Abstract:
A method for making a vertical stand up package having one or more open or closed compartments within the package, and method and apparatus for manufacturing the same, constructed by modification to existing vertical form, fill and seal packaging machines. The invention involves producing a flat bottom bag that can stand upright having an internal compartment from a single sheet of flexible packaging film. A different product can be placed into the compartment. The compartment can also be used as a dipping well. In one aspect a multi-compartment package can be made.

Description:
BACKGROUND OF THE INVENTION 
   1. Technical Field 
   The present invention relates to a method for making a vertical stand-up package having a compartment constructed using a modified vertical form, fill, and seal packaging machine, and the apparatus and method for making same, that provides for a single piece construction of a vertical stand-up package. The invention allows for use of existing converter and packaging technology to produce a stand up package having one or more open or closed compartments with minimal increased cost and minimal modification. 
   2. Description of Related Art 
   Vertical form, fill, and seal packaging machines are commonly used in the snack food industry for forming, filling, and sealing bags of chips and other like products. One such packaging machine is seen diagrammatically in  FIG. 1 . This drawing is simplified and does not show the cabinet and support structures that typically surround a machine, but it demonstrates the working of the machine well. Packaging film  110  is taken from a roll  112  of film and passed through tensioners  114  that keep it taut. The film then passes over a former  116 , which directs the film into a vertical tube around a product delivery cylinder  118 . As the tube is pulled downward by drive belts  120  the vertical tube of film is sealed along its length by a vertical sealer  122 , forming a back seal  124 . The machine then applies a pair of heat sealing jaws  126  against the tube to form a transverse seal  128 . This transverse seal  128  acts as the top seal on the bag  130  below the sealing jaws  126  and the bottom end seal on the bag  132  being filled and formed above the jaws  126 . After the transverse seal has been formed, a cut is made across the sealed area to separate the finished bag  130  below the seal  128  from the partially completed bag  132  above the seal. The tube is then pushed downward to draw out another package length. Before the sealing jaws form each transverse seal, the product to be packaged is sent through the product delivery cylinder  118  and is held within the tube above the transverse seal  128 . The material that is fed into the form, fill and seal machine is typically a packaging film such as polypropylene, polyester, paper, polyolefin extrusions, adhesive laminates, and other such materials, or from layered combinations of the above. For many food products, where flavor retention is important, a metalized layer will form the inner most layer. 
   One modification to a vertical form, fill, and seal packaging machine is disclosed in U.S. Pat. No. 6,722,106 (“the &#39;106 Patent”), which is assigned to the same assignee as the present invention. The &#39;106 Patent discloses a method for making a free standing package called a vertical stand up pouch. The modification uses two forming plates  104  and a tension bar  102  to hold the packaging film tube in tension from inside the tube. Tension is applied on the outside of the film and in the opposite direction of the tension provided by the forming plates  104  by a fixed or stationary tucker mechanism  106  positioned between the forming plates  104 . When the tucker bar  106  is properly positioned, it provides a crease or fold in the tube of the packaging film between the two forming plates  104 . This creates a gusset  135  that permits the package to stand upright on the gusset  135 . The crease is formed prior to formation of the transverse seal by the seal jaws  126 . Consequently, once the transverse seal is formed, the crease becomes an integral feature of one side of the package. 
   The vertical form and fill machine thereafter operates basically as previously described in the prior art, with the sealing jaws  126  forming a lower transverse seal (and upper transverse seal for the bag below), and product being introduced through the forming tube  101  into the sealed tube of packaging film which now has a crease on one side. The film is then pulled downward by moving belts  120  and the upper transverse seal is formed, thereby completing the package. An example of the vertical stand up package formed is shown in  FIGS. 2   a  and  2   b . The outside layer of packaging film show the graphics  179  oriented 90 degrees clockwise from graphics orientation normally present on a pillow pouch formed by a standard prior art vertical form, fill and seal machine. As shown in  FIG. 2   b  the transverse seals  128  of the vertical stand up package are oriented vertically once the bag stands up on one end as shown in  FIG. 2   b .  FIG. 2   a  shows the crease  176  that was formed by the tucker bar  106  and forming plates  104  shown in  FIG. 1  to create a gusset  135  that permits the package to stand upright. Various modifications of the vertical stand up pouch, methods for making the pouch, and apparatuses for making the pouch are disclosed in U.S. Pat. Nos. 6,729,109 and 6,679,034. 
