Abstract:
The disclosure is directed to machines for manufacturing a flexible pouch that sterilizes the flexible pouch material, seals the fitment within the pouch, and inspects the fitment installation. A sterilization chamber in the machine a box having an oxygen supplied entry compartment, a hydrogen peroxide supplied center compartment, and an oxygen supplied exit compartment. To a secure the fitment within the flexible pouch, a seal bar including a center cavity disposed between a pair of sideways L-shaped portions is used. After the fitment is installed into the flexible pouch, it is inspected with a digital photograph analysis apparatus.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority of U.S. Provisional Patent Application Ser. No. 61/880,363 filed on Sep. 20, 2013, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to machines for manufacturing a flexible pouch with a fitment. Specifically, to a machine that sterilizes the flexible pouch material, seals the fitment within the pouch, and inspects the fitment installation. 
     BACKGROUND OF THE INVENTION 
     Various types of disposable portable containers are known in the art for storing a fluid or dry product such as a liquid, granular material, powder, or the like. Examples of containers include a cup, a metal can, a plastic bottle, a glass bottle, or a flexible pouch. Consumers prefer the convenience of flexible pouches over other types of containers due to their shape, size, shelf life, and storage adaptability. Manufacturers recognize the packaging benefits of a flexible pouch since the pouch can be formed and filled on the same manufacturing line. An example of a method and apparatus for filling a flexible pouch with a product is disclosed in commonly assigned U.S. Pat. No. 6,199,601 which is incorporated herein by reference. 
     The flexible pouch is made from a flexible film, preferably an extrusion or a laminate composed of sheets of plastic and aluminum or the like. An outer layer of material may include preprinted information such as a logo or the like to provide the customer with information regarding the contents of the pouch. 
     It is known to produce flexible pouches on form-fill-seal machines. These machines operate at high speed to produce the pouches from a roll of flexible film. The film is first drawn through the machine and folded over a plow to double the material into a sleeve. A gusset is then formed in the bottom. If the contents of the pouch will be food or beverage, the sleeve is passed through a hydrogen peroxide bath to sterilize the film. The sleeve then passes through seal bars which form side edges and shape the gussets. The sleeve is then separated into individual pouches. In some cases a fitment spout and cap is inserted as a unit into the top and sealed or the fitment is mounted and filled through the spout and then the cap is installed. It is important to make sure that the fitment is properly aligned and properly sealed into the pouch to prevent leakage. 
     SUMMARY OF THE INVENTION 
     A machine for producing a flexible pouch with a fitment includes a housing. A sterilization chamber apparatus is disposed with the housing. The sterilization chamber apparatus has an entry compartment supplied with oxygen, a center compartment supplied with hydrogen peroxide, and an exit compartment supplied with oxygen. The machine also includes a sealing apparatus having a seal bar disposed within the housing. The seal bar has a center cavity disposed between a pair of sideways L-shaped portions and rectangular recesses. Further disposed within the housing of the machine is a digital photograph inspection apparatus that has a digital camera and electronic control unit. The machine operates by moving flexible laminate material formed into a sleeve through the entry compartment, the center compartment and the exit compartment. Next, a fitment is inserted into the sleeve and the sleeve sealed to form the flexible pouch. The fitment is sealed in place with the seal bar. After the fitment is installed, the fitment installation is inspected with the digital photograph inspection apparatus. 
     A sterilization chamber apparatus for use in the manufacture of a flexible pouch made of laminate material includes a box having an entry compartment, a center compartment, and an exit compartment. A first tube is at least partially disposed with the entry compartment. The first tube supplies oxygen to the entry compartment from an oxygen supply. A second tube is at least partially disposed within the exit compartment. The second tube supplies oxygen to the exit compartment from the oxygen supply. A third tube is at least partially disposed within the center compartment. The third tube supplies hydrogen peroxide to the center chamber from a hydrogen peroxide supply. Laminate material is moved into the entry compartment supplied with oxygen. The laminate material is then moved through the center compartment supplied with hydrogen peroxide. Afterwards, the laminate material is moved through the exit compartment supplied with oxygen and out of the box, thus sterilizing the laminate material. 
