Easy pour bag

Vertical fill and form bags fabricated from flexible packaging film are provided with at least one transverse seal at an oblique angle. Upon opening, the oblique angled seal provides a natural use easy pour dispensing feature. The bag is intuitively and ergonomically easy to use to facilitate controlled pouring without spilling. The bag are especially useful for bulk particulate contents especially consumer food products such as ready-to-eat cereals for use in food service venues such as universities and hospitals. Apparatus and method of preparation for the productions of the easy pour bulk bags are described including using transverse sealers at least one of which is oriented at an angle such as to impart the oblique angled transverse seal.

BACKGROUND OF THE INVENTION

The present invention relates to the art of packaging, to packaged products and to their methods of preparation. More particularly, the present invention relates to an easy pour bag fabricated from a flexible packaging film especially for food products.

A wide variety of products are packaged in bags or pouches fabricated from flexible packaging film especially vertical form fill and seal bags. These packaged bag products are often for bulk quantities of contained materials, especially dry materials. For example, bulk quantities can be for household use such as for water softener salt, cement, garden or landscaping materials or chemicals, (e.g., fertilizer, sand, mulch), pet food, etc. Bulk quantities can be packaged for commercial or industrial applications. Among commercial applications, the present invention finds particular suitability for use in food service applications. For example, a wide variety of food products are packaged in bulk for food service venues such as cafeterias (especially college or university or military facilities, hospitals or nursing homes, etc.), hotels, and restaurants.

In particular, ready-to-eat or breakfast cereals are typically packaged in bulk for use at food service venues. Once opened, the contents can be used to fill particular food dispensers (See, for example, US Des 384,863 “Bulk Dispenser For Comestibles” issued Oct. 14, 1997 to Danemayer or US Des. 390,753 “Bulk Dispenser For Comestibles” issued Feb. 17, 1998 to Danemayer, or U.S. Pat. No. 5,826,754 “Bulk Dispenser For Comestibles” issued Oct. 27, 1998).

Conventional pouches or bags include closure transverse seals or closure generally at right angles to the bag body. While useful, opening and dispensing the contents from such bulk opened bag can be awkward resulting in spillage of the food product. Not only does such spillage result in lost product but also spilled product requires clean-up. With a conventional bag, when the bag of, for example, cereal is poured into a bulk dispenser the intuitive way for the user to hold the bag is by the main body holding both the bag material and the cereal. This is awkward and adds to the mess that is generated when pouring. When the top seal is changed from the conventional 90° or right angle (relative to the main bag body) to an oblique angle as in the present invention, it becomes more natural for the user to grab the bag by the side. The bag forms a natural handle increasing the ease of pouring and reducing the probability of spilling cereal. This natural handle is a benefit resulting from the top seal being placed at an oblique angle. Also, while such problems of conventional bags and the advantages of the present easy pour bag are applicable to the filling of Ready-To-Eat cereal dispensers, such problems of conventional bags and advantages of the present bags are even more applicable when the bags are used to add contents to individual cereal bowls in large numbers such as for school cafeterias.

Thus, it would be desirable for such bulk pouches to include a feature that facilitates dispensing therefrom. Moreover, it would be desirable for such an easy pour feature be intuitively easy to use without need for instruction.

BRIEF SUMMARY OF THE INVENTION

The present invention addresses these and other concerns in the structure of bag packages. In one article aspect, the present invention resides in containers or packages such as bags or pouches10fabricated from a flexible packaging film having an easy pour feature. The bag10has a longitudinally extending body12having an upper and a lower openings. The bag includes a first or lower transverse flexible closure20(e.g., seam, or seal) for closing the lower opening and an opposed upper flexible transverse closure22for closing the upper opening. The bag10is further characterized in that at least one transverse closure is at an oblique angle relative to the longitudinally extending body.

The present invention provides an apparatus100useful in the fabrication of containers10of the present invention. Apparatus100includes a means for providing a continuous ribbon of flexible film packaging material36; a means30for forming the film material into a container having at least one transverse seal at an oblique angle, and a means for filling the container with contents46.

The present invention provides methods of producing the present package including forming at least a first transverse closure to a bag having a body with at least one open end, said transverse closure being at an oblique angle to the body. Additional objects, features and advantages of the method and apparatus for loading bags in accordance with the present invention will become more readily apparent from the following detailed description of the preferred embodiment thereof when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views.

Where used in the various Figures of the drawings, the same numerals designate the same or similar parts. Furthermore, when the terms “top”, “bottom”, “first”, “second”, “side”, “end”, “edge”, “front”, “back”, “inner”, “outer”, “upper”, “lower”, and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawings as it would appear to a person viewing the drawings and are utilized only to facilitate describing the preferred embodiment.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides to easy pour bags characterized by at least one transverse closure being at an oblique angle; to apparatus for forming such bags; and, to methods of their preparation.

