US20240109704A1 - Flexible pouch for an alcoholic beverage - Google Patents

Flexible pouch for an alcoholic beverage Download PDF

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Publication number
US20240109704A1
US20240109704A1 US18/376,033 US202318376033A US2024109704A1 US 20240109704 A1 US20240109704 A1 US 20240109704A1 US 202318376033 A US202318376033 A US 202318376033A US 2024109704 A1 US2024109704 A1 US 2024109704A1
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US
United States
Prior art keywords
seal
pouch
flexible pouch
layer
wall
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
US18/376,033
Inventor
R. Charles Murray
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Pouch Pac Innovations LLC
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Pouch Pac Innovations LLC
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Filing date
Publication date
Application filed by Pouch Pac Innovations LLC filed Critical Pouch Pac Innovations LLC
Priority to US18/376,033 priority Critical patent/US20240109704A1/en
Publication of US20240109704A1 publication Critical patent/US20240109704A1/en
Pending legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/008Standing pouches, i.e. "Standbeutel"
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D65/00Wrappers or flexible covers; Packaging materials of special type or form
    • B65D65/38Packaging materials of special type or form
    • B65D65/40Applications of laminates for particular packaging purposes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/52Details
    • B65D75/58Opening or contents-removing devices added or incorporated during package manufacture
    • B65D75/5805Opening or contents-removing devices added or incorporated during package manufacture for tearing a side strip parallel and next to the edge, e.g. by means of a line of weakness
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/52Details
    • B65D75/58Opening or contents-removing devices added or incorporated during package manufacture
    • B65D75/5861Spouts
    • B65D75/5872Non-integral spouts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/52Details
    • B65D75/58Opening or contents-removing devices added or incorporated during package manufacture
    • B65D75/5861Spouts
    • B65D75/5872Non-integral spouts
    • B65D75/5877Non-integral spouts connected to a planar surface of the package wall
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/52Details
    • B65D75/58Opening or contents-removing devices added or incorporated during package manufacture
    • B65D75/5861Spouts
    • B65D75/5872Non-integral spouts
    • B65D75/5883Non-integral spouts connected to the package at the sealed junction of two package walls
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D85/00Containers, packaging elements or packages, specially adapted for particular articles or materials
    • B65D85/70Containers, packaging elements or packages, specially adapted for particular articles or materials for materials not otherwise provided for
    • B65D85/72Containers, packaging elements or packages, specially adapted for particular articles or materials for materials not otherwise provided for for edible or potable liquids, semiliquids, or plastic or pasty materials

Definitions

  • the present invention relates generally to a flexible pouch for packaging a product and, more specifically, to a flexible pouch for packaging a beverage containing alcohol.
  • Various types of disposable containers are known to those skilled in the art for storing fluid and/or dry products such as a liquid, granular material, powder, and the like.
  • Examples of such containers include metal cans, plastic bottles, glass bottles, and flexible pouches.
  • consumers prefer the convenience of flexible pouches over other types of containers due to the shape, size, shelf life, and storage capability thereof.
  • a flexible pouch can be formed and filled on a single manufacturing line and thereby reduce storage space, logistics related to the manufacture and shipping of filled flexible pouches, etc. As such, manufacturers have recognized the packaging benefits with respect to flexible pouches.
  • the present disclosure provides an improved flexible pouch for a liquid or beverage, e.g., having an alcoholic content.
  • the flexible pouch includes a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and a first side edge and a second side edge extending therebetween the upper edge and the lower edge.
  • the pouch also includes an opening structure or mechanism disposed in the panel for accessing the beverage having an alcoholic content contained within the pouch.
  • a flexible pouch and method of making a flexible pouch is provided that utilizes a laminate material that is transparent or opaque.
  • a further advantage of the present invention is that a flexible pouch and method of making a flexible pouch is provided that is cost effective to manufacture.
  • the flexible pouch retains its shape as the product is removed.
  • Still yet a further advantage of the present invention is that a flexible pouch and method of making the flexible pouch is provided that retains its flavor, color, aroma, and taste over the shelf life of the product.
  • a flexible pouch for alcoholic beverages includes a front wall and a back wall defining a compartment.
  • An opening structure is in fluid communication with the compartment.
  • the front wall and/or the back wall is composed of a panel of film laminate.
  • the film laminate includes an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE).
  • PET polyethylene terephthalate
  • PE polyethylene
  • the front wall and the back wall are joined together by a top seal.
  • the top seal includes a double seal disposed along a top edge of the front wall and the back wall.
  • the double seal may include at least one heat seal.
  • the double seal may include a first heat seal and a second heat seal.
  • the double seal may include a first ultrasonic seal and a second heat seal. The provision of a double seal helps prevent leakage, for example by removing excess moisture during the filling process, and reduces oxygen permeability by providing a structurally sound top seal.
  • the middle barrier layer may comprise a titanium oxide film.
  • the middle barrier layer may comprise a silicon oxide film.
  • the laminate structure may include further interlayers.
  • a layer of ethylene vinyl alcohol (EVOH) may be provided between the outer layer and the inner layer.
  • a layer of nylon may be provided between the outer layer and the inner layer.
  • the opening structure may include a tear notch disposed between the top seal and the compartment. Additionally, the opening structure may include a resealable zipper disposed between the tear notch and the compartment.
  • the opening structure may include a fitment with a spout extending through the top seal.
  • the flexible pouch may include a bottom gusset disposed at a bottom edge of the first wall and the second wall.
  • a method of forming a flexible pouch for alcoholic beverages includes forming a pouch panel from a film laminate, the film laminate including an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE); forming a pouch body from the pouch panel, the pouch body including a first wall and a second wall defining a compartment with an open top; filling the compartment with a product; and sealing the open top with a top seal, the top seal joining the first wall and the second wall together.
  • PET polyethylene terephthalate
  • PE polyethylene
  • Sealing the open top with the top seal may include forming a double seal along a top edge of the first wall and the second wall.
  • the double seal may be formed by heat sealing a first seal along the top edge and then heat sealing a second seal in a region of the first seal.
  • double seal may be formed by ultrasonic welding a first seal along the top edge and then heat sealing a second seal in a region of the first seal.
  • the middle barrier layer may comprise a titanium oxide film or a silicon oxide film.
  • Forming the pouch body may include providing an opening structure in the pouch panel, the opening structure in fluid communication with the compartment.
  • the opening structure may include at least one of a tear notch, a resealable zipper, and a weakened straw pierceable portion.
  • the opening structure includes a fitment (e.g., a spout).
