POUCH ASSEMBLY

Abstract

A balloon valve and pouch assembly 1 is mounted in a neck portion of a balloon and comprises a balloon valve 2 and a pouch 3. The pouch 3 is adapted to receive and retain an illumination device 100 in a predetermined position. The valve 2 has a valve inlet 2A and a valve outlet 2B provided at an opposite end of the valve 2. The valve 2 is delimited by sealing path 4 and layers 2C, 2D. The pouch 3 comprises an opening 3A through which an illumination device 100 can be inserted and a closed opposite end of the pouch 3B. The pouch 3 is delimited by the first sealing path 5 and layers 3C, 3D. The layers 3C, 3D are heat-sealed together along a first sealing path 5, which is substantially V-shaped, with the open end of the V-shape defining the pouch opening 3A and the closed end of the V-shape defining the closed end of the pouch 3B.

Claims

1-25. (canceled)

26. A pouch assembly for use in an inflatable toy, the pouch assembly comprising: a pouch comprising a pouch upper layer and a pouch lower layer, the pouch upper layer and the pouch lower layer being sealed together along a first sealing path, wherein the pouch is adapted to receive and retain an illumination device in a predetermined position.

27. An assembly according to claim 26 wherein the pouch is delimited by the first sealing path, the pouch upper layer and the pouch lower layer.

28. An assembly according to claim 26 wherein the pouch comprises an opening through which an illumination device can be inserted.

29. An assembly according to claim 28 wherein the opening is provided at one end of the pouch and an opposite end of the pouch is closed.

30. An assembly according to claim 26 wherein the pouch comprises gripping means adapted to retain a light in a predetermined position.

31. An assembly according to claim 30 wherein the gripping means is provided as one or more projections.

32. An assembly according to claim 31 wherein the one or more projections are formed by the first sealing path.

33. An assembly according to claim 26 wherein the assembly is provided with one or more heat resistant patches.

34. An assembly according to claim 26 wherein the assembly is formed of a heat-sealable material.

35. An assembly according to claim 26 wherein the assembly comprises a valve.

36. An assembly according to claim 35 wherein the valve comprises a valve upper layer and a valve lower layer, the valve upper layer and the valve lower layer being sealed together along a second sealing path so that the valve is delimited by the second sealing path, the valve upper layer and the valve lower layer.

37. An array of pouch assemblies, the array comprising a plurality of pouch assemblies according to claim 26 wherein the pouch assemblies are connected together.

38. An inflatable toy comprising a pouch assembly according to claim 26, wherein the pouch assembly is mounted in a neck of the inflatable toy.

39. An inflatable toy according to claim 38 wherein the inflatable toy comprises an illumination device.

40. A method of manufacturing a pouch assembly comprising a pouch, wherein the pouch is adapted to receive and retain an illumination device in a predetermined position, the method comprising the steps of: (a) providing a pouch upper layer and a pouch lower layer; (b) sealing the together the pouch upper layer and the pouch lower layer to form a pouch.

41. A method according to claim 40 wherein step (a) further comprises providing a valve upper layer and a valve lower layer, and step (b) further comprises sealing the together the valve upper layer and the valve lower later to form a valve.

42. A method according to claim 40 wherein, in step (a), at least one of the pouch upper layer, the pouch lower layer, where present the valve upper layer and where present the valve lower layer is provided with one or more heat-resistant patches.

43. A method according to claim 40 wherein, in step (a), the pouch upper layer, the pouch lower layer, where present the valve upper layer and where present the valve lower layer are provided on a single film.

44. A method according to claim 40 wherein, in step (b), the pouch upper layer and the pouch power layer are sealed together along a first sealing path to define the pouch.

45. A method according to claim 41 wherein, in step (b) the valve upper layer and valve lower layer are sealed together along a second sealing path to define the valve.

46. A method according to claim 41 wherein, in step (a), the pouch upper layer is connected to the pouch lower layer by a pouch fold line; the pouch lower layer is connected to the valve upper layer by an intermediate cut line; and the valve upper layer is connected to the valve lower layer by a valve fold line.

47. A method according to claim 46 wherein the method comprises, after step (a) and before step (b): cutting the intermediate cut line to separate the pouch lower layer from the valve upper layer; folding along the valve fold line so that the valve upper layer is arranged on the valve lower layer; folding along the pouch fold line so that the pouch upper layer is arranged on the pouch lower layer.

48. A method according to claim 40 wherein the method comprises, after step (b) or where present step (c), inserting an illumination device into the pouch; and mounting the pouch assembly in an inflatable toy.

49. A method according to claim 40 wherein the method comprises, after step (b) or where present step (c), arranging the pouch assembly in inflatable toy material; optionally cutting the inflatable toy material; and sealing the assembly in the inflatable toy material.