   Another self standing flexible pouch is disclosed in U.S. Pat. No. 6,679,630 also assigned to the same assignee as the present invention.  FIG. 3   a  is cross-sectional view of the self standing flexible package disclosed in the &#39;630 Patent. Referring to  FIG. 3   a , the &#39;630 Patent teaches a package  70  having a flap  78  formed by creating a bend  84  in the film to form an inner portion of flap  78 . An opening  90  is formed between the inner and outer portions of the flap  78 .  FIG. 3   b  shows a completed package  70  in a standing or display position. Referring to  FIGS. 3   a  and  3   b , as package  70  is shown standing, flap  78  extends outward and away from back forming pocket  80 . To enclose and retain any product within the package a back seal  124  seals the film tube and transverse end seals  128  seal the terminal ends of package  70 . The transverse seals  128  also serve to retain the flap  78  to the terminal ends of package  70 . Unfortunately, the &#39;630 Patent requires the flap  78  to be manually drawn away from the back for the package  70  to stand erect with the use of a flap  78 . Thus, the package requires manual manipulation to stand up. In addition, because packages are typically opened at the transverse seals, product can spill out of the package after the package is opened, when the package is in the stand up position. Thus, there is a need to provide a package having a compartment or pocket that permits the compartment to hold different contents than are held in the main portion of a package when the package stands erect. Consequently, a need exists for a vertical stand-up package having one or more open compartments that are accessible while the package is standing erect that minimizes the use of film. 
   The prior art discloses other containers often associated with TV dinners having multi-compartment food containers where the compartments are adjacent and integrated into the container. Unfortunately, many of these food containers are made from more expensive thermoforming techniques. Consequently, a need exists for a multi-compartment food container that can be made from an economical modification of a vertical form, fill, and seal machine. 
   SUMMARY OF THE INVENTION 
   The proposed invention involves producing a vertical stand up package having one or more open or closed compartments constructed from a single sheet of material using a vertical form, fill, and seal machine modified with a spiral former, a first and second filling structure, and a gusseting mechanism. The former receives flexible packaging film and forms a tube having an overlap end and an inner end. The overlap is sealed to the tube thereby causing the inner end to form an internal compartment wall. The gusseting mechanism creates a vertical tuck along the length of the bag while it is being formed permitting the package to stand up once the transverse end seals are made. 
   The method disclosed and the package formed as a consequence is a substantial improvement over prior art packages having a compartment. The method works on existing vertical form, fill, and seal machines requiring little modification. There are no jaw carriage modifications involved. The bag makers can be easily converted back to a pillow pouch configuration with a relatively few simple changes. The same metalized or clear laminations used as materials in pillow pouches can also be used with the invention. The above as well as additional features and advantages of the present invention will become apparent in the following written detailed description. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein: 
       FIG. 1  is a perspective view of a prior art form, fill, and seal machine. 
       FIGS. 2   a  and  2   b  are perspective views of prior art vertical stand-up packages. 
       FIG. 3   a  is a cross-sectional view of a prior art package capable of self support having a pouch. 
       FIG. 3   b  is a perspective view of a prior art package. 
       FIG. 4  is a perspective view of one embodiment of the present invention depicting a modified form, fill, and seal machine. 
       FIG. 5   a  is a simplified top view of the dual delivery tube assembly of one embodiment of the present invention. 
       FIG. 5   b  is a cut away perspective view of the package in accordance with one embodiment of the present invention. 
       FIG. 5   c  is a cut-away side view of the package in accordance with one embodiment of the present invention. 
