may be a multi-compartment pouch.
It may be that the multi-compartment water-soluble pouch is closed by affixing
a second closed
pouch such that the combined pouch comprises three water-soluble substrates.
The second
pouch may be a multi-compartment pouch
In yet another aspect the present invention provides a continuous motion
rotatable forming
machine for producing multi-compartment water-soluble pouches, the machine
comprising a
rotatable former having compartment forming cavities into which a base web can
be formed,
wherein the forming machine is configured so that at least one compartment of
a pouch is
formed and filled before at least one other compartment of the pouch is formed
and filled, and
only once all compartments have been formed is the pouch closed and sealed by
affixing a
lidding web.
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It may be that at least one compartment is empty, i.e. not filled. It may be
that at least two
compartments are formed simultaneously.
It may be that the lidding web comprises a web of formed filled and sealed
pouches. It may be
that the machine comprises two formers of which at least one is a horizontal
former wherein
5 each former is able to produce water-soluble pouches comprising one or
more compartments,
the lidding films of which are then sealed or bonded together to form a
combined pouch. It may
be that the machine comprises two formers of which at least one is a
horizontal former wherein
each former is able to produce water-soluble pouches comprising one or more
compartments,
the lidding film of pouches on one former closing pouches on the other former
to form a
10 combined pouch.
In yet another aspect the present invention provides a multi-compartment water-
soluble pouch
comprising two water-soluble substrates wherein a plurality of compartments is
formed
sequentially in a base web and each sequentially formed compartment is filled
before a further
compartment is formed until all compartments have been formed whereupon the
pouch is closed
and sealed by affixing a lidding web.
It may be that at least one compartment is empty, i.e. not filled. It may be
that at least two
compartments are formed simultaneously.
It may be that the pouch is affixed to a second closed pouch such that the
combined pouch
comprises four water-soluble substrates. It may that the pouch is is affixed
to a second open
pouch such that the combined pouch comprises three water-soluble substrates.
It may be that the
second pouch comprises one or more compartments.
It may be that at least two compartments are filled with a greater weight of a
powder or granular
composition than the weight of liquid or gel filled into any other
compartment.
It may be that each compartment is formed by and between the base web and
lidding web.
It may be that the pouch is symmetrical about a weld line between the base web
and the lidding
web.
In yet another aspect the present invention provides a method of making a
water soluble multi-
compartment pouch on a continuous motion rotatable forming machine having
compartment
forming cavities into which a base web can be formed, wherein the forming
machine is
configured so that at least one compartment of a pouch is formed and filled
before at least one
other compartment of the pouch is formed and filled, and only once all
compartments have been
formed is the pouch closed by sealing with a lidding web.
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It may be that at least one compartment is empty, i.e. not filled. It may be
that at least two
compartments are formed simultaneously.
It may be that the multi-compartment water-soluble pouch is affixed to a
second closed pouch
such that the combined pouch comprises four water-soluble substrates. It may
be that the
lidding web of the multi-compartment water-soluble pouch comprises a lidding
web comprising
a second closed pouch such that the combined pouch comprises three water-
soluble substrates.
It may be that the second closed pouch comprises one or more compartments.
Aspects of the invention described herein may overcome the difficulties in the
prior art
described above of filling pouches comprising two substrates and containing
multiple
compartments, by forming and filling containers in the base web at separate
stations along the
web. These aspects are described herein as sequential forming and filling. The
term container
describes an open pocket created within the base web as a result of the
forming process.
In contrast, our earlier aforementioned applications describe forming
containers in the base web
contemporaneously (at the same moment) and subsequently filling the containers
contemporaneously (at the same moment). Sequential forming and filling may be
of particular
use for powder or granule filling without the use of point filling heads,
allowing greater
flexibility of filling and resulting in multi-compartment pouches which have
hitherto not been
possible to produce.
Powders or granules are often filled by spreading the powder or granules upon
the surface of an
already formed base web and then removing the excess by means of a scraper or
doctor blade,
leaving the powder or granules filling the formed container or a plurality of
formed containers
wherein there is substantially no powder or granules left upon the unformed
portions of the base
web.
The base web may be formed into cavities within the former by different means
known to those
skilled in the art, including therefore vacuum forming, if necessary assisted
by pre-treating the
base web by spraying it with or passing it through a water mist, and/or by pre-
heating the base
web (thermoforming).
Once formed, the base web may be held by vacuum within the cavity throughout
the process of
filling, sealing and separating the pouches by transverse and web direction
knives from a
combined base web and top or lidding web. Many water-soluble substrates,
especially those
based substantially upon poly-vinyl alcohol, are subject to what is known as
shrink-back after
forming but by holding the base web tightly within the cavity throughout the
filling, sealing and
cutting operations, shrink-back of the base web may be prevented.
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The foregoing is a summary and thus, by necessity, contains simplifications,
generalizations,
and omissions of detail. Any or all of the features, limitations,
configurations, components,
subcomponents, systems, and/or subsystems described above may be used in
combination.
