WO2019113568A1

WO2019113568A1 - Tortuous path for a flexible valve

Info

Publication number: WO2019113568A1
Application number: PCT/US2018/064663
Authority: WO
Inventors: Christopher J. Ludwig
Original assignee: Illinois Tool Works Inc.
Priority date: 2017-12-08
Filing date: 2018-12-10
Publication date: 2019-06-13

Abstract

The present disclosure relates to a valve and method for forming a valve. A bubble is formed between a first/base layer and a second/bubble of plastic film. A third/channel layer is applied to the second/bubble layer to form a channel. The channel includes an inlet, an outlet, and a first and second tortuous path/leg between the inlet and the outlet. The tortuous paths/legs formed between an exterior channel wall/seal and either side of an interior channel wall/seal. A physical characteristic of the bubble biases the channel from an open position towards a closed position that restricts flow of the contents from the inlet to the outlet. The tortuous paths/legs prevent dispensation of contents when the channel is in the closed position.

Description

PCT APPLICATION TORTUOUS PATH FOR A FLEXIBLE VALVE

BACKGROUND OF THE DISCLOSURE

[0001] This application claims priority of U.S. Provisional Application Serial No.

62/596,453, filed on December 8, 2017, the contents of the disclosure of which are incorporated by reference herein for all purposes.

Field of the Disclosure

[0002] The present disclosure relates to a bubble valve (i.e., a flexible valve, a plastic or polymeric valve) for flexible containers containing liquid, and a method for forming the bubble valve. A bubble is formed between a bubble layer and a base layer of plastic film. A channel layer is applied to the bubble layer to form a channel.

Description of the Prior Art

[0003] Prior art packaging in the food/beverage, personal care and household care industries is primarily a combination of a rigid bottle or semi-flexible tube with a rigid fitment or cap of varying dispense types. Transition to flexible pouches for the main body of the container has continued to utilize similar, still rigid, fitments. There exists a need within these industries to complete the transition in order to create a fully flexible solution.

[0004] Prior art embodiments of a flexible valve for flexible pouches required many manufacturing steps, material, and time. Configurations - shape, dimension, film type, etc. - of a flexible valve must also be chosen depending on the specific needs of the product and/or consumer or user requirements. Such specific needs include, for example, but are not limited to, opening force of the valve, closing (i.e., shut-off) force of the valve, flow characteristics (i.e., opening/closing responsiveness) of the valve, and viscosity of contents in a package. There exists a need for a configuration of flexible valve for lower viscosity contents. OBJECTS AND SUMMARY OF THE DISCLOSURE

[0005] It is therefore an object of the present disclosure to provide an improved valve for customer applications. These and other objects are attained by providing a valve made of a channel and an enclosed bubble that can be attached to a flexible package to enable the controlled release of contents by means of applying pressure. A tortuous path between the channel and bubble of the flexible valve is provided for additional control of content release.

[0006] In a presently contemplated valve for permitting selective dispensing of contents of a package, a bubble is formed between a first layer and a second layer of film, and a channel is formed between the second layer and a third layer of film. The channel includes an inlet and an outlet. The channel further includes a first tortuous path/leg and a second tortuous path/leg between the inlet and the outlet. The tortuous paths/legs are formed between an exterior channel wall/seal and either side of an interior channel wall/seal. A physical characteristic of the bubble biases the channel from an open position towards a closed position that restricts flow of the contents from the inlet to the outlet. The tortuous paths/legs prevent dispensation of contents through leakage or error by capturing the contents between the exterior channel wall/seal and the interior channel wall/seal.