       FIG. 5   d  depicts a cut away top view of one embodiment of the present invention having salsa poured into the compartment. 
       FIG. 6   a  is a front view of one embodiment of the vertical stand-up package having a compartment. 
       FIG. 6   b  is a perspective bottom view of the package depicted in  FIG. 6   a.    
       FIG. 7   a  is a perspective view of a folding device adjacent the vertical form fill and seal machine along line  7 A— 7 A of  FIG. 4  in accordance with one embodiment of the present invention. 
       FIG. 7   b  is a perspective view of the folding device depicted in  FIG. 7   a  along line  7 B— 7 B of  FIG. 4   
       FIG. 7   c  is a perspective view of a folding device depicted in  FIG. 7   a  along line  7 C— 7 C of  FIG. 4 . 
       FIG. 8   a  is a simplified top view of the multi-delivery tube assembly in accordance with one embodiment of the present invention. 
       FIG. 8   b  is a cut-away perspective view of the package made from the assembly depicted in  FIG. 8   a    
   

   DETAILED DESCRIPTION 
     FIG. 4  is a perspective view of one embodiment of the present invention depicting a modified form, fill, and seal machine. A spiral former  426  receives the packaging film  110  and directs the compartment terminal end  410  around a fill tube or first filling structure  418  to receive a first item  718 . The former  426  simultaneously directs the tube terminal end  622  (film overlap end) to overlap the compartment terminal end  410  (film inner end). Thus, in the embodiment shown, the spiral former  426  creates a tube having an enclosed channel in communication with a first filling structure  418  and an open channel in communication with a second filling structure  420 . The second filling structure  420  is adjacent the first filling structure  418  and situated so as to permit a second item  720  to be placed in the open channel. The open channel becomes the compartment when the package is sealed. 
     FIG. 5   a  is a simplified top view depicting the former and dual delivery tube assembly of one embodiment of the present invention. In the embodiment shown, an indention in the first filling structure  418  creates a channel for placement of the second filling structure  420 . This indention, however, is not required and is shown to be illustrative of one embodiment. The film tube comprises an inner compartment wall  640  bounded by a compartment terminal end  410  and a compartment seal end  422 . 
   Referring to  FIGS. 4 and 5   a , as the film tube is pulled downward by drive belts  120 , the vertical tube terminal end  622  of film is sealed to the compartment seal end  422  by a vertical sealer  122 . The vertical sealer  122  can use heat seal or cold seal technology. The tube then passes over two forming plates  104  and a tension bar  102 . A tucker bar  106 , positioned between the forming plates  104 , provides a crease or fold in the tube of packaging film between the two forming plates  104 . The sealing jaws  126  then form a first end seal. 
     FIG. 5   b  is a cut away perspective view of the package in accordance with one embodiment of the present invention. Referring to  FIGS. 5   a  and  5   b , the lap seal  522 , created by the vertical sealer  122 , has sealed the seal end  422  of the compartment wall  640  and the tube terminal end  622 . The compartment terminal end  410  of the compartment wall  640  is secured within the package by the first end seal  631  at the location generally depicted by numeral  412 . A compartment  620  is thereby formed that is bounded by an overlapped segment of film  520 , or overlap wall  520  of the tube, the lap seal  522  and the compartment wall  640 . The main portion  618  is bounded by the compartment wall  640  and the gusset  680 . 
     FIG. 5   c  is a cut-away side view of the package in accordance with one embodiment of the present invention. In the embodiment shown, the package  600  comprises two compartments  618   620  open to one another. A first item  718  rests in the main portion  618  of the package  600  while a second item  720  is disposed within the compartment portion  620  of the package  600 . The first and second items are separated by a compartment wall  640 . As shown by  FIG. 5   c , the package is formed by a single sheet of film formed into a tube having an overlap wall  520 . The terminal end  622  of the overlap wall  520  is sealed with a lap seal  522  to the compartment seal end  422  of the compartment wall  640 . It should be noted that the height of the compartment wall  640  can be adjusted as desired. Additionally, as will be discussed in greater detail below, the top of the compartment wall  640  can be sealed to the overlap wall  520  to form a closed compartment. Such embodiment could prove advantageous, for example, to permit placement of a liquid in either compartment or to prevent the compartments from sharing headspace. 