  • FIG. 1 is a schematic view of one laminate material for a flexible pouch that is transparent;
  • FIG. 2 is a schematic view of one laminate material for a flexible pouch that is transparent;
  • FIG. 3 is a schematic view of one laminate material for a flexible pouch that is transparent;
  • FIG. 4 is a schematic view of one laminate material for a flexible pouch that is transparent;
  • FIG. 5 is a schematic view of one laminate material for a flexible pouch that is transparent
  • FIG. 6 is a schematic view of one laminate material for a flexible pouch that is transparent
  • FIG. 7 is a schematic view of one laminate material for a flexible pouch that is opaque
  • FIG. 8 is a schematic view of one laminate material for a flexible pouch that is opaque
  • FIG. 9 is a side view of a transparent flexible pouch for an alcoholic beverage with a zipper, bottom gusset and tear strip opening;
  • FIG. 10 is a bottom view of a transparent flexible pouch for an alcoholic beverage with a zipper, bottom gusset and tear strip opening;
  • FIG. 11 is a side view of a transparent flexible pouch for an alcoholic beverage with a zipper, bottom gusset, straw and tear strip opening;
  • FIG. 12 is a top view of a transparent flexible pouch for an alcoholic beverage of FIG. 9 with the straw positioned in the pouch;
  • FIG. 13 is a side view of a half transparent half opaque flexible pouch for an alcoholic beverage with a zipper, bottom gusset and tear strip opening;
  • FIG. 14 is a bottom view of a half transparent half opaque flexible pouch for an alcoholic beverage with a zipper, bottom gusset and tear strip opening;
  • FIG. 15 is a cross-sectional view of a flexible pouch according to FIGS. 9 - 14 ;
  • FIG. 16 is a side view of opaque flexible curved side pouch for an alcoholic beverage with a bottom gusset
  • FIG. 17 is a side view of a transparent flexible pouch for an alcoholic beverage with a fitment and bottom gusset
  • FIG. 18 is a bottom view of a transparent flexible pouch for an alcoholic beverage with a fitment and bottom gusset
  • FIG. 19 is a side view of an opaque flexible pouch for an alcoholic beverage with a fitment and bottom gusset
  • FIG. 20 is a cross-sectional view of a flexible pouch with a fitment and bottom gusset, according to FIGS. 17 - 19 ;
  • FIG. 21 is a side view of an opaque flexible pouch for an alcoholic beverage with a straw access and bottom gusset
  • FIG. 22 is a bottom view of an opaque flexible pouch for an alcoholic beverage with a straw access and bottom gusset
  • FIG. 23 is a side view of a transparent flexible pouch for an alcoholic beverage with a zipper and tear strip opening;
  • FIG. 24 is a side view of a transparent flexible pouch for an alcoholic beverage with a fitment and bottom gusset
  • FIG. 25 is a flowchart of an exemplary method for making a flexible pouch for an alcoholic beverage.
  • the pouch 10 may be filled with a product and sealed.
  • Various shapes are contemplated for the pouch.
  • the pouch 10 may have a generally cylindrical shape, a box-like shape, an hourglass shape or another shape. It is contemplated that the pouch may contain a single portion or multiple portions of the product.
  • the product is a beverage having an alcoholic content, such as from 10 to 20% alcohol.
  • the flexible pouch 10 is preferably formed from a roll of preprinted material of extruded or laminate layers. The material is typically a three, or four, or five or more gauge material, or two laminations of material or the like. The outer layer is usually preprinted.
  • the pouch 10 comprises a laminate material of a plurality of film layers (e.g., a film laminate).
  • the laminate material may include an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE).
  • PET polyethylene terephthalate
  • PE polyethylene
  • the middle barrier layer may comprise a film of silicon oxide (SiOx) such as SiO 2 and/or titanium oxide (TiOx) such as TiO 2 , which materials protect against oxygen permeability while being generally regarded as safe for consumption.
  • Further layers may be provided between the outer and inner layers, such as a layer of ethylene vinyl alcohol and/or a layer of nylon.
  • the pouch may be transparent.
  • Various laminate structures may be utilized for the transparent pouch.
  • FIG. 1 One example of a transparent laminate, as shown in FIG. 1 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), a layer of Aluminum oxide (AlOx), nylon and a layer of polyethylene (PE).
  • PET polyethylene terephthalate
  • EVOH ethylene vinyl alcohol
  • AlOx Aluminum oxide
  • nylon a layer of polyethylene
  • PE polyethylene
  • a layer of titanium oxide or titanium dioxide (TiOx) may be used instead of aluminum oxide.
  • TiOx titanium oxide
  • the titanium oxide provides a barrier to against oxygen permeability and is considered safe for consumption.
  • FIG. 2 Another example of a transparent laminate, as shown in FIG. 2 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), a layer of Silicon oxide (SiOx), nylon and a layer of polyethylene (PE).
  • PET polyethylene terephthalate
  • EVOH ethylene vinyl alcohol
  • SiOx Silicon oxide
  • nylon a layer of polyethylene (PE).
  • FIG. 3 Another example of a transparent laminate, as shown in FIG. 3 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), a layer of Silicon oxide (SiOx), and a layer of polyethylene (PE).
  • PET polyethylene terephthalate
  • EVOH ethylene vinyl alcohol
  • SiOx Silicon oxide
  • PE polyethylene
  • FIG. 4 Another example of a transparent laminate, as shown in FIG. 4 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), a layer of Aluminum oxide (AlOx), and a layer of polyethylene (PE).
  • PET polyethylene terephthalate
  • EVOH ethylene vinyl alcohol
  • AlOx Aluminum oxide
  • PE polyethylene
  • the aluminum oxide may be replaced with titanium oxide (TiOx).
  • FIG. 5 Another example of a transparent laminate, as shown in FIG. 5 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), a layer of nylon and a layer of polyethylene (PE).
  • PET polyethylene terephthalate
  • EVOH ethylene vinyl alcohol
  • nylon a layer of nylon
  • PE polyethylene
  • FIG. 6 Another example of a transparent laminate, as shown in FIG. 6 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), and a layer of polyethylene (PE).
  • PET polyethylene terephthalate
  • EVOH ethylene vinyl alcohol
  • PE polyethylene
  • the pouch may be opaque.
  • Various laminate structures may be utilized for the opaque pouch.
  • opaque laminate material structure may include an outer layer of polyethylene terephthalate (PET), a layer of aluminum (Al), a layer of nylon and a layer of polyethylene (PE).
  • PET polyethylene terephthalate
  • Al aluminum
  • nylon polyethylene
  • PE polyethylene
  • the layer of aluminum may be replaced with a layer of titanium oxide (TiOx).
  • TiOx titanium oxide
  • the titanium oxide provides a barrier to against oxygen permeability and is considered safe for consumption.
  • opaque laminate material structure may include includes an outer layer of polyethylene terephthalate (PET), a layer of aluminum (Al), and a layer of polyethylene (PE).
  • PET polyethylene terephthalate
  • Al aluminum
  • PE polyethylene
  • the layer of aluminum may be replaced with TiOx or SiOx.
  • the outer layer of PET may have a thickness ranging from 10-20 microns ( ⁇ m). Additionally or alternatively, the layer of SiOx and/or the layer of TiOx may respectively have a thickness of 5-15 ⁇ m. Additionally or alternatively, the layer of nylon may have a thickness of 10-20 ⁇ m. Additionally or alternatively, the layer of EVOH may have a thickness of 5-25 ⁇ m. Additionally or alternatively, the layer of PE may have a thickness of 50-200 ⁇ m.
  • the above-described laminate material structures are well suited for packaging a beverage having an alcoholic content, such as wine or beer or another liquor, to add strength to the walls of the pouch, and to preserve the product.
  • the pouch may be transparent, allowing the contents of the pouch to be viewed.
  • the pouch may also be opaque when desired.
  • the outer PET layer may be printed with any desired indicia.
  • the AlOx, SiOx, and TiOx materials provide a transparent barrier layer that also ads strength.
  • the Al and EVOH layers provide a vapor barrier preventing introduction of air and oxygen. Nylon protects the Al, SiOx, TiOx, or EVOH layer from cracking in a lager pouch application.
  • the PE layer acts as a barrier between the middle barrier layer and the compartment, and provides organoleptic protection from the development of undesirable flavors.
  • the pouch 10 is formed from at least one panel of laminate material, as described above.
  • the panel has an inner surface that is adjacent the product, and an outer surface.
  • the pouch 10 formed out of the panel has a front wall 12 and a back wall 14 defining a compartment A.
  • the front and back walls 12 , 14 may be formed out of a single panel or separate panels.
  • Each wall 12 , 14 is further defined by an upper edge 16 , an opposed lower edge 18 , and first and second side edges 20 extending therebetween the upper and lower edges 16 , 18 .
  • the side edges 20 of the panel may form a sealed seam.
  • the pouch 10 may include two side seams if made from two panels or from one panel. The seam may be a flat seam.
  • the edges are joined along two side seams.
