Method for manufacturing an ingredient package

Tandem, vertically-aligned vertical form, fill, and seal (VFFS) assemblies enable a method for manufacturing an ingredient package. An inner ingredient-bearing package is manufactured by a first superior VFFS assembly, which inner package is then downwardly displaced to a second inferior VFFS assembly. The inner package and a second ingredient are deposited (filled) into an open-ended outer packaging material being formed by the inferior VFFS assembly. After deposing the inner package and the second ingredient into the formed outer package, the outer package and inner package are sealed to one another at superior ends thereof to finally form an ingredient package. The finally formed package may be removed from partially formed packages in superior adjacency thereto. The finally formed package compartmentalizes the first and second ingredients for later consumer consumption.

FIELD

The present disclosure generally relates to methods for manufacturing an ingredient or foodstuff package having distinct ingredient or foodstuff compartments. More particularly, the present disclosure relates to an ingredient package manufacturing method which enables package formation via tandem vertical form, fill, and seal assemblies.

BACKGROUND

Gasified candy, when exposed to moisture, tends to melt when in prolonged contact therewith. Given a sufficient amount of exposure to moisture (as for example, when exposed to one's mouth), the candy shells surrounding carbon dioxide gas bubbles essentially melt thereby releasing carbon dioxide gas, which action is often described as a popping sensation in one's mouth. The candy, to have its intended affect, should preferably be melted at the time of consumption and therefore separated from ingredients that may tend to otherwise prematurely melt the candy shells and release the popping gas. The candy, however, is often times enjoyed in conjunction with other food items or foodstuffs having significant moisture content such as pudding. In order to successfully serve both pudding and gasified candy for simultaneous consumption, it is necessary to separate the two ingredients prior to consumption. Packaging that enables the consumer to simultaneously and conveniently carry both ingredients in a single package for simultaneous consumption and enjoyment is therefore desirous.

Gasified candy and pudding are exemplary ingredients, however. Other foodstuffs or ingredients that may benefit from compartmentalized separation prior to consumption include any number of probiotic products and/or products containing active cultures such as yogurt or cottage cheese juxtaposed against other sugary ingredients or foodstuffs such as fruit, fruit-based ingredients, jams, and jellies. Some of the more pertinent prior art relating to packaging directed to compartmentalizing ingredients or constituent parts prior to active admixture and the like is described hereinafter.

U.S. Pat. No. 3,861,522 ('522 Patent), which issued to Llewellyn et al., discloses a Compartmented Package having Variable Volume Compartments. The '522 Patent teaches a compartmented package in which a longitudinal diaphragm, made of film, is sealed to the inner wall of a circular tubular member, also made of film, to form at least two continuous longitudinal linear junctures therebetween in a manner such that the volumes of the resulting compartments are variable. A two-compartment package having infinite relative volume variability in both compartments is stated to be the preferred embodiment.

U.S. Pat. No. 4,495,748 ('748 Patent), which issued to Rowell, discloses certain Containers and Machine for Making Them. The '748 Patent teaches a container preferably made from sheet plastics comprising a bag containing a tubular valve member, the bag being sealed with a seam at each end, the top seal having an opening therein for entry of an access tube into the valve member, and the valve member having a sealing seam which facilitates piercing of the access tube through the valve member into the bag. A second bag may be provided within the first bag. A machine is disclosed for making the containers continuously from sheets of material.

U.S. Pat. No. 4,681,228 ('228 Patent), which issued to Kerry et al., discloses a Package Filled with a Water Soluble Toxic Pulverulent or Granular Product. Kerry et al. note that some chemical products are so toxic that they must not come into contact with parts of the human body. The '228 Patent teaches a package of such a construction that during filling and transport thereof and during the release of product therefrom, the risk of anyone coming into contact with the product is restricted to a minimum, is characterized in that the product is situated in a closed inner container consisting of a water-soluble flexible material, and that the filled inner container is placed inside a closed outer container consisting of a flexible material which is resistant to water, both the inner container and the outer container consisting of a flexible tube which is closed near the two ends by a transverse joint and the end strips of the inner container are connected to the joining strips of the outer container in a manner such that between the contents of the inner container and the said joining strips there is a certain distance, and that a tear line is made in an exposed part of one of the end strips of the inner container.

U.S. Pat. No. 6,935,086 ('086 Patent), which issued to Benkus et al., discloses a double-bag package, and method for manufacturing the same, constructed by modification to existing Double Bag Package and Perforation Knife. The '086 Patent teaches certain form and fill packaging machines and perforation knives. In a preferred embodiment thereof, a double-bag package is produced from a single sheet of packaging film by feeding a roll of film having graphics printed sideways rather than vertically into a vertical form, fill and seal packaging machine and using a novel perforating/cutting knife to alternately cut and perforate transverse seals. The perforating/cutting knife has teeth in the shape of oblique triangular pyramids, with each tooth having three cutting edges. The perforating/cutting knife produces self-correcting T-shaped perforation patterns capable of capturing and redirecting errant tears for fail-safe directional separation.

