VALVE APPLICATION SYSTEM AND METHOD

A valve application system includes a rotary cutter configured to cut individual valves from a valve string. The valve string is configured to be fed between the rotary cutter and a vacuum transfer tool where the rotary cutter is configured to cut the individual valves from the valve string. The valves are configured to be transferred from the vacuum transfer tool to the ultrasonic anvil. A web is configured to be fed between the ultrasonic anvil and the ultrasonic horn where the valves are ultrasonically sealed to the web.

BACKGROUND

Technical Field

The subject matter described herein relates to systems and methods for forming a package (such as a pouch, bag, or the like), and more particularly to systems and methods for coupling valves to webs of material.

Discussion of Art

Certain products are retained in packages, such as pouches. The pouches are formed of flexible polymers, such as polyolefin-based packaging films. The pouches can be used to retain and contain liquids, for example.

Certain packages include a valve that is configured to be selectively opened and closed. In the closed position, the valve prevents fluids within the package from passing out of the package. In the open position, the valve allows the fluid to be poured or otherwise dispensed from the package. In short, valves have been developed to contain liquids within flexible packaging with the intent of using a flexible to semi-rigid, controllable method of containment.

Traditional 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 (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. Such provides both a flow control mechanism and re-closeable feature, enhances the overall sustainability profile and cost reduction of the packaging through material reduction and operational efficiency gains, and improves performance expectations in the growing e-commerce market.

A typical valve applicator utilizes intermittent motion to pull a string of valves, arranged in head-to-toe configuration, separates the valve into a single unit via a guillotine style blade, and applies the valve to a vacuum drum and seal to the film utilizing a traditional heat seal platen. However, the typical valve applicator is limited in terms of speed by a heat-sealing dwell time to an application speed of no greater than sixty valves per minute.

BRIEF DESCRIPTION

A need exists for a system and a method for efficiently and effectively applying (such as securing or otherwise coupling) valves to a web of material to form packages, such as pouches.

With that need in mind, certain embodiments of the present disclosure provide a valve application system including a rotary cutter configured to cut individual valves from a valve string. The valve string is configured to be fed between the rotary cutter and a vacuum transfer tool where the rotary cutter is configured to cut the individual valves from the valve string. The valves are configured to be transferred from the vacuum transfer tool to the ultrasonic anvil. A web is configured to be fed between the ultrasonic anvil and the ultrasonic horn where the valves are ultrasonically sealed to the web.

In at least one embodiment, the valves in the valve strings are arranged in a side-by-side configuration.

In at least one example, the rotary cutter, the vacuum transfer tool, the ultrasonic anvil, and the ultrasonic horn are at a common location. As a further example, the rotary cutter, the vacuum transfer tool, the ultrasonic anvil, and the ultrasonic horn form a common assembly.

In at least one embodiment, the rotary cutter includes a first drum, the vacuum transfer tool comprises a second drum, the ultrasonic anvil comprises a third drum, and the ultrasonic horn comprises a fourth drum. As a further example, the first drum, the second drum, the third drum, and the fourth drum are configured to rotate. As a further example, the first drum rotates in a first direction, the second drum rotates in a second direction in opposition to the first direction, the third drum rotates in a third direction in opposition to the second direction, and the fourth drum rotates in a fourth direction in opposition to the third direction. In at least one example, the first direction and the third direction are counterclockwise, and the second direction and the fourth direction are clockwise.

In at least one embodiment, the rotary cutter, the vacuum transfer tool, the ultrasonic anvil, and the ultrasonic horn are configured to continually rotate during operation.

Certain embodiments of the present disclosure provide a valve application method, comprising feeding a valve string between a rotary cutter and a vacuum transfer tool; cutting, by the rotary cutter, individual valves from the valve string; transferring the valves from the vacuum transfer tool to an ultrasonic anvil; feeding a web between the ultrasonic anvil and an ultrasonic horn; and ultrasonically sealing the valves to the web between the ultrasonic horn and the ultrasonic anvil.

DETAILED DESCRIPTION

Certain embodiments of the present disclosure provide a valve application system and method that exhibit a significantly higher application rate, as compared to the typical valve applicator, through use of rotary motion and ultrasonic sealing. Embodiments of the present disclosure provide systems and methods associated with the application of flexible valves to a piece of film (web) to be used in relation to a finished flexible pouch.

