WO2017079714A1

WO2017079714A1 - Packing material pockets

Info

Publication number: WO2017079714A1
Application number: PCT/US2016/060759
Authority: WO
Inventors: Avinash RAMESH; Garud Bindiganavale SRIDHAR; Rajesh Luharuka; Alberto PALAZZI
Original assignee: Schlumberger Technology Corporation; Schlumberger Canada Limited; Services Petroliers Schlumberger; Schlumberger Technology B.V.
Priority date: 2015-11-06
Filing date: 2016-11-07
Publication date: 2017-05-11
Also published as: AR106615A1

Abstract

A spreader of a packaging machine utilized for packing material or product into pockets. The spreader may spread apart two adjacent edges of thin flexible material as the thin flexible material is moved along the packaging machine to successively open the pockets formed from the thin flexible material to permit the product to be transferred into the pockets by the packaging machine. The spreader may include an opening to accommodate therethrough the product being transferred into the pockets by the packaging machine.

Description

PACKING MATERIAL POCKETS

Cross-Reference to Related Applications

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 62/252,129, entitled "SYSTEM TO PACK FIBERS INTO PACKETS," filed November 6, 2015, the entire disclosure of which is hereby incorporated herein by reference.

Background of the Disclosure

[0002] Fibers or fibrous material may be utilized in various industries as additives or ingredients to form fluids or mixtures. For example, in the oil and gas industry, fibrous material may be utilized to form various well treatment fluids. However, fibrous material typically has light specific gravity and low bulk density and, in its free or bulk state, may be difficult to handle or transport. Accordingly, fibrous material may be dispensed into a packaging machine and packaged into individual pouches or pockets. Once packaged, the fibrous material pockets may be easier to handle and transport.

[0003] Packaging machines, such as horizontal form-fill-seal (HFFS) machines, are well known in the packaging industry to package conventional solids and liquids that can be fed by gravity. However, packaging fibrous material into small pockets is challenging at least partially because of its light specific gravity and low bulk density.

Summary of the Disclosure

[0004] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify

indispensable features of the claimed subject matter, nor is it intended for use as an aid in limiting the scope of the claimed subject matter.

[0005] The present disclosure introduces a packaging machine operable to fill a flexible pocket with material. The packaging machine includes a source of the material, a fill tube to convey the material from the source, and a spreader connected with the fill tube and that opens the flexible pocket. The spreader includes an opening extending through the spreader to convey the material into the pocket. The spreader also includes a pathway extending through the spreader to evacuate gas out of the pocket as the material is conveyed into the pocket through the opening.

[0006] The present disclosure also introduces a spreader of a packaging machine, the spreader able to spread apart two adjacent edges of thin flexible material as the thin flexible material is moved along the packaging machine to successively open pockets formed from the thin flexible material, thus permitting a product to be transferred into the pockets by the packaging machine. The spreader includes an opening to accommodate therethrough the product being transferred into the pockets by the packaging machine.

[0007] The present disclosure also introduces a method that includes unwinding long thin flexible material from a roll, and folding the flexible material substantially in half in a longitudinal direction such that opposing edges of the flexible material are adjacent each other. The folded flexible material is sealed together at spaced intervals to form pockets. The folded flexible material is moved horizontally along a spreader located between the adjacent edges of the folded flexible material to spread apart the adjacent edges of the folded flexible material. Product is transferred into the pockets through a space between the spread apart edges of the folded flexible material.

[0008] These and additional aspects of the present disclosure are set forth in the description that follows, and/or may be learned by a person having ordinary skill in the art by reading the materials herein and/or practicing the principles described herein. At least some aspects of the present disclosure may be achieved via means recited in the attached claims.

Brief Description of the Drawings

[0009] The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

[0010] FIG. 1 is a schematic view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure.

[0011] FIG. 2 is a schematic view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure.

[0012] FIG. 3 is a schematic view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure. [0013] FIG. 4 is a perspective view of at least a portion of an example implementation of apparatus according to one or more aspects of the present disclosure.

[0014] FIG. 5 is a top view of the apparatus shown in FIG. 4 according to one or more aspects of the present disclosure.

[0015] FIGS. 6-9 are top views of example implementations of the apparatus shown in FIG. 5 according to one or more aspects of the present disclosure.

[0016] FIGS. 10-12 are enlarged views of a portion of example implementations of the apparatus shown in FIG. 5 according to one or more aspects of the present disclosure.

Detailed Description

[0017] It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments.

Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for simplicity and clarity, and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact.

[0018] FIG. 1 is a schematic view of at least a portion of a horizontal form-fill-seal (HFFS) machine 100 showing an example packaging machine comprising or utilized in conjunction with a filling device 102 according to one or more aspects of the present disclosure. The HFFS machine 100 may be operable to construct or form pouches, bags, packets, or pockets from a continuous sheet or web of thin flexible material, such as thermoplastic film, wound on a roll, while simultaneously filling or packing the pockets with bulk material or product and sealing the filled pockets as the pockets move through various stations or portions of the HFFS machine 100. The pockets may be filled with bulk material or product, including solids, liquids, and gels. The roll of flexible material may include labeling and artwork applied to the exterior or interior of the material. Although thermoplastic film is the most commonly used packaging material, HFFS machines may also be utilized to form continuous metalized foil/film, paper, and fabric pockets or other containers by changing edge sealing/seaming methods.