Consequently, those skilled in the art will appreciate that the summary is
illustrative only and is
not intended to be in any way limiting. Other aspects, inventive features, and
advantages of the
devices and/or processes described herein, as defined by the claims, will
become apparent in the
detailed description set forth herein and taken in conjunction with the
accompanying drawings
wherein:
Figure 1 shows plan and sectional views of a multi-compartment pouch made from
two
substrates according to the present invention;
Figure 2 shows plan, sectional and perspective views of a multi-compartment
pouch made from
two substrates according to the present invention;
Figure 3 shows plan, sectional and perspective views of a multi-compartment
pouch made from
two substrates according to the present invention;
Figure 4 shows plan, sectional and perspective views of a multi-compartment
pouch made
from two substrates according to the present invention;
Figure 5 shows plan, sectional and perspective views of a multi-compartment
pouch made
from two substrates according to the present invention;
Figure 6 shows plan, sectional and perspective views of a multi-compartment
pouch made from
two substrates according to the present invention;
Figure 7 shows plan, sectional and perspective views of a multi-compartment
pouch made from
two substrates according to the present invention;
Figure 8 shows plan, sectional and perspective views of a multi-compartment
pouch made from
two substrates according to the present invention;
Figure 9 shows plan, sectional and perspective views of a multi-compartment
pouch made from
two substrates according to the present invention;
Figure 10 shows plan, sectional and perspective views of a multi-compartment
pouch made
from two substrates according to the present invention;
Figure 11 shows plan, sectional and perspective views of a multi-compartment
pouch made
from two substrates according to the present invention;
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Figure 12 shows plan, sectional and perspective views of a multi-compartment
pouch made
from two substrates according to the present invention;
Figure 13 shows plan, sectional and perspective views of a multi-compartment
pouch made
from two substrates according to the present invention;
Figure 14 shows plan, sectional and perspective views of a multi-compartment
pouch made
from two substrates according to the present invention;
Figure 15 shows plan, sectional and perspective views of a multi-compartment
pouch made
from two substrates according to the present invention;
Figure 16 shows plan, sectional and perspective views of a multi-compartment
pouch made
from two substrates according to the present invention;
Figure 17 shows plan, sectional and perspective views of of a multi-
compartment pouch made
from two substrates according to the present invention;
Figure 18 shows reconfiguration of a formed pouch to a symmetrical
configuration;
Figure 19 shows arrangements for filling a multi-compartment pouch comprising
two
compartments;
Figure 20 shows an arrangement for filling a multi-compartment pouch
comprising three
compartments;
Figure 21 shows arrangements of the filling heads for filling multi-
compartment pouches;
Figure 22 shows an embodiment of a horizontal rotatable forming machine for
producing
pouches from two substrates;
Figure 23 shows an embodiment of a horizontal rotatable former machine and a
cylindrical
rotatable forming machine for producing pouches from four substrates;
Figure 24 shows an embodiment of a horizontal rotatable former machine and a
cylindrical
rotatable forming machine for producing pouches from three substrates;
Figure 25 shows an embodiment of two horizontal rotatable forming machines for
producing
pouches from four substrates;
Figure 26 shows an embodiment of two horizontal rotatable forming machines for
producing
pouches from three substrates;
Figure 27 shows a pouch with three compartments;
Figures 28 and 29 show a method sequentially forming and filling the pouch of
Figure 27
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Figure 30 shows apparatus for forming sequentially forming the compartments of
the pouch
shown in Figure 27;
Figure 31 shows another apparatus for forming sequentially forming the
compartments of the
pouch shown in Figure 27;
Figure 32 shows a method of sequentially forming and filling a pouch with two
compartments;
Figure 33 shows a method of sequentially forming and filling a pouch with
three compatments;
Figure 34 shows a method of sequentially forming and filling a pouch with four
compartments;
Various multi-compartment pouches 1 are shown in Figures 1 to 17 and
summarised in the
following Table:
Figure Number Configuration in Plan View Number of
Compartments
1 Circular or Elliptical with a complete perimetric 2
compartment
2 Circular or Elliptical with a divided perimetric 3
compartment
3 Triangular with rounded corners and a complete 2
perimetric compartment
4 Triangular with rounded corners and a divided 3
perimetric compartment
5 Square or Rectangular with a complete 2
perimetric compartment
6 Square or Rectangular with a divided perimetric
compartment and a divided central 4
compartment
7 Horseshoe 2
8 Horseshoe with a divided external compartment 3
9 Central Tee compartment 3
Central H compartment 3
11 Rectangular with a divided perimetric 3
compartment
12 Rectangular with a divided perimetric 3
compartment
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13 L-shaped external compartment 2
14 Wedge compartments 2
15 Wedge compartments with a central 3
compartment
16 Shamrock compartments 4
17 Clover Leaf compartments 3
Each pouch 1 is formed from two water soluble substrates 2, 3 which may be
referred to as a
base web 2 and a top or lidding web 3. Any suitable water soluble substrates
may be employed.
Pouches 1 having two compartments la, lb are shown in Figures 1,3,5,7,13,14.