International Publication No. WO 94/27886, authored by Richter et al., discloses a Container with Multiple Chambers, to Package Components Separately Prior to Use in Admixture. The Richter et al. publication teaches a package for accommodating a product having at least two components, which package has at least two self-contained chambers in which the individual components of the product can be stored in such a manner that they are hermetically separated from one another. The individual chambers are connected together in such a manner that they can be separated from one another only by destroying at least one chamber wall. The end regions of the chamber walls are in the form of a common closure for the individual chambers such that the individual chambers can only be opened simultaneously. In the preferred embodiment, the package comprises at least one folded carton having essentially a front and a back wall, side walls, bottom flaps and top flaps, inside which carton are arranged in a fixed manner at least two tube-like inner sachets each of which accommodates one of the components directly and which represent the chambers for the individual components, and the top end regions of which that project out of the inside of the folded carton form the common closure after the inner sachets have been filled separately.

From a review of these publications and other prior art generally known in the relevant art, it will be seen that the prior art does not teach a package for coaxially aligning and compartmentalizing constituent ingredients of a final mixture. Further, the prior art does not teach certain methodology for finally serving foodstuffs or presenting ingredients by axial displacement relative to package assembly, whereby plural foodstuffs or ingredients are coaxially presented for mixture at the time of consumption. The prior art thus perceives a need for a package assembly and methodology associated therewith that provides consumers with a novel means for receiving and consuming multiple ingredients, the admixture of which has arguably greater delectable value than the sum of its parts.

SUMMARY

Accordingly, an ingredient separating package is provided, which functions to package and present plural ingredients which may, upon presentation, affect an opportune admixture. The coaxial and non-coaxial packages comprise at least one inner tube or inner barrier, an outer tube or barrier, first and second package ends, and a longitudinal package axis extending intermediate the first and second package ends. The inner and outer tubes may extend coaxially about the package axis. The inner tube receives an inner ingredient and the outer tube receives both the inner tube, laden with the inner ingredient, and an outer ingredient. The inner and outer tubes are sealed at the first and second package ends. The inner tube thereby prevents untimely ingredient inter-contact, the outer tube thereby seals the coaxial package from ambient matter such as air, debris, or other matter that may be considered problematic to affect a proper ingredient admixture.

The inner and outer tubes may be sealed to one another at the first and second package ends and may comprise certain manually enabled, end-opening structure as may be preferably defined by state of the art singular, paired, continuous, or skipped laser scoring. Thereby, the user may selectively unseal or open a select package end (typically the top package end as directed by external graphical indicia) and coaxially dispense the inner and outer ingredients for further effect or action.

Certain methodology is further presented as reflective of the disclosed structures in terms of coaxial and non-coaxial ingredient presentation, foodstuff service, and package manufacture. In this regard, the that ingredient packages may be finally formed by first forming an ingredient-receiving inner tube, the inner tube having first and second inner tube ends and a longitudinal tube axis, the first inner tube end being sealed, the second inner tube end being open. A first ingredient may then be properly deposited into the inner tube via the second inner tube end, the first ingredient extending in radial adjacency to the tube axis. A matter-receiving outer tube is also be formed, which outer tube has first and second outer tube ends, the first outer tube end being sealed, the second outer tube end being open. A second ingredient and the inner tube may then be deposited into the outer tube via the second outer tube end, the inner and outer tubes and the first and second ingredients being substantially coaxial. The second inner and outer tube ends may then be simultaneously sealed to one another thereby finally forming a coaxial or non-coaxial ingredient package.

DETAILED DESCRIPTION

Referring now to the drawings with more specificity, a preferred methodology for manufacturing the ingredient or foodstuff package assembly is generally depicted inFIGS. 16-18, while an embodiment of a coaxial package assembly10is generally illustrated and referenced inFIGS. 1-5,14,16, and18. An embodiment of a non-coaxial ingredient or foodstuff package assembly102is generally referenced inFIGS. 19-21. The coaxial package assembly10is designed primarily for compartmentalizing and packaging ingredients or foodstuffs in coaxial relation to one another and for presenting the coaxially aligned ingredients or foodstuffs to the consumer. The non-coaxial package assembly102is designed primarily for compartmentalizing and packaging ingredients or foodstuffs to the consumer. It will be seen from a comparative inspection ofFIGS. 16-18that the method for manufacturing package assembly10is essentially enabled by way of vertically-positioned, tandemly cooperative vertical form, fill, and seal (VFFS) packaging machines or assemblies. In this regard, it will be seen that a first or superior VFFS packaging assembly15is generally depicted inFIGS. 16 and 17and a second or inferior VFFS packaging assembly19is generally depicted inFIGS. 16 and 18.