[0019] The HFFS machine 100 may include a roll 104 of thin and flexible thermoplastic material or film 106, which may be unwound and folded longitudinally substantially in half at a forming station 108 to provide a double layered web of film 106 with a fold 110 at the bottom and two adjacent edges 112 at the top of the film 106. The film 106 may be guided by a plurality of rollers 114 to a first sealing station 1 16 operable to fuse or seal the film 106 to form contiguous compartments, bags, pouches, packets, or pockets 120 along the web of film 106. The film 106 may be moved between bottom sealing elements 122 (one of the sealing elements is obstructed from view) of the first sealing station 1 16, such as may engage and continuously fuse or seal the two layers of film 106 together along the fold 1 10 to form a bottom seal 124. As the two layers are already bound together at the fold 110, the bottom sealing elements 122 may be omitted from the FIFFS machine 100.

[0020] The film 106 may then be moved and momentarily stopped (i.e., indexed) to permit side sealing elements 126 to engage and fuse or seal the two layers of film 106 together along the vertical to form side seals 128 of the contiguous pockets 120 formed along the film 106. The sealing elements 126 may fuse or seal the two layers of film 106 from the fold 110 or the bottom seal 124 upwardly a distance that is less than full height of the two layers of film 106. For example, the sealing elements 126 may fuse or seal the two layers of film 106 most or majority of the distance from the fold 110 or bottom seal 124 to the upper edges 112 of the two layers of film 106. The area of the film 106 located above the side seals 128 may be referred to hereinafter as an upper sealing area 130. The sealing elements 126 may be movably mounted to the FIFFS machine 100 to permit the sealing elements 126 to move horizontally, as indicated by arrows 127, to selectively engage and fuse or seal the two layers of film 106 together. Although not shown for clarity and ease of understanding, the sealing elements 126 may be operatively connected with linear actuators, such as magnetic or pneumatic linear actuators, to facilitate horizontal movement of the sealing elements 126.

[0021] The film 106 may then be moved to and momentarily stopped at a filling station 132 wherein each successive pocket 120 is opened and filled with a predetermined bulk material or product via the filling device 102. The filling device 102 may comprise a source 134 of the bulk material, such as a hopper, a chute, a container, or another device operable to receive and/or temporarily store the bulk material prior to being transferred or packed into the pockets 120. A fill tube 136 may extend from the source 134 and transfer the bulk material towards and/or into the pockets 120. The fill tube 136 may terminate with a film spreader 138, such as may be operable to spread the two layers of film 106 and, thus, open the pockets 120 as the contiguous pockets 120 are moved along the HFFS machine 100, such as may permit the pockets 120 to be filled with the bulk material. The spreader 138 may be at least partially disposed between the two layers of film 106 along the upper sealing area 130. The spreader 138 may be disposed between the upper edges 1 12 of the film 106 above the side seals 128 such that the spreader 138 may not contact or split the side seals 128 previously formed by the sealing members 126.

During filling operations, as the pockets 120 are indexed or moved through the filling station 132, the spreader 138 may separate or spread apart the upper edges 112 of the film 106 to successively open each pocket 120 and permit the bulk material to be transferred or packed into each pocket 120 from the source 134 via the fill tube 136.

[0022] As the contiguous pockets 120 are indexed and filled with the bulk material, outer profile or surfaces of the spreader 138 may press against or otherwise contact inner surface of each layer of film 106 along the sealing area 130 to form a seal or otherwise prevent or reduce the amount of the bulk material escaping from the pocket 120 between the spreader 138 and the film 106. The spreader 138 may comprise one or more air or gas pathways 140 extending through the spreader 138, such as may permit air or other gasses displaced by the bulk material to be evacuated from the pockets 120 during the filling operations. As the displaced air may be evacuated through the pathways 140, the amount of air and, thus, bulk material being ejected out of the pocket 120 between the spreader 138 and the film 106 may also be reduced.