   Referring to  FIGS. 4 ,  5   a , and  5   b , upon completion of the first end seal  631 , a first item  718  can be dropped through a first filling structure  418  in communication with the main portion  618  of the tube. Similarly, a second item  720  can be dropped through a second filling structure  420  in communication with the compartment portion  620  of the tube. The items can be dropped simultaneously. Once the first item  718  and second item  720  have been placed in the package, a second end seal can be provided by the sealing jaws  126 . 
     FIG. 6   a  is a front view of one embodiment of the vertical stand up package having a compartment.  FIG. 6   b  is a bottom perspective view of the package depicted in  FIG. 6   a . The flexible vertical stand up package  600  rests on the gusset  680  having a crease  676  and, unlike a standard pillow pouch package, the end seals  631  are oriented in a vertical direction. A score line  615  can facilitate opening the package by removing the top. In a preferred embodiment, the lap seal  522  is located adjacent the gusset  680  to provide additional stability for the stand up package  600 . 
   One advantage of the package formed by the present invention is that complementary items can be stored in the package. For example, in one embodiment the first item can comprise tortilla chips and the second item can comprise pre-packaged salsa. The salsa can be pre-packaged in a traditional pillow package by a prior art vertical form, fill, and seal machine similar to that depicted in  FIG. 1 . The vertical stand up package can then be opened, the pre-packaged salsa can be retrieved from the open compartment, opened, and poured into the pouch from which it was retrieved. In an alternative embodiment, salsa or other liquid can be directly placed into a closed compartment. 
     FIG. 5   d  depicts a cut away top view of one embodiment of the present invention having salsa poured into the compartment  620 . Salsa, when poured into the compartment  620 , applies pressure at the compartment wall  640  and can press the compartment wall  640  in the direction of the arrows  623  shown in  FIG. 5   c  and  FIG. 5   d  to form a dipping well. Surprisingly, when the compartment terminal end  410  is folded over a portion of the compartment wall  640 , the integrity of the compartment  620  is enhanced and salsa, or other product, is less likely to spill from the compartment  620  over the compartment wall  640  into the main portion  618  of the package. Thus, the present invention permits a consumer to purchase a package having chips and salsa, and to then use the package to consume the chips and salsa directly from the stand up package without the chips spilling out of the package or using (and potentially dirtying) a salsa dish. Such package can be ideal for picnics or anytime a ready-to-eat product is desired. 
     FIG. 7   a  is a perspective view of a folding device adjacent the vertical form fill and seal machine along line  7 A— 7 A of  FIG. 4  in accordance with one embodiment of the present invention.  FIG. 7   b  is a perspective view of the folding device depicted in  FIG. 7   a  along line  7 B— 7 B of  FIG. 4 .  FIG. 7   c  is a perspective view of a folding device depicted in  FIG. 7   a  along line  7 C— 7 C of  FIG. 4 . Referring to  FIGS. 4 ,  5   c ,  7   a – 7   c , the rolled edge can be formed with a folding device  700  near the former  426  to permit a portion of the film which eventually becomes the compartment wall  640  terminal end  410  to fold over a portion of itself so as to provide a j-shaped rolled edge or fold having a trough  411  and a terminal end  410 . In the embodiment shown, the folding device  700  comprises a tucker bar  702  and a pair of rollers  704   705 . The angle that the tucker bar  702  engages the film  110  can be adjusted to obtain the desired fold. In the embodiment shown, the v-shaped bottom roller  704  comprises a channel  706 . The top disc-shaped roller  705  is disposed within the channel  706 . The tucker bar  702 , positioned between the tensioner  114  and the pair of rollers  704   705  provides a j-shaped fold having a terminal end  410  and a trough end  411 . 