Pouches 1
5 having three compartments la, lb, lc are shown in Figures
2,4,8,9,10,11,12,15,17. Pouches
having four compartments 1,1b, lc, ld are shown in Figures 6,16. Each pouch 1
is symmertical
about a weld line 4 between the base web 2 and top lidding web 3. Each
compartment
la, lb, lc, ld is fomed between the base web 2 and the top or lidding web 3.
The footprint 5 of
the pouches 1 and the number, shape and arrangement of the compartments la,
lb,lc,ld is
10 exemplary only and other configurations that may be employed will be
apparent to those skilled
in the art. The term "footprint" is defined as the plan view of the pouch 1 as
seen from above
the top or lidding web 3 of the pouch 1.
Water-soluble substrates are often by the very nature of the materials,
lacking in rigidity. As a
result, when forming a water soluble pouch from two water soluble substrates,
the resulting
15 pouch will itself have a tendency to lack rigidity or planar strength
which will give an
unattractive floppy aspect to the pouch when handled by the consumer. Such a
lack of rigidity
or planar strength is referred to herein as planar distortion. Whilst the
majority of water-soluble
substrates capable of being formed, for example thermoformed or vacuum formed,
are at the
present time, made substantially from polyvinyl alcohol resins, other water-
soluble substrates
capable of being formed may be used to practise the present invention.
Planar distortion of multi-compartment pouches may be overcome or
significantly reduced in
this invention by one or more of the following factors:
i) relative position and/or shape of the compartments la, lb, lc,ld within
the footprint 5.
ii) filling each compartment la, lb, lc, ld to a level of at least 80%,
preferably at least 90%,
of the available volume,
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iii) selecting the relative thicknesses of the top lidding web 3 and the
base web 2 in order to
utilise the retraction or shrinkback of the base web 2 after the webs have
been sealed together
and the pouch ejected from the forming machine or apparatus,
These factors and their impact on planar distortion of the resulting pouch 1
are now discussed.
It may be that these factors can be employed separately, or in combination of
any two, or
preferably in a combination of all three. The invention extends to and
includes pouches 1 so
formed. Aspects of the invention referred to herein may include any of these
factors and we do
not intend the invention to be limited to those aspects specifically
mentioned.
POSITION AND/OR SHAPE OF COMPARTMENTS
Planar distortion may be reduced by employing a perimetric compartment as one
of the
compartments. The term "perimetric" in this context describes a compartment
which is situated
around the perimeter of the pouch. In its simplest form, the perimetric
compartment may be
square or rectangular with rounded corners, allowing maximum use of the area
of the footprint,
and hence providing maximum possible compartment fill volumes. When viewed
from above
the top lidding web, such a square or rectangular perimetric compartment may
follow the cut
edges of the pouch with its outer limit set back from the cut edges of the
pouch, for example at
least 1.5mm from the cut edges of the pouch. A square or rectangular
perimetric compartment
may be rejected for marketing or other reasons in favour of other shapes, such
as triangular with
rounded corners, or pentagonal with rounded corners, or circular or elliptical
although these
shapes are by no means limiting. It will be apparent that departing from a
square or rectangular
perimetric compartment can reduce the combined fill volume of the compartments
within the
pouch and leave a larger flange around the perimetric or semi-perimetric
compartment.
The perimetric compartment may be divided into two or more separate
compartments in order to
increase the number of compartments within a pouch of a given footprint.
However, by sub-
dividing the perimetric compartment, there may be a loss of planar stability.
The invention
overcomes this loss of planar stability by compartmental design. As an
example, if the
perimetric compartment is divided into two semi-perimetric compartments, the
pouch may,
unless corrective design features are introduced to prevent it, flex about a
line joining the seal
areas between the semi-perimetric compartments. A multi-compartment pouch
which is able to
flex will be less appealing to the consumer than one which has planar
stability.
One or more of the compartments within the multi-compartment pouch may be left
unfilled in
order to provide additional resistance to planar distortion of the pouch.
COMPARTMENT FILL LEVELS
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Planar distortion may be reduced by filling each compartment of the pouch to
at least 80%,
preferably at least 90%, of its available volume. Such a percentage fill of
the available volume
of each compartment has been found to contribute to planar stability of the
pouch.
WEB THICKNESSES
The thickness of the top lidding web3 may be selected to be between 30% and
90%, preferably
between 50% and 75%, of that of the base web 2. By this means, when, after the
pouches 1
have been sealed and ejected from the machine, the base web 2 retracts or
shrinks back to
reduce the internal volume of each compartment. The pressure so generated
within each
compartment of the pouch 1 causes the thinner top lidding web 3 to distend,
typically to a
greater degree than the shrinkage of the base web 2, thereby increasing the
internal volume of
each compartment of the pouch 1. This can result in the formation of a
substantially
symmetrical pouch 1 about the weld line 5. This reconfiguration of pouches 1
ejected from
cavities 6 of a rotable former 7 configured with a cylndrical surface is shown
in Figure 18. The
former may 7 may be circular as shown in Figure 18 although this is not
essential and other
configurations of former may be employed, for example a rotable former
configured with a flat
horizontal surface.. Examples of cylindrical and horizontal formers that may
be employed are
shown and described in W02011/061628 to which the reader is directed for
further details.