[0023] The quantity of bulk material that is transferred to each pocket 120 may be regulated by a material transfer device (not shown) operable to introduce a predetermined quantity of the bulk material into the source 134 or fill tube 136 to be transferred into each pocket 120. In an example implementation, the bulk material may be measured or controlled by a flow rate control valve, such as a knife gate valve, a butterfly valve, a globe valve, among other examples. The bulk material may also be measured by a feeder device, such as a metering feeder, a screw feeder, an auger, and/or conveyor, among other examples. The material transfer device may also comprise a weight or mass sensor, such as may generate a signal of information indicative of weight or mass of the bulk material transferred into the source 134, the fill tube 136, or otherwise allocated to be transferred into the pockets 120. [0024] When a predetermined quantity of the bulk material is transferred into the pocket 120, the film 106 may be moved further along the HFFS machine 100 until the filled pocket 120 arrives at the second sealing station 142. The second sealing station may include upper sealing elements 144 operable to engage and fuse or seal the two layers of film 106 along the upper sealing area 130 to form an upper seal 146. The upper seal 146 may extend horizontally between the side seals 128 and vertically between the upper edges 1 12 and the side seals 128 to seal the bulk material within the pockets 120. The sealing elements 144 may be movably mounted to the HFFS machine 100 to permit the sealing elements 144 to move horizontally, as indicated by arrows 145, to selectively engage and fuse or seal the layers of film 106 together. Similarly to the sealing elements 126, the sealing elements 144 may be operatively connected with linear actuators (not shown), such as magnetic or pneumatic linear actuators, to facilitate horizontal movement of the sealing elements 144.

[0025] The sealing and/or air evacuation operations provided by the spreader 138 may prevent or reduce the amount of the airborne bulk material accumulating on the inner surface of each layer of film 106 along and/or above the spreader 138 during filling operations. As the spreader 138 may be disposed along or against the inner surfaces of the two layers of film 106 along the upper sealing area 130, the spreader 138 may prevent or reduce the amount of bulk material being carried by the escaping air and settling along the sealing area 130. A clean or contaminant-free upper sealing area 130 may permit or facilitate formation of a proper upper seal 146 to retain the bulk material within the pockets 120. For example, bulk material particles located between the two layers of film 106 within the sealing area 130 may impede formation of the upper seal 146, such as by preventing fusion of the two layers of film 106 and/or by forming pathways through which air and, thus, bulk material can escape. The bulk material within the upper seal 146 may also weaken the upper seal 146, which may cause the upper seal 146 to separate or otherwise fail, permitting the pocket 120 to open and expel the bulk material.

[0026] The sealing elements 122, 126, 144 described above may be operable to transfer energy to the film 106 to fuse or seal both layers of film 106, as described above. When operated, each sealing element 122, 126, 144 may transfer energy to one or both layers of film 106 to heat one or both layers of film 106, such as may cause the layers of film 106 to fuse or seal when pressed together. For example, heat may be generated or transferred to one or both of the layers of film 106 in the form of light (e.g., laser), electric current, or ultrasonic or radio- frequency waves. Heat may also be conducted from the sealing elements 122, 126, 144 to one or both layers of film 106.

[0027] Once the contiguous filled pockets 120 are sealed, the contiguous pockets 120 may be moved to and momentarily stopped at a cutting station 148 wherein each successive pocket 120 is cut or otherwise separated from an adjacent pocket 120. The cutting station 148 may comprise opposing cutting elements 150 or other cutting means operable to vertically cut or separate the filled pockets 120 along the side seals 128. The cutting elements 150 may be movably mounted to the HFFS machine 100 to permit the cutting elements 150 to move horizontally, as indicated by arrows 151, to selectively engage and separate the filled pockets 120. Similarly to the sealing elements 126, 144, the cutting elements 150 may be operatively connected with linear actuators (not shown), such as magnetic or pneumatic linear actuators, to facilitate horizontal movement of the cutting elements 150. The separated pockets 120 may be dropped into a container (not shown), onto a conveyor (not shown), or another storage and/or transport means and moved to a packaging and shipping area.

[0028] Although FIG. 1 shows the filling device 102 implemented as a portion of or utilized in conjunction with the HFFS machine 100, it is to be understood that one or more portions of the filling device 102 within the scope of the present disclosure may be implemented as a portion of or utilized in conjunction with other packaging machines, including vertical form-fill-seal (VFFS) machines and rotary drum packaging machines, among other examples.

[0029] The bulk material or product, such as may be utilized within the scope of the present disclosure, may include fibers or fibrous material. Fibrous material typically has a light specific gravity and low bulk density and, in its free state, may be difficult to move or otherwise handle. Accordingly, fibrous material may be dispensed into the HFFS machine 100 or another packaging machine within the scope of the present disclosure and packaged into individual bags, pouches, packets, or pockets, such as pockets 120. Once packaged, the fibrous material pockets 120 may be easier to handle and/or transport.

[0030] Examples of fibrous material within the scope of the present disclosure may include fiberglass, phenol formaldehydes, polyesters, polylactic acid, cedar bark, shredded cane stalks, mineral fiber, and hair, among other examples. Fibrous material within the scope of the present disclosure may be utilized as an additive or an ingredient of a hydrocarbon well treatment fluid or mixture. Thus, once the fibrous material is packaged into the pockets 120, the fibrous material may be transported to a hydrocarbon wellsite to be mixed with liquids and other solids to form the well treatment fluid. Once at the wellsite, the fibrous material may be transferred into a mixer or blender via a material handler or mover, such as via a conveyer, a transfer belt, a bucket elevator, or a feeding screw to be combined with fluids and other solids to form the well treatment fluid. The fluids forming the well treatment fluid may include aqueous fluids, including fresh water, brine, mud, or another liquids comprising water. To help break apart the pockets 120 of fibrous material or otherwise release the fibrous material from the pockets 120, the film 106 forming the pockets 120 may be or comprise a water-soluble film. Accordingly, once the water-soluble pockets 120 are introduced into the mixer containing an aqueous fluid, the pockets 120 will dissolve or otherwise break down to free the fibrous material, permitting the fibrous material to mix with the other ingredients. Once the well treatment fluid is formed, the fluid may be conveyed to one or more pumps at an oilfield or wellbore surface and injected into a wellbore penetrating a subterranean formation during an oilfield or wellbore treatment operation, such as drilling, cementing, hydraulic fracturing, acidizing, chemical injecting, coiled tubing operations, and/or water jet cutting operations, among other examples.