  • the seal may be an ultrasonic seal or a heat weld or a combination of both or the like.
  • a bottom gusset 26 may be positioned between the lower edges 18 of the pouch 10 and form a base, enabling the pouch 10 to stand upright unsupported.
  • the pouch 10 incorporates an opening structure 28 for accessing the contents of the pouch.
  • opening structures 28 are known in the art for this purpose, and is non-limiting. The position of the opening structure is determinable by many factors, such as type of opening mechanism.
  • the opening structure 28 may be positioned in an upper edge, a lower edge or side edge, or front wall or back wall, or on an insert or gusset. It should be appreciated that the opening structure 28 may be incorporated into the pouch 10 prior to filling the pouch 10 .
  • One example of an opening structure is a tear-off portion 30 .
  • the tear-off portion 30 usually has an integral tear notch 32 .
  • the tear notch 32 is typically formed near an outermost edge of a seam, for initiating the removal of the tear-off portion, such as a side edge 20 .
  • Another example of an opening structure 28 is a resealable zipper 34 .
  • Another example of an opening structure 28 is a weakened straw pierceable portion 36 in the pouch 10 for receiving a straw.
  • an opening structure 28 is a fitment such as a removable and replaceable cap 38 secured to a spout 40 , or a tap, or the like.
  • a fitment such as a removable and replaceable cap 38 secured to a spout 40 , or a tap, or the like.
  • caps and spouts may be utilized.
  • the spout is sealed into the upper edges of the panel using a sealing structure, such as an ultrasonic seal or a heat weld, or the like, as described below.
  • the spout 40 may include a removable seal to prevent leakage of the product or evidence of tampering.
  • the flexible pouch 10 includes a top seal 22 joining the front wall 12 and the back wall 14 together.
  • the top seal 22 may comprise a double seal 24 A, 24 B to help prevent leakage of contents and oxygen or air from entering into the compartment containing the product.
  • the double seal 24 A, 24 B may be provided along the top of the pouch 10 (e.g., along the top edge 16 ), above the opening mechanism 28 (e.g., above the tear line, zipper, etc.), to seal the front and back walls 12 , 14 together after filling the pouch with the liquid product.
  • the double seal 24 A, 24 B may extend continuously from first edge seam 20 to second side edge seam 20 , and seals the first and second walls 12 , 14 together.
  • the double seal 24 A, 24 B may include a first seal 24 A at the top edge 16 , and a second seal 24 B in a region of the first seal 24 A (e.g., the second seal 24 B is adjacent to the first seal 24 A).
  • the first seal 24 A and the second seal 24 B may extend generally parallel to one another. Additionally or alternatively, the first seal 24 A and the second seal 24 B are arranged adjacent to one another. Additionally or alternatively, the first seal 24 A and the second seal 24 B at least partially overlap (e.g., overlap in at least one region) and/or abut one another.
  • first seal 23 A and the second seal 24 B are arranged separate from one another (e.g., a gap is present (interposed) between the first seal 24 A and the second seal 24 B).
  • the double seal structure along the top edge helps prevent the ingress of oxygen/air during the filling process to maintain a structurally sound, air-tight seal for extended shelf-life, as discussed below.
  • the double seal 24 A, 24 B may comprise two heat seals.
  • the double seal 24 A, 24 B may comprise an ultrasonic seal and a heat seal.
  • the ultrasonic seal may form the first seal 24 B and the heat seal may form the second seal 24 A.
  • ultrasonic welding as the inner seal 24 B is preferred to heat sealing, as ultrasonic welding is more effective through liquids.
  • the flexible pouch 10 may advantageously include other features that are known in the art.
  • the pouch 10 may include a feature such as an ergonomic shape.
  • the width across the pouch is less in the middle, than at the upper edge or lower edge. That is, one or both of the side edges 20 may form an arc or curve, which facilitates controlling the volume of the compartment.
  • the overall hourglass shape assumed by the pouch 10 due to the internal pressure within the pouch 10 facilitates holding of the pouch in the hand of a user.
  • the flexible pouch 10 may incorporate any of the above-described features in any combination.
  • the finished pouch may assume various shapes as influenced by the type of product and intended usage of the pouch.
  • a flexible pouch 10 that includes a transparent laminate material.
  • the pouch includes a bottom gusset 26 , zipper opening 34 and a tear notch 32 .
  • a top seal 22 in the form of a double seal 24 A, 24 B is provided along the top edge 16 , above the tear notch 32 (e.g., the tear notch 32 is disposed between the top seal 22 and the zipper 34 .
  • the pouch 10 may include a straw 33 attached thereon, as shown in FIG. 11 . After the tear notch 32 is removed, the zipper 34 may be opened and tightened around the straw 33 as shown in FIG. 12 .
  • a flexible pouch 10 that includes a transparent laminate material (e.g., forming the panel of the front wall 12 ) and an opaque laminate material (e.g., forming the panel of the back wall 14 ).
  • the pouch includes a bottom gusset 26 , zipper opening 34 and a tear notch 32 with top seal 22 (including double seal 24 A, 24 B) disposed along top edge 16 above tear notch 32 (e.g., tear notch 32 is between zipper 34 and top seal 22 ).
  • FIG. 15 shows a cross-sectional view of a flexible pouch 10 according to FIGS. 9 - 14 .
  • the flexible pouch 10 includes an opening structure 28 comprising a tear notch 32 disposed at an upper end of the seam/seal formed along the side edges 20 and a resealable zipper 34 providing access (fluid communication) to the compartment A.
  • a top seal 22 is formed along the top edge 16 to join the film of the front wall 12 with that of the back wall 14 , wherein the top seal 22 includes a double seal 24 A, 24 B disposed above the tear notches 32 (e.g., the tear notches 32 are disposed between the second seal 24 B and the zipper 34 ).
  • the example illustrated in FIG. 15 shows a gap running between first and second seals 24 A, 24 B.
  • first and second seals 24 A, 24 B may at least partially overlap one another and/or abut one another without a gap therebetween, at least in one region.
  • a bottom gusset 26 is disposed at the bottom edge 18 .
  • FIG. 15 shows the side edges 20 as straight, it will be appreciated that the side edges 20 may be curved (e.g., inwardly curved or concave) to provide an ergonomic profile.
  • FIG. 16 there is shown an embodiment of a flexible pouch 10 that includes an opaque laminate material.
  • the pouch includes an ergonomic shape with curved side walls 20 .
  • Various fitments or tear notches may be utilized.
  • a transparent laminate with an ergonomic shape may be utilized.
  • a top seal may be provided along the top edge 16 , sealing the top of the pouch 10 between side edges 20 .
  • the bottom 18 may be provided with a bottom gusset 26 , as shown and described with reference to FIG. 14 .
  • FIGS. 17 - 20 there is shown an embodiment of a flexible pouch 10 that includes a bottom gusset 26 , and a spout 40 .
  • the spout 40 is adapted to receive a cap 38 .
  • FIGS. 17 and 18 illustrate the flexible pouch 10 formed from a transparent laminate material.
  • FIG. 19 there is shown an embodiment of a flexible pouch 10 that includes an opaque laminate material.
  • the pouch 10 includes a bottom gusset 26 (cf. FIG. 18 ), and a spout 40 with a double seal 24 A, 24 B along the top edge 16 .
  • the spout 40 is adapted to receive a cap 28 (cf. FIG. 20 ). It should be realized that a transparent laminate material may also be utilized.
  • FIGS. 17 - 20 the spout 40 is sealed together with the front and back walls 12 , 14 via the top seal 22 in the form of a double seal 24 A, 24 B.
  • a first seal 24 A may be formed by heat sealing or ultrasonic sealing the spout 40 to the front and back walls 12 , 14 .
  • a second peripheral seal 24 B may be formed by heat sealing along the top edge 16 .