Whilst the reduction in planar distortion provided by any single factor may
not be sufficient to
assure planar rigidity of the pouch, when all three factors are combined,
there is an unexpected
increase in planar rigidity which in turn provides a marketing advantage to
the multi-
compartment pouch of the present invention.
Referring now to Figures 19 and 20, examples of filling multi-compartment
pouches 1
according to the present invention are illustrated although these examples are
by no means
limiting. The number of pouches 1 formed, filled and sealed across the web of
a machine is
known as the number of tracks or lanes.
In Figure 19, filling of pouches 1 with two compartments la, lb similar to the
pouch shown in
Figure 14 is illustrated. The rotatable former 7 of the pouch making machine
may be
configured as shown and described in W02011/061628 with a cylindrical surface
7a or
alternatively with a flat horizontal surface. The compartments la, lb may be
filled by heads
8a,8b. The heads 8a,8b may be point fillers. The heads 8a,8b may be configured
to add a liquid,
gel, powder or granules, for example nozzle injectors for liquids or gels or
augur fillers for
powders or granules. Heads 8a,8b may be connected to a feed for the same or
different
materials. The heads 8a, 8b may be arranged with a space offset in the
direction of movement
of the surface 7a and fire simultaneously (option A) or with no space offset
and fire at slightly
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different set points (option B). A similar arangmeent may be provided for each
track or lane
across the web of the machine. Heads in different tracks or lanes may be
connected to the same
or different supplies of material. This method is equally applicable where the
multi-
compartment pouch comprises more than two compartments. Generally, a filling
head is
provided for each compartment.
In Figure 20, filling of pouches 1 with three compartments la, lb, lc similar
to the pouch shown
in Figure 15 is illustrated. The rotatable former 7 of the pouch making
machine may be
configured as shown and described in W02011/061628 with a cylindrical surface
7a or
alternatively with a flat horizontal surface. The compartments la, lb, 1 c may
be filled by heads
8a,8b,8c. The heads 8a,8b,8c may be point fillers. The heads 8a,8b,8c may be
configured to
add a liquid or gel or a powder or granules, for example nozzle injectors for
liquids and gels or
augur fillers for powders and granules. In this embodiment, the heads 8a,8b
are configured to
add a liquid or gel and head 8c is configured to add a powder or granules.
Heads 8a,8b may be
connected to a feed for the same or different liquids or gels. A similar
arrangement may be
provided for each track or lane across the web of the machine. Heads in
different tracks or
lanes may be connected to the same or different supplies of material. Other
arrangements of
heads 8a,8b,8c for delivering any combination of liquids, gels, powders and
granules are
envisaged. This method is equally applicable where the multi-compartment pouch
comprises
two or more compartments. Generally a filling head is provided for each
compartment.
Referring now to Figure 21, methods of arranging the heads are illustrated.
The heads may be
arranged to create space for a plurality of heads within the confined space
available. In one
arrangement, the heads may be inclined to each other. For example, a head 8a
for a liquid or gel
and a head 8b for a powder or granules may be inclined to each other. In
another arrangement, a
head 8b for a powder or granules may be provided with a chute 9. The liquid or
gel filling head
8a and chute 9 may be inclined to each other. The heads 8a, 8b may be arranged
to follow the
cavity 6 of the former 7 as it advances so that the time available for
completion of the filling
operation is thereby increased and the product being filled is spread more
evenly along the
compartment in the base web.
By use of the above filling arrangements and/or by the programming of the
software integrating
the filling operation with the running speed of the machine, it may be
possible to fill the
compartments of a multi-compartment pouch 1 during a time interval of up to
one second. In
this way, the machine may be capable of providing an output of approximately
60 pouches per
minute for each track or lane of the machine. In the case of granular or
powder solid products,
the filling equipment is typically a multi-head auger filler and in the case
of liquid products, the
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filling equipment is typically cylinder operated nozzle injectors with a cut
off such that no drips
arrive on the base web surrounding the cavities. Such contamination of the
base web can
subsequently inhibit good sealing of the base web with the top or lidding web.
Hitherto, the
filling operation has not allowed such filling speeds across so many tracks,
preventing the
compartments of a multi-compartment pouch from being filled within such a
short time interval.
Embodiments of pouch forming machines are shown in Figures 22 to 26 wherein
like reference
numerals are used to indicate the same or similar parts such that the
operation of the same or
similar parts will be understood from a description of any emebodiment without
being repeated
for other .embodiments.
An embodiment of a pouch forming machine 20 is shown in Figure 22 comprising a
horizontal
rotatable former 21. The term horizontal rotatable former describes a machine
wherein part of
the former 21 comprises a horizontal surface or section 21a. The former 21 may
comprise an
endless belt (only part of the former is shown in Figure 22). The machine is
configured to form
multi-compartment pouches from two water soluble substrates by sequential
forming and filling
each compartment of the pouch. In this embodiment, the former is provided with
pouch
forming cavities 23 configured to form pouches with three compartments but it
will be
understood this is not limiting and the cavities 23 can be configured to form
pouches having two
or more compartments.