Throughout the specification and claims, percentages are by weight and temperatures in degrees Centigrade unless otherwise indicated. Each of the referenced patents and patent applications are incorporated herein by reference.

The present invention is now illustrated in greater detail by way of the following detailed description, but it should be understood that the present invention is not to be construed as being limited thereto.

Referring now to the drawings and especially toFIG. 1, an easy pour container according to the preferred teachings of the present invention is shown in the drawings and generally designated10. In the preferred form, the container10is a flexible or pliable bag or pouch such as fabricated from a flexible packaging film13especially for food products. While throughout the specification and claims particular attention is paid to larger bags such as for food service, both smaller containers or pouches as well as other embodiments are contemplated. Bag10includes a longitudinally extending body12having a first or lower opening sealed by a first or lower transverse closure or seal20and opposed second or upper opening sealed by a second or upper transverse closure or seal22.

The body12includes opposed major surface such as a first or front major surface14and a second or rear major surface16. The body12can be fabricated by any flexible packaging film material13. Single ply flexible packaging film materials such as polyethylene or polypropylene or various blends are popular for materials that are not sensitive and do not require special protection, e.g., water softener salt or sand. More sophisticated food packaging flexible films are well known such as various laminated or multi-layered films that provide particular combinations of desired packaging features. For example, for food packages for Ready-to-Eat cereal products (“RTE” cereals“), composite or laminated packaging flexible film materials are well known that are clear thus revealing their contents yet nonetheless provide high levels of moisture barrier properties. In other variations, the packaging film material13can be opaque such having a foil layer for improved or superior moisture barrier properties. Various combinations of transparent and opaque packaging films are known and contemplated for use herein.

In the preferred form, the body12can be in the form of a tube. In certain variations, the tube is formed of flexible film material13already formed into a tube and having a single continuous curved surface such as forming a cylinder. Referring now briefly toFIG. 7, more commonly, the flexible film material is provided in the form of a continuous roll or ribbon19having opposed free side edges21A and21B or margins. The film material13is advanced around a forming horn or funnel40(as described in more detail below) and is formed into the tube by sealing the opposed free edges21A and21B together to form a longitudinally extending seal such as the rear lap or fin seal18depicted inFIG. 1. Typically such a longitudinal seal18is positioned on the major face surface that is used as the rear major face panel such that the seal18interferes less with packaging graphics.

In other variations (not shown), two ribbons or rolls of packaging material can be provided with opposed side seals to form the package body and without a rear longitudinal seal. In still other variations (not shown), a tube is formed by sealing the two free edges21A and21B together in a single fin seal to provide a body having only a single longitudinal seal (typically a side seal) to provide a tube having one curvilinear side edge and an opposed side seal but no front or rear seals.

Referring again toFIG. 1, the present package includes a first or lower transverse flexible end closure20(e.g., seam, or seal) for closing the lower bag opening and an opposed upper flexible transverse end closure22for closing the bag upper opening. The bag is further characterized in that at least one transverse end closure is at an oblique angle relative24to the longitudinally extending body. In the preferred form, the at least one oblique angle transverse end closure is the upper closure. In more preferred forms, both the upper and lower transverse closures are at an oblique angle. In the most preferred embodiment, both the upper and lower transverse seal closures are at an acute oblique angle of the same value such that the upper and lower transverse seals are parallel as seen inFIGS. 1 and 2. This allows for one set of sealing jaws to perform forming of both the lower and upper seals20and22.

In other variations such as seen inFIG. 5, the bag10includes at least one transverse closure or seal at an acute oblique angle such as the upper transverse closure depicted. In the embodiment depicted inFIG. 5, the lower transverse closure, however, is at a conventional right angle such as the top seal22depicted. Thus, the embodiment depicted inFIG. 5has only a single transverse closure at an oblique angle. While useful, the embodiment depicted is not as easily fabricated and requires multiple sealing jaws for fabrication; namely one at right angles and a second set oriented at an acute angle.

FIG. 2depicts that in the preferred form the oblique angled closure is at an acute angle24ranging from about 10° to about 45°, preferably about 15° to 30°. At an acute angle of less than 10° the spout formed upon opening of the bag for use forms a pour spout that provides less functionality or improvement over the conventional rectangular bag form. At a transverse seal angle of greater than 45°, the bags10become increasingly difficult to pack in a rectangular cardboard case. Comparable obtuse oblique angles can be used (seeFIG. 6) and can range from about 100° to 135° except that the pour spout formed is to the opposite bag side.