  • FIG. 20 shows an example of one side edge 20 being curved and the other side edge 20 extending straight, although it will be appreciated that both side edges may be straight or curved.
  • FIGS. 21 and 22 there is shown an embodiment of a flexible pouch 10 that includes an opaque laminate material.
  • the pouch includes a bottom gusset 26 , and a piercable straw aperture 36 .
  • a transparent laminate material may also be utilized.
  • a top seal may be provided along the top edge 16 , extending laterally between side edges 20 .
  • FIG. 23 there is shown an embodiment of a flexible pouch 10 that includes a transparent laminate material.
  • the pouch 10 includes a single laminate sheet without a bottom gusset, and includes zipper opening 34 and a tear notch 32 .
  • top seal 22 may be disposed along the top edge 16 , as discussed above.
  • FIG. 24 there is shown an embodiment of a flexible pouch 10 that includes a transparent laminate material.
  • the pouch includes a bottom gusset 26 , and a spout 40 .
  • the spout is adapted to receive a cap.
  • a hole may be included in a corner of the pouch 10 .
  • a top seal may be provided, as discussed with reference to FIGS. 17 - 20 .
  • FIG. 25 a flowchart of an exemplary method 200 for making a flexible pouch is shown. Although the steps associated with the blocks of FIG. 25 will be described as being separate tasks, in other embodiments, the blocks may be combined or omitted. Further, in other embodiments, the steps may be performed in a different order.
  • the method 200 may include laminating a plurality of layers together including an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE) to form a pouch panel.
  • the middle barrier layer may be chosen from SiOx, TiOx, and AlOx.
  • the middle barrier layer is configured to prevent permeability of oxygen and air into the sealed compartment. Further layers, such as nylon and ethylene vinyl alcohol (EVOH), may also be provided.
  • the pouch panel may be transparent or opaque. Further, the step 205 may be repeated if a second pouch panel is to be used to form the flexible pouch 10 .
  • a pouch body is formed from the pouch panel (or two pouch panels) wherein the pouch panel(s) is sealed together to form the pouch body including front and back walls defining a compartment and having a pair of opposite side seal/seam edges 20 and a bottom (e.g., including bottom gusset 26 ) with an open top.
  • An opening structure 28 e.g., resealable zipper 34 , piercable straw hole 36 , tear strip 32 , fitment/spout 40 ) may be incorporated at or near the open top.
  • the compartment of the pouch body is filled with product (e.g., an alcoholic beverage). This may be performed in an inert atmosphere and/or with gas purge.
  • product e.g., an alcoholic beverage
  • the filled pouch body is sealed along the top edge 16 to form a top seal 22 closing the open top.
  • the top seal 22 may comprise a double seal 24 A, 24 B to help prevent leakage and ingress of oxygen.
  • the double seal 24 A, 24 B is provided along the top of the pouch 10 , above the opening mechanism 28 (e.g., above the tear line, zipper, etc.), to seal the front and back walls 12 , 14 together.
  • the double seal may include heat sealing the open top at a first seal station (forming a first heat seal), and then forming a second heat seal in a region of or adjacent to the first heat seal.
  • the second heat seal may be formed at a second seal station that repeats the heat sealing in a region of the first seal.
  • the double seal ensures no leaking should some product have contaminated the inside of the seal area during the first heat sealing, which contamination may cause a weak seal that can leak in the area of the moisture.
  • the second hot seal helps ensures the area is well and tightly sealed, thereby enhancing the structural integrity of the top seal.
  • the double seal may include a first ultrasonic seal followed by a hot seal. More specifically, a first seal is formed along the open top using ultrasonic welding techniques to form the first seal.
  • the ultrasonic first seal utilizes the principles of ultrasonic acoustic vibrations to generate heat at a molecular level inside the films themselves and this energy joins the two materials together.
  • Ultrasonic weld tools e.g., anvil or sonotrodes
  • a second seal in the form of a hot seal is heat sealed along the top of the pouch.
  • the hot/heat seal may be formed outside the first ultrasonic seal (e.g., so that the ultrasonic seal is disposed between the hot/heat seal and the contents). The second heat seal ensures that any remaining moisture is removed and helps prevent leakage.
  • the spout seal may be heated as the spout is positioned in the open top between the front and back walls 12 , 14 , and then a heated seal bar is provided to heat seal the spout fitment to the front and back walls to form a first heat seal 24 A.
  • a second heat seal 24 B may then be formed in a region of the first heat seal to ensure that the area is well and tightly sealed.
  • the spout 40 may be incorporated into the pouch 10 in step 210 (e.g., prior to filling with product). Alternatively, the spout 40 may be incorporated into the pouch 10 after the filling step 215 (e.g., in step 220 ).
  • the seals used herein are peripheral seals that form a permanent bond between layers of the pouch that is not intended to rupture.
  • a peripheral seal is a fixed barrier and has a peel strength significantly greater than that of the frangible seal.
  • the bond of the peripheral seal is solid between the different layers to form a barrier, or permanent seal between the layers. That is, the peel strength of the peripheral seal is limited only by the burst properties of the materials used to form the peripheral seal.
  • the peel strength of the peripheral seal is in a range between 9.18 and 11.22 pounds per square inch of force to rupture the peripheral seal.
  • one or more pouch panels formed from a laminate material (e.g., film laminate) together with the double seal structure provides a flexible pouch 10 that retains its flavor, color, aroma, and taste over the shelf life of the product.
  • the double seal may include two seals adjacent to one another, optionally running in parallel.
  • the two seals may at least partially overlap and/or abut.
  • the first and second seals 24 A, 24 B may overlap and/or abut along an entire extend of the top seal 22 (e.g., from one side edge to the other side edge).
  • the two seals may be separate from one another (e.g., a gap may be present between the first and second seals), at least in one region or optionally along an entire extent of the top seal 22 .
  • more than top seal may comprise more than two seals (e.g., formed from heat and/or ultrasonic welding) without departing from the scope of the disclosure.
  • the pouch may have various shapes and sizes and include various opening structures. Any of the embodiments described above may include different opening structures or laminate materials other than a specifically described.
  • the pouch may include one or more frangible seals.
  • a frangible seal may be formed (e.g., ultrasonically welded) in the compartment.
  • top seal 22 may instead correspond to a bottom seal where the top is sealed by a peripheral seal and the bottom is open for filing, without departing from the scope of the disclosure.
  • references to a single element are not necessarily so limited and may include one or more of such element. Further, all numbers expressing dimensions, ratios and the like, used in the specification and claims, are to be understood to encompass tolerances and other deviations as represented by the term “about” or “approximately.”

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Abstract

A flexible pouch for alcoholic beverages and a method of making a flexible pouch are disclosed. The flexible pouch includes a front wall and a back wall defining a compartment. An opening structure is in fluid communication with the compartment. The front wall and/or the back wall is composed of a panel of film laminate. The film laminate includes an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE). The front wall and the back wall are joined together by a top seal.

Description

    CROSS-REFERENCE TO RELATED APPLICATIONS
  • This application claims priority to U.S. Prov. App. No. 63/412,722 filed on Oct. 3, 2022, the contents of which are hereby incorporated by reference in its entirety.
  • TECHNICAL FIELD
  • The present invention relates generally to a flexible pouch for packaging a product and, more specifically, to a flexible pouch for packaging a beverage containing alcohol.
  • BACKGROUND
  • Various types of disposable containers are known to those skilled in the art for storing fluid and/or dry products such as a liquid, granular material, powder, and the like. Examples of such containers include metal cans, plastic bottles, glass bottles, and flexible pouches. In some instances, consumers prefer the convenience of flexible pouches over other types of containers due to the shape, size, shelf life, and storage capability thereof. In addition, a flexible pouch can be formed and filled on a single manufacturing line and thereby reduce storage space, logistics related to the manufacture and shipping of filled flexible pouches, etc. As such, manufacturers have recognized the packaging benefits with respect to flexible pouches.