[0007] In a presently contemplated method of forming a valve, a bubble is formed by applying a bubble seal between a first and a second layer thus capturing an enclosed material in the bubble. A channel is formed by applying an interior channel seal between the second layer and a third layer, and applying an exterior channel seal between the second layer and the third layer. The channel includes an inlet, an outlet, and a first and second tortuous path/leg between the inlet and the outlet. The tortuous paths/legs are formed between an exterior channel wall/seal and either side of an interior channel wall/seal. The bubble includes a physical characteristic that biases the channel from an open position towards a closed position that restricts flow of the contents from the inlet to the outlet. The tortuous paths/legs prevent dispensation of contents through leakage or error by capturing the contents between the exterior channel wall/seal and the interior channel wall/seal. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Further objects and advantages of the disclosure will become apparent from the following description and from the accompanying drawings, wherein:

[0009] Figures 1 A-l C are various views illustrating layers and assembly of a valve of the present disclosure;

[00010] Figure 2 is a top view of a non-tortuous configuration of a valve;

[00011] Figure 3 is a top view of a tortuous configuration of a valve;

[00012] Figures 4A-4B are various views illustrating the tortuous configuration of a valve;

[00013] Figures 5 A-5B illustrate typical use of a package including a valve;

[00014] Figure 6 illustrates a further possible embodiment for a valve; and

[00015] Figure 7 is a schematic which illustrates a possible method and apparatus for manufacturing a valve of the present disclosure.

DETAILED DESCRD7TION OF THE PREFERRED EMBODIMENTS

[00016] Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one sees that Figures 1A-1C disclose a valve 10 (i.e., a plastic, a flexible, a bubble, or a polymeric valve), comprising a bubble 12 and a channel 14. The valve 10 is attachable to a package 100 (i.e., a container or a pouch), the package having an internal volume for retaining contents which a user may dispense through the valve 10.

[00017] The bubble 12 includes an enclosed material within the volume. The enclosed material is trapped between a base layer 16 (i.e., a first exterior layer) of film and a bubble layer 18 (i.e., at least one interior layer) of film to create the bubble 12 of a desired shape and size to act as a flow regulator with respect to channel 14. The channel 14 is formed around the bubble 12 by two layers - the bubble layer 18 and a channel layer 20 (i.e., a second exterior layer) - sealed together through which liquid can flow through channel 14. Some embodiments may implement a panel portion of the package 100 as one of layers 16, 18, 20. [00018] In some embodiments, the enclosed material inside the bubble 12 is a gas, fluid or a liquid. In many applications, the enclosed material is air. In such embodiments, the pressure of the liquid or the gas is a physical characteristic of the bubble 12 that biases the channel 14 from an open position towards a closed position. In another embodiment, the enclosed material is a solid such as, for example, but not limited to, a urethane sponge or a rubber nub. In such embodiments, the elasticity of the solid imparts or affects a physical characteristic of the bubble 12 that biases the channel 14.

[00019] The shaping and dimensions of the bubble 12 and the channel 14, along with the film types of the layers 16, 18, 20, can be customized to the specific needs of the product and/or consumer or user requirements. Such specific needs include, for example, but are not limited to, opening force of the valve 10, closing (i.e., shut-off) force of the valve 10, flow characteristics (i.e., opening/closing responsiveness) of the valve 10, and viscosity of contents in a package.

[00020] Figures 1A, IB, and 1C illustrate a formed channel layer embodiment of the valve 10 of the present disclosure. The valve 10 includes a first/base layer 16 (i.e., a first exterior layer), a second/bubble layer 18 (i.e., at least one interior layer), and a third/channel layer 20 (i.e., a second exterior layer). The layers may be made of plastic (or polymeric) film and some variant of a flexible plastic film. The plastic film is made of, for example, but not limited to, polyethylene and/or polypropylene or a combination thereof.

[00021] A static planar footprint 22 is embossed or formed on the bubble layer 18 of plastic film. The static planar footprint 22 is typically formed using at least one of vacuum forming and thermoforming processes. The bubble layer 18 with embossed static planar footprint 22 is applied to the base layer 16. The bubble 12 is thereby typically formed from the enclosed material captured between the bubble layer 18 and the base layer 16 with the static planar footprint 22 and a pre-tension height ("X" as illustrated in Figure IB). Figure IB illustrates the assembly after the application of the bubble layer 18 to the base layer 16. The step of applying the base and bubble plastic film layers 16, 18 to each other is accomplished by, for example, but not limited to, sealing the two layers of plastic film together typically using heat or ultrasonics. [00022] Next, the channel layer 20 is applied to the bubble layer 18. The channel layer 20 is sealed to at least one of the base layer 16 and the bubble layer 18 typically using heat or ultrasonics. In some embodiments, the channel layer 20 embossed with a channel footprint 24 formed using at least one of vacuum forming and thermoforming processes. A channel 14 forms between the channel layer 20 and the bubble layer 18. The channel 14 will allow and control dispensing of products from an internal volume of a package when a consumer or user applies a pressure by squeezing the package (see element 100 in Figures 5A-5B). When a user applies a pressure less than the pressure between the bubble 12 and the channel 14 (i.e., an opening threshold), the channel 14 is in a closed position and contents do not flow past the valve 10.