50. A method according to claim 40 wherein the method comprises manufacturing an array of pouch assemblies, wherein step (a) comprises providing respective pouch upper layers, pouch lower layers, where present valve upper layers and where present valve lower layers; and step (b) comprises sealing together the pouch upper layers and the pouch lower layers to form respective pouches, and where present the valve upper layers and the valve lower layers to form respective valves.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0082] In order that the invention may be more clearly understood, an embodiment thereof will now be described, by way of example only, with reference to the accompanying drawings, of which:

[0083] FIG. 1 shows a sectional view of a balloon having a balloon valve and pouch assembly mounted in a neck portion of the balloon, in accordance with the present invention;

[0084] FIG. 2 shows the balloon of FIG. 1 wherein an illumination device is retained in the assembly;

[0085] FIG. 3 shows a portion of a film used to manufacture the assembly of the balloon of FIG. 1;

[0086] FIG. 4 shows an exploded perspective view of the balloon of FIG. 1; and

[0087] FIG. 5 shows an exploded perspective view of the balloon of FIG. 1 wherein an illumination device is retained in the assembly.

DETAILED DESCRIPTION

[0088] With reference to FIGS. 1 to 5, a balloon valve and pouch assembly 1 is mounted in a neck portion of a balloon and comprises a balloon valve 2 and a pouch 3. The pouch 3 is adapted to receive and retain an illumination device 100 in a predetermined position.

[0089] As shown in FIGS. 2 and 5, the illumination device 100 comprises a battery (not shown), an electrical circuit (now shown), a button switch 101 operable to switch the device on or off, a light emitting diode (LED) as an illumination element 102 operable to emit light when the device is switched on, and a removable pull tab 103 configured to prevent electrical connection between the battery and the illumination element 102. As a person skilled in the art will appreciate, the pull tab 103 is arranged between electrical contacts in the electrical circuit and prevents flow of electrical charge and thus illumination of the illumination element 102; and can be removed from the electrical contacts to permit flow of electrical charge and thus illumination of the illumination element 102. The pull tab prevents inadvertent drainage of battery power.

[0090] The valve 2 has a valve inlet 2A and a valve outlet 2B. The valve inlet 2A is provided at one end of the valve 2 and the valve outlet 2B is provided at an opposite end of the valve 2. The valve 2 comprises a valve upper layer 2C and a valve lower layer 2D. The layers 2C, 2D are heat-sealed together along a second sealing path 4, which includes a substantially rectangular portion 4A adjoining a substantially funnel-shaped potion 4B. The funnel-shaped portion 4B is arranged towards the valve inlet 2A and the rectangular portion 4A terminates towards the valve outlet 2B. The valve 2 is self-sealing. The valve 2 is delimited by the second sealing path 4 and the layers 2C, 2D.

[0091] The pouch 3 comprises an opening 3A through which an illumination device 100 can be inserted (see FIGS. 2 and 5). The opening 3A is provided at one end of the pouch 3 and an opposite end of the pouch 3B is closed. The pouch 3 comprises a pouch upper layer 3C and a pouch lower layer 3D. The layers 3C, 3D are heat-sealed together along a first sealing path 5, which is substantially V-shaped, with the open end of the V-shape defining the pouch opening 3A and the closed end of the V-shape defining the closed end of the pouch 3B. The pouch 3 is delimited by the first sealing path 5 and the layers 3C, 3D.

[0092] The pouch 3 is arranged on and heat sealed to the valve 2 so that the valve inlet 2A is arranged towards the pouch opening 3A and the valve outlet 2B is arranged towards the closed end 3B of the pouch. The pouch 3 comprises two gripping projections 3E, 3F which are adapted to retain the illumination device 100 in a predetermined position. The projections 3E, 3F are formed by the first sealing path 5; face radially inwards, towards each other; and project towards the closed end of the V-shape at an oblique angle with respect to the longitudinal axis of the V-shape. The projections 3E, 3F contact and support the button switch 101 and thereby help securely retain the illumination device 100 in a predetermined position in the pouch 3. The LED illumination element 102 extends between the projections 3E, 3F, towards the closed end of the pouch, and is retained by and within the first sealing path 5 (see FIGS. 2 and 5).

[0093] The balloon valve and pouch assembly 1 is provided with heat-resistant patches 6A, 6B. The heat-resistant patches 6A, 6B comprise heat-resistant ink, which prevents the occurrence of heat-sealing (e.g. see FIG. 3). The patches 6A are provided on the valve layers 2C, 2D and are substantially torch shaped. Specifically, on each layer 2C, 2D, a patch 6A starts at the funnel-shaped portion of the second sealing path 4 and terminates approximately half-way down the second sealing path 4. On each layer 3C, 3D, a patch 6B is provided towards the pouch opening 3A and another patch 6B is provided between the gripping projections 3E, 3F and towards the closed end 3B of the pouch.

[0094] The layers 2C, 2D, 3C, 3D of the assembly 1 are manufactured from a single low-density polyethylene film 10 having a thickness of about 25 microns.

[0095] A method of manufacturing an array of balloon valve and pouch assemblies is described below.

