POUCH WITH FLAT VALVE

Abstract

A thin film valve including a flexible thin film front panel, a flexible thin film rear panel sealed to the front panel along two opposite sides thereof to form a normally closed, self-sealing thin film valve having an openable duct, the duct having first and second open ends, the first end of the duct being openable into a container sealingly affixed to the valve, and a frangible seal sealing the second end of the duct between the two sealed side edges.

Claims

1. A thin film valve comprising: a flexible thin film front panel; a flexible thin film rear panel sealed to the front panel along two opposite sides thereof to form a normally closed, self-sealing thin film valve having an openable duct; the valve being sealingly affixable to a pouch; the duct having first and second open ends; the first end of the duct being openable into a pouch sealingly affixed to the valve; and a frangible seal sealing the second end of the duct between the two sealed side edges.

2. The valve according to claim 1, further comprising at least one crease across the duct.

3. The valve according to claim 1, wherein the valve is sealingly affixable asymmetrically to a pouch.

4. A flexible pouch having at least one sealed edge, the pouch comprising: a normally closed self-sealing thin film valve sealingly affixed in said sealed edge; said valve formed of a flexible thin film front panel and a flexible thin film back panel sealed on two opposite sides to define an openable duct between them providing flow communication from outside the pouch to an internal space in the pouch; at least one edge of the valve inside the pouch being unsealed, so as to provide flow communication between the duct and an internal space inside the pouch; a first sealing line including at least two portions, a first portion wherein the front and back panels of the pouch are sealed to each other, and a second portion, collinear with the first portion of the sealing line, along which the front panel of the valve is sealed to an inside wall of the front panel of the pouch and the back panel of the valve is sealed to an inside wall of the sealed edge of the pouch; and a second sealing line wherein a portion of only one of the front and back panels of the valve is sealed to an inside wall of the pouch and the other panel is not sealed to the pouch.

5. The pouch according to claim 4, wherein the valve further includes a frangible sealed third edge extending between the two side edges, sealing the outer opening of the duct and the valve.

6. The pouch according to claim 4, wherein the valve is creased in at least one place across the duct, to provide an improved seal for the duct, thus preventing leakage through the duct.

7. The pouch according to claim 4, wherein one of said front panel and said back panel of the valve is longer than the other and both extend beyond the sealed edge of the pouch.

8. The pouch according to claim 4, including a plurality of said thin film flexible valves sealed in a single pouch.

9. The pouch according to claim 4, including at least two individual internal compartments contained within the pouch and separated by an additional seal inside the pouch.

10. The pouch according to claim 9, further comprising a normally closed thin film valve in each said internal compartment.

11. The pouch according to claim 10, wherein said additional seal is configured to be broken so as to allow flow communication between adjacent internal compartments.

12. A method of forming a pouch having a sealed edge, the method comprising: sealingly affixing a normally closed self-sealing thin film valve in said sealed edge; said valve formed of a flexible thin film front panel and a flexible thin film back panel sealed on two opposite sides to define an openable duct between them providing flow communication from outside the pouch to an internal space in the pouch; at least one edge of the valve inside the pouch being unsealed, so as to provide flow communication between the duct and an internal space inside the pouch; sealing said pouch and said valve along a first sealing line including at least two portions, a first portion wherein the front and back panels of the pouch are sealed to each other, and a second portion, collinear with the first portion of the sealing line, along which the front panel of the valve is sealed to an inside wall of the front panel of the pouch and the back panel of the valve is sealed to an inside wall of the sealed edge of the pouch; and sealing said pouch and said valve along a second sealing line wherein a portion of only one of the front and back panels of the valve is sealed to an inside wall of the pouch and the other panel is not sealed to the pouch.

13. The method according to claim 12, further comprising: forming at least one internal seal in said plastic pouch, thereby creating at least two individual internal compartments in the pouch.