[00023] Figure 1C illustrates the assembly after the application of the channel layer 20. The channel 14 and the bubble 12 are formed. The channel layer 20 is applied to the bubble layer 18 and the base layer 16 under tension. During application of the channel layer 20, the bubble 12 undergoes a transformation. The bubble 12 decreases in height from the pre-tension height "X" (Figure IB) to a post-tension height "Y2" (Figure 1C). Along with the post-tension height, the bubble 12 has an increased or higher internal pressure (i.e., the enclosed material is compressed). The static planar footprint 22 of the bubble 12 remains the same. However, the overall volume has decreased because the height has decreased, and thus the internal pressure has increased because the same amount of enclosed material (e.g., ambient air) is trapped between the bubble layer 18 and the base layer 16 in the bubble 12. Alternately, a flat channel layer embodiment, with no channel footprint/thermoforming, may be used (not illustrated).

[00024] In one embodiment, the pressure of the enclosed material is the physical characteristic of the bubble 12 that biases the channel 14 from the open position towards the closed position, thus restricting flow of the contents through the valve 10. In another embodiment, the height of the bubble 12 is the physical characteristic of the bubble 12 that biases the channel 14 from the open position towards the closed position. During manufacturing, tension of the channel layer 20 during application and sealing to the bubble layer 18 can be customized to the specific needs of the product and/or consumer or user requirements. In some embodiments, the tension of the channel layer 20 (i.e., the second exterior layer) is another physical characteristic that biases the channel 14 from the open position towards the closed position. [00025] Figure 2 illustrates a non-tortuous configuration of a channel seal 21 between the bubble layer 18 and the channel layer 20. The channel seal 21 is illustrated as a double seal to increase integrity, but single seals may likewise be used. The channel seal 21 defines the channel 14 so as to have an inlet 32 (receiving product from the container with is typically attached to valve 10 by flanges or attachment sections 33) and an outlet 34 (dispensing product to the consumer or user through a gap in the channel seal 21). The bubble 12 is illustrated as defined by a bubble seal 19 (along or offset from the footprint 22 described above with respect to Figures 1A-1C).

[00026] Figure 3 illustrates a tortuous configuration of a channel seal 21 between the bubble layer 18 and the channel layer 20. The channel seal includes exterior channel wall 21A-B and interior channel wall 21C. A first section 21 A of the exterior channel wall 21A-B is outside of the interior channel wall 21C, while a second section 21B of the exterior channel wall 21A-B is inside of the interior channel wall 21 C. The channel seal 21 defines the channel 14 so as to have an inlet 32 (receiving product from the container with is typically attached to valve 10 by flanges or attachment sections 33) and an outlet 34 (dispensing product to the consumer or user through a gap in the channel seal 21). The bubble 12 is illustrated as defined by a bubble seal 19 (along or offset from the footprint 22 described above with respect to Figures 1A-1C; illustrated as a double seal to increase integrity, but single seals may likewise be used).