In at least one embodiment, the valve application system includes a series of four rotary drums. Valves are manufactured in a side-by-side configuration, in contrast to a head-to-toe configuration. A valve string flows in a parallel plane and same direction as a web flow. The valve string passes between a rotary cutting blade and a vacuum drum that provides a cutting anvil. This vacuum drum transfers valves cut from the valve string and deposits the valves on a second vacuum drum contained in an ultrasonic sealing anvil pattern. That second vacuum drum rotates the individual valves into position and mates a rotary (lobed) ultrasonic horn to seal the valve into position on the web that is moving continuously, such as at rates up to 300 pouches per minute.

As described herein, a package, such as a pouch, is formed from a web of material. A valve is sealingly secured to the web. The web can then be rolled, folded, and/or the like to form a liquid tight retaining package having the valve that is configured to be selectively opened and closed. The package can be formed from one or more webs, such as one or more films, formed of a material. The web(s) can be formed of polyethylene, PET, LDPE, and/or the like. The web(s) can be formed of plural layers coupled together, such as via lamination, heat sealing, extrusion, cold sealing (sealing with an adhesive and application of pressure but without heating), and/or the like. In at least one embodiment, the web(s) is provided as a flexible sheet, which can be rolled, folded, and/or the like to form a liquid tight retaining package.

FIG.1illustrates a schematic block diagram of a valve application system100, according to an embodiment of the present disclosure. The valve application system100may include a rotary cutter102, a vacuum transfer tool104, an ultrasonic anvil106, and an ultrasonic horn108. The rotary cutter102, the vacuum transfer tool104, the ultrasonic anvil106, and the ultrasonic horn108may be at a common location110. In at least one embodiment, the rotary cutter102, the vacuum transfer tool104, the ultrasonic anvil106, and the ultrasonic horn108can form (for example, are part of) a common assembly112. As an example, the rotary cutter102, the vacuum transfer tool104, the ultrasonic anvil106, and the ultrasonic horn108can be contained within a common housing. Optionally, one or more of the rotary cutter102, the vacuum transfer tool104, the ultrasonic anvil, and the ultrasonic horn108may be outside of a housing.

In operation, a valve string114can be fed between the rotary cutter102and the vacuum transfer tool104. The valve string114may be a continuous string of individual valves connected in a side-by-side configuration.

FIG.2illustrates a simplified lateral view of the valve string114, according to an embodiment of the present disclosure. In at least one embodiment, the valve string114may include plural individual valves116connected together in a side-by-side configuration. Each valve116may include an inlet118and an outlet120. When a valve116is sealingly secured to a package, the inlet118may receive a fluid (such as liquid) from a main body of the package. When the valve116is in the open position, the fluid can be dispensed from the outlet120.

Referring toFIGS.1and2, the valve string114can be fed between the rotary cutter102and the vacuum transfer tool104. The rotary cutter102may cut the individual valves116from the valve string114. In at least one example, the blades of the rotary cutter102may separate the individual valves116, which are directly transferred to the vacuum transfer tool104. As another example, as the individual valves116are separated from the valve string114, the valves116can be spaced a predetermined distance on the rotary cutter102, and rotated onto the vacuum transfer tool104.

The vacuum transfer tool104may exert a vacuum force that transfers the individual valves116onto an outer surface of the vacuum transfer tool104. The vacuum transfer tool104may maintain the valves116on the outer surface, through the vacuum force, as the vacuum transfer tool104rotates in opposition to the rotary cutter102(e.g., rotates in an opposite direction). The vacuum transfer tool104may rotate the valves116onto the ultrasonic anvil106, which can rotate in opposition to the vacuum transfer tool104. In at least one embodiment, the ultrasonic anvil106also may apply a vacuum force, which can transfer the valves116onto an outer surface of the ultrasonic anvil106at a predetermined spacing.

The ultrasonic anvil106may continue to rotate and bring the valves116into a location between the ultrasonic anvil106and the ultrasonic horn108, which may rotate in opposition to the ultrasonic anvil106. A web122can be fed between the ultrasonic anvil106and the ultrasonic horn108. The ultrasonic horn108may exert ultrasonic energy into the web122while the valves116are located between the ultrasonic horn108and the ultrasonic anvil106, thereby ultrasonically sealing the valves116to the web122at predetermined locations where the ultrasonic energy is applied.

In at least one embodiment, the rotary cutter102may include or is otherwise coupled to an actuator124, such as a rotary motor, that causes the rotary cutter102to rotate. Similarly, the vacuum transfer tool104may include or may otherwise be coupled to an actuator126, such as a rotary motor, that causes the vacuum transfer tool104to rotate. Similarly, the ultrasonic anvil106may include or be otherwise coupled to an actuator128, such as a rotary motor, that causes the ultrasonic anvil106to rotate. Similarly, the ultrasonic horn108may include or be otherwise coupled to an actuator130, such as a rotary motor, that causes the ultrasonic horn108to rotate.