As is well known in the arts, VFFS packaging machines or assemblies are commonly used for forming, filling and sealing packages of snack foods and the like. Such packaging machines or assemblies commonly direct (as at vector arrows50) certain packaging film51(as pre-selected or engineered for preferably packaging the target foodstuff or ingredient) from a sheet roll52and forms the film51into a vertical tube around a product delivery cylinder or collar53as generally depicted and referenced in the noted figures. The vertical tube is then typically either vertically lap-sealed or vertically fin-sealed along its length to form a back seal. In this case, a lapped back seal or lap seal is preferably formed as at54to finally form the cylindrical superior tube11as generally depicted and referenced inFIG. 17, and a finned back seal or fin seal is preferably formed as at55to finally form the cylindrical inferior tube12as generally depicted inFIG. 18. The preference for the noted seals, namely lap seal54versus fin seal55, is described in more detail below.

After forming the back seal, a typical VFFS machine or assembly directs (as at vectors60) a pair of heat-sealing jaws or facings56against the tube to form a transverse seal57as further illustrated and referenced in the noted figures. This transverse seal57acts as the top seal on the inferior package as well as the bottom seal on the superior package being filled and formed above. The product to be packaged, such as certain foodstuffs or ingredients, is dropped through the product delivery cylinder or collar53, into open-ended tube, and is held within the tube above the bottom transverse seal in substantially uniform radial adjacency to a longitudinal packaging axis. After the open-ended tube has received certain ingredients, the film tube is displaced downward to draw out another package length. A transverse seal is formed above the product, thus sealing it within the film tube and forming a package of product. It may be seen from an inspection ofFIGS. 16 and 18, that inner tube11is transversely sealed in like manner at both its superior end and inferior end to enclose a first foodstuff or ingredient26in an inner package27. In most cases, the package below said transverse seal is separated from the rest of the film tube by cutting across the sealed area. In this case, however, inner package27is not separated from the continuous film in superior adjacency thereto, but rather is downwardly displaced into assembly19. Assembly19thus, receives both a second foodstuff or ingredient28and inner package27as generally depicted inFIGS. 16 and 18.

Notably, from an inspection of the figures, it will be readily understood that the drawings are simplified, and do not show certain support structures that typically surround such machines or assemblies. It will be further seen, however, that packaging film51is taken from a sheet roll52and passed through tensioners that keep the film51taut. The film then passes over a former, which directs the film into a vertical tube around a product delivery cylinder or collar53. In this case, as the inner tube11is pulled or directed downward by drive belts58, the inner tube of film is sealed along its length by a lap sealer61thereby preferably forming lapped back seal54. The machine then applies a pair of heat-sealing jaws56against the tube to form transverse seal57.

As earlier specified, this transverse seal57acts as the top seal on the inferior package below the sealing jaws56(as comparatively depicted inFIGS. 16 and 18) and the bottom seal on the superior package being filled and formed above the jaws56. After the transverse seal57has been formed, the package27is then displaced downward to draw out another package length. Before the sealing jaws56form the transverse seals57, the first foodstuff26is dropped through the product delivery cylinder53and is held within the inner tube11above the transverse seal57. The inner package27and second foodstuff28are then deposited into an inferior outer tube12formed in substantially the same manner as tube11(but having a larger transverse diameter). After a transverse seal58has been formed, the resulting coaxial ingredient package assembly10is then displaced downward to draw out another package length of the outer packaging film. A cut may then be made across the sealed area as at58to separate the finally formed package10from the partially formed package10above the seal58.

The method of manufacture disclosed may thus be said to comprise the steps of vertically sealing longitudinal edges of a first or inner packaging material thereby forming a first tubular sleeve such as inner tube11, having a superior and inferior open end. After forming the first tubular sleeve, the inferior end thereof is preferably transversely sealed, thereby forming an open-ended inner foodstuff-receiving compartment. A first foodstuff or ingredient may then be deposited into the open-ended inner foodstuff-receiving compartment, after which the inner foodstuff-receiving compartment may be downwardly displaced to a tube-encasing position62as generally referenced inFIG. 18.

Once the inner foodstuff-receiving compartment or package27is received at the tube-encasing position, a second outer tubular sleeve such as outer tube12may be formed about the inner foodstuff-receiving compartment by vertically sealing the longitudinal edges of a second packaging material at the tube-encasing position. The second or outer tubular sleeve is thereby left with opposite sleeve ends open at this juncture. The inferior end of the second tubular sleeve may then be preferably transversely sealed to form an open-ended outer foodstuff-receiving compartment, into which second foodstuff or ingredient28may be deposited. After the second foodstuff is deposited, the superior ends of the inner and outer foodstuff-receiving compartments may be simultaneously sealed to one another as at58(it being noted that transverse seal57is preferably sealed to seal58during this process) to finally form coaxial foodstuff package assembly10. The assembly10may then be downwardly displaced to a cut off position, whereafter the package assembly10may be cut or otherwise removed from the first and second packaging materials adjacent the superior ends of the inner and outer tubes for removing the coaxial foodstuff package from the first and second packaging materials.