[0031] The apparatus within the scope of the present disclosure may also be utilized to handle and package other bulk materials, such as powders and other particulate materials. The particulate materials may include other additives or ingredients of well treatment fluids, such as friction reducers, accelerators, retarders, fluid-loss additives, dispersants, extenders, weighting agents, lost circulation additives, among other examples.

[0032] FIG. 2 is an enlarged schematic view of a portion of an example implementation of the HFFS machine 100 shown in FIG. 1 according to one or more aspects of the present disclosure and designated in FIG. 2 by numeral 200. The HFFS machine 200 is substantially similar in structure and operation to the HFFS machine 100 depicted in FIG. 1, including where indicated by like reference numbers, except as described below. The following description refers to FIGS. 1 and 2, collectively.

[0033] The HFFS machine 200 may comprise a filling device 202 operable to open and fill the contiguous pockets 120 with the bulk material during packaging operations. The filling device 202 may comprise a source 204 of the bulk material, such as a container, operable to receive and/or temporarily store the bulk material prior to being transferred or packed into the pockets 120. A fill tube 206 may extend from the source 204 and transfer the bulk material towards and/or into the pockets 120. The fill tube 206 may terminate with a film spreader 208 comprising an opening 210 aligned with the fill tube 206. The spreader 208 may be at least partially disposed between the two layers of film 106 along the upper sealing area 130 of the film 106, such as may permit the spreader 208 to separate or spread apart the two layers of film 106 along the sealing area 130 and, thus, successively open each pocket 120 as the film 106 containing the contiguous pockets 120 is moved along the spreader 208. The spreader 208 may be disposed between the upper edges 112 of the film 106 above the side seals 128 such that the spreader 208 may not contact or split the side seals 128 previously formed by the sealing members 126. The spreader 208 may be disposed between the two layers of film below the upper edges 112 of the film 106, however, the spreader 208 may also extend above the upper edges 112 of the film 106. During filling operations, as the film 106 containing the pockets 120 is moved and momentarily stopped when the spreader 208 and one of the pockets 120 are aligned, the spreader 208 may separate or spread apart the adjacent upper edges 112 of the film 106 to open the pocket 120 and permit the bulk material to be transferred into the pocket 120 from the source 204 via the fill tube 206 and opening 210. For clarity and ease of understanding, the film 106 is depicted in FIG. 2 using phantom lines to avoid visually obstructing portions of the filling device 202, including the spreader 208. FIG. 2 also depicts an outline of the source 204 to avoid visually obstructing other portions of the filling device 202, including the spreader 208.

[0034] The source 204 may comprise an opening 216 operable to receive therethrough a predetermined quantity of the bulk material. A chute or funnel 218 may be included at the opening 216, such as may help direct the bulk material into the source 204 through the opening 216. As described above, the quantity of bulk material that is intended to be transferred into each pocket 120 may be regulated by a material transfer device (not shown) operable to introduce the predetermined quantity of the bulk material into the source 204 through the opening 216. The filling device 202 may be operable to transfer the predetermined quantity of bulk material from the source 204 into the pockets 120 and/or compress the bulk material prior to and/or while the bulk material is being transferred into the pockets 120. For example, the filling device 202 may further comprise a plunger 212 operable to move horizontally along the source 204, as indicated by arrows 213, to move the bulk material toward the fill tube 206 and compress or pack the bulk material remaining in the source 204. The filling device 202 may further comprise a plunger 214 operable to move vertically into and along a wall of the source 204, as indicated by arrows 215, to move the compressed bulk material remaining within the source 204 through the fill tube 206 and into the pocket 120. The plunger 214 may move through the fill tube 206, the opening 210, and into the pocket 120 to compress or pack the bulk material within the pocket 120. The profile or geometry of the plunger 214 may be similar to, but slightly smaller than, the profile or geometry of the fill tube 206 and/or the opening 210, such as to optimize the area of contact between the plunger 214 and the bulk material. The plungers 212, 214 may be operatively connected with linear actuators (not shown), such as magnetic or pneumatic linear actuators, to facilitate the intended movement of the plungers 212, 214.

Compressing the bulk material may compact or reduce the volume of the bulk material, such as may permit more bulk material to be transferred into the pocket 120. The compression operations described above may be performed in multiple stages, during which a portion (e.g., half) of the total bulk material allocated for transfer into the pocket 120 may be transferred into and compressed within the pocket 120 at a time.