The bag10can include graphics26preferably on the front major surface or panel14. In preferred form, the graphics are positioned proximate upper flexible transverse end closure22so as to naturally indicate or suggest to the user which end is the upper end. (By proximate is meant less than 1/3 height of the bag or the distance between the upper and lower transverse seals.)FIGS. 2,4,4A,5and6further illustrates that the bag10can include a pair of end opening flaps27proximate upper flexible transverse end closure. Conveniently, such flaps27can extend for about 10-20 mm in length beyond the closure20. Such flaps27facilitate controlled opening of the end product by pulling apart seal closure22. In other variations (not shown), the container10can be provided with other easy open features such as cuts, nicks, tear-open strings and the like. In other variations, the film material can be selected to either facilitate or resist tearing depending upon particular needs of end use applications. In still other variations, the bags can be provided with reclosure features such as zip-lock bands.

Referring now briefly toFIG. 3, it can be seen that the upper transverse seal closure or seam22can include an upper pair of left side gussets28as well as an upper pair of right side gussets (not shown). Likewise the lower transverse seal20can include a right and left pairs of side gussets (not shown). The transverse seal side gussets generally facilitate bag formation. However, as best seen inFIGS. 4 and 4A, the upper pair of left side gussets28can also serve to form an easy pour spout feature29upon opening of the upper transverse closure22.

In a preferred embodiment, the package10is configured for food service to hold about 0.75-1.5 kg of RTE cereal. Conveniently, the package has a fill volume of about 3-5 liters.

Referring once again toFIG. 7there is shown an apparatus useful in the fabrication of containers10of the present invention generally designated by reference numeral100. Apparatus100can include a means for providing a continuous ribbon of flexible film packaging material36; a means30for forming the film material into a container having at least one transverse seal at an oblique angle; and, a means for filling the container with contents46. The forming mechanism30has been denoted generally in block form.

The packaging film supply means36can supply the film13in the form of a tube. In the preferred embodiment depicted inFIG. 5, however, the film supply means36can supply the flexible packaging film material13in the form of a continuous ribbon19having opposed free side edges21A and21B.

In the preferred embodiment wherein the film13is supplied in the form of a continuous ribbon and not in the form of a tube, then the means for forming30can include a means for forming the continuous ribbon19into a tube42including a hollow forming horn, tube or funnel40. As can be understood fromFIG. 7, the flexible film roll stock13as it is drawn from its rolled condition is urged or formed on forming horn or funnel40into a tube or trough-like configuration42. The marginal portions or free ends21A and21B of the stock12are urged into engagement and are heated by and the container forming means30can additionally include, a first vertically oriented sealer32to form a length-wise or longitudinally extending sealing together or seal18of the tube42that becomes the container or pouch10. The film13can contain repetitive graphics and other display information (e.g., ingredients listings, nutritional information, usage instructions, used container recycling information, production codes, etc.) in a repetitive pattern including station indexing indicia.

In one specific illustrative embodiment for the production of bulk bags having an internal volume of about 3-5 liters, the film stock13can have a width of about 50-65 cm.

Container forming means30can additionally include an upper horizontal or transverse sealer34that seals the bottom of the tube42being formed by the forming means30to provide a first lower transverse seal or closure20having an oblique angle. To provide a lower transverse seal having an oblique angle, the upper sealer34can be positioned at the desired oblique angle relative to vertical.

Container forming means30can additionally include a second lower horizontal or transverse sealer36to provide an upper transverse seal or closure22having an oblique angle seals the upper end of a preceding envelope42that results in a completed pouch or bag10. To provide in the preferred form an upper transverse seal having an oblique angle, the second or lower sealer36can be positioned at the desired oblique angle relative to vertical. In other variations, sealers34and36can be oriented at an obtuse angle relative to vertical.

In the preferred form, sealer means32,34and36can be a heat sealer and can comprise a pair heat seal jaws to provide a heat seal type seal and the film13can be a heat sealable type packaging film. In another embodiment, the sealers32,34and36can be a pressure sealer comprising a pair of pressure jaws and used to impart a pressure seal and film material13can be a pressure sealable film packaging material rollstock.

Forming means30can additionally include a cutter means38for severing the lower container10that has already been completed from the yet to be completed envelope configuration42. Conveniently as depicted inFIG.7, cutter means38(e.g., a knife) can be positioned intermediate sealers34and36. In the preferred embodiment of parallel transverse acute angled seals, a single cutter can be employed that is likewise oriented at an angle to provide a cut parallel to the transverse seals.

The seal jaws34and36are operated at timed intervals associated with the roll stock supply advance speed to provide bag of desired length and thus internal storage volume. In a preferred illustrative example for the provision of bags having an internal volume of about 3-5 liters, the bag length between transverse seals can extend for a length or height of about 35-60 cm, preferably about 40-50 cm.