  • Although flexible pouches have been used for some time to package and distribute various products; however, previous pouches have not provided adequate protection for the product stored therein, specifically, alcoholic beverages. Previous flexible pouches resulted in inadequate levels of oxygen permeability and sensory qualities, such as taste, flavor, aroma, and color, due to the composition and structure of the flexible pouch. Specifically, the formulation of the pouch panel that forms the pouch and the seal that closes off the pouch after filling with product.
  • SUMMARY
  • Accordingly, the present disclosure provides an improved flexible pouch for a liquid or beverage, e.g., having an alcoholic content. The flexible pouch includes a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and a first side edge and a second side edge extending therebetween the upper edge and the lower edge. The pouch also includes an opening structure or mechanism disposed in the panel for accessing the beverage having an alcoholic content contained within the pouch.
  • One advantage of the present invention is that a flexible pouch and method of making a flexible pouch is provided that utilizes a laminate material that is transparent or opaque. A further advantage of the present invention is that a flexible pouch and method of making a flexible pouch is provided that is cost effective to manufacture. Yet a further advantage of the present invention is that the flexible pouch retains its shape as the product is removed. Still yet a further advantage of the present invention is that a flexible pouch and method of making the flexible pouch is provided that retains its flavor, color, aroma, and taste over the shelf life of the product.
  • According to an aspect, a flexible pouch for alcoholic beverages is disclosed. The flexible pouch includes a front wall and a back wall defining a compartment. An opening structure is in fluid communication with the compartment. The front wall and/or the back wall is composed of a panel of film laminate. The film laminate includes an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE). The front wall and the back wall are joined together by a top seal.
  • Pursuant to an implementation, the top seal includes a double seal disposed along a top edge of the front wall and the back wall. The double seal may include at least one heat seal. For example, the double seal may include a first heat seal and a second heat seal. As another example, the double seal may include a first ultrasonic seal and a second heat seal. The provision of a double seal helps prevent leakage, for example by removing excess moisture during the filling process, and reduces oxygen permeability by providing a structurally sound top seal.
  • In an example, the middle barrier layer may comprise a titanium oxide film.
  • In another example, the middle barrier layer may comprise a silicon oxide film.
  • The laminate structure may include further interlayers. For example, a layer of ethylene vinyl alcohol (EVOH) may be provided between the outer layer and the inner layer. As another example, a layer of nylon may be provided between the outer layer and the inner layer.
  • The opening structure may include a tear notch disposed between the top seal and the compartment. Additionally, the opening structure may include a resealable zipper disposed between the tear notch and the compartment.
  • In another example, the opening structure may include a fitment with a spout extending through the top seal.
  • The flexible pouch may include a bottom gusset disposed at a bottom edge of the first wall and the second wall.
  • According to another aspect, a method of forming a flexible pouch for alcoholic beverages is disclosed. The method includes forming a pouch panel from a film laminate, the film laminate including an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE); forming a pouch body from the pouch panel, the pouch body including a first wall and a second wall defining a compartment with an open top; filling the compartment with a product; and sealing the open top with a top seal, the top seal joining the first wall and the second wall together.
  • Sealing the open top with the top seal may include forming a double seal along a top edge of the first wall and the second wall. The double seal may be formed by heat sealing a first seal along the top edge and then heat sealing a second seal in a region of the first seal. Alternatively, double seal may be formed by ultrasonic welding a first seal along the top edge and then heat sealing a second seal in a region of the first seal.
  • The middle barrier layer may comprise a titanium oxide film or a silicon oxide film.
  • Forming the pouch body may include providing an opening structure in the pouch panel, the opening structure in fluid communication with the compartment. The opening structure may include at least one of a tear notch, a resealable zipper, and a weakened straw pierceable portion. Pursuant to another example, the opening structure includes a fitment (e.g., a spout).
  • Other features and advantages of the present invention will be readily appreciated, as the same becomes better understood after reading the subsequent description taken in conjunction with the accompanying drawings.
  • It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein and together with the description serve to explain the principles and operations of the claimed subject matter.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a schematic view of one laminate material for a flexible pouch that is transparent;
  • FIG. 2 is a schematic view of one laminate material for a flexible pouch that is transparent;
  • FIG. 3 is a schematic view of one laminate material for a flexible pouch that is transparent;
  • FIG. 4 is a schematic view of one laminate material for a flexible pouch that is transparent;
  • FIG. 5 is a schematic view of one laminate material for a flexible pouch that is transparent;
  • FIG. 6 is a schematic view of one laminate material for a flexible pouch that is transparent;
  • FIG. 7 is a schematic view of one laminate material for a flexible pouch that is opaque;
  • FIG. 8 is a schematic view of one laminate material for a flexible pouch that is opaque;
  • FIG. 9 is a side view of a transparent flexible pouch for an alcoholic beverage with a zipper, bottom gusset and tear strip opening;
  • FIG. 10 is a bottom view of a transparent flexible pouch for an alcoholic beverage with a zipper, bottom gusset and tear strip opening;
  • FIG. 11 is a side view of a transparent flexible pouch for an alcoholic beverage with a zipper, bottom gusset, straw and tear strip opening;
  • FIG. 12 is a top view of a transparent flexible pouch for an alcoholic beverage of FIG. 9 with the straw positioned in the pouch;
  • FIG. 13 is a side view of a half transparent half opaque flexible pouch for an alcoholic beverage with a zipper, bottom gusset and tear strip opening;
  • FIG. 14 is a bottom view of a half transparent half opaque flexible pouch for an alcoholic beverage with a zipper, bottom gusset and tear strip opening;
  • FIG. 15 is a cross-sectional view of a flexible pouch according to FIGS. 9-14 ;
  • FIG. 16 is a side view of opaque flexible curved side pouch for an alcoholic beverage with a bottom gusset;
  • FIG. 17 is a side view of a transparent flexible pouch for an alcoholic beverage with a fitment and bottom gusset;
  • FIG. 18 is a bottom view of a transparent flexible pouch for an alcoholic beverage with a fitment and bottom gusset;
  • FIG. 19 is a side view of an opaque flexible pouch for an alcoholic beverage with a fitment and bottom gusset;
  • FIG. 20 is a cross-sectional view of a flexible pouch with a fitment and bottom gusset, according to FIGS. 17-19 ;
  • FIG. 21 is a side view of an opaque flexible pouch for an alcoholic beverage with a straw access and bottom gusset;
  • FIG. 22 is a bottom view of an opaque flexible pouch for an alcoholic beverage with a straw access and bottom gusset;
  • FIG. 23 is a side view of a transparent flexible pouch for an alcoholic beverage with a zipper and tear strip opening;
  • FIG. 24 is a side view of a transparent flexible pouch for an alcoholic beverage with a fitment and bottom gusset;
  • FIG. 25 is a flowchart of an exemplary method for making a flexible pouch for an alcoholic beverage.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • Referring to FIGS. 1-24 a flexible pouch 10 is illustrated. The pouch 10 may be filled with a product and sealed. Various shapes are contemplated for the pouch. The pouch 10 may have a generally cylindrical shape, a box-like shape, an hourglass shape or another shape. It is contemplated that the pouch may contain a single portion or multiple portions of the product. In this example, the product is a beverage having an alcoholic content, such as from 10 to 20% alcohol. The flexible pouch 10 is preferably formed from a roll of preprinted material of extruded or laminate layers. The material is typically a three, or four, or five or more gauge material, or two laminations of material or the like. The outer layer is usually preprinted. Pursuant to an implementation, the pouch 10 comprises a laminate material of a plurality of film layers (e.g., a film laminate). The laminate material may include an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE). The middle barrier layer may comprise a film of silicon oxide (SiOx) such as SiO2 and/or titanium oxide (TiOx) such as TiO2, which materials protect against oxygen permeability while being generally regarded as safe for consumption. Further layers may be provided between the outer and inner layers, such as a layer of ethylene vinyl alcohol and/or a layer of nylon.