14. A container having a frangible top opening, the container comprising: a flexible pouch sealingly coupled to the top opening; a normally closed, self-sealing thin film valve having an openable duct sealingly affixed to the pouch, the valve including a flexible thin film front panel; a flexible thin film rear panel sealed to the front panel along two opposite sides thereof to form the duct; the duct having first and second open ends; the first end of the duct being openable into the pouch; at least one edge of the pouch inside the container being unsealed, so as to permit flow communication between the duct and an internal space inside the container.

15. The valve according to claim 2, wherein the valve is sealingly affixable asymmetrically to a pouch.

16. The pouch according to claim 5, wherein the valve is creased in at least one place across the duct, to provide an improved seal for the duct, thus preventing leakage through the duct.

17. The pouch according to claim 5, wherein one of said front panel and said back panel of the valve is longer than the other and both extend beyond the sealed edge of the pouch.

18. The pouch according to claim 5, including a plurality of said thin film flexible valves sealed in a single pouch.

19. The pouch according to claim 5, including at least two individual internal compartments contained within the pouch and separated by an additional seal inside the pouch.

20. The pouch according to claim 19, further comprising a normally closed thin film valve in each said internal compartment.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention will be further understood and appreciated from the following detailed description taken in conjunction with the drawings in which:

[0017] FIGS. 1a to 1d are schematic plan view, front sectional view, perspective view and side sectional illustrations, respectively, of a flexible film pouch with a flat film valve, constructed and operative in accordance with one embodiment of the present invention;

[0018] FIGS. 1e to 1g are schematic front sectional, perspective and side sectional illustrations, respectively, of a pouch according to the invention with a straw inserted through the valve;

[0019] FIG. 2 is a schematic side sectional view of a valve in a pouch according to the invention, showing equal pressure on the front and back panels of the valve exerted by liquid or gas in a pouch;

[0020] FIG. 3 is a cross sectional view of a pouch with a valve according to other embodiments of the invention with folds to prevent leakage, or air from entering the pouch;

[0021] FIG. 4 is a schematic illustration of a valve installed in a beverage can, according to further embodiments of the invention;

[0022] FIG. 5 is a valve in a disposable baby's feeding bottle, constructed and operative in accordance with one embodiment of the present invention;

[0023] FIG. 6 is a schematic illustration of a plurality of valves in one flexible pouch, according to embodiments of the invention;

[0024] FIG. 7a is a schematic perspective illustration of a portion of a flexible pouch with multiple valves and multiple pouches, according to other embodiments of the invention;

[0025] FIG. 7b is a schematic sectional illustration of the flexible bag of FIG. 7a with a straw inserted in one valve and opening an internal compartment;

[0026] FIG. 8 is a schematic illustration of a pouch according to the invention showing the valve sealed on three sides;

[0027] FIGS. 9a and 9b are schematic plan view and side sectional illustrations of a pouch according to further embodiments of the invention, with symmetric front and back welding of the valve to the pouch;

[0028] FIGS. 10a to 10c are schematic front plan view, rear plan view and side sectional illustrations of a pouch according to further embodiments of the invention, with asymmetric front and back welding of the valve to the pouch along the entire width of the valve;

[0029] FIGS. 10d and 10e are front and side view illustrations of a pouch according to further embodiments of the invention, with asymmetric front and back welding of the valve to the pouch along the entire width of the valve, showing bending of the valve under pressure;

[0030] FIGS. 11a and 11b are schematic front and rear illustrations of a pouch according to further embodiments of the invention, with asymmetric front and back welding of the valve to the pouch along a partial width of the valve; and

[0031] FIG. 12 is a schematic illustration of a pouch according to another embodiment of the invention, with front and back panels of different lengths.

DETAILED DESCRIPTION OF THE INVENTION

[0032] The present invention relates to an improved, inexpensive, flexible, self-sealing thin film valve that can easily be opened and easily be closed many times. This valve is configured and adapted to be coupled to container, e.g., a plastic bag or pouch or a can, in any conventional manner. The thin film valve includes a flexible thin film front panel, a flexible thin film rear panel sealed to the front panel along two opposite sides thereof to form a normally closed, self-sealing thin film valve having an openable duct, the duct having first and second open ends, the first end of the duct being openable into a container sealingly affixed to the valve, and a frangible seal sealing the second end of the duct between the two sealed side edges. One option is to form a plastic pouch using the blown film extrusion technology of manufacturing conventional plastic (polyethylene) bags. The pouch is made to contain liquids, semi-liquids, powders and solids. The flat film valve defines a duct that can be opened to add substances to the pouch, for example, water, or to dispense material from the pouch. The normal state of the duct is closed, due to the geometry and the material of the valve and due to pressure inside the pouch. Preferably, the valve is heat welded, or affixed in any other manner, such as sewing, gluing, etc., in a seam of the plastic pouch or to the top wall of a can.