A base web 24 is unwound from an unwinding station 25 and a first open pocket
or container 26
is formed in the base web at 27 and filled at 28. A second open pocket or
container 29 is
formed in the base web at 30 and filled at 31. A third open pocket or
container 32 is formed in
the base web at 33 and filled at 34. A lidding web 35 is unwound from an
unwinding station 36
and affixed to the base web at 37 thereby sealing and closing all the open
pockets or containers
26, 29, 32 in the base web to form multi-compartment pouches 38 within the
cavities 23. The
combined base web and lidding web is then moved to a cutting station 39 where
the pouches 38
are separated from the combined web. In this embodiment, the top or lidding
web 35 is affixed
to the base web 24 by solvent welding by wetting the lidding web 35 at 40.
Other methods of
affixing the top or lidding web may be employed such as heat sealing.
It is important to note that many possible designs of multi-compartment
pouches having at least
two compartments may be produced employing the machine 20 by appropriate
design of the
pouch forming cavities. For example, the machine 20 may produce any of the
pouches shown
in Figures 1 to 17 although this is not limiting on the scope of the
invention. Each compartment
may be sequentially formed and filled with different compositions.
Alternatively, where more
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than one compartment contains the same composition, these compartment may be
formed and
filled simultaneously with at least one other compartment being formed and
filled sequentially.
Further embodiments of a pouch forming machine 20' are shown in Figures 23 and
24
comprising a combination of two rotatable formers wherein one rotatable former
is a horizontal
5 rotatable former 21 similar to Figure 22 and the other rotatable former
is a cylindrical rotatable
former 41. The term cylindrical rotatable former describes a machine where the
former 41
comprises a circular surface or section 41a. The cylindrical former 41 is
positioned above the
horizontal section 21a of the horizontal former 21. The former 41 is provided
with pouch
forming cavities 42 and may comprise a drum.
10 In Figure 23, multi-compartment water pouches 38 comprising a water-
soluble base web 24 and
a water-soluble top or lidding web 35 are formed on the horizontal rotatable
former 21 as
described previously and water-soluble pouches 38' comprising a water soluble
base web 24'
and a water soluble top or lidding web 35' are formed on the cylindrical
former 41. The
pouches 38,38' are brought together in register and combined by joining the
top or lidding webs
15 35,35'to each other at 44. The resulting combined pouch is formed from
four water soluble
webs or substrates. In this embodiment, the pouch 38' comprises a single
compartment filled at
43. In other embodiments, the pouch 38' may comprise more than one
compartment. The
pouches 38,38' may comprise any of the pouches shown in Figures 1 to 17
although this is not
limiting on the scope of the invention. In other embodiments, the pouch 38 may
be a single
20 compartment and the pouch 38' may be multi-compartment.
In Figure 24, the top or lidding web 35 is omitted and the open pouches or
containers formed by
the base web 24 on the former 21 are closed by the top or lidding web 35' of
the pouches 38'
on the former 41. The resulting pouch is formed from three water soluble webs
or substrates
Further embodiments of a pouch forming machine 20" are shown in Figures 25 and
26
comprising a combination of two rotatable formers wherein both rotatable
formers are
horizontal rotatable formers 21,21" similar to Figure 22 with a horizontal
lower section 21b" of
the former 21" positioned above the horizontal upper section 21a of the former
21.
In Figure 25, multi-compartment pouches 38 comprising a water-soluble base web
24 and a
water-soluble top or lidding web 35 are formed on the horizontal rotatable
former 21 as
described previously and water-soluble pouches 38" comprising a water soluble
base web 24"
and a water soluble top or lidding web 35" are formed on the horizontal former
21". The
pouches 38,38" are brought together in register and combined by joining the
top or lidding webs
35,35" to each other at 44. The resulting combined pouch is formed from four
water soluble
webs or substrates. An additional cutting station 39" may be provided in at
least the transverse
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21
direction so that the closed pouches 38" produced on the upper horizontal
former 21", despite
the vacuum holding them within the cavities 23"ot the former 21", are not
dislodged as the
former 21" passes over the roller at 45..
In this embodiment, the pouch 38" is a multi-compartment pouch formed in
similar manner to
the pouch 38. In other embodiments, the pouch 38" may comprise a single
compartment or any
other design with two or more compartments. The pouches 38,38" may comprise
any of the
pouches shown in Figures 1 to 17 although this is not limiting on the scope of
the invention.
In Figure 26, the top or lidding web 35 is omitted and the open pouches or
containers formed by
the base web 24 on the former 21 are closed by the top or lidding web 35" of
the pouches 38"
on the former 21". The resulting pouch is formed from three water soluble webs
or substrates
By way of non-limiting example, a multi-compartment water soluble pouch 60
with three
compartments 60a,60b,60c is shown in Figure 27. The method of sequentially
forming and
filling the pouch 60 is illustrated in Figures 28 and 29.