[0096] The film 10 is provided with printed markings corresponding to respective valve upper layers 2C, valve lower layers 2D, pouch upper layers 3C, pouch lower layers 3D, fold lines 7 connecting each pouch upper layer 3C to its corresponding pouch lower layer 3D, intermediate cut lines 8 connecting each pouch lower layer 3D to its corresponding valve upper layer 2C, valve fold lines 9 connecting each valve upper layer 3C to its corresponding valve lower layer 3D, and optionally markers which provide a visual indication of whether or not the layers 2C, 2D, 3C, 3D are correctly aligned when folded together in position (as detailed below). In this way, a plurality of printed markings corresponding to respective balloon valve and pouch assemblies are provided side-by-side on the film. The longitudinal axes of the printed markings corresponding to the respective balloon valve and pouch assemblies are arranged in parallel to each other. A portion of the film is illustrated in FIG. 3. For simplicity, only markings for a single assembly 1 is shown in FIG. 3. In other words, the film 10 includes a plurality of further balloon valve and pouch assemblies 1, connected together side-by-side, extending along axis ‘X’ as shown in FIG. 3.

[0097] The film 10 is also provided with heat resistant patches 6A, 6B, which comprise heat-resistant ink. The heat resistant patches 6A, 6B prevent the occurrence of heat-sealing in the areas of the film on which the patches 6A, 6B are provided.

[0098] The film 10 is cut along each intermediate cut line 8 so that the valve upper layers 2C are separated from the pouch lower layers 3D.

[0099] The film 10 is folded along the valve fold lines 9 so that the valve upper layers 2C are arranged on the valve lower layers 2D, such that the heat-resistant patches 6A provided on the valve upper layers 2C overlap with the heat-resistant patches 6A provided on the valve lower layers 2D.

[0100] The film 10 is folded along the pouch fold lines 7 so that the pouch upper layers 3C are arranged on the pouch lower layers 3D, such that the heat resistant patches 6B provided on the pouch upper layers 3C overlap with the heat-resistant patches 6B provided on the pouch lower layers 3D.

[0101] The valve upper layers 2C are heat sealed to the valve lower layers 2D along second sealing paths 4 to thereby define respective valves 2. Each valve 2 is thus delimited by the layers 2C, 2D and its respective second sealing path 4. Each valve 2 has a valve inlet 2A and a valve outlet 2B.

[0102] The pouch upper layers 3C are heat sealed to the pouch lower layers 3D along first sealing paths 5 to thereby define respective pouches 3. Each pouch 3 is thus delimited by the layers 3C, 3D and its respective first sealing path 5. Each pouch 3 has at one end thereof a pouch opening 3A through which an illumination device 100 can be inserted, and at an opposite end thereof 3B is closed.

[0103] With respective valves 2 and pouches 3 now formed, the pouches 3 are arranged on the valves 2 so that the pouch lower layers 3D are arranged on the valve upper layers 2C. In this way, the pouch openings 3A are proximal to the valve inlets 2A and the closed ends 3B of the pouches are proximal to the valve outlets 2B. The abovementioned optional markers can be used to align the valves 2 and the pouches 3.

[0104] The respective valves 2 and pouches 3 are heat sealed together at various tacking locations.

[0105] A person skilled in the art will appreciate that heat sealing at the tacking locations must not interfere with the valves 2 and the pouches 3.

[0106] An end of the valves 2 towards the fold lines 7 is cut off, so that the valve 2 is open at both ends, the cut-off end defining the valve outlet 2B and the opposite end defining a valve inlet 2A.

[0107] An array of balloon valve and pouch assemblies 1 is thus manufactured, wherein the respective balloon valve and pouch assemblies 1 are connected together side-by-side. As a person skilled in the art will appreciate, the respective balloon valve and pouch assemblies 1 can be individualised using any suitable cutting means.

[0108] A person skilled in the art will appreciate that the order of occurrence of the folding, cutting and sealing steps may be varied as required.

[0109] A method of manufacturing a foil balloon comprising an assembly 1 according to the present invention is described below.

[0110] An illumination device 100 having a button switch 101 and an LED illumination element 102 is inserted through the pouch opening, so that the button switch 101 is retained in the pouch by the gripping projections 3E, 3F and the LED illumination element 102 projects between the gripping projections 3E, 3F towards the closed end 3B of the pouch and is retained by and within the first sealing path 5.

[0111] With the illumination device 100 received in the assembly 1, the assembly 1 is arranged between two foil sheets of balloon material, which are substantially identical in shape and dimensions. The foil sheets are heat-sealed together along their periphery and subsequently cut to shape to form a balloon including a neck portion in which the assembly 1 is mounted. The components of the illumination device 100 are obscured from view.

[0112] Optionally, an electrostatic attractive force may be applied to the assembly 1 and/or the foil sheets of balloon material prior to sealing together the assembly 1 and the foil sheets. This holds in position the assembly 1 and the foil sheets and prevents inadvertent separation thereof.

[0113] The above embodiment is described above by way of example only. Many variations are possible without departing from the scope of protection as defined by the appended claims. In particular, whilst a balloon is described in the above embodiment, a person skilled in the art will appreciate that the present invention extends to other inflatable toys.