[00027] A tortuous path of the channel 14 is defined between portions of the channel seal 21. Figure 4 A illustrates portions of the tortuous path of the valve 10. Contents travel through the inlet 32 towards a narrowing of the channel 14. Next, the contents can flow on either side (e.g., left or right) of the bubble 12. A first tortuous path/leg is defined between the first section 21 A of the exterior channel wall 21 A-B and the interior channel wall 21C (i.e., between an outer side of the interior channel wall 21 C and the exterior channel wall 21 A-B). A first tortuous path/leg is defined between the second section 2 IB of the exterior channel wall 21 A-B and the interior channel wall 21C (i.e., between an inner side of the interior channel wall 21C and the exterior channel wall 21 A-B). As shown in Figures 4 A and 4B, the tortuous flow paths include reversals of substantially 180 degrees, within areas wherein the flow paths may have a reduced diameter. [00028] Contents of a lower viscosity with a consistency/thickness similar to, for example, but not limited to, water, might enter the first tortuous path (and possibly the second tortuous path) of the channel 14 without application of pressure by the user onto the package 100. However, the bend/turn between the first tortuous path/leg and the second tortuous path/leg prevents contents from reaching an overlap section of the channel 14 (i.e., where the bubble 12 is proximate to the channel 14) and exiting through the outlet 34.

[00029] Figure 4B illustrates a content flow path through the valve 10 with the tortuous configuration illustrated in Figure 3. To overcome impedance on the flow of contents by the first and second tortuous paths/legs (i.e., between the exterior channel wall 21A-B and the interior channel wall 21 C), the user applies pressure to the package (as illustrated in Figure 5). The pressure will cause the contents to flow through the tortuous paths/legs on either side of the valve 10 and also overcome the bias of the channel 14 (due to the physical characteristic of the bubble 12), placing the channel 14 in the open position and allowing contents to flow through the outlet 34.

[00030] Figures 5 A and 5B illustrate typical use of a container 100, containing liquid or lotion-type (or similar) product 200 as dispensed via valve 10. In Figure 5 A, the consumer or user squeezes the container, package or pouch 100 so as to dispense liquid, lotion or similar product 200 through the valve 10. The channel 14 is thus in the open position in Figure 5 A. As shown in Figure 5B, the consumer or user then releases pressure on the container, package or pouch 100 so as to stop flow of the liquid, lotion or similar product 200 through valve 100. The channel 14 is thus in the closed position in Figure 5B - the physical characteristic of the bubble 12 biases the channel 14 to the closed position from the open position and restricts flow of the contents from the inlet 32 to the outlet 34 (i.e., through the channel 14, valve 10).

[00031] The first and second tortuous paths/legs (not visible in Figures 5B) prevent contents from flowing because the liquid/lotion type product 200 would have to overcome gravity to pass around the interior channel wall 21 C. The product 200 may be caught between the exterior channel wall 21A-B and the interior channel wall 21C in the tortuous paths/legs, but cannot progress to the overlap portion (where the channel 14 is proximate to the bubble 12) and through the outlet 34 until the user applies pressure again as in Figure 5A. [00032] Figure 6 illustrates an inverted embodiment of the valve 10 of the disclosure. This embodiment includes an increased tortuous path, to the point where the bubble 12 is considered to be optional and may just be an enlarged dispensing volume in the fluid flow path. As shown in Figure 6, the egg-shaped bubble seal 19, partially co-extensive with exterior channel walls 21 A, 2 IB) has an inverted orientation from that shown in Figure 3. That is, in Figure 6, the area 12 within bubble seal 19 (which may include a bubble) has an enlarged end, including interior channel wall 21C, pointed toward the product side or inlet 32 (receiving product through inlet 32 via channel 14 as defined by the lower portion 21 " of channel seal 21) of the valve 10 and a narrow end oriented toward the consumer side or outlet 34 (dispensing product to the consumer end or user through a gap in the upper portion 21 ' of channel seal ,21). Channel 14 includes a partially obstructive transverse bubble seal portion 19' and a first partially obstructive transverse channel seal portion 23. Additionally, a second partially obstructive channel seal portion 25 is adjacent to the first partially obstructive channel seal portion 23 overlays a portion of the bubble seal 19. This results in a tortuous path through gaps 27A or 27B, which include a reversal of flow direction of substantially 180 degrees, between the ends of the second partially obstructive channel seal portion 25 and the channel seal 21, thereby providing a route to the larger end of area 12 (which may include a bubble, no bubble, or a partially inflated bubble, the need for the bubble being, in some applications, reduced due to the increased flow resistance achieved by the tortuous flow path), bounded by bubble seal 19 from there to outlet 34. This illustrates that manipulation of the bubble and path geometry can be implemented to achieve varying degrees of difficulty for the liquid to flow. Less or more tortuous paths are envisioned as additional embodiments.