  • In one aspect, the pouch may be transparent. Various laminate structures may be utilized for the transparent pouch.
  • One example of a transparent laminate, as shown in FIG. 1 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), a layer of Aluminum oxide (AlOx), nylon and a layer of polyethylene (PE). Pursuant to an implementation, instead of aluminum oxide, a layer of titanium oxide or titanium dioxide (TiOx) may be used. The titanium oxide provides a barrier to against oxygen permeability and is considered safe for consumption.
  • Another example of a transparent laminate, as shown in FIG. 2 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), a layer of Silicon oxide (SiOx), nylon and a layer of polyethylene (PE).
  • Another example of a transparent laminate, as shown in FIG. 3 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), a layer of Silicon oxide (SiOx), and a layer of polyethylene (PE).
  • Another example of a transparent laminate, as shown in FIG. 4 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), a layer of Aluminum oxide (AlOx), and a layer of polyethylene (PE). Pursuant to an implementation, the aluminum oxide may be replaced with titanium oxide (TiOx).
  • Another example of a transparent laminate, as shown in FIG. 5 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), a layer of nylon and a layer of polyethylene (PE).
  • Another example of a transparent laminate, as shown in FIG. 6 , includes an outer layer of polyethylene terephthalate (PET), a layer of ethylene vinyl alcohol (EVOH), and a layer of polyethylene (PE).
  • In one aspect, the pouch may be opaque. Various laminate structures may be utilized for the opaque pouch.
  • One example, as shown in FIG. 7 , of opaque laminate material structure may include an outer layer of polyethylene terephthalate (PET), a layer of aluminum (Al), a layer of nylon and a layer of polyethylene (PE). Pursuant to an implementation, the layer of aluminum may be replaced with a layer of titanium oxide (TiOx). The titanium oxide provides a barrier to against oxygen permeability and is considered safe for consumption.
  • Another example, as shown in FIG. 8 , of opaque laminate material structure may include includes an outer layer of polyethylene terephthalate (PET), a layer of aluminum (Al), and a layer of polyethylene (PE). The layer of aluminum may be replaced with TiOx or SiOx.
  • In the above examples, the outer layer of PET may have a thickness ranging from 10-20 microns (μm). Additionally or alternatively, the layer of SiOx and/or the layer of TiOx may respectively have a thickness of 5-15 μm. Additionally or alternatively, the layer of nylon may have a thickness of 10-20 μm. Additionally or alternatively, the layer of EVOH may have a thickness of 5-25 μm. Additionally or alternatively, the layer of PE may have a thickness of 50-200 μm.
  • The above-described laminate material structures are well suited for packaging a beverage having an alcoholic content, such as wine or beer or another liquor, to add strength to the walls of the pouch, and to preserve the product. The pouch may be transparent, allowing the contents of the pouch to be viewed. The pouch may also be opaque when desired. The outer PET layer may be printed with any desired indicia. The AlOx, SiOx, and TiOx materials provide a transparent barrier layer that also ads strength. The Al and EVOH layers provide a vapor barrier preventing introduction of air and oxygen. Nylon protects the Al, SiOx, TiOx, or EVOH layer from cracking in a lager pouch application. The PE layer acts as a barrier between the middle barrier layer and the compartment, and provides organoleptic protection from the development of undesirable flavors.
  • Referring to FIGS. 9-24 , the pouch 10 is formed from at least one panel of laminate material, as described above. The panel has an inner surface that is adjacent the product, and an outer surface. The pouch 10 formed out of the panel has a front wall 12 and a back wall 14 defining a compartment A. The front and back walls 12, 14 may be formed out of a single panel or separate panels. Each wall 12, 14 is further defined by an upper edge 16, an opposed lower edge 18, and first and second side edges 20 extending therebetween the upper and lower edges 16, 18. The side edges 20 of the panel may form a sealed seam. The pouch 10 may include two side seams if made from two panels or from one panel. The seam may be a flat seam. In an example of a pouch 10 formed using two panels of material, the edges are joined along two side seams. The seal may be an ultrasonic seal or a heat weld or a combination of both or the like. A bottom gusset 26 may be positioned between the lower edges 18 of the pouch 10 and form a base, enabling the pouch 10 to stand upright unsupported.
  • In one aspect, the pouch 10 incorporates an opening structure 28 for accessing the contents of the pouch. Various types of opening structures 28 are known in the art for this purpose, and is non-limiting. The position of the opening structure is determinable by many factors, such as type of opening mechanism. The opening structure 28 may be positioned in an upper edge, a lower edge or side edge, or front wall or back wall, or on an insert or gusset. It should be appreciated that the opening structure 28 may be incorporated into the pouch 10 prior to filling the pouch 10. One example of an opening structure is a tear-off portion 30. The tear-off portion 30 usually has an integral tear notch 32. The tear notch 32 is typically formed near an outermost edge of a seam, for initiating the removal of the tear-off portion, such as a side edge 20. Another example of an opening structure 28 is a resealable zipper 34. Another example of an opening structure 28 is a weakened straw pierceable portion 36 in the pouch 10 for receiving a straw.
  • Still a further example of an opening structure 28 is a fitment such as a removable and replaceable cap 38 secured to a spout 40, or a tap, or the like. Various types of caps and spouts may be utilized. The spout is sealed into the upper edges of the panel using a sealing structure, such as an ultrasonic seal or a heat weld, or the like, as described below. The spout 40 may include a removable seal to prevent leakage of the product or evidence of tampering.
  • Pursuant to an implementation, the flexible pouch 10 includes a top seal 22 joining the front wall 12 and the back wall 14 together. The top seal 22 may comprise a double seal 24A, 24B to help prevent leakage of contents and oxygen or air from entering into the compartment containing the product. The double seal 24A, 24B may be provided along the top of the pouch 10 (e.g., along the top edge 16), above the opening mechanism 28 (e.g., above the tear line, zipper, etc.), to seal the front and back walls 12, 14 together after filling the pouch with the liquid product. The double seal 24A, 24B may extend continuously from first edge seam 20 to second side edge seam 20, and seals the first and second walls 12, 14 together. The double seal 24A, 24B may include a first seal 24A at the top edge 16, and a second seal 24B in a region of the first seal 24A (e.g., the second seal 24B is adjacent to the first seal 24A). The first seal 24A and the second seal 24B may extend generally parallel to one another. Additionally or alternatively, the first seal 24A and the second seal 24B are arranged adjacent to one another. Additionally or alternatively, the first seal 24A and the second seal 24B at least partially overlap (e.g., overlap in at least one region) and/or abut one another. Alternatively, the first seal 23A and the second seal 24B are arranged separate from one another (e.g., a gap is present (interposed) between the first seal 24A and the second seal 24B). The double seal structure along the top edge helps prevent the ingress of oxygen/air during the filling process to maintain a structurally sound, air-tight seal for extended shelf-life, as discussed below.
  • Pursuant to an implementation, the double seal 24A, 24B may comprise two heat seals. Pursuant to another implementation, the double seal 24A, 24B may comprise an ultrasonic seal and a heat seal. In this case, the ultrasonic seal may form the first seal 24B and the heat seal may form the second seal 24A. It should be appreciated that ultrasonic welding as the inner seal 24B is preferred to heat sealing, as ultrasonic welding is more effective through liquids.
  • It should be appreciated that the flexible pouch 10 may advantageously include other features that are known in the art.