Stated another way, the method of manufacturing the coaxial ingredient package may be said to comprise the steps of coaxially aligning first and second ingredient-delivery cylinders or collars (such as collars53) about a vertical tube-forming axis101as depicted and referenced inFIGS. 17 and 18. Notably, the step of coaxially aligning the first and second ingredient-deliver collars may be preferably defined by a substantially vertical coaxial alignment. In this regard, it will be noted that during manufacture, tube-forming axis101is coaxial with a package axis100, which axis100is referred to in more detail below. An ingredient-receiving inner tube11may then be formed about the first ingredient-delivery cylinder, the inner tube being formed from a continuous sheet of first packaging film, the first packaging film having inner and outer first film surfaces. The inner first film surface may be preferably sealed to the outer first film surface as for example, via a lap-sealing process, resulting in an inner tube having open first and second inner tube ends. The first inner tube end is then preferably sealed.

After sealing the first inner tube end, a first ingredient may be delivered and deposited into the inner tube via the first ingredient-delivery cylinder and the still open second inner tube end. The inner tube and the first ingredient may then be coaxially displaced through the second ingredient-delivery cylinder, whereafter a matter-receiving outer tube (such as outer tube12) may be formed about the inner tube via the second ingredient delivery cylinder. Similar to the inner tube, the outer tube is also preferably formed from a continuous sheet of second packaging film, the second packaging film having inner and outer second film surfaces, the outer second film surface being pre-printed or pre-provided with graphics and similar other markings for notifying onlookers of package contents. The inner second film surface is preferably vertically fin-sealed unto itself, resulting in an outer tube having first and second open outer tube ends.

Before delivering and depositing a second ingredient to the outer tube, the first end thereof may be preferably sealed about the first inner tube end. Notably, the second ingredient is deposited about the inner tube via the second ingredient-delivery cylinder and the second outer tube end, whereafter the second inner and outer tube ends may be sealed to one another thereby finally forming a coaxial ingredient package. The finally formed coaxial ingredient package may then be cut or otherwise removed from the first and second packaging films. The coaxial ingredient package may be coaxially displaced to a package removal position as at reference numeral64inFIG. 18before being cut from the first and second packaging films. A select package end may be preferably (and transversely) scored after sealing the second inner and outer tube ends for enabling ease of access to the package ingredients, as described in more detail below.

It is contemplated that the finally formed coaxial package assembly10is designed primarily for compartmentalizing and packaging ingredients or foodstuffs in coaxial relation to one another and for presenting the coaxially aligned ingredients or foodstuffs to the consumer. In this last regard, it has been noted that certain foodstuffs and/or ingredients are often best stowed or compartmentalized until the time of consumption or admixture. Thus, the coaxial ingredient package assembly may well function to package plural ingredients or foodstuffs in distinct coaxial compartments and preferably comprises at least one plastic, pliable, or pinchable inner foodstuff barrier or tube11as illustrated and referenced inFIGS. 1-4,6, and8-13, and16; and a plastic, pliable, or pinchable outer foodstuff barrier or tube12as illustrated and referenced inFIGS. 1-5, and7-16. Further, the package assembly10may be said to preferably comprise first and second package ends13as generally depicted and referenced inFIGS. 1,3-5, and9-15; and a longitudinal package axis100as depicted and referenced inFIGS. 1-4,8, and14.

Turning now to the embodiment ofFIGS. 19-21, the package102is similar in construction and method of manufacture to that of the package10discussed above, but is not coaxial. More specifically, the package102includes and inner foodstuff barrier111disposed within an outer foodstuff barrier112. The inner foodstuff barrier111may have an outer layer116that contains an inner foodstuff126and separates the inner foodstuff126from an outer layer124of outer foodstuff barrier111and an outer foodstuff128contained therein. The inner and outer foodstuffs126and128may be different, or they may be the same. Also similar to the previously-discussed package10, the package110has sealed first and second ends113, a lap seal120between ends of the outer layer116of the inner foodstuff barrier111, and a fin seal122between ends of the outer layer124of the outer foodstuff barrier112, as illustrated inFIG. 18. As illustrated inFIG. 21, the outer foodstuff128does not necessarily surround the inner foodstuff barrier111.

The preferred packaging films or material structures or layers used in the construction will necessarily be based on the product(s) or ingredients being packaged by the barriers of the package. The material outer layer of the inner tube is preferably compatible with the material inner layer of the outer tube. In this regard, it is contemplated that an ethylene vinyl acetate copolymer (EVA) sealant layer may be preferably added to the outer layer of the inner tube and also added as an inner layer of the outer tube. A foil or metalized film layer may be preferably sandwiched intermediate sealant layers to affect a more robust oxygen/moisture barrier layer. Alternatively, it is contemplated that the inner tube may incorporate an extruded polypropylene (PP) or low density polyethylene for a sealant layer as well as having an extruded PP sealant layer on the outer tube.