Optionally, less than all the rotary cutter102, the vacuum transfer tool104, the ultrasonic anvil106, and the ultrasonic horn108may include or be otherwise coupled to an actuator. For example, a single actuator, such as that of the rotary cutter102, can be used to cause the rotary cutter102to rotate. Because the rotary cutter102, the vacuum transfer tool104, the ultrasonic anvil106, and the ultrasonic horn108may have surfaces that contact one another, rotation of the rotary cutter102may cause corresponding rotation in each of the vacuum transfer tool104, the ultrasonic anvil106, and the ultrasonic horn108. The rotational feeding of the materials in this way can allow for a faster rate of production of the valves116and applying the valves116to the webs.

The valve string114can be fed between the rotary cutter102and the vacuum transfer tool104by a separate feed actuator, such as a linear feed motor. Similarly, the web122can be fed between the ultrasonic anvil106and the ultrasonic horn108by a separate feed actuator, such as a linear feed motor. Optionally, the valve string114and the web122can be fed (for example, drawn in) by rotation of the rotary cutter102, the vacuum transfer tool104, the ultrasonic anvil106, and/or the ultrasonic horn108.

As described herein, the valve application system100includes the rotary cutter102configured to cut individual valves116from the valve string114. The valve string114is configured to be fed between the rotary cutter102and the vacuum transfer tool104where the rotary cutter102is configured to cut the individual valves116from the valve string114. The valves116are configured to be transferred from the vacuum transfer tool104to the ultrasonic anvil106(such as via rotation of the vacuum transfer tool104and the ultrasonic anvil106). The web122is configured to be fed between the ultrasonic anvil106and the ultrasonic horn108where the valves116are ultrasonically sealed to the web122.

FIG.3illustrates a simplified lateral view of the valve application system100, according to an embodiment of the present disclosure. The rotary cutter102can include a drum or cylinder200that is configured to rotate about a first axis202in the direction of arc A, such as a counterclockwise direction. The vacuum transfer tool104can include a drum or cylinder204that is configured to rotate about a second axis206in the direction of arc B, which is in opposition to the direction of arc A, such as in a clockwise direction. The ultrasonic anvil106can include a drum or cylinder208that is configured to rotate about a third axis210in the direction of arc C, which is in opposition to the direction of arc B, such as in a counterclockwise direction. The ultrasonic horn108can include a drum or cylinder212that is configured to rotate about a fourth axis214in the direction of arc D, which is in opposition to the direction of arc C, such as in a clockwise direction.

During operation, each of the rotary cutter102, the vacuum transfer tool104, the ultrasonic anvil106, and the ultrasonic horn108may repeatedly or continually rotate (that is, in continuous motion). Further, the valve string114and the web122are may be in continuous or repeated motion. The valve string114and the web122can be linearly fed, and can move in parallel together, and in unison. The valve string114may be within a first plane220, and the web122may be in a second plane222. In at least one embodiment, the first plane220is parallel with the second plane222. Optionally, the first plane220and the second plane222may not be parallel. Also, optionally, the valve string114and the web122can be fed in opposite directions.

The valve string114may pass between a cutting blade of the rotary cutter102, and the vacuum transfer tool104, which can provide a vacuum drum that provides a cutting anvil in relation to the rotary cutter102. This vacuum transfer tool104can transfer the cut valves116from the valve string114, and may deposit the valves116on the ultrasonic anvil106. This anvil106may provide a second vacuum drum, such as may be contained in an ultrasonic sealing anvil pattern. The ultrasonic anvil106may rotate the individual valves116into position and can mate the ultrasonic horn106(for example, a rotary (lobed) ultrasonic horn) to seal the valves116into position on the web122, which is moving continuously or repeatedly, such as at rates up to 300 pouches per minute.

FIG.4illustrates a flow chart of a valve application method, according to an embodiment of the present disclosure. Referring toFIGS.1-4, at300, the valve string114may be formed having plural individual valves116connected together in a side-by-side configuration. In at least one other embodiment, the valves116can be connected in an end-to-end configuration. At302, the valve string114may be fed between the rotary cutter102and the vacuum transfer tool104. At304, the valves116can be cut (that is, separated) from the valve string114between the rotary cutter102and the vacuum transfer tool104. At306, the valves116may be transferred from the vacuum transfer tool104to the ultrasonic anvil106. At308, the valves116can be ultrasonically sealed to the web122that is fed between the ultrasonic anvil106and the ultrasonic horn108.