[0035] As each successive pocket 120 is filled with the bulk material, outer profile or opposing side or outer surfaces 220 of the spreader 208 may press against or otherwise contact inner surface of each layer of film 106 along the sealing area 130 to form a seal or otherwise prevent or reduce the amount of the bulk material escaping from the pocket 120 between the surfaces 220 and the inner surfaces of each layer of film 106. The spreader 208 may comprise one or more air or gas pathways 222 extending vertically through the spreader 208, such as may permit air or other gasses displaced by the bulk material to be evacuated from the pockets 120 as the bulk material is being transferred into the pockets 120. As the displaced air may be evacuated through the pathways 222, the amount of air and, thus, bulk material being ejected upwardly out of the pocket 120 between the surfaces 220 of the spreader 208 and the inner surfaces of each layer of film 106 may also be reduced. Such sealing and/or evacuation operations provided by the spreader 208 may prevent or reduce the amount of the airborne bulk material moving upwardly along and/or above the spreader 208 and accumulating on the sealing area 130 of the inner surface of each layer of film 106 during filling operations. As described above, a clean upper sealing area 130 may permit formation of the upper seal 146 to retain the bulk material within the pockets 120.

[0036] FIG. 3 is an enlarged schematic view of a portion of an example implementation of the HFFS machine 100, 200 shown in FIGS. 1 and 2 according to one or more aspects of the present disclosure and designated in FIG. 3 by numeral 300. The HFFS machine 300 is substantially similar in structure and operation to the HFFS machine 100, 200, including where indicated by like reference numbers, except as described below. The following description refers to FIGS. 1, 2, and 3, collectively.

[0037] The HFFS machine 300 may comprise a filling device 302 operable to open and fill the contiguous pockets 120 with the bulk material. The filling device 302 may comprise a source 304 of the bulk material, such as a material chute, operable to receive and direct the bulk material into a fill tube 306, which may transfer the bulk material towards and/or into the pockets 120. The fill tube 306 may terminate with a film spreader 208 comprising an opening 210 aligned with the fill tube 306. As described above, the spreader 208 may be at least partially disposed between the two layers of film 106 along the upper sealing area 130 of the film 106, such as may permit the spreader 208 to separate or spread apart the two adjacent edges 112 of the film 106 along the sealing area 130 and, thus, successively open each pocket 120 as the film 106 containing the contiguous pockets 120 is moved along the spreader 208. Similarly as in FIG. 2, the film 106 is depicted in FIG. 3 using phantom lines to avoid visually obstructing portions of the filling device 302, including the spreader 208. FIG. 3 also depicts an outline of the source 304 to avoid visually obstructing other portions of the filling device 302.

[0038] The source 304 may comprise an opening 308 operable to receive therethrough a predetermined quantity of the bulk material. As described above, the quantity of the bulk material that is intended to transferred into each pocket 120 may be regulated by a material transfer device (not shown) operable to introduce the predetermined quantity of the bulk material into the source 304 via the opening 308. The filling device 302 may be operable to push the bulk material through the fill tube 306 into the pockets 120 and/or compress the bulk material transferred into the pockets 120. For example, the filling device 302 may further comprise a plunger 310 operable to move vertically, as indicated by arrows 311, to move the bulk material within the fill tube 306 into the pocket 120. The plunger 214 may be operable to move through the fill tube 306, the opening 210, and into the pocket 120 to compress the bulk material within the pocket 120. The profile or geometry of the plunger 310 may be similar to, but slightly smaller than, the profile or geometry of the fill tube 306 and/or the opening 210, such as to optimize the area of contact between the plunger 310 and the bulk material. The plunger 310 may be operatively connected with a linear actuator (not shown), such as a magnetic or pneumatic linear actuator, to facilitate the intended movement of the plunger 310. As described above, compressing the bulk material may compact or reduce the volume of the bulk material, such as may permit more bulk material to be transferred into the pocket 120. [0039] As each successive pocket 120 is filled with the bulk material, outer profile or surfaces 220 of the spreader 208 may press against or otherwise contact inner surface of each layer of film 106 along the sealing area 130 to form a seal or otherwise prevent or reduce the amount of the bulk material escaping from the pocket 120 upwardly between the surfaces 220 and the inner surfaces of each layer of film 106. The spreader 208 may comprise one or more air or gas pathways 222 extending vertically through the spreader 208, such as may permit air or other gasses displaced by the bulk material to be evacuated from the pockets 120 as the bulk material is being transferred into the pockets 120.

[0040] FIGS. 4 and 5 are perspective and top views of an example implementation of the spreader 208 shown in FIGS. 2 and 3 according to one or more aspects of the present disclosure. The following description refers to FIGS. 1-5, collectively.