The inner ingredient or foodstuff barrier11is preferably formed by way of first or superior VFFS assembly15as generally depicted inFIG. 16and may preferably comprise a composite polymer material comprising state of the art materials such as polypropylene, polyester, paper, polyolefin extrusions, adhesive laminates, and other such materials. It is noted that for many ingredients, foodstuffs, or food products, flavor retention is highly important. In this regard, as is noted in the prior art, metalized food-contacting layers or surfaces provide excellent flavor retention when juxtaposed adjacent ingredients. Thus, it is contemplated that a foil or metalized film be incorporated to preferably or alternatively form an oxygen/moisture barrier layer or food or ingredient-protecting layer. The foil or metalized film layer is preferably sandwiched intermediate sealant layers. The innermost surface or layer14and the outermost surface or layer16of foodstuff barrier11as generally referenced inFIG. 6.

The film composition of inner foodstuff barrier11generally depicted inFIG. 6should in any event be ideally suited for use on vertical form and fill machines for the packaging of foodstuff ingredients or food products, as the methodology involved in constructing package assembly10preferably involves the use of tandem VFFS machines or assemblies as generally depicted inFIG. 16. Both the innermost surface14of barrier11and the outermost surface or layer16of barrier11should provide excellent food-contacting, barrier-enveloping properties (as would be the case, for example, when EVA sealant layers coat a foil or metalized film layer). Further, the outermost surface16of barrier11should enable sealing attachment to the innermost surface14.

In this regard, it is noted that state of the art techniques for forming a preferred longitudinal lap seal may involve the use of OPP or metalized polyethylene terephtalate (PET) as an intermediate layer of a 3-layer lamination, the outer sealant layers in this case preferably being formed from EVA sealant. Excellent results may be achieved by utilizing OPP or PET coated with an EVA type sealant as the outside or outermost surface16of barrier11insofar as the same enables state of the art heat sealing of the longitudinal back seal (or transverse seal) of the film. This type of sealant further ensures a more cooperative seal with the inner most sealant layer of the outer tube. Notably, there is no requirement for an ink layer for the inner ingredient or foodstuff barrier11as viewable graphics and the like may be considered superfluous, the same being otherwise hidden or blocked from view by the outer barrier12.

With reference toFIGS. 6 and 8, it will be seen that a portion of the inside surface layer14is mated with a portion of the outside surface or layer16in the area indicated by an arrow (inFIG. 6) to form a lap seal20(referenced inFIG. 8). The lap seal20in this area may typically be accomplished by applying heat and pressure to the film in such area. The lap seal design shown in the noted figures thus helps to insure that the product to be placed inside the formed package will be protected or isolated from matter radially external to the inner foodstuff barrier11.

It is contemplated that inner foodstuff barrier11may preferably comprises a longitudinal lap seal20of the type generally described and depicted inFIG. 8so as to minimize packaging material volume extending into the interstices17between the inner foodstuff barrier11and the outer foodstuff barrier12, which interstices17is generally referenced inFIG. 8. From a comparative consideration ofFIGS. 2 and 8, it will be understood that providing a lap seal20on barrier11will not only minimize packaging material volume, but maximize the outer foodstuff volume18and minimize obstruction(s) during axial displacement of the outer foodstuff or ingredient28. The outer foodstuff volume18is generally referenced inFIG. 2, and the outer foodstuff28is generally depicted and referenced inFIGS. 4,9,14, and16.

The outer foodstuff barrier12is preferably formed by way of second or inferior VFFS assembly19tandemly juxtaposed in inferior adjacency to assembly15as further generally depicted inFIG. 16. Outer foodstuff barrier12may also preferably comprise a composite polymer material comprising state of the art materials such as polypropylene, polyester, paper, polyolefin extrusions, adhesive laminates, and other such materials. As has been noted, many foodstuffs or food products benefit from the use of a foil or metalized film oxygen/moisture barrier layer to retain food flavor. Thus, it is contemplated that a foil or metalized film barrier layer may preferably be sandwiched as the intermediate layer of a 3-layer lamination to form outer foodstuff barrier12. The innermost layer or surface23and the outermost layer or surface24of foodstuff barrier12are generally referenced inFIG. 7.

The film composition of outer foodstuff barrier12generally depicted inFIG. 7should in any event be also be ideally suited for use on vertical form and fill machines for the packaging of food-based ingredients or food products, as the methodology involved in constructing package assembly10preferably involves the use of tandem VFFS machines or assemblies15and19. The innermost surface23of barrier12should provide excellent adhesion properties (as would, for example, an EVA sealant layer) and should enable sealing attachment unto itself. In this last regard, it is noted that state of the art techniques for forming a fin seal22may also involve the use of OPP or PET as the intermediate layer of a triplex film. Excellent results may be achieved by utilizing OPP or PET for the intermediate layer as sandwiched intermediate innermost surface23and outermost layer or surface24of barrier12, the preferred EVA sealant layer of surface23enabling state of the art heat sealing of the longitudinal back seal (or transverse seal) of the film. Notably, outer foodstuff barrier12may comprise an outer ink or graphics layer for the presentation of graphics that can be viewed through a transparent outside layer24, which outside layer24may be preferably defined by polypropylene or similar other material overlying the food-protecting OPP or PET materials.