In one example, a valve application system is provided. This system may include a rotary cutter that may cut individual valves from a valve string, and a vacuum transfer tool. The valve string may be fed between the rotary cutter and the vacuum transfer tool where the rotary cutter can be cut the individual valves from the valve string. The system also may include an ultrasonic anvil. The valves may be transferred from the vacuum transfer tool to the ultrasonic anvil. The system also may include an ultrasonic horn. A web can be fed between the ultrasonic anvil and the ultrasonic horn, where the valves can be ultrasonically sealed to the web.

The valves in the valve strings may be arranged in a side-by-side configuration. The rotary cutter, the vacuum transfer tool, the ultrasonic anvil, and the ultrasonic horn can be at a common location, instead of being at different locations (such as different areas that require removal and transportation of materials between the different locations). The rotary cutter, the vacuum transfer tool, the ultrasonic anvil, and the ultrasonic horn may form a common assembly. The rotary cutter may include a first drum, the vacuum transfer tool may include a second drum, the ultrasonic anvil may include a third drum, and the ultrasonic horn may include a fourth drum, with each drum rotatable around or about a different axis. These axes may be parallel to each other. The first drum, the second drum, the third drum, and the fourth drum may each rotate. The first drum may rotate in a first direction, the second drum may rotate in a second direction in opposition to the first direction, the third drum may rotate in a third direction in opposition to the second direction, and the fourth drum may rotate in a fourth direction in opposition to the third direction.

The first direction and the third direction may be the counterclockwise direction, and the second direction and the fourth direction may be the clockwise direction. The rotary cutter, the vacuum transfer tool, the ultrasonic anvil, and the ultrasonic horn may continually or repeatedly rotate during operation.

In another example, a valve application method is provided. The method may include feeding a valve string between a rotary cutter and a vacuum transfer tool, cutting (by the rotary cutter), individual valves from the valve string, transferring the valves from the vacuum transfer tool to an ultrasonic anvil, feeding a web between the ultrasonic anvil and an ultrasonic horn, and ultrasonically sealing the valves to the web between the ultrasonic horn and the ultrasonic anvil.

The valves in the valve strings may be arranged in a side-by-side configuration. The rotary cutter, the vacuum transfer tool, the ultrasonic anvil, and the ultrasonic horn may be at a common location. The rotary cutter, the vacuum transfer tool, the ultrasonic anvil, and the ultrasonic horn may form a common assembly.

The rotary cutter may include a first drum, the vacuum transfer tool may include a second drum, the ultrasonic anvil may include a third drum, and the ultrasonic horn may include a fourth drum.

The method may also include rotating the first drum, the second drum, the third drum, and the fourth drum. The first drum may be rotated in a first direction, the second drum may be rotated in a second direction in opposition to the first direction, the third drum may be rotated in a third direction in opposition to the second direction, and the fourth drum may be rotated in a fourth direction in opposition to the third direction.

the first direction and the third direction may be counterclockwise, while the second direction and the fourth direction can be clockwise. The method also may include repeatedly or continually rotating the rotary cutter, the vacuum transfer tool, the ultrasonic anvil, and the ultrasonic horn during operation.

In another example, valve application system is provided. This system may include a rotary cutter that can cut individual valves from a valve string. The valves in the valve strings may be arranged in a side-by-side configuration. The rotary cutter may include a first drum configured to rotate in a first direction. The system also may include a vacuum transfer tool. The valve string may be fed between the rotary cutter and the vacuum transfer tool, where the rotary cutter can cut the individual valves from the valve string. The vacuum transfer tool may include a second drum configured to rotate in a second direction in opposition to the first direction. The system also may include an ultrasonic anvil. The valves can be transferred from the vacuum transfer tool to the ultrasonic anvil. The ultrasonic anvil may include a third drum configured to rotate in a third direction in opposition to the second direction. The system also may include an ultrasonic horn. A web can be fed between the ultrasonic anvil and the ultrasonic horn where the valves can be ultrasonically sealed to the web, wherein the ultrasonic horn comprises a fourth drum configured to rotate in a fourth direction in opposition to the third direction. The rotary cutter, the vacuum transfer tool, the ultrasonic anvil, and the ultrasonic horn may continually or repeatedly rotate during operation.

The rotary cutter, the vacuum transfer tool, the ultrasonic anvil, and the ultrasonic horn may be at a common location.

As described herein, embodiments of the present disclosure provide systems and methods for efficiently and effectively applying (such as securing or otherwise coupling) valves to a web of material to form packages, such as pouches.