Referring to Figures 28 and 29, a former 61 has a cavity 62 with three
recessed areas
62a,62b,62c corresponding to the compartments 60a.60b,60c of the pouch 60. A
base web 63 is
formed into area 62a to form an open pocket or container for compartment 60a.
Compartment
60a is then filled for example with a powder or granules by a belt feeder 64.
The feeder 64 may
have a scraper blade 66 to prevent overfilling of the compartment 60a. Next,
the base web 63 is
formed into area 62b to form an open pocket or container for compartment 60b.
Compartment
60b is then filled for example with a powder or granules by a belt feeder 64.
Finally the base
web 63 is formed into area 62c to form an open pocket or container for
compartment 60c.
Compartment 60c is then filled for example with a liquid or gel by a nozzle
feeder 65. The
sequentially formed and filled compartments 60a,60b,60c can then be closed and
sealed by a top
or lidding web (not shown) by any of the methods and machines described
previously.
By means of sequential forming and filling, it may be possible to form and
fill open pockets or
containers in a base web to form compartments which, in plan view, "overlap"
each other in the
direction of travel of the web. In this way, multi-compartment pouches
containing overlapping
compartments can be made employing the sequential forming and filling method
described
herein which could not be made by conventional methods employing
contemporaneous forming
of the compartments followed by filling due to filling constraints. The above
method may be
employed for any design of multi-compartment pouch.
Sequential forming of the base web 63 may be effected by different methods.
One method
involves applying a vacuum to each recessed area 62a,62b,62c of the cavity 62
in turn.
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Preferably the vacuum is maintained in each area in which the base web 63 is
formed and filled
until the pouch 60 is ejected from the former 61. Sequential forming and
filling offers the
advantage of greater space, longer filling times and therefore ease of filling
for powders or
granules which do not flow freely from the filling heads.
.The sequential vacuum supply to the cavities 62 may be provided in various
ways. Generally
mechanical methods of vacuum control are preferred as being potentially more
reliable than, for
example, an electrical method that would require spinning electrical
connections. Two methods
of arranging the vacuum supply for sequential forming the base web 63 to form
open pockets or
containers corresponding to compartments 60a,60b,60c of the pouch 60 are
described below
with reference to Figures 30 and 31, although other methods will be envisaged
by those skilled
in the art.
In Figure 30, a vacuum shoe arrangement for sequential forming of base web 63
is employed
comprising three vacuum slots 66a,66b,66c wherein each slot 66a,66b,66c
controls the vacuum
start and stop to each of the three recessed areas 62a,62b,62c respectively,.
The slots
66a,66b,66c are of different lengths and are configured so that stop point is
the same for all
recessed areas 62a,62b,62c in order to release the pouch from the cavity 62.
The first slot 66a
has the earliest start point, then the second slot 66b and lastly the third
slot 66c. In this way the
vacuum is applied first to the area 62a through vacuum slot 66a so that the
base web 63 can be
drawn into the area 62a only to form an open pocket or container corresponding
to compartment
60a which can then be filled. Whilst the vacuum to the area 62a is maintained,
the vacuum is
next applied to the area 62b through vacuum slot 66b so that the base web 63
can be drawn into
the second area 62b to fon an open pocket or container corresponding to
compartment 60b
which can then be filled. Whilst the vacuum to the areas 62a,62b is
maintained, the vacuum is
applied to the area 62c through slot 66c so that the base web 63 can be drawn
into the area 62c
to form an open pocket or container corresponding to compartment 60c which can
then be
filled... When all the pockets or containers have been formed and filled, a
lidding web (not
shown) can be affixed to the base web 63 around the open pockets or containers
to close and
seal the compartments to form the multi-compartment pouch 60. The pouch 60 can
then be
separated from the combined web, the vacuum supply to all three recessed areas
released and
the pouch ejected from the cavity 62 in the rotatable former either by falling
under gravity or by
ejection with compressed air or a combination of both on to a suitable
conveyor system.
In Figure 31, a vacuum valve arrangement for sequential forming of base web 63
is employed
comprising three vacuum valves 67a,67b,67c wherein each valve 67a,67,67c
controls the
vacuum start and stop to each of the three recessed areas 62a,62b,62c
respectively. Each valve
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67a,67b,67c is mechanically controlled by an actuator 68a,68b,69c co-operable
with a straight
cam 69a,69b,69c arranged underneath the valve. The cams 69a,69b,69c are of
different lengths
and are configured so that the stop point is the same for all recessed areas
62a,62b,62c in order
to release the pouch from the cavity 62. The first cam 69a is the longest,
then the second cam
69b and the third cam 69c is the shortest. . In this way vacuum valve 67a is
actuated first to
apply vacuum to the area 62a so that the base web 63 can be drawn into the
area 62a only to
form an open pocket or container corresponding to compartment 60a which can
then be filled.
Whilst the vacuum to the area 62a is maintained, the vacuum valve 67b is next
actuated to apply
vacuum to the area 62b so that the base web 63 can be drawn into the second
area 62b to form
an open pocket or container corresponding to compartment 60b which can then be
filled.