In this last regard, it will be noted that a longitudinal fin seal22is to be preferred for longitudinally sealing the back of outer foodstuff barrier12, which fin seal22is generally depicted inFIGS. 2,8, and9. Outer foodstuff barrier12may preferably comprises a longitudinal fin seal22of the type generally described and depicted so as to maximize the outermost (hermetic) seal integrity of the package assembly, it being generally understood that fin seals generally provide superior hermetic seals. Further, in contradistinction to the inner lap seal20which functions to provide a benefit by reducing interstitial packaging material volume, there is no equal benefit of this type external to the package and thus the outer fin seal22is to be preferred to provide a superior seal and barrier to matter external to the package assembly10such as air, bacteria, debris, etc. Alternatively, however, it is contemplated that a lap seal may also be used to back seal the outer foodstuff barrier12, for example in situations requiring conservation of materials.

The fin seal variation generally depicted also provides that the product to be placed in the formed package will be protected from the ink layer by the inside surface or layer23. Again, the outside layer24does not normally contact any packaged foodstuff product. In the preferred embodiment depicted inFIG. 7, the inside surface or layer23is folded over and then sealed on itself in the area indicated by the arrows. Again, this seal is accomplished by the application of heat and pressure to the film in the area illustrated as may be seen from a general inspection ofFIG. 16at reference numeral25.

It should perhaps be reiterated that the packaging materials that are fed into the form, fill and seal machines shown inFIG. 16are preferably packaging film(s), 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 may form the innermost layer, and in the case of inner foodstuff barrier11, a metalized layer may form both the innermost surface or layer14and the outermost surface or layer16.

As may be further seen from an inspection ofFIG. 16, the inner foodstuff barrier11functions to receive an inner ingredient or inner foodstuff26and thereby forms an inner (food) package27. The inner ingredient or inner foodstuff26is further illustrated and referenced inFIGS. 2,4,9, and14. The outer foodstuff barrier12, in turn, receives the inner food package27and an outer foodstuff28in substantially coaxial relation about the package axis100. The inner foodstuff barrier11essentially functions to prevent contact intermediate the inner foodstuff26and the outer foodstuff28as further depicted inFIGS. 2,4,9,14, and16. The outer foodstuff barrier12essentially functions to prevent contact intermediate the outer foodstuff28and radially ambient matter or matter radially external to package assembly10(such as air or debris).

Finally, the first and second package ends13are preferably heat-pressure sealed to finally seal the package assembly10. The sealed first and second package ends13effectively function to selectively prevent contact intermediate the inner and outer foodstuffs26and28and axially ambient matter or matter axially external to package assembly10. In this last regard, the notion of selectively preventing contact intermediate the inner and outer foodstuffs26and28and axially ambient matter is meant to convey that the user may elect to enable contact therebetween, as for example, by opening the package assembly10. It is thus contemplated that the coaxial foodstuff package or package assembly10may further preferably comprise certain manually-enabled, end-opening means for enabling a user to manually (in other words, with one's hand and/or fingers) open a select package end, the select package end being selected from the group consisting of the first and second package ends13, but which may preferably be situated adjacent the top end as directed by implied by graphical indicia viewable via the outer package structures.

It is further contemplated that the end-opening means may be defined by certain select scoring as selected from the group comprising a singular score line30as generally depicted inFIGS. 11 and 13; paired score lines31as generally depicted inFIGS. 3,10,12, and14; continuous score lines32as generally depicted inFIGS. 12-14, and skipped score lines33as generally depicted inFIGS. 3,10, and11. It will be seen from an inspection of the noted figures that the select scoring may be preferably transversely aligned or orthogonal to the package axis100for enabling a user to remove the select package end as comparatively depicted inFIGS. 10 and 14. It is further contemplated that the select scoring may be preferably laser scored as a means to enhance the user's ability to manually, evenly and simultaneously open the compartments38and39containing the inner foodstuff26and the outer foodstuff28, respectively, to ambient matter, including, a user's mouth101as generally depicted inFIG. 15.

In this last regard, it is contemplated that the preferred opening technology take the form of or be defined by a laser score. The laser score will be both on the inner tube11and the outer tube12. It is further contemplated that the laser score may be preferably applied while the packages are in the web configuration, prior to being formed into a tube. As heretofore stated, the score can be of many different designs; a solid score, a skip score (as shown by dotted lines), a double score where the scores are preferably about 1 mm apart making it easier to align the inner and outer scores for a clean removal of the select package end (i.e. the top) of each tube. By using a laser score the entire select package end (i.e. the top) of the tube can be removed, making the dispensing of the ingredients or inner and outer foodstuffs26and28inside much cleaner or with minimal axial obstruction(s).