     A method to sterilize laminate material used to manufacture a flexible pouch includes first providing a laminate material in a sleeve shape. Once the sleeve has been provided, oxygen gas is blown into the sleeve. After oxygen gas has been blown into the sleeve, hydrogen peroxide gas is blown into the sleeve. Finally, after the hydrogen peroxide gas has been blown into the sleeve, oxygen gas is again blown into the sleeve. 
     Once the sleeve has been sterilized, a flexible pouch can be formed from the sleeve by sealing and cutting the sleeve. A fitment can also be inserted and sealed within an edge of the flexible pouch. To help secure the fitment within the flexible pouch a seal bar is used. The seal bar includes a center cavity disposed between a pair of sideways L-shaped portions and a rectangular recess. 
     After the fitment is installed into the flexible pouch, it is inspected. A method to inspect the fitment within the flexible pouch includes providing a flexible pouch with a fitment. The fitment includes a canoe body with a top surface. The flexible pouch includes a top edge. A digital photo is taken of the pouch with the fitment. In the photo, the top edge of the pouch and the top surface of the canoe are identified. The identified top edge of the pouch and the identified top surface of the canoe body are compared with a rectangular model of the pouch. The flexible pouch is rejected if the top edge of the pouch is not generally parallel with the top surface of the canoe. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a perspective view of a machine for producing a flexible pouch; 
         FIG. 2  shows a perspective view of sterilization chamber apparatus with a portion cut away; 
         FIG. 3  shows a perspective view of the sterilization chamber apparatus of  FIG. 2  with laminate material; 
         FIG. 4  shows a top plan view of the sterilization chamber apparatus of  FIG. 2  with the top removed; 
         FIG. 5  shows a schematic view of the sterilization chamber apparatus of  FIG. 2 ; 
         FIG. 6  shows a perspective view of a seal bar; 
         FIG. 7  shows a perspective view of a top portion of a flexible pouch with a fitment; 
         FIG. 8  shows a top plan view of a pair of seal bars used in a fitment sealing apparatus; 
         FIG. 9  shows a view of a digital inspection photograph of a pouch with a too deep fitment; 
         FIG. 10  shows a view of a digital inspection photograph of a pouch with a too high fitment; 
         FIG. 11  shows a view of a digital inspection photograph of a pouch with a misaligned fitment; 
         FIG. 12  shows a view of a digital inspection photograph of a pouch with a properly installed fitment; 
         FIG. 13  shows a view of a digital inspection photograph of a pouch with a misaligned fitment; 
         FIG. 14  shows a view of a digital inspection photograph of a pouch with a properly installed fitment; 
         FIG. 15  shows a view of a digital inspection photograph of a pouch with a too high fitment; 
         FIG. 16  shows a view of a digital inspection photograph of a pouch with a too high fitment and an untightened cap; and 
         FIG. 17  shows a flowchart of a method for sterilizing, making, and inspecting a flexible pouch with a fitment. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference now to the figures, an embodiment of the claimed invention is shown and discussed. The improvements include an improved method and apparatus for sterilization, a fitment  27  alignment inspection device, and an improved seal mechanism for the fitment  27 . The improvements may be used together on one machine  25  or separately depending on the application. 
     As seen in  FIG. 1 , a fill, form, and seal machine  25  for producing a flexible pouch  26  with a fitment  27  from flexible laminate material  28  is shown. The machine  25  is protected by a housing  29  which covers, at least in part, operational structures of the machine  25 . Some of the structures disposed within the housing  29  include a sterilization chamber apparatus  30 , a fitment  27  sealing apparatus  32  and a digital photograph inspection apparatus  35 . 