[0033] The valve is a flexible, flat, thin polymeric foils barrier assembly formed of two flexible plastic foils, a front and back panel, sealed or welded on two opposite side edges to define a duct between them. The valve is also sealed or welded on a third edge between the two side edges, sealing the outer opening of the duct and the valve. The valve remains open along at least one edge thereof inside the pouch, so as to permit flow communication between the duct and an internal space inside the pouch. The valve is sealed to and between the front and back panels of the pouch. In this way, the filled plastic pouch remains hermetically sealed until the outer edge seal is torn or removed, thereby preventing inadvertent dispensing of the contents and preventing the ingress of dirt or bacteria into the interior space of the pouch. Material inside the pouch applies pressure on the front and back of the flat valve, helping to maintain the duct closed. For purposes of the present invention, material includes any liquid, gas, powder or other substance stored in the pouch for later use. The two side edges of the valve may be sealed together parallel to one another or at an angle to one another. Preferably, the valve is bent or creased in at least one place, to provide an improved seal for the valve, thus preventing leakage through the duct. The duct can be opened by inserting a straw, a needle, a funnel or any other filling apparatus between the front and the back panel of the valve. When the duct is opened, liquids, gases, powders or solids can be inserted into or removed from the interior of the pouch. The normal state of the valve is closed, due to the film material of which the valve is formed and its geometry, and due to the pressure of the material in the pouch surrounding the valve, which applies pressure to both the front and back panels of the valve's film. Another way to improve the sealing of the valve is by asymmetrical attachment of the valve to the pouch, so that when pressure is applied in the pouch, the valve bends by itself.

[0034] Before explaining the invention in detail, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. For clarity, non-essential elements were omitted from the drawings.

[0035] FIGS. 1-12 of the drawings illustrate various film valves 10, 40, 50 and 60 used in conjunction with a pouch or bag made from flexible material. These pouches are openable and re-sealable pouches defining an internal space for holding food and/or drink products. FIG. 4 illustrates a valve used in conjunction with a can. The pouches 10, 40, 50 and 60 are suitable for packaging and dispensing a liquid, gas, powders and solids suitable for industry use or food consumption. Used herein, liquid means any product that is a flowable non-solid product including but not limited to, aqueous and non-aqueous solutions, solutions having a determinable viscosity, emulsions, pastes, gels and dispersions.

[0036] The panels of the pouch include a flexible film material, for example, low density polyethylene, nylon, polyester, polyurethane, and laminates. It is possible that either the front or back panel (or both) of the pouch is made at least in part from a flexible, transparent material, thus allowing the interior space of the pouch and its contents to be visually observable through at least a portion of the front or back panel.

[0037] According to the invention, each pouch has at least one thin flexible valve which prevents the contents within the pouch from being released inadvertently. The valve is opened by insertion of a straw, a needle, a funnel or any other filling apparatus into the valve. Once the valve is open, material can be added to the pouch or material within the pouch can be removed from the pouch via the straw or other opening device, or poured out through the open valve.