The present disclosure further provides certain foodstuff service and/or presentation methodology inherently taught by the structure(s) heretofore disclosed and described. For example, a certain foodstuff service method is contemplated whereby contact between plural foodstuffs may be prevented prior to final foodstuff service. In this regard, the method is contemplated as comprising certain steps including, aligning an inner foodstuff such as inner foodstuff26about a foodstuff axis such as package axis100. The step of inner foodstuff alignment may be structurally achieved by bounding or packaging the inner foodstuff with a first foodstuff barrier such as inner foodstuff barrier11as generally depicted inFIG. 15at35. The methodology may further comprise a step of coaxially aligning at least one outer foodstuff such as outer foodstuff28about the inner foodstuff (and the foodstuff axis). The step of outer foodstuff coaxial alignment may be structurally achieved by bounding or packaging the outer foodstuff(s) with a second or secondary foodstuff barrier(s) such as outer foodstuff12as generally depicted inFIG. 15at36.

After the respective foodstuffs are axially aligned, the same may be sealed from ambient matter (such as air or debris) for stowing and/or transporting the ingredients or foodstuffs and the foodstuffs may be unsealed or opened to ambient matter (such as a plate or one's mouth) prior to final foodstuff service. After opening or unsealing the otherwise sealed foodstuffs, it is contemplated that the methodology may involve the step of finally serving the inner and outer foodstuffs to the foodstuff consumer, as for example, by setting the coaxially aligned foodstuffs in front of the foodstuff consumer or by dispensing the foodstuffs from coaxial alignment directly to the foodstuff consumer, as for example, by dispensing the contents directly into one's mouth as generally depicted inFIG. 15.

Notably, the step(s) of foodstuff alignment and foodstuff sealing may be defined by the process of packaging the foodstuff in respective foodstuff sheathing such as inner and outer foodstuff barriers11and12. Thus, the methodology here contemplated may further involve the step of preventing foodstuff contact during the step of coaxial foodstuff alignment. Further, the inner and outer foodstuffs may be simultaneously and axially displaced during final foodstuff service as for example, by squeezing, pinching (as at37inFIGS. 9 and 14) or otherwise forcing the foodstuffs from the structures herein specified, which structures may be defined as an inner chamber38and an outer chamber39both of which are generally referenced inFIG. 8.

In this last regard, it is contemplated that the user may elect to allow gravitational force to pull foodstuffs or other ingredient contents from the inner and outer chambers38and39as generically depicted inFIG. 14where both gravitational force (in other words, the weight of package contents as depicted at vector arrow40) and the user's pinching action37may operate to force foodstuffs26and28from chambers38and39for further processing. Thus, it may be said that inner and outer foodstuffs may be manually forced into axial displacement by pinching the foodstuffs along the foodstuff axis.

Typically, after having been finally served the foodstuffs, the user may elect to mix the foodstuffs out of coaxial or concentric alignment. This may be achieved in any number of ways, not the least of which is via mouth-mixing the foodstuffs as implicitly shown inFIG. 15. Notably, should the user elect to dispense container contents directly into one's mouth from the open select package end, admixture of ingredients may be effectively achieved thereby to effect flavor and enjoyment prior to admixed foodstuff or ingredient consumption.

It is contemplated that the process of presenting foodstuff(s) according to the teachings herein, differ somewhat from foodstuff service methodology heretofore set forth. The presentation method or method for coaxially presenting plural foodstuffs to a foodstuff consumer is believed to essentially comprise the steps of coaxially aligning a plurality of foodstuffs about a foodstuff axis. The process of coaxial foodstuff alignment is believed to set up the process of axial displacement of foodstuffs along the foodstuff axis, which process, in turn, sets up the process of coaxial presentation of foodstuffs to a foodstuff consumer. In other words, after axially displacing the coaxially aligned foodstuffs, the same may be presented to the foodstuff consumer. As before, the plural foodstuffs may be prevented from contacting one another during coaxial foodstuff alignment. Further, should the foodstuffs benefit from being sealed from ambient matter (as for example for stowage on a market shelf), it is further contemplated that the foodstuffs may be sealed from ambient matter and opened prior to axial foodstuff displacement, the displacement may be effectively achieved or effected by way of pinching action or other forceful means as heretofore contemplated.

While the above description contains much specificity, this specificity should not be construed as limitations on the scope of the invention, but rather as an exemplification of the invention. The disclosed preferred embodiments have illustrated a two chamber foodstuff package. However, a foodstuff package comprising more than two distinct compartments according to the teachings set forth herein is contemplated. Should the manufacturer elect to form three or more compartments, it is contemplated that inner barriers should take the form of inner foodstuff barrier11and the outermost barrier should take the form of outer foodstuff barrier12.

Further, a foodstuff or other ingredient package for packaging and presenting plural foodstuffs or ingredients is disclosed. The package essentially comprises at least one inner foodstuff or ingredient barrier (such as barrier11), an outer foodstuff or ingredient barrier (such as barrier12), first and second package ends, and at least one longitudinal package axis (such as axis100). The inner foodstuff barrier extends intermediate the outer foodstuff barrier and the package axis for receiving an inner foodstuff and forming an inner food package or packages. The outer foodstuff barrier receives the inner food package(s) and an outer foodstuff, which essentially fills the interstitial cavity intermediate the outer barrier and the inner food package(s). The inner foodstuff barrier essentially functions to prevent contact intermediate the inner and outer foodstuffs, and the outer foodstuff barrier essentially functions to prevent contact intermediate the outer foodstuff and radially ambient matter.