     The sterilization chamber apparatus  30  of the machine  25  can be seen in  FIGS. 2-5 . The sterilization chamber  30  includes a box  37  having an entry compartment  40 , a center compartment  41  and an exit compartment  42 . The entry compartment  40  includes a first tube  45  that is at least partially disposed within the entry compartment  40 . The first tube  45  supplies oxygen to the entry compartment  40  from an oxygen supply  47 . The exit compartment  42  includes a second tube  49  that is at least partially disposed within the exit compartment  42 . The second tube  49  supplies oxygen to the exit compartment  42  from the oxygen supply  47 . The oxygen supply  47  may be a common supply for both the first and second tube  49 . Alternatively, the first tube  45  and second tube  49  could have their own individual oxygen supply  47 . The center compartment  41  includes a third tube  52  that is at least partially disposed within the center compartment  41 . The third tube  52  supplies hydrogen peroxide (H2O2) to the center compartment  41  from a hydrogen peroxide supply  54 . 
     Laminate material is moved though the entry compartment  40 , the center compartment  41 , and the exit compartment  42  to be sterilized. In the entry compartment  40  and the exit compartment  42 , the oxygen forms a barrier to prevent hydrogen peroxide from escaping the center compartment  41 . Hydrogen peroxide escaping from the center compartment  41  will mix with the oxygen in the entry compartment  40  or exit compartment  42  to form water. 
     The box  37  is formed by a front wall  57 , a rear wall  58 , and end walls  59 . The walls  57 ,  58 ,  59  may be formed of a suitable clear material such as Plexiglas. The box  37  is additionally formed by a top wall  62  and a bottom wall  63  which may be constructed out of metal or other suitable material. The center compartment  41  is separated from the entry compartment  40  and exit compartment  42  by two interior walls  65 . The entry compartment  40  is formed by one end wall  59  and one interior wall  65 . The exit compartment  42  is formed between the other interior wall  65  and other end wall  59 . The end walls  59  and interior walls  65  have slits  67  through which the laminate material is passed into and out of the compartments  40 ,  41 ,  42  when the machine  25  is in operation. 
     An oxygen diffuser  70  is mounted to the first tube  45  and second tube  49  within the entry compartment  40  and the exit compartment  42 . The oxygen diffuser  70  extends vertically in the entry compartment  40  and the exit compartment  42 . 
     A hydrogen peroxide diffuser  73  is mounted to the third tube  52  within the center compartment  41 . The hydrogen peroxide diffuser  73  is an elongated tube having a plurality of openings. The hydrogen peroxide diffuser  73  is suspended by the third tube  52  attached to the top of the center compartment  41 . The hydrogen peroxide diffuser  73  is aligned horizontally, or parallel to a direction of movement of the laminate material, within the center compartment  41  when in operation. 
     The oxygen supply  47  includes an oxygen tank  76 , an oxygen pump  77 , and an oxygen heater  78 . The oxygen is delivered from the oxygen tank  76  by the oxygen pump  77  through the oxygen heater which heats the hydrogen peroxide to 50° centigrade. The oxygen is then pumped by the oxygen pump  77  through a hose to the first tube  45  and second tube  49  at a pressure greater than that of ambient air. 
     The hydrogen peroxide supply  54  includes a hydrogen peroxide tank  81 , a hydrogen peroxide pump  82  and a hydrogen peroxide heater  83 . The hydrogen peroxide is delivered from the hydrogen peroxide tank  81  by the hydrogen peroxide pump  82  through the hydrogen peroxide heater  83  which heats the hydrogen peroxide to 70° centigrade. The hydrogen peroxide is then pumped through a hose to the third tube  52  and hydrogen peroxide diffuser  73  at a pressure greater than that of the pumped oxygen. Heating of the hydrogen peroxide and oxygen promotes the interaction there-between to form water, as discussed above. 
     An opening finger  85  is mounted to extend downwardly from the top of the entry compartment  40 . The finger  85  has a sufficient diameter, or width, to separate laminate material in the box  37  as discussed below. The sufficient diameter, or width, of the opening finger  85  can be determined by comparison to the width of the oxygen diffuser  70  and the hydrogen peroxide diffuser  73 . The width of the oxygen diffuser  70  and the hydrogen peroxide diffuser  73  are measured in a perpendicular direction as compared to the direction of travel of the flexible laminate material in the box  37 . The width or diameter of the opening finger  85  is equal to or greater than the width of the oxygen diffuser  70  and the hydrogen peroxide diffuser  73 . The opening finger  85  can be made of plastic, metal, or other suitable material. 