[0038] FIGS. 1a to 1d are schematic plan view, front sectional view, perspective view and side sectional schematic illustrations, respectively of a flexible pouch 10, according to embodiments of the invention, having a flat film valve 12 disposed in the pouch. The valve 12 consists of a front panel 11 and a back panel 13. The front and back panels can be of the same length or one can be longer than the other. The front and back panels are connected, as by heat welding, along two side edges, here illustrated as non-parallel edges 15 and 17, defining a normally closed duct 16 therebetween. It will be appreciated that the seal does not necessarily have to be non-parallel to the edges. Rather, the seal may be parallel or may be angled, for example to form a V, where the top and bottom of the valve remain open, forming the duct. Valve 12 is also sealed into the pouch along a sealing line adjacent the third edge at the edge of the pouch, extending between side edges 15 and 17, by a frangible seal. At least one edge inside the pouch 10, is not sealed, permitting flow communication between the duct 16 and the interior of pouch 10. This can be seen more clearly in FIG. 8, described in detail below.

[0039] The duct 16 is opened by insertion of a straw, needle, funnel or any other suitable filling device 21 into duct 16, between the front and rear panels. This can be seen, for example, in FIGS. 1e to 1g, schematic perspective, front sectional, and side sectional illustrations, respectively, of pouch 10 with a straw inserted through the valve.

[0040] Once the valve is open, material can be added to the contents of the pouch or material within the pouch can be removed from the pouch via the straw or filling device, or poured out through the open valve. When the straw or other filling device is removed, the valve 12 closes. Thus, under pressure of the material inside the pouch, the sealing of the valve is tightened, as shown by the arrows in FIG. 2. Preferably, the valve is also manually pressed to ensure sealing closure, although this is not required.

[0041] The valve is placed at the edge of the pouch, between the front and rear panels of the pouch 10, before it is sealed. The pouch is sealed 14 along its open edge, sealing the valve in place. A protective material is placed in the duct 16 in the valve during heat sealing, as is known in the industry, to prevent the duct from being sealed inadvertently during manufacture of the pouch. Alternatively, the valve can be welded or sealed asymmetrically, as described in detail with regard to FIGS. 10a and 10b. Alternatively, or in addition, creases can be provided across the valve to improve sealing, as described in detail with regard to FIG. 3.

[0042] To further improve the performance of the valve of the present invention, preferably one or more creases or folds are created across the valve 18 in at least one, but preferably two or more locations along the length of the valve 18. FIG. 3 is a cross sectional view of a film valve with several folds. The creases or folds close the duct at those locations, thereby preventing leakage through the valve, once it has been unsealed. The folds 18 in FIG. 3 are parallel to one another. In other embodiments, the folds 18 are at various angles, for example, 10 degrees, 20 degrees, or 45 degrees from one another. Other angles of the creases relative to one another and relative to the edges of the pouch are possible, depending on the material in the pouch and its viscosity. Here, too, the front and back panels can be of the same length or one can be longer than the other. In this embodiment, too, the valve can be welded or sealed asymmetrically, as described in detail with regard to FIGS. 10a and 10b. If desired, an external edge of the valve may be sealed by means of a frangible seal, as described below.

[0043] In another embodiment, a pouch having a film valve 32 can be incorporated in a can 30, such as a beverage can, as seen in FIG. 4. This allows re-sealing of the can if only a portion of the contents have been consumed, so that they will not spill out until the user inserts a straw. In addition, it permits liquids and other substances to be easily refilled in a can, if desired. Once the straw or tubing is removed, the valve 32 closes to prevent liquid from spilling out.

[0044] According to some embodiments of the invention, the pouch is affixed to the top wall of the can with the valve disposed beneath the breakaway portion of the lid. In this way, when the breakaway portion of the lid is removed and the can is opened, the external, upper part of the valve is exposed, providing access to the duct in the valve for inserting a straw into the can. It will be appreciated that, in this embodiment, the pouch is open at its bottom end inside the can. Here, too, the front and back panels can be of the same length or one can be longer than the other. Alternatively, or in addition, creases can be provided across the valve to improve sealing, as described in detail with regard to FIG. 3.

[0045] The pouch of the present invention can be used, as well, as a disposable aseptic baby's bottle 40, where the nipple 47 is part of the pouch or tube, as seen in FIG. 5. Nursing mothers can collect their milk aseptically in the pouch, and then later, from the same pouch, feed their babies. Alternatively, the disposable baby bottle can be distributed with formula in it. The disposable baby bottle pouches or tubes can be distributed as single use portions, with one only needing to add water through the film valve. If desired, air can enter into the bottle through the valve to balance the pressure inside and prevent babies' stomach gas pain.