[0041] The spreader 208 may be formed from or otherwise comprise stainless steel, nylon, Teflon, Delrin, and/or other materials having a low coefficient of friction. The outer surfaces 220 of the spreader 208 may be smooth or comprise channels, protrusions, or ribs 410 extending longitudinally along the opposing side surfaces 220 of the spreader 208 to help the spreader 208 to seal against the film 106 and/or prevent the movement of the bulk material perpendicularly with respect to the ribs 410 between the opposing side surfaces 220 and the foil 106. The outer surfaces 220 and/or edges 221 of the spreader 208 may be rounded, such as to increase surface area of contact with the foil 106, help seal against the foil 106, and/or to prevent the spreader 208 from cutting into or otherwise damaging the foil 106.

[0042] The air or gas pathways 222 may be or comprise apertures or bores extending vertically through the spreader between upper and lower surfaces of the spreader 208. The pathways 222 may be located on opposing sides of the opening 210. The pathways 222 may permit air or other gasses displaced by the bulk material to be evacuated from the pockets 120 as the bulk material is being transferred into the pockets 120, while retaining the bulk material within the pocket 120. For example, the pathways 222 may be small enough to prevent or reduce the amount of bulk material escaping out of the pocket 120 through the pathways 222. The pathways 222 may comprise a geometry, such as a curved geometry, that may prevent or reduce the amount of material escaping out of the pocket 120 through the pathways 222.

[0043] The spreader 208 may comprise a substantially elongated geometry having a length 402 that is substantially longer than width 404 of the spreader 208. Outer profile 209 of the spreader 208 may be generally saucer shaped or elliptical shaped, such as may permit the spreader 208 to separate or spread the upper edges 1 12 of the film 106 while maintaining a seal against the film 106. Each opposing longitudinal end of the spreader 208 may comprise a generally wedge shaped geometry and/or a V-shaped profile. The opening 210 of the spreader 208 may also comprise a substantially elongated profile, such as an elliptical profile. Each opposing longitudinal end of the opening 210 may be flat or truncated, such as may permit formation of the pathways 222. The profile of the opening 210 may be similar to the outer profile 209 of the spreader 208, such as may optimize the size or area of the opening 210.

[0044] The geometry of the spreader 208, including the length 402, width 404, and height 406 may depend on dimensions of the pockets 120 and/or the foil 106. For example, the length 402 of the spreader 208 may be substantially similar to length 121 of the pockets 120. The width 404 may be such that the spreader 208 contacts (and perhaps stretches) the film 106 to form a seal between the outer surfaces 220 of the spreader 208 and the inner surfaces of the film 106 without permanently deforming or damaging the film 106. The width 404 of the spreader 208 may be such that the spreader 208 opens up the pockets 120 enough or to a degree sufficient to permit the bulk material to be transferred into the pockets 120. The height 406 of the spreader 208 may be such that the side surfaces fit between the upper edges 112 of the film 106 and the upper ends of the side seals 128. However, as described above, the height 406 may be longer, such that a portion of the outer surfaces 220 of the spreader 208 extends above the upper edges 112 of the film 106. In an example implementation, the height 406 of the spreader 208 may range between about .79 millimeter (1/32 inch) and about 12.7 millimeters (1/2 inch). However, for large pockets 120, the height of the spreader can exceed 12.7 millimeters.

[0045] FIGS. 6-9 are top views of example implementations of the spreader 208 shown in FIG. 5 according to one or more aspects of the present disclosure and designated in FIGS. 6-9 by numerals 412, 414, 416, 418, respectively. The following description refers to FIGS. 5-9, collectively.

[0046] The spreader 412 is shown comprising an elongated elliptical shaped outer profile 420. The spreader 414 is shown comprising an opening 422 having an elongated rectangular profile. The spreader 416 is shown comprising an opening 424 having an elongated elliptical shaped profile that is not flat or truncated at opposing ends. The spreader 418 is shown comprising an opening 426 having a substantially circular profile.

[0047] FIGS. 10-12 are enlarged views of a portion of example implementations of the spreader 208 shown in FIG. 5 according to one or more aspects of the present disclosure and designated in FIGS. 10-12 by numerals 430, 432, 434, respectively. The following description refers to FIGS. 5 and 10-12, collectively.

[0048] The air or gas pathways 222 of the spreader 208 may be implemented in various ways other than a single aperture or bore extending through the spreader 208. The pathways 222 may be implemented as filters or filter elements, such as may be operable to permit air or other gasses to be evacuated from the pockets 120 while retaining the bulk material within the pockets 120. For example, the pathways 222 may be implemented as a plurality of holes or bores 436 extending through the spreader 430 on opposing sides of the opening 210. The pathways 222 may be implemented as an air or gas permeable material 438 disposed within an aperture or bore 440 extending through the spreader 432 on opposing sides of the opening 210. The pathways 222 may also be implemented as a fine mesh 442 disposed within or extending across an aperture or bore 444 extending through the spreader 434 on opposing sides of the opening 210.