     A pair of rollers  88  is mounted to extend downwardly from the top of the exit compartment  42 . The rollers  88  are positioned close enough together to bring the laminate material previously separated by the opening finger  85  back together. Each roller  88  rotates about an axis that is generally vertical within the box  37 . The rollers  88  apply force to the laminate material to bring the material back together while minimizing resistance to the laminate material in the direction the material travels within the box  37 . The rollers  88  can be made of plastic, metal or other suitable material. 
     The fitment  27  sealing apparatus  32  includes a seal bar  91  for securing the fitment  27  within the pouch  26 , as shown in  FIGS. 6-8 . The fitment  27  sealing apparatus uses a pair of opposing seal bars  91  that sandwich the flexible pouch  26  and fitment  27  to provide a robust and secure seal of the fitment  27  within the pouch  26 . 
     The seal bar  91  has a center cavity  93  disposed between a pair of sideways L-shaped portions  95  and recesses  97 . The center cavity  93  is dimensioned and formed to seal the pouch  26  against a canoe body  99  of the fitment  27 . The sideways L-shaped portion  95  has a long horizontal portion  102  which is dimensioned to extend from a side edge  105  of the pouch  26  to abut the canoe  99 . The sideways L-shape portion  95  also includes a second portion  107  which extends vertically along the edge of the canoe  99 . The rectangular recess  97  of the seal bar  91  are located above the horizontal portion  102  of the “L”  95 . 
     When the machine  25  is operated, a method of sterilizing, forming, and inspecting flexible pouch  26  with a fitment  27  is performed, as laid out by the flow chart in  FIG. 17 . First a laminate film  29  from a roll is pulled over a plow  110  to fold the film into a sleeve  111  having a U shape, thereby providing the sleeve  111  at step S 1 . A gusset is formed in the bottom by a fixture which folds the bottom of the sleeve  111  into a “W shape”. The sleeve  111  is then guided by rollers into the entry compartment  40  as shown in  FIG. 3 . The ends have slits  67  formed to receive the sleeve  111  into and out of the chamber. The slits  67  are slightly larger than the sleeve  111 . 
     Then opening finger  85  is mounted to extend downwardly from the top of the entry compartment  40  to slightly above the gusset portion of the sleeve  111 . The finger  85  has sufficient diameter to separate the sides of the sleeve  111 , thereby opening the sleeve at step S 2 . A diffusing tube extends into the sleeve  111  upstream of the finger  85  to blow dry oxygen that was heated to about 50 degrees centigrade into the interior of the sleeve  111 , steps S 3  and S 4 . The slit  67  on the interior wall  65  of the entry compartment  40  has an opening large enough to permit the sleeve  111 , as separated by the finger  85 , to pass through the slit  67  in an open position to the center compartment  41 . 
     Within the center compartment  41  the hydrogen peroxide diffuser  73  extends into the sleeve  111  to blow hydrogen peroxide that was heated to about 70 degrees centigrade gas directly into the interior of the sleeve  111  and against the bottom gusset, steps S 5  and S 6 . The H2O2 moves upwardly from the sleeve  111  around the exterior of the sleeve  111  and over the bottom of the gusset thus sterilizing both the inner and outer sides of the sleeve  111  and gusset. An exhaust pipe  115  is mounted to the bottom of the center compartment  41  to draw out the H2O2 gas. The sleeve  111  then passes into the exit compartment  42  through the interior wall  65  of the exit compartment  42  which has a slot dimensioned to receive the sleeve  111  in an open state. 
     Within the exit compartment  42 , the second tube  49  for supplying oxygen extends downwardly from the top to blow oxygen from the heater at 50° centigrade into the sleeve  111 , step S 7 . The oxygen is blown into the sleeve  111  to block any hydrogen peroxide which passes from the center compartment  41  into the exit compartment  42 . The sleeve  111  then is passed through a pair of rollers  88  extending downwardly in the exit compartment  42  to close the sterilized sleeve  111 , step S 8 . The sleeve  111  is drawn out of the exit compartment  42  through a slit  67  in the exterior wall of the exit compartment  42 . 