  • The pouch 10 may include a feature such as an ergonomic shape. Thus, the width across the pouch is less in the middle, than at the upper edge or lower edge. That is, one or both of the side edges 20 may form an arc or curve, which facilitates controlling the volume of the compartment. The overall hourglass shape assumed by the pouch 10 due to the internal pressure within the pouch 10 facilitates holding of the pouch in the hand of a user.
  • It is contemplated that the flexible pouch 10 may incorporate any of the above-described features in any combination. In addition, the finished pouch may assume various shapes as influenced by the type of product and intended usage of the pouch.
  • Referring to FIGS. 9-12 , there is shown an embodiment of a flexible pouch 10 that includes a transparent laminate material. The pouch includes a bottom gusset 26, zipper opening 34 and a tear notch 32. A top seal 22 in the form of a double seal 24A, 24B is provided along the top edge 16, above the tear notch 32 (e.g., the tear notch 32 is disposed between the top seal 22 and the zipper 34. In one aspect, the pouch 10 may include a straw 33 attached thereon, as shown in FIG. 11 . After the tear notch 32 is removed, the zipper 34 may be opened and tightened around the straw 33 as shown in FIG. 12 .
  • Referring to FIGS. 13 and 14 , there is shown an embodiment of a flexible pouch 10 that includes a transparent laminate material (e.g., forming the panel of the front wall 12) and an opaque laminate material (e.g., forming the panel of the back wall 14). The pouch includes a bottom gusset 26, zipper opening 34 and a tear notch 32 with top seal 22 (including double seal 24A, 24B) disposed along top edge 16 above tear notch 32 (e.g., tear notch 32 is between zipper 34 and top seal 22).
  • FIG. 15 shows a cross-sectional view of a flexible pouch 10 according to FIGS. 9-14 . The flexible pouch 10 includes an opening structure 28 comprising a tear notch 32 disposed at an upper end of the seam/seal formed along the side edges 20 and a resealable zipper 34 providing access (fluid communication) to the compartment A. A top seal 22 is formed along the top edge 16 to join the film of the front wall 12 with that of the back wall 14, wherein the top seal 22 includes a double seal 24A, 24B disposed above the tear notches 32 (e.g., the tear notches 32 are disposed between the second seal 24B and the zipper 34). The example illustrated in FIG. 15 shows a gap running between first and second seals 24A, 24B. It will be appreciated that that the first and second seals 24A, 24B may at least partially overlap one another and/or abut one another without a gap therebetween, at least in one region. A bottom gusset 26 is disposed at the bottom edge 18. Although FIG. 15 shows the side edges 20 as straight, it will be appreciated that the side edges 20 may be curved (e.g., inwardly curved or concave) to provide an ergonomic profile.
  • Referring to FIG. 16 , there is shown an embodiment of a flexible pouch 10 that includes an opaque laminate material. The pouch includes an ergonomic shape with curved side walls 20. Various fitments or tear notches may be utilized. Additionally, a transparent laminate with an ergonomic shape may be utilized. Moreover, a top seal may be provided along the top edge 16, sealing the top of the pouch 10 between side edges 20. The bottom 18 may be provided with a bottom gusset 26, as shown and described with reference to FIG. 14 .
  • Referring to FIGS. 17-20 , there is shown an embodiment of a flexible pouch 10 that includes a bottom gusset 26, and a spout 40. The spout 40 is adapted to receive a cap 38. FIGS. 17 and 18 illustrate the flexible pouch 10 formed from a transparent laminate material.
  • Referring to FIG. 19 , there is shown an embodiment of a flexible pouch 10 that includes an opaque laminate material. The pouch 10 includes a bottom gusset 26 (cf. FIG. 18 ), and a spout 40 with a double seal 24A, 24B along the top edge 16. The spout 40 is adapted to receive a cap 28 (cf. FIG. 20 ). It should be realized that a transparent laminate material may also be utilized.
  • In FIGS. 17-20 , the spout 40 is sealed together with the front and back walls 12, 14 via the top seal 22 in the form of a double seal 24A, 24B. For example, as shown more clearly in FIGS. 19 and 20 , a first seal 24A may be formed by heat sealing or ultrasonic sealing the spout 40 to the front and back walls 12, 14. A second peripheral seal 24B may be formed by heat sealing along the top edge 16. FIG. 20 shows an example of one side edge 20 being curved and the other side edge 20 extending straight, although it will be appreciated that both side edges may be straight or curved.
  • Referring to FIGS. 21 and 22 , there is shown an embodiment of a flexible pouch 10 that includes an opaque laminate material. The pouch includes a bottom gusset 26, and a piercable straw aperture 36. It should be realized that a transparent laminate material may also be utilized. Although not shown, a top seal may be provided along the top edge 16, extending laterally between side edges 20.
  • Referring to FIG. 23 , there is shown an embodiment of a flexible pouch 10 that includes a transparent laminate material. The pouch 10 includes a single laminate sheet without a bottom gusset, and includes zipper opening 34 and a tear notch 32. It will be appreciated that top seal 22 may be disposed along the top edge 16, as discussed above.
  • Referring to FIG. 24 , there is shown an embodiment of a flexible pouch 10 that includes a transparent laminate material. The pouch includes a bottom gusset 26, and a spout 40. The spout is adapted to receive a cap. A hole may be included in a corner of the pouch 10. A top seal may be provided, as discussed with reference to FIGS. 17-20 .
  • Referring to FIG. 25 , a flowchart of an exemplary method 200 for making a flexible pouch is shown. Although the steps associated with the blocks of FIG. 25 will be described as being separate tasks, in other embodiments, the blocks may be combined or omitted. Further, in other embodiments, the steps may be performed in a different order.
  • At step 205, the method 200 may include laminating a plurality of layers together including an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE) to form a pouch panel. The middle barrier layer may be chosen from SiOx, TiOx, and AlOx. The middle barrier layer is configured to prevent permeability of oxygen and air into the sealed compartment. Further layers, such as nylon and ethylene vinyl alcohol (EVOH), may also be provided. The pouch panel may be transparent or opaque. Further, the step 205 may be repeated if a second pouch panel is to be used to form the flexible pouch 10.
  • At step 210, a pouch body is formed from the pouch panel (or two pouch panels) wherein the pouch panel(s) is sealed together to form the pouch body including front and back walls defining a compartment and having a pair of opposite side seal/seam edges 20 and a bottom (e.g., including bottom gusset 26) with an open top. An opening structure 28 (e.g., resealable zipper 34, piercable straw hole 36, tear strip 32, fitment/spout 40) may be incorporated at or near the open top.
  • At step 215, the compartment of the pouch body is filled with product (e.g., an alcoholic beverage). This may be performed in an inert atmosphere and/or with gas purge.
  • At step 220, the filled pouch body is sealed along the top edge 16 to form a top seal 22 closing the open top. As described above, the top seal 22 may comprise a double seal 24A, 24B to help prevent leakage and ingress of oxygen. The double seal 24A, 24B is provided along the top of the pouch 10, above the opening mechanism 28 (e.g., above the tear line, zipper, etc.), to seal the front and back walls 12, 14 together.
  • The double seal may include heat sealing the open top at a first seal station (forming a first heat seal), and then forming a second heat seal in a region of or adjacent to the first heat seal. The second heat seal may be formed at a second seal station that repeats the heat sealing in a region of the first seal. The double seal ensures no leaking should some product have contaminated the inside of the seal area during the first heat sealing, which contamination may cause a weak seal that can leak in the area of the moisture. The second hot seal helps ensures the area is well and tightly sealed, thereby enhancing the structural integrity of the top seal.