[0049] In view of the entirety of the present disclosure, including the figures and the claims, a person having ordinary skill in the art will readily recognize that the present disclosure introduces an apparatus comprising a packaging machine operable to fill a flexible pocket with material, wherein the packaging machine comprises: (A) a source of the material; (B) a fill tube operable to convey the material from the source; and (C) a spreader connected with the fill tube and operable to open the flexible pocket, wherein the spreader comprises: (i) an opening extending through the spreader and operable to convey the material into the pocket; and (ii) a pathway extending through the spreader and operable to evacuate gas out of the pocket as the material is conveyed into the pocket through the opening.

[0050] The material may be or comprise particulate material and/or fibrous material. The material may be or comprise an ingredient of a hydrocarbon well treatment fluid.

[0051] Another material forming the flexible pocket may be or comprise a water-soluble film.

[0052] The spreader may comprise a substantially elliptical profile, a substantially saucer shaped profile, and/or a substantially elongated profile having V-shaped opposing ends.

[0053] The opening may comprise a substantially elongated profile and/or a substantially elliptical profile.

[0054] The pathway may be further operable to prevent the material from escaping out of the pocket through the pathway. [0055] The pathway may be or comprise a plurality of holes extending through the spreader and operable to evacuate the gas out of the pocket while retaining the material within the pocket.

[0056] The pathway may be or comprise a gas filter operable to transmit the gas out of the pocket while preventing transmission of the material out of the pocket.

[0057] The pathway may be or comprise a first pathway, the spreader may further comprise a second pathway, and the first and second pathways may be located on opposing sides of the opening.

[0058] An outer surface of the spreader may be operable to contact an inner surface of the flexible pocket to prevent the material from moving out of the flexible pocket between the outer surface of the spreader and the inner surface of the flexible pocket.

[0059] The packaging machine may further comprise a plunger operable to move through the opening into the flexible pocket to compress the material within the pocket.

[0060] The packaging machine may be or comprise a form-fill-seal machine operable to form the flexible pocket from a flexible film, fill the flexible pocket with the material, and seal the flexible pocket filled with the material. As the flexible film moves through the form-fill-seal machine, the spreader may be operable to spread apart adjacent edges of the flexible film to open the flexible pocket.

[0061] The present disclosure also introduces an apparatus comprising a spreader of a packaging machine, wherein the spreader is operable to spread apart two adjacent edges of thin flexible material as the thin flexible material is moved along the packaging machine to successively open pockets formed from the thin flexible material to permit a product to be transferred into the pockets by the packaging machine, and wherein the spreader comprises an opening operable to accommodate therethrough the product being transferred into the pockets by the packaging machine.

[0062] The product may be or comprise fibrous material. The product may be or comprise an ingredient of a hydrocarbon well treatment fluid.

[0063] The thin flexible material may be or comprise a water-soluble film.

[0064] The spreader may be connected to a fill tube operable to transfer the product from a product source through the opening into the pockets.

[0065] The opening may be operable to accommodate therethrough a plunger operable to move through the opening into the pockets to compress the product within the pockets. [0066] The spreader may comprise a substantially elliptical profile, a substantially saucer shaped profile, and/or a substantially elongated profile having V-shaped opposing ends.

[0067] The opening may comprise a substantially elongated profile and/or a substantially elliptical profile.

[0068] The spreader may further comprise a pathway extending through the spreader separate from the opening and operable to transmit air out of the pockets as the product is transferred into the pockets through the opening. The pathway may be further operable to prevent the product from escaping out of the pockets through the pathway. The pathway may be or comprise a plurality of holes extending through the spreader and operable to evacuate the air out of the pockets while retaining the product within the pockets. The pathway may be or comprise an air filter operable to transmit the air out of the pockets while preventing

transmission of the product out of the pockets. The pathway may be or comprise a first pathway, the spreader may further comprise a second pathway, and the first and second pathways may be located on opposing sides of the opening.

[0069] An outer surface of the spreader may be operable to contact inner surface of the flexible pockets to prevent the product from moving out of the flexible pockets between the outer surface of the spreader and the inner surface of the flexible pockets.

[0070] The packaging machine may be or comprise a form-fill-seal machine operable to form the flexible pockets from a flexible film, fill the flexible pockets with the product, and seal the flexible pockets filled with the product. As the flexible film moves through the form-fill-seal machine, the spreader may be operable to spread apart adjacent edges of the flexible film to successively open the flexible pockets.

[0071] The present disclosure also introduces a method comprising: unwinding long thin flexible material from a roll; folding the flexible material substantially in half in a longitudinal direction such that opposing edges of the flexible material are adjacent each other; sealing together the folded flexible material at spaced intervals to form pockets; moving the folded flexible material horizontally along a spreader located between the adjacent edges of the folded flexible material to spread apart the adjacent edges of the folded flexible material; and transferring product into the pockets through a space between the spread apart edges of the folded flexible material.

[0072] The product may be or comprise fibrous material. The product may be or comprise an ingredient of a hydrocarbon well treatment fluid. [0073] The method may further comprise directing the product into a wellbore as part of a wellbore treatment operation. The wellbore treatment operation may comprise conveying the well treatment fluid to one or more pumps at a wellbore surface and injecting the wellbore treatment fluid into the wellbore during and oilfield or treatment operation, such as, but not limited to, drilling, cementing, hydraulic fracturing, acidizing, chemical injecting, coiled tubing operations, and/or water jet cutting operations, or the like, as will be appreciated by those skilled in the art.