[00033] Figure 7 is a schematic which illustrates a possible method and apparatus 300 for manufacturing the valve 10. The layout of apparatus 300 is directed to the embodiments with the base layer 16, bubble layer 18, and channel layer 20. The polymeric or similar sheet material for the bubble layer 18 is provided by bubble layer unwind or spool 302. The bubble footprint 22 (i.e., bubble shape, planar static footprint) is formed by the bubble layer thermoformer 304. The polymeric or similar sheet material for the base layer 16 is provided by base layer unwind or spool 306 and is sealed to the bubble layer 18 by bubble to base ultrasonic sealer 308 (i.e., applying bubble seal 19). The polymeric or similar sheet material for the channel layer 20 is provided by channel layer unwind or spool 310 and is optionally shaped by channel layer thermoformer 314 (i.e., channel footprint 24). The channel layer 20 is sealed to the combination of the base layer 16 and bubble layer 18 by channel to bubble ultrasonic sealer 316 (i.e., applying channel seal 21). The resultant concatenation of bubble valves is accumulated on finished valve rewind 318. The valves may be separated from each other in a separate manufacturing step, possibly at a different place and time, for the final formation of the containers, packages or pouches.

[00034] In one embodiment of method and apparatus 300, the exterior channel wall 21A- B and the interior channel wall 21 C (both of the channel seal 21) are created/applied by the same ultrasonic sealer 316. In another embodiment, the exterior channel wall 21A-B is created/applied before the interior channel wall 21C by the same or separate ultrasonic sealers 316. In yet another embodiment, the interior channel wall 21 C is created/applied before the exterior channel wall 21A-B by the same or separate ultrasonic sealers 316. Thus, there can be one, two, or more channel seals / sealing process steps.

[00035] A printer 312 provides the desired printing onto bubble layer 18. The coating, such as, but not limited to, nitrocellulose or silicone, is intended to eliminate or minimize the sealing of the channel layer 20 to the bubble layer 18 - possibly closing the channel 14 and impairing the operation of the valve 10 - at the thermoformer 316. The method and apparatus 300 illustrated in Figure 6 may be reorganized or expanded to accommodate additional layers of film or processes.

[00036] The tortuous path configuration of the valve 10 illustrated in Figures 3, 4A, and 4B adds additional paths/legs that the liquid product 200 must navigate in the valve 10 before encountering the formed bubble 12. The objective is to address low viscosity (i.e., thinner) liquids that are more inclined to find passageways for leakage through the channel 14 to outlet 34. The tortuous configuration incorporates a path that (if the pouch is being held upside down to dispense) allows the liquid to fall downward via gravity but then navigate back upwards before once more turning a corner and reaching the initial tip of the bubble. In a pure hanging condition (e.g., as illustrated in Figure 5B), this should create a difficult enough path that the liquid product 200 will not leak out under gravitational force alone but can still be dispensed given a strong enough application of squeeze force to the pouch 100. [00037] The present disclosure illustrates a tear-shaped bubble 12 and channel walls 21 , 21 A-B, 21C that proximate portions of the tear-dropped shape. Other shapes of the bubble 12, bubble seal 19, channel 14, channel seal 21, and first and second tortuous paths are possible. Manipulating the individual legs of the path and dimensions of the channel 14 through with the liquid will flow will vary the performance of the valve 10. Additional configurations - for example, but not limited to, valves with more than three layers, valves with various seal configurations, alternate bubble and channel designs - are described in commonly owned and copending International Patent Application No. PCT/US 17/61500, filed November 14, 2017 and entitled "BUBBLE VALVE FOR FLEXIBLE PACKAGING," the entire contents of which is hereby incorporated by reference.

[00038] Thus, the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby.