Whilst the vacuum to the areas 62a,62b is maintained, the vacuum valve 67c is
actuated to
apply vacuum to the area 62c so that the base web 63 can be drawn into the
area 62c to form an
open pocket or container corresponding to compartment 60c which can then be
filled... When
all the pockets or containers have been formed and filled, a lidding web (not
shown) can be
affixed to the base web 63 around the open pockets or containers to close and
seal the
compartments to form the multi-compartment pouch 60. The pouch 60 can then be
separated
from the combined web, the vacuum supply to all three recessed areas released
and the pouch
ejected from the cavity 62 in the rotatable former either by falling under
gravity or by ejection
with compressed air or a combination of both on to a suitable conveyor system.
In arrangement of Figure 31, a simple vacuum shoe or some kind of a vacuum
manifold for the
initial vacuum connection to the valve block 70 is required. However, the cams
69a,69b,69c
can be configured to be adjustable to alter the vacuum start and/or stop
points to change the
valve timing. For example the cams 69a,69b,69c may be made of two pieces (dove
tailed, for
example) which allows for length adjustment. Such adjustment may be effected
remotely. This
may allow easier adjustment of the valve timing compared to the arrangement of
Figure 30
where the vacuum shoe has to be removed and either replaced by a vacuum shoe
with different
length slots or the slots cut to change the length and the shoe refitted.
A further advantage of the arrangement of Figure 31 is that there is only one
vacuum line going
to the valve block for the valves 67a,67b,67c for each of the recessed areas
62a,62b,62c. In the
arrangement of Figure 30, individual lines from the vacuum shoe to each
recessed area
62a,62b,62c are required.
In some embodiments the cavities 62 in the former may be heated by internal
and/or external
heaters to assist forming the base web 63 into the cavities. In some
embodiments the base web
63 may pass over a heated roller prior to being drawn into the first recessed
area 62a. In some
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embodiments, the base web 63 may be heated prior to be drawn into the second
and/or third
recessed areas to maintain flexibility of the web and assist forming into the
recessed areas.
Such heating may be effected from above for example by means of externally
mounted hot air
jets or externally mounted infra-red heaters.
Figure 32 illustrates an example, which is by no means limiting, of a two
compartment pouch
70 that can be produced on a machine similar to Figure 22 wherein a first open
pocket or
container 71 is formed in a base web and in this example filled using a belt
feeder 72 or similar
type area filler and only once the first container 71 has been filled, is a
second open pocket or
container 73 sequentially formed in the base web and in this example, filled
using a point feeder
74. The feeders 72,74 may be replaced by any other feeders to suit the product
added to the
containers 71,73.
Figure 33 illustrates an example, which is by no means limiting, of a three
compartment pouch
80 that can be produced on a machine similar to Figure 22 wherein a first open
pocket or
container 81 is formed in a base web and in this example filled using a belt
feeder 82 or similar
type area filler and only once the first container 81 has been filled is a
second open pocket or
container 83 sequentially formed in the base web and in this example filled
using a belt feeder
84 or similar type area filler and only once the second container 83 has been
filled, is a third
container 85 sequentially formed in the base web and in this example filled
using a point feeder
86. The feeders 82,84,86 may be replaced by any other feeders to suit the
product added to the
containers 81,83,85. In a modification, containers 81 and 83 may be formed and
filled
simultaneously and container 85 formed and filled sequentially.
Figure 34 illustrates an example, which is by no means limiting, of a four
compartment pouch
90 that can be produced on a machine similar to Figure 22 wherein a first
container 91 is formed
in a base web and in this example filled using a belt feeder 92 or similar
type area filler and only
once the first container 91 has been filled, is a second container 93
sequentially formed in the
base web and in this example filled using a belt feeder 94 or similar type
area filler and only
once the second container 93 has been filled are a third container 95 and a
fourth container 96
formed simultaneously in the base web and in this example, filled
simultaneously using point
feeders 97 and 98 respectively. The feeders 92,94,97,98 may be replaced by any
other feeders
to suit the product added to the containers 91,93,95,96. In other
arrangements, containers 91,
93, 95 and 96 may each be formed and filled sequentially. In other
arrangements, containers 91
and 93 may be formed and filled simultaneously and containers 95 and 96 may be
formed and
filled sequentially. Other combinations of simultaneous and sequential forming
and filling of
the containers will be apparent to those skilled in the art.
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Figure 35 illustrates examples, which are by no means limiting, of pouch
designs which may be
produced by means of the present invention.
Figure 35(i) illustrates a two compartment pouch 100 where typically, although
the nature of
each composition as described hereafter is by no means limiting, open pocket
or container 101
5 is formed first in a base web and filled with a powder or granular
composition by means of a
belt feeder or similar type area feeder, and container 102 is formed second
and filled with a
liquid or gel composition filled by means of a point feeder. The pouch 100 is
then closed by
means of a lidding web.