[0074] The flexible material may be or comprise a water-soluble film.

[0075] The method may comprise sealing together the folded flexible material at spaced intervals to seal the pockets containing the product.

[0076] The method may comprise separating the sealed pockets containing the product.

[0077] Spreading apart the adjacent edges of the folded flexible material may open up the pockets, and transferring the product into the pockets may comprise transferring the product into the opened pockets.

[0078] Transferring the product into the pockets may comprise transferring the product into the pockets through an opening extending through the spreader. In such implementations, the method may comprise, while the product is being transferred into the pockets, evacuating air out of the pockets through an air pathway extending through the spreader separate from the opening.

[0079] While the product is being transferred into the pockets, the flexible material may seal against the spreader to reduce evacuation of air between the spreader and flexible material.

[0080] While the product is being transferred into the pockets, the spreader may engage the flexible material to prevent the product from moving out of the pockets between the spreader and the flexible material.

[0081] The method may comprise moving a plunger into the pockets though the space between the spread apart edges of the folded flexible material to compress the product within the pockets.

[0082] The method may be a method of operating a horizontal form-fill-seal machine.

[0083] The foregoing outlines features of several embodiments so that a person having ordinary skill in the art may better understand the aspects of the present disclosure. A person having ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. A person having ordinary skill in the art should also realize that such equivalent constructions do not depart from the scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.

[0084] The Abstract at the end of this disclosure is provided to comply with 37 C.F.R. § 1.72(b) to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Claims

WHAT IS CLAIMED IS:

1. An apparatus comprising:

a packaging machine operable to fill a flexible pocket with material, wherein the packaging machine comprises:

a source of the material;

a fill tube operable to convey the material from the source; and

a spreader connected with the fill tube and operable to open the flexible pocket, wherein the spreader comprises:

an opening extending through the spreader and operable to convey the material into the pocket; and

a pathway extending through the spreader and operable to evacuate gas out of the pocket as the material is conveyed into the pocket through the opening.

2. The apparatus of claim 1 wherein the material is or comprises particulate and/or fibrous

material, and wherein another material forming the flexible pocket is or comprises a water- soluble film.

3. The apparatus of claim 1 wherein:

the spreader comprises at least one of:

a substantially elliptical profile;

a substantially saucer shaped profile; and/or

a substantially elongated profile having V-shaped opposing ends;

the opening comprises at least one of:

a substantially elongated profile; and/or

a substantially elliptical profile;

the packaging machine is or comprises a form-fill-seal machine operable to:

form the flexible pocket from a flexible film;

fill the flexible pocket with the material; and

seal the flexible pocket filled with the material; and

as the flexible film moves through the form-fill-seal machine, the spreader is operable to spread apart adjacent edges of the flexible film to open the flexible pocket.

4. The apparatus of claim 1 wherein the pathway comprises a gas filter operable to transmit the gas out of the pocket while preventing transmission of the material out of the pocket.

5. The apparatus of claim 1 wherein the packaging machine further comprises a plunger operable to move through the opening into the flexible pocket to compress the material within the pocket.

6. A method comprising:

unwinding long thin flexible material from a roll;

folding the flexible material substantially in half in a longitudinal direction such that opposing edges of the flexible material are adjacent each other;

sealing together the folded flexible material at spaced intervals to form pockets;

moving the folded flexible material horizontally along a spreader located between the adjacent edges of the folded flexible material to spread apart the adjacent edges of the folded flexible material;

transferring product into the pockets through a space between the spread apart edges of the

folded flexible material through an opening extending through the spreader; and

evacuating air out of the pockets through an air pathway extending through the spreader separate from the opening while the product is being transferred into the pockets.

7. The method of claim 6 wherein the product is or comprises fibrous material.

8. The method of claim 6 wherein the product is or comprises an ingredient of a hydrocarbon well treatment fluid and wherein the method further comprises directing the product into a wellbore as part of a wellbore treatment operation.

9. The method of claim 6 wherein the flexible material is or comprises a water-soluble film.

10. The method of claim 6 further comprising sealing together the folded flexible material at spaced intervals to seal the pockets containing the product.

11. The method of claim 6 further comprising separating the sealed pockets containing the product.

12. The method of claim 6 wherein spreading apart the adjacent edges of the folded flexible material opens up the pockets, and wherein transferring the product into the pockets comprises transferring the product into the opened pockets.

13. The method of claim 6 wherein, while the product is being transferred into the pockets, the flexible material seals against the spreader to reduce evacuation of air between the spreader and flexible material.

14. The method of claim 6 wherein, while the product is being transferred into the pockets, the spreader engages the flexible material to prevent the product from moving out of the pockets between the spreader and the flexible material.

15. The method of claim 6 further comprising moving a plunger into the pockets though the space between the spread apart edges of the folded flexible material to compress the product within the pockets.