Claims

CLAIMS What is Claimed is;

1. A valve for permitting selective dispensing of contents of a package, comprising:

a first layer, a second layer, and a third layer, the second layer disposed between the first and third layers;

a bubble formed between the first layer and the second layer by applying a bubble seal; and

a channel formed between the second layer and the third layer by applying at least one channel seal, the channel including

an inlet and an outlet,

an exterior channel wall/seal,

an interior channel wall/seal,

a first tortuous path/leg formed between the exterior channel wall/seal and an outer side of the interior channel wall/seal, and

a second tortuous path/leg formed between the exterior channel wall/seal and an inner side of the interior channel wall/seal,

wherein a physical characteristic of the bubble biases the channel from an open position towards a closed position that restricts flow of the contents from the inlet to the outlet, and wherein the tortuous paths/legs prevent dispensation of contents when the channel is in the closed position.

2. The valve of Claim 1 wherein the bubble includes a physical material and the physical characteristic of the bubble includes the physical material therewithin.

3. The valve of Claim 2 wherein the physical characteristic includes the pressure of the physical material or the elasticity of the physical material..

4. The valve of Claim 2 wherein the physical material is a fluid, gas or liquid.

5. The valve of Claim 2 wherein the physical material is air.

6. The valve of Claim 1 wherein the first tortuous path/leg and the second tortuous path/leg restricts flow of the contents from the inlet to the outlet.

7. The valve of Claim 1 wherein the first tortuous path/leg and the second tortuous path/leg include portions of narrowed diameter.

8. The valve of Claim 1 wherein the first tortuous path/leg and the second tortuous path leg include at least one reversal in direction of substantially 180 degrees..

9. A method of forming a valve, comprising the steps of:

forming a bubble by applying a bubble seal between a first and a second layer, capturing an enclosed material in the bubble during application of the bubble seal, forming a channel by applying at least one channel seal between the second layer and a third layer,

wherein the channel includes an inlet, an outlet, and a first and second tortuous path/leg between the inlet and the outlet, the tortuous paths/legs formed between an exterior channel wall/seal and either side of an interior channel wall/seal, and

10. The method of Claim 1 wherein the bubble includes a physical material and the physical characteristic of the bubble includes the physical material therewithin.

11. The method of Claim 10 wherein the physical characteristic includes the pressure of the physical material or the elasticity of the physical material..

12. The method of Claim 10 wherein the physical material is a fluid, gas or liquid.

13. The method of Claim 10 wherein the physical material is air.

14. The method of Claim 9 wherein the first tortuous path/leg and the second tortuous path/leg restricts flow of the contents from the inlet to the outlet.

15. The method of Claim 9 wherein the first tortuous path/leg and the second tortuous path/leg include portions of narrowed diameter.

16. The method of Claim 9 wherein the first tortuous path/leg and the second tortuous path leg include at least one reversal in direction of substantially 180 degrees.

17. A valve for permitting selective dispensing of contents of a package, comprising:

an enlarged dispensing volume formed between the first layer and the second layer by applying a bubble seal; and

an inlet and an outlet, an exterior channel wall/seal,

an interior channel wall/seal,

a first tortuous path/leg formed between the exterior channel wall/seal and an outer side of the interior channel wall/seal, providing a path from the inlet to the enlarged dispensing volume with at least one change in direction of flow path of substantially 180 degrees; and

a second tortuous path/leg formed between the exterior channel wall/seal and an inner side of the interior channel wall/seal, providing a path from the inlet to the enlarged dispensing volume with at least one change in direction of flow path of substantially 180 degrees.

18. The valve of Claim 17 further including a first partially obstructive transverse channel seal portion and wherein the at least one change in direction of the flow path occurs at a gap between ends of the first partially obstructive transverse channel seal portion and the at least one channel seal.

19. The valve of Claim 18 further including a second partially obstructive transverse channel seal portion outwardly adjacent from the first partially obstructive transverse channel seal portion.

20. The valve of Claim 17 wherein the enlarged dispensing volume is egg-shaped with a larger end directed toward the inlet and the small end directed toward the outlet, and wherein the first and second tortuous paths feed into the smaller end..