  • Pursuant to another example, the double seal may include a first ultrasonic seal followed by a hot seal. More specifically, a first seal is formed along the open top using ultrasonic welding techniques to form the first seal. The ultrasonic first seal utilizes the principles of ultrasonic acoustic vibrations to generate heat at a molecular level inside the films themselves and this energy joins the two materials together. Ultrasonic weld tools (e.g., anvil or sonotrodes) focus the energy on the point at which the welding should take place and friction is generated in milliseconds and the process removes the moisture and makes a dry seal. Then, a second seal in the form of a hot seal is heat sealed along the top of the pouch. The hot/heat seal may be formed outside the first ultrasonic seal (e.g., so that the ultrasonic seal is disposed between the hot/heat seal and the contents). The second heat seal ensures that any remaining moisture is removed and helps prevent leakage.
  • When a fitment in the form of a spout 40 is used, the spout seal may be heated as the spout is positioned in the open top between the front and back walls 12, 14, and then a heated seal bar is provided to heat seal the spout fitment to the front and back walls to form a first heat seal 24A. A second heat seal 24B may then be formed in a region of the first heat seal to ensure that the area is well and tightly sealed. Under certain circumstances, the spout 40 may be incorporated into the pouch 10 in step 210 (e.g., prior to filling with product). Alternatively, the spout 40 may be incorporated into the pouch 10 after the filling step 215 (e.g., in step 220).
  • It will be appreciated that the seals used herein (e.g., top seal 22 including double seals 24A, 24B, side seals along side edges 20) are peripheral seals that form a permanent bond between layers of the pouch that is not intended to rupture. A peripheral seal is a fixed barrier and has a peel strength significantly greater than that of the frangible seal. As such the bond of the peripheral seal is solid between the different layers to form a barrier, or permanent seal between the layers. That is, the peel strength of the peripheral seal is limited only by the burst properties of the materials used to form the peripheral seal. In some embodiments described herein, the peel strength of the peripheral seal is in a range between 9.18 and 11.22 pounds per square inch of force to rupture the peripheral seal.
  • The provision of one or more pouch panels formed from a laminate material (e.g., film laminate) together with the double seal structure provides a flexible pouch 10 that retains its flavor, color, aroma, and taste over the shelf life of the product.
  • It will be appreciated that the double seal may include two seals adjacent to one another, optionally running in parallel. The two seals may at least partially overlap and/or abut.
  • Pursuant to an implementation, the first and second seals 24A, 24B may overlap and/or abut along an entire extend of the top seal 22 (e.g., from one side edge to the other side edge). Pursuant to another implementation, the two seals may be separate from one another (e.g., a gap may be present between the first and second seals), at least in one region or optionally along an entire extent of the top seal 22. Moreover, it will be appreciated that more than top seal may comprise more than two seals (e.g., formed from heat and/or ultrasonic welding) without departing from the scope of the disclosure.
  • As can be seen from the above descriptions, the pouch may have various shapes and sizes and include various opening structures. Any of the embodiments described above may include different opening structures or laminate materials other than a specifically described.
  • Although not shown, the pouch may include one or more frangible seals. For example, a frangible seal may be formed (e.g., ultrasonically welded) in the compartment.
  • It will be appreciated that although the flexible pouch is described with reference to an alcoholic beverage, it will be appreciated that other liquid beverages are contemplated herein.
  • It will further be appreciated that the top seal 22 may instead correspond to a bottom seal where the top is sealed by a peripheral seal and the bottom is open for filing, without departing from the scope of the disclosure.
  • The present invention has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, the present invention may be practiced other than as specifically described.
  • It should be understood that references to a single element are not necessarily so limited and may include one or more of such element. Further, all numbers expressing dimensions, ratios and the like, used in the specification and claims, are to be understood to encompass tolerances and other deviations as represented by the term “about” or “approximately.”
  • The use of “e.g.” in the specification is to be construed broadly and is used to provide non-limiting examples of embodiments of the disclosure, and the disclosure is not limited to such examples. Uses of “and” and “or” are to be construed broadly (e.g., to be treated as “and/or”). For example and without limitation, uses of “and” do not necessarily require all elements or features listed, and uses of “or” are inclusive unless such a construction would be illogical.
  • All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those knowledgeable in the technologies described herein unless an explicit indication to the contrary in made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary. Further, the use of “at least one of” is intended to be inclusive, analogous to the term and/or. As an example, the phrase “at least one of A, B and C” includes A only, B only, C only, or any combination thereof (e.g. AB, AC, BC or ABC). Additionally, use of adjectives such as first, second, etc. should be read to be interchangeable unless a claim recites an explicit limitation to the contrary.

Claims (20)

What is claimed is:
1. A flexible pouch for alcoholic beverages, comprising:
a front wall and a back wall defining a compartment;
an opening structure in fluid communication with the compartment;
at least one of the front wall and the back wall composed of a panel of a film laminate, the film laminate including an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE); and
wherein the front wall and the back wall are joined together by a top seal.
2. The flexible pouch of claim 1, wherein the top seal includes a double seal disposed along a top edge of the front wall and the back wall.
3. The flexible pouch of claim 2, wherein the double seal includes a first heat seal and a second heat seal.
4. The flexible pouch of claim 2, wherein the double seal includes a first ultrasonic seal and a second heat seal.
5. The flexible pouch of claim 1, wherein the middle barrier layer is a titanium oxide film.
6. The flexible pouch of claim 1, wherein the middle barrier layer is a silicon oxide film.
7. The flexible pouch of claim 1, wherein the film laminate further includes a layer of ethylene vinyl alcohol (EVOH) between the outer layer and the inner layer.
8. The flexible pouch of claim 1, wherein the film laminate further includes a layer of nylon between the outer layer and the inner layer.
9. The flexible pouch of claim 1, wherein the opening structure includes a tear notch, and wherein the tear notch is disposed between the top seal and the compartment.
10. The flexible pouch of claim 8, wherein the opening structure further includes a resealable zipper, the resealable zipper disposed between the tear notch and the compartment.
11. The flexible pouch of claim 1, wherein the opening structure is a fitment including a spout extending through the top seal.
12. The flexible pouch of claim 1, further comprising a bottom gusset disposed at a bottom edge of the first wall and the second wall.
13. A method of forming a flexible pouch for alcoholic beverages, comprising:
forming a pouch panel from a film laminate, the film laminate including an outer layer of polyethylene terephthalate (PET), a middle barrier layer, and an inner layer of polyethylene (PE);
forming a pouch body from the pouch panel, the pouch body including a first wall and a second wall defining a compartment with an open top;
filling the compartment with a product; and
sealing the open top with a top seal, the top seal joining the first wall and the second wall together.
14. The method of claim 13, wherein sealing the open top with the top seal includes forming a double seal along a top edge of the first wall and the second wall.
15. The method of claim 14, wherein forming the double seal includes heat sealing a first seal along the top edge and then heat sealing a second seal in a region of the first seal.
16. The method of claim 14, wherein forming the double seal includes ultrasonic welding a first seal along the top edge and then heat sealing a second seal in a region of the first seal.
17. The method of claim 13, wherein the middle barrier layer is a titanium oxide film.
18. The method of claim 13, wherein the middle barrier layer is a silicon oxide film.
19. The method of claim 13, wherein forming the pouch body includes providing an opening structure in fluid communication with the compartment.
20. The method of claim 19, wherein the opening structure includes at least one of a tear notch, a resealable zipper, and a weakened straw pierceable portion.
US18/376,033 2022-10-03 2023-10-03 Flexible pouch for an alcoholic beverage Pending US20240109704A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US18/376,033 US20240109704A1 (en) 2022-10-03 2023-10-03 Flexible pouch for an alcoholic beverage

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202263412722P 2022-10-03 2022-10-03
US18/376,033 US20240109704A1 (en) 2022-10-03 2023-10-03 Flexible pouch for an alcoholic beverage

Publications (1)

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US20240109704A1 true US20240109704A1 (en) 2024-04-04

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