   While the folding device  700  as shown comprises a tucker bar  702  and a pair of rollers  704   705 , in one embodiment, the folding device  700  comprises the tucker bar  702 . In one embodiment, the trough end  411  of the fold passes through the channel  706  of the bottom v-shaped roller  704 . The outer edge of the disc-shaped top roller  705  is bounded on two sides by the packaging film  110  as the packaging film  110  passes through the channel  706  of the bottom v-shaped roller  704 . In one embodiment, the former  426  comprises a gutter  710  mounted adjacent the edge of the former. The gutter  710  can be substantially perpendicular to the former edge. 
     FIG. 8   a  is a simplified top view of the multi-delivery tube assembly in accordance with one embodiment of the present invention. In the embodiment shown, extensions  160  are attached to the first filling structure  418 . As shown in  FIG. 8   a , the multi-delivery tube assembly comprises a first filling structure  418 , a second filling structure  420  and a third filling structure  421 . In addition, the multi-delivery tube assembly depicted in  FIG. 8   a  comprises a first vertical sealer  122 , a second vertical sealer  124  and a third vertical sealer  126  for sealing portions of the overlap segment  520  of film to a portion of the inner compartment wall  640 . 
     FIG. 8   b  is a cut-away perspective view of the package made from the assembly depicted in  FIG. 8   a . As shown in the Figure, the overlap segment  520  comprises a first longitudinal seal  522 , a second longitudinal seal  524 , and a third longitudinal seal  526 . In the embodiment shown, the package comprises three compartments  618   620   621  closed from one another. In one embodiment, one or more of the longitudinal seals  522   524   526  comprises a cold seal. Cold seal technology is well known in the art and is widely used to close food packages having heat-sensitive foods such as chocolate bars where heat sealing of the package is not desirable. Cold seal adhesives are typically coated or printed onto a flexible packaging film to permit sealing of the package with pressure. 
   It should be noted that there are several potential embodiments of the present invention. For example, referring to  FIG. 8   b , in one embodiment if the third longitudinal seal  526  is omitted, the package can have a first compartment  618 , a sealed second compartment  620  and a third open compartment  621 . Thus, a package having two compartments  618   621  open to one another and a closed compartment  620  can be produced. 
   Examples of package applications, such as complementary products that can be packaged together in the main portion and compartment include crackers and cheese, cake mix and pre-packaged icing, or ready to eat cereal, milk, and/or a utensil such as a spoon. A pre-packaged seasoning can be placed in the compartment portion and a dehydrated food, such as noodles, can be placed in the main portion. The seasoning can be removed, water added to the main portion  618 , the entire package can then be heated in a microwave, the seasoning can be added, and the consumer can consume the food product directly from the main portion  618  of the package. 
   Promotional items can be also placed in the compartment with product placed in the main portion of the package. Thus, a consumer desiring to immediately access the promotional item can easily do so without immersing one&#39;s hand and fingers in product. For example, a promotional coupon can be placed into compartment portion of the package while potato chips are placed into the main portion. A consumer may only want a portion of potato chips, but may want to also access the promotional coupon. The promotional coupon, in prior art packages having no compartment often falls to the bottom of the package. Thus, a consumer may be forced, in a prior art package, to dig with his or her hand through the potato chips in order to access the promotional coupon. The present invention, on the other hand, permits a consumer to simply reach directly into the compartment to retrieve the promotional coupon without contacting product. The food package need not be limited to shelf-stable food products. For example, the package of the present invention can be used to store cereal and pre-packaged milk in the refrigerated section of a grocery store. 
   The present invention can be achieved with relatively inexpensive modification of existing form, fill, and seal machinery to produce a vertical stand up package having one or more open or closed compartments. Further, the multi-compartment package of the present invention is one-half to one-third the cost of a multi-compartment thermoformed package. 
   While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.