     The sleeve  111  is then passed to a station with a heat seal bar which begins the formation of the pouch  26  by placing a tack seal at the bottom corner of every other pouch  26 . The tack seal is placed to hold the pouch  26  and gusset in a closed position as the sleeve passes further downstream to a station where the side seal is formed with a heat bar and then to a cutting station where the pouches  26  are separated by a knife from each other, step S 9 . The pouches  26  are then grabbed by grippers and moved to a station where the pouches  26  are opened, step S 10 . The pouch  26  is then moved to a station where a fitment  27  having a cap  108  is positioned in the top of the pouch  26 , step S 11 . The fitment  27  is delivered from a bowl feeder through a sterilization chamber having hydrogen peroxide. The pouch  26  is moved to a station where a seal bar tack seals the front and back panels to the canoe body  99  and then the pouch  26  with fitment  27  is moved to a station the seal bar  91  forms a second seal over the top edge  121  of the pouch  26  and canoe body  99  of the fitment  27 , step S 12 . The second seal is done at a higher temperature (250° C.) and pressure. The seal bar  91  used at the higher temperature and pressure has a center cavity  93  between the pair of sideways “L” shaped portions and rectangular recesses, as described above. As shown in  FIGS. 6-8 , the sideways “L” seal creates a deep sideways “L” in the pouch  26  which has a vertical portion  117  which extends into the distal edge of the canoe  99  and a horizontal portion  119  extending from the canoe to the side edge of the pouch  26 . The pouch  26  thus formed results in an inverted L shaped groove formed in the pouch  26  which forms a very tight seal barrier between the contents of the pouch  26  and the side edge of the canoe  99  to prevent any separation and leakage occurring from or in the pouch  26  particularly at the juncture of flexible laminate material and canoe  99 . The pouches  26  are then moved to a station where a cooling bar is applied at a temperature of 140° C. to the seal, step S 13 . 
     The pouch  26  then is moved to a fill station where the cap  108  is removed and the pouch  26  is filled through the spout of the fitment  27 . After the pouch  26  is filled, it is then moved to a capping station where a robotic arm screws the cap  108  to the proper position. The pouch  26  is then moved to the digital photograph inspection apparatus  35  where a digital camera takes a photograph of a portion of the pouch and fitment. The photograph is received by a comparing module, or electronic control unit configured to run recognition software. As further described below, recognition software is used to recognize the top edge  121  of the pouch  26 , the top surface  123  of the canoe body  99 , and the lower edge  125  of the cap  108 . The lines are then compared to a stored rectangular model of the pouch  26  and cap  108 , or to each other, to determine whether the top of the canoe  99  is properly aligned with the top edge  121  of the pouch  26  and the cap  108  is properly tightened on the spout by checking the gap between the bottom of the cap  108  and the top of the canoe body  99 , step S 14 . If the canoe is not aligned horizontally or flush with the top edge  121  of the pouch  26 , the pouch  26  is rejected and a signal is sent to a discharge station where the pouch  26  is dropped into rejected passage and sent to scrap, S 15 . If the pouch, fitment, and cap are proper, the assembly is accepted and sent to be packaged for shipment, step S 16 . 
     To inspect the installation of the fitment  27  within the pouch  26  at step S 14 , and the installation of a cap  108  to the fitment  27  the video inspection device  35  is used. The video inspection device  35  includes a digital camera in communication with an electronic control unit. The digital camera takes a digital photograph of at least a portion of the flexible pouch  26 , fitment  27  and cap  108 . The digital photograph is sent to the electronic control unit for processing. The video inspection device  35  can additionally include a monitor  109  to allow an operator of the machine  25  to view the photographs taken by the digital camera. 