The first and second package ends are sealed for selectively preventing contact intermediate the inner and outer foodstuffs and axially ambient matter. In this regard, it is contemplated that a multiaxial foodstuff package may be gleaned from the teachings set forth herein wherein the foodstuff package may comprises plural inner foodstuffs bound by certain inner foodstuff barriers and a single outer foodstuff which fills the interstitial space intermediate the inner foodstuff barrier(s) and the outer foodstuff barrier. Further, in terms of a foodstuff presentation method, the method for presenting plural foodstuffs to a foodstuff consumer may be said to comprise the steps of axially displacing axially aligned plural foodstuffs along the foodstuff axes for axially presenting plural foodstuffs to a foodstuff consumer; and presenting the axially aligned and axially displaced foodstuffs to the foodstuff consumer. This method may be preferably defined by coaxially aligning the plural foodstuffs or ingredients prior to axial displacement.

It will be seen that the types of ingredients storable in the package do not necessarily have to be overtly reactionary with one another as would be the case with gasified candy and moisture-laden ingredients such as pudding. The package may well function to separate ingredient pairs and the like such as cottage cheese on the outside and a fruit sauce on the inside (similar to the ingredients of BREAKSTONE'S®/KNUDSEN® COTTAGE DOUBLES® brand(s) snack packs); chocolate sauce on the outside and marshmallow cream on the inside; pudding on the outside and whipped cream on the inside; peanut butter on the outside and jelly on the inside; ketchup on the outside and mustard on the inside; and pudding on the outside and gasified candy on the inside. The package can be manufactured so that the contents including both foodstuffs can be visible through the transparency of the film used for the package or the exterior product can be partially seen through the transparency of the film so that the outer package can also carry the brand name and advertising of the manufacturer as needed.

The foregoing may be said to further teach or disclose certain methodology for manufacturing the coaxial ingredient package. In this regard, it is noted that coaxial ingredient package may be finally formed by first forming an ingredient-receiving inner tube, the inner tube having first and second inner tube ends and a longitudinal tube axis, the first inner tube end being sealed, the second inner tube end being open. A first ingredient may then be properly deposited into the inner tube via the second inner tube end, the first ingredient extending in radial adjacency to the tube axis. A matter-receiving outer tube may also be formed, which outer tube has first and second outer tube ends, the first outer tube end being sealed, the second outer tube end being open. A second ingredient and the inner tube may then be deposited into the outer tube via the second outer tube end, the inner and outer tubes and the first and second ingredients being substantially coaxial. The second inner and outer tube ends may then be (simultaneously) sealed (to one another) thereby finally forming a coaxial ingredient package.

It is further contemplated that the inner and outer tubes may be vertically and/or coaxially aligned before depositing the second ingredient and the inner tube into the outer tube. Further, it is noted that the finally formed coaxial ingredient package has first and second package ends. In this regard, it is contemplated that a select package end may be scored after sealing the second inner and outer tube ends, the select package end being selected from the group consisting of the first and second package ends. Preferably, the inner tube is lap-sealed during inner tube formation, whereas the outer tube may be selectively sealed during outer tube formation. In this regard, it is contemplated that the outer tube may be sealed as selected from the sealing type group consisting of lap sealing and fin sealing.

It is further contemplated that the inner tube with upper and lower ends open may be fed through the second forming collar and make and the bottom seals of the inner and outer tube may be formed simultaneously. The inner and outer product or first and second ingredients could then be fed or deposited into the inner and outer tubes via the open ends at the same time and the top seal for both the inner and outer tubes could be made at the same time. This approach may help the filling process if the inner product would have the tendency to bow out and choke off the outer package.

It is thus contemplated that the method of manufacturing a unidirectional or coaxial ingredient package, which method may comprise the steps of initially forming at least one ingredient-receiving inner tube and an outer ingredient-receiving outer tube (for receiving the inner tube(s)), the inner and outer tubes each having first and second tube ends and unidirectional tube axes. Notably, the unidirectional tube axes may be preferably coaxially aligned for forming a coaxial unidirectional package. After the inner and outer tubes are formed, first inner and outer tube ends may be (simultaneously) sealed, thereby leaving the second inner and outer tube ends open for subsequent ingredient deposition. After depositing a first ingredient into the inner tube and a second ingredient into the outer tube via the open second tube ends, the second inner and outer tube ends may be sealed for finally forming the unidirectional ingredient package.

Accordingly, although the invention has been described by reference to preferred embodiments, certain alternative embodiments, and certain methodology, it is not intended that the novel assembly or methods be limited thereby, but that modifications thereof are intended to be included as falling within the broad scope and spirit of the foregoing disclosure, the following claims and the appended drawings.