[0046] FIG. 6 is an illustration of a pouch 50 with multiple valves 12. This allows not only for larger portions to be packaged, but allows one the option of sharing their beverage with a friend. Alternatively, one can drink their beverage from a straw inserted in one of the valves, while the other one is being used to add additional substance, flavors, fragrances, etc., to the drink. The valves in this embodiment can have front and back panels of the same length or one can be longer than the other. The valves can be welded or sealed symmetrically or asymmetrically, as described in detail with regard to FIGS. 9a and 10a. Alternatively, or in addition, creases can be provided across one or more of the valves, to improve sealing, as described in detail with regard to FIG. 3. One or more of the valves may be provided with a frangible seal at their external end, as described below.

[0047] FIGS. 7a and 7b illustrate a pouch 60 with both multiple valves 62, and multiple internal compartments 64 contained within the pouch 60. Compartments 64 are separated via an additional seal 63 creating the individual internal compartments. A liquid, gel, powder or solid in the pouch surrounding the value applies pressure to both front and back of the valve, thereby keeping the valve sealed. Preferably, each internal compartment has a valve providing access thereto, although this is not required. In this way, each internal compartment can be filled or emptied separately after manufacture, if desired. Here, too, the front and back panels can be of the same length or one can be longer than the other. Alternatively, the valves can be welded or sealed asymmetrically, as described in detail with regard to FIGS. 10a and 10b. Alternatively, or in addition, creases can be provided across the valves to improve sealing, as described in detail with regard to FIG. 3. If desired, one or more of the valves may be provided with a frangible seal at their external end, as described below.

[0048] If it is desired to mix the contents of two of the internal compartments 64, a straw or tube 66 is inserted through one of the valves 62, as shown in FIG. 7b, breaking through the internal seal 63. This opens the inner compartment and allows the contents contained within it to fall through to and mix with the contents of the adjacent compartment. The user may shake, or knead the contents together, and then drink, freeze, heat, bake, or microwave, as needed.

[0049] Alternatively, a pouch 60 may contain a gas, liquid, power, or other substance and, based upon which valve the user selects, the user can enhance his or her enjoyment of the substance within the pouch by either choosing to use the contents within the smaller compartment or not. For example, if one compartment of the pouch contains iced coffee, and a separate compartment contains extra sugar, one can select to use the extra sugar or not, based upon which valve they choose.

[0050] If there are two people sharing the same pouch, and if they have different taste preferences, they can both enjoy it as they like it. The first one drinks the iced coffee as is. Watching through the transparent window of the pouch, they know when they have reached the half way mark and can switch. The second person then proceeds to insert his straw through the valve with the extra sugar, opens the smaller compartment with the straw, and mixes the coffee.

[0051] Referring now to FIG. 8, there is shown in greater detail a pouch 70 according to the invention with a valve 72 sealed on three sides. It will be appreciated that each of the examples described in this application is also sealed on three sides, in this manner. As can be seen, the valve 72 includes two elongate side walls 74 connecting the front panel to the back panel, an external end wall 76 extending outwards from the edge of the pouch 70, and an internal end wall 78 inside the pouch. After filling the pouch, preferably during manufacture, external end wall 76 is also sealed, as by heat sealing, or in any other fashion. This will maintain the pouch aseptic for a long time, during storage and transportation.

[0052] When a user wishes to insert additional material, mix material in internal compartments, or remove contents from the pouch, the frangible sealed external end wall 76 of the valve 72 is cut or torn off, thereby permitting opening of duct 75 as described above. Tear indicators 79 and/or a frangible end portion may be provided for ease of removing the end wall of the valve.