Figures 35 (ii), 35(v), and 35 (ix) illustrate different three compartment
pouches 110 where
10 typically, although the nature of each composition as described
hereafter is by no means
limiting, an open pocket or container 111 is formed first in a base web and
filled with a powder
or granular composition by means of a belt feeder or similar type area feeder,
open pocket or
container 112 is formed second and filled with a powder or granular
composition by means of a
belt feeder or similar type area feeder, and container 113 is formed third and
filled with a liquid
15 or gel composition filled by means of a point feeder. The pouch 110 is
then closed by means of
a lidding web.
Figures 35(iii), 35(iv), 36(vi) and 35(vii) illustrate different four
compartment pouches 120
where typically, although the nature of each composition as hereafter
described is by no means
limiting, an open pocket or container 121 is formed first in a base web and
filled with a powder
20 or granular composition by means of a belt feeder or similar type area
feeder, container 122 is
formed second and filled with a powder or granular composition by means of a
belt feeder or
similar type area feeder, containers 123 and 124 are formed and filled either
sequentially or
contemporaneously with the same or different liquid or gel composition(s)
filled by means of
point feeders. The pouch 120 is then closed by means of a lidding web.
25 Figure 35 (viii) illustrates a six compartment pouch 130 where
typically, although the nature of
each composition as hereafter described is by no means limiting, container 131
is formed first in
a base web and filled with a powder or granular composition by means of a belt
feeder or
similar type area feeder, container 132 is formed second and filled with a
powder or granular
composition by means of a belt feeder or similar type area feeder, and
containers 133, 134, 135,
and 136 are formed and filled either sequentially or contemporaneously and
filled with the same
or different liquid or gel composition(s) by means of point feeders. The pouch
is then closed
by means of a lidding web.
For the two compartment pouch illustrated in Figure 35(i), the method of fill
may be as follows:
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26
1. Vacuum is applied to form container 101 in the base web
2. Container 101 is filled by a belt feeder or similar type area filler
5. Whilst maintaining the vacuum to form container 101, vacuum is
applied to form
container 102
6. Container 102 is filled with a point type filler, i.e auger or liquid
nozzle.
For the remaining pouches illustrated in Figure 35 the method of fill may be
the same wherein:
1. Vacuum is applied to form container 111,121,131 only in the base web
2. Container 111,121,131 is filled by a belt feeder or similar type area
filler
3. Whilst maintaining the vacuum to form container 111,121,131, vacuum is
applied to
form container 112,122,132 in the base web
4. Container 112,122,132 is filled by similar means as container
111,121,131
5. Whilst maintaining the vacuum to form containers 111,112,121,122,131,12,
vacuum is
applied to form containers 113,123,133 and above (134, 135, 136) in the base
web
6. Containers 113,123,133 and above (134,135,136) are filled with a point
type filler, i.e
auger, or liquid nozzle.
The construction and arrangement of the elements as shown in the exemplary
embodiments are
illustrative only. Although only a few embodiments of the present disclosure
have been
described in detail, those skilled in the art who review this disclosure will
readily appreciate that
many modifications are possible (e.g., variations in sizes, dimensions,
structures, shapes and
proportions of the various elements, values of parameters, mounting
arrangements, use of
materials, colors, orientations, etc.) without materially departing from the
novel teachings and
advantages of the subject matter recited. The elements and assemblies may be
constructed from
any of a wide variety of materials that provide sufficient strength or
durability, in any of a wide
variety of colors, textures, and combinations. Additionally, in the subject
description, the word
"exemplary" is used to mean serving as an example, instance, or illustration.
Any embodiment
or design described herein as "exemplary" is not necessarily to be construed
as preferred or
advantageous over other embodiments or designs. Rather, use of the word
"exemplary" is
intended to present concepts in a concrete manner. Accordingly, all such
modifications are
intended to be included within the scope of the present disclosure. Other
substitutions,
modifications, changes, and omissions may be made in the design, operating
conditions, and
arrangement of the preferred and other exemplary embodiments without departing
from the
scope of the appended claims.
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For purposes of this disclosure, references to the orientation of the elements
in this description
are merely used to identify the various elements as they are oriented in the
FIGURES. These
terms are not meant to limit the element which they describe, as the various
elements may be
oriented differently in various applications. Further, the order or sequence
of any process or
method steps may be varied or re-sequenced according to alternative
embodiments. Any
means-plus-function clause is intended to cover the structures described
herein as performing
the recited function and not only structural equivalents but also equivalent
structures. Other
substitutions, modifications, changes and omissions may be made in the design,
operating
configuration, and arrangement of the preferred and other exemplary
embodiments without
departing from the scope of the appended claims. For example, the methods and
apparatus
described herein may be adapted to produce multi-compartment pouches wherein
all
compartments of the pouch are filled with a composition or wherein at least
one compartment is
filled and at least one compartment is empty (i.e. not filled). All
combinations of filled and
empty compartments may be produced by the method and apparatus described
herein. Multi-
compartment pouches may have the compartments formed simultaneously or
sequentially or a
combination of simultaneous and sequentially formed compartments may be
produced by the
method and apparatus described herein.