     The electronic control unit is configured to isolate a portion  112 , or box, within the digital photograph and identify features within the portion  112 . The identification is typically done by way of contrast comparison. A border line between areas of different contrast, color, texture, etc., is identified. The shape and location of the identified border lines are compared to model lines, or other parameters, in the electronic control unit, thereby allowing the electronic control unit to identify a top edge  121  of the pouch  26 , a top surface  123  of the canoe portion of the fitment  27 , a bottom edge  125  of the cap  108  secured to the fitment  27 , etc. 
     Depending on the camera angle taking the photograph of the pouch  26 , different lines can be identified. For example, as illustrated in  FIGS. 9-12 , the photograph can be taken from a top front perspective view. In the top front perspective view, the top edge  121  of the flexible pouch  26  may be identified by border lines having an arcuate portion near the center of the isolated portion connected with generally straight and horizontal portions near the sides of the isolated portion (as shown by the alternated long-short dashed lines in  FIGS. 9-12 ). The top surface  123  of the fitment  27  may be identified as a borderline with an arcuate shape near the center of the isolated portion (as shown by the dashed lines in  FIGS. 9-12 ). The bottom edge  125  of the cap  108  may be identified as a border line with an arcuate shape near the center of the isolated area above the identified top edge  121  of the pouch  26  and/or the identified top surface  123  of the canoe (as shown by the dotted line in  FIGS. 9-12 ). In situations where the top surface  123  of the canoe is located above the top edge  121  of the pouch  26 , the center arcuate portion of the top edge  121  will not be visible, and the top edge  121  of the pouch  26  identified will be identified by the generally straight and horizontal portions near the sides of the isolated portion. In situations where the top surface  123  of the canoe cannot be distinguished from the arcuate portion of the top edge  121  of the pouch  26 , such as when they are flush with each other, the electronic control unit will identify both as being located in the same location. 
     The photograph may also be taken from a front elevation view, as illustrated in  FIGS. 13-16 . In the front elevation view, the top edge  121  of the pouch  26 , the top surface  123  of the canoe, and bottom edge  125  of the cap  108  are all straight border lines. The electronic control unit distinguishes between the lines based on their length and location relative to each other. The bottom edge  125  of the cap  108  is the top most identification line (shown by the dotted line in  FIGS. 13-16 ). The top edge  121  of the pouch  26  is the bottom most identification line (shown by the alternating short-long dashed line in  FIG. 13-16 ). The top surface  123  of the fitment  27  (shown by the dashed line in  FIGS. 13-16 ) is located between the bottom edge  125  of the cap  108  and the top edge  121  of the pouch  26 . 
     When analyzing the lines to inspect the fitment  27 , the angle/orientation and location of one line relative to another line is considered. For example, in the top perspective view, when the arcuate portion of the top edge  121  of the pouch  26  and the arcuate portion of the top surface  123  of the canoe are either spaced apart by an equidistance along their length, or identically overlap along their length, the electronic control unit can determine that the fitment  27  is properly aligned within the pouch  26 . When the spacing between the arcuate portion of the top edge  121  of the pouch  26  and the arcuate portion of the top surface  123  of the canoe increases/decreases from right to left, or vise versa, then the electronic control unit can determine that fitment  27  is improperly aligned within the pouch  26 . 
     The electronic control unit may also determine when the fitment  27  is located in a proper vertical position within the pouch  26 . For example, when the vertical distance between the top edge  121  of the pouch  26  and the arcuate portion of the top surface  123  of the canoe is higher than a predetermined amount, or outside a tolerance level, the fitment  27  is determined to not be in a proper location. 
     Additionally, the electronic control unit may be configured to determine when the cap  108  is properly installed. For example, the vertical distance between the identified border lines representing the top surface  123  of the canoe and bottom edge  125  of the cap  108  is determined by the electronic control unit. When the distance between the top surface  123  of the canoe and bottom edge  125  of the cap  108  is above a threshold amount, or outside of a tolerance level, the electronic control unit determines that the cap  108  is not properly installed, for example when a thread on type cap  108  has not been fully tightened. 
     The invention is not restricted to the illustrative examples described above. Examples described are not intended to limit the scope of the invention. Changes therein, other combinations of elements, and other applications will occur to those skilled in the art without deviating from the spirit of the described invention.