[0053] In some embodiments, the valve is connected to the pouch symmetrically, as seen in FIGS. 9a and 9b. In the illustrated embodiment, the outer edge of pouch 80 is sealed to itself along two lines, 84 and 86, displaced from one another, from both side edges of the valve 82 to the side edges of the pouch. Similarly, the valve is sealed or welded collinearly to the pouch along two sealing lines, 84 and 86. As seen in FIG. 9b, along both lines 84 and 86, the valve is welded or otherwise sealed to the pouch on both front and back of the valve, i.e., the front panel of the valve is welded to the inside wall of the front panel of the pouch and the back panel of the valve is welded to the inside wall of the back panel of the pouch.

[0054] As described above, the valve is closed by the pressure exerted on the front and back panels of the valve. However, if a tiny gap is formed between the panels of the valve when the straw is removed, leakage might occur through the gap of the valve. To create the required increase of the pressure on the panels relative to the pressure in the gap to ensure complete closing of the valve, the valve is welded to the pouch in an asymmetric fashion. This asymmetry causes the valve to bend, thereby preventing flow through the duct and closing the valve completely. FIGS. 10a to 10c are schematic front, rear and side sectional illustrations of a pouch 90 with asymmetric welding of the valve 92. It should be noted that this type of welding can also be utilized in all the other exemplary valves described in this application. Pouch 90 is a flexible pouch having at least one sealed edge, with a normally closed self-sealing thin film valve sealingly affixed in the sealed edge. As described above, the valve is formed of a flexible thin film front panel and a flexible thin film back panel sealed on two opposite sides to define an openable duct between them providing flow communication from outside the pouch to an internal space in the pouch. At least one edge of the valve inside the pouch is unsealed so as to provide flow communication between the duct and the internal space inside the pouch. The valve is joined to the pouch by a first sealing line 94, 94 including at least two portions, a first portion 94 wherein the front and back panels of the pouch are sealed to each other, and a second portion 94, collinear with the first portion of the sealing line, along which the front panel of the valve is sealed to an inside wall of the front panel of the pouch and the back panel of the valve is sealed to an inside wall of the sealed edge of the pouch. The valve is also joined to the pouch by a second sealing line 96, 96 spaced from first sealing line 94, 94, wherein a portion of only one of the front and back panels of the valve is sealed to an inside wall of the pouch and the other panel is not sealed to the pouch 98. The external welding lines 94, of the valve to the pouch on both front and back must be continuous, thus sealing the pouch with the valve, while on the internal line 96, the valve is welded to the pouch only on a portion of one line. The one sided welding of the valve to the pouch on the inner line of the pouch welding, causes the valve to bend and to create the extra force in the valve that helps the pressure on the walls to overcome the pressure in the gap. The bending of the valve ensures the sealing of the duct of the valve and the pouch. FIGS. 10d and 10e are illustrations of a valve 82 asymmetrically welded to the pouch 80 when pressure is applied.

[0055] It will be appreciated that weld 96 along the pouch is optional but not necessary. Weld 96, sealing the panel of the pouch to the panel of the valve along the sealed line, can be of any desired lengthall along the width of the valve, or along only a small portion of the width of the valve, as shown at numeral 99 in FIGS. 11a and 11b, respective front and rear views of a pouch according to alternative embodiments of the invention. This option can also be incorporated into any of the embodiments of FIGS. 1a to 8. FIG. 12 is a schematic illustration of a pouch 100 according to other embodiments of the invention. In this embodiment, the front panel 104 and the back panel 106 of the valve 102 are of different lengths. This permits a user to pull the longer panel in order to facilitate opening the duct 108 to insert a straw or other device of opening the valve. It will be appreciated that valves having front and back panels of different lengths can be incorporated into any one of the pouches described above. It will further be appreciated that, while it is preferable that the valve extend beyond the sealing line with the pouch, as it is easier to insert a separator and open the valve, alternatively, the valve can extend only up to the sealing line sealing the valve to the pouch.

[0056] It will be appreciated that it is a feature of the invention that at least a portion of the two foil panels of the valve are in sealing engagement with each other so as to close the duct, thereby sealing the pouch. There is no space between the panels of the valve except when a separator is inserted between them, as described in each of the embodiments above.

[0057] While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. It will further be appreciated that the invention is not limited to what has been described hereinabove merely by way of example. Rather, the invention is limited solely by the claims which follow.