Attention is now directed to contents supply means41that delivers a measured quantity or supply of contents46from an upper hopper (not shown) into the envelope or trough42that results in the completed pouch10. The contents can be either liquid, or, in the preferred form, solid particulates especially free flowing particulates. The particulates can be individual pieces of food such as RTE cereal, pet rations or livestock feed rations, popcorn (whether popped or kernel popcorn), fried snacks (e.g., potato chips, corn chips), peanuts, candies, gelled shaped fruit pieces, etc. The contents can be non food application particulates such as water softener salt pellets, landscaping materials such as pebbles or mulch, fertilizer pellets, pool chemicals (e.g., chlorination pellets). In other minor variations, the particulates can be smaller sized such as foods including flours, baking mixes, bulk ingredients, e.g., sugar, milk solids, salt, starch, chocolate powder, soy flour. Non food smaller particulates can include cement, sand, mortar mix or joint compound or any common dry material.

Contents supply means41can be seen to include the inner passageway43of funnel40. The flow of the contents46is downwardly such as by gravity feed as indicated by a direction arrow44. In certain variations, the contents supply means41can additionally include dust control elements such as a vacuum (not shown) or headspace gas supply (for controlled atmosphere packaging, e.g., nitrogen, CO2,). In other variations, more than one type of contents can be supplied to the bag or container10to provide blends of contents. In still other variations, the vacuum or air removal can be practiced to provide a bag10having a reduced air or even vacuum packaging.

After sealing by the sealers32,34and36, the abovementioned severance by the cutter38enables the completed filled bag10to fall gravitationally onto a take away conveyor50there beneath, the directional movement of the completed bag10for subsequent placement in cases or cartons being indicated by the arrows48.

Of course, while the present invention finds particular suitability for use in connection with vertical form and fill bag, the present invention can also be used in horizontal form and fill flexible bag packaging equipment.

Now that the basic construction of apparatus100according to the preferred teachings of the present invention have been set forth, a method of operation of apparatus10for the production of bags or containers10can be explained and some of the advantages of apparatus100can be highlighted.

In its method of preparation aspect, the present invention resides in methods of forming bag10having at least on transverse seal at an oblique angle. The methods can comprise a first step of providing a continuous supply of flexible film packaging material in the form of a continuous roll or ribbon of film rollstock as described in detail above.

As the film stock is drawn or unwound from the roll, the present methods can include the step of forming or folding the ribbon of film into an envelope or trough-like configuration by a forming mechanism to form a partially formed bag having an upper opening. This step can include the bringing together in confronting relationship the marginal or opposed free edges of the ribbon or strip of film material. The step can further include the sub-step of sealing the marginal portions thereof to provide a longitudinally extending seal. In preferred form, the free edges are brought together so as to form a lap seal.

The forming step can further include a sub-step of forming a lower transverse seal of the bottom of the envelope or trough-like configuration just formed. The forming step can further include a sub-step of forming a second upper transverse sealing therebelow that seals and closes the top or upper opening of the preceding or previously formed bag, thereby completing the closing of the preceding bag. In preferred form, each transverse seal is at an oblique angle (relative to vertical or longitudinally extending fin or lap seal). In more preferred form, each oblique angled transverse seal is at an equal angle such that the transverse seals are parallel. Also, the method is preferably practiced (such as by placement of the first and second means relative placement in respect of each other) to provide the upper transverse seal with about 10-20 mm of extra film material such as to provide a end opening flaps proximate the upper transverse seal.

During the forming step, the methods can include a step of adding or supplying a quantity of contents (and whatever other ingredients are to be included) through the funnel or other channel means into the folded configuration as the envelope or trough is longitudinally sealed along marginal portions thereof.

The present forming step can additionally include a sub-step of severing or cutting the preceding pouch, which has been filled and sealed, between the two transverse seals. The bags10so prepared are each characterized by at least one transverse seal being at an oblique angle. The bags10are permitted to fall freely onto a takeaway conveyor50there beneath. Thus, the bags are successively severed or cut from the laminated stock to provide a series of filled bags which are deposited on a conveyor.

Upon opening, the oblique angled seal provides a natural use easy pour dispensing feature. The bag is intuitively and ergonomically easy to use to facilitate controlled pouring without spilling. The bag are especially useful for bulk particulate contents especially consumer food products such as ready-to-eat cereals for use in food service venues such as universities and hospitals. For, example, containers of the present invention can be used to hold quantities of Ready-To-Eat cereals that are then used to fill cereal dispensers. The containers also find particular suitability for use in cafeterias for elementary schools where the bags' cereal contents are used to fill manually a large number of bowls with small quantities of ready-to-eat cereals for children. In such use environments, minimization of loss or